Step 1. Rotate knob of the gas control to the “OFF” position.
Step 2. Turn off gas supply to the water heater.
Step 3. Disconnect the gas supply line from gas control.
Step 4. Turn off the water supply and drain the water heater completely.
Step 5. Remove the outer jacket burner access door.
Step 6. Right side inner door removal:
a) Disconnect the red wire leads from the resettable thermal switch.
b) Remove two (2) 1/4” hex drive screws from RIGHT side inner door.
c) Remove two (2) 1/4” hex drive screws from FLANGE SECTION of inner door.
d) Remove the right side inner door and set aside. Be careful to not damage gasket material on inner door.
Step 7. Removal of gas control:
a) Disconnect main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and thermopile wire (white) from gas control.
b) Remove gas control from water heater by rotating counter clockwise. DO NOT use a wrench on the gas control body, damage to the gas control may occur. If necessary, use a length of 1/2″ NPT pipe threaded into gas inlet of gas control.
Step 8. Install new gas control into water heater:
a) Install a new gas control into water heater by rotating clockwise. DO NOT use a wrench on the gas control body, as damage to the gas control may occur. If necessary, use a length of 1/2″ NPT pipe threaded into gas inlet of gas control.
AS CONTROL REPLACEMENT (cont.)
Step 8. Install new gas control into water heater (cont.):
b) Reattach the main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and thermopile wire (white) to the gas control. Attach the inner door wire (red) to the positive (+) terminal and the thermopile wire (white) to the negative (-) terminal.
c) Gather piezo igniter wire, thermopile wire (white), inner door wire (red), and pilot alongside of feedline using new wire tie provided.
d) Reconnect gas supply piping to inlet of gas control.
Step 9. Reinstallation of inner door assembly:
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
Tears
Gasket adhesion to inner door
Missing material
Material left on combustion chamber
Cracks
Other imperfections that will inhibit proper seal
Dirt or debris
If the gasket is not affected by any of the above, gasket replacement will not be required.
If replacement is required, replace using new gasket kit following the instructions provided
with kit.
b) Clean any gasket residue or other debris from combustion chamber surface before
installing the inner door/gasket assembly.
c) Position thermopile wire, pilot tube, and piezo wire against left side inner door flange gasket.
DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that the thermopile and pilot tube are not in position to interfere with outer jacket burner access door installed.
Step 9. Reinstallation of inner door assembly (cont.):
d) Firmly place right side inner door flange against the left side inner door flange and secure with two (2) 1/4” hex drive screws from Step 6c. DO NOT OVER TIGHTEN SCREWS.
e) Align the right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted openings. Verify seal integrity around the combustion opening. Secure right side inner door using two (2) 1/4” hex drive screws from Step 6b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against the combustion chamber.
Step 10. Reconnect two (2) red wire leads from pilot assembly and gas control to resettable thermal
switch.
NOTE: wire terminations are interchangeable with either resettable thermal switch connection.
Step 11. Replace the outer jacket burner access door.
Step 12. Reconnect the gas supply to gas control.
Step 13. Resume water supply to the water heater. Be sure the tank is full of water before resuming operation.
Step 14. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the Installation and Operation Manual.
