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Basic parts and operation of gas
water heater This page shows basic parts found on residential gas water heaters and describes general operation of heater. E-mail: geno03245w@gmail.com Back to 14 things needed for gas water heater |
Fig 1 Larger image 2017 Energy factor or Unified Energy Factor (EF or EUF) is a formula that subtracts a percentage of tank volume, and is partly based on usage of heater: 40 gallon tank: 61.5% efficiency 50 gallon tank: 60% efficiency 38.5-40% of heat goes up flue pipe into atmosphere. | Basic parts Gas water heaters are NOT standardized. Figs 1-2 show parts found on all atmospheric vent heaters where natural updraft of air pulls fresh air into combustion chamber while toxic combustion by-product goes up flue pipe into atmosphere. The flue baffle helps hold heat inside tank, adding heat to water without restricting upward flow of toxic air. Parts not shown: Electronic gas control valve, FVIR or flammable vapor protection, FV or gasoline vapor sensor, thermocouple, thermopile, manifold assembly including burner and pilot assembly etc. Parts that are installed on other types residential heaters but not shown include: power vent blower, flue damper motor, helical heat exchanger, condensate drain, etc. Types of gas water heaters Resources TP valve code Repair water heater valves Remove short water heater nipple Replace drain valve How much does it cost to run gas water heater | Fig 2 Larger image Combustion by-product includes CO NOx SO CO2 and acidic water. CO: Carbon monoxide/ NOx: Nitrogen oxides: nitric oxide and nitrogen dioxide/ SO: Sulfur oxide/ CO2: Carbon dioxide ... each by-product is an environmental poison that must be vented from house to prevent death of occupants. |
 Honeywell Electronic
gas controls tyhat are used on atmospheric heaters are powered by a
thermopile instead of thermocouple. The thermopile is positioned inside combustion chamber, just above pilot flame.
Larger imageWhen heated, the thermopile produces more current than thermocouple, enabling use of circuit board that controls the electromagnets inside gas control valve, and records status and error events. Two wires, red and white, carry current from thermopile to gas valve, The wires pass through a TCO (thermal cut off) located on front of combustion chamber. The TCO trips if combustion chamber exceeds temperature limit. From the TCO, the two wires plug into front of gas control valve where they connect to circuit board. TCO is a resettable part located on front of combustion chamber. The thermostat located on back of gas control is a metal-tipped plastic tube that contains a variable resistor that connects to circuit board via 3 wires. The gas valve interprets change in resistance as change in water temperature. When water temperature drops below thermostat set point, the circuit board activates the manifold electromagnet, releasing gas to burner. Pilot flame ignites burner. The ECO or high limit is part of the circuit board. If water inside tank exceeds 180°F, the circuit board will cut off gas to heater, shutting down both pilot and burner, and issue error code as series of blinks. |
Basic gas
valve thermostat for atmospheric heaters Gas water heaters have a control valve that connects to household gas line, then releases gas in specific amounts to pilot light and burner. Gas valves are different based on design of heater, and BTU rating of burner. So a heater with 30,000 BTU would have different gas valve than heater with 40,000 BTU, even though both valves might appear identical. Check model number located on side of valve. Gas valves have a thermostat probe located on backside of valve that extends into water. The probe estimates water temperature. Gas valve responds to input from probe to turn burner on and off. If water temperature inside tank exceeds high limit (typically 170-180°F), the gas valve responds by shutting off gas to heater. Troubleshoot etc Troubleshoot gas control valve thermostat How to replace water heater gas valve How to light gas water heater Buy: Gas water heater thermostats Amazon AO Smith gas valves at Amazon Buy: AO Smith gas water heater at Amazon Bradford White gas water heater Rheem gas water heater at Amazon |
 White Rodgers
and Robert Shaw Mechanical
control valve thermostats are powered by a thermocouple that is positioned inside combustion chamber, just above pilot flame.
