Whirlpool BFG2F4040T3NOV 7K Instruction manual

Pilot light will not stay lit/ Read information on pages below: Also read your manual
More resources: http://waterheatertimer.org/How-to-install-gas-water-heater.html#troubleshoot
http://waterheatertimer.org/How-to-test-water-heater-thermocouple.html
http://waterheatertimer.org/How-to-repair-Rheem-FVIR.html
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Too small a pilot flame, flame is not clear blue (clean combustion parts and combustion chamber)
Bad thermocouple (replace) How to test thermocouple: Light pilot. Release pilot button after 60 seconds.
If pilot goes out, then thermocouple is probably bad
No gas at pilot: ECO or energy cut off stops gas flow to pilot and burner if overheating condition occurred.
If pilot will not ignite at all, then ECO is probably tripped, or gas valve is bad. (Replace gas control valve
and/or re-set ECO if model has thermal protection switch located on front of combustion door) If gas is
available and some flame is present, the ECO is not tripped.
Bad gas valve (replace)
Water, rust inside combustion chamber can mean vent condensate dripping down water heater and
extinguishing flame. Can also mean vent cover missing and rain entering water heater. (Check condition of
vent pipes)
Pilot light burns/ goes out later: (Test for proper air draw up vent, check for spillage. Open window and get
more fresh air to water heater, FVIR tripped)
Pilot and burner ignites, but creates black soot:
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Dirty/Blocked Burner Tube (Clean)
Clean burner and tube
Pilot orifice
Dirty Pilot Orifice (have cleaned by qualified person, also clean with carburetor cleaner and compressed
air)
Bad LP pressure (have set by qualified person), low NG pressure (call gas company), not enough fresh air
* Check thermocouple is securely screwed into thermostat assembly. Finger tight plus 1/4 turn
* Check that end of thermocouple is sitting in the pilot light flame, and not fallen away.
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* Thermocouple may have failed and requires replacement: remove old thermocouple
and take to hardware store for matching replacement. Take photos before removal.
Read manual. Some thermocouples require removal of burner.
* Condensation dripping down vent can extinguish pilot light. This implies venting issue, inspect
vent for holes, light match under vent hood and see if draft pulls smoke immediately upward.
Thermocouple
* Thermocouple and pilot tubes must have gradual bends without kinks or pinches
* Make sure gas is turned on. Gas shut-off handle must be parallel with gas line.
* Gas pressure may be low, check pressure or have utility company check pressure
* Galvanized pipe is not suitable for gas line. Galvanized flakes will stick inside gas control valve.
Replace gas control valve and replace galvanized pipe with black pipe or flexible yellow gas line.
* Thermostat may have failed and requires replacement. Refer to part number in manual
or on side of gas valve.
Gas control valve thermostat
* Air or dirt in gas line can cause loss of gas: dis-assemble and clean or replace
* Pilot line or orifice may be clogged. Read manual for yearly cleaning and maintenance procedure.
* Are other gas appliances working? If not, check with gas company
* Was a new power-vented appliance recently installed in house? This can draw air down water heater vent.
* Inadequate combustion air can cause water heater to shut down for safety reasons. Open doors and window.
* If vent is shared with furnace, vent air from other gas appliance can blow out pilot.
* Improper venting on roof can cause backdraft that blows out pilot. Vent must meet local code. Call plumber.
* Do not expose water heater to stored chemicals like bleach and pool chemicals. Avoid corrosive atmospheres.
Vent problems: READ about NEGATIVE PRESSURE below
* Read manual for necessary yearly maintenance on burner. Also see illustrations below .
* Replace burner and pilot assembly. See Fig 4
Troubleshoot chart with cause and action:
Unable to light pilot
Pilot does not light
1. Gas supply turned off
2. Gas cock knob dial not positioned
correctly
3. Defective thermocouple
4. Defective safety magnet assembly
5. Pilot burner orifice clogged
6. Pilot tube pinched or clogged
7. Poor thermocouple connection
8. Air in gas line
9. Thermostat’s single use ECO is
tripped
10. Gas valve defective
1. Poor thermocouple connection
2. Thermocouple defective
3. Thermocouple not in pilot flame
Pilot does not stay lit
4. Defective safety magnet assembly
5. Venting downdraft (or other
improper draft)
Turn on gas supply
Check lighting instructions. Set control
knob
Check and replace thermocouple
Check and replace gas valve
Clean or replace
Clean, repair or replace
Check and tighten
Purge air from gas line
Check ECO and replace gas valve
Check gas valve
Tighten connection at gas valve
Check thermocouple and replace
Move tip of thermocouple so it is
immersed in pilot flame
Check magnet and replace gas valve
Check for proper up draft venting.
