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Perform Gas Leak Test
WARNING
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
Check for gas leaks with soap and water solution
any time work is done on a gas system.
CAUTION
Water Damage Hazard.
Can damage electrical components in the
WV8860.
Do not spray soap and water solution on the
WV8860 housing. Do not use an excessive
amount of soap and water to perform the gas
leak test.
Gas Leak Test
1. Paint pipe connections upstream of the water
heater control with a rich soap and water solution.
Bubbles indicate a gas leak.
2. If a leak is detected, tighten the pipe connection.
3. Stand clear of the burner while lighting to prevent
injury caused from hidden leaks that could cause
flashback in the appliance burner compartment.
4. With the burner in operation, paint the pipe joints
(including adapters) and the control inlet and outlet
with a rich soap and water solution.
5. If another leak is detected, tighten the adapter
screw, joints, and pipe connections.
6. Replace the part(s) if a leak cannot be stopped.
Check the Gas Input and Burner Flow
Rate
WARNING
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
Follow these warnings exactly:
1. Do not exceed input rating stamped on
appliance nameplate or manufacturer
recommended burner orifice pressure for size
of orifice(s) used. Follow instructions of
appliance manufacturer.
2. IF CHECKING GAS INPUT BY CLOCKING GAS
METER: Make certain there is no gas flow
through the meter other than to the appliance
being checked. Other appliances must remain
off with the pilots extinguished (or that
consumption must be deducted from the meter
reading). Convert flow rate to Btuh as
described in form number 70-2602, Gas
Controls Handbook, and compare to Btuh input
rating on appliance nameplate.
3. IF CHECKING GAS INPUT WITH MANOMETER:
Make sure the manual gas shutoff switch is in
the OFF position before removing outlet
pressure tap plug to connect the manometer
(pressure gauge). Also, move the manual gas
shutoff switch to the OFF position when
removing the gauge and replacing the plug.
Also shut off gas supply before disconnecting
manometer and replacing plug. Repeat Gas
Leak Test at plug with main burner operating.
WV8860C WATER HEATER CONTROLS
Procedure to Check the Gas Input
and Burner Flow Rate
1. Check the full rate manifold pressure listed on the
appliance nameplate. Water heater control full rate
outlet pressure should match this rating.
2. With burner operating, check the water heater con-
trol flow rate using the meter clocking method or
check pressure using a manometer connected to
the outlet pressure tap on the water heater control.
See Fig. 5.
MAINTENANCE
WARNING
Fire or Explosion Hazard. Can cause severe injury,
death or property damage.
Do not attempt to take apart or clean the gas
valve inside the WV8860 control. Improper
cleaning or reassembly can cause gas leakage.
The WV8860 uses the combustion chamber temperature
profile during heating cycles to determine if the burner is
operating properly. Lint and dust buildup or other
obstacles that could restrict combustion air flow to the
appliance might cause the control to shut down (Error
Code 10). Thoroughly clean all air intakes to the
appliance and remove all obstacles to combustion air
flow before restarting an appliance shut down by Error
Code 10. Periodically clean lint and dust from the
appliance and keep air-flow to the appliance free from
obstacles to prevent shut down due to Error Code 10.
The maintenance program should include regular
checkout of the control as outlined in the Startup and
Checkout section, and the control system as described in
the appliance manufacturer literature.
Maintenance frequency must be determined individually
for each application. Some considerations are:
1. Cycling frequency. Appliances that may cycle
10,000 times annually should be checked monthly.
2. Intermittent use. Appliances that are used season-
ally should be checked before shutdown and again
before the next use.
3. Consequence of unexpected shutdown. Where the
cost of an unexpected shutdown would be high, the
system should be checked more often.
4. Dusty, wet or corrosive environment. Since these
environments can cause the control to deteriorate
more rapidly, the system should be checked more
often.
The system should be replaced if:
• It does not perform properly on checkout or
troubleshooting.
• The control is likely to have operated for more than
150,000 cycles.
• The control is wet or looks as if it has been wet.
TROUBLESHOOTING
Troubleshooting With Status
Indicator Assistance
1. Pilot burner must be lit. If not, push and hold Pilot
knob and light pilot with piezo. Error code will be
displayed when thermopile heats up. Error code
can be recognized by counting the number of
5
34-00019—03
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