Whirlpool Residential Gas Water Heater with the Flame Lock Safety System - Manual (Page 25)

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Check the door gasket for damage or imbedded debris 1.
prior to installation.
Inspect the viewport for damage and replace as required. 2.
Insert the manifold assembly into the burner 3.
compartment making sure that the tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 28B).
Inspect the door gasket and make sure there is no 4.
fiberglass insulation between the gasket and the
combustion chamber.
Replace the two screws which secure the manifold 5.
assembly door to the combustion chamber and tighten
securely. 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.
Reconnect the red wire leads to the thermal switch 6.
(Figure 25), the manifold tubing (3/4” wrench), pilot
tubing (7/16” wrench), and thermopile wires to the gas
control valve/thermostat. (See Figure 22 for the correct
position of the thermopile wires.) Do not cross-thread
or apply any thread sealant to the fittings.
NOTE: L.P. Gas systems use reverse (left-hand) threads
on the manifold tube.
Reconnect the igniter wire. 7.
Turn the gas supply on and refer to the “Lighting 8.
Instructions” on page 17.
Figure 28A
Combustion Chamber
Door Gasket
Bracket
Flame-trap
Figure 28B
Manifold Assembly Close-up
Close-up inside view of
the combustion chamber.
Manifold Tube
Bracket
Tab
Slot
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 29). Use only factory authorized piezoelectric
igniter parts for replacement.
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 igniter if defective. 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 fine grit sandpaper.
VAC
Pilot/
Thermopile
Bracket
Electrode
Thermopile
Pilot
Igniter Button
Wire to Electrode
Figure 29
Gas Igniter Assembly
Replacing the Manifold Assembly
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.
WARNING
Cleaning the Combustion Chamber and
Flame-trap
1. Follow procedure outlined in “Removing the Manifold
Assembly”.
2. Use a vacuum cleaner/shop vac to remove all loose
debris in the combustion chamber (Figure 28A). Use
compressed air to clear any dust or debris that may
have accumulated in the flame-trap.
3. Reassemble following the procedure under “Replacing
the Manifold Assembly”.
Check for leaks by brushing on an approved 9.
noncorrosive leak detection solution. Bubbles forming
indicate a leak. Correct any leak found. IMPORTANT:
All leaks must be fixed immediately.
Replace the outer door. 10.