Door-Burner Assembly Removal/Replacement - A.O. Smith GPVL-50 Service Handbook

DOOR-BURNER ASSEMBLY REMOVAL/REPLACEMENT

INNER DOOR/MANIFOLD/BURNER ASSEMBLY
Important: Use only factory authorized replacement parts.
If you lack the necessary skills to properly perform the
installation, you should not proceed, but get help from a
qualifi ed service technician.
Tools required:
•
3/4" Open-End Wrench
•
Phillips Head Screwdriver
•
Ratchet with 1/4" socket or 1/4" nutdriver
•
Flashlight
Removing Inner Door/Manifold/Burner Assembly
1. Set the gas control valve/thermostat to its lowest
setting by turning the knob counter-clockwise to the
VAC point (see Figure 3).
2. Turn gas control switch to the "OFF" position and turn
"OFF" the gas supply to the unit (see Figure 3).
3. Disconnect the electrical power to the water heater
from the wall outlet.
4. Remove the outer door from the unit.
5. Unplug all the electrical connections from the bottom
of the gas control valve/thermostat (see Figure 7).
6. Using a 3/4" open end wrench remove the manifold
tube from the gas control valve/thermostat (turning
counter-clockwise for natural gas, clockwise for L.P.).
Grasp the manifold tube and push down slightly to
free the manifold tube from the gas control valve/
thermostat (see Figure 7).
7. Remove the insulation pad on the inner door by cutting
it if necessary. Keep the insulation in a safe place for
reusing it later.
8. Use a 1/4" nutdriver or 1/4" socket & ratchet to loosen
the 2 hex head screws on the inner door so the inner
door/manifold/burner assembly can be removed (see
Figure 7).
9. Remove inner door/manifold/burner assembly by
grasping the manifold and pull back slowly. Rotating
it to the left to clear the igniter and fl ame sensor. Care
should be taken when inner door and burner assembly
passes through jacket opening that it does not damage
any of the electrical wiring (see Figure 9).
Caution Must Be Taken
Prior to installing the new inner door/manifold/burner, look
inside the burner chamber to fully understand the correct
positioning of the burner assembly and burner manifold
tab. It is necessary to use a fl ashlight to ensure correct
placement. Care must be taken so as to not damage any
electrical wiring or components as you are installing the
new inner door/manifold/burner assembly.
Extra caution should be taken to ensure that electrical
wiring, fi berglass insulation or any other object is not
between door gasket and combustion chamber shield.
Note: If the burner door gasket (see Figure 9) is worn
or damaged it needs to be replaced. See section "Door
Gasket Replacement".
8
ELECTRICAL
CONNECTIONS
NOTE: OUTER DOOR AND INSULATION NOT SHOWN FOR CLARITY.
Figure 7
MANIFOLD
TUBE NUT
HEX HEAD
SCREWS