Installation Guide

22
A. Remove the Manifold/Burner Assembly
1. Turn off the gas supply to the water heater at the manual gas
shut-off valve (Figure 26). This valve is typically located be-
side the water heater. Note the position of the shut-off valve
in the open/on position, then proceed to turn it off.
2. On the lower front of the water heater, locate the gas control
valve/thermostat (Figure 30). Before per forming any mainte-
nance, it is important to turn the temperature dial on the gas
control valve/thermostat to its lowest setting.
3. On top of the gas control valve/thermostat, turn the gas
control knob to the “OFF” position.
4. Remove the outer door.
5. Remove the two screws securing the manifold/burner as-
sembly to the combustion chamber (Figure 30).
6. Disconnect the following items from the gas control valve/
thermostat: thermocouple, pilot tube, and manifold tube
(each has right-hand threads). See Figure 30.
7. Disconnect the igniter wire from the piezo igniter button. See
Figure 30.
8. Grasp the manifold tube and push down slightly to free the
manifold, pilot tube, and thermocouple.
9. Carefully remove the manifold/burner assembly from the
burner compartment.
NOTICE: Be sure not to damage internal parts
B. Convert the Gas Control Valve/Thermostat
1. Remove the cap (shown in Figure 31), then remove the con-
version fitting by turning it counter-clockwise with an adjust-
able wrench.
2. Thread the opposite end of the conversion fitting into the
opening by turning it clockwise, then tighten it hand tight.
A. If you are converting the unit to use LP gas (propane),
verify that the “LP” arrow on the fitting is pointing toward
the gas control valve/thermostat. The red band on the
fitting should touch the metal boss. See Figure 31.
B. If you are converting the unit to use natural gas, verify
that the “NAT” arrow on the fitting is pointing toward the
gas control valve/thermostat. The blue band on the
fitting should touch the metal boss. See Figure 31.
3. Replace the cap.
C. Install the Conversion Manifold/Burner Assembly
1. Check the door gasket for damage or imbedded debris prior to
installation. See Figure 42.
2. Inspect the view port for damage and replace as required.
3. Insert the replacement manifold/burner assembly into the
burner compartment, making sure that the tip of the manifold
tube engages in the slot of the bracket inside the combustion
chamber. See Figure 43.
4. Inspect the door gasket and make sure there is no fiberglass
insulation between the gasket and the combustion chamber.
5. Replace the two screws which secure the manifold/burner
assembly door to the combustion chamber and tighten se-
curely. Once the manifold/burner assembly door is tightened,
visually inspect the door gasket between the manifold/burner
assembly door and the combustion chamber for spaces or
gaps that would prevent a seal.
WARNING! Do not operate the water heater if the door gas-
ket does not create a seal between the manifold door and the
combustion chamber. Failure to observe this warning could
lead to personal injury or death.
6. Reconnect the manifold tube, pilot tube, and thermocouple
to the gas control valve/thermostat. See Figure 30. Do not
cross-thread or apply any thread sealant to these fittings.
The thermocouple nut should be started and turned all the
way in by hand. Tighten an additional quarter turn with a
7/16” open-end wrench.
NOTICE: If you were supplied with a new ferrule nut in a
parts kit, follow these steps to connect the pilot tube:
A.) Install the ferrule nut into the gas valve at the pilot tube
location, hand tight only. B.) Insert the pilot tube into the fer-
rule nut until the tube bottoms out, then tighten the nut with
a 7/16” wrench until the crimp connection seals to the pilot
tube. C.) Continue to tighten until the nut is tight in the gas
valve.
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the Lighting Instructions.
9. With the burner lit, check the gas control valve/ thermostat
supply line, manifold component block, manifold tube, and
pilot tube connections for leaks. Check for leaks by brush-
ing on an approved non-corrosive leak detection solution.
Bubbles forming indicate a leak. Correct any leak found.
WARNING! All leaks must be fixed immediately. Failure to
do so could lead to personal injury or death.
10. Verify proper operation; replace outer door.
11. Place the conversion label next to the rating plate. (The
conversion label shows the type of gas that your water heater
has been converted to use.)
THERMOCOUPLE
MANIFOLD TUBE
PILOT
TUBE
WITH
FERRULE
NUT
GAS CONTROL VALVE / THERMOSTAT
MANIFOLD
SCREWS (2)
MANIFOLD
TUBE
THERMOCOUPLE
VIEW PORT
TWO PIECE
WIRE CONNECTOR
MANIFOLD
DOOR
THERMAL
SWITCH
PILOT
TUBE
PIEZO
IGNITER
BUTTON
GAS CONTROL VALVE/
THERMOSTAT
CONVERSION FITTING
CAP
LP GAS:
“LP” ARROW POINTS TOWARD THE
GAS CONTROL VALVE/ THERMOSTAT.
RED BAND TOUCHES METAL BOSS.
NATURAL GAS:
“NAT” ARROW POINTS TOWARD THE GAS
CONTROL VALVE/ THERMOSTAT.
BLUE BAND TOUCHES METAL BOSS.
FIGURE 30.
FIGURE 31.