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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
WV8840A.
Do not spray soap and water solution on the
WV8840A 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.
WV8840A 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
control 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 WV8840A control. Improper cleaning or
reassembly can cause gas leakage.
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
seasonally 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 envi-
ronments 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 flashes of
the status indicator after a three second pause. One
single flash (with set point knob in PILOT position)
indicates that the control is in normal operation.
2. Observe status indicator on control; check and
repair the system as noted in Table 3 on page 6.
Flash codes are displayed with a three-second
delay between cycles. A continuous solid light
indicates system shutdown when knob is turned
from a temperature setting to OFF position. When
the solid light is present, the pilot and main valve
will not hold. When the status indicator goes out,
the user can restart the system. (Approximate
shutdown time is one minute.)
5
69-2247—05
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