Replacing the Manifold 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 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.

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 34).

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 and 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 yellow wire leads to the thermal switch (Figure 27), the manifold tubing (3/4” wrench) and pilot tubing (7/16” wrench), to the gas control valve/ thermostat. Do not cross-thread or apply any thread sealant to the fittings.

NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube.

7.If replacing the pilot tube, install ferrule nut supplied with kit into the gas valve at the pilot tube location, hand tight only. Insert pilot tube into ferrule nut until tube bottoms out then tighten nut with a 7/16” wrench until crimp connection seals to pilot tube. Continue to tighten until the nut is tight in gas valve.

8.Reconnect the igniter wire to the gas control valve/ thermostat.

9.Turn the gas supply on and check for leaks. Test the water heater by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found.

10.Refer to the “Lighting Instructions” on page 16. 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

11.Replace the outer door.

Figure 34	Close-up inside view of
Manifold Assembly Close-up	the combustion chamber.
Burner	Tab
Burner
	Slot
Manifold Tube	Bracket
Manifold Tube

Igniter System

The STP (Spark to Pilot) igniter system consists of the pilot, electrode, and wire. The pilot is ignited by an electric spark generated when the gas control valve/thermostat sends an electrical signal to the electrode. Use only factory authorized STP igniter parts for replacement.

Figure 35

Gas Igniter Assembly

Igniter Wire

Connection

Point

Pilot

Electrode

Pilot/Igniter-Flame

Sensor Bracket