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
3.Drain the water heater. Refer to the section of Draining and Flushing 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
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 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. 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 for leaks. Test all connections by brushing on an approved noncorrosive
•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:
TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.
Flame Lock™ Safety System Operational Checklist
1.Manifold gasket properly sealed.
2.Viewport not damaged or cracked.
3.
4.Two piece wire connector properly installed.
5.No leaks at pilot and manifold connection.
6.Manifold door screws securely tightened.
7.Depress the button on the thermal switch.
TROUBLESHOOTING CHART
PROBLEM |
| POSSIBLE CAUSE(S) |
| CORRECTIVE ACTION |
BURNER WILL NOT IGNITE | 1. | Pilot not lit | 1. | Light pilot |
| 2. | Thermostat set too low | 2. | Turn temp. dial to desired temperature |
| 3. | No gas | 3. | Check with gas utility company |
| 4. | Dirt in the gas lines | 4. | Notify |
| 5. | Pilot line clogged | 5. | Clean, locate source and correct |
| 6. | Main burner line clogged | 6. | Clean, locate source and correct |
| 7. | 7. | Replace thermocouple | |
| 8. | 8. | Replace thermostat | |
| 9. | Heater installed in a confined area | 9. | Provide fresh air ventilation |
SMELLY WATER | 1. | Sulfides in the water | 1. | Replace the anode with a special anode |
BURNER FLAME YELLOW- | 1. | Insufficient secondary air | 1. | Provide ventilation to water heater |
LAZY | 2. | Low gas pressure | 2. | Check with gas utility company |
| 3. | Flue clogged | 3. | Clean, locate source and correct |
| 4. | Main burner line clogged | 4. | Clean, locate source and correct |
| 5. | Heater installed in a confined area | 5. | Proper fresh air ventilation |
| 6. | Obstruction in main burner orifice | 6. | Clean or replace orifice |
PILOT WILL NOT LIGHT OR | 1. | 1. | Replace igniter pilot assembly | |
REMAIN LIT | 2. | The thermal switch tripped | 2. | See Pilot Light Troubleshooting Flowchart |
| 3. | Thermocouple connection loose | 3. | section |
| Finger tighten; then 1/4 turn with wrench | |||
| 4. | Air in gas line | 4. | Bleed the air from the gas line |
| 5. | Low gas pressure | 5. | Check with gas utility company |
| 6. | No gas | 6. | Check with gas utility company |
| 7. | Dirt in gas lines | 7. | Notify |
| 8. | Cold drafts | 8. | Locate source and correct |
| 9. | Thermostat ECO switch open | 9. | Replace thermostat |
| 10. | Pilot line or orifice clogged | 10. | Clean, locate source and correct |
| 11. | 11. | Replace thermocouple | |
| 12. | Air for combustion obstructed | 12. | See maintenance section for inspection and |
| 13. | Flammable vapors incident, Flame Lock™ | 13. | cleaning of flame trap |
| Replace water heater, eliminate flammable | |||
|
| function utilized |
| vapors source. Call |
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