Kenmore Power Miser 6 Manual
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21 Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 22). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass may need to be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures. IMPORTANT: Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts. If solder connections are used, solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings. IMPORTANT: Always use a good grade of joint compound and be certain that all fittings are drawn up tight. 1. Install the water piping and fittings as shown in Figure 22. Connect the cold water supply (3/4” NPT) to the cold water inlet fitting. Connect the hot water supply (3/4” NPT) to the hot water outlet fitting. IMPORTANT: Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes. Do not remove the inserts within the heat traps. 2. The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement. 3. The manufacturer of this water heater recommends installing a tempering valve or an anti-scald device in the domestic hot water line as shown in Figure 23. These valves reduce the point-of-use temperature of the water by mixing cold and hot water and are readily available for use. 4. If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under “Closed System/Thermal Expansion.” 5. Install a shut-off valve in the cold water inlet line. It should be located close to the water heater and be easily accessible. Know the location of this valve and how to shut off the water to the heater. 6. A temperature and pressure relief valve must be installed in the opening marked “Temperature and Pressure (T & P) Relief Valve” on the water heater. A discharge line must be added to the opening of the T&P Relief Valve. Follow the instructions under “Temperature and Pressure Relief Valve.” 7. After piping has been properly connected to the water heater, remove the aerator at the nearest hot water faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained. Close the faucet and check all connections for leaks. HOT WATER OUTLETCOLD WATER INLET PRESSURE REDUCING VALVE WITH BYPASS COLD WATER SUPPLY TO FIXTURES COLD WATER INLET VALVE (SHUT-OFF VALVE) IN A CLOSED SYSTEM USE A THERMAL EXPANSION TANK TEMPERATURE AND PRESSURE (T&P) RELIEF VALVE (OPTIONAL TOP T&P RELIEF VALVE NOT SHOWN) 6” MAXIMUM AIR GAP DRAIN LINE 3/4” ID MINIMUM DRAIN METAL DRAIN PAN 1” MINIMUM MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142. DISCHARGE PIPE (DO NOT CAP OR PLUG) FIGURE 22. COLD WAT E R INLET HOT WAT E R OUTLETTEMPERED WATER TO FIXTURES TEMPERING VALVE (SET TO 120°F) FOLLOW THE TEMPERING VALVE MANUFACTURER’S INSTRUCTIONS UNTEMPERED HOT WATER FIGURE 23. Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. • Use only pumps, valves, or fittings that are compatible with potable water. • I t i s r e c o m m e n d t h a t o n l y f u l l f l o w b a l l o r g a t e v a l v e s a r e u s e d in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended. • Use only 95/5 tin-antimony or other equivalent solder. Any lead based solder must not be used. • Piping that has been treated with chromates, boiler seal, or other chemicals must not be used. • Chemicals that may contaminate the potable water supply must not be added to the piping system. WATER SYSTEM PIPING
22 For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF VALVE.” (See Figure 24). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22. The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve’s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate. IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any valve between the relief valve and the tank. The Temperature & Pressure Relief Valve:• Must not be in contact with any electrical part. • Must be connected to an adequate discharge line. • Must not be rated higher than the working pressure shown on the rating plate of the water heater. The Discharge Line: • Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line. • Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line. • Must terminate a maximum of six inches above a floor drain or external to the building. • Must be capable of withstanding 250°F (121°C) without distortion. • Must be installed to allow complete drainage of both the valve and discharge line. T&P Relief Valve and Pipe Insulation 1. Locate the T&P Relief Valve on the water heater. 2. Locate the slit running the length of the insulation. 3 Spread this slit open and slip it up under the T&P Relief Valve. See Figure 25. Apply gentle pressure to the insulation to ensure it is fully seated on the T&P Relief Valve. Once sealed secure the insulation with a section of tape. IMPORTANT: The insulation or tape should not block or cover the T&P Relief Valve drain opening. Also the insulation or tape should not block or hinder access to the T&P Relief Valve manual relief lever. 4. Next locate the hot water (outlet) & cold water (inlet) pipes to the water heater. 5. Select one of the sections of pipe insulation and locate the slit that runs the length of the insulation. 6. Spread the slit open at the base of the insulation and slip it over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure it is fully seated around the cold water pipe. Also ensure that the base of insulation is flush with the water heater. Once seated, secure the insulation with a section of tape. 7. Repeat steps 5 through 6 for the hot water (outlet) pipe. T&P RELIEF VALVE DRAIN LINET&P RELIEF VALVEMANUAL RELIEF LEVERT&P RELIEF VALVE INSULATION FIGURE 25. Closed System/Thermal Expansion As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature- pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty. A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Thermal expansion tanks are available from Sears stores and through the Sears Service Centers. Contact the local plumbing inspector, water supplier and/or the Sears Service Center for assistance in controlling these situations. (For additional information, see the Troubleshooting Guide later in this manual.) Temperature and Pressure Relief Valve Explosion Harzard • Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code. • Properly sized temperature- pressure relief valve must be installed in opening provided. • Can result in overheating and excessive tank pressure. • Can cause serious injury or death. TEMPERATURE AND PRESSURE (T&P) RELIEF VALVE (OPTIONAL TOP T&P RELIEF VALVE NOT SHOWN) DRAIN LINE 3/4” ID MINIMUM DRAIN 1” MINIMUM 6” MAXIMUM AIR GAP METAL DRAIN PAN DISCHARGE PIPE (DO NOT CAP OR PLUG) FIGURE 24.
