American Water Heater 6510238 Piezoelectric Igniter System, Testing the Igniter System

5.Replace the (6) 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. Do not operate the water heater if the door gasket is not sealed.

6.Reconnect the manifold tubing (L.P. models have left- hand threads), pilot tubing, and thermocouple to the thermostat. Do not cross-thread or apply any thread sealant to these fittings. The thermocouple nut should be started and turned 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.

7.Reconnect the igniter wire.

8.Turn gas supply on and refer to the "Lighting Instructions" on page 17-18.

9.Check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method. All leaks must be fixed immediately.

10.Replace the outer door.

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 24A and 24B). Use only factory authorized piezoelectric igniter parts for replacement.

Figure 24A: Natural Gas Ignitor Assembly
Igniter Button	Thermocouple
	Pilot
Wire	.125
to	Tip
Electrode
	Electrode
Snap-on Connector

Figure 24B: L.P. Ignitor Assembly

Igniter
Button
Pilot	Thermocouple
.125
Wire	Tip
to
electrode	Electrode
Snap-on Connector

24

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 them 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.

Removing and Replacing the Gas Control Valve/Thermostat

Important: The gas control valve/thermostat is a standard valve. Use only factory authorized replacement parts.

1.On the gas control valve/thermostat turn the temperature dial counterclockwise to its lowest setting. Turn the gas control knob clockwise to the "OFF" position (Figure 17).

2.Turn off the gas at the manual shutoff valve on the gas supply pipe (Figure 6).

3.Drain the water heater. Refer to the section of "Draining and Flushing" on page 21 and follow the procedure.

4.Disconnect the igniter wire from the igniter button. Remove the igniter button by depressing front and rear holding tabs and lift. Disconnect the thermocouple, pilot tube, and manifold tube (L.P. models have left-hand threads) at the thermostat (Figure 19).

5.Refer to "Gas Piping" (Figure 6) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas valve/thermostat.

Notice: When removing the gas control valve/thermostat do not use pipe wrench or vise to grip body. Do not insert any type of blunt instrument into the inlet or outlet connections. Using these type tools may result in damage to the gas control valve/thermostat.

6.Turn the gas control valve/thermostat counterclockwise. Remove the gas control valve/thermostat.

To replace the gas control valve/thermostat reassemble in reverse order.

·Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of gas valve that screws into tank.

·Be sure to remove the pilot ferrule nut from the new gas control valve/ thermostat.

·Turn gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method.

·Be sure tank is completely filled with water before lighting and activating the water heater. Follow the "Lighting Instructions" on page 17-18.

·If additional information is required, contact the Service Department at: 1-800-999-9515.