Larger imageWhen heated, the thermocouple produces small current. The current travels up the copper tube where it makes electrical contact with the gas control valve. The current powers the safety magnet, or gas supply electromagnet. Mechanical gas controls combine the TCO (thermal cut off) function with the ECO (energy cut off) located inside thermostat probe. Both are wired in series using two red wires coming from the ECO, that travels from backside of gas control down to the TCO located on front of combustion chamber. If the TCO is tripped off because of high heat inside combustion chamber, then current passing through the ECO is stopped, cutting power to gas supply electromagnet which cuts off all gas. Likewise, if water temperature inside tank exceeds high limit (180°F), then the single-use ECO trips, gas supply is cut off and valve needs replacement. By design, the TCO should trip first, so water inside tank never reaches 180°F. The thermostat on back of gas control is a variable resistor that interprets temperature change as resistance. When temperature drops below thermostat set point, the current drops and manifold electromagnet releases gas to burner. Another image |
 Honeywell Electronic gas controls that are used on power vent, power direct vent and flue dampered heaters are powered by 120 volt or by 24 volt AC from a transformer. Some models and brands of heater have a small transformer that converts the 120 volt into 24 volt, and the gas valve is powered by 24 volt. While other heaters use 120 volt to power the gas valve and operation of heater. Buy Example Honeywell gas control valve at Amazon Reliance NG at Amazon |
The gas valves shown left and right are different from
gas valves shown above. All water heater gas valves control the gas supply and operation of the heater, but these gas valves are used for water heaters that plug into 120 volt outlet and have blower or damper assisted combustion. The 120 household voltage is used to power the gas valve ... or powers a 24 volt AC transformer that powers the gas valve and is used to operate the blower or damper motor, the electronic control system, and combustion cycle. Heaters using these gas valves do not require thermopile or thermocouple. Types of household water heaters |
 White Rodgers Intellivent Electronic gas controls are used on power vent, power direct vent heaters and are powered by 120 volt. Buy Buy Intellivent gas control at Amazon White Rodgers/ Rheem Intellivent gas control AO Smith intellivent AO Smith Intellivent at Amazon AO Smith White Rodgers |
 Inside
gas controlHoneywell electronic gas control used for atmospheric vented heaters receive power from thermopile that supplies electric current to a circuit board (see images). The circuit board has 3 connection points that supply power to electromagnets. The main gas supply magnet shuts off gas to pilot and burner if TCO trips or if pilot light goes out, or if water heater is turned off. The manifold magnet responds to temperature measurements and turns gas on to main burner during the call for heat. Mechanical gas control valves also have electromagnet that receives current from thermocouple (see image), but there is no circuit board. The gas supply must be kept dry and clean or the gas control can clog and fail. When working on water heaters, installing and repairing, care must be taken to keep gas lines clean. Any debris or moisture entering gas valve can cause failure, requiring replacement of gas valve. |
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 Thermal cutoff (TCO)
is a resettable thermal switch located
on the front of combustion chamber door.The TCO is integral with the thermocouple or thermopile depending on type of gas control valve. When temperature inside combustion chamber exceeds thermal rating, the TCO will turn off circuit from thermocouple or thermopile, causing the main electromagnet inside gas control to stop receiving electric current. The main electromagnet de-energizes and shuts off gas to pilot and burner. Temperature cutoff points for TCO range from 160°C to 200°C depending on model. The pilot has to be relit after the TCO cools down below 120° F The TCO has 2 functions: 1) Respond to flammable vapor ignition and 2) Respond to high temperatures caused by inadequate air supply etc. Causes of tripped TCO are dirty combustion parts, clogged vent... these things cause overheated combustion chamber. Solution: Push in button to reset, replace TCO, clean burner parts (how to clean burner), check vent is drafting air (check the draft), get more air to unit (troubleshoot air supply). Is the thermal switch bad? For example TCO trips when combustion chamber is not hot. Test the TCO thermal switch. Temporarily jumper a wire across the two terminals and see if water heater functions. Buy: Thermal reset |
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The
TCO or thermal cut off
