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Replacing the Gas Valve Important: The rubber gasket that seals the gas valve tothe venturi manifold must be used (previous gaskets maybe reused, if in good condition). Make sure the gasket isproperly inserted into the recess on the gas valve prior toinstallation (see figure 25 for exact placement of the rubbergasket). 1. Remove the O-ring from the flange (removed from theold gas valve) and replace it with the one providedin the gas valve kit (model VK8115V, part number 6903775.) 2. Reattach the elbow flange to the gas valve. Tighten all four screws securely. 3. Place the three T-25 Torx screws through the proper holes in the venturi manifold flange. See figure 25. 4. Properly install a new rubber gasket (provided) asshown in figure 25. 5. Position the gas valve and start all three screws(projecting downward from the venturi manifold) intothe gas valve. A T-25 Torx wrench has been provided in the gas valve replacement kit (model VK8115V, part number 6903775.) Note: All three T-25 Torx screws must be properly tightened to secure the seal between the gas valve and the venturimanifold. 6. Reconnect the pressure tap to the port on the new gasvalve (see figure 25). 7. Reconnect the external gas supply line to the gas piping on the gas valve. Be sure to use approved Teflon tape or pipe joint compound suitable for gas piping. Note: Use a second pipe wrench on the gas piping insidethe skirt to avoid cracking the gas valve or the cast fitting. 8. Reconnect the electrical plug to the gas valve andsecure it with the screw provided. 9. Turn gas supply on and check for leaks. Use a chloride- free soap and water solution (bubbles formingindicate a leak) or other approved method. All leaks must be fixed immediately. 10. Be sure tank is completely filled with water before restoring power to the water heater. Follow operating instructions on Page 25. 11. Ensure proper operation of the water heater, then reinstall the access door. If additional information is required, contact the ProductService and Support Group at 1-800-456-9805. Figure 25 28 TROUBLESHOOTING Ignition Control Module (ICM) LED Error Codes: (Flashes visible through viewport in access door) FLASHES INDICATED PROBLEM CONTROL REACTION 1 Pressure Switch Closed SC* 2 Pressure Switch Open SL 3 Failed Ignition SL3 4 Gas Valve Hardware Fault SL 5 Flame Sense Hardware Fault SC 6 False Flame SL** 8 Ignition Control Hardware Fault SL 9 Ignition Control Software Fault SL Rapid L1 Polarity Detection SC SL (Soft Lockout): Control Automatically resets after 60 minutes. SL3 (Soft Lockout/Hard Lockout): Control automatically resets after 60 minutes, with a maximum of 3 resets, followed by hard lockout requiring service. SC (Self Clearing): Control will function normally as soon as it no longer detects the previously indicated fault. * when pressure switch or blower relay opens ** when fl ame is no longer sensed. † Blower Isolation Relay is used on models 150,000 BTU/Hr and above. Note: If unit goes into a soft or hard lock-out the ignition control module can be reset by cycling power to the water heater. SOFTWARE OPERATION SEQUENCE IGNITION CONTROL MODULE SOFTWARE OPERATION SEQUENCE * For 175,000 BTU/Hr models and above the flame establishing period is six seconds. For the first 3 seconds the gas valve is off. 30 REPAIR PARTS LIST/DIAGRAM ITEM NO. PARTS DESCRIPTION 1 1” NPT x 3” BRASS NIPPLE 2 THERMOSTAT SENSOR BUSHING 3 O-RING 4 THERMOSTAT SENSOR/ECO 5 INVERTED FLARE NUT 6 PLUG 7 VINYL TUBING 8 PRESSURE SWITCH 9 COMBUSTION BLOWER 10 4 INCH DIAMETER BLOWER GASKET 11 BURNER (NATURAL AND L.P. SAME) 12 6 INCH DIAMETER BURNER GASKET 13 HOT SURFACE IGNITER 14 IGNITER BRACKET 15 VENTURI MANIFOLD 16 REDUCING COUPLING 17 AIR INLET PIPE ASSEMBLY 18 GAS VALVE 19 1/2” NPT 90 DEGREE INLET FLANGE 20 1/2” NPT X 2” NIPPLES 21 1/2” NPT ELBOWS 22 1/2” NPT X 4.5” NIPPLE 23 RED LED 24 YELLOW LED 25 GREEN LED 26 THERMOSTAT BEZEL 27 TEMPERATURE SELECTOR KNOB 28 THERMOSTAT BOARD 29 IGNITION CONTROL 30 TRANSFORMER 31A 2” CONDENSATE TRAP ASSEMBLY 31B 3” CONDENSATE TRAP ASSEMBLY 32 COLD WATER TUBE ASSEMBLY 33 TEMPERATURE AND PRESSURE RELIEF VALVE 34 DRAIN VALVE 35 POTENTIOMETER 36 VENTURI GASKET (not pictured) 37 BLOWER ISOLATION RELAY 150,000+ BTU/Hr TOOLS REQUIRED FOR SERVICING TOOL FUNCTION VOLT OHMMETER MEASURE VOLTAGE/RESISTANCE CLAMP-ON AMMETER MEASURE CURRENT STOPWATCH CLOCK GAS CONSUMPTION CALCULATOR CALCULATE INPUT RATE U-TUBE MANOMETER READ INLET GAS PRESSURE 3/16” ID PLASTIC TUBING - 2 FT CONNECT MANOMETER #1 & #2 PHILLIPS SCREWDRIVERS REMOVE DOORS AND CONTROLS 12” PIPE WRENCH (2 REQUIRED) REMOVE GAS LINE 1/2” COMBINATION WRENCH REMOVE BLOWER AND BURNER 1/2” SOCKET AND RATCHET REMOVE BLOWER AND BURNER 3/8” COMBO WRENCH/NUT DRIVER REMOVE IGNITER T-25 TORX WRENCH REMOVE THE GAS VALVE (ALSO HELPFUL - 9/32” and 5/16” COMBINATION WRENCHES) 1 1 3 3 32 3 1 A 2 9 3 0 2 8 35 24 2 3 2 7 2 6 2 5 9 1 7 1 8 1 2 1 5 1 0 1 1 1 4 1 3 1 9 2 0 2 1 2 2 6 5 43 2 1 7 8 34 3 7 1 6 31B When ordering repair parts...

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