Bradford White LG250H653N Light Duty Atmospheric Vent Gas Service Manual

Bradford White LG250H653N Light Duty Atmospheric Vent Gas Service Manual
Flammable Vapor Ignition Resistant
Water Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RG130T*(N,X)
RG140T*(N,X)
RG150T(N,X)
RG140S*(N,X)
RG150L*(N,X)
RG150S*(N,X)
LG255H*(N.X)
LG275H*(N,X)
LG250H65*(N,X)
RG2100H*(N,X)
RG230S*(N,X)
RG230T*(N,X)
RG240S*(N,X)
RG240T*(N,X)
RG250H*(N,X)
RG250L*(N,X)
RG250S*(N,X)
RG250T*(N,X)
RG250H*(N,X)
RG255H*(N,X)
RG275H*(N,X)
(*) Denotes Warranty Years
Manual 238-51542-00C REV 08/19
Save this manual for future reference
The Bradford White
DEFENDER
Safety System®
Flammable Vapor Ignition Resistant Water Heaters
Table of Contents
Page
Introduction………………………………………………………………………………...4
---
..
Troubleshooting Charts…………………………………………………………….…...6
---
Inner Door Gasket Removal, Inspection, and Replacement………………………..12
RG-I
Thermocouple/Thermopile Testing and Replacement………………………….…..15
..
RG-II
..
Pilot Assembly Inspection Cleaning and Replacement……………………………..18
RG-III
..
Piezo Igniter, Electrode Testing and Replacement……………………………..…..19
RG-IV
White Rodgers Mechanical Gas Valve Testing and Replacement…………….…..20
RG-V
Electronic Gas Control Testing, Disassembly, and Replacement………………
…..25
RG-VI
Burner Operation Inspection, Adjustment, Cleaning, and Replacement…………..35
RG-VII
.…..37
Resettable Thermal Switch Testing and Replacement………………………..…
RG-VIII
Flame Arrestor Cleaning………………………………………………..39
RG-IX
Diptube and Anode Inspection and Replacement……………………………….…..40
RG-X
Parts Diagram……………………………………………………………………….…..42
---
Notes………..…………………………………………………………………………
…...43
---
ScreenLok
®
2
2
Service
Procedure
WARNING: If the information in these instructions is not followed
exactly, a fire or explosion may result in property damage, personal
injury, or death.
For Your Safety
Do not store or use gasoline or other flammable, combustible, or
corrosive vapors and liquids in the vicinity of this or any other
appliance.
– WHAT TO DO IF YOU SMELL GAS
x Do not try to light any appliance.
x Do not touch any electrical switch; do not use any
phone in your building.
x Immediately call your gas supplier from a neighborʼs
phone. Follow the gas supplierʼs instructions.
x If you cannot reach your gas supplier, call the fire
department.
– Installation and service must be performed by a qualified
installer, service agency, or the gas supplier.
DANGER
DO NOT store or use gasoline or
other flammable, combustible, or
corrosive vapors and liquids in the
vicinity of this or any other appliance.
IMPORTANT
Before proceeding, please inspect the
water heater and its components for
possible damage. DO NOT install any
water heater with damaged
components. If damage is evident
then please contact the supplier where
the water heater was purchased or the
manufacturer listed on the rating plate
for replacement parts.
WARNING
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE
IF YOU ARE NOT CERTAIN OF THE FOLLOWING:
x Liquefied petroleum gases/propane gas and
natural gas have an odorant added by the gas
supplier that aids in the detection of the gas.
x Most people recognize this odor as a “sulfur” or
“rotten egg” smell.
x Other conditions, such as “odorant fade” can
cause the odorant to diminish in intensity, or
“fade”, and not be as readily detectable.
x If you have a diminished sense of smell or are in
any way unsure of the presence of gas,
immediately contact your gas supplier from a
neighborʼs telephone.
Gas detectors are available. Contact your gas
supplier, or plumbing professional, for more
information.
Water heaters are heat producing appliances. To
avoid damage or injury, do not store materials
against the water heater or vent-air intake system.
