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Removing and Replacing the Gas
Control Valve/Thermostat
Important: The gas control valve/thermostat is a standard
valve with wire leads that connect to a thermal switch.
Removing the Gas Valve:
1. On the gas control valve/thermostat turn the
temperature dial counterclockwise to its lowest setting.
Depress the dial stop and turn the gas control knob
clockwise to the "OFF" position (Figure 19).
2. Turn off the gas at the manual shut-off valve on the gas
supply pipe (Figure 3).
3. Drain the water heater. Refer to the section of "Draining
and Flushing" on page 20 and follow the procedure.
4. Disconnect the igniter wire from the igniter button.
Remove the igniter button by depressing front and rear
holding tabs and lift. Remove igniter bracket. Disconnect
the thermocouple (right-hand threads), pilot tube, two
wire leads at the thermal switch, and manifold tube at
the gas control valve/thermostat (Figure 22). Note: L.P.
gas systems use reverse (left-hand) threads on the
manifold tube.
5. Refer to "Gas Piping" (Figure 3) and disconnect the
ground joint union in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.
6. To remove the gas valve, thread a correctly sized
pipe into the inlet and use it to turn the gas valve
(counterclockwise.) Do not use pipe wrench or
®
Flame Guard
Safety System Operational Checklist
1. Manifold gasket properly sealed.
2. Viewport not damaged or cracked.
3. Flame-trap free of debris and undamaged.
4. Two piece wire connector properly installed.
TROUBLESHOOTING CHART
PROBLEM
BURNER WILL NOT IGNITE
SMELLY WATER
BURNER FLAME YELLOW-
LAZY
PILOT WILL NOT LIGHT OR
REMAIN LIT
24
POSSIBLE CAUSE(S)
1.
Pilot not lit
2.
Thermostat set too low
3.
No gas
4.
Dirt in the gas lines
5.
Pilot line clogged
6.
Main burner line clogged
7.
Defective thermocouple
8.
Defective thermostat
9.
Heater installed in a confined area
1.
Sulfides in the water
1.
Insufficient secondary air
2.
Low gas pressure
3.
Flue clogged
4.
Main burner line clogged
5.
Heater installed in a confined area
6.
Obstruction in main burner orifice
1.
Defective igniter
2.
The thermal switch tripped
3.
Thermocouple connection loose
4.
Air in gas line
5.
Low gas pressure
6.
No gas
7.
Dirt in gas lines
8.
Cold drafts
9.
Thermostat ECO switch open
10. Pilot line or orifice clogged
11. Defective thermocouple
12. Air for combustion obstructed
13. Flammable vapors incident, Flame Guard
function utilized
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 valve may result.
Replacing the Gas Valve:
To replace the gas control valve/thermostat, reassemble
in reverse order. Important: This water heater has a
resettable thermal switch installed. DO NOT attempt to
disable or modify this feature in any way. When replacing
the gas valve, thread a correctly sized pipe into the inlet
and use it to turn the gas valve (clockwise.) DO NOT
OVER TIGHTEN, damage may result.
•
Be sure to use approved Teflon tape or pipe joint
compound on the gas piping connections and fitting on
the back of the gas control valve that screws into tank.
•
Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat.
•
Turn the gas supply on and check the gas supply and
gas valve for leaks. Test the supply connections by
brushing on an approved noncorrosive leak detection
solution. Bubbles forming indicate a leak. Correct any
leak found.
•
Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
"Lighting Instructions" on page 17. With the water heater
lit check for leaks at the manifold and pilot connections.
Bubbles forming indicate a leak. Correct any leak found.
•
If additional information is required, contact the Service
Department at: 1-800-999-9515.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the thermal switch button to verify it is operational.
CORRECTIVE ACTION
1.
Light pilot
2.
Turn temp. dial to desired temperature
3.
Check with gas utility company
4.
Notify utility-install trap in gas line
5.
Clean, locate source and correct
6.
Clean, locate source and correct
7.
Replace thermocouple
8.
Replace thermostat
9.
Provide fresh air ventilation
1.
Replace the anode with a special anode
1.
Provide ventilation to water heater
2.
Check with gas utility company
3.
Clean, locate source and correct
4.
Clean, locate source and correct
5.
Proper fresh air ventilation
6.
Clean or replace orifice
1.
Replace igniter pilot assembly
2.
See Pilot Light Troubleshooting Flowchart
section
3.
Finger tighten; then 1/4 turn with wrench
4.
Bleed the air from the gas line
5.
Check with gas utility company
6.
Check with gas utility company
7.
Notify utility-install dirt trap in gas line
8.
Locate source and correct
9.
Replace thermostat
10. Clean, locate source and correct
11. Replace thermocouple
12. See maintenance section for inspection and
cleaning of flame trap
®
13. Replace water heater, eliminate flammable
vapors source. Call 1-800-999-9515
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Table of Contents
Troubleshooting
