Wife text me a couple nights ago. Said she ran a bath and there was no hot water. Only lukewarm at best. I was away working so I FaceTimed her and ran a start sequence on the hot water tank. It did its normal start and ran but then cut out. I had her take the thermostat down to minimum and close the gas valve until I got home.
Got home this morning and turned the thermostat to max. Heater ran as normal. Went to downstairs bathtub and turned faucet to max hot and only got lukewarm water. Went back to the tank and set my sights on the thermostatic mixing valve. Hot water piping into the valve was very hot. Cold water in was cold, but the outlet was just barely warm. There's the problem. Valve is stuck. I did a quick google search which showed many others with the same problem. I tried turning the valve by hand but it was seized, a problem that another's also had lol. There was a plumbing video that showed a plumber take the cap off and grab the brass fitting with a pair of channel locks. I used vice grips and with just a little bit of force, I was able to break thru the resistance and then I was able to turn the valve by hand throughout its entire travel. I kept the tub flowing and cycled the valve. Set it back to hot and tested the water temperature at the tub. Tempered hot water is back and flowing beautifully to all faucets throughout the house now. Easy 5 min fix.
Tank is a 50USG Polaris PR50-130-2NV. Condensing type and stainless steel. Never seen one before. Was manufactured in October 2022 and installed by previous owners sometime in early 2023. I originally thought I was facing a flame failure due to a smoked ignitor as these tanks have their ignitors double as an electronic flame sensor but she was all good.
Honeywell AM-1 Series thermostatic mixing valve. Another quality Honeywell product!
I guess it could be worse.... Most people change out the guts on these things with a rebuild kit, a task that is very likely to be in my future.
The heater had been running and supplying us with hot water since we moved into the place in June. But I found that it would cut out before it got to its temperature setpoint. Not sure if it was hitting its ECO or not but I decided to break into the combustion air supply piping to find the air filter that these units ship with. Yah..... the filter was a touch on the dirty side lol. Cleaned it up and no more early cut outs since!!!