Bradford-White B4 User Manual
Internet Version for Reference Only
Installation, Operation and Maintenance Instructions Document 2143
C O R P O R A T I O N
B W
RADFORD HITE
®
Installation, Operation
and Maintenance
Instructions for
Copper Brute
Volume Water Heaters
Model B4
Sizes 175-400
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualied in hot water heater installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in ue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not followed exactly, a re or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the re department.
Installation and service must be performed by a qualied installer, service agency, or gas
supplier.
H2317000-
Internet Version for Reference Only
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Copper Brute B4 Volume Water Heaters
Page 3
TABLE OF CONTENTS
BRADFORD WHITE
SECTION 1.
General Information
1.1 Introduction..................................................... 3
1.2 Warranty.........................................................3
1.3 Technical Assistance ...................................... 3
SECTION 2.
Installation Instructions
2.1 General Information........................................ 4
2.2 Field Assembly ............................................... 4
2.3 Site Location................................................... 5
2.3.1 Installation Information ...................................5
2.3.2 Outdoor Installation (U.S. only) ......................5
2.3.3 Flooring - Typical Installation .......................... 6
2.4 Combustion and Ventilation Air Supply........... 6
2.4.1 Outdoor Air Supply ......................................... 7
2.4.2 Indoor Air Supply ............................................7
2.4.3 Exhaust Fans or Vents ................................... 7
2.5 Venting of Combustion Products ....................8
2.5.1 General Information........................................ 8
2.5.2 Replacement of Existing Heater.....................8
2.6 Water Flow .....................................................8
2.6.1 Reversible Water Connections.......................8
2.6.2 Water Chemistry........................................... 11
2.6.3 Freeze Protection ......................................... 11
2.6.4 Water Hardness............................................ 11
2.6.5 Pump Requirements..................................... 11
2.6.6 Pressure Buildup in Water System............... 14
2.6.7 Pressure Relief Valve ...................................14
2.6.8 Water Pressure............................................. 14
2.6.9 Pump Installation..........................................14
2.6.10 Storage Tank Installation .............................. 15
2.6.11 Thermal Circulation of Hot Water in
Cold Water Supply Lines..............................15
2.7 Gas Supply and Piping.................................15
2.7.1 General Instructions .....................................15
2.7.2 Special Precautions for Propane Gas ..........16
2.8 Electrical Wiring............................................ 16
2.9 Combined Space Heating/Potable
Water Heating Systems................................ 16
2.9.1 Combined Space Heating............................. 16
SECTION 3.
Operating Instructions
3.1 Normal Operating Sequence........................16
3.2 Start-Up Procedure....................................... 21
3.3 Setting the Temperature Controls................. 21
3.3.1 Remote Water Heater Temperature
Control:.........................................................21
3.3.2 Internal Water Heater Temperature
Control:.........................................................22
3.4 Adjustment for Minimum Input Rate
(models with modulating gas valve) .............22
3.5 Hi-Limit Switch Checkout.............................. 22
3.6 Shut-Down Procedure .................................. 22
SECTION 4.
Maintenance
4.1 General Instructions .....................................23
4.2 Replacement of Gas Controls ......................23
4.3 Heat Exchanger............................................ 25
4.3.1 Inspecting the Heat Exchanger ....................25
4.3.2 Cleaning the Heat Exchanger....................... 25
SECTION 5.
Troubleshooting
5.1 Gas Pressure Tests ...................................... 26
5.1.1 Checking the Main Line Gas Pressure.........26
5.1.2 Checking the Manifold
Regulated Gas Pressure .............................. 26
5.2 Electrical Troubleshooting ............................ 26
5.2.1 Heater Does Not Come On ..........................27
5.2.2 Testing the Transformer................................ 27
5.2.3 Testing the Electrical Power Supply .............28
5.2.4 Testing the Manual Reset
Hi-Limit Switch.............................................. 28
5.2.5 Testing the Flow Switch................................28
5.2.6 Testing the Fusible Link
(Flame roll-out switch) .................................. 28
5.2.7 Testing the Fuse ........................................... 29
5.2.8 Testing the Ignition Control
(for spark ignition)......................................... 29
5.2.9 Testing the High Voltage Ignition Lead.........29
5.2.10 Testing the Safety Shutoff
(for standing pilot)......................................... 30
5.2.11 Testing the Safety Shutoff
(for automatic pilot)....................................... 30
5.2.12 Testing the Igniter Electrode.........................30
5.2.13 Testing the Pilot Thermocouple
(for standing pilot)......................................... 30
5.2.14 Testing for Pilot burner
(for spark ignition)......................................... 30
5.2.15 Testing for Burner Ignition
(for standing pilot)......................................... 31
5.2.16 Heater Will Not Shut Off ............................... 31
5.2.17 On-Off Main Burner Cycling .........................31
5.2.18 Testing the Terminal Strip/External
Controls ........................................................ 31
Internet Version for Reference Only
Copper Brute B4 Volume Water Heaters
A
8-1/2 in.