23 Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 32.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the rating plate. If you have any questions or doubts, consult your gas supplier or gas utility company.WARNING Explosion Hazard Replace view port if glass is missing or damaged. Failure to do so can result in death, explosion or fire. FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: FLAMMABLE If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINESA.C. D. B. BEFORE LIGHTINGsmell all around the appliancearea for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GASDo not try to light any appliance.Do not touch any electric switch; do not use anyphone in your building.Immediately call your gas supplier from a neighborsphone. Follow the gas suppliers instructions.If you cannot reach your gas supplier, call the firedepartment. Use only your hand to push in or turn the gas controlknob. Never use tools. If the knob will not push in orturn by hand, dont try to repair it, call a qualifiedservice technician. Force or attempted repair mayresult in a fire or explosion.Do not use this appliance if any part has been underwater. Immediately contact a qualified installer orservice agency to replace a flooded water heater.Do not attempt to repair the unit! It must be replaced! LIGHTING INSTRUCTIONS TOP KNOB FIGURE A OFF POSITION OFFON PILOT FIGURE B PILOT POSITION OFFON PILOT FIGURE C ON POSITION OFFON PILOT 1. 2. 1.TO TURN OFF GAS TO APPLIANCESet the thermostat to lowest setting (PILOT LIGHTING).Push gas control knob down slightly and turn clock- wise to OFF. Do not force. SEE FIGURE A. FIGURE D 1. 10. 11 . 12. 13. 2. 3. 5. 6. 7. 8. 9. STOP!Read the safety information above on this label. Set the thermostat to lowest setting(PILOT LIGHTING).Turn thermostat dial fully clockwise until it stops.Push the gas control knob down slightly and turnclockwise to OFF. SEE FIGURE A. NOTE: Knob cannot be turned from PILOT to OFF unless knob is pushed down slightly. Do not force. Wait ten (10) minutes to clear out any gas. If you then smell gas, STOP! Follow B in the safety information above on this label. Ifyou dont smell gas,go to next step.This unit is equipped with a push button pilot ignitor, on the gas control. Continue to hold the gas control knob down for about one (1) minute after the pilot is lit. Release the gascontrol knob and it will pop back up. Pilot shouldremain lit. If it goes out , repeat step (3) through (9). Itmay take several minutes for air to clear the lines before the pilot will light. If knob does not pop up when released, stop and immediately call your service technician or gas supplier.If the pilot will not stay lit after several tries, turn the gas control knob clockwise to OFF and call your service technician or gas supplier. SEE FIGURE A At arms length away, turn gas control knobcounterclockwise to ON. SEE FIGURE C.Set thermostat to desired setting. Remove the outer burner door located below 4.the gas control. which is used to light the pilot. Locate the ignitor Turn gas control knob counterclockwiseto PILOT. SEE FIGURE B. Once the pilot flame is established replace theouter burner door. THERMOCOUPLE MAIN BURNER PILOT The pilot is located on the left side of the burner. Itcan be located by looking through the glass view portwhile pressing the piezo ignitor button several times. Look for a spark at the pilot location, Figure D. Once the pilot has been found, push the gas knoball the way down. Immediately press the pilot ignitorbutton rapidly (4) to (5) times. If the pilot will notlight, repeat step (3) through (9). This appliance has a pilot which is lit by a piezo-electric spark gas ignition system. Do not openthe inner door of the appliance and try to lightthe pilot by hand. DANGER: Hotter water increases the risk ofscald injury. Consult the instruction manual before changing temperature. DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS. Immediately call a qualified service technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater.E. PIL0T THERMOSTAT DIAL GAS CONTROL KNOBGAS CONTROL PIEZO IGNITOR 120° MARK OPERATING YOUR WATER HEATER