is located on front of combustion chamber. If temperature inside combustion chamber exceeds 180°F (160°-200° depending on model), the TCO trips and causes gas control valve to shut off gas to burner. The model shown in picture has electronic Honeywell gas valve with a thermopile instead of thermocouple. With this type gas valve, the TCO turns off current produced by the thermopile. If the gas control valve is no longer receiving current, it will shut down and turn off gas to pilot and burner. The TCO protects the gas valve thermostat, and prevents water inside tank from exceeding 180°, which would trip the ECO located inside the thermostat probe. If the ECO trips, the gas valve can be reset in most circumstances, but might need to be replaced. In this regard, the resettable TCO saves expensive repairs. |
  Fig-6
shows water heater with
temperature sensor instead of resettable TCO. The sensor has 2 wires
that connect to the gas valve in a separate port
located in center of valve ... marked 'sensor wires' in the
image. The resistance value 5.39 to 5.9 ohms.Fig-7 on right larger image is Low NOx manifold assembly that reduces NOx by 33%. Some states mandate reduction of NOx, nitrogen oxide, a poison that is released into atmosphere by burning gas at higher temperatures. Other states have leaders that embrace an environment devoid of life. Typical water heater without the low NOx burner simply mixes air and fuel vapor. Ignition 'almost always has some zones operating at or above peak NOx formation.' Low NOx burner keeps flames from reaching the NOx formation temperatures. Heating water using solar energy does not require burning gas at the home or business location, although burning fuel is most likely used to manufacture, transport and install solar heater. Explanation of error codes |
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Fig-8 shows water heater
model with thermopile, indicating it is made for Honeywell electronic
gas valve. Models with mechanical gas valve have thermocouple which can be identified by the copper tube going into combustion chamber, whereas the thermopile is identified by 2 wires entering the combustion chamber. If heater has electronic gas valve, the TCO turns off current produced by the thermopile that sits inside the pilot flame, same as thermocouple. Heat from the pilot causes current to flow on wires to gas control. The wires are also connected to the TCO. If the TCO trips, the gas valve is no longer receiving current and will shut down and turn off gas to burner. natural or LP gas manifolds: 1/2” OD carbon steel tubing with .026” wall thickness |
 Image from burner assembly, or
manifold assembly salvaged off old water heater shows
the fixed-positioned bracket that holds pilot, thermopile and igniter. The
piezo igniter creates spark that ignites pilot light. The pilot flame
burns clear blue when water heater is receiving adequate air supply and
gas pressure. The pilot light performs three jobs: 1) Heat the
thermocouple or thermopile that creates small electric current that
powers operation of gas control that also
2) signals gas
control valve that pilot is lit, and 3) ignites the gas when it is
released down the manifold tube and comes out of burner.A thermopile is basically several thermocouples put together. The thermopile produces more current than thermocouple. Thermopile produces enough current to power circuit board inside the electronic gas valves so it can compile status of heater operation, issue error codes via LED status light, and control operation of heater. A thermocouple produces a small current for a mechanical gas valve, but not enough current for the circuit board on electronic gas control. |
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 With
the mechanical gas control valve thermostats,
the pilot flame heats the end of a thermocouple. A
thermocouple is
2 dissimilar  metals
joined together that produce small current when
heated. The small electric current travels from the thermocouple
though a hollow tube that contains a wire inside. The thermocouple tube
screws into to bottom of the control valve, where it
connects to an electromagnet. If the pilot light is ON and thermocouple is sitting in the pilot flame, and the thermocouple is working and making electrical connection to the gas control, then the electromagnet is energized. The electromagnet holds open the safety valve as long as the pilot flame is heating the thermocouple. If the pilot light is out, then the electromagnet closes the safety valve, and no gas can enter gas control. When pilot is re-lit, the magnet makes audible sound that can be detected when troubleshooting. If the pilot flame is extinguished, it can take up to 180 seconds for the thermocouple to cool sufficiently for the electromagnet to de-energize and close the safety valve. The safety valve determines if gas can flow into gas control. If safety valve is open, then gas control operates normally, and releases gas continually to the pilot light through the pilot gas regulator valve, and releases gas to burner through the main regulator valve when thermostat probe detects water temperature is below set point as selected on dial located on front of gas control.  