(216mm)
INLET OUTLET
TOP VIEW
C C
OPTIONAL
VENT CAP FOR
OUTDOOR USE
DRAFTHOOD
DRAFTHOOD MUST
BE INSTALLED IN
THE FIELD
HEADER
LOCATION
OUTLET
40-9/16 in. (1030mm)
INLET
5-1/2 in.
(140mm)
26-1/2 in.
SIDE VIEW
V
30-3/16 in. (767mm)
B
Page 3
SECTION 1.
General Information
1.1 Introduction
This manual provides installation, operating, and
maintenance instructions for Copper Brute Volume
Water Heaters, Sizes 175 through 400. Review all
application and installation procedures completely
before proceeding with the installation. Experience
has shown that most operating problems are caused by
improper installation.
1.2 Warranty
The Copper Brute heaters are sold with a limited
factory warranty.
Make all warranty claims to an authorized
Bradford White representative or directly to the
factory. Claims must include the heater serial number
and model (this information can be found on the rating
plate), installation date, and name of the installer.
Shipping costs are not included in the warranty
coverage.
Some accessory items are shipped in separate
packages. Inspect everything for damage immediately
upon delivery, and advise the transporter of any
shortages or damage. Any such claims should be led
with the transporter. The transporter will not accept a
claim from the shipper, Bradford White.
The warranty does not cover damage caused by
improper installation, operation, or eld modication.
1.3 Technical Assistance
Consult Bradford White or your local wholesaler
with any questions or problems involving the
specication, installation and operation of Bradford
White equipment. An experienced technical support
staff is ready to assist in assuring the proper
performance and application of Bradford White
products.
Dimensions shown in inches cm.
Gas Connection
Size Water C C V
Connect. U.S. Only (Indoor) Vent
Nat. Propane Size A B (Outdoor) Dia.
Size in. mm in. mm in. mm in. cm in. cm in. cm in. cm in. mm
175 3/4 19 1/2 13 11/2 38 18 46 261/2 67 141/16 36 23/2 60 6 152
250 3/4 19 1/2 13 11/2 38 221/2 57 31 79 181/16 47 243/4 63 7 178
325 3/4 19 1/2 13 11/2 38 263/4 68 353/4 91 193/16 49 257/8 66 8 203
400 3/4 19 1/2 13 11/2 38 313/4 80 401/4 102 225/8 58 267/8 68 9 229
Note: Dimensions may vary.
Figure 1. General conguration.
Internet Version for Reference Only
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Copper Brute B4 Volume Water Heaters
Page 5
HO
T
HO
T
BRADFORD WHITE
SECTION 2.
Installation Instructions
2.1 General Information
WARNING
Follow local regulations with respect to installation
of carbon monoxide (CO) detectors and
manufacturer's maintenance schedule of the heater.
Install the Copper Brute heaters in accordance
with the procedures in this manual (or the warranty
may be voided), local codes and ordinances. In the
absence of such codes, install the heaters in accordance
with the latest edition of the National Fuel Gas Code,
ANSI Z223.1. In Canada, the installation must be
in accordance with CAN1-B149.1 or .2 and local
codes. The authority having jurisdiction may require
the installation conform to the Standard for Controls
and Safety Devices for Automatically Fired Heaters,
ANSI/ASME CSD-1. Any changes to the heater, gas
controls, gas orices, wiring or draft diverter may void
the warranty. If eld conditions require a change to
any of the above, consult the factory.
All gas-red products require correct installation
to assure safe operation. The requirements for heaters
include the following:
1. Field assembly of drafthood or vent cap (see
Section 2.2).
2. Appropriate site location (clearances) and
ooring.
