Nature Of The Problem
The flexible connector manufacturer has informed us that excessive vibration can result in failure of their connector. We have conducted extensive testing to determine that the vibration on certain models of barn (principally BulkTobac and Long) can lead to failure of the connector. In the interest of safety, regardless of the model of barn, the existing connector must be replaced on all HeatX units.

Solution
We have tested and approved a new copper connector assembly to replace the existing flexible connector between the control arm and the burner. The connector is available at no charge. We will pay $10.00 per connector for the inconvenience of changing the connector unless BulkTobac service personnel carry out the work.

Please find attached the instructions for the removal of the existing flexible connector and the replacement with the new copper connector assembly. The process takes approximately 10 minutes per barn.

HeatX Copper connector assembly and warning label installation instructions

Tools Required: wrenches (7/8", 3/4", 11/16") or 2 adjustable wrenches, bottle of soapy water, 1/4" nut driver.
Parts Required: Copper connector retrofit kit PN: 61778040, 1 x thread sealant stick per shipment.

Before removing the existing flexible metal hose cut off the gas supply to the manifold and turn off the electrical supply to the burner controls. The shut off valve is located at the top of the control arm, see figure 1 below for "off" position.

STEP 1. Holding the connector bodies in place with a wrench unscrew the retaining nut on the ends of the flexible hose. See figure 2 below.

STEP 2. Unscrew the connector bodies from the elbow at the burner and the gas control arm. Unscrew the elbow and orifice holder assembly from the burner. The complete orifice holder will be removed. Check that the orifice is tight in the holder. Screw the orifice holder back into the burner and align the elbow to toward the control arm.

STEP 3. Apply the thread sealant provided onto the new connector body ends as shown below. Note: only apply sealant to the ends that go into the elbow and the gas manifold. See figure 3 below.

STEP 4. Screw the connector bodies into the elbow at the burner and the gas control arm. Tighten them securely with a wrench.

STEP 5. Loosen the screws securing the control arm mounting bracket as shown in figure 4 below.

STEP 6. Take the copper tube assembly and push back the Viton seal about 1/4" from both ends. Fully insert the ends of the copper tube into the connector bodies as shown in figure 5 below. The copper tube can be bent slightly to fit into the connectors. DO NOT crimp or over bend the copper tube.

STEP 7. Screw the retaining nuts onto the connector body. Take care not to put too much pressure on the orifice holder. Bend the copper tube to relieve any pressure as necessary. With a wrench holding the connector bodies in place, tighten the nuts securing the gas line using another wrench.

STEP 8. Using the burner alignment gage shown in figure 6 below, check that the orifice holder is square to the burner mounting plate. The alignment of the burner is essential to prevent direct flame contact with the firing tube, which will result in premature failure of the heat exchanger.

If the orifice holder is out of square apply pressure to realign it. It may be necessary to disconnect the control arm end of the copper tube and reform the bend in the copper tube to relieve the pressure on the connection.

STEP 9. Tighten the control arm assembly mounting brackets and recheck the burner alignment.

STEP 10. Open the manual gas shut off valve at the top of the manifold. Turn on the power to the burner.

STEP 11. With the burner in operation check the new connector for leaks by spraying the soap water solution onto the threaded connections. If any bubbles indicating a gas leak are present turn off the burner immediately and turn off the gas supply. To repair any leaking connections repeat the above sequence and increase the application of thread sealant.

STEP 12. Remove the existing warning labels on the ignition control box and replace them with the combination hazard label PN 42834160. Position the fire hazard label PN 42834150 as shown in figure 7 below.

STEP 13. On the rating plate locate the serial number. Write the serial number on the Certification Form. After all the barns are completed mail the form to us using the postage paid envelope provided with the kit.