A.O. Smith PCG2J4040T3NOV 100, PCG6240T403NOV 100 manual Installing the Air Intake Chamber Box

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14.Rotate the top of the air intake chamber box from left to right (only a few inches in both directions) while pulling outward at the bottom removing the air intake chamber box from the combustion chamber pipe saving the air intake chamber gasket for reinstallation (Figure 49).

15.Unplug the air pressure tubing from the back of the old air intake chamber box (Figure 50).

16.The wire harness goes through the rubber wire protector in the back of the air intake chamber box (Figure 50).

17.Reach inside the air intake chamber box and push on the center of the rubber wire protector pushing it and the wiring harness wires to the outside of the air intake chamber box.

18.Remove the wiring harness from the wire channeling in the back center of the air intake chamber box. The old air intake chamber box is now separated and can be discarded (Figure 50).

Installing the Air Intake Chamber Box:

19.Insert the fan wiring harness wire through the back and into the fan box compartment by threading the connector through the opening and insert in approximately 6 inches of wiring (up to the rubber wire protector) (Figure 50).

20.Push the rubber wire protector into place in the back of the air intake chamber box (Note: the rubber wire protector must be positioned properly and locked into place around both sides of the air intake chamber box) (Figure 50).

21.Position the wiring harness wire in the wiring channeling molded down the back center of the air intake chamber box (Figure 50).

22.Connect the air pressure tubing to the fitting on the air intake chamber box and route tubing in molded inlaid of the air intake chamber box (Figure 50).

23.Reinstall the air intake chamber gasket (removed in step 14) on the back lower portion of the new air intake chamber box (Figure 51).

24.Install the new air intake chamber box to the combustion chamber pipe. Using a small amount of soapy water will help. Do not get any water or soapy water on any electrical connections or gas control components (see Figure 52). (NOTE:

UNDUE PRESSURE OR SUDDEN FORCE SUCH AS HAMMERING OR BEATING ON THE AIR CHAMBER BOX WITH ANY OBJECT INCLUDING YOUR HANDS WILL DAMAGE THE AIR INTAKE CHAMBER BOX AND RESULT IN FAILURE TO THE HEATER’S OPERATION.

Figure 49.

 

 

AIR INTAKE

 

 

CHAMBER BOX

 

 

REMOVAL

 

 

 

ROTATE FROM

 

 

LEFT TO RIGHT

 

 

AND

 

 

PULL OUTWARD

 

 

CHAMBER GASKET

 

Figure 50.

RUBBER WIRE

 

 

 

 

PROTECTOR

 

WIRE HARNESS INSIDE

 

WIRE CHANNELING

REAR SIDE OF

 

 

 

 

THE AIR INTAKE

 

 

CHAMBER BOX

AIR PRESSURE TUBING

 

CONNECTION

 

Figure 51.

REINSTALL

CHAMBER GASKET

NEW AIR INTAKE

CHAMBER BOX

Figure 52.

AIR INTAKE

CHAMBER BOX

INSTALLATION

ROTATE FROM

LEFT TO RIGHT

AND

PUSH INWARD

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Contents Models ALL Technical and Warranty Questions Service Handbook Tools Required for servicing gas modelsFire or Explosion Harzard Breathing Hazard Carbon Monoxide GasTable of Contents Basic Installation & Operation Installation of Residential GAS Water HeaterCombustion AIR and Vent System Requirements Carbon Monoxide WarningReference Vent Connectors Connector must be firmly attached Gas Control Valve/Thermostat Lower Control Know the Water HEATER’S Component PartsElectronic Control Display Upper Control Air Intake Chamber Fan Burner/Manifold Door AssemblyPressure Switch Power Anode Rod HOW the Water HEATER’S Component Parts are ConnectedWater Heater Operation Sequence of OperationFILLING, Draining and Flushing the Water Heater Tank For Your Safety Read Before Operating Lighting InstructionsAdjusting the Temperature on Electronic Control Display Hotter CoolerFault Code Retrieval Using the Electronic Control DisplayFault Code Diagnostics Reviewing Fault Codes FV-Sense Reset SequenceElectronic Control Display Troubleshooting Electronic Control DisplayControl Display Troubleshooting Control Display Status Problem SolutionLDO-SW, OPEN, and Clean Screen Troubleshooting Flowchart YESCleaning the Combustion Chamber and Air Diverter Assembly External Inspection and CleaningCleaning the Air Intake Chamber Screen Removing the Electronic Control Display Electronic Control Display Removal / ReplacementInstalling the Electronic Control Display Powered Anode ROD Removal / Replacement Removing the Powered Anode RodInstalling the Powered Anode Rod Installing the Pressure Switch Pressure Switch Removal / ReplacementRemoving the Pressure Switch Transformer Removal / Replacement Removing the TransformerInstalling the New Transformer AIR Intake Chamber BOX Removal / Replacement Removing the Air Intake Chamber BoxInstalling the Air Intake Chamber Box Installing the Fan in the Air Intake Chamber Box Wiring Harness Removal / Replacement PressureReplacing the Wiring Harness Installing the New Wiring HarnessUndue Pressure or Sudden Force AIR Intake Chamber FAN Removal / Replacement Removing the Fan from the Air Intake ChamberInstalling the Fan in the Air Intake Chamber Box Pressure Tubing Removal / Replacement Installing the Air Intake Chamber Box Inner DOOR/MANIFOLD/BURNER Assembly Removal / Replacement GAS ControlInstallation Caution Must Be Taken TABFlame SENSE/HOT Surface Igniter Removal / Replacement Replacing the Flame Sense/Hot Surface Igniter AssemblyBurner Removal / Replacement Installing New Burner Removing Old BurnerPressure Burner Orifice Removal / Replacement Installing New Burner Orifice Removing Old Burner OrificeReinstalling The Inner Door/Manifold/Burner Assembly GAS Control VALVE/THERMOSTAT Removal / Replacement Removing the Gas Control Valve/ThermostatInstalling the Gas Control Valve/Thermostat Checking the GAS Supply Pressure Checking the Gas Supply PressureGAS Water Heater Sizing Guide Leakage CheckpointsGeneral Information Formulas and ConversionsMM millimeters =Inches X