Use proper care to avoid unnecessary contact
(especially by children) with the water heater and
vent-air intake components. UNDER NO
CIRCUMSTANCES SHOULD FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT
THINNER BE USED OR STORED IN THE
VICINITY OF THIS WATER HEATER, VENT-AIR
INTAKE SYSTEM OR IN ANY LOCATION FROM
WHICH FUMES COULD REACH THE WATER
HEATER OR VENT-AIR INTAKE SYSTEM.
WARNING
Hydrogen gas can be produced in an operating
water heater that has not had water drawn from the
tank for a long period of time (generally two weeks
or more). HYDROGEN GAS IS EXTREMELY
FLAMMABLE. To prevent the possibility of injury
under these conditions, we recommend the hot
water faucet to be open for several minutes at the
kitchen sink before you use any electrical appliance
which is connected to the hot water system. If
hydrogen is present, there will be an unusual sound
such as air escaping through the pipes as hot water
begins to flow. DO NOT smoke or have open flame
near the faucet at the time it is open.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW,
LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE
RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIM THAT MIGHT
RESULT FROM EXCESSIVE TEMPERATURE AND
PRESSURES.
CAUTION
If sweat fittings are to be used DO NOT apply heat to
the nipples on top of the water heater. Sweat the tubing
to the adapter before fitting the adapter to the water
connections. It is imperative that heat is not applied to
the nipples containing a plastic liner.
3
3
INTRODUCTION
The Bradford White DEFENDER Safety System®
®
The Bradford White DEFENDER Safety System was designed to resist the ignition of flammable
vapors that can occur outside of the water heater. Use and installation are nearly identical to
previous versions of atmospherically fired and vented water heaters. A number of exclusive
design features are incorporated in the system that will require additional knowledge on the part of
the qualified service provider. The following information will instruct service professionals on the
function, proper diagnosis and repair of water heaters employing the Bradford White DEFENDER
Safety System.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the opening in the
jacket. This air travels down and around the combustion chamber and enters through holes in the
very bottom of the corrosion-resistant combustion chamber. The air then travels up through the
oriented flame arrestor plate louvers, where the velocity of the air is increased, and its direction
altered. The air then mixes in a normal manner with the supplied gas and is efficiently combusted,
producing very low NOx emissions.
In the case where trace amounts of flammable vapors are present in the air flowing into the
combustion chamber, the vapors are harmlessly ignited by the burner/pilot flame. If flammable
vapors are in sufficient quantity to prevent normal combustion, the burner/pilot flame is shut down.
Should the flammable vapors continue to the burner, the flame arrestor plate prevents the flames
from traveling backwards and igniting vapors outside of the combustion chamber. The calibrated,
multipurpose thermal switch recognizes this and shuts down the pilot and main burner. This switch
also deactivates the burner and pilot in the unlikely event of restricted airflow caused by severe lint,
dust, or oil accumulation on the arrestor plate.
4
4
It is intended for this manual to be used by qualified service personnel for the primary purpose
of troubleshooting and repair of the Bradford White DV Series water heaters.
The Honeywell Icon Gas Control will display status codes in the event of abnormal operation.
Status codes are listed in the troubleshooting charts found in this service manual. The
troubleshooting charts will also indicate the probable cause for the status code and direct the
service professional to a service procedure to properly diagnose the abnormal operation.
In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent
system to determine the problem.
Contact the Bradford White technical support group immediately if diagnosis cannot be made
using the methods described in this service manual.
Tools Required for Service
Manometer: A liquid “U” tube type or a digital (magnahelic) type can be
used. This device is used to measure gas and/or air pressure
and vacuum.
Multi-Meter: A digital type is strongly recommended. This device is used
to measure electrical values. The meter you select must have
the capability to measure volts AC, volts DC, amps,
micro-amps, and ohms.
Electronic Probes: In some cases, standard multi-meter probes will damage or
simply not be effective to obtain certain voltage and ohm
readings. It will be necessary to have special electronic “pin”
type multi-meter probes. These probes are available at most
electronic wholesale outlets.
