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  #1  
Old 12-20-2009, 01:04 PM
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Water heater problems...

I've been struggling with a gas water heater in the townhouse for over 5 days now... it's Whilpool 30gal gas burner from 2003 - not in a bad shape, but lately very problematic...

It started losing pilot flame out of the blue - I've tracked over there twice to light it backup but I knew there must be another problem. Finally called the 1-800 number and spoke to someone who advised me that the warranty is over but they can send me a kit for free to solve the 'pilot light not staying on problem'... surely I accepted.

The kit arrived the next day - with 4 pages of instructions. It took quite a bit to get the replacement in but at the end the heater had a brand new 'innards' down in the firebox so I felt good about it. The flame stayed on, while I was there... I was hopeful...

Two days later - wouldn't you know it another phone call. Sure enough the pilot light is out again...

I'm really at a loss as to what could be going on. I guess it's possible that the whole gas valve/regulator is acting up and it's time for a new water heater.

One thing that's puzzling me is this: the instruction manual for the kit installation went into great pains to insure that the firebox is well sealed. So if the firebox is sealed so well, how does it get fresh air for the flame to stay on?! Maybe the fresh air supply vent (wherever that is) is clogged? It might make sense, since it's having the same problem with the new kit in place...

Any advice would be welcome.

Thanks,
James

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Last edited by MercFan; 12-20-2009 at 01:47 PM.
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  #2  
Old 12-20-2009, 01:44 PM
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Sealing the fire box is important to keep drafts from blowing out the pilot light.
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  #3  
Old 12-20-2009, 01:47 PM
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They usually have an adjustment for the size of the pilot flame. Increase this slightly and your problem might disappear.
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  #4  
Old 12-20-2009, 02:05 PM
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when that happens, I usually replace the thermocouple.
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  #5  
Old 12-20-2009, 03:17 PM
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Quote:
Originally Posted by kerry View Post
when that happens, I usually replace the thermocouple.
I am guessing that is what was in the kit.
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  #6  
Old 12-20-2009, 03:18 PM
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Quote:
Originally Posted by kerry View Post
when that happens, I usually replace the thermocouple.
Agreed........that's probably the best solution.
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  #7  
Old 12-20-2009, 03:20 PM
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There is a forum for waterheaters of course...
Mainly the questions get answered by the mod there.
http://www.waterheaterrescue.com/TheTank.html
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1998 C230 330,000 miles (currently dead of second failed EIS, yours will fail too, turning you into the dealer's personal human cash machine)
1988 F150 144,000 miles (leaks all the colors of the rainbow)
Previous stars: 1981 Brava 210,000 miles, 1978 128 150,000 miles, 1977 B200 Van 175,000 miles, 1972 Vega (great, if rusty, car), 1972 Celica, 1986.5 Supra
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  #8  
Old 12-20-2009, 03:25 PM
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Just doing a quick search over there, they are mentioning a thing called "thermal release device" (TRD) which can go bad.

http://www.thetankatwaterheaterrescue.com/forums/view_topic.php?id=1666&forum_id=3&highlight=trd
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1998 C230 330,000 miles (currently dead of second failed EIS, yours will fail too, turning you into the dealer's personal human cash machine)
1988 F150 144,000 miles (leaks all the colors of the rainbow)
Previous stars: 1981 Brava 210,000 miles, 1978 128 150,000 miles, 1977 B200 Van 175,000 miles, 1972 Vega (great, if rusty, car), 1972 Celica, 1986.5 Supra
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  #9  
Old 12-20-2009, 04:17 PM
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Thanks guys - like, the replacement kit came ready to install/replace. I basically consisted of everything new in the firebox, except the brass orifice which I was instructed to remove (with great pains) and place in the new unit. That orifice is what delivers the right amount of gas to the burner... nothing to do with the pilot light....

I called Whirlpool and they said that I need to replace the gas valve - which is the only thing left to replace, besides the actual steel tank at this point. Since it's Sunday I'm going to wait until tomorrow to get a new gas valve in the supply house and hopefully THAT problem will be solved....
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  #10  
Old 12-20-2009, 04:35 PM
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Did you tell Whirlpool you are a mile high?
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1984 300SD 315k--daughter's car
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  #11  
Old 12-20-2009, 06:31 PM
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I had this same problem and of course, it would manifest itself on cold mornings when I needed a shower...

Anyway, it was the little nut that secures the thermocouple to the control valve. All it needed was to be wiggled around some and cinched down a little tighter. That was about 4 years ago and it's been fine ever since.
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  #12  
Old 12-20-2009, 06:33 PM
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Is this a rental unit with the heater in a cabinet? If it re-lights relatively easily and burns clean blue when you've got the cabinet open, then I'd lean toward it being a vent issue. It lights when you open the door because you give fresh air.

If it's near the furnace, there might be other vent issues where the furnace is drawing air and blowing out the pilot. Check the ducts and maybe the filters.

Also verify the thermocouple rod is adjusted to the correct position relative to the pilot light flame. If it's too far away it'll shut off the gas.

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