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Fill Update V2.1

Minor Versionm

by Jonathan Paul Doerr

  1. Disconnect the steam module from power cord, tap lines, drain tubing and water inlet. Use a 2.5 mm hex wrench or a #2 phillips (depending on age of module) to remove the screws holding the top panel, both side panels and the back panel that holds the fan. Use a 2.5 mm hex wrench or a #2 phillips (depending on age of module) to remove the screws holding the top panel, both side panels and the back panel that holds the fan.
    • Disconnect the steam module from power cord, tap lines, drain tubing and water inlet.

    • Use a 2.5 mm hex wrench or a #2 phillips (depending on age of module) to remove the screws holding the top panel, both side panels and the back panel that holds the fan.

  2. Probe Locations change with build revisions. Disconnect the fill and safety probe connectors. Disconnect the temperature probe connection.
    • Probe Locations change with build revisions.

    • Disconnect the fill and safety probe connectors.

    • Disconnect the temperature probe connection.

    • With the P2 connections removed removed, detach the green P2 phoenix connector from the main board.

  3. Relocate fill probe to the far end of the boiler away from the heating element. Replace the fill probe with the probe provided with the kit
    • Relocate fill probe to the far end of the boiler away from the heating element.

    • Replace the fill probe with the probe provided with the kit

    • use provided cap and crush washer to seal the unused port.

  4. Attach RTD probe wire to new P2 phoenix connector as shown. Insert the provided P2 phoenix connector into the main board and attach lead to the temperature probe.
    • Attach RTD probe wire to new P2 phoenix connector as shown.

    • Insert the provided P2 phoenix connector into the main board and attach lead to the temperature probe.

  5. Disconnect fill solenoid wiring connector from fill valve disconnect fill valve wiring from the board.
    • Disconnect fill solenoid wiring connector from fill valve

    • disconnect fill valve wiring from the board.

    • If steam module has the AC Power Board adapter attached at the P2 port, remove and discard as this is no longer needed.

    • We will come back to the valve wiring later

  6. Attach Gicar RL30 box to electronic enclosure with the provided bolt. Pair wires from the Gicar fill box to their counterparts on the 5v power supply.  Green with green, blue with blue and black with black. Once completed, wiring should resemble picture 3.
    • Attach Gicar RL30 box to electronic enclosure with the provided bolt.

    • Pair wires from the Gicar fill box to their counterparts on the 5v power supply. Green with green, blue with blue and black with black.

    • Once completed, wiring should resemble picture 3.

  7. Wires numbered 6,5 and 4 terminate at the 5VDC power supply as shown in previous step. Wire 3 is the fill probe wire. attach the other end of the wire to the fill probe once the probe has been relocated.
    • Wires numbered 6,5 and 4 terminate at the 5VDC power supply as shown in previous step.

    • Wire 3 is the fill probe wire. attach the other end of the wire to the fill probe once the probe has been relocated.

  8. Locate the chase in the electronics enclosure lace solenoid control wiring through the chase
    • Locate the chase in the electronics enclosure

    • lace solenoid control wiring through the chase

  9. Wire 2 is a grey wire that terminates at the negative 24VDC terminal at the 24VDC power Supply (V-). Wire 2 is a grey wire that terminates at the negative 24VDC terminal at the 24VDC power Supply (V-).
    • Wire 2 is a grey wire that terminates at the negative 24VDC terminal at the 24VDC power Supply (V-).

  10. Wire 1 is a grey wire that terminates at the fill valve and should be connected in the the solenoid boot. Crimp an insulated connector )E-0059-01) on wire to plug into the Gicar fill control.
    • Wire 1 is a grey wire that terminates at the fill valve and should be connected in the the solenoid boot.

    • Crimp an insulated connector )E-0059-01) on wire to plug into the Gicar fill control.

  11. The fill valve +24VDC wire is red and terminates at the 24VDC power supply positive terminal (V+). The fill valve +24VDC wire is red and terminates at the 24VDC power supply positive terminal (V+).
    • The fill valve +24VDC wire is red and terminates at the 24VDC power supply positive terminal (V+).

  12. Review your wiring
    • Review your wiring

    • Loation 6: Black wire - terminates at the 5VDC power supply where an existing black wire is already in place

    • Location 5: Blue Wire - terminates at the 5VDC power supply where an existing blue wire is already in place

    • Location 4: Green and yellow wire - terminates at the 5VDC power supply where an existing green and yellow wire is already in place

    • Location 3: Grey wire - terminates at the fill probe

    • Location 2: Grey wire - terminates at the 24VDC power supply negative terminal (-V)

    • Loation 1: Grey wire - terminates at the ODE fill valve solenoid

    • not shown in image - Red wire from the ODE solenoid will terminate at the 24VDC power supply positive terminal (+V)

  13. You will need to update the Fill valve to the ODE fill valve to complete this update. Follow this link to  Steam Update Kit (AS-0078-01)
  14. Remove steam outlet tube(s). Remove steam outlet tube(s).
    • Remove steam outlet tube(s).

  15. Locate the terminal connector that joins the fill valve wiring to the wiring harness.  Using a small flat driver,  loosen the terminal screws and remove the valve wiring. Loosen the nut attaching the fill valve assembly to the water inlet connection on the back manifold using a 17mm wrench. Loosen the nut attaching the fill valve assembly to the steam boiler with a 17mm wrench.
    • Locate the terminal connector that joins the fill valve wiring to the wiring harness. Using a small flat driver, loosen the terminal screws and remove the valve wiring.

    • Loosen the nut attaching the fill valve assembly to the water inlet connection on the back manifold using a 17mm wrench.

    • Loosen the nut attaching the fill valve assembly to the steam boiler with a 17mm wrench.

  16. Carefully remove the fill valve assembly from the module. It is easiest to tilt and slide the assembly toward the back of the module and slide out of the right hand side of the module.
    • Carefully remove the fill valve assembly from the module. It is easiest to tilt and slide the assembly toward the back of the module and slide out of the right hand side of the module.

  17. The arrow on the valve body should point against the incoming flow of water note the directional flow of the check valve stage tubing, check valve and valve orientation for installation
    • The arrow on the valve body should point against the incoming flow of water

    • note the directional flow of the check valve

    • stage tubing, check valve and valve orientation for installation

    • Don't tighten the connections until the components are staged properly.

  18. Tighten connections and  ensure that the boiler inlet tube connection approaches the inlet fitting at approximately a 2 o'clock position . Stage the ODE valve into the module. Tighten the fitting to the inlet manifold first. Then connect the inlet tube to the boiler.
    • Tighten connections and ensure that the boiler inlet tube connection approaches the inlet fitting at approximately a 2 o'clock position .

    • Stage the ODE valve into the module. Tighten the fitting to the inlet manifold first.

    • Then connect the inlet tube to the boiler.

  19. With tubing secure, connect solenoid boot to the solenoid. Locate the chase at the base of the electrical compartment Lace the solenoid wires through the chase to connect to the Gicar fill control
    • With tubing secure, connect solenoid boot to the solenoid.

    • Locate the chase at the base of the electrical compartment

    • Lace the solenoid wires through the chase to connect to the Gicar fill control

  20. check your work.
    • check your work.

    • Make sure your level probe height is set.

    • Reinstall module and turn power to position 1 to fill.

    • Turn to position 2 to heat.

Finish Line

One other person completed this guide.

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Member since: 07/22/2014

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