Thermometer: Used to measure water temperature. An accurate
thermometer is recommended.
Water Pressure Gage: Used to measure water supply pressure. Also used to
determine tank pressure by adapting to the drain valve of the
heater.
Various Hand Tools: Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”,
1/2”), 12” crescent wrench, allen wrench set, screw drivers
(common & Phillips), 1/4” nut driver, pliers (common & needle
nose), socket set, side cutters, wire cutters, wire strippers,
wire crimpers, torpedo level, small shop vacuum, step ladder,
flashlight, and 5-gallon pail.
5
5
White Rodgers Mechanical Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom
Pilot will not light
Probable Cause
1.No incoming gas or too low
gas pressure.
2.Gas control knob set to
wrong position.
3.Gas control knob not being
fully depressed when
attempting to light pilot.
4.Pilot orifice or pilot tube is
obstructed or kinked.
5.Pilot electrode not sparking to
pilot.
6.Piezo igniter not functioning.
1.Poor thermocouple
connection at combination
thermostat/gas valve.
2.Thermocouple not fully
engaged in pilot assembly
bracket.
3.Pilot flame is not fully
enveloping the thermocouple
Pilot will not stay lit bulb.
4.Weak or defective
when button is
thermocouple.
released
5.Open ECO in
combination thermostat/
gas valve.
6.Defective magnet in
combination thermostat/gas
valve.
7.Resettable thermal switch
has opened.
Pilot will light but
the main burner
will not come on
1.Combination thermostat/gas
valve set too low for desired
water temperature.
2.Combination
thermostat/gas valve
temperature is satisfied.
3.Insufficient gas supply or
low gas pressure.
4.Combination thermostat/gas
valve has wide differential or
is out of calibration.
Corrective Action
1. Turn on gas supply and/or check
line pressure.
2. Review lighting instruction. Set gas
control knob to correct position.
3. Review lighting instruction. Fully
depress gas control knob.
4. Clean, repair or replace.
5. Verify correct electrode position.
Replace pilot assembly.
6. Replace piezo igniter.
1. See Service
Procedure RG-V
2. See Service
Procedure RG-III
3. See Service
Procedure RG-III
4. See Service
Procedure RG-IV
1. Check connection at combination
thermostat/gas valve. Proper
tightness should be finger tight
+ a 1/4 turn.
2. Inspect thermocouple to ensure
that it is fully engaged into pilot
bracket.
3. Clean pilot orifice and verify pilot
tube is clear; check gas supply
1. See Service
and line pressure.
Procedure RG-II
4. Check thermocouple and replace 2. See Service
if necessary.
Procedure RG-V
5. Check ECO continuity and replace 3. See Service
combination thermostat/gas valve
Procedure RG-V
if necessary.
6. Check magnet operation and
replace combination
thermostat/gas valve if necessary.
7. Determine cause of switch
activation. To reset, depress
button on resettable thermal
switch located on inner door.
1. Adjust temperature dial on
combination thermostat/gas
valve.
2. Check temperature dial
setting on combination
thermostat/gas valve.
3. Check gas supply and line
pressure.
4. Check combination
thermostat/gas valve for
proper operation, replace if
necessary.
6
6
Service
Procedure
1. See Installation
and Operation
Manual.
2. See Service
Procedure RG-V
3. See Service
Procedure RG-V
White Rodgers Mechanical Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom
Probable Cause
1. Insufficient combustion air
supply.
Pilot goes out
periodically (after 2. Incorrect or clogged vent
heating cycles,
system/vent terminal, or
once a day, once
incorrect location.
a week etc.)
3. Inconsistent gas supply or
gas pressure.
Not enough hot
water
1. Combination thermostat/gas
valve set too low for desired
water temperature.
2. Cold inlet water temperature
is very cold.
3. High demand periods.
4. Incorrectly sized water
heater for application.
5. Combination thermostat/gas
valve is out of calibration/not
functioning.