Check for other drafts that could blow
out the pilot light
Inspect and clean flue way
Inspect and clean supply tube and pilot
burner
Check and adjust supply side
6. Clogged flue
7. Pilot partially clogged
8. Improper gas pressure
PILOT WILL NOT LIGHT OR REMAIN
LIT
Power vent
9. Negative pressure
10. Backdraft
11. Water dripping down vent
Turn off all household vent fans to see if
pilot will light. Ventilate water heater
location. Raise height of outdoor vent
termination.
Power vent models: install condensate tee.
Correct venting problem
1. Low gas pressure
2. Air in gas line
3. No gas
4. Dirt in gas lines
5. Pilot line or orifice clogged
6. Thermocouple connection loose
7. Defective thermocouple
8. Cold drafts
1. Check with gas utility company
2. Bleed air from gas line.
3. Check with gas utility company
4. Notify utility-install dirt trap in gas line
9. Thermostat ECO switch open**
10. Pilot and bleed tubes switched at the
thermostat
Main burner will not stay
lit
1. Low gas pressure
2. Main burner orifice clogged
3. Main burner supply tube clogged or
pinched
4. Defective magnet assembly
5. Defective thermocouple
6. Poor thermocouple connection
7. Defective main valve
8. Improper venting
5. ***Clean, locate source and correct
6. Finger tighten-then 1/4 turn with wrench
7. Replace thermocouple
8. Locate source and correct
9. Replace thermostat
10. Switch pilot and bleed tube at the fittings
located on the
thermostat bottom.
Check gas supply pressure
Clean or replace
Clean, repair or replace
Check and replace gas control valve
Check and replace thermocouple
Inspect and tighten
Replace gas control valve
Check venting for proper sizing and
down drafts
Fig 1
Fig 2 Typical Robertshaw Gas Thermostat/ Gas control
valve. Read more about ECO below.
If Gas control valve senses temperatures over 180ºF, it
will trip ECO fuse located inside gas control valve.
Many water heaters require replacement of gas valve
after thermal event. Other gas water heaters have resettable thermal switch with wires leading to valve.
Threaded end of thermocouple screws into bottom of Gas control valve and other end sit in holder next to burner
pilot light. End of thermocouple must be in the pilot flame. Heat from flame is converted into small electric
current that signals Gas control to keep gas flowing. When thermocouple is defective. or if pilot flame goes out or
if thermocouple has slipped out of the pilot flame, then Gas control turns off gas to pilot and shuts off gas to
burner. When installing thermocouple, don’t overtighten or it will crush the insulator and short out the 11
milivolts produced by thermopile. Use fingers to start threads. Rule of thumb is finger tight plus 1/4 turn adding
another 1/8 turn if thermocouple is loose. Make sure not to cross thread thermocouple in Gas control valve.
USE burner brush to clean gas lines, and pilot tube.
CONTAMINANTS IN THE GAS PIPING MAY FOUL THE GAS
CONTROL /THERMOSTAT CAUSING A MALFUNCTION, FIRE
OR EXPLOSION. BE SURE ALL GAS PIPING IS CLEAN AND
CLEAR ON THE INSIDE BEFORE ATTACHING THE GAS LINE.
WATER HEATER AND ANY OTHER GAS FUEL BURNING
APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR
FOR PROPER VENTILATION OF THE FLUE GASES.
LP water heater: Manifold tube and burner are reverse thread
***Clean burner
Disconnect thermocouple, pilot tube, bleed tube and manifold
extension at the thermostat.
L.P. gas systems use reverse (lefthanded) threads on the manifold
tube.
Grasp the manifold tube and push down slightly to free the
manifold, pilot tube, bleed tube and thermocouple. Pull the burner
out slightly to free it from the holding bracket. Tilt the burner to one
side and remove it from the burner compartment.
