A.O. Smith Water Heater installation instructions OT ETwF, ,NGB, Replacing the Thermocouple

2.Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 24).

PILOT ASSEMBLY

SCREWS,

BURNER

(BOTTOM VIEW)

FIGURE 24.

Replacing the Thermocouple

1.Remove the manifold/burner assembly as directed previously.

2.Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connector from the manifold door (Figure 25).

3.Remove the burner, see Removing the Burner from the Manifold/Burner Assembly.

4.Pull the thermocouple from the pilot assembly (Figure 26).

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.

6.Position the new thermocouple through the larger opening of the two piece wire connector (Figure 25). 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 buner (Figure 24.)

8.See Replacing the Manifold/Burner Assembly.

FERRULE NUT

_" IGNITER WIRE

THERMOCOUPL_

PILOT PILOT BRACKET

OT ETwF, ,NGB

"RETAINER

° ' i'

MANIFOLD TUBE

PILOT TUBE

\ MANIFOLD/BURNER

I_ _ TWO PIECE

I_'--W,RECONNECTORDOOR OPENING

FIGURE 25.

S

FIGURE 26.

Replacing the Pilot/Pilot Tube Assembly

1.Remove the manifold/burner assembly. See Removing the Burner from 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 25.)

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 assembly.

3.Take off the burner by removing the two (2) screws located underneath the burner. See Figure 24.

4.Remove and keep the screw securing the pilot assembly to the pilot bracket. (Figure 27)

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 27)

SCREW

OLD PILOT ASSEMBLY,

	OTHER FITTINGS
PILOT TUBE	NOT	SHOWN
	FOR	CLARITY

IGNITER WIRE

THERMOCOUPLEFIRST BEND(S)

FIGURE 27.

7.Route the new pilot tube, thermocouple, and igniter wire through the manifold/burner door opening. (Figure 25)

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 28)

PILOT TUBE

IGNITER WIRE

THERMOCOUPLE

TWO PIECE WIRE CONNECTOR

FIGURE 28.

26