3. Sufcient combustion and ventilation air.
4. Adequate venting of combustion products.
5. Adequate water ow.
6. Properly sized gas meter and piping.
7. Proper electrical wiring.
This manual provides the information needed to
meet these requirements. Review all application and
installation procedures completely before continuing
the installation.
a. Remove the top ller plate, stamped “HOT”, by
slipping a ne-blade screwdriver into the slot at
the rear of the plate and gently prying it up (see
Figure 2).
b. Remove the two screws attaching the adapter
plate to the top assembly and lift it out (see
Figure 3).
c. Remove the vent cap or drafthood from its
package.
d. Disengage the ue transition ring from the stack
extension and place it on top of the collector
assembly as shown in Figure 4.
Figure 2. Top ller plate. Figure 3. Adapter plate.
Figure 4. Flue transition Figure 5. Vent cap with
ring. adapter plate
(outdoor).
2.2 Field Assembly
The Copper Brute heater is shipped from the
factory with the top assembly in the low-prole
conguration for outdoor installations.
The Copper Brute heater is design certied
for indoor installation when equipped with a
special drafthood, which must be installed without
modication. The part number for the drafthood is on
the heater rating plate. Follow this procedure to make
the conversion:
Figure 6. Drafthood with Figure 7. Drafthood switch
adapter plate receptacle.
(indoor).
Internet Version for Reference Only
Copper Brute B4 Volume Water Heaters
e. Slide the adapter plate over the bottom of the
stack extension as shown in Figure 5. Fit the
stack extension down over the ue transition
ring. Seat the adapter plate on the top assembly
and secure it with two screws (see Figure 6).
f. Indoor models, size 175 and 250 only, require
an adapter cable (included with product). The
cable connects the blocked vent safety switch
(BVSS) on the bell of the external draft hood to
the 6-position Molex plug on the side of the unit
(see Figure 7). Refer to instruction sheet included
with cable.
2.3 Site Location
2.3.1 Installation Information
Closet Installation
(unacceptable)
A closet is any 4 sided enclosure
which is less than 16* times the
total volume of all the gas red appliances within the enclosure.
Page 5
Room Installation
(acceptable)
A room is any enclosure which is
at least 16* times greater than the
total volume of all the gas red appliances within the enclosure
WARNING
Improper installation or maintenance can cause
nausea or asphyxiation from carbon monoxide
in ue gases which could result in severe injury,
property damage, or death.
Avoid placing the heater in locations where it can
be damaged by water or condensate leakage. If this is
not possible, provide a suitable drain pan to catch and
divert any leakage. The pan must not block natural
ow of air around the heater.
Locate the heater to provide adequate clearance
on all sides for inspection, service and to provide
adequate air circulation for proper operation.
Locate the heater so the clearances from
combustible surfaces shown in Table 1 and Figure 8
are met.
Locate the heater on a waterproof oor with a
oor drain and a 6 inch (152 mm) minimum curb on
all four sides to protect the building if heater repairs
are needed.
Indoors Outdoors
Clearance from: inch mm inch mm
Top 37 940 Unobstructed
Water conn. side 12 305 Unobstructed
Opposite side 6 152 6 152
Front Alcove Unobstructed
Rear 6 152 6 152
Vent* 6 152 —
Flooring Combustible Combustible
Service clearance = 36 inches (914mm) at front of heater,
and 18 inches (457mm) at water connection side.
*1" (25mm) if double wall vent is used.
Table 1. Minimum Boiler Clearances
from Combustible Surfaces.
Alcove Installation
(acceptable)
An alcove suitable for the installation of a heater is a restricted section of a room not separated from
the room by a door or partition and
which meets the minimum clearances specied in this manual.
* When the ceiling height exceeds 8 feet, you are only allowed to consider 8 feet when calculating the total volume of the enclosure.
Figure 8. Alcove installation.
2.3.2 Outdoor Installation
Caution
Outdoor installations are not recommended in areas
where the danger of snow blockage exists. Copper
Brute heaters can be installed in the standard lowprole, grate top conguration as received from the
factory, or with an optional vent cap.
Locate the heater in an open, unroofed area.
Do not locate the heater below or adjacent to any
doors, windows, louvers, grills, etc., which connect
in any way with an inhabited area of a building, even
though the access might be through another structure
such as a garage or utility room (see Figure 9 and
Table 1). There must be a minimum of 4 feet (1.22
m) horizontally and vertically between the heater and
any door, window, or gravity inlet to a building (see
Figure 10).
If the heater is installed close to a structure,
protect it from rain water runoff with rain gutters on
the roof or other measures. Do not locate the heater
near sprinkler systems that could spray water on it.
