Installation Guide

30
DOOR GASKET
COMBUSTION CHAMBER
FOR CLARITY, THE INLET AIR OPENING IS NOT SHOWN.
FIGURE 42.
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.

removed.
 Replace door gasket if damaged.
 Failure to follow these instructions can result in
death, explosion, or fire.
Replace manifold component block if missing or
1. Check the door gasket for damage or imbedded debris prior to
installation (Figure 45).
2. Inspect the viewport for damage and replace as required
(Figure 40).
3. Insert the new manifold/burner assembly into the burner
compartment, making sure that the tab of the manifold tube
engages the slot of the bracket inside the combustion chamber
(Figure 46).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber (Figure 45).
5. Tighten the two screws that secure the manifold/burner
assembly to the combustion chamber. (Use a 1/4” SAE nut
driver.) 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 manifold tube (3/4” SAE wrench) and pilot
tube (7/16” SAE wrench) to the gas control valve/thermostat
(Figure 39). Do not cross-thread or apply any thread sealant
to the fittings.
IMPORTANT: If you were supplied with a new ferrule
nut in a parts kit, follow these steps to connect the
pilot tube:
1.) Install the ferrule nut into the gas valve at the pilot tube
location, hand tight only. 2.) Insert the pilot tube into the ferrule
nut until the tube bottoms out, then tighten the nut with a 7/16”
SAE wrench until the crimp connection seals to the pilot tube.
3.) Continue to tighten until the nut is tight in the gas valve.
7. Connect the white and red wires to the gas control valve/
thermostat as shown in Figure 39.
8. Reconnect the igniter wire (Figure 39).
9. Turn on the gas supply to the water heater at the manual gas
shut-off valve (Figure 27).
10. Follow the lighting instructions on the front of the water heater.
With the main burner lit, check for leaks at the manifold and
pilot connections by brushing on an approved noncorrosive leak
detection solution. If such a solution is not available, use a mixture
of hand dish washing soap and water (one part soap to 15 parts
water) or children’s soap bubble solution. Bubbles forming indicate
a leak. Correct any leak found.
11. Verify proper operation, then replace the outer door.
MANIFOLD TUBE
TIP
BRACKET
SLOT
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
FIGURE 43.
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. See Figure 44.
SNAP-ON CONNECTOR
IGNITER
BUTTON
WIRE
TO
ELECTRODE
THERMOCOUPLE
PILOT
PILOT
BRACKET
ELECTRODE
TIP
.125” *
* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.
FIGURE 44.