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Removing and Replacing the Gas
Control Valve/Thermostat
IMPORTANT: The gas control valve/thermostat is a
standard valve with a right-hand thread thermocouple. Use
only factory authorized replacement parts.
Removing the Gas Valve:
1. Turn the gas control knob on the combination gas control
valve/thermostat clockwise to the "OFF" position. NOTE:
Depress the dial stop on Robertshaw valves before
turning the gas control knob. See Lighting Instructions on
the water heater.
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" section and follow the procedure.
4. Disconnect the igniter wire from the igniter. NOTE: There
are two types of igniters. 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. If you have the square igniter, slide
the igniter bracket backwards away from the gas valve
to remove it. Disconnect the thermocouple (right-hand
threads), pilot tube, and manifold tube at the gas control
valve/thermostat (Figure 22).
5. Refer to "Gas Piping" section (Figure 3) and disconnect
the ground joint union in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.
Flame Lock™Safety System Operational Checklist
1. Burner door gasket properly sealed.
2. Viewport not damaged or cracked.
3. Flame-trap free of debris and undamaged.
4. Two piece wire connector properly installed.
5. No leaks at pilot and manifold connection.
6. Burner door screws securely tightened.
TROUBLESHOOTING CHART
PROBLEM
BURNER WILL NOT IGNITE
SMELLY WATER
PILOT WILL NOT LIGHT
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.
Non-functioning thermocouple
8.
Non-functioning thermostat
9.
Heater installed in a confined area
1.
Sulfides in the water
1.
Air in gas line
2.
No gas
3.
Dirt in gas lines
4.
Pilot line or orifice clogged
5.
Cold drafts
6.
Thermostat ECO switch open
7.
Non-functioning igniter
8.
Flammable vapors incident, Flame
Lock
TM
function utilized
9.
Low gas pressure
10. Air for combustion obstructed
11. Pilot dirty
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
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. 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
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 for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show 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"
•
If additional information is required, contact the Service
Department at: 1-877-817-6750.
®
TEFLON
is a registered trademark of E.I. Du Pont De Nemours and Company.
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.
Bleed the air from the gas line
2.
Check with gas utility company
3.
Notify utility-install dirt trap in gas line
4.
Clean, locate source and correct
5.
Locate source and correct
6.
Replace thermostat
7.
Replace igniter pilot assembly
8.
Eliminate flammable vapor source(s)
Call 1-877-817-6750
9.
Check with gas utility company
10. See maintenance section for inspection and
cleaning of flame-trap & burner
11. Clean pilot
tape or pipe joint
®
25
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