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 all of the sudden - I've tracked over there twice to light it backup but I knew there must be another problem. Finally called the 1-800 number on the label 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 getting clogged? It might make sense, since it's having the same problem with the new kit in place...

Any advice would be welcome.

Thanks,

I would doubt it has a fresh air problem as you would notice it when the main burner flame kicks on then it would be really starved.

Maybe you could first shut off gas and remove your old gas valve and take it with you to hardware store.

Is there enough gas flow to your building? When I had a gas boiler installed the pipe into the building had to be enlarged to carry enough gas for that plus four people's gas stoves plus a 75 gal. vented through the wall hot water heater.

If the gas incoming is not enough, pilot lights will shut off I was told when they came out to put the larger pipe in.

Do you think your usage might be overloading the supply?

This may not be applicable to your problem.

But . . .

Several years ago, shortly after I purchased a 10 unit apartment building, I had a similar problem of the pilot light going out routinely.

I would go over and relight it, and everything seemed fine FOR A FEW DAYS. Then it would go out again.

What we eventually determined was that the tank (and, it was a LARGE one) had a hairline crack that would open wider when hot and allow water to drip out and extinguish the pilot light.

This was a very slight leak, but enough to put the pilot out. The heat would cause the water to evaporate, and the crack would close back up, so there was no evidence of leakage.

After replacing the gas valve, if that doesn't solve the problem, I guess you'll have to get a new water heater. After all, that one is 6 years old and they don't last like they used to.

Clara

Just called Xcel Energy (local service company) - they sent a man out to check our gas pressure to the Town house - ours is one of 4 units in the building. He (service tech) said that the pressure coming to the meter from the street was normal... no telling if there is some loss between the meter and the house, but I'd doubt it...

I wonder if it is not a fresh air problem. A few years ago we had one that would go out and while watching the fire noticed it would begin to turn yellow and seemed to soot a little.

We worked on the area in the bottom of the water heater below the burner to allow the air to get to the fire. If memory serves me correctly, that seemed to fix the problem.

Did you transfer the burner jet from the old unit? Don't ask me why I would ask this question.

I had a similar problem years ago...it went on for a month or two. I found that a spider had made a web in the gas flow line that heats the thermocouple, there was a good size flame but it was just to the side of the thermo couple. It would stay lit for a few days then go out. I cleaned the tube and the flame then hit the thermocouple straight on and it has been running for years now.