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2012

How to troubleshoot gas water heater

Install gas water heater
Turn off gas
When gas handle is perpendicular across gas line, then gas is OFF

Leave house if you smell gas.

Do not turn on light switch or touch any light switch or electrical device that might cause static spark

Water

Emergency steps for leaking water heater
Troubleshoot leaking water heater
Flooded water heater
Gas water heater parts
Basic parts
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Prevent problems

Maintain water heater and it will last many years beyond warranty. Read manual and links below.
How to maintain water heater
    1)  Read about anode rods
    2)  Read about stray current corrosion
    3)  How to flush water heater
    4) Inspect for leaks
    5)  9 ways to save with water heater
    6) Water heater safety precautions
    7) Read manual and follow maintenance schedule and precautions
2012
Troubleshoot gas water heater starts here: Your manual will have troubleshooting steps
SEARCH using Ctrl+F for browser Find feature
Water heater manufacturers
Links below contain valuable resources for troubleshooting gas water heater.
Recommend also Tank water heater forum
Post a question, or Use search feature at tank to find information available nowhere else.
Burner will not stay lit
Burner flame is yellow
Tank water heater forum
Thermocouple Test and replacement
How to test water heater thermocouple
How to replace thermcouple 2/ Utube
How to replace thermocouple pdf
Test thermocouple
Test thermocouple and thermopile

How to install thermocouple when burner must be removed

Troubleshoot water heater gas control valve
How to test White Rodgers gas valve p14
How to test Honeywell Icon gas valve p23
How to test Robertshaw gas valve p14
Troubleshoot Intellivent gas valve
Burner goes out when knob turned to ON

Replace gas control
How to replace gas control
Replace gas control
How to replace water heater gas valve
How to replace Honeywell gas control
LP heaters have left-hand threads
Calibrate gas control valve
Gas valve manufacturers
Operation and safety
Safety magnet

ECO
Test ECO on Robertshaw- White Rodgers
ECO on Robershaw,White Rodgers, Honeywell pg 17

FVIR
How to repair Rheem TRD
FVIR troubleshoot
FVIR troubleshoot for intellivent
2006 FVIR bulletin
How to repair Rheem FVIR
Intellivent FVIR troubleshoot and reset

Venting
Minimum vent distance from window
Power vent tables
Gas venting specs
Water heater vent test/ pdf
Avoid corrosive atmospheres
Conditions where outdoor air supply is needed
Square footage per BTU
General troubleshoot and service manuals:
Troubleshoot gas water heater
Troubleshoot gas water heater2
Test if thermal device needs replacement/ pdf
How to test piezo igniter
Reliance 2006 troubleshoot handbook/ pdf
AO-Smith-service-manual/ pdf
AO Smith service manual
AO Smith service manuals
AO Smith Technical bulletins
Bradford White Service Manual/ pdf
Bradford White service manuals
Bradford White technical bulletins
American troubleshooting guides
State service manual
Icon gas valve error codes

Dampered water heater troubleshoot/ pdf
Hot surface igniter troubleshoot/ pdf
American gas water heater service manual
American power vent service manual
Reliance FVIR manual
Power vent service manual
Intellivent service manual
Whirlpool Energy Smart Gas Service/ pdf
Bock HEC service manual
Bock W series service manual
Polaris troubleshoot and install manual
Rheem service bullitens
Rheem parts guide 2006 out of date/ pdf
Rheem-Ruud 2009 parts list/ pdf
Rheem parts list 2010

Pipe size and capacity
Pipe size & BTU chart
Pipe capacity
Gas pipe capacity .pdf

Safety
Water heater safety precautions before starting
Water heater precautions/ pdf
Gas-water-heater-Safety-Precautions
Gas valve safety
Thermal expansion
Insulation blanket

Convert to different gas
Convert water heater to different gas
Convert to different gas 2
How to replace gas control valve
Cautions for convert to different gas

pilot light troubleshoot
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Pilot light troubleshoot:
Clean the air intake, and get more fresh air to unit.
Use mirror to look upward, and to one side, through sightglass to see that pilot flame is clear blue.
How to light gas water heater
Pilot light goes out
Burner goes out when control knob turned to ON
Pilot light will not stay lit/ pdf
Pilot outage/ pdf
Attic Ventilation and Pilot Outage
Pilot outage and negative pressure
Pilot light maintenance/ pdf
Ventilating tight-house/ pdf
Pilot light troubleshoot
Pilot goes out when thermostat set lower
Pilot problem or ECO or gas control?
Wind blows out pilot light
Pilot light or thermocouple?
Negative pressure blows out pilot

Igniter/ Blower

How to check the igniter
Electronic spark troubleshoot
Power vent troubleshoot
Troubleshoot hot surface ignition
How to check blower motor
Check blower motor

