Pilot Removal and Cleaning

	COMBINATION FLAME SENSOR/
BURNER ORIFICES	IGNITOR AND PILOT BURNER LOCATION

BURNERS

BURNER HOLD-DOWN LOCATION

TYPICAL BURNER TRAY ILLUSTRATED

BURNER TRAY REMOVAL

1.Shut-off power and gas supply to the heater. Disconnect union(s) and pilot tubing, then loosen and remove burner hold-down screws.

2.Disconnect wires at gas valve and slide burner drawer out.

GAS VALVE REMOVAL

1.Shut-off gas supply to the heater. Remove gas piping to gas valve inlet.

2.Disconnect wires, pilot tubing and bleed line, if required.

3.Turn vertical gas pipe from manifold slightly and unscrew gas valve.

4.Reverse above procedure to re-install.

MAIN BURNER AND ORIFICE REMOVAL

1.Remove screws and burner hold-down bracket.

1.Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burner tray.

2.Remove pilot and bracket, clean pilot of debris, small bugs, etc., with wire or small brush.

3.Replace pilot, pilot tubing, sensor ignition wires and check for leaks.

HIGH LIMIT OR TANKSTAT REMOVAL

1.Turn off electrical power.

2.Remove front inspection panel.

3.Remove wires to high limit and loosen screws holding high limit to cabinet.

4.Remove wedge clip holding sensing bulb in control well.

5.Remove high limit and install a new one.

6.Check control operation before leaving job.

NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usu- ally necessitates replacement of these parts.

2.Lift burners from slotted spacer and slide from orifices. Clean with a wire brush.

3.Orifices usually do not need to be replaced. To clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling.

HEAT EXCHANGER REMOVAL

1.Shut water, gas and electricity off, close valves and relieve pressure, remove relief valve.

2.Remove side inspection panels.

3.Remove top holding screws.

4.Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels.

5.Loosen bolts and disconnect flange nuts on in/out header, loosen union (s) at gas pipe, and slide heater away from piping until studs clear the heater.

6.Remove heat exchanger corner brackets.

7.Remove combustion chamber clips at the four corners of the heat exchanger.

8.Lift heat exchanger straight up using caution not to damage refractory.