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Replacing the Manifold/Burner Assembly
WARNING
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
There should be no space between the gasket part
of
the
manifold
door
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.
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.P. Gas systems use reverse (left-hand) threads on
the manifold tube.
7.
Connect the white (-) thermopile wire to the gas control
valve/thermostat. Then connect the red thermal switch
wires to the thermal switch on the 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).
to
the
combustion
chamber.
and
combustion
chamber.
10. 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.
DOOR GASKET
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. (See Figure 42).
VAC
Wire to Electrode
Do
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.
32
BRACKET
FLAME ARRESTOR
TIP
FIGURE 40.
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
SLOT
TIP
BRACKET
FIGURE 41.
Thermopile
Pilot
Pilot/
Thermopile
Bracket
Electrode
FIGURE 42.
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