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Replacing the Burner Door Assembly
WARNING
Explosion Hazard
Tighten all burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
damaged.
Replace manifold component block 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 viewport for damage and replace as required.
3. Insert the burner door assembly into the burner
compartment.
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
5. Replace the four screws which secure the burner door
assembly to the combustion chamber and tighten
securely. There should be no space between the
gasket part of the burner door and combustion
chamber. IMPORTANT: Do not operate the water heater
if the door gasket does not create a seal between the
burner door and the combustion chamber.
6. Reconnect the manifold tubing (3/4" wrench), pilot
tubing (7/16" wrench), temperature sensor wires, and
thermopile wires to the gas control valve/thermostat.
(See Figure 22 for the correct position of the thermopile
wires.) Do not cross-thread or apply any thread sealant
to the fittings.
7. Reconnect the igniter wire.
8. Turn the gas supply on and refer to the "Lighting
Instructions" on page 18.
9. 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.
26
Figure 28A
Combustion Chamber
Door Gasket
Figure 28B
Close-up inside view of the combustion chamber
Combustion Chamber
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter
button, electrode, and wire. The pilot is ignited by an
electric spark generated when the igniter button is pressed.
(See Figure 29). Use only factory authorized piezoelectric
igniter parts for replacement.
Figure 29
Gas Igniter Assembly
VAC
Wire to Electrode
Igniter Button
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-
off valve. Watch the electrode tip while activating the igniter.
A visible spark should jump from the electrode. To avoid
shock, do not touch the burner or any metal part on the
pilot or pilot assembly. If no spark is visible, check the wire
connections and make sure the electrode is not broken.
Replace the igniter if defective. Dirt and rust on the pilot or
electrode tip can prevent the igniter spark. Wipe clean with
a damp cloth and dry completely. Rust can be removed
from the electrode tip and metal surfaces by lightly sanding
with an emery cloth or fine grit sandpaper.
Combustion Chamber
Pilot
Electrode
Thermopile
Pilot/Thermopile Bracket
(Opposite Side)
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Troubleshooting
