Service Manual

Service Procedure III

Burner Tube Inspection and Replacement (Continued)

Burner Tube Inspection

Inspect burner tube as follows (ceramic

fiber mesh burner, water heaters prior to

serial number “CK”):

a) Visually inspect ceramic fiber mesh; mesh should be uniform in appearance without large

gaps, tears, or fraying. Mesh should have uniform pattern allowing for unrestricted gas flow.

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.

2. Inspect burner tube as follows (metal fiber mesh burner, water heaters with “CK” serial

number or later):

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

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

replacement procedure below.

Burner Tube Replacement Procedure

Note: New metal fiber mesh burner is the replacement burner for the ceramic fiber sock burner. The length of

burner will NOT be the same as the previous ceramic burner. Provide the model and serial number for the

correct replacement burner.

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

a) Tears d) Dirt or debris

b) Missing material e) Other imperfections that would inhibit proper seal

c) Cracks

If gaskets are NOT affected by any of the above, gasket replacement is not required.

2. Install burner tube with gaskets into burner mounting insert. Be sure gasket surfaces are free of debris.

3. Reconnect the blower/gas valve/transition assembly to burner mounting insert. Secure using nuts from

step 8 on previous page.

4. Carefully reinstall flame sensor with gasket and igniter with gasket and secure with screws from step 7

on previous page. Reconnect wire harnesses to sensor and igniter.

5. Reconnect wire harnesses to blower motor and to the gas valve.

6. Reconnect PVC venting, gas supply and silicone tubing to gas valve. Turn on gas to heater and check

for gas leaks, repair any gas leaks found.

7. Restore 120 volt power supply to water heater and confirm proper operation following the lighting

instructions on the lighting instruction label or the lighting instruction located in the Installation and

Operating Instruction Manual.

8. Replace the surround cover on the top of the water heater.

WARNING

Heater components may be HOT when performing

the following steps in this procedure. Take

necessary precaution to prevent personal injury.