With the electronic gas control valve, the pilot flame heats a thermopile instead of thermocouple. The thermopile works on same principle as thermocouple, except is larger and creates more current than thermocouple, enough current to power a circuit board inside the gas control valve. Unlike thermocouple, the current from thermopile travels to gas control valve through two wires that connect to front of gas control. The circuit board controls a series of self-check routines, error compilations of water heater operation, etc and uses electromagnets to control flow of gas that enters the gas control, and gas going to pilot and burner. See basic gas water heater parts If no current is produced by thermocouple or thermopile, then gas to the valve is shut off until pilot is re-lit or defective thermocouple or thermopile replaced. The temperature-reading thermostat on a gas valve is located inside a copper tube that protrudes into tank and reads water temperature. When water temperature drops below selected thermostat setting, then the gas valve releases gas through the manifold tube and into the burner located in combustion chamber. How to adjust temperature Gas flows out of the burner where pilot light ignites gas. If burner is dirty, sooted or obstructed, the gas may not light immediately, resulting in unburned gas building up until it reaches the pilot flame causing explosion hazard. Sooted and dirty burner and yellow flame indicate this problem. After cleaning the burner and the combustion chamber, the gas should burn blue with bits of red and yellow. Clean burner |
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 FV sensor mounted on outside of
gas water heater is first layer of protection:The FV sensor flammable vapor sensor is different than FVIR system flammable vapor ignition system. FVIR systems vary by
manufacturer or brand.
The FV sensor is located on front of many water heaters near the
bottom. The sensor will trip if it senses gasoline vapors in
the air. It
does not respond to other types of flammable vapors. FV sensor is same across all brands. FVIR system is located inside the water heater and responds to all sources of flammable vapor ignition, and in some models, responds to overheating events caused by miscalibrated thermostat or failed TCO etc. The FV sensor will trip if it senses gasoline vapors in the air. It does not respond to other types of flammable vapors. Research shows that gasoline is the most common cause of fire or explosion caused by water heater. Note: FV Sensor does not prevent the ignition of flammable vapors, the FVIR System is designed to reduce the risk of flammable vapor-related fires.  FV sensor is installed inside a plastic case to keep
it
dry and clean...
if the sensor is blocked, or has been covered with dust, leaves, water
etc, it will not function. The sensor must have continuity, so a small current of electricity can pass through the sensor that signals to gas control valve that no gasoline vapor is detected. The FV sensor is easily tested using multimeter and easily replaced by plugging new one into terminal slots.  Buy:Flammable sensor kit Multimeters at Amazon Electric testers at Amazon Resource: How FV sensor works How to test FV sensor |
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 Thermostat
probe or sensor is immersed in water inside tank.Water temperature around the thermostat probe can drop 15-25° before main burner is activated. Thermostat probe is same-similar for most water heater control valves. The thermostat (copper tube) contains two things: the ECO (energy cut off), and a temperature probe thermistor.'" ''Thermistors are thermally (heat) sensitive variable resistors. A change in water temperature changes the resistance (measured in ohms) of the thermistor. The gas  control valve interprets
change in resistance as a
change in temperature and uses information to
activate and deactivate call for heat."ECO (energy cut off) will trip if water inside residential tank exceeds 180-188°F high limit. This will cause thermostat to shut off gas to burner. ECO is typically single-use, and gas control must be replaced. The mechanical gas control valves can not be reset, but the TCO (thermal cut off) located on front of combustion chamber should trip off before water reaches that temperature. . Some of the electronic gas control valves can be reset such as Intellivent (used on some power vent models), and the Honeywell valve are resettable after overheat event. Models vary, and reset is not possible for every condition. Calibrate Gas control valve: Calibration on Gas valve is approximate by 5-8°F. If calibration is far off, then rotate dial so temp at faucet is good. If thermostat comes out of calibration, and on-off temps do not match the temperature setting, or the water heater lets temperature drop too low before activating the burner, then the gas valve must be replaced. There is no adjustment. If temperatures fluctuate, then plumbing is first suspect. Check temperature of water at TP valve and at water heater drain valve. Check for stacking or crossover If plumbing checks out, gas control might be bad. Resources: How water heater thermostat work How to adjust temperature/ with basic repair manuals for gas valves |
