D1/D2 Direct Vent Pilot Replacement Model #: D INSTALLER: Leave these instructions with consumer. CONSUMER: Retain for future reference.

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1 D1/D2 Direct Vent Pilot Replacement Model #: D INSTALLER: Leave these instructions with consumer. CONSUMER: Retain for future reference. This pilot kit is for installation on a D1/D2 series direct vent by a qualified professional service technician. Note: The design of your existing pilot may slightly vary from the one depicted in this instruction; the replacement procedure is the same. TOOLS REQUIRED: Phillips screwdriver, needle nose pliers, 5/ 16 " and 7/ 16 " nut driver, 5/ 8 " and 7/ 16 " open-end wrench. The technician should reference the main owner's manual (provided with the direct vent) to assist in the removal and replacement of parts involved in this procedure. D1 model shown Fig. 1-1 Gain access to interior of unit REMOVE DIRECT VENT INSERT AND COMPONENTS CAUTION: Ensure the appliance is OFF and completely cool prior to any servicing. 1. Remove the barrier screen and surround pieces. 2. Turn off the gas supply to the unit and disconnect the power supply cord. 3. If the temperature is at or below 60 during this procedure, remove the batteries from the remote receiver to prevent the automatic pilot thermostat feature from lighting the pilot. 4. Remove the glass panel, decorative media, all fl oor panels, and burner(s). For D1 models, remove the grate and air fl ow screen or ember screen. For D2 models, remove the pilot screen and cover plate. 5. Remove the hardware that is securing the unit to the fireplace fl oor. Then carefully slide the unit forward. Note: The vent adapter will need to be removed. 6. At this stage, the interior of the insert should appear similar to that of Fig Fig. 1-2 Remove screws - pilot assembly Fig. 1-3 Remove screws - burner tray Left side of insert Remove screws along the tray REMOVE EXISTING PILOT ASSEMBLY 1. Use the 5/ 16 " nut driver to remove the two screws found on the front of the pilot assembly (see Fig. 1-2). 2. Remove all screws along burner tray (see Fig. 1-3). 3. Remove three screws along control box, then remove box (see Fig. 1-4). Fig. 1-4 Remove control box Control box ROBERT H. PETERSON CO East Proctor Avenue City of Industry, CA

2 4. Use the 7/ 16 " open-end wrench to remove the pilot gas line from the valve (see Fig. 2-1). 5. Disconnect the two ignition wires and ground wire from the control module (see Fig. 2-2). 6. If installed, use the 5/ 16 " nut driver to remove the pilot ground wire screw on bottom rear of sidewall (see Fig. 2-3). 7. Remove the screw (securing pilot and valve ground wires) on bottom front of sidewall (see Fig. 2-4). 8. Use the 5/ 8 " open-end wrench to remove the two gas lines from the adapter located near the control module (see Fig. 2-5). Interior of control box Fig. 2-1 Remove pilot gas line Procedure continued on next page Interior of control box Fig. 2-2 Disconnect ignition wires Left bottom side of insert Fig. 2-3 Remove screw - pilot ground wire Left bottom side of insert Fig. 2-4 Remove screw - pilot & valve ground wires Interior of control box 2 Fig. 2-5 Remove gas lines

3 9. Carefully remove the burner tray from the interior of the insert, ensuring all applicable wires/lines pull through the sidewall (see Fig. 3-1). Important: Be sure to completely remove the old burner tray gasket that is exposed after removing the tray. 10. Remove the two grommets found in the side and bottom of the burner tray (see Fig. 3-2). Retain for future use. Carefully pull wires/lines Remove INSTALL NEW PILOT ASSEMBLY 1. Pull the existing pilot assembly out of the burner tray, then insert the new one as shown. Begin by routing the ground wire and pilot gas line through the hole in the side of the tray. See Fig Route the ignition wires through the hole in the bottom of the burner tray (see Fig. 3-4). 3. Insert the grommet with the two small holes into the tray opening and ensure the ignition wires are properly installed as shown (see Fig. 3-5). Fig. 3-1 Remove burner tray (and gasket below) Bottom grommet Side grommet Fig. 3-2 Remove grommets in burner tray Procedure continued on next page Fig. 3-3 Remove existing pilot & insert new Hole in bottom of burner tray Fig. 3-4 Route ignition wires Bottom of burner tray Ensure grommet is secure 3 Fig. 3-5 Insert grommet - ignition wires

