Replacing the Manifold/Burner Assembly

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 39 & 40).

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/ burner assembly door to the combustion chamber and tighten securely. Once the manifold/burner assembly door is tightened, visually inspect the door gasket between the manifold/burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal. 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.During the following procedure, do not cross-thread or apply any thread sealant to any of the fittings listed below. First, reconnect the manifold tubing to the gas control valve/ thermostat. NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

NOTE: If a ferrule nut needs to be installed for the pilot tube, locate the one provided with your parts kit. Install it in the gas control valve/thermostat at the pilot location, hand tight only.

Next, insert the pilot tube into the ferrule nut until it bottoms out. NOTE: Hold the tube in this position. Tighten the ferrule nut with a wrench until the crimp connection seals to the pilot tube. Continue to tighten until the nut is tight in the gas

control valve/thermostat. Finally, start the thermocouple nut and turn it all the way in by hand. An additional quarter turn with a 3/8” open-end wrench will then be sufficient to seat the lockwasher. When you are finished, connect the two wire leads that go to the thermal switch.

7.Reconnect the igniter wire.

8.Turn gas supply on and refer to the Lighting Instructions.

9.With the burner lit, check the gas control valve/thermostat supply line, manifold component block, manifold tube, and pilot tube connections for leaks. 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.

FLAME ARRESTOR BRACKET

DOOR GASKET

TIP

FIGURE 39.

CLOSE-UP INSIDE VIEW OF

THE COMBUSTION CHAMBER.

SLOT

TIP BRACKET

MANIFOLD TUBE

FIGURE 40.

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. (Figure 41). Use only factory authorized piezoelectric igniter parts for replacement.

IGNITER

BUTTON

		THERMOCOUPLE
		PILOT
WIRE		.125” *
WIRE	PILOT	TIP
TO	PILOT	TIP
ELECTRODE	BRACKET	ELECTRODE

SNAP-ON CONNECTOR

* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.

FIGURE 41.

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