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Heat Exchanger Reversal
Procedure for Residential Models
1. Remove right and left side access panels. See
Figure 26.
Figure 26. Access Panels
2. Disconnect wires at high limit, AGS (automatic gas
shut-off), water pressure switch on the in/out header,
and ProTek Shield bonding wire. See Figure 27.
Figure 27. Component Wiring Locations – In/Out Header
3. Remove the thermostat temperature sensor by
loosening the compression fitting nut. Re-route the
sensor to left side of the heater. See Figure 28.
Figure 28. Thermostat Temperature Sensor Location
4. Remove (12) nuts holding the inlet/outlet and return
headers to the tube sheets. Clean off tube sheet
area where the gasket seats. Also clean off the
header and the gasket. Apply a non-petroleum-
based lubricant to the gasket such as Aqualube.
Re-attach the headers to the opposite sides, making
sure they are installed in an upright position. Do not
over-tighten. Torque should not exceed 7 ft/lb. See
Figure 27.
5. Reconnect high limit, AGS, water pressure switch
wires, and ProTek Shield bonding wire.
6. Insert the temperature sensor into the compression
fitting, so that the sensor is flush with the top of the
fitting. Tighten 1/2 turn past hand-tight.
7. Allow for water flow through the heater and check for
leaks.
8. Re-attach access panels to the opposite sides.
For instructions on reversing the heat exchanger
connections on ASME models, call your factory
representative.
F10652
5. ELECTRICAL WIRING
NOTE: If it is necessary to replace any of the original
wiring, use 105°C wire or its equivalent, and/or 150°C
wire or its equivalent, like the original wiring.
A
WARNING: Digital heaters are factory-wired for
240 VAC, 1Ph, 60Hz power supply. DO NOT attempt to
operate at 208 VAC.
The standard field-wiring connection is on the right side of
the heater.
To wire the heater from the left side, follow these steps:
1. Remove the two (2) screws that hold the front door
to the heater. Remove and set aside door for better
access to wiring.
F10653
2. Remove the four (4) screws that hold down the
junction box to the sway brace.
3. Remove the transformer cover located on the far
right by removing one (1) screw.
4. Remove the two (2) screws that hold down the
transformer.
5. Remove the one (1) screw that holds down the
ground wires.
6. Disconnect P6 connector from PC board.
7. Remove transformer from its current location and
relocate it on the far left side of the heater.
8. Re-route all high-voltage wires and ground wires
through the left jacket side of heater.
F10654
9. Re-install P6 connector, ground wires (SPG),
transformer, junction box, front door, and plug right
side with the left side's grommet plug.
NOTE: 7/8" diameter holes not utilized on jacket and
control box can be used for fireman switch, auxiliary
control interface or power vent (D-2) wiring.
19
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