Step 1. Rotate the knob of the gas valve to the “OFF” position.
Step 2. Turn off gas supply to the water heater.
Step 3. Disconnect the gas supply line from the gas valve.
Step 4. Turn off 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 resettable thermal switch wire leads (leading from gas valve) and remove the wire tie from the feedline.
b) Remove two (2) 1/4” hex drive screws from the right side inner door.
c) Remove two (2) 1/4” hex drive screws from the flange section of inner door.
d) Remove the right side inner door and set aside. Be careful to not damage the gasket material on the inner door.
Removal of gas valve:
a) Disconnect the main burner feedline, pilot tube and thermocouple from the gas valve. Remove the burner from combustion chamber.
NOTE: Feed line nut for natural gas control uses right hand threads; L.P. control uses left hand thread.
b) Remove piezo bracket with piezo igniter (refer to Service Procedure RG-IV) from gas valve.
c) Remove gas valve from water heater, rotating counter clockwise using a control body wrench or a length of 1/2″ NPT pipe threaded into inlet of control.
Installation of gas valve:
a) Install new gas valve using a control body wrench or a length of 1/2″ NPT pipe threaded into inlet of control. DO NOT OVER TIGHTEN. Use caution not to damage cast aluminum body of gas valve. Be certain not to damage the bundled wire leads.
NOTE: Gas valve must be installed in proper upright position to assure the feedline will align properly at the inner door flange. DO NOT OVER TIGHTEN.
If control is turned past proper alignment, DO NOT reverse direction to align.
b) Reattach piezo bracket with piezo igniter to gas valve.
c) Reattach main burner feedline, pilot tube and thermocouple to gas valve.
NOTE: Feedline nut for natural gas control uses right hand threads; L.P. control uses left hand thread.
d) Gather wire leads of gas valve and piezo igniter and secure alongside of feedline using new wire tie provided.
e) Connect gas supply piping to inlet of control. Use back up wrench on wrench boss of control, NEVER use back up wrench on body of control.
Step 9. Reinstallation of inner door assembly:
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
Gasket adhesion to inner door
Other imperfections that will inhibit proper seal
Material left on combustion chamber
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 provided instructions.
Step 9. Reinstallation of inner door assembly (cont.):
b) Clean any gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly.
c) Position thermocouple, pilot tube and piezo wire against left side inner door flange gasket. DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that thermocouple and pilot tube are not in position to interfere with outer jacket burner access door when reinstalled.
d) Firmly place the right side inner door flange against the left side inner door flange and secure with two (2) 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) 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 combustions chamber.
Step 10. Reconnect wire leads from gas valve to resettable thermal switch (see photo in Step 6).
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 the gas valve.
Step 13. Resume water supply to the water heater. Be sure the tank is full of water.
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.