State Industries GSX - Manual (Page 22)

22
OTHER FITTINGS
NOT SHOWN
FOR CLARITY
IGNITER WIRE
THERMOCOUPLE
TWO PIECE
WIRE CONNECTOR
RETAINER
CLIP
PILOT TUBE
PILOT BRACKET PILOT
MANIFOLD TUBE
MANIFOLD/BURNER
DOOR OPENING
FERRULE NUT
Figure 25
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.
• 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.
2. Inspect the view port for damage and replace as
required.
3. Insert the manifold/burner assembly into the
burner compartment making sure that the tip of the
manifold tube engages in the slot of the bracket
inside the combustion chamber (Figures 32 & 33).
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/burner assembly door to the combustion
chamber and tighten securely. Once the manifold/
burner assembly door is tightened, visually inspect
the door gasket between the manifold/burner
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. During the following procedure, do not cross-
thread or apply any thread sealant to any of the
fittings listed below. First, reconnect the manifold
tubing to the gas control valve/thermostat. NOTE:
L.P. gas systems use reverse (left-hand) threads
on the manifold tube.
NOTE: If a ferrule nut needs to be installed for the
pilot tube, locate the one provided with your parts
kit. Install it in the gas control valve/thermostat at
the pilot location, hand tight only. Next, insert the
pilot tube into the ferrule nut until it bottoms out.
NOTE: Hold the tube in this position. Tighten the
ferrule nut with a wrench until the crimp connection
seals to the pilot tube. Continue to tighten until
the nut is tight in the gas control valve/thermostat.
Finally, start the thermocouple nut and turn it all the
way in by hand. An additional quarter turn with a
3/8” open-end wrench will then be sufficient to seat
the lockwasher. When you are finished, connect
the two wire leads that go to the thermal switch.
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the Lighting
Instructions.
9. With the burner lit, check the gas control valve/
thermostat supply line, two piece wire connector,
manifold tube, and pilot tube connections for
leaks. 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.
DOOR GASKET
FLAME ARRESTOR BRACKET
TIP
(MANIFOLD TUBE)
Figure 26
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT