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Replacing the Burner Door Assembly
1. Check the door gasket for damage or imbedded debris
prior to installation.
2. Inspect the viewport for damage and replace as required.
3. Insert the burner door assembly into the combustion
chamber and slide it completely forward. Note: When
inserting the burner door assembly, tip the burner end up
slightly to ensure it engages with the burner bracket.
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the door gasket and the
combustion chamber (See Figure 30).
5. Replace the two screws, which secure the burner door
assembly to the combustion chamber and tighten
securely. Once the burner door assembly is tightened,
visually inspect the door gasket between the burner door
assembly 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 burner door assembly and the
combustion chamber.
6. Reconnect the manifold tubing, pilot tubing, and
thermocouple to the 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 1/2 - 3/4 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 “Operating Instructions”.
GAS CONTROL VALVE
THERMOSTAT
BURNER DOOR
ASSEMBLY
FIGURE 30.
9. Check for leaks by brushing on an approved noncorrosive
leak detection solution. Bubbles will show a leak. Correct
any leak found.
10. Replace the outer door.
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 electrode
should be centered between the pilot and thermocouple. (See
Figure 31). Use only factory authorized piezoelectric igniter
parts for replacement.
PILOT
BRACKET
PILOT
THERMOCOUPLE
ELECTRODE
IGNITER
BUTTON
WIRE
TO
ELECTRODE
SNAP-ON CONNECTOR
FIGURE 31.
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
electrode if defective. NOTE: The electrode is part of the pilot
assembly and cannot be replaced separately. 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 fi ne grit sandpaper.