Whirlpool 89263, BFG1J5040T3NOV 5K Replacing the Manifold Assembly, Piezoelectric Igniter System

Replacing the Manifold Assembly

WARNING

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.

Explosion Hazard

Tighten both manifold door screws securely.

Remove any fiberglass between gasket and combustion chamber.

Figure 28A

Combustion Chamber

Flame-trap

Door Gasket

Bracket

Replace viewport if glass is missing or damaged.

Replace two piece wire connector 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.

WARNING

Explosion Hazard Replace viewport if glass is missing or damaged. Failure to do so can result in death, explosion or fire.

2.Inspect the viewport for damage and replace as required.

3.Insert the manifold assembly into the combustion chamber making sure that the tab of the manifold tube engages in the slot of the bracket inside the combustion chamber (Figure 28B).

4.Inspect the door gasket and make sure there is no fiberglass insulation between the door 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. 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 two wire leads to the thermal switch, the manifold tubing, pilot tubing, and thermopile to the gas control valve/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.

7.Reconnect the igniter wire.

8.Turn gas supply on and refer to the “Lighting Instructions” on page 16.

Figure 28B	Close-up inside view of
Manifold Assembly Close-up	the combustion chamber.

Tab

Bracket Slot

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 Igniter Assembly

			RGY SMART M				Pilot
						OD
		NE		NORMA
		E			L	E
				120°		LO	Thermopile
ODE
		T				W
		O 0°
		H 15
M
D	L
R
A	A°
D M2
	0
N R1
A
TO
	SN	W
		O
		L					.125”
		VA	C	PILOT		OFF
				Wire to Electrode			Electrode
Igniter Button							Pilot Bracket

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.

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