18 • Residential Standard Gas Water Heater Service Handbook
SER
VICE PR
OCEDURE
S
B.
Installing the New Pilot/
Thermopile Assembly
1. 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.
2. Route the new pilot tube and
wires through the opening in the
manifold door. See Figure 18 on
page 17.
PILOT/THERMOPILE ASSEMBLY
PILOT/THERMOPILE
ASSEMBLY
IGNITER
CONNECTOR
THERMAL
SWITCH
CONNECTORS
ΈZt/Z^Ή
PILOT
THERMOPILE
KEEdKZΈ^Ή
ΈKEEdd
GAS CONTROL VALVE/
d,ZDK^ddΉ
FOR CLARITY, PILOT
TUBE NOT SHOWN .
Figure 19.
PILOT ASSEMBLY FOR CAST
BURNER NOT SHOWN.
EXPLODED VIEW OF PILOT/THERMOPILE ASSEMBLY.
FOR INFORMATIONAL PURPOSES ONLY. THE PILOT/THERMOPILE
ASSEMBLY SHOULD BE INSTALLED/SERVICED AS A SINGLE UNIT.
DO NOT DISASSEMBLE.
PILOT
PILOT BRACKET
ORIFICE
ΈKDWKEEd^Ή
PILOT TUBE
THESE TWO PARTS MAY BE
COMBINED ON SOME MODELS.
THERMOPILE
Figure 20.
3. Using the pilot screw removed
earlier, attach the new pilot/
thermopile assembly. Reattach
the burner to the manifold using
the screws removed earlier. NOTE:
If your burner includes a burner
scoop, make sure that it is oriented
to the pilot side of the manifold
tube. See Figure 17 on page 17.
4. Reinstall the manifold component
block in the manifold door. Ensure
that the pilot tube and wires are
positioned as shown in Figure 21.
5. 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.
6. Before you proceed to the next
step, install the new brass ferrule
nut in the gas control valve/
thermostat’s pilot tube opening,
HAND TIGHT ONLY.
7.
Install the manifold/burner
assembly.
RED THERMAL SWITCH WIRE
CONNECTIONS AT
MANIFOLD DOOR
ZΈнΉd,ZD>^t/d,t/Z
CONNECTS TO THE GAS CONTROL
VALVE\THERMOSTAT.
t,/dΈͳΉd,ZDKW/>
WIRE CONNECTS TO THE GAS
CONTROL VALVE\
THERMOSTAT.
/'E/dZt/ZW^^^
THROUGH CENTER OF
DE/&K>KDWKEEd
>K<Έ^D>>^d,K>Ή
W/>KddhW^^^d,ZKh',KddKD,K>
K&DE/&K>KDWKEEd>K<Έ>Z'^d,K>Ή
d,ZDKW/>t/Z^W^^
d,ZKh',dKW,K>K&
DE/&K>KDWKEEd
BLOCK
MANIFOLD
KDWKEEd
BLOCK
Figure 21.
External Inspec
Ɵ
on and
Cleaning of the Base-
Ring Filter
1. At least annually, check the base-
ring filter for any dust or debris that
may have accumulated on the filter
screen. See Figure 22. NOTE: If the
water heater is located in an area
that is subjected to lint and dirt,
it may be necessary to check the
base-ring filter more frequently.
2. Follow the Lighting Instructions to
turn off the water heater and allow
it to cool for 10 minutes before
attempting to clean the base-ring
filter.
3. Use a vacuum cleaner with a hose
attachment to remove any dust or
debris that may have accumulated
on the filter. NOTE: If you are
unable to inspect or clean the base-
ring filter, follow the “Cleaning the
Combustion Chamber and Flame
Arrestor” instructions.
4. After the base-ring filter has
been cleaned, follow the Lighting
Instructions to return the water
heater to service.
DOOR GASKET
FLAME ARRESTOR
COMBUSTION CHAMBER
BASE-RING
FILTER
Figure 22.
Cleaning the
Combus
Ɵ
on Chamber
and Flame Arrestor
1. Follow procedure outlined in
“Removing the Manifold/Burner
Assembly.”
2. Use a vacuum cleaner/shop vac
to remove all loose debris in
the combustion chamber. See
Figure 22. Use compressed air to
clear any dust or debris that may
have accumulated in the flame-
arrestor. (To clean the flame
arrestor, you may use a soft plastic
brush under water heater. Vacuum
lint from brush. Repeat until brush
is clean.)
