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6.
Remove the two screws that fastens the anti-
rotation bracket on the left side of the gas valve
(see Figure 29).
7.
Remove the pilot gas tube and copper
thermocouple shield, if present, from the gas
valve.
Caution
Label all wires prior to disconnection. Wiring errors
can cause improper and dangerous operation.
8.
Tag and remove all wires from the gas valve
terminals.
9.
Pull the burner tray out of the heater (see
Figure 29).
NOTE: Due to sharp edges on the metal burners, wear
protective gloves for the next steps.
10.
Hold the gas burner or pilot burner firmly, and
push it away from the manifold until it is clear of
the orifice. Slide the burner to be replaced out of
the burner tray (see Figure 30).
Figure 30. Burner removal.
15.
Connect the pilot gas tube to the pilot assembly
and the gas valve.
16.
Install the anti-rotation bracket to the inner panel
and fasten with two screws (see Figure 29).
17.
Install manifold bracket and fasten with screws.
18.
Connect the service union in the gas line, and
screw the main gas pipe to the gas valve (see
Figure 29).
19.
Turn on gas valve following the lighting
instructions found on the inside of the heater.
20.
Turn on the main gas supply at the manual gas
cock or the meter.
21.
Check the system for leaks using a soap solution.
Caution
Since some leak test solutions (including soap and
water) may cause corrosion or stress cracking, rinse
the piping with water after testing.
22.
Reconnect the electrical wires to the gas valve in
accordance with the wiring diagram found on the
inside of the heater.
23.
Install the front access door on the heater.
24.
Turn all electrical power to the heater on.
4C. HEAT EXCHANGER
4C-1. Inspecting the Heat Exchanger
To check the scale buildup, periodically inspect
the tube having the highest temperature as follows:
1.
Open the drain valve on the left side of the
heater.
2.
Remove the large, hex-head plug located on the
right side of the heater under the in/out header
(see Figure 31). Perform this inspection after 60
days of and after 120 days of operation. This will
establish a regular inspection routine.
11.
To replace the gas burner, insert the burner into
the slot at the rear of the burner tray, line it up
with the proper orifice and snap it into position.
12.
To replace the pilot burner, install the pilot
assembly on the new pilot burner and install it in
the burner tray.
13.
Slide the burner tray back into the heater and
fasten it with two screws.
14.
Screw the new gas valve onto the manifold pipe.
Make sure the arrow on the bottom of the gas
valve that indicates the direction of gas flow is in
the proper direction. Also make sure the brass
fitting is on the right side.
Plug
Figure 31. Scale inspection.
