American Water Heater 319407-002 Removing and Replacing the Gas Control Valve/Thermostat

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, flue damper, igniter, and flammable vapor sensor

Removing the Gas Control Valve/Thermostat:

1.Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 5).

2.Move the ON/OFF switch on the gas control valve/ thermostat to the “OFF” position to turn off the water heater and unplug from the wall outlet. (Figure 22).

3.Drain the water heater. Refer to the section of “Draining and Flushing” and follow the procedure.

4.Disconnect the wire harness, flammable vapor sensor wires, and igniter wire from the gas control valve/ thermostat. Disconnect pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/ thermostat (Figure 27). NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube.

5.Refer to “Gas Piping” (Figure 5) 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 control valve/thermostat, thread a 4” section of gas 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.

Gas Control Valve/Thermostat:

To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a 4” section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (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 the water heater 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 16.

•With the burner lit, check the gas control valve/ thermostat supply line, manifold component block, manifold tube, and pilot tube connections for leaks. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. IMPORTANT: All leaks must be fixed immediately

•If additional information is required, contact the Service Department at: 1-877-817-6750.

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.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.

TROUBLESHOOTING CHART

PROBLEM		POSSIBLE CAUSE(S)		CORRECTIVE ACTION
BURNER WILL NOT IGNITE	1.	Pilot will not light	1.	See PILOT WILL NOT LIGHT OR REMAIN
	2.	Thermostat set too low	2.	LIT
				Turn temp. dial to desired temperature
	3.	No gas	3.	Check with gas utility company
	4.	Dirt in the gas lines	4.	Notify utility-install trap in gas line
	5.	Pilot line clogged	5.	Clean, locate source and correct
	6.	Main burner line clogged	6.	Clean, locate source and correct
	7.	Non-functioning gas control valve/thermostat	7.	Replace gas control valve/thermostat
	8.	Heater installed in a confined area	8.	Provide fresh air ventilation
	9.	Flue Damper not functioning	9.	Cycle power to the water heater off and on. If
				problem persists replace the flue damper
PILOT WILL NOT LIGHT OR	1.	Non-functioning Pilot\Igniter-Flame Sensor	1.	See Status Light Code Troubleshooting Table
REMAIN LIT	2.	The thermal switch tripped	2.	section
				See Pilot Light Troubleshooting Flowchart
	3.	Igniter wire connection loose	3.	section
				Seat connector firmly in socket
	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 utility-install dirt trap in gas line
	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.	Air for combustion obstructed	11.	See maintenance section for inspection and
	12.	FV Senor Lockout	12.	cleaning of flame trap.
				Contact a qualified person to reset the sensor
	13.	Flue Damper not functioning	13.	Cycle power to the water heater off and on. If
				problem persists replace the flue damper

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