Testing the Igniter System

Turn off the gas to the water heater at the manual gas shut-off valve. Watch the electrode tip while activating the igniter. A visible spark should jump from the electrode. To avoid shock, do not touch the burner or any metal part on the pilot or pilot assembly. If no spark is visible, check the wire connections and make sure the electrode is not broken. Replace the igniter if defective. Dirt and rust on the pilot or electrode tip can prevent the igniter spark. Wipe clean with a damp cloth and dry completely. Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper.

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 (Figure 11).

2.On the lower front of the water heater, locate the gas control valve/thermostat (see Figure 32). 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. 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 igniter wire from the igniter. 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 the igniter bracket from the gas valve. Disconnect the thermocouple (right-hand threads), pilot tube, and manifold tube at the gas control valve/thermostat (Figure 31). NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube. Also, disconnect the thermal switch wires.

6.Refer to “Gas Piping” section (Figure 11) 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 a 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, thermocouple, 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 number on the water heater.

TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.

FVIR System Operational Checklist

1.Manifold gasket properly sealed.

2.Viewport not damaged or cracked.

3.Flame-arrestor free of debris and undamaged.

4.Manifold component block properly installed.

5.No leaks at pilot and manifold connection.

6.Manifold door screws securely tightened.

7.Depress the button on the thermal switch.

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