A.O. Smith PCG250T403NOV 100, PCG6240T403NOV 100 Installing the Fan in the Air Intake Chamber Box

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25.Install the air intake chamber box by rotating the top of the air intake chamber box from left to right (only a few inches in both directions) while pressing on the bottom portion of the air intake chamber box. When properly installed the air intake chamber box will be in place against the water heater’s side aligning with the screw holes.

26.Secure the air intake chamber box to the water heater’s side by reusing the 4 screws removed in step 13 (Figure 53).

Installing the Fan in the Air Intake Chamber Box:

27.Plug the electrical connections of the fan into the wiring harness: Align the electrical connections in such a position as to ensure the locking portions of the connections are on the same side. Gently push the electrical connectors together until the snap lock on the wiring harness engages the angular lock on the fan connector. Do Not use undue force in pushing these connectors together (Figure 54). (Note: Connectors are designed in such a manner if the connection is not properly aligned they will not lock together).

28.Replace the fan inside the air intake chamber box. It is imperative that the square portion of the fan air outlet be placed inside the raised square portion of the air intake chamber fan compartment (Figure 55).

29.Ensuring the fan is properly aligned in the air intake chamber, secure the fan in place using the 2 screws removed in step 9 (Figure 55).

30.Route the wiring inside the fan box to the outer edge of the fan in such a manner to ensure it will not be pinched or damaged upon installation of the air intake screen (Figure 55).

31.Install the air intake chamber screen, ensuring that the prongs of the lower portion of the air intake chamber screen are in place in the holding slots. Using the 2 screws removed in step 6, secure the air intake chamber screen (Figure 56).

32.Reattach the 3-wire wiring harness connector to the gas control valve (Figure 47).

33.Check the air hose tubing connection to the pressure switch to ensure the tubing has not loosen up or pulled off.

34.Turn on the electrical and the gas supplies to the water heater. Plug in the electric connection from the transformer to the electric outlet (Figure 46).

35.Restart the water heater by following the directions on the “Lighting and Operating Instructions” label located on the front of the water heater.

36.Upon verifying proper operation of the water heater, replace the manifold cover/outer door.

Figure 53.

SECURE WITH

SCREWS REMOVED

EARLIER

Figure 54.

FAN

GENTLY PUSH THE ELECTRICAL

CONNECTORS TOGETHER UNTIL

IT IS SNAP LOCKED.

Figure 55.

INSTALL THE FAN USING THE

 

TWO SCREWS REMOVED

FAN

EARLIER.

Figure 56.

INSTALL THE AIR INTAKE

CHAMBER SCREEN.

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Contents Models ALL Technical and Warranty Questions Tools Required for servicing gas models Service HandbookBreathing Hazard Carbon Monoxide Gas Fire or Explosion HarzardTable of Contents Installation of Residential GAS Water Heater Basic Installation & OperationCarbon Monoxide Warning Combustion AIR and Vent System RequirementsReference Vent Connectors Connector must be firmly attached Know the Water HEATER’S Component Parts Electronic Control Display Upper ControlGas Control Valve/Thermostat Lower Control Burner/Manifold Door Assembly Pressure SwitchAir Intake Chamber Fan HOW the Water HEATER’S Component Parts are Connected Power Anode RodSequence of Operation Water Heater OperationFILLING, Draining and Flushing the Water Heater Tank Lighting Instructions For Your Safety Read Before OperatingHotter Cooler Adjusting the Temperature on Electronic Control DisplayUsing the Electronic Control Display Fault Code DiagnosticsFault Code Retrieval FV-Sense Reset Sequence Reviewing Fault CodesElectronic Control Display Electronic Control Display TroubleshootingControl Display Status Problem Solution Control Display TroubleshootingLDO-SW, OPEN, and Clean Screen YES Troubleshooting FlowchartExternal Inspection and Cleaning Cleaning the Air Intake Chamber ScreenCleaning the Combustion Chamber and Air Diverter Assembly Electronic Control Display Removal / Replacement Installing the Electronic Control DisplayRemoving the Electronic Control Display Removing the Powered Anode Rod Powered Anode ROD Removal / ReplacementInstalling the Powered Anode Rod Pressure Switch Removal / Replacement Removing the Pressure SwitchInstalling the Pressure Switch Removing the Transformer Transformer Removal / ReplacementInstalling the New Transformer Removing the Air Intake Chamber Box AIR Intake Chamber BOX Removal / ReplacementInstalling the Air Intake Chamber Box Installing the Fan in the Air Intake Chamber Box Pressure Wiring Harness Removal / ReplacementInstalling the New Wiring Harness Replacing the Wiring HarnessUndue Pressure or Sudden Force Removing the Fan from the Air Intake Chamber AIR Intake Chamber FAN Removal / ReplacementInstalling the Fan in the Air Intake Chamber Box Pressure Tubing Removal / Replacement Installing the Air Intake Chamber Box GAS Control Inner DOOR/MANIFOLD/BURNER Assembly Removal / ReplacementTAB Installation Caution Must Be TakenReplacing the Flame Sense/Hot Surface Igniter Assembly Flame SENSE/HOT Surface Igniter Removal / ReplacementBurner Removal / Replacement Removing Old Burner Installing New BurnerPressure Burner Orifice Removal / Replacement Removing Old Burner Orifice Installing New Burner OrificeReinstalling The Inner Door/Manifold/Burner Assembly Removing the Gas Control Valve/Thermostat GAS Control VALVE/THERMOSTAT Removal / ReplacementInstalling the Gas Control Valve/Thermostat Checking the Gas Supply Pressure Checking the GAS Supply PressureLeakage Checkpoints GAS Water Heater Sizing GuideFormulas and Conversions General InformationMM millimeters =Inches X