Whirlpool BFG1F4040T3NOV, 4220 Replacing the Manifold Assembly, Piezoelectric Igniter System

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.

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 burner compartment 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 gasket and the combustion chamber.

5.Replace the two screws, which secure the manifold assembly door to the combustion chamber and tighten securely. Once the manifold assembly door is tightened, visually inspect the door gasket between the manifold 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.Reconnect the two wire leads to the thermal switch, the manifold tubing, pilot tubing, and thermocouple to the gas control valve/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 7/16” 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.

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.

Figure 28A
Combustion Chamber	Flame-trap	Bracket
Door Gasket
		Tab

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

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							Thermocouple
Natural Gas & L.P. Gas			Natural Gas
							Pilot
Igniter Assemblies
	Igniter
	Button	Pilot						Tip .125 *
		Bracket						Electrode
		Thermocouple		Pilot				Pilot
	Wire							Bracket
	to							L.P. Gas
	electrode
Snap-on Connector		.125 *			Tip	Electrode

* Note: Spark gap distance measured from electrode tip to pilot.

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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