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primary heat exchanger (# 401) to the
secondary heat exchanger (# 418). Note
the loca on and orienta on of the two
metal compression brackets (# 421 &
#422).
Remove the screw securing the
27
igniter
fi xing
plate
Carefully set the igniter fi xing plate
assembly and screw aside for re-
installa on.
Remove the eighteen screws
28
securing the plas c exhaust duct
(# 431) to the secondary heat exchanger.
Replacing the secondary heat
exchanger:
WARNING! The heat exchanger
assembly must be properly installed to
prevent exhaust gases from leaking.
Failure to follow can cause carbon
monoxide poisoning or death.
With the new secondary heat
29
exchanger (# 418) res ng upside
down on a solid surface. Check the gasket
for any cuts or imperfec ons. Place the new
gasket (# 432) on the bo om of the new
secondary heat exchanger and verify the
screw hole alignment. Secure the plas c
exhaust duct to the secondary heat
exchanger with the eighteen screws
removed earlier. Hand ghten all screws
and check to make sure all screws are fully
seated.
Reinstall the igniter fi xing plate
30
(# 711) to the secondary heat
exchanger using the screw removed
earlier.
Reinstall both header connec ons
31
(# 472 & # 473) to the secondary
heat exchanger using the screws
removed earlier. Inspect the O-rings, if
any cuts or nicks are present replace
them immediately. See Figure 68 for
correct orienta on of the fi ngs.
Inspect the gasket (# 420)
32
58
•
On-Demand Water Heater Service Handbook for X3P Models
a ached to the bo om of the primary
heat exchanger (# 401). Replace it if any
cuts or any other issues are present.
This gasket is 2 pieces. Take care to
make sure there isn't a gap between the
gaskets where they line up. A ach the
Primary Heat Exchanger to the top of
(#711).
the Secondary Heat Exchanger. Check
alignment of the screw holes. Using the
ten screws and two metal compression
brackets (# 421 & # 422) secure the
Primary
Heat
Secondary Heat Exchanger. NOTICE:
Hand ghten all screw connec ons, do
not use an electric screwdriver or drill.
Re-a ach the support bracket to the
primary heat exchanger with the three
screws removed earlier.
Reconnect the copper pipe
33
(# 467) using the 16-25A metal
fastener. Use the provided O-ring.
Inspect the O-rings if any cuts or nicks
are present replace it immediately. See
Figure 68 on page 57.
Rea ach the green and gray wires to
34
the igniter rod. Route the green wire
through the cable guides on the front of the
primary heat exchanger. See See Figure 69
on page 57.
NOTICE: Read this step carefully
35
before performing any ac ons.
To assist with installa on have one of
the screws that secures the side
connec on of the heat exchanger
assembly affi xed to the long magne c
p screwdriver and within easy reach.
Li the heat exchanger assembly and lt
the top back and slide it in and up. The
top of the plas c exhaust duct will mate
with the exhaust port on the top of the
water heater enclosure. The heat
exchanger assembly must then be
supported by hand, while installing the
screws securing it to the enclosure. See
See Figure 67 on page 57. Use the
magne c screwdriver with the screw
already affi xed to it to secure the assembly.
Install the remaining screw to the side
bracket. Next install the four screws that
secure the moun ng bracket to the back
of the water heater enclosure.
exchanger inlet. See See Figure 63 on
page 56. Use the 16-25A metal
fastener. When placing the fastener,
posi on the top (fl at sec on) of the
Exchanger
to
the
fastener to the ten o' clock posi on.
heat exchanger.
O-ring. Inspect the O-ring, if any cuts or
nicks are present replace it immediately.
Use the 6-15 metal fastener removed
earlier. See Figure 62 on page 56.
outlet and the water outlet tee. Inspect
the O-rings, if any cuts or nicks are
present replace them immediately. Use
the 16-25A metal fasteners removed
earlier. See Figure 61 on page 56.
Exchanger inlet pipe. See Figure 65 on
page 57.
assembly (# 112). Secure it with the two
screws removed earlier. See Figure 57 on
page 56.
Reference the wiring diagram on page
28 or in the maintenance sheet for
placement.
the special tab must be facing outward.
Reconnect the copper pipe
36
(#466) to the secondary heat
Reconnect the rubber drain line
37
to the bo om of the secondary
Reconnect the small copper drain
38
pipe (# 465). Use the provided
Reconnect the copper pipe (# 468)
39
to the primary heat exchanger
Reconnect the ceramic block
40
heater from the Primary Heat
Rea ach
the
fan
41
assembly to the mixing chamber
Connect the Fan Blower motor
42
wire to the computer board.
Reconnect the fl ame rod connector
43
(Yellow wire). When connec ng
blower
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