A.O. Smith PCG2J5040T3NOV 100 manual Inner DOOR/MANIFOLD/BURNER Assembly Removal / Replacement

INNER DOOR/MANIFOLD/BURNER ASSEMBLY REMOVAL / REPLACEMENT

Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician.

Tools required: 3/4” Open-End Wrench or Crescent Wrench, Phillips Head Screwdriver, Ratchet with 1/4” socket or 1/4” Nut Driver.

Removing Old Inner Door/Manifold/Burner Assembly:

1.Set the gas control valve/thermostat to its lowest setting by pressing the “COOLER” and “HOTTER” buttons together at the same time holding for 1 second. Then press the “COOLER” button to the lowest setting (Figure 81).

2.Turn gas control switch to the “OFF” position (located right side of the gas control valve/ thermostat) and turn off the gas supply to the unit (Figure 82).

3.Disconnect the electric connection by unplugging the transformer from the wall outlet (Figure 82).

4.Remove the manifold cover/ outer door from the unit by depressing on the lower portion and pulling outward.

5.Unplug all the electrical connections from the bottom of the gas control valve/thermostat (Figure 83).

6.Disconnect the electrical flag terminals and air pressure tubing to the pressure switch (Figure 84).

7.Using a 3/4” open end wrench or a crescent wrench remove the manifold tube from the gas control valve/thermostat (turning counterclockwise -natural gas). Grasp the manifold tube and push down slightly to free the manifold tube from the gas control valve/thermostat (Figure 83).

8.Use a 1/4” nut driver or 1/4” socket & ratchet to loosen the 2 hex head screws on the inner door so the inner door/manifold/burner assembly can be removed (Figure 85).

9.Remove inner door/manifold/burner assembly by grasping the manifold and pulling straight back. Care should be taken when inner door and burner assembly passes through jacket opening that it does not damage any of the electrical wiring or the air pressure hose (Figure 86).

Figure 81.

HOTTER COOLER

Electronic Control Display

Figure 82.

ON

OFF

ON/OFF

SWITCH

UNPLUGGED

Figure 83.

IMPORTANT:
WHEN BRUSHING ON AN		GAS CONTROL
APPROVED NONCORROSIVE
LEAK DETECTION SOLUTION,		VALVE/THERMOSTAT
DO NOT SPLASH SOLUTION
ONTO ELECTRICAL CON-
NECTIONS.
		PRESSURE
MANIFOLD TUBE		SWITCH/FAN,
		FV SENSOR
POWER SUPPLY	IGNITER/	CONNECTOR
TRANSFORMER	FLAME
CONNECTOR	SENSE	DISPLAY, ANODE
	CONNECTOR	ROD CONNECTOR

Figure 84.

PRESSURE

SWITCH

MANIFOLD

TUBE

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