State Industries GS6, GSX, GPX manual Replacing the Thermocouple and GAS Control VALVE/THERMOSTAT

REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT

FERRULE NUT

THERMOCOUPLE

IGNITER WIRE

PILOT PILOT BRACKET

OTHER FITTINGS

NOT SHOWN

FOR CLARITY

RETAINER

CLIP

MANIFOLD TUBE

PILOT TUBE	MANIFOLD/BURNER
TWO PIECE	DOOR OPENING
WIRE CONNECTOR

Figure 25

Replacing the Manifold/Burner Assembly

WARNING

Explosion Hazard

•Tighten both manifold door screws securely.

•Remove any fiberglass between gasket and combustion chamber.

•Replace viewport if glass is missing or damaged.

•Replace two piece wire connector if missing or removed.

•Replace door gasket if damaged.

•Failure to follow these instructions can result in death, explosion, or fire.

1.Check the door gasket for damage or imbedded debris prior to installation.

2.Inspect the view port for damage and replace as required.

3.Insert the manifold/burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber (Figures 32 & 33).

4.Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber.

5.Replace the two screws, which secure the manifold/burner assembly door to the combustion chamber and tighten securely. Once the manifold/ burner assembly door is tightened, visually inspect the door gasket between the manifold/burner assembly door and the combustion chamber

for spaces or gaps that would prevent a seal. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6.During the following procedure, do not cross- thread or apply any thread sealant to any of the fittings listed below. First, reconnect the manifold tubing to the gas control valve/thermostat. NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

NOTE: If a ferrule nut needs to be installed for the pilot tube, locate the one provided with your parts kit. Install it in the gas control valve/thermostat at the pilot location, hand tight only. Next, insert the pilot tube into the ferrule nut until it bottoms out. NOTE: Hold the tube in this position. Tighten the ferrule nut with a wrench until the crimp connection seals to the pilot tube. Continue to tighten until the nut is tight in the gas control valve/thermostat. Finally, start the thermocouple nut and turn it all the way in by hand. An additional quarter turn with a 3/8” open-end wrench will then be sufficient to seat the lockwasher. When you are finished, connect the two wire leads that go to the thermal switch.

7.Reconnect the igniter wire.

8.Turn gas supply on and refer to the Lighting Instructions.

9.With the burner lit, check the gas control valve/ thermostat supply line, two piece wire connector, manifold tube, and pilot tube connections for leaks. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. IMPORTANT: All leaks must be fixed immediately.

10.Replace the outer door.

FLAME ARRESTOR BRACKET

DOOR GASKET

TIP

(MANIFOLD TUBE)

Figure 26

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