Converting 3.5 to 4.0 - VBM Dual Boiler -

Converting 3.5 to 4.0 – VBM Dual Boiler

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35-40-01
  • cut tiewrap #1
  • unplug #2 and #3
  • unscrew #4
35-40-02
  • unplug #3b and replace with #2
35-40-03
  • unscrew #5
35-40-04
35-40-05
  • wrap #6 with teflon tape #6b
35-40-06
  • screw #6 where #5 was
35-40-07
  • unscrew #9 and #10 to remove frame #8
35-40-08
  • take note of all wires attached to old brain unit
35-40-09
  • take note of all wires attached to old brain unit
35-40-10
35-40-11
  • take note of all wires attached to new brain unit
35-40-12
  • take note of all wires attached to new brain unit
35-40-13
  • new braint unit on top / old brain unit on bottom
    • #11 –> #11b
    • #12 –> #12b
    • #13 –> #13b
    • #14 –> #14b
    • #7 –> #15
35-40-14
  • new brain unit on left / old brain unit on right
    • #23 –> #23b
35-40-15
  • take note of all wires attached to new brain unit
35-40-16
  • this is part #
  • #25 long end links to #20? gray on the other end
  • #26 short end link to #21? blue on the other end
35-40-17
  • #20 gray wire links to #25 long on the other end
  • #21 blue wire link to #26 short on the other end
35-40-18
  • this is part # RELESTATICODS
  • #27 & #28 long screw side / load 1 & 2
    • #26 –> #27
    • #25 –> #28
  • #29 & #30 short screw side / load 3 & 4
35-40-19
  • #32 black wire screws into load 4
  • #33 red wire screws into load 3
35-40-20
  • #34 is the cover for relay
  • #35 is the frame for the brain unit
35-40-21
  • #34a and #34b hold the cover for the relay
  • #35a and #35b hold the frame for the brain unit
  • #36a and #36b hold the relay – note these 2 won’t be easily removed until you remove the cover #34
35-40-22
  • now you can move the frame #35 to the side and remove the relay cover #34
35-40-23
  • now you can hold the nuts #36c and #36d to remove the screws
35-40-24
  • The new relay will be placed next to the old relay. You will need to drill 2 new holes so both relays can be mounted.
  • First put the 2 relays together. Then measure the distance between the openings where the mounting screws go.
35-40-25
  • The new holes you will drill is located in the circles as indicated in the picture to the right
35-40-26
  • Measure existing hole for installed relay from a common point, ex right side and top side. Transfer those measurements 1 3/4 inches away from existing holes.
35-40-27
  • Drill new holes.
  • WARNING: Make sure any parts and wires are cleared on the other side.
35-40-28
  • In order for the old relay to fit with the new cover, the wires on load 1 and 2 need to be rotated
35-40-29
  • Here is a picture of the new positioning of the wires on load 1 and 2
35-40-30
  • Place the old relay inside the machine aligning with the new drilled holes.
35-40-31
  • Place the new relay inside the machine next to the old relay.
35-40-32
  • Plug #31 into the connection next to #13b
35-40-33
  • Place new cover over the relays
  • 2 new holes need to be drilled to mount the new cover in place.
  • Mark the 2 holes as indictated in the picture.
35-40-34
  • Drill new holes.
  • WARNING: Make sure any parts and wires are cleared on the other side.
35-40-35
  • Insert the new relay cover in and screw in place.
  • You can also screw back in the brain unit frame.
35-40-36
  • Now we need to modify the power switch.
  • Unscrew the switch using an allen key.
35-40-37
  • Use a flathead screwdriver to remove the plastic bracket and metal frame
35-40-38
  • Slide the see through rubber covering up to get access to the wires
35-40-39
  • unscrew the connection with the white wires
35-40-40
  • There are 2 white wires: 1 thick, 1 thin. Cut the thin wire.
35-40-41
  • The white wire you just cut is tie wrapped to other wires. Slide the white wire out from the rest.
35-40-42
  • You can now screw back the connection with the thicker white wire.
35-40-43
  • On the heating element of the boiler, you will see a thin white wire similar to the one you cut.
35-40-44
  • Remove the wire from the heating element.
  • Cut the terminal on the end.
35-40-45
  • Strip the white covering to reveal the wire underneath.
35-40-46
  • Thread the wire from the switch through the heating element cap.
35-40-47
  • Twist the 2 wires together.
35-40-48
  • Add the terminal to the connected wires.
35-40-49
  • Attach the newly constructed wire to the heating element.
35-40-50
  • Reinstall the brain unit bracket.
35-40-51
  • Contratulations! The machine has now been upgraded. Take note of how the wires are posititoned.

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