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Form No. PMG-60M-0705
21
MAINTENANCE
j.
Close the drain valve under the booster
heater and turn the water supply ON
checking for leaks at all fittings.
k. Connect wiring to new pump motor and install
wiring compartment cover.
l.
Purge the air from the system. Turn on the
electrical supply and allow pump to displace
air out of the heat exchanger and holding tank
by running several rinse cycles on the
dishwashing machine. Test all connections
for tightness.
m. Turn on gas supply (CHECK ALL FITTINGS
FOR LEAKS) and follow start-up procedures.
6. Temperature/Pressure Gauge Replacement
a. Shut off electrical power to the heater.
b. Shut off water supply and open drain valve to
remove water in the piping.
c. Remove temperature/pressure gauge from
pipe fitting connection.
d. Reverse above procedure to re-install.
7. Temperature/Pressure Relief Valve Replacement
a. Shut off electrical power to the heater.
b. Shut off water supply and open drain valve to
remove water in the tank below the relief
valve level.
c. Disconnect drain pipe from valve.
d. Remove temperature/pressure relief valve.
e. Reverse above procedure to re-install.
8. Low Water Cut Off Replacement
a. Shut off electrical power to the heater.
b. Remove screws for electronics cover and
slide out front.
c. Mark wires and disconnect from old module.
d. Reverse above procedure to re-install.
9. Tank High Limit Replacement
a. Shut off electrical power to the heater.
b. Shut off water supply and open drain valve to
remove water in the piping and pump.
c. Remove screws for electronics cover and
slide out front.
d. Remove limit from enclosure,
disconnecting leads.
e. Loosen 3/8" (10 mm) tank fitting packing nut
then remove fitting.
f. Reverse above procedure to re-install.
10.Orifice Replacement (for High Altitude Orifice
Size Change or Orifice Repair)
a. Shut off electrical power and gas supply to
the heater.
b. Remove front panel.
c. Disconnect gas supply line at the internal
union located after the regulator valve.
d. Remove four (4) screws holding manifold to
combustion chamber.
e. Slide manifold assembly out.
f. Unscrew brass orifices from the black
distribution manifold.
g. Install new orifices as required.
NOTE: If this is a high altitude change, refer to
the tables in the HIGH ALTITUDE
INSTALLATION & OPERATION section for the
appropriate diameter to drill the orifice blanks for
your elevation.
h. Reverse the procedure above to re-install,
checking burners and seals to prevent gas
leaks.
11. Heat Exchanger Replacement
a. Shut off gas supply.
b. Shut off electrical supply.
c. Shut off water supply.
d. ALLOW UNIT TO COOL DOWN TO ROOM
TEMPERATURE.
e. Open the drain valve under the booster
heater to remove water from the tank and
pump assembly.
f. Remove front cover and shut off internal
gas valve.
g. Drain water from the heat exchanger drain
plug into pan or tray (less than 16 oz. [498 g]).
h. Unwrap insulation from front of the heat
exchanger.
i.
Mark and disconnect water lines from the
heat exchanger. Use a second backup
wrench on the fittings, discard used washers
(new ones are provided).
j.
Disconnect gas manifold union.
k. Disconnect pilot line from gas valve.
l.
Disconnect wire leads to high limit on side of
the heat exchanger.
m. Remove top three (3) screws of inner flue
access cover.
n. There are four (4) screws holding the
manifold to the burner assembly remove the
top two (2) screws.
o. Slide the burner out of the heat exchanger.
p. Slide the heat exchanger assembly out of
the booster.
g. Remove pump motor cover and disconnect
wiring connections to the pump motor.
h. Remove bolts and nuts holding pump
assembly to flanges (save bolts and nuts).
i.
Install new pump assembly using new
O-rings (supplied with pump assembly)
starting with lower bolts first (FLOW ARROW
MUST POINT UPWARD).
Summary of Contents for POWERMITE PMG-60
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