Check the burner to see if it is dirty or clogged. The burner may be
cleaned with soap and hot water. If a sooty condition exists, refer
to your manual’s Troubleshooting Chart
When re-connecting manifold extension and bleed tube and pilot
tube, do NOT use thread sealants.Teflon tape is not needed.
Typical parts
1. Thermostat
2. Pilot Supply Tube
3. Thermocouple
4. Burner Supply Tube
5. Burner Orifice
6. Burner
7. Pilot Burner NG
8. Drain Valve Shroud
9. Drain Valve
10. Jacket Door
11. Inner Door
12. Flue Baffle
12A. Flue Baffle Hanger
13. Anode Rod
14. Draft
15. T&P Relief Valve
Fig 4
ECO/ energy cut off –or- High-Limit –or- Thermal cut off
Instruction manual will say if ECO is located inside Gas control. ‘Singleuse’ means Gas control valve must be replaced after ECO is tripped
Advisory says not to jumper across the wires on back of Gas control
valve. Operating Gas control valve without ECO protection can cause
water heater explosion due to run-away overheating and excessive
pressure inside tank.
** ECO: WATER TEMPERATURES IN
EXCESS OF 180° F WILL CAUSE HIGH LIMIT
CONTROL (ECO) TO OPEN AND SHUT OFF
GAS SUPPLY TO UNIT. THE HIGH LIMIT
CONTROL IS A SINGLE USE TYPE THAT
WILL REQUIRE REPLACEMENT OF
THERMOSTAT BEFORE THE BURNER CAN
OPERATE.
DO NOT BYPASS OR JUMPER THE ECO.
THIS WILL VOID WARRANTY AND RELEASE
MANUFACTURER FROM
LIABILITY FOR ANY ACCIDENT RESULTING
FROM ELIMINATING THE ECO FROM THE
WATER HEATER CIRCUIT.
Whirlpool resettable thermal switch or ECO/energy-cut-off is located on
combustion chamber door. Wires from ECO thermal switch connect to
Gas control.
ECO can be located inside Gas control and also on combustion door. If
Gas control ECO is tripped, then Gas control has to be replaced. ECO
trips when temperatures reach more than 180ºF. The ECO protects
water heater in event of failed thermostat, or failed Gas control valve,
or overheating caused by dirty and poorly maintained burner
If ECO thermal switch is tripped, burner
will not operate
Combustion air must be free of acidforming chemicals such as sulfur, fluorine,
Trace amounts of chemical will damage gas water heater
and chlorine. These elements are found in
aerosol sprays, detergents, bleaches, cleaning
solvents, air fresheners, paint and varnish
removers, refrigerants, process chemicals and
wax, and many other commercial and household
products. When burned, vapors from these
products form highly corrosive acid compounds.
These products should not be stored near the
water heater or air inlet.
If burner parts are rusted, pilot might not light.
http://waterheatertimer.org/How-to-repair-Rheem-FVIR.html
FV sensor or FVIR
Rheem FV sensor, or FVIR, trips and
shuts off air supply to combustion
chamber. FV event is caused when
Flammable Vapors enter water heater.
Tripped FV prevents flashover, fire and
explosion inside house: Replace sensor
kit.
Test gas pressure, bleed air out of gas line
Attics, basements, closets need adequate incoming air supply. Very hot air in attic will cause oxygen molecules to
separate and no longer support pilot flame. Open doors and windows, and add vents to get air to water heater.
Backdraft and tight house, furnace, fireplace, and other gas appliances that draw air etc, can combine with
mechanical vent fans such as range hood, bathroom fans, to create negative pressure inside house that blows out
pilot light.
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Test vent draft.
If vent is not drafting, or has backdraft, then
pilot will blow out or not keep burning.
If burner is rusted, check if condensation is
running down inside the vent pipe.
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NEGATIVE PRESSURE
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Flooded water heater must be replaced.
http://waterheatertimer.org/Flooded-water-heater.html
Water heater safety precautions:
http://waterheatertimer.org/Water-heater-safety-precautions.html
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For service manuals and other useful information and illustrations:
http://waterheatertimer.org/How-to-install-gas-water-heater.html#troubleshoot
Typical manual.
http://waterheatertimer.org/pdf/Rheem-ResPowerVent_PVR50-80.pdf
Typical service manual
http://waterheatertimer.org/pdf/44943-D-FVIR-Brad-White.pdf