State Industries GSX - Manual (Page 23)

23
MANIFOLD TUBE
TIP BRACKET
SLOT
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
Figure 27
Removing and Replacing the Gas Control
Valve/Thermostat
IMPORTANT: This water heater has a resettable
thermal switch installed. Do not attempt to disable
or modify this feature in any way. Use only factory
authorized replacement parts.
Removing the Gas Valve:
1. Turn off the gas supply to the water heater at the
manual gas shut-off valve. This valve is typically
located beside 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. Before
performing any maintenance, 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. NOTE: On
the White-Rodgers® gas control valve/thermostat
the knob stop must first be depressed before turning
the gas control knob. See Lighting Instructions on
the water heater.
4. Drain the water heater. Refer to the section of
“Draining and Flushing” section and follow the
procedure.
5. Disconnect the piezo igniter wire from the piezo
igniter button. NOTE: There are two types of
igniters. If you have the square igniter, slide the
igniter bracket backwards away from the gas valve
to remove it. If you have the round igniter, first
remove the igniter from the bracket by depressing
front and rear holding tabs and lift. Next remove
igniter bracket from the gas valve. Disconnect
the thermocouple, pilot tube, the two connectors
attached to the thermal switch, and manifold tube
at the gas control valve/thermostat. NOTE: L.P.
gas systems use reverse (left-hand) threads on the
manifold tube.
6. Refer to “Gas Piping” section and disconnect the
ground joint union in the gas piping. Disconnect
the remaining pipe from the gas control valve/
thermostat.
7. To remove the gas control valve/thermostat, thread
a correctly sized pipe into the inlet and use it to turn
the gas control valve/thermostat (counterclockwise.)
Do not use pipe wrench or equivalent to grip body.
Damage may result, causing leaks.
Do not insert any sharp objects into the inlet or outlet
connections. Damage to the gas control valve/
thermostat may result.
Replacing the Gas Valve:
1. To replace the gas control valve/thermostat,
reassemble in reverse order. When replacing
the gas control valve/ thermostat, thread a
correctly sized pipe into the inlet and use it to
turn the gas valve (clockwise.) DO NOT OVER
TIGHTEN or damage may result. NOTE: Use an
approved
TEFLON ® tape or pipe compound only
on the threaded section of the gas control valve/
thermostat that screws into the tank.
2. Reconnect the gas piping to the gas control valve/
thermostat. NOTE: Use an approved Teflon tape or
pipe compound on the gas piping connections.
3. Attach the igniter and bracket to the new gas control
valve/thermostat, clipping it at the back edge of
thermostat and snapping it into place. NOTE: Do not
use the (pilot) ferrule nut supplied with the new gas
control valve/thermostat, unless the existing nut is
not usable. Reconnect the pilot tube, manifold tube,
igniter wire, and thermal switch wires. NOTE: L.P.
gas systems use reverse (left-hand) threads on the
manifold tube.
4. Fill the tank completely with water. NOTE: To purge
the lines of any excess air, keep the hot water
faucet open for 3 minutes after a constant flow of
water is obtained.
5. Turn on the gas supply and test the gas supply
connections by brushing on an approved
noncorrosive leak detection solution. Bubbles
forming indicate a leak. Correct any leak found.
6. Check the operation of the burner by following the
lighting instructions on the front of the water heater.
With the burner lit, check the gas control valve/
thermostat supply line, manifold tube and pilot tube
connections for leaks.
7. Verify proper operation and then replace the outer
door.
8. If additional information is required, contact Residential
Technical Assistance by referencing the phone
number on the water heater.
TEFLON ® is a registered trademark of E.I. Du Pont De Nemours and Company
REPLACING THE THERMOCOUPLE AND GAS CONTROL VALVE/THERMOSTAT