Hatco pmg-60m-0705(7) User Manual

Form No. PMG-60M-0705

21

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.

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).