Avoid locations where wind deection off nearby
structures might cause wind loading and downdraft
conditions. Where downdraft conditions exist, locate
the heater at least 3 feet (0.91 m) from the structure.
Internet Version for Reference Only
Copper Brute B4 Volume Water Heaters
Page 7
WINDOW
OR GRILL
INDOOR
ROOM
WRONG
4 ft
(1.2m)
4 ft
(1.2m)
4 ft
(1.2m)
Page 6
Figure 9. Incorrect outdoor installation.
BRADFORD WHITE
Concrete slab must extend out
a minimum of 12 in. (305mm) on
all sides.
Bradford White
UNIT
(Side View)
Base For Combustible Floors
Roof - Wood and Steel Construction
Figure 11. Standard base for combustible oor.
Mounting Platform must extend
out a minimum of 12 in. (305mm)
on all sides.
Figure 10. Outdoor location installation.
2.3.3 Flooring - Typical Installation
Do not install the heater directly on carpeting
without placing a non-combustible platform between
the carpeting and the heater. If the heater is installed in
a carpeted alcove, the entire oor of the alcove must
be covered by a non-combustible panel. The panel
must be strong enough to carry the total weight of the
heater and all piping, pumps, and any other equipment
attached to the heater. For rooftop installation, see
Figure 11 through Figure 13.
Bradford White
20 Gauge
Galvanized
Sheet Metal
Cap
Roong
Figure 12. Typical roof mounting.
Base For Combustible Floors
Bradford White
(Side View)
UNIT
(Side View)
Raised Mounting
Platform (Wood)
UNIT
Base Rail
Flashing
Roof
Base Rail
20 Gauge
Galvanized
Sheet Metal
Cap
2.4 Combustion and Ventilation
Air Supply
All indoor installations must have openings to
outside air for combustion, ventilation and dilution of
ue gases from inside the building (see Figure 14 and
Table 2 ). Bradford White does not recommend indoor
installations that do not provide combustion air from
outside the building.
Base For Combustible Floors
Flashing 4x4 Stringer
Figure 13. Typical roof mounting with standard
combustible mount base.
Roof
Roong
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Copper Brute B4 Volume Water Heaters
10 ft.
(3.0m)
2 ft. (0.6m)
Listed
Vent
Cap
Storm Collar
Roof Jack
Adequate
Air Supply
To
Room
To
p and
Botom
1/14 in. (6mm)
Minimum Pitch
Per Foot of
Horizontal Pipe
Draf
thood
12 in.
(305mm)
All Sides
Vent terminated at
least 24 in.
(610mm) above
any object within
10 ft. (3.0m)
Page 7
Required Net Free Opening Area
Directly from Outside
At Top At Bottom
2
cm2
Mode in.2 cm2 in.
175 44 284 44 284
250 63 406 63 406
325 82 529 82 529
400 100 645 100 645
Note: For screens or louvers, add 50%.
Table 2. Air Openings to Outside.
Notes:
1. The drafthood must sit directly on top of the heater
as shown and must not be altered in any manner.
2. An Underwriters' Laboratories listed vent cap is re quired to eliminate downdraft and allow the heater
to function properly.
3. Use approved roof tting.
Figure 14. Indoor installation and venting.
requirements specify that the space shall communicate
with the outdoors in accordance with method 1 or 2,
In the United States, the most common
which follow. Where ducts are used, they shall be of
the same cross-sectional area as the free area of the
openings to which they connect.
Method 1:
Two permanent openings, one commencing
within 12" (30 cm) of the top and one commencing
within 12" (30 cm) of the bottom of the enclosure
shall be provided. The openings shall communicate
directly, or by ducts, with the outdoors or spaces that
freely communicate with the outdoors. When directly
communicating with the outdoors directly, or through
vertical ducts, each opening shall have a minimum
free area of 1 square inch per 4000 Btu/hr (550 square
mm/kW) of total input rating of all equipment in the
enclosure. When communicating to the outdoors
through horizontal ducts, each opening shall have a
minimum free area of not less than 1 square inch per
2000 Btu/hr (1100 square mm/kW) of total input rating
of all equipment in the enclosure.
Method 2:
One permanent opening, commencing within
12" (30 cm) of the top of the enclosure shall be
permitted. The opening shall directly communicate
with the outdoors or shall communicate through a
vertical or horizontal duct to the outdoors or spaces
that directly communicate with the outdoors, and shall
have a minimum free area of 1 square inch per 3000
Btu/hr (734 square mm/kW) of the total input rating of
all equipment located in the enclosure. This opening
must not be less than the sum of the areas of all vent
connectors in the conned space.
