INSTALLATION
REPLACEMENT INFORMATION
Gas supply
pipe
REMOVING OLD CONTROL
1. Turn off gas supply to the water heater at the manual gas
shut-off valve. This valve is typically located beside the
water heater.
2. Locate the gas control valve/thermostat. Before performing
any maintenance, turn the temperature dial on the gas
control valve/thermostat to the lowest setting. (See To light
Appliance Figure 2)
Gas shut-off
valve
Union
(metal-to-metal)
3. On the top of the gas control valve turn the gas control
knob to the “Off” position. (See To light Appliance Figure A)
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NOTE: On the White-Rodgers gas control valve/
thermostat the knob stop must first be slightly
depressed before turning the gas control knob.
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B
Drip leg
(sediment trap)
A
To pilot
burner
Pipe cap
4. Close the cold water inlet valve to the water heater and
open a nearby hot water faucet.
5. Connect a hose to the drain valve and terminate it to an
adequate drain. Open water heater drain valve by turning
handle counterclockwise to drain water heater tank.
To main burner
To thermocouple
Figure 1. Typical gas connection
3. If control had an ignitor, transfer the ignitor and bracket
removed from the old gas control valve to the new one.
IMPORTANT: DO NOT proceed to the following steps
until the water heater is completely drained.
4. Reconnect manifold tube (burner), pilot tube, ignitor
wire (if present), flying leads (if present), Thermocouple
nut (thermocouple nut should be hand tightened and
then turned an additional ¼ turn with small wrench. DO
NOT OVERTIGHTEN. Do not use pipe joint compound
or TEFLON tape on manifold, pilot, and thermocouple
connections.
5. Reconnect union. DO NOT use joint compound or TEFLON
tape on union connection.
6. Close the water heater drain valve by turning the handle to
the right (clockwise). Open the cold water supply valve to
the water heater to fill the water heater tank.
6. On some water heaters, the outer door may need to be
removed.
7. If control doesn’t have a piezo ignitor, skip to step (8) or
disconnect the piezo ignitor wire from the piezo ignitor
button.
NOTE:There are two types of ignitors. If you have the
square ignitor, slide the ignitor bracket backward away
from the gas valve to remove it. If you have a round
ignitor, first remove the ignitor from the bracket by
depressing front and rear holding tabs and lift. Next
remove ignitor bracket from the gas valve. Keep ignitor
and bracket.
NOTE:The cold water supply valve must be left open
when the water heater is in use.
Keep the nearby hot water faucet open for 3 minutes after a
constant flow of water is obtained to purge the lines of any
excess air. Check all new water piping for leaks. Repair as
needed.
8. Disconnect the thermocouple, pilot tube, and manifold
(burner) tube. Some control may have two wires (flying
leads) attached to the thermal switch that must be
disconnected as well.
9. Disconnect the union joint in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.
10. Remove the control by turning it counterclockwise. If
needed, a short piece of ½” black iron pipe can be screwed
into the control inlet to increase leverage.
CAUTION
!
Never use this water heater unless it is completely filled
with water.To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning ON gas to the water heater.
INSTALLING NEW CONTROL
All piping must comply with local and state ordinances or with
the National Fuel Gas Code (ANSI Z223.1–NFPA 54), which-
ever applies.
7. Turn on gas shutoff valve.
Dirt or contamination in the gas line can block the control from
operating creating a risk of explosion, injury or death. To protect
the control from dirt/contamination, a drip leg or sediment trap
(see Figure 1) must be installed in the piping to the control.
1. To replace the gas control valve/thermostat, reassemble
in reverse order. When replacing the gas valve, use a
short piece of pipe to help turn control. (Clockwise) DO
NOT OVER TIGHTEN or damage may result. Use an
approved pipe compound on the threads that screw into
the tank and to the gas pipe that screw into the gas control
valve/thermostat. Do not use TEFLON tape. Do not apply
compound to first two threads on gas pipe.
WARNING
DO NOT USE OPEN FLAME OR ANY KIND OF SPARKTO
CHECK FOR LEAKS. Serious injury of death from fire or
explosion could result.
!
8. BEFORE LIGHTING THE PILOT, CHECK THE GAS
LINES FOR LEAKS. Use a soapy water solution. DO NOT
test for gas leaks using a match or open flame.
Brush the soapy water solution on all gas pipes, joints,
and fittings. Check for bubbling soap indicating you have a
leak. Turn OFF the gas and make the necessary repairs.
Recheck for leaks. Rinse off soapy solution and wipe dry.
2. Reconnect the gas piping to the gas control valve/
thermostat. Use new black iron pipe that has been properly
reamed. If old pipe is used, be sure it is clean and free from
rust and scale.
9. Affix the new Lighting instruction label on the water heater
to cover the existing label.
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