HYDROQUIP BX9431 Double Barrel Heater Gasket Kit Instructions

: June 13, 2024
: HYDROQUIP

Table of Contents

HYDROQUIP BX9431 Double Barrel Heater Gasket Kit
Product Information
1)_
Kit contains
Tools required
INSTRUCTIONS
5)**
Trouble shooting gasket leaks
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

HYDROQUIP BX9431 Double Barrel Heater Gasket Kit

Product Information

Double Barrel Heater Gasket Kit #48-0041A-K

Kit Contents	Tools Required

4 Gaskets
2 Sensor O-rings
2 3/4 Barb O-rings| Phillips Screwdriver
Clean Rag

Attention: Service repair to the spa and/or heater should be performed by a qualified technician or licensed electrician. These instructions must be provided to the person performing the work. Read this entire instruction prior to starting work. If you do not understand these instructions or are unable to perform the steps required to replace the gaskets, STOP! and contact your heater provider for assistance.

Attention: Product damaged by incorrect installation, alteration, or freeze damage is not covered under warranty.

Step 1: Accessing the heater

The spa water must be drained to perform this repair.
Completely disconnect the power to the spa by turning off the spa’s electrical breaker.
In addition to removing the plumbing hoses from the heater, you need to disconnect the electrical cord from the spa control.

It is important to mark and note where and how wires and plumbing hoses are connected to accurately reconnect.
Incorrect placement of wiring or plumbing hoses may lead to spa system or heater malfunction, circuit board damage, and water leaks, and pose a potential hazard to the spa user.

_DO NOT remove the hex screws from the foot brackets for this service (DIA.

1)_

Step 2: Removing gaskets from manifold (Refer to DIA. #1 for item and location)

Remove 6 stainless screws from the turn-around manifold with a Philips screwdriver.
Pull to remove the manifold from the heater tubes.
Discard existing gaskets and wipe the tubing clean with a rag.

Step 3: Installing new gaskets on the Manifold

Inspect that gaskets and tube ends are clean and grease-free prior to assembly.

Dry fit new gaskets into manifold body then insert tubes (DIA. #1- #2). Caution, do not apply lubricant or sealant on gaskets or tubing. The Turn-Around Manifold is universal and has no upside.
Lay down the rag and place the heater on the end pushing against the ground to keep the manifold in place while inserting the stainless screws through Foot Bracket and into the pre-drilled holes (DIA. #2).
To ensure an expert seal, hand-tighten screws in the recommended harmonic pattern (DIA. #3) until snug.
Warning: Using a drill driver may apply too much torque and strip out the manifold holes voiding the warranty.
DIA #1
DIA #2
DIA #3
SENSOR FITTING O-RINGS
DIA #5
O-RINGS 3/4 Barb Fittings

Step 4: Removing gaskets from heater body (Refer to DIA. #4 for item and location)

Remove 6 stainless screws from the heater body with a Philips screwdriver.
Pull to separate the body from the heater tubes.
Discard existing gaskets and wipe the tubing clean with a rag.

Step 5: Installing new gaskets on the heater body (Refer to DIA. #4)

Inspect that all components are clean and grease-free prior to assembly.

Dry fit new gaskets into the body then insert tubes (DIA. #4). Caution, do not apply lubricant or sealant on gaskets.
Use DIA. #3 for a recommended harmonic pattern to tighten screws until snug.
Do not loosen or remove Hex Screws from the foot bracket (DIA. #1).

Kit contains

4 Gaskets
2 Sensor O-rings
2 3/4” Barb O-rings

Tools required

Phillips Screwdriver
Clean Rag

ATTENTION! Service repair to the spa and/or heater should be performed by a qualiﬁed technician or licensed electrician. These instructions must be provided to the person performing the work.
Read this en re reinstruction prior to starting work. If you do not understand these instructions or are unable to perform the steps required to replace the gaskets, STOP! and contact your heater provider for assistance.
ATTENTION! Product damaged by incorrect installed on, altera on, or freeze damage is not covered under warranty

INSTRUCTIONS

Step 1 Accessing heater

A. The spa water must be drained to perform this repair.
B. Completely disconnect power to the spa by turning oﬀ the spa electrical breaker
C. In addition to removing the plumbing hoses from the heater, you may also need to disconnect the electrical cord from the spa control

IT IS IMPORTANT to mark and note where and how wires and plumbing hoses are connected to accurately reconnect. Incorrect placement of wiring or plumbing hoses may lead to spa system or heater malfunctioning, circuit board damage, water leaks, and pose a potential hazard to the spa user.

DO NOT remove the “hex screws” from the foot brackets for this service (DIA. #1)

Step 2 Removing gaskets from manifold (Refer to DIA. #1 for item and loca on)

A. Remove 6 stainless screws from turn around manifold with a Philips screwdriver
B. Pull to remove manifold from heater tubes
C. Discard existing gaskets and wipe tubing clean with a rag

Step 3 Installing new gaskets on the Manifold
Inspect that gaskets and tube ends are clean and grease-free prior to assembly

A. Dry ﬁt new gaskets into manifold body then insert tubes (DIA. #1- #2). Cau on, do not apply lubricant or sealant on gaskets or tubing. The Turn-Around Manifold is universal and has no upside
B. Lay down the rag and place the heater on the end pushing against the ground to keep the manifold in place while inserting the stainless screws through Foot Bracket and into the pre-drilled holes (DIA. #2)
C. To insure an expert seal, hand the screws in the recommended harmonic pattern (DIA. #3) un l snug
WARNING! Using a drill driver may apply too much torque and strip out the manifold holes voiding the warranty

Step 4 Removing gaskets from heater body (Refer to DIA . #4 for the item and loc an on)

A. Remove 6 stainless screws from the heater body with a Philips screwdriver
B. Pull to separate body from heater tubes
C. Discard existing gaskets and wipe tubing clean with a rag

Step 5 Installing new gaskets on heater body (R ef er to DIA. #4)

A. Inspect that all components are clean and grease-free prior to assembly
B. Dry ﬁt new gaskets into the body then insert tubes (DIA. #4). Cau on, do not apply lubricant or sealant on gaskets
C. Use DIA. #3 for recommended harmonic pern to tighten screws un l snug
D. Do not loosen or remove “Hex Screws” from the foot bracket (DIA. #1)

**Step 6 Replacing all Sensor and 3/4” Barb Fi ng O-Rings (Refer to DIA.

5)**

A. Remove sensor ﬁngs using 1/2” open-end wrench turning counterclockwise.
B. Lightly lubricate the new O-rings with non-drying lubricant (silicone lube etc.) before installing.
C. R e-thread sensor ﬁngs back into the heater body ﬁnger gh t. Use a wrench to tighten the sensor ﬁng maximum 1/2 turn WARNING sensor ﬁngs can break if overtightened.
D. R emove 3/4” Barb ﬁngs, replace O-rings, and Lightly lubricate the new O-rings with non-drying lubricant (silicone lube, etc.) before installing. Re-install 3/4” Barb ﬁngs.

Step 7 Re-installing heater and testing for leaks

A. Place heater and reconnect water supply hoses and electrical in the same fashion as removed in step 1
B. Fill the spa and turn the power supply on at the breaker
C. Program the spa heater pump “on” and conﬁrm water ﬂow through the heater
D. Inspect heater for leaks coming from gaskets

Trouble shooting gasket leaks

Gaskets can be removed and reinstalled again using these steps. Leaks can be caused by dented or bent tube ends, tubes not completely inside the manifold or body, loose screws, debris between tube and gaskets, and lubricants placed on tubes.