Install Instructions

2
TR/HL and SMART Series
Thermostat Replacement Instructions
HL Series - Installed Prior To 1998
1. Disconnect power to the water heater.
2. Remove the old thermostat knob. DO NOT
DISCARD THE KNOB.
3. Slide the plastic flanges up on the domestic pip-
ing allowing clearance to lift the top black lid.
4. Remove the capillary tube and sensing bulb
from the drywell located under the lid, on the
top of the tank near the domestic hot water out-
let tapping.
5. Disconnect the (3) wires connected to the ther-
mostat beneath the lid.
6. To remove the thermostat from the lid and bezel
ring, remove the (2) mounting screws.
7. Discard the thermostat in a proper manner,
unless the distributor has requested its return.
8. Reconnect the (2 of 3) wires to the new thermo-
stat as shown in Figure 1A or 1B. DO NOT con-
nect the yellow/green ground wire.
9. Mount the new thermostat to the lid and bezel
ring with the (2) mounting screws. Position the
indication mark on the bezel ring 90º counter-
clockwise from the wire connections. Figure 2
10. Re-insert the capillary line and sensing bulb into
the drywell until the bulb reaches the bottom.
• If the bulb does not slide into the drywell,
remove the burrs inside the drywell with a
3/8” drill to a depth of 1 1/2”.
Make sure capillary line is not kinked or dam-
aged. A defective capillary line can cause the
thermostat to fail, resulting in a situation that
can result in severe personal injury or death.
11. Reposition the lid on the tank and slide the plas-
tic flanges flush to the lid.
12. Reconnect power to the water heater.
13. Install the old knob and adjust the thermostat to
desired temperature according the instructions
at the end of this document.
HL Series - Installed After 1998
1. Disconnect power to the water heater.
2. Remove the old thermostat knob. DO NOT
DISCARD THE KNOB.
3. Pry the large black plug (on which the thermo-
stat is mounted) from the top lid. Use extreme
care not to damage the top lid.
4. Remove the capillary line and sensing bulb
from the drywell located under the black plug.
5. Disconnect the (3) wires connected to the ther-
mostat.
6. To remove the thermostat from the black plug
and bezel ring, remove the (2) mounting screws.
7. Discard the thermostat in a proper manner,
unless the distributor has requested its return.
8. Reconnect the (2 of 3) wires to the new thermo-
stat as shown in Figure 1A or 1B. DO NOT con-
nect the yellow/green ground wire.
9. Mount the new thermostat to the plug and bezel
ring with the (2) mounting screws. Position the
indication mark on the bezel ring 90º counter-
clockwise from the wire connections. Figure 2
10. Re-insert the capillary line and sensing bulb into
the drywell until the bulb reaches the bottom.
• If the bulb does not slide into the drywell,
remove the burrs inside the drywell with a
3/8” drill to a depth of 1 1/2”.
Make sure capillary line is not kinked or dam-
aged. A defective capillary line can cause the
thermostat to fail, resulting in a situation that
can result in severe personal injury or death.
11. Re-insert the large black plug into the top lid
cut-out
12. Reconnect power to the water heater.
13. Install the old knob and adjust the thermostat to
desired temperature according the instructions
at the end of this document.
WARNING
WARNING