TroubleshootingGuide
29|Page
REPLACINGTHEHEATEXCHANGER
Therearemanypossiblecausesofaheatexchangerfailure:
• Contaminated air with a high level of dust, lint, sand, grease, aerosols or other contaminants,
can become airborne and enter the air intake.The contaminants build up within the fan and
burner assembly causing abnormal flame conditions due to
lack of combustion air, damaging
manycomponentsoftheunit.
• Scalecanbuildupfromveryhardwater.Limescalewillformontheinsideoftheheat
exchangertubesreadilyathightemperatures.Thisscaleprohibitsheatfromreachingthewater
whichcausesexcessiveheatwithintheheatexchanger
copper,anditwilleventuallyburnand
leak.
Alongwithchangingtheheatexchanger,itisimportanttoidentifytheCAUSEoftheneedfor
replacement,andfixtheproblemsoitdoesnotoccuragain
1) TOOLS
‐Gatherthefollowingmaterialstogether:
a. Degreaserinapumpactionbottle
b. Sheetof100GritSandpaper
c. #2 PhilipsScrewDriver
d. Needle‐NosedPliers
e. DuctTape
f. Flashlight
g. AirCompressor
h. OldTowels,atLeastThree
2) PREPARETHEUNIT
a. POWER
‐Disconnectpowertoyourunit.
b. GAS
‐Shutoffthegassupplytotheunit.
c. WATER
–Draintheunit.Refertop.21forinstructions.
3) REMOVEMANIFOLD/GASASSEMBLY,BURNER
a. Followsteps1‐7oftheprevioussection,“CleaningtheCombustionComponents”.Thiswill tell
youhowtoremovethePCB,manifold/gasassembly,andburner
4) WIRES
‐Thereareseveralwireclipsthatneedtoberemovedtofreetheheatexchanger
a. LocatethebrownwireclipconnectedtotheGFI,anddisconnectit.
b. Onthebottomlef t, disconnecttheceramicheatingelements(whitewires).
c. Locatethewhitebypassva lveclipontheleft‐
handsideofthecombustionchamberwith
red/blackwires.Disconnectit.
d. Upwardstowardtheleftside,removeablueconnectiontotheover‐heatcutofffuse
e. Removethetwospadeconnectionsonthehighlimitswitch.
f. Disconnecttheigniterplug(purplewiresandblueplug)atthe
bottomright.
g. Alongthebottom,disconnecttheplugintotheproportionalvalve(red&whitewires).
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