Removing The Burner From The Manifold/Burner Assembly; Replacing The Pilot/Thermopile Assembly - A.O. Smith GDV Instruction Manual

REMOVING THE BURNER FROM THE MANIFOLD/
BURNER ASSEMBLY
NATURAL GAS (LOW NOX) & L.P. GAS BURNER
1. Take off the burner by removing the two (2) screws located
underneath the burner.
2. Check the burner to see if it is dirty or clogged. The burner may
be cleaned with soap and hot water (Figure 24).Important: DO
NOT remove the orifi ce.
SCREWS
BURNER
(BOTTOM VIEW)
FIGURE 24

REPLACING THE PILOT/THERMOPILE ASSEMBLY

1. Remove the manifold door assembly as described in "Remov-
ing the Manifold/Burner Assembly" section.
2. Remove the burner to access the pilot/thermopile assembly.
Remove and keep the screws securing the burner to the mani-
fold (Figure 24).
Important: DO NOT remove the orifi ce.
3. Remove the screw securing the pilot/thermopile assembly to
the pilot bracket and keep for reuse later (Figure 25).
4. Lift the retainer clip straight up from the back of the manifold
component block (using a fl at-blade screwdriver), then remove
the manifold component block from the manifold door (Figure
25). Important: Be careful not to bend or alter the position of
the pilot tube. It will be used as a bending template for the new
pilot assembly. Note the placement/order of the wires in the
manifold component block.
5. Lift the pilot/thermopile assembly (including the igniter wire)
from the manifold assembly.
THERMOPILE
PILOT
CONNECTOR
TUBE
IGNITER
WIRE
MANIFOLD
COMPONENT
BLOCK
FIGURE 25
6. Read this step carefully before proceeding. Using the old
pilot/pilot tube assembly as a guide, bend the new pilot tube
to match the old one. Make only the bends closest to the pilot
before going to the next step.
PILOT ASSEMBLY
(BOTTOM VIEW)
PILOT / THERMOPILE
ASSEMBLY SCREW
WHITE
WIRE
RETAINER
CLIP
MANIFOLD
DOOR
BURNER AND OTHER
FITTINGS NOT SHOW
FOR CLARITY.
THERMOPILE
CONNECTOR
WHITE
WIRE
IGNITER
CONNECTOR
7. Route the new pilot tube, igniter wire and thermopile wire
through the opening in the manifold door. See Figure 25.
8. Using the pilot screw removed earlier, attach the
new pilot/thermopile
er to the manifold using the screws removed earlier.
Note: Make sure the burner scoop is oriented to the pilot side
of the manifold tube (Figure 24).
9. Reinstall the manifold component block in the manifold door.
Ensure that the pilot tube and wires are positioned as shown
in Figure 27.
MANIFOLD
COMPONENT
BLOCK
IGNITER WIRE PASSES
PILOT TUBE PASSES
THROUGH CENTER OF
THROUGH TOP
HOLE OF MANIFOLD
COMPONENT BLOCK
COMPONENT BLOCK
(SMALLEST HOLE)
(LARGEST HOLE)
10. Carefully bend the new pilot tube to match the bend of the
manifold tube.
Note: When bending, DO NOT crimp or crease the pilot tube.
11. Before you proceed to the next step, install the new brass fer-
rule nut in the gas control valve/thermostat's pilot tube open-
ing, HAND TIGHT ONLY.
12. Install the manifold/burner assembly. Refer to the "Replacing
the Manifold/Burner Assembly" section for instructions.
27
THERMOPILE
PILOT
PILOT/THERMOPILE
ASSEMBLY
PILOT TUBE NOT
SHOWN FOR CLARITY
FIGURE 26
assembly. Reattach
THERMOPILE WIRES
PASS THROUGH
MANIFOLD BOTTOM HOLE OF
MANIFOLD
COMPONENT BLOCK
FIGURE 27
the burn-