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Replacing the Manifold Assembly
Explosion Hazard
Tighten both manifold door screws
securely.
Remove any fiberglass between the door
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 do so 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 manifold assembly into the burner
compartment making sure that the tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 28B). Note: The tab is
located at the bottom of the burner on L.P. gas models.
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
assembly door to the combustion chamber. Tighten
securely. There should be no space between the
gasket part of the manifold door and combustion
chamber. Do not operate the water heater if the door
gasket is not sealed.
6. Reconnect the two wire leads to the thermal switch,
the manifold tubing, pilot tubing, and thermocouple to
the thermostat. Important: DO NOT attempt to disable
or modify the thermal switch in any way. Do not cross-
thread or apply any thread sealant to these fittings.
•
Note: L.P. gas systems use reverse
(left-hand) threads on the manifold tube.
•
The thermocouple nut should be started and
turned all the way in by hand. An additional
quarter turn with a 7/16" open-end wrench will
then be sufficient to seat the lockwasher.
7. Reconnect the igniter wire.
8. Turn gas supply on at the manual gas shut-off valve,
and check the gas supply and gas valve for leaks. Test
the supply connections by brushing on an approved
noncorrosive leak detection solution. Bubbles forming
indicate a leak. Correct any leak found.
9. Follow the lighting instructions on page 17. With the
water heater lit check for leaks at the manifold and pilot
connections. Bubbles forming indicate a leak. Correct
any leak found.
10. Verify proper operation and then replace the outer door.
Figure 28A
Combustion Chamber
Door Gasket
Figure 28B
Manifold Assembly
Close-up
Manifold tube
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.
The spark gap of 0.125 inch is set when the electrode is
installed at the factory. (See Figure 29). Use only factory
authorized piezoelectric igniter parts for replacement.
Figure 29
Natural Gas & L.P. Gas
Igniter Assemblies
Igniter
Button
Thermocouple
Wire
to
electrode
Snap-on Connector
* Note: Spark gap distance measured from electrode tip to pilot.
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.
Flame-trap
Bracket
Tab
Close-up inside view of
the combustion chamber.
Tab
Bracket
Thermocouple
Natural Gas
Pilot
Pilot
Bracket
Electrode
Pilot
.125 *
Tip
Electrode
Slot
.125 *
Tip
Pilot
Bracket
L.P. Gas
23
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Table of Contents
Troubleshooting
