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24
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. Turn the gas control/temperature knob 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” on page 20 and follow the procedure.
4. Disconnect the igniter wire from the igniter button.
Disconnect the thermopile, pilot tube, two wire leads at
the thermal switch, and manifold tube at the gas control
valve/thermostat (Figure 22).
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.
Flame Lock
™
Safety System Operational Checklist
TROUBLESHOOTING CHART
Replacing the Gas Valve:
To replace the gas control valve/thermostat, reassemble in
reverse order. IMPORTANT: 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 the gas supply and
gas valve for leaks. Test the supply connections 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 water heater
lit check for leaks at the manifold and pilot connections.
Bubbles forming indicate a leak. Correct any leak found.
• 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.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the button on the thermal switch.
1. Manifold door gasket properly sealed.
2. Viewport not damaged or cracked.
3. Flame-trap free of debris and undamaged.
4. Two piece wire connector properly installed.
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
BURNER WILL NOT IGNITE 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 thermopile
8. Non-functioning thermostat
9. Heater installed in a confined area
1. Light pilot
2. Turn temp. dial to desired temperature
3. Check with 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 thermopile
8. Replace thermostat
9. Provide fresh air ventilation
SMELLY WATER 1. Sulfides in the water 1. Replace the anode with a special anode
BURNER FLAME YELLOW-
LAZY
1. Insufficient secondary air
2. Low gas pressure
3. Flue clogged
4. Main burner line clogged
5. Heater installed in a confined area
6. Obstruction in main burner orifice
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
PILOT WILL NOT LIGHT OR
REMAIN LIT
1. Non-functioning igniter
2. The thermal switch tripped
3. Thermopile connection loose
4. Air in gas line
5. Low gas pressure
6. No gas
7. Dirt in gas lines
8. Cold drafts
9. Thermostat ECO switch open
10. Pilot line or orifice clogged
11. Non-functioning thermopile
12. Air for combustion obstructed
13. Flammable vapors incident, Flame Lock
™
function utilized
1. Replace igniter pilot assembly
2. See Pilot Light Troubleshooting Flowchart
section
3. Seat connector firmly in socket
4. Bleed the air from the gas line
5. Check with gas utility company
6. Check with gas utility company
7. Notify utility-install dirt trap in gas line
8. Locate source and correct
9. Replace thermostat
10. Clean, locate source and correct
11. Replace thermopile
12. See maintenance section for inspection and
cleaning of flame trap
13. Replace water heater, eliminate flammable
vapors source. Call 1-877-817-6750