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| How gas water heaters work |
 Larger imageHow atmospheric vent water heater works This type heater vents straight up through the roof and requires no electric outlet for operation. Note the image on right shows mechanical gas control valve, copper tube for thermocouple, and the TCO that connects to gas valve and is integral with the thermocouple, cutting off electrical current from thermocouple so the gas entering gas valve is shut off, but TCO wires don't enter combustion chamber. This model does not have thermopile. Mechanical gas control valves use thermocouple that can be identified by copper tube connecting to bottom of gas control valve. It's also important to note that each model water heater must have a gas valve that matches the design of the heater. So an electronic gas control cannot be retrofit to replace mechanical gas control. A matching gas control must be used. Sequence of operation -The gas valve thermostat controls on-off operation. It senses that water inside tank is below set point. -If the pilot light is ON, the pilot flame heats the thermocouple or thermopile. The thermocouple or thermopile creates a small current that travels to gas control valve. -If the small current arrives at the gas control, and the control is functioning, then gas is released to the burner. -If the pilot flame is positioned correctly in front of burner, at the correct distance, and gas pressure is good, then the pilot light ignites the fuel. -When temperature of water inside tank reaches the high set point, for example 120°F, the gas control valve thermostat turns off gas supply. The water heater goes into standby mode until water temperature drops below thermostat set point again. -If a problem occurs and temperature of water inside tank exceeds the 180°F high limit, the ECO trips and gas control valve turns off all gas. -Once repairs have been made to correct cause of overheating, the gas control valve may require replacement. -If the thermostat comes out of calibration, and is no longer reading correct temperature, it requires replacement of gas control valve. Resources: How to troubleshoot gas control valve How to troubleshoot thermocouple and thermopile |
  How
power vent water heater worksTwo types of power vent water heaters Power vent water heater (pictured on right) has one pipe connected to top of water heater, and derives all incoming air from inside the home and releases combustion gas in a sealed vent installed either horizontally through a side wall, or vertically through roof. Power direct vent has two pipes connected to top of water heater, one for intake and one for vent. Power direct vent derives all incoming air from outside the home through a sealed intake pipe and is vented through roof or side wall, and outside air supply can come from roof or side wall. Both types power vent heaters require 120 volt electric outlet for operation. Improper grounding or reverse hot-neutral polarity can cause ignition failure and/or short cycling (repeat on-off attempts). Operation sequence: -The thermostat senses water inside tank is below set point and closes a circuit that turns on the 120 volt blower located on top of water heater. -The blower pulls air upward through the combustion chamber and into the vent pipe, releasing toxic combustion by-products, including NOx SO CO CO2 and acidic water vapor, into the atmosphere, where it creates an exciting new future for the planet, rendering the product obsolete at some point. Alternative for some: Connect solar panels directly to electric water heater -At the blower, the vacuum safety switch is connected to blower via rubber tube. The rush of air through the vent pipe creates vacuum pressure. -The vacuum or pressure switch measures the vacuum created by the blower and verifies the blower is operating at speed. This ensures the blower can evacuate combustion gasses and support complete burning of fuel. Complete burning prevents explosion hazard caused by ignitable fuel gathering inside combustion chamber or vent pipe. The efficiency of gas water heater combustion is typically 60-61%, with the remaining 39-40% of heat going up the flue pipe. Calculate efficiency -Once the blower operation and flow of air is confirmed by the vacuum switch, it closes (turns on) a small circuit that signals the gas valve thermostat that the blower is working. -If the 120 volt outlet has correct voltage, polarity and grounding, the gas valve electronic control board activates the hot surface igniter, if the igniter is not burned out or needing to be cleaned, and it tests between 15-18 ohms at room temperature, the igniter glows red with heat as gas is released down the burner tube, through the orifice into the burner head. -If the gas pressure good, and the orifice is clean and correctly sized, and hot surface igniter and burner head are clean and in good working order, and the igniter is correct distance away so the gas comes into contact with igniter, and igniter is positioned correctly in