24 Checking the Draft Burn harzard Hot water discharge. Keep clear of relief valve discharge outlet. After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft (Figure 26). Make sure all other appliances in the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the draft hood. A steady flame drawn into the opening indicates proper draft. MATCHRELIEF OPENIN G DRAFT HOOD FIGURE 26. If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and/or air supply requirements. Burner Flames Inspect the burner flames through the viewport and compare them to the drawing in Figure 27. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored flame. Contact a qualified technician if the flame is not satisfactory. FIGURE 27. Emergency Shut Down IMPORTANT: Should overheating occur or the gas supply fails to shut off, turn off the water heater’s manual gas control valve and call a qualified technician. Water Temperature Regulation Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature limiting valves are available. Read instruction manual for safe temperature setting. Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30°F (16.7 °C) higher or lower at the point of use such as, bathtubs, showers, sink, etc. HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. See Figure 23. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, see Figure 28. Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater. Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower. NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is recommended by most dishwasher manufacturers. The thermostat of this water heater has been factory set at its lowest position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The mark is indicative of approximately 120°F (49°C) and is the preferred starting point. See Figure 28 on the next page. Some states have a requirement for a lower setting. Turn the water temperature dial clockwise ( ) to decrease the temperature, or counterclockwise ( ) to increase the temperature. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.
25 INDEX BAR TEMPERATURE DIAL 160°F WHITE RODGERS GAS VALVE GAS CONTROL KNOB (OFF-PILOT-ON) 150°F 140°F 130°F120°FTemperature Time to Produce 2nd & 3rd Settings Degree Burns on Adult Skin VERY HOT= approx. 160°F (71°C) About 1/2 second C = approx. 150°F (66°C) About 1-1/2 seconds B = approx. 140°F (60°C) Less than 5 seconds A = approx. 130°F (54°C) About 30 seconds = approx. 120°F (49°C) More than 5 minutes LOW = approx. 80°F (27°C) - - - - - - - - - - - - - - - - NOTE: During low demand periods when hot water is not being used, a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs. If hot water use is expected to be more than normal, a higher thermostat setting may be required to meet the increased FIGURE 28. demand. When leaving your home for extended periods (vacations, etc.) turn the temperature dial to its lowest setting. This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather.
26
SERVICE AND ADJUSTMENT
Tank (Sediment) Cleaning
Sediment build-up on the tank bottom may create varying amount of
noise, and if left in the tank will cause permanent tank failure. In some
water areas, you may not be able to drain all sediment deposits by
simply draining the tank. In these cases, Mag-Erad (part no. 23600)
can be used to help remove the sediment deposits. This may be
ordered from the Sears Service Center. For ordering, refer to the
“Parts Order List” section.
Vent System Inspection
At least once a year, a visual inspection should be made of the
venting system. You should look for:
• Obstructions which could cause improper venting. The
combustion and ventilation air fl ow must not be obstructed.
• Damage or deterioration which could cause improper venting
or leakage of combustion products.
• Rusted fl akes around top of water heater.
Be sure the vent piping is properly connected to prevent escape of
dangerous fl ue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the fl ue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
If when inspecting the vent system you fi nd sooting or deterioration,
something is wrong. Call the local gas supplier to correct the problem
and clean or replace the fl ue and venting before resuming operation
of the water heater.
Burner Inspection
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a fl ooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a Sears Service Center to replace a fl ooded water heater.
Do not attempt to repair the unit! It must be replaced!
At least once a year, a visual inspection should be made of the main
burner and pilot burner. See Figure 29.
You should check for sooting. Soot is not normal and will impair
proper combustion.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can
result in a fi re causing death, serious injury, or property damage.
FIGURE 29.
Burner Cleaning
In the event your burner needs cleaning, follow these instructions:
If inspection of the burner shows that cleaning is required, turn the
gas control knob clockwise (
) to the “OFF” position, depressing
slightly.
NOTE: The knob cannot be turned from “PILOT” to “OFF” unless
knob is depressed slightly. DO NOT FORCE.
The burner needs to be removed for cleaning. Call the Sears Service
Center to remove and clean the burner and correct the problem that
required the burner to be cleaned.
