State Industries GSX, GS6, GPX Removing the Manifold/Burner Assembly, Replacing the Thermocouple

REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT

Removing the Manifold/Burner Assembly

1.Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off.

2.On the lower front of the water heater locate the gas control valve/thermostat. Before performing any maintenance, it is important to turn the temperature dial on the gas control valve/thermostat to its lowest setting.

3.On top of the gas control valve/thermostat turn the gas control knob to the “OFF” position. NOTE: On the White-Rodgers® gas control valve/thermostat the knob stop must first be depressed before turning the gas control knob. See Lighting Instructions on the water heater.

WHITE RODGERS GAS VALVE	ROBERTSHAW GAS VALVE
PILOT	PILOT
TUBE	TUBE
THERMOCOUPLE	THERMOCOUPLE
	MANIFOLD TUBE
MANIFOLD TUBE

Figure 22

4.Remove the outer door.

5.Remove the two screws securing the manifold door assembly to the combustion chamber.

GAS CONTROL VALVE/

THERMOSTAT

	PIEZO
	IGNITER
MANIFOLD	BUTTON
TUBE	PILOT
THERMOCOUPLE	TUBE
	TCO
VIEW PORT	SWITCH
	MANIFOLD
	DOOR
MANIFOLD	TWO PIECE
SCREWS (2)
	WIRE CONNECTOR

Figure 23

6.Disconnect the thermocouple (right-hand thread), pilot tube, the igniter wire from the igniter button, the two connectors attached to the TCO switch, and manifold tube at the gas control valve/thermostat. NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube.

7.Grasp the manifold tube and push down slightly to free the manifold, pilot tube, and thermocouple.

8.Carefully remove the manifold/burner assembly from the burner compartment. NOTE: Be sure not to damage internal parts.

Removing the Burner from the Manifold/ Burner Assembly

Natural Gas (Low Nox) & L.P. Gas Burner

1.Take off the burner by removing the two (2) screws located underneath the burner.

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

PILOT ASSEMBLY

(BOTTOM VIEW)

SCREWS

BURNER

(BOTTOM VIEW)

Figure 24

Replacing the Thermocouple

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

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.

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

4.Pull the thermocouple from the pilot assembly.

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 bottom opening of the two piece wire connector. Be sure igniter wire is positioned through the middle opening of the two piece wire connector.

7.Re-attach the burner. Note the orientation of the burner.

8.See Replacing the Manifold/Burner Assembly.

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