| Task | Description | Duration |
|---|
| 1 | Safety is the most important step. These procedures must be done by a licensed competent technician | 0 minutes |
| 2 | Rod Assembly - Disconnect power to your unit by either unplugging it from the wall outlet, or by the circuit breaker, depending on the setup. Press the GFI ‘TEST (OFF)’ button; if the red light does not come on, power is successfully disconnected | 20 minutes |
| 3 | Rod Assembly - Remove the front cover. | 20 minutes |
| 4 | Rod Assembly - a. Locate the black, yellow, and orange wires located in the center of the unit.b. Remove the three Phillips head screws holding the panel in place. c. Pull the assembly out. Do not lose the circular window. | 20 minutes |
| 5 | Rod Assembly - It is important to be very gentle with the sensor rods while cleaning them, as they will easily bend out of place. Their original position relative to the burner needs to be unaltered to function properly. a. Clean the flame sensor with 100 grit sandpaper, thoroughly to a bright finish. b. Clean the air fuel ratio rod with 100 grit sandpaper, thoroughly to a bright finish. | 20 minutes |
| 6 | Rod Assembly -Reassemble the unit in reverse order – sight glass, gasket, rods, and metal cover. Key points to remember: a. Connect all 3 wires on front of burner. b. Inspect all of the gaskets. c. Be sure the circular burner window is still in place. | 20 minutes |
| 7 | Combustion Components - Disconnect power to your unit by either unplugging it from the wall outlet, or by the circuit breaker, depending on the setup. Power is disconnected if the GFI light does not come on after pressing the test/off button. Shut off the gas supply. | 20 minutes |
| 8 | Combustion Components - Remove the front cover. | 20 minutes |
| 9 | Combustion Components - a. Remove the three central computer board screws. b. Remove the two screws holding the left or right computer board in place. c. FOR RIGHT SIDE: Remove the three screws holding the GFI in place | 20 minutes |
| 10 | Combustion Components - a. Remove the manifold plate screws. They are wide pan head Philips screws, located on the edges of the stamped metal plate of the gas manifold. b. Remove the brass gas valve screw. c. Remove the wire holding the Easy?Link wires in place. d. Disconnect the clear plastic tube from beneath the combustion chamber. e. Gently lift up the manifold & gas valve assembly to dislodge it from the gas inlet, and gently let it hang. | 20 minutes |
| 11 | Combustion Components - Now proceed to remove the burner assembly. a. Remove the five wide pan head Philips screws holding the burner to the combustion chamber. There are three at the top of the burner. There are two at the bottom of the burner to the back of the combustion chamber. b. Disconnect the rod assembly: Orange flame sensor, Yellow AFR, Black igniter wire c. Remove the burner. It may be hard to take out, so try the following: i. With pliers, grasp between the oval air vents in the front of the burner on the far left and pull firmly. Repeat on the right vent. ii. Now pull from the center and it should slide out readily. d. Inspect the gasket. (Minor surface tears are allowable, Major separations are not acceptable) | 20 minutes |
| 12 | Combustion Components -Clean the burner a. Protect the burner gasket from direct water pressure. IF the gasket becomes compromised, please contact the technical service department for further assistance. b. Thoroughly saturate the burner with the cleaning solution from the top, down through the slots, as well as the openings in the front of the burner until the burner is soaking wet. c. Let the burner sit for 5 minutes. d. Remove the burner from the solution. Set the burner in a sink in its normal upright position and wash the burner with a high flow of water down into the slots, starting at the back and moving forward. Again, ensure that no contact is made with the gaskets. e. Use compressed air to clear excessive water from the burner after rinsing. Inspect the gasket. (Minor surface tears are allowable. Major separations are not acceptable) | 20 minutes |
| 13 | Combustion Components - The fan is probably coated with dust as well. a. Place a towel at the bottom of the heat exchanger to cover the square port to the fan. This towel will catch all the dust blown in the next step. b. Use compressed air to blow into the fan. It will rotate and dust will fly out of the fan housing into the towel above | 20 minutes |
| 14 | Combustion Components - Inspect the combustion chamber with a bright flashlight. a. Remove the exhaust venting from top of the unit for the DV model b. Place one towel at the bottom of the combustion chamber, protecting the discharge of the fan (fan port), as well as drape another towel covering the square opening of the combustion chamber (to prevent airborne debris) c. Turn on the shop vacuum and vacuum all of the dirt from the combustion chamber. d. At the same time, with the air compressor, blow air down through the top of the heat exchanger through the vent collar to remove additional contaminants. | 20 minutes |
| 15 | Combustion Components - If there is a white, crusty solid buildup in the heat exchanger, please contact the technical service department for further instruction. | 20 minutes |
| 16 | Combustion Components - Clean the flame sensor and AFR with sandpaper, thoroughly to a bright finish. It is important to be very gentile with the sensor rods while cleaning them, as they will easily bend out of place. Their original position relative to the burner needs to be unaltered in order to function properly. | 20 minutes |
| 17 | Combustion Components - Reassemble the unit in reverse order. Key points to remember: a. Inspect all of the gaskets. b. Be aware of the black O?ring and mesh filter on the gas valve inlet. c. Reconnect the plastic tube from the gas valve to the bottom of the combustion chamber. d. Reattach all components that the manifold screws secure in their places. e. Reconnect all wires to the computer board and any other clips. f. Do not have any screws left over | 20 minutes |