Other methods of introducing combustion and
ventilation air are acceptable, providing they conform
to the requirements in ANSI Z223.1, or applicable
codes.
In Canada, Table 2 does not apply. Consult
local building and safety codes or, in absence of such
requirements, follow CAN/CGA B149.
NOTE: Check with louver manufacturers for net
free area of louvers. If screens or louvers are installed,
add 50 percent for each screen/louver to the net free
area Check all local codes applicable to combustion
air.
2.4.1 Outdoor Air Supply
When combustion air comes directly through an
outside wall, each opening must have a minimum free
area of at least one square inch for each 4,000 BTU/h
input of the total input rating of all appliances in the
enclosed area. (In Canada, refer to CGAB149.1 and .2.)
2.4.2 Indoor Air Supply
Conned and non-conned areas have different
requirements for installation. Consult the latest edition
of the National Gas Code for installation requirements.
2.4.3 Exhaust Fans or Vents
Any equipment which uses air or removes air
from the heater room can use up the combustion air
supply or reverse the natural draft action of the venting
system. This could cause ue products to build up in
the heater room. More air must be supplied to make up
for the decrease.
Internet Version for Reference Only
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Copper Brute B4 Volume Water Heaters
Page 9
BRADFORD WHITE
2.5 Venting of Combustion Products
2.5.1 General Information
When installed indoors, the drafthood must be
connected to a venting system. The venting system
must be installed by a qualied installer and in
accordance with the latest edition of ANSI Z223.1. In
Canada, the installation must be in accordance with
CAN1-B149.1 or .2, and any local codes that apply.
The vent pipe must have a listed vent cap, and
extend at least 2 feet (0.6 m) above any object within a
10 foot (3.0 m) radius.
NOTE: Do not use sheet metal screws at the
snap lock joints of Type B double-wall gas vents.
Do not weld or bolt the vent pipe to the heater
drafthood. The weight of the stack must not rest on the
heater. The drafthood and heater top must be easily
removable for normal heater service and inspection.
WARNING
Avoid ending heater vents near air conditioning or
air supply fans. The fans can pick up exhaust ue
products from the heater and return them inside the
building, creating a possible health hazard.
Avoid horizontal runs of the vent pipe and 90
degree elbows, reductions, and restrictions. Horizontal
runs should have at least a 1/4 inch (6.3 mm) rise per
foot in the direction of ow. Support a vent connector
for the design and weight of the material used to
maintain clearances and physical damage and separate
of joints.
Always use double-wall or insulated vent pipe
(Type B or equivalent).
WARNING
In cold weather, uninsulated outside vents can
chill the rising ue products, blocking the natural
draft action of the venting system. This can create
a health hazard by spilling ue products into the
heater room.
Avoid oversize vent piping or extremely long
runs of the pipe which may cause too much cooling
and condensation of ue gasses.
When the installation of a power vent or draft
fan in the venting system is necessary, qualied
personnel should design the installation following
good engineering practices and all applicable codes.
A suitable draft switch must be wired into the heater
control circuit at the terminal designated Field
Interlock to keep the heater from ring unless there is
a positive draft.
2.5.2 Replacement of Existing Heater
When a heater is removed from a common
venting system, the venting system may be too large
for proper venting of the other appliances connected
to it.
If replacing an existing heater with a Copper
Brute heater and the existing heater was connected
to a common venting system, the common venting
system must comply with ANSI Z223.1/National Fire
Protection Association (NFPA) 54. When resizing any
portion of the common venting system, the common
venting system should be resized to approach the
minimum size as determined using the tables in
ANSI Z223.1/NFPA 54, Appendix G. In Canada, the
common venting system should be resized so the
installation will be in accordance with CAN/CGA
B149.1 or .2.
2.6 Water Flow
2.6.1 Reversible Water Connections
Bradford White ships the heater with the
water connections on the right side. The heater can
be installed with the water connections on either
side. It could be necessary, or helpful, to switch the
connections to the left side to improve access for
installation service. Have a professional service
technician perform this modication before installing
the heater using the following procedures:
1. Remove the front cover.
2. If there is a vent cap or drafthood installed, they
must be removed before removing the grate top
assembly. On indoor installations (sizes 175-
250), the drafthood switch must be disconnected
at the left side of the heater.
