10
FLAME SENSOR AND/OR HOT SURFACE IGNITER
Important: Use only factory authorized replacement parts.
If you lack the necessary skills to properly perform the
installation, you should not proceed, but get help from a
qualified service technician.
Tools required:
3/4” Open-End Wrench
Phillips Head Screwdriver
Ratchet with 1/4” socket or 1/4” nutdriver
Flashlight
Flat Blade screwdriver
Removing Inner Door/Manifold/Burner Assembly:
Set the gas control valve/thermostat to its lowest
setting by turning the knob counter-clockwise to the
VAC point (see Figure 3).
Turn gas control switch to the “OFF” position and turn
“OFF” the gas supply to the unit (see Figure 3).
Disconnect the electrical power to the water heater
from the wall outlet.
Remove the outer door from the unit.
Unplug all the electrical connections from the bottom
of the gas control valve/thermostat (see Figure 11).
Using a 3/4” open end wrench remove the manifold
tube from the gas control valve/thermostat (turning
counter-clockwise for natural gas, clockwise for L.P.).
Grasp the manifold tube and push down slightly to
free the manifold tube from the gas control valve/
thermostat (see Figure 11).
Remove the insulation pad on the inner door by cutting
it if necessary. Keep the insulation in a safe place for
reusing it later.
Use a 1/4” nutdriver or 1/4” socket & ratchet to loosen
the 2 hex head screws on the inner door so the inner
door/manifold/burner assembly can be removed (see
Figure 11).
Remove inner door/manifold/burner assembly by
grasping the manifold, rotating it to the left to clear the
igniter and flame sensor and pulling back. Care should
be taken when inner door and burner assembly passes
through jacket opening that it does not damage any
of the electrical wiring (see Figure 13).
Removing Flame Sensor And/Or Hot Surface Igniter:
Note: The configuration of the flame sensor and igniter
allows you to replace them separately. It is recommended
to clean the flame sensor when you replace the igniter.
Lift the retainer clip straight up from the back of
the manifold component block (using a flat-blade
screwdriver), then remove the manifold component
block from the manifold door (see Figure 14).
Disconnect the wiring connection between the flame
sensor/igniter and valve.
Removeandretainthescrew(s) securingtheflamesensor
and/or hot surface igniter assembly (see Figure 14).
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Remove and discard the old flame sensor and/or hot
surface igniter assembly.
Install the new Flame Sensor and/or Hot Surface
Igniter.
Route the new flame sensor and/or hot surface igniter
connector wire through manifold/burner door opening.
Secure the assembly to the bracket using screw(s)
removed in step 3 above.
Reconnect the wiring connection between the flame
sensor/igniter and the valve.
Reposition the manifold component block in the
manifold door opening and secure it with the retainer
clip.
Caution Must Be Taken
Prior to installing the new inner door/manifold/ burner
assembly, look inside the burner chamber to fully
understand the correct positioning of the burner assembly
and burner manifold tab. It may be necessary to use a
flashlight to ensure correct placement. Care must be taken
so as to not damage any electrical wiring or components
as you are installing the new inner door/manifold/burner
assembly.
Extra caution should be taken to ensure that electrical
wiring, fiberglass insulation or any other object is not
caught between door gasket and combustion chamber
shield.
Note: If the burner door gasket (see Figure 9) is worn
or damaged it needs to be replaced. See section “Door
Gasket Replacement”.
Re-installing Inner Door/Manifold/Burner Assembly
Insert the manifold/burner assembly in the burner
chamber compartment, making sure that the tip of burner
manifold tab engages in the proper slot of the bracket
(see Figure 12). The tip end of the burner manifold MUST
be placed in the slotted portion under the condensation
pan to obtain proper installation (see Figure 12).
Important:
• The tip end of the burner manifold MUST be placed
in the upper slotted portion for models with input rate
of 40,000 to 50,000 Btu/hr to obtain proper installation.
• The tip end of the burner manifold MUST be
placed in the lower slotted portion for models with
input rate of 60,000 to 75,000 Btu/hr to obtain proper
installation.
After confirming no materials of any type are between
door gasket and combustion chamber shield, align
the screws on the inner door with the screw holes
on the combustion chamber and tighten with 1/4”
nutdriver or 1/4” socket & ratchet (see Figure 11).
After tightening the inner door screws, visually inspect
area around door gasket and skirt for spaces or
gaps. The door gasket MUST be sealed completely
in order for the water heater to perform properly.
DONOTOPERATETHEWATERHEATERIFTHEDOOR
GASKET DOES NOT CREATE A SEAL BETWEEN
MANIFOLD DOOR AND COMBUSTION CHAMBER.
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FLAME SENSOR AND IGNITER REMOVAL/REPLACEMENT