4 4. Route the supplied pilot ground wire through the hole in the side of the burner tray to the area in front of the pilot assembly (see Fig. 4-1). 5. Insert the grommet with the small and large hole into the tray opening and ensure the wires and line are properly installed as shown (see Fig. 4-2). Note: The two wires must be inserted into the small grommet hole. The pilot gas line must be inserted into the large grommet hole. 6. Ensure the old burner tray gasket is completely removed. Then install the new supplied gasket. Ensure to align it with the screw holes below. See Fig Note: It is recommended to spray the area below the gasket with multipurpose adhesive prior to placement. 7. Insert the burner tray while carefully routing all wires/ lines through the hole found in the side if the insert (see Fig. 4-4). 8. Place the pilot assembly over the burner tray bracket. Align the ground wire over the left screw hole. Then fasten using the two screws. See Fig Important: Ensure the ground wire is routed as shown. Slide the insulation directly up against the hex screw. Ground wire Fig. 4-1 Route pilot ground wire Gas line through large hole Side of burner tray Ensure grommet is secure Fig. 4-2 Insert new grommet - ground wires & gas line Procedure continued on next page Fig. 4-3 Install new burner tray gasket Left side of insert Fig. 4-4 Insert burner tray Install ground wire Fig. 4-5 Install pilot assembly 4

5 9. Refasten the burner tray (see Fig. 5-1). 10. Reconnect the two gas lines to the adapter located near the control module (see Fig. 5-2). 11. Install the pilot gas line to the valve (see Fig. 5-3). 12. Locate the ground wire and connect it to the "CN2" connection on the control module (see Fig. 5-4, A). 13. Locate the ignition wire marked "SPARK" and connect it to the "CN3" connection on the control module (see Fig. 5-4, B). 14. Locate the second ignition wire (non-marked) and connect it to the "CN4" connection on the control module (see Fig. 5-4, C). Refasten screws along the tray Fig. 5-1 Refasten burner tray Procedure continued on next page Fig. 5-2 Reconnect gas lines Fig. 5-3 Install pilot gas line C B A Fig. 5-4 Install ignition wires 5

6 15. Install the pilot and valve ground wires (see Fig. 6-1). 16. Install the pilot ground wire (see Fig. 6-2). PILOT ORIFICE CONVERSION (if applicable) 1. Use the 7/ 16 " open-end wrench to carefully loosen the pilot head a half-turn counter-clockwise (see Fig. 6-3). Note: DO NOT fully loosen/remove the pilot head. 2. Use the fl athead screwdriver to push the pilot orifi ce lever (located at base of pilot head) completely to the opposite side (see Fig. 6-4). Important: Ensure the lever is completely pushed to the side the unit is being converted to. Reference Fig. 6-5 and the table below. Left bottom side of insert Left bottom side of insert Fig. 6-1 Install pilot & valve ground wires Orifice Lever Position Red Visible on Lever NAT/Clear Lever Gas Type L.P. Gas Nat. Gas Fig. 6-2 Install pilot ground wire Fig. 6-3 Loosen pilot head Fig. 6-4 Adjust orifi ce lever (Pilot head) Red = L.P. Gas NAT/Clear = Nat. Gas Fig. 6-5 Orifi ce lever settings 6

7 3. After confi rming step 2 has been properly performed, retighten the pilot head until it is properly positioned toward the sensor as shown in Fig REINSTALL DIRECT VENT INSERT AND COMPONENTS, PERFORM LEAK TEST Reference the main owner's manual provided with the direct vent for complete details on re-installing the unit and its components. 1. Ensure all controls are in the OFF position, then turn on the gas supply to the unit. 2. Reinstall the burner(s). For D2 models, install the fl oor panels at this time. 3. Reinstall the batteries to the remote receiver (if removed). 4. Light the appliance per the main owner's manual and verify proper ignition and operation. 5. LEAK TEST: Test at all connections for leaks using an appropriate soapy water solution. If bubbles appear, a leak is present. Turn off the gas and tighten at all connections. Repeat until no leaks are present. If a leak persists, turn off the gas supply and contact the local gas company or dealer. NEVER USE A FLAME TO CHECK FOR LEAKS. 6. Allow the unit to completely cool, then reinstall the control box (see Fig. 7-2). 7. Carefully slide the unit back into position in the fireplace. Simultaneously slide the vent adapter into the top of the insert and refasten. 8. For D1 models, reinstall the air fl ow screen or ember screen, fl oor panels, and grate. For D2 models, reinstall the cover plate and pilot screen. 9. Reinstall the decorative media and glass panel. 10. Reconnect the power supply cord. 11. Re-secure the unit to the fi replace fl oor, then reinstall the surround and barrier screen. Fig. 7-1 Retighten pilot head Fig. 7-2 Reinstall control box 7

8 NOTES PAGE Please use this page to record any information that you may want to have at hand. 8