27
Housekeeping
Vacuum around base of water heater for dust, dirt, and lint on
a regular basis.
Fire and Explosion Harzard
Do not obstruct combustion air
openings at the bottom of the
water heater.
Do not use or store flammable
vapor products such as gasoline,
solvents or adhesives in the
same room or area near water
heater or other appliance.
At least annually, check the
base-ring filter and flame arrester
for any dust, lint, or debris that
may have accumulated. Clean
as necessary.
Can cause serious injury or death.
AT LEAST ANNUALLY, A VISUAL INSPECTION SHOULD
BE MADE OF THE BASE-RING FILTER AND FLAME
ARRESTER. CLEAN IF LINT ACCUMULATIONS ARE
NOTICED.
INSTALLED IN SUITABLE AREA: To ensure sufficient ventilation
and combustion air supply, proper clearances from the water
heater must be maintained. See “Installation Instructions.”
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent
to the water heater because they could catch on fire.
Anode Rod Inspection
The anode rod is used to protect the tank from corrosion.
Most hot water tanks are equipped with an anode rod. The
submerged rod deteriorates to protect the tank. Instead of
corroding the tank, water ions attack and eat away the anode
rod. This does not affect the water’s taste or color. The rod
must be maintained to keep the tank in operating condition.
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
indicates high water conductivity and should be checked and/
or replaced more often than an anode rod that appears to be
intact. Replacement of a depleted anode rod can extend the
life of your water heater. Inspection should be conducted by
calling the Sears Service Center for an authorized contractor.
At a minimum, the anode(s) should be checked annually after
the warranty period.
Temperature-Pressure Relief Valve Operation
The temperature-pressure relief valve must be manually
operated at least once a year.
Burn harzard
Hot water discharge.
Keep clear of relief valve
discharge outlet.
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of
the temperature-pressure relief valve discharge line, and (2)
that the water discharge will not cause any property damage, as
the water may be extremely hot. See Figure 30.
FIGURE 30.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instructions,
and replace the temperature-pressure relief valve with a new
one.
If the temperature-pressure relief valve on the appliance
weeps or discharges periodically, this may be due to thermal
expansion. You may have a check valve installed in the
water line or a water meter with a check valve. Consult the
Sears Service Center for further information. Do not plug the
temperature-pressure relief valve.
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up during
operation. The water heater should be drained if being shut
28 down during freezing temperatures. To drain the tank, perform the following steps: 1. Turn off the gas to the water heater at the manual gas shut- off valve. 2. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4. Connect a hose to the drain valve and terminate it to an adequate drain. NOTE: The drain hose should be rated for at least 200°F. If the drain hose does not have this rating, open the cold water inlet valve and a nearby hot faucet until the water is no longer hot. 5. Open the water heater drain valve and allow all the water to drain from the tank. Flush the tank with water as needed to remove sediment. 6. Close the drain valve, refill the tank, and restart the heater as directed under the “Operating Your Water Heater” section. If the water heater is going to be shut down for an extended period, the drain valve should be left open. IMPORTANT: Condensation may occur when refilling the tank and should not be confused with a tank leak. Service Before calling for repair service, please read the Troubleshooting Guide in this manual. If a condition persists or you are uncertain about the operation of the water heater, let the Sears Service Center check it out. Contact Sears Service Center at: 1-800-4-MY-HOME® (1-800-469-4663).
