25
Figure 31
Pilot/Thermopile Assembly
Pilot/Ignitor-Flame Sensor
Assembly
Igniter Wire
Pilot
Tube
Filter Installation and Cleaning
IMPORTANT: It is essential that the fi lter be installed
properly. If you encounter diffi culty installing the fi lter
or have a question, please call the Service & Warranty
Department at 1-877-817-6750.
Failure to install (and clean) the air filter assembly properly
can allow dust and lint to restrict the air supply to the water
heater. If that occurs, the pilot light could go out or the
thermal switch could shut the water heater off. A service
call could be needed to clean the flame trap. These condi-
tions are not defects and are not covered by the warranty.
Figure 32A
Air Filter Assembly Installation:
Air Filter
assembly
Filter Clip
Install the air filter assembly as described below and clean
as needed. Replace the air filter assembly with a new one
if it is damaged.
1. Before installing the air filter assembly, remove any dust,
lint or debris (including any packaging materials or tape)
from under the water heater. For existing installations,
a visual inspection of the flame-trap is recommended.
Refer to “External Inspection & Cleaning of the Flame-
trap.”
2. Wrap the filter around the base of the water heater.
Cut to fit around a sensor if present. Trim excess filter
material with scissors but allow filter material to overlap
a few inches (Figure 32B).
3. The filter should fit snugly against the base of the water
heater with no gaps. The filter must fit flush against the
bottom of the drain pan and/or floor. Hold the filter in
place, then stretch the filter clip over the overlapped
joint and hook in place (Figure 32B).
4. Check the filter at least every three months and clean
as necessary. After installation, the filter may be cleaned
by using a vacuum cleaner with a brush attachment to
remove lint and dust. NOTE: Because the amount of
dust and lint in the air can vary, your filter may need to
be inspected/ cleaned more often. In some instances,
the filter may need to be removed and washed using
mild hand soap and water to remove any oily residue.
After washing, allow to dry and properly reinstall.
Never operate the water heater without a clean air filter.
NOTE: To prevent any bending of the pilot bracket, use
pliers to hold the pilot assembly bracket while loosening
the pilot nut.
4. Pull the pilot tube from the pilot assembly (Figure 31).
IMPORTANT: Be careful not to bend or alter the position
of the pilot assembly components.
5. Use a screwdriver to remove the screws securing the
Pilot/Igniter - Flame Sensor Assembly. Keep the screws
for reattachment.
6. Using the old pilot/pilot tube assembly as a guide, bend
the new pilot tube to match the old one. Make only the
bends closest to the pilot before going to the next step.
7. Push the new pilot tube and igniter wire through the hole
in the manifold door (See Figure 30). Reconnect the pilot
tube and tighten the nut securing it to the pilot assembly.
IMPORTANT: Keep the pilot orifice in the pilot when
making the connection. DO NOT operate the water
heater without the pilot orifice installed. Reattach the
pilot assembly to the manifold.
8. Be sure the igniter wire is positioned through the
bottom opening of the manifold component block. See
“Replacing Manifold Assembly” section.