front of a gas jet, the gas will ignite and burn blue. Flame sensor confirms that flame is present and signals the gas valve to continue releasing gas. The igniter remains hot to continually ignite the flow of gas. Water temperature inside tank begins to heat as poison by-product goes up vent pipe. -If the water heater has pilot light instead of hot surface igniter, the burner assembly has a pilot tube instead of igniter wires that connects to gas control valve. The control valve releases gas into the pilot tube continually as long as thermopile is functioning and correctly positioned in the pilot flame so it sends small electric current to gas control valve, signaling that pilot flame is working. If the pilot flame and thermopile system are working, the ignition sequence is ok to release gas once the blower operation is confirmed. -If the blower is not operating, or running at lower speed because of a brownout or lack of voltage, malfunction or improper venting, the vacuum switch does not receive enough vacuum pressure and will not close, and the ignition sequence will not take place. -The blower has a resettable thermal safety switch that monitors vent temperatures. If temperature on vent pipe at the blower exceeds 180°, the thermal switch opens (shuts off) the circuit between gas control valve and pressure switch. The vacuum switch resets to open position and gas valve thermostat turns off gas supply until vent pipe cools, after which the heat cycle begins again. With modern electronic gas control valves, repeated failures in the ignition and heating sequence are recorded by the gas control valve. When errors exceed parameter, the gas control valve issues error code. -If temperature of water inside tank exceeds high limit set point of thermostat, then gas control valve turns off all gas. Older style gas control valve may require replacement. Newer gas control valves can be reset (with exceptions) once repairs have been made to correct cause of overheating. If the thermostat comes out of calibration, and is no longer performing, it requires replacement of gas control valve. -When temperature inside tank reaches the set point, for example 120°F, the gas control valve thermostat turns off gas to burner, and a moment later turns off blower. The water heater goes into standby mode until water temperature drops below thermostat set point again. Resources: Intellivent wiring How to troubleshoot gas water heater Troubleshoot power vent water heater Troubleshoot power vent gas valves |
 TP valve 2 in 1 protection against excessive pressure and excessive temperature Resources TP valve code Troubleshoot and replace TP Troubleshoot water heater valves |
 Drain valve Use hose cap to solve dripping drain valve Resource How to troubleshoot and replace drain valve |
 Anode rod Prevent rusted tank, prolong life of water heater Resources How to replace anode rod How to maintain water heater |
| 14 things needed for gas water heater & .pdf resources | |
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What you need for
operation of gas water heater. Troubleshoot gas water heater 1) Basic parts and operation 2) Adequate incoming air supply ... issues: closed doors, tightly insulated house, very hot attic. 3) Adequate air supply getting to burner... issues: dirty vent screen, dirty environment, maintenance. 4) Thermal cutoff ... TCO ... issues: failed part, maintenance, vent. 5) Flammable vapor lockout .... issues: exposure to vapors, bad FV sensor, failed FV system, 6) Fuel supply to gas valve thermostat ... natural gas and propane are different ... issues: wrong gas, low pressure, moisture in pipe, undersized gas meter, supply line too small for BTU rating. 7) Gas valve thermostat regulates fuel supply ... issues: not enough gas, failed thermostat, failed gas control valve. 8) Fuel supply from thermostat to burner ... issues: maintenance, thermocouple-thermopile, gas control valve. 9) Clean and replace burner ... issue: periodic maintenance requires burner inspection, cleaning, and possible replacement 10) Functioning thermopile-thermocouple-pilot light ... issues: misalignment, failure of part. 11) Ignition of fuel supply by pilot light or hot surface igniter ... issues: pilot light, piezo igniter, electrode. 12) Power vent water heater troubleshoot ... issues: pressure switch, blower, blower sequence from gas control, outlet polarity 13) Venting combustion byproduct .... issues: vent in disrepair, other vents in house drawing air 14) Misc troubleshoot manuals |
Current gas water heater timer on
marketThe Aquanta wifi-controlled gas water heater timer interfaces with the COM port on WV series Honeywell gas valve for atmospheric heaters. It does not interface with power vent Honeywell, but works with power vented heaters by connecting to incoming voltage. This means the Aquanta works with both types of Honeywell gas valves Aquanta does not work with mechanical gas valves.  Buy:Aquanta for gas water heaters Aquanta for electric water heaters Resource Aquanta-gas-electric timer-Installation |
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