6. Out of spec dip tube is
diluting hot water with cold
water.
Corrective Action
Service
Procedure
1. Verify adequate combustion air
is available to the unit. Check
and clear jacket slot openings of
any dirt, dust, restrictions or
other obstructions. Inspect flame 1. See Service
arrestor plate and clean with stiff
Procedure RGbristled brush and compressed
VIII
air to remove any debris
2. See Service
accumulation.
Procedure RG-V
2. Check venting for proper sizing
and proper operation.
3. Check gas supply and line
pressure.
1. Check dial on combination
thermostat/gas valve.
2. Extremely cold water going into
the heater will decrease the
amount of hot water produced. It
may be necessary to temper
1. See Service
incoming water supply.
Procedure RG-V
3. Adjust high demand usage.
2. See Service
Procedure RG-IX
4. Contact plumbing professional.
5. Check combination
thermostat/gas valve for proper
operation, replace if necessary.
6. Inspect dip tube and replace if
necessary.
7
7
White Rodgers Electronic Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.
LED Status
Control Status
None (LED not on
or flashing)
Indicates control is off. Main
and pilot burner are off.
Probable Cause
Gas valve is functioning normally. Gas valve is
not powered. Light pilot.
One flash every
four seconds
Not an error. Indicates pilot is
lit and main burner is off.
Gas valve is powered and waiting for the set
point knob to be turned to a water temperature
setting. If the set point knob is at desired setting,
the thermostat is satisfied.
One flash every
second
Not an error. Indicates main
valve is open and main
burner is lit.
Thermostat is calling for heat. Water heater
operating normally and is in heat cycle.
Not an error. Indicates that
the control is in shutdown
mode.
Set point knob was recently turned to “OFF”
position. Wait until LED goes out before
attempting to relight.
Two flashes and
three second
pause
Low thermopile voltage; main
burner not lit.
Loose thermopile connections or weak pilot
flame.
Four flashes and
three second
pause
Temperature cut-out limit
reached causing shutdown.
Excessive temperatures may have been
reached. Shut off the control and reduce the
water temperature. Thoroughly verify control
operation, replace if exceeding setpoint.
Five flashes and
three second
pause
Electronics, sensor, or gas
valve fault detected.
Control may be wet or damaged. Verify all
connections are tight; if problem persists replace
the control.
Solid ON
8
8
Honeywell V1 Gas Control Troubleshooting Chart
V
Flammable Vapor Ignition Resistant Water Heaters
Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.
LED Status
Control Status
Probable Cause
Service Procedure
Pilot assembly is not lit.
Gas control is not
powered. Light pilot.
If the pilot will not stay lit
replace pilot assembly. If
problem persists replace
gas control.
One flash and
three second
pause
1. If setpoint knob is in “PILOT”
position then pilot flame is
detected. Turn setpoint knob
to desired setting.
2. If the setpoint knob is
already at the desired
setting, the water heater is
satisfied.
1. Gas control is
powered and waiting
for setpoint knob to
be turned to a water
temperature setting.
2. Water heater is
satisfied and
operating normally.
Normal operation.
LED on
continuously
(solid)
Setpoint knob has been recently
turned to the “OFF” position. Wait
until LED goes out before
attempting to relight.
Setpoint knob was
turned to “OFF”
position.
LED will go out and the
control will function
normally once the pilot is lit.
Two flashes
and three
second pause
Weak pilot signal detected.
System will reset when pilot
flame is sufficient.
1. Thermopile failure.
2. Unstable pilot.
3. Pilot tube blocked or
restricted.
Three flashes
and three
second pause
Insufficient water heating.
System will reset.
1. Thermal sensor out
of calibration.
2. Faulty gas control.
None (LED not
on or flashing)
1. See Service Procedure IV
2. See Service Procedure II
3. See Service Procedure II
Replace gas control.
9
9
Honeywell V1 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.
LED Status
Four flashes
and three
second pause
Control Status
Probable Cause
Excessive tank temperature.
System must be reset.
1. Temperature sensor
out of calibration.
