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INSTRUCTIONS TO INSTALL

SPARK IGNITER AND SENSOR HARNESS ON

DH/1-40 (CE MARK) KETTLE

Part No. 153013

DH/1-40 SPARK IGNITER AND SENSOR HARNESS

2

1) Disconnect gas and electric power supply to the unit.

2) List of Parts in the Kit

Bill of Material for Part Number 153014 - Field Kit

Part Number (Alt V)

Part Description

Quantity

Unit of Measure

005654

WASHER LOCK #10

2

EA

012845

BAR FLAT 1/32" X 1/2

10

IN

014812

WASHER PLAIN #10

2

EA

160466

HEAT SHRINK TUBING, 200 DEG C

0.167

FT

003874

SLEEVING SIZE 7/16

8

FT

160953

WIRE, DIRECT SPARK, DH (CE)

KETTLES

1

EA

160999

CABLE TIE, HIGH TEMPERATURE

10

EA

160952

WIRE, IGNITION SENSOR, DH(CE)

KETTLES

1

EA

132289 Rev C

FRONT BURNER SHROUD - DH/1-40 &

DH-60

1

EA

153013

INSTRUCTION SHEET FOR FIELD

CONVERSION

1

EA

3) Preparation

a) Tilt kettle so the burners and ignition controls are accessible from the rear.

b) Remove burner covers located below the burner assembly.

1. Burner shroud bottom cover

2. Burner shroud front and sides

c) Remove lower access panel on kettle supporting column

d) Remove cover on ignition module control

e) Disconnect existing wiring harness from spark electrode and sensor electrode.

f) Disconnect the spark connector and sensor connector at ignition module.

g) Remove sensor and spark wires along with the silicone sealant from the plastic connector

between the supporting column and ignition module box.

h) Thread out both wires and discard.

i) Disconnect fasteners at both ends to remove ground wire for the electronic ignition system.

DH/1-40 SPARK IGNITER AND SENSOR HARNESS

3

4) Install Ground Strap

a) Take ground strap from the field service kit (part no. 012845) and attach it to the spark

connector bracket. Use washer and lock washer provided.

b) Form the strap as shown and attach other end of the grounding strap to the kettle ground

connection. Use washer and lock washer provided.

c) After forming the ground strap, excess strap length may be cut

5) Install Ignition Wires

a) Install Igniter Wire Assembly (160995) first.

b) Thread the igniter and sensor end of wire and sleeve assembly though the hole on sheet metal

part provided (burner shroud front – 132289).

DH/1-40 SPARK IGNITER AND SENSOR HARNESS

4

c) Place one piece of high temperature heat shrink tube (160466) over the electrode.

d) Pull the electrical connector on wire assembly out of the fiberglass sleeve.

e) Connect the male connector of wire assembly to the spark electrode.

f) Slide the other end of heat shrink tube (160466) over the terminal of igniter wire assembly (Part

No. 160995) and on to the wire past the terminal.

g) Apply heat to heat shrink tube using an industrial hot air blower so that it is shrinks securely

over the base of brass connector, exposed ceramic and electrical connection. Excess sleeve

over the orange wire will not shrink to encase the wire but it should be left open to eliminate

condensation.

h) Pull the high temperature fiberglass sleeve over the heat shrink tube all the way up to the base

of metal bracket so that it completely covers the igniter assembly below the metal bracket.

i) Hold the fiberglass sleeve in this position by clamping a high temperature plastic wire clamp

(160999).

j) Repeat above steps (17 through 25) to install the Sensor wire assembly (160996) to the flame

sensor electrode in identical manner.

DH/1-40 SPARK IGNITER AND SENSOR HARNESS

5

6) Route Ignition Wires

a) Route both wire assemblies with fiberglass sleeve along the gas inlet line tie them to

the gas line with high temperature wire ties (160999).

b) CAUTION- Be careful to route the fiberglass sleeve away from the combustion chamber

and maintain it towards the front of the kettle.

c) Once the wire assemblies are inside the trunion arm, route them through the plastic

connector into the ignition module box with fiberglass sleeve intact.

d) Connect the two wires to ignition module.

DH/1-40 SPARK IGNITER AND SENSOR HARNESS

6

e) Fill the plastic connector with silicone sealant to prevent moisture migration.

f) Reinstall all panels and burner cover below the burner assembly.

g) Turn on the electric and gas supply and test unit for proper ignition sequence as

described in the operator manual.