Heat Exchangers

Kit Information

⚠️ Failure to correctly assemble the components according to these instructions may result in electric shock, injury, or death.

Items Inside Product Box

Before installation, please make sure all parts are located inside the product box.

TOOLS/MATERIALS REQUIRED: Phillips head screwdriver

Instructions

1. Turn off and disconnect 120 V power supply.
2. Turn off water supply, and drain water from isolation valves or a pressure relief valve.
3. Turn off gas supply.
4. Remove front panel by removing the two screws and releasing the two latches.
5. Disconnect combustion fan harness, venturi control harness, position sensor harness, gas solenoid harness, exhaust thermistor harness, igniter harness, flame rod harnesses, over heat switch harness, and igniter wire. Remove screw to disconnect ground wire (Figure 1).
6. Remove screw from gas tube bracket. Rotate and remove gas tube bracket from gas valve. Hold the gas pipe and the gas valve assembly, and pull down the gas pipe so that the gas valve assembly is disconnected from the gas pipe. Remove screws around perimeter of fan mounting flange. Remove two bottom screws first and top screw last (Figure 2).
7. Lift fan and gas valve assembly upward, then rotate forward to remove fan and gas valve assembly (Figure 3). Note: Noise filter is fragile. Do not hold the noise filter or apply strong force to the noise filter.
8. Remove screw securing the PC board to the unit. Remove controller and PC board, and pump board (pump model only) from their location and let them rest next to the water heater (Figure 4).
9. Disconnect five white wire connections and one blue wire connection below the secondary heat exchanger.
10. Remove 4 retention clips from the pipes connecting to the heat exchanger and the hose clamp from the condensate hose (Figure 5).
11. Remove 6 heat exchanger screws from the top and bottom of the heat exchanger (Figure 6).
12. Remove the heat exchangers/exhaust duct assembly from the body of the water heater. On the back of the heat exchangers/exhaust duct assembly, locate and remove 6 screws securing the exhaust duct to the heat exchangers (Figure 7).
13. Remove 2 retention clips securing secondary connecting pipe and remove the pipe. Do not discard the retention clips and the pipe as they will be installed onto the new heat exchangers during reassembly (Figure 8).
14. Remove lime thermistor on the left of the heat exchangers (Figure 9).

Reassembly

Throughout reassembly process, inspect if gaskets and O-rings have any damages. Replace damaged gaskets or O-rings. Also, install ceramic heaters, thermistor and sensor properly, and connect connectors properly.

1. Install the lime thermistor into a new provided heat exchanger (Figure 9).
2. Install the secondary connecting pipe using 2 retention clips to secure it (Figure 8).
3. Install 1 ceramic heater on the secondary connecting pipe (Figure 8).
4. Install the new exhaust duct gasket onto the exhaust duct assembly (Figure 10). You see flat surface of the exhaust duct gasket if the gasket is installed properly.
5. Install the exhaust duct assembly using 6 screws to secure it (Figure 7).
6. Replace existing exhaust gasket with the new exhaust gasket (Figure 11).
7. Install the heat exchanger assembly using 6 screws to secure the heat exchanger into place (Figure 6).
8. Install the retention clips onto the connecting pipes. Install the hose clamp onto the condensate hose. Reconnect the white wire connections and the blue wire connection below the secondary heat exchanger (Figure 5).
9. Install the controller, the PC board and the pump board (pump model only) to the unit using 1 screw to secure it (Figure 4).
10. Install the new check valve and its gasket into an opening of burner plate (Figure 12).
11. Install the fan/gas valve assembly back into the unit, connecting the bottom of the gas valve to the gas inlet pipe (Figure 3).
12. Secure the fan/gas valve assembly to the opening of the burner plate using 3 screws (Figure 2).
13. Install the gas tube bracket by placing it onto the pipe by pushing up to the connection of the gas valve and the pipe. Then rotate the bracket left to align the screw holes (Figure 2).
14. Secure the gas tube bracket using 1 screw (Figure 2).
15. Reconnect the igniter and flame rod harnesses to the electrode and flame rods, and attach the igniter wire. Attach a screw to connect the ground wire (Figure 1).
16. Reconnect the combustion fan harness, the venturi control harness, the position sensor harness, the gas solenoid harness, the exhaust thermistor harness and over heat switch harness (Figure 1).
17. Reconnect and turn on 120 V power supply, water supply and gas supply.
18. Perform leak detection test for gas and water.
19. After all checks have been successfully completed, reinstall the front panel using the two screws and two latches to secure it.

Diagram Descriptions

Figure 1: Shows various harnesses and wires connected to the water heater components, including the ground wire, igniter harness, combustion fan harness, venturi control harness, position sensor harness, gas solenoid harness, exhaust thermistor harness, flame rod harnesses, and over heat switch harness.

Figure 2: Illustrates the removal of the gas tube bracket and screws around the fan mounting flange. It also shows the gas tube bracket and the connection points for the gas valve assembly.

Figure 3: Depicts the fan and gas valve assembly being lifted and rotated out of the unit, highlighting the noise filter.

Figure 4: Shows the location of the PC board, controller, and pump board (if applicable), secured by a screw.

Figure 5: Illustrates the disconnection of wire connections and the removal of retention clips and a hose clamp from the heat exchanger and condensate hose.

Figure 6: Shows the location of the 6 heat exchanger screws on the top and bottom of the heat exchanger.

Figure 7: Depicts the heat exchanger/exhaust duct assembly and the 6 screws securing the exhaust duct to the heat exchangers.

Figure 8: Shows the secondary connecting pipe, ceramic heater, and the 2 retention clips used to secure the pipe.

Figure 9: Illustrates the location of the lime thermistor on the heat exchangers.

Figure 10: Shows the installation of the new exhaust duct gasket onto the exhaust duct assembly, indicating the correct orientation with a flat surface.

Figure 11: Depicts the replacement of the existing exhaust gasket with a new exhaust gasket.

Figure 12: Shows the installation of the new check valve and its gasket into the burner plate.