A.O. Smith Water Heater FVlR System Operational, Checklist, Possible Causes

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(Rtape 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, 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

FVlR System Operational		Checklist
1.	Manifold gasket properly sealed.		5.	No leaks	at pilot and manifold connection.
2.	Viewportnot damaged or cracked.		6.	Manifold door screws securely tightened.
3.	Flame-arrestorfree of debris and undamaged.		7.	Depress	the button on the thermal switch

4.Two piece wire connector properly installed.

PROBLEM

BURNER WILL NOT IGNITE

SMELLY WATER

BURNER FLAME YELLOW- LAZY

PILOT WILL NOT LIGHT OR REMAIN LIT

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.Insufficient secondary air

2.Low gas pressure

3.Water heater flue or vent system blocked

4.Main burner line clogged

5.Heater installed in a confined area

6.Obstruction in main burner orifice

1.Non-functioning igniter

2.The thermal switch tripped

3.Wire lead connection at thermal switch loose

CORRECTIVE ACTION

1.Light pilot

2.Turn tem£. dial to desired temperature

3.Check wtth 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 Ltght Troubleshooting Flowchart section

3.Remove and reconnect the wire leads at

thermal switch, confirm connections are tight and not loose

4.	Thermocouple				connection loose		4.	Finger tighten; then 1/4 turn with			wrench
5.	Air in gas		line				5.	Bleed	the air from	the gas line
6.	Low gas		pressure				6.	Check with gas utility company
7.	No gas			lines			7.	Check with gas utility company
8.	Dirt	in gas					8.	Notify	utility-install	dirt trap in gas line
9.	Cold	drafts					9.	Locate	source and	correct
10.	Thermostat			ECO		switch open	10.	Replace thermostat
11.	Pilot	line or orifice				clogged	11.	Clean,	locate source and correct
12.	Non-functioning				thermocouple		12.	Replace thermocouple
13.	Air for combustton					obstructed	13. See maintenance			section for inspection and
								cleaning of flame trap
14.	Flammable			vapors		incident, FVIR	14.	Replace water heater, eliminate			flammable
	function actuated							vapors source. Contact Residential Technical
								Assistance

29