Pressure switch
Test pressure switch
Air pressure switch testing
Intellivent wiring
Pressure switch replacement
Check pressure switch

General how-to
Find age of water heater
How to replace drain valve
Leaking water heater
How to read the gas meter
Clean sediment out of tank and periodic flushing
How to install electric water heater
Thermal expansion tank
Noisy-gas-water-heater

Common water heater problems:
Low hot water pressure
Stacking
Crossover
Flooded water heater
Typical manuals
Typical power vent manual
Sample Rheem Gas water heater manual
Bradford White service manuals
AO smith Service manuals
Whirlpool manuals
Cleaning water heater
Example: cleaning combustion chamber
Example: how to clean combustion chamber
Clean sediment out of water heater



Troubleshoot Rheem Tankless

Troubleshoot Bosch tankless
Troubleshoot electric water heater

Post questions on professional water heater forum
Electricians forum
Troubleshoot by gas control valve
Icon gas valve
Adjust temp on Honeywell gas valve
Icon gas valve error codes
Full service manual
Honeywell Gas valve video
Bradford White Service manual

Bradford White service manual 2
More Bradford White service manuals
How to clean burner
Kenmore: Temperature settings and error codes
How to replace Honeywell gas control valve
How to test gas control valve

ECO limit 199° F
How to light Honeywell gas valve
Dampered Fury gas troubleshooting codes
Induced draft troubleshoot codes
Error codes
Error codes2
Service manual
Power vent water heater issues
Sequence of operation

How to replace water heater gas valve


Error codes and adjust temp on Intelli-vent gas valve
Troubleshoot Intellivent/ pdf
Intellivent service manual
Intellivent FVIR trpubleshoot and reset
Sample manual
Intellivent wiring
Power direct vent troubleshoot
Sequence of operation
Intellivent error codes-troubleshoot

How to replace water heater gas valve

White Rogers thermostat
Troubleshooting/ pdf
Service manual for power vent model
Service manual for atmospheric model
How to light gas water heater
How to replace water heater gas valve
White Rodgers Propane replace install, set temp
gas valve setting
Service manual
Service manual 2
American Standard service manual 6Mb size
White Rodgers gas control valve replacement pdf
Power vent water heater issues
Magnet testing
How to light gas water heater
How to replace water heater gas valve
White Rodgers NG replace, install, set temp
Honeywell Smart Valve AO Smith
Honeywell Smart Valve
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Temperature settings and features
Smart valve error codes
Smart Valve service manual
Service manual
Service manual
Install smart valve & troubleshoot
AO Smith Service manual
Suburban water heater service manual

Whirlpool energy smart gas water heater manual

Robert Shaw models
Robert Shaw troubleshooting/ pdf
General troubleshoot/ pdf
Magnet testing
Recalibrate gas control/ pdf
How to light gas water heater
How to replace water heater gas valve
SIT gas control valve for water heater
SIT gas control valve for water heater
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How to light and set temperature SIT gas control
Honeywell electronic water heater controller
Honeywell electronic water heater controllers
Power vent
Power vents:
Power vent water heater issues
American power vent service manual
Anode covered by power vent
Robert shaw gas control valve
Robert Shaw 120Volt input gas control valve
Wiper Control and Gas Valve assembly
Triangle pointed upward is 120 degrees F
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Error Codes and troubleshoot
Guardian power vent Robert Shaw error code
Rheem parts list
American power flex parts
General manual with lighting instructions
Replace water heater gas control and FV
Check pressure switch, blower, gas control
Sequence of operation
How to light water heater

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Flame trap inspection
Clean air intake on AO Smith, State, American, Reliance, Whirlpool water heaters

Rheem, Richmond, Ruud, GE heaters require removal of combustion parts to clean arrestor screen inside unit.
Soot on gas burner
Soot implies dangerous situation
Gas may not be buring fully
See image on right

Soot on top of heater also implies danger.

Flame should burn clear blue
Low gas pressure.
Dirty combustion parts.
Poor incoming air supply.
Inadequate venting.

