Troubleshooting Chart

Flame Lock™ Safety System Operational Checklist

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 shut-off valve on the gas supply pipe (Figure 3).

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 (right-hand threads), pilot tube, two wire leads at the thermal switch, and manifold tube at the gas control valve/thermostat (Figure 22). NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

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 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.

Flame Lock™ Safety System Operational Checklist

1.Manifold 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.Manifold door screws securely tightened.

7.Depress the button on the thermal switch.

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 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 thermocouple	7.	Replace thermocouple
	8.	Non-functioning thermostat	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.	Non-functioning igniter	1.	Replace igniter pilot assembly
REMAIN LIT	2.	The thermal switch tripped	2.	See Pilot Light Troubleshooting Flowchart
	3.	Thermocouple connection loose	3.	section
	3.	Thermocouple connection loose	3.	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 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.	Non-functioning thermocouple	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
	13.	Flammable vapors incident, Flame Lock™	13.	Replace water heater, eliminate flammable
		function utilized		vapors source. Call 1-877-817-6750