2. Faulty gas control.
Five flashes
and three
second pause
Temperature sensor fault.
1. Damage to the
temperature sensor,
resistance is out of
range, or sensor is
unplugged.
2. Faulty gas control.
1.See Service Procedure VI
2.Replace gas control.
Six flashes
and three
second pause
Water leak detected by
accessory module.
Excessive amount of
water in drain pan/water
dam.
Seven flashes
and three
second pause
Gas control electronic fault
detected.
1. Control needs to be
reset.
2. Control is wet or
physically damaged.
1. Check T&P valve.
2. Check all water fittings.
3. Pressurize and leak test
tank.
Eight flashes
and three
second pause
Standing pilot remains on
while setpoint knob is in
“OFF” position.
Pilot valve stuck in
open position.
10
10
Service Procedure
Replace gas control.
1. Reset gas control
2. Replace gas control.
Replace gas control.
Honeywell V2 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Observe colored LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.
LED Status
Control Status
Probable Cause
None (LED not on Millivolt power is not
or flashing)
present. Light pilot.
Gas valve is functioning
normally. Gas valve is not
powered. Light pilot.
One flash every
four seconds
(LED green)
If the pilot will not stay lit
replace pilot assembly. If
problem persists, replace
gas control.
The knob can be turned to a
desired setpoint temperature.
Normal operation.
One flash every
second
(LED green)
Not an error. Indicates
pilot is lit and main
burner is off.
Service Procedure
None. Control will automatically
Not an error. Indicates
shut main burner off when water
Normal operation.
main valve is open and
temperature reaches the setpoint
main burner is lit.
temperature.
Two flashes and
three second
pause (LED
yellow)
Low thermopile voltage; Check thermopile and its
main valve not turned on. connections. Check pilot flame.
Four flashes and
three second
pause (LED red)
Temperature cut-out
limit reached, causing
shutdown.
Five flashes and
three second
pause (LED red)
Check water temperature sensor
and its connection for open
Electronics, sensor, or
circuits, shorts, or differences in Replace gas control.
gas valve fault detected.
resistance between the two
sensor elements.
Solid ON
(LED red)
Not an error–indicates
None; wait until LED turns off if
that the control is in OFF
you want to restart system.
position.
1. See Service Procedure IV
2. See Service Procedure II
3. See Service Procedure II
Check the valves and the water
temperature sensor. Reduce the
Replace gas control.
water temperature setpoint.
Verify control operation, replace
if exceeding setpoint.
LED will go out and the
control will function normally
once the pilot is lit.
11
11
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
Inner Door Removal Procedure
Step 1.
Rotate knob of the combination thermostat/gas valve
to the “OFF” position.
Step 2.
Remove the outer jacket burner access door.
Step 3.
Inner Door Removal:
a) Disconnect resettable thermal switch wire leads (leading from gas
control/gas valve).
b) Remove two (2) 1/4” hex drive screws from right side inner door.
c) Remove two (2) 1/4” hex drive screws from flange section of inner door.
d) Remove two (2) 1/4” hex drive screws from left side inner door.
e) Remove inner door and inspect per Step 4.
Step 4.
Fully inspect inner door gaskets for the following:
ƔGasket adhesion to inner door
ƔTears
ƔMaterial left on combustion chamber (around opening)
ƔMissing material
ƔCracks
ƔOther imperfections that will inhibit proper seal
ƔDirt or debris
If the gasket is not affected by any of the above, gasket replacement is not required. If replacement
is required, proceed to Inner Door Gasket Replacement Procedure.
Inner Door Gasket Replacement Procedure
GASKET OVERLAP
MUST BE AS
SHOWN ±1/32"
RECOMMENDED
PATTERN FOR RTV
SEALANT
PLACE FLANGE
SECTIONS FIRST
EXPANDED
VIEW
12
VIEW WITH
GASKETS IN
PLACE
12
ENLARGED
VIEW OF
FLANGE AREA
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
Installation of Inner Door with Gasket
Step 1.
Clean any