This is dangerous because unburned gas can accumulate inside combustion chamber or inside the flueway. Causing ignition.
This situation will overheat combustion chamber and trip ECO, TCO and FV system, causing water heater to stop working.
Follow product manual for correct maintenance protocol

How to read gas meter

Definitions and formulas/ pdf
Pipe size BTU chart
Pipe capacity
Square footage per BTU
Pilot orifice
Pilot tube orifice
Clean with compressed air or carburetor cleaner
Standing pilot light maintenance
Burner brush

Burner brush
Burner brush
Flexible brush
2 brushes
Clean water heater burner
Use wire brush to clean burner assembly and combustion chamber. When re-starting cold tank, expect condensation dripping until tank reaches temperature.
Example: how to clean combustion chamber
Clean water heater burner line
Expanded image
Gas water heater burner assembly
Water heater burner assembly with piezo igniter
How to clean burner
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How to remove burner
LP gas water heater burner
Burner for LP gas is made of cast iron because LP gas burns hotter.
Comparison NG-LP
Manifold tube and pilot tube are also made heavier to resist pressure & high heat of burning LP gas
Example shows rusty burner that has not been cleaned
Gas control valve for LP gas will accept left-hand threads for pilot and manifold tubes
Gas water heater burner
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NG gas burners are different than LP burners.
LP has more pressure and higher temp
Bradford White Piezo igniter
Bradford White Piezo igniter
How to test piezo igniter
Bradford White gas water heater service manual
Gas water heater
Gas water heater
How to remove burner
Flame rod sensor
Location of flame sensor and igniter vary by model and brand of water heater.
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Hot surface igniter troubleshoot

Sand carbon deposits off igniter.
Avoid touching igniter

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Intellivent troubleshoot Manual
Power vent surface ignition
Tip of flame sensor must be directly in front of burner port.
Use a nickle to set 7/64 gap.
Natural gas flame sensor will be bent, while propane will be straight.
Gas burner without piezo igniter
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Burner flame is yellow
Gas control thermostatLarger image
White Rodgers gas control valve replacement pdf
ECO wires/ thermocouple/ manifold tube/ pilot tube/ piezo igniter
How to test water heater thermocouple
LP heaters have left-hand threads

How to install thermocouple when burner must be removed
Gas valves
Larger image
Don't overtighten gas line to control valve or damage to control valve can occur.
How to set temperature on gas valves
Remove gas valve
How to replace gas control
Replace gas control
Operation and safety
How to replace Honeywell gas control
Buy universal gas control wrench
Or make a wrench out of plywood
Whirlpool ECO thermal switch
Whirlpool resettable TCO thermal switch trips when combustion get too hot. Prevents overheating: Clean burner parts.
If pilot or burner is reveiving any amount of gas, then ECO is not tripped
Test ECO
Gas water heater ECO Water heater Gas valve thermostat has Energy Cut Off
When ECO senses overheating inside tank, the ECO trips and shuts off gas.
If water heater burner or pilot has gas, then ECO is not tripped.
Gas valve must be replaced. Read more
How to replace gas control
Replace gas control
Test ECO on Robertshaw- White Rodgers Must have continuity

FVIR water heater:

How to repair Rheem FVIR
FVIR troubleshooting guide
Symptom of FV failure
'If pilot stays on without problems as long as gas valve is in PILOT position, but you then turn to ON position and main burner flutters and disappears within 30 seconds then 99% chance TRD is tripped.' (On Rheem heaters, look for signs of shattered glass on combustion floor.)
Same symptoms can be bad gas control
Air enters combustion chamber from below burner.


SP20172 FV sensor shuts off gas and trips air shut-off



FVIR shut off
FV sensor, or FVIR, trips and shuts off gas & air supply to combustion chamber.
TRD or FVIR tripped
Rheem uses glass vial that cannot be replaced
How to fix Rheem TRD
If system is tripped, the bulb glass is visible on floor of combustion chamber.
FV system: When water heater is exposed to flammable vapor, and the vapor ignites inside combustion chamber, the FV system immediately shuts off air supply to combustion and prevents a flashover or explosion inside the room.

Each water heater has a different design.
Call manufacturer for instructions for replacing or resetting FV.

FVIR troubleshoot guide
Rheem water heater parts list 2006
Rheem parts list 2010


   Read more2  Read more3
Raise water heater 18" off floor
Raise water heater 18" off floor to avoid flood damage and flammable vapors
Help prevent FVIR event by installing gas water heater at least 18" off the floor.

#1) Make sure there is adequate fresh air, and that air is clean and list free, and does not have trace chemicals.

#2) Always turn off gas to water heater when painting with oil-base paint or oil-base varnish, and when cleaning with solvent-based products, and when pouring gasoline etc.
For example when storing gasloine near water heater, the water heater should sit minimum 18" off floor, gasoline should be tightly capped, and do not pour gas to fill gas tank in same room as water heater.
Ventilate attic
Larger image              Read pdf
Attic ventilation is needed for gas water heater.
Increase ventilation to water heater
Dusty environments Avoid dusty environment that will clog air intake, cause unburned fuel, and create fire hazard
-Do not install cold water line above gas valve where condensation drips on valve.  
-Annually clean burner area with wire brush and vacuum cleaner. read1 read2
Troubleshoot and clean gas water heater

Remove chemicals from same room as water heater.
-Chemicals corrode water heater parts and vent pipe. 'Spray propellants, cleaning solvents, refrigerants, swimming pool chemicals, calcium and sodium chloride, household bleach, waxes and process chemicals are corrosive at very low levels with no odor." Read Bradford White Pdf pg2-8    Read Rheem pdf
Trace chemicals
Outlet polarity If gas valve is connected to electricity, the outlet polarity must be correct
Water heater must be grounded. Poor ground can prevent flame. GFCI circuit can cause short cycling. If outlet is not dedicated or has GFI, other loads such as florescent lighting can cause short cycling.