3. If the unit is in the low-prole outdoor
conguration, remove the hex-head screws
(see Figure 15) and lift the grate top assembly
straight up.
4. Remove the screws that fastens the ue collector
holddown clamps and remove the clamps (see
Figure 16).
5. Remove the ue collector assembly by lifting it
out of the chassis.
6. Remove the screws that fastens the gap closures
and put them aside.
7. Remove the three grommets.
8. Remove the drain valves and plug. There is one
hex plug on the left side, near the rear of the
jacket. The drain valves are located on the left
side and right side of the heater (see Figure 15).
9. Remove the four screws that fastens the metal
channels covering the capillary tube on the right
side of the jacket, and lay the channels aside.
Internet Version for Reference Only
Copper Brute B4 Volume Water Heaters
Clamp
Bracket
Heat
Exchanger
Bracket
In/Out Header
Clamp
Flue Collector
REAR TILE COVER
FLOW SWITCH
CONDUIT
GAP CLOSURE
GROMMET
DRAIN
VALV
E
METAL CHANNEL
(FOR CAPILLAR
Y TUBE)
TERMINAL STRIP
HEAT EXCHANGER
ASSEMBLY
GAP CLOSURE
DRAIN PLUG
DRAIN VALV
E
REAR TILE
COVER
HEX HEAD
SCREWS
MANUAL RESET
HIGH LIMIT
SWITCH BOX
Page 9
Figure 15. Heat exchanger reversal.
Figure 16. Flue collector Holddown Clamps.
Internet Version for Reference Only
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Copper Brute B4 Volume Water Heaters
Page 11
3.1 in.
(79mm)
2.4
in.
(61mm)
2.4
in.
(61mm)
Attach Capillary
Covers
on
Left Side
LEFT
0.9 in.
dia
(23mm)
(Two holes)
FRONT
1.9 in.
(48mm)
Retaining
Clip
2-Stage/
Operating
Controller
Header
Modulating (if
installed)
Inlet Oulet
High Limit
BRADFORD WHITE
10. In the control compartment, nd the manual reset
high-limit switch box (see Figure 15) and loosen
the screw on the top to remove the cover.
11. Loosen the screw that fastens the white wire and
remove it from the terminal. Pull it out through
the top of the case and separate the other white
wire from the red wire coming from the fuse
Figure 17. Sensory bulb locations.
Figure 18. Retaining clip removal.
Figure 19. Hole location, left side.
holder. Gently pull the two white wires out of the
control compartment and coil them on top of the
heat exchanger.
12. A temperature control sensing bulb is located
in the front of the header on the inlet side and a
manual reset hi-limit sensing bulb is located on
the back side of the header on the outlet side (see
Figure 17). Remove these sensing bulbs from the
header. The following steps for removal apply to
all sensing bulbs:
a. If there is more than one capillary tube coming
out of the header, label the capillary tubes.
b. Loosen the screw on the capillary tube
retaining clip, then gently pry the clip apart
until it comes free from the temperature
control (see Figure 18).
c. Pull the sensing bulbs out of the temperature
control.
d. Gently pull the capillary tubes into the control
compartment.
e. Pull the temperature sensing bulb out of the
header, and temporarily route it to the front of
the heater.
13. Use a pair of diagonal cutters to cut the plastic
tie around the wire bundle in the control
compartment.
14. On the terminal strip, disconnect the two brown
wires from No. 5 and No. 6 terminals.
15. Remove the ow switch conduit retaining clip
and the elbow leading into the jacket.
16. Reach inside the control compartment and
release the retaining nut in the upper right corner.
The nut should only be nger-tight.
17. When the conduit is pulled away from the jacket,
pull the two brown wires out of the control
compartment. Coil the conduit and wires on top
of the heat exchanger.
18. Use a chassis punch to put two 7/8 inch (22
mm) holes in the front left side of the jacket (see
Figure 19).
19. Remove the front and rear tile covers (see
Figure 15).
20. Lift out the heat exchanger assembly, turn it 180
degrees, and reseat the unit in the heater with the
water connections on the left side.
21. Reinstall the front and rear tile covers.
22. Push the capillary tube(s) out through the lower
hole in the left side of the jacket.
23. Install the sensing bulb(s) into the appropriate
temperature control (keep in mind that the
positions of the inlet and outlet have been
reversed. The inlet is now behind the outlet).
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