Service Manual

Burner Tube Inspection

Step 1. a) Outer fiber mesh should be uniform with no tears or deterioration.

b) Gently squeeze burner tube, Burner tube should feel firm without any soft areas

around the sides or at the bottom.

c) Visually inspect inside burner tube, Burner tube should be intact with no areas of

deterioration. Ports

should be free of any debris.

Step 2.If burner tube is affected by any of the above, replacement is required. Refer to burner

tube replacement

procedure below.

Burner Tube Replacement Procedure

Step 1.Fully inspect burner flange gaskets, igniter and flame sensor gaskets for the following:

a) Tears d) Dirt or debris

b) Miss

ing material e) Other imperfections that would inhibit proper seal

c) Cracks

If gaskets are NOT affected by any of the above, gasket replacement i

s not required.

Step 2.Install burner tube with gaskets into mounting assembly. Be sure gasket surfaces are free

of debris.

Step 3. Reinstall the

burner plate with combustion assembly with the nuts that were removed from step 12 on previous

page. Tighten the nuts evenly.

Step 4. Carefully reinstall flame

sensor with gasket and direct spark igniter (DSI) with gasket and secure with

screws from step 11 on previous page. .

Step 5. Replace the

insulation from step 9 form the previous page.

If the insulation was damaged in the removal process it needs to be replaced.

Step 6. Re-install

the jacket head and components that were removed in step 8 from the previous page.

Step 7. Reconnect wire harnesses to the flame sensor, spark rod conne

ction, blower, damper, circulator, flow switch,

blocked vent switch and thermostat sensor.

Step 8. Reconnect PVC damper assembly, gas supply and silicone

tubing to gas valve. Turn on gas

supply to heater and check for gas leaks, repair any gas leaks found.

Step 9. Restore 120 volt power s

upply to water heater and confirm proper operation following

the lighting instructions on the lighting instruction label or the lighting instruction located

the installation and operating instruction manual.

Step 10. Replace surround cover on top of water heater.

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.