Unplug cord. Test for continuity between ground prong on plug and manifold tube on gas valve.
Connect water heater to different outlet. Test outlet with circuit analyzer
Gas valves How to set temperature on gas valves
If you maintain the tank: keep chemicals out of same room, attach bare copper ground wire between hot and cold pipes, flush tank each 6 months, clean burner each year as shown in manual, read the manual entirely for specific information about your model, and inspect/replace anode rod every 2-3 years then basic 6-year tank can last much longer. 
Test water heater vent      How to test water heater vent.
Let main burner operate for 5 minutes.
Then put match near vent hood.
Smoke from match should get sucked into vent
Water heater vent test/ pdf
Checking the draft
Read more at Tank
Attach vent hood to water heater
Flue pipe safety
See larger

During typical water heater combustion, hydrogen content of fuel is burned and the result is hot gases. One of these hot gases is steam or water vapor. Adequate venting or air draw up vent is required so gases vent outside. 
When there is inadequate draw, the water vapor cools and condenses on inside wall of vent pipe. This condensation water is acidic (pH 3-5) and corrosive. It will corrode steel metals and other materials.
Improper venting causes water to drip down vent into combustion chamber of gas water heater. Parts inside combustion chamber rust. Holes develop in bottom of water heater. Inspect combustion chamber for rust and water.

If steel vent pipe is not venting, the vent pipe will rust and get holes, or joints will fall apart. This situation causes hot gases to enter home and poses serious risk of odorless CO poisoning.

Simple test for proper venting: Pipes are not rusted or covered with white condensate. No water on top of tank. Burner inspection does not show excessive rusting. Light match under vent pipe and see if smoke immediately draws upwards. If smoke does not draw, then call plumber.
Flue Pipe Safety
Read manual for flue pipe clearances so hot vent pipe does not touch or come near combustibles.
Rusted flue pipe -or-water on top of gas water heater could indicate serious problem.
Call a plumber if you are uncertain.
Check pipes and flexible connectors for leaks.

If water coming from flue pipe:
1. Vent cover could be missing > rain water entering flue (replace cover)

2. Flue pipe clogged with bird nest or come apart or damp from improper venting: danger of odorless Carbon Monoxide poisioning

Serious danger from CO poisoning, a plumber should be called if you are uncertain about vent pipe water leak
Read troubleshooting at forum
See u-tube video
Read about CO detector

Glass lined steel water heater
How to replace anode rod
Minimum distance of vent pipe from window     Minimum distance of vent pipe from window
Side-wall vent pipe must be 4 feet away from windows and doors. And 3 feet away from inside corners.
Larger image with more information
Power direct-vent clearances
Venting a gas water heater
Conditions where outdoor air supply is needed

Additional links

How to flush gas water heater

Troubleshoot electric water heater

9 ways to save with water heater

How to test elements

Electricity from pole to breaker box

See basic 120V and 240V water heater circuits

Drop wire from attic

Replace circuit breaker

Wire nuts and how to twist wire

How to wire off-peak water heater


How to install gas water heater
Recirculation system
Hot water circulation system
Solar water heater
9+ ways to save with water heater

Motorized shut off valve

Clean sediment from tank
Cutler Hammer C25BUB230A
Contactors

Anode rods
Troubleshoot Rheem Tankless

Troubleshoot Bosch Tankless

Troubleshoot gas water heater

Troubleshoot electric water heater

Compare all water heater timers

My art website
Intermatic enclosures
Intermatic trippers and parts
Do it yourself
Do it yourself water heater

Low hot water pressure

Atwater water heater resources

Leaking water heater

Remove water heater from attic


Remove old element
water heater safety precautions
Water heater safety precautions

How to wire Cooper 277
UPM-timers-and-manuals.html
Woods timers and manuals
GE-timers-and-manuals.html Sylvania timers and manuals
ST01C Intermatic ST01C timer

Utilitec-timers

Aube timers
Horsepower ratings for countdown timers

Leviton timers
Tork-consumer-timers-and-manuals.html Box timers
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