29 MAINTENANCE OF YOUR WATER HEATER Replacement Parts IMPORTANT: The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician. Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1-800-4-MY-HOME (1-800-469-4663). When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4. parts description See the Parts Order List section for a list of available repair parts. External Inspection & Cleaning of the Base-Ring Filter 1. At least annually, check the base-ring filter (Figure 38) for any dust or debris that may have accumulated on the filter screen. 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 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. Removing the Manifold/Burner Assembly 1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater (Figure 11). Note the position of the shut-off valve in the open/on position then proceed to turn it off. 2. On the lower front of the water heater, locate the gas control valve/thermostat (see Figure 32). Before performing any maintenance, it is important to turn the temperature dial on the gas control valve/thermostat to its lowest setting. 3. On top of the gas control valve/thermostat, turn the gas control knob to the “OFF” position. THERMOCOUPLE MANIFOLD TUBE PILOT TUBE WHITE RODGERS GAS VALVE FIGURE 31. 4. Remove the outer door. 5. Remove the two screws securing the manifold door assembly to the combustion chamber (Figure 32). MANIFOLD SCREWS (2)TWO PIECE WIRE CONNECTOR MANIFOLD DOOR THERMAL SWITCH PILOT TUBE PIEZO IGNITER BUTTON GAS CONTROL VALVE/ THERMOSTAT MANIFOLD TUBE THERMOCOUPLE VIEW PORT FIGURE 32. 6. Disconnect the thermocouple (right-hand thread), pilot tube, the igniter wire from the igniter button, the two connectors attached to the thermal switch, and manifold tube at the gas control valve/thermostat. (Figures 31 & 32.) NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube. 7. Grasp the manifold tube and push down slightly to free the manifold, pilot tube, and thermocouple. 8. Carefully remove the manifold/burner assembly from the b u r n e r c o m p a r t m e n t . N O T E : B e s u r e n o t t o d a m a g e i n t e r n a l parts. 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 33). BURNER (BOTTOM VIEW) SCREWS PILOT ASSEMBLY (BOTTOM VIEW) FIGURE 33. Replacing the Thermocouple 1. Remove the manifold/burner assembly as directed previously. 2. Lift the retainer clip straight up from the back of the two piece wire connector (using a flat-blade screwdriver), then remove the two piece wire connector from the manifold door (Figure 34.) 3. Remove the burner. See “Removing the Burner from the Manifold/Burner Assembly.” 4. Pull the thermocouple from the pilot assembly (Figure 35). IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components. 5. Insert the thermocouple tip into the holes provided in the pilot bracket until it clicks into place. NOTE: The base of the thermocouple must be flush with the base of the pilot bracket.
30 7. Route the new pilot tube, thermocouple, and igniter wire through the manifold/burner door opening. (Figure 34) 8. Re-attach the pilot assembly to the pilot bracket and secure using the screw removed earlier. 9. Position the new pilot tube through the largest opening of the two piece wire connector. NOTE: The largest opening should be located at the top position. The igniter wire should be located in the middle opening and thermocouple in the bottom opening. (Figure 37) TWO PIECE WIRE CONNECTOR PILOT TUBE IGNITER WIRE THERMOCOUPLE FIGURE 37. 10. Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip. 11. Carefully bend the new pilot tube and thermocouple to match the bend of the manifold tube. NOTE: When bending, DO NOT crimp or crease the pilot tube or thermocouple. (Figure 34) 12. Before you proceed to the next step, install the new brass ferrule nut in the gas control valve/thermostat’s pilot tube opening. HAND TIGHTEN ONLY. 13. See “Replacing the Manifold/Burner Assembly.” Cleaning the Combustion 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 (Figure 38). Use compressed air to clear any dust or debris that may have accumulated in the flame-arrestor. DOOR GASKETFLAME ARRESTOR COMBUSTION CHAMBER BASE-RING FILTER FIGURE 38. 3. Reassemble by following the procedure under “Replacing the Manifold/Burner Assembly.” 6. Position the new thermocouple through the bottom opening of the two piece wire connector (Figure 34). Be sure igniter wire is positioned through the small opening of the two piece wire connector. 7. Re-attach the burner. Note the orientation of the burner (Figure 33.) 8. See “Replacing the Manifold/Burner Assembly.” OTHER FITTINGS NOT SHOWN FOR CLARITY IGNITER WIRE THERMOCOUPLE TWO PIECE WIRE CONNECTOR RETAINER CLIP PILOT TUBE PILOT BRACKETPILOT MANIFOLD TUBE MANIFOLD/BURNER DOOR OPENING FERRULE NUT FIGURE 34. FIGURE 35. Replacing the Pilot/ Pilot Tube Assembly 1. Remove the manifold/burner assembly. See “Removing the Manifold/Burner Assembly.” 2. Lift the retainer clip straight up from the back of the two piece wire connector (using a flat-blade screwdriver), then remove the two piece wire connector from the manifold door (Figure 34.) 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. 3. Take off the burner by removing the two (2) screws located underneath the burner. See Figure 33. 4. Remove and keep the screw securing the pilot assembly to the pilot bracket. (Figure 36) 5. Remove and keep the old pilot/pilot tube assembly. 6. Using the old pilot/pilot tube assembly as a guide, bend the new pilot tube and new thermocouple to match the old ones. NOTE: Make only the bends closest to the pilot before going to the next step. (Figure 36) FIRST BEND(S) OTHER FITTINGS NOT SHOWN FOR CLARITY PILOT TUBE THERMOCOUPLE IGNITER WIRE SCREW OLD PILOT ASSEMBLY FIGURE 36.