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Removing and Replacing the Gas
Control Valve/Thermostat
Removing the Gas Control Valve/Thermostat:
1. Turn the gas control/temperature knob to the "OFF"
position (Figure 19A).
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 on "Draining
and Flushing" and follow the procedure.
4. Disconnect the igniter wire from the igniter lead wire.
Disconnect the temperature sensor wire, then use
needle nose pliers to disconnect the red (+) and white
(-) thermopile wires. Disconnect the pilot tube (7/16"
wrench) and manifold tube (3/4" wrench) 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.
,
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 a pipe wrench or equivalent to grip body. Damage
may result. 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 17.
• If additional information is required, reference the
number on the cover of this manual for service information.
Flame Lock ®Safety System Operational Checklist
1. Burner door gasket properly sealed. 4. Manifold component block properly installed.
2. Viewport not damaged or cracked. 5. No leaks at pilot and manifold connection.
3. Flame-trap free of debris and undamaged. 6. Burner door screws securely tightened.
TROUBLESHOOTING CHART
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
BURNER WILL NOT IGNITE 1. Pilot not tit
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
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
SMELLY WATER
BURNER FLAME YELLOW-
LAZY
PILOT WILL NOT LIGHT OR
REMAIN LIT
9. Heater installed in a confined area 9. Provide fresh air ventilation
1. Sulfides in the water 1. Replace the anode with a special anode
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. Non-functioning igniter
2. Thermopite connection loose
3. Air in gas line
4. Proper Lighting Sequence not followed.
Gas Control / Temperature Knob was not
held in for sufficient time.
5. Low gas pressure
6. No gas
7. Dirt in gas lines
8. Cold drafts
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. Seat connector firmly in socket
3. Bleed the air from the gas line
4. Do not attempt to relight if the red light is lit
and the pilot flame is not visible through the
view port. Wait until the red light is no longer
lit, then follow lighting instructions on the water
heater.
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
26
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