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Replacing
the Manifold/Burner
Assembly
10
Explosion Hazard
Tighten both manifold
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 view port for damage and replace as required.
3.
Insert
the
manifold/burner
assembly
into
the
burner
compartment,
making sure that the tip of the manifold tube
engages in the slot of the bracket inside the combustion
chamber (Figures 40 & 41).
4.
Inspect
the door gasket
and
make
sure there
is no
fiberglass
insulation
between
the
gasket
and
the
combustion chamber.
5.
Tighten
the
two
screws
which
secure
the
burner/
manifold
assembly
to
the
combustion
chamber.
There
should
be no space
between
the gasket
part
of
the
manifold
door
and
combustion
chamber.
IMPORTANT:
Do not operate the water heater if the door
gasket does not create a seal between the manifold door
and the combustion chamber.
6.
Reconnect
the manifold tube (3/4" wrench) and pilot tube
(7/16" wrench)
to the gas control valve/thermostat.
Do
not cross-thread
or apply any thread sealant to the fittings.
IMPORTANT: If you were supplied with a new ferrule nut in
a parts kit, follow these steps:
1 .) Install the ferrule nut into the gas valve at the pilot tube
location, hand tight only. 2.) Insert the pilot tube into the
ferrule nut until the tube bottoms out, then tighten the nut
with a 7/16" wrench until the crimp connection seals to the
pilot tube. Continue to tighten until the nut is tight in the gas
valve.
NOTE: L.R Gas systems use reverse (left-hand) threads on
the manifold tube.
7.
Connect the white and red wires to the gas control valve/
thermostat
as shown in Figure 33. Also, ensure that the
red thermal switch wires are connected
to the thermal
switch on the manifold door (Figure 38).
8.
Reconnect the igniter wire (Figure 33).
9.
Turn on the gas supply to the water heater at the manual gas
shut-off valve (Figure 11).
Follow the lighting instructions
on the front of the water
heater.
With the
main
burner
lit, check for
leaks
at
the manifold
and pilot connections
by brushing
on an
approved
noncorrosive
leak
detection
solution,
or
a
mixture of hand dish washing soap and water (one part
soap to 15 parts water) or childrens soap bubble solution.
Bubbles forming indicate a leak. Correct any leak found.
Verify proper operation
and then replace the outer door.
FLAMEARRESTOR
BRACKET
TiP
FIGURE 40.
TIP
MANIFOLD
TUBE
CLOSE-UP
INSIDE
VIEW
OF
THE
COMBUSTION
CHAMBER.
__SLOT
BRACKET
FIGURE 41.
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 42).
)lie
Pilot/
3lie
Bracket
Electrode
Igniter
Button
FIGURE 42.
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.
32
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