D1/D2 Direct Vent
Pilot Replacement
Model #: D1-30-705
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.
D1 model shown
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.
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.
Fig. 1-2 Remove screws - pilot assembly
4. Remove the glass panel, decorative media, all floor panels,
and burner(s).
For D1 models, remove the grate and air flow screen or
ember screen.
For D2 models, remove the pilot screen and cover plate.
Remove screws
along the tray
5. Remove the hardware that is securing the unit to the fireplace
floor. Then carefully slide the unit forward.
Fig. 1-3 Remove screws - burner tray
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. 1-1.
Left side
of insert
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).
Control
box
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
ROBERT H. PETERSON CO. • 14724 East Proctor Avenue • City of Industry, CA 91746
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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).
Interior of
control box
Fig. 2-1 Remove pilot gas line
5/8"
8. Use the
open-end wrench to remove the two gas
lines from the adapter located near the control module
(see Fig. 2-5).
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
Fig. 2-5 Remove gas lines
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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).
Carefully pull
wires/lines
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.
INSTALL NEW PILOT ASSEMBLY
Remove
Fig. 3-1 Remove burner tray (and gasket below)
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. 3-3.
Bottom grommet
Side grommet
2. 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. 3-2 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
Fig. 3-5 Insert grommet - ignition wires
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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. 4-3.
Note: It is recommended to spray the area below
the gasket with multipurpose adhesive prior to
placement.
Ground wire
Fig. 4-1 Route pilot ground wire
Gas line through
large hole
Side of burner tray
Ensure
grommet is
secure
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.
Fig. 4-2 Insert new grommet - ground wires & gas line
Align the ground wire over the left screw hole. Then
fasten using the two screws. See Fig. 4-5.
Important: Ensure the ground wire is routed as shown.
Slide the insulation directly up against the
hex screw.
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
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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).
Refasten
screws along
the tray
Fig. 5-1 Refasten burner tray
14. Locate the second ignition wire (non-marked) and
connect it to the "CN4" connection on the control
module (see Fig. 5-4, C).
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
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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)
Left bottom
side of insert
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 flathead screwdriver to push the pilot orifice
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.
Orifice Lever Position
Gas Type
Red Visible on Lever
L.P. Gas
NAT/Clear Lever
Nat. Gas
Fig. 6-1 Install pilot & valve ground wires
Left bottom
side of insert
Fig. 6-2 Install pilot ground wire
Fig. 6-3 Loosen pilot head
Fig. 6-4 Adjust orifice lever
(Pilot head)
Red = L.P. Gas
NAT/Clear = Nat. Gas
Fig. 6-5 Orifice lever settings
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3. After confirming step 2 has been properly performed,
retighten the pilot head until it is properly positioned
toward the sensor as shown in Fig. 7-1.
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.
Fig. 7-1 Retighten pilot head
2. Reinstall the burner(s).
For D2 models, install the floor 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.
Fig. 7-2 Reinstall control box
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 flow screen or ember
screen, floor 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 fireplace floor, then reinstall
the surround and barrier screen.
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NOTES PAGE
Please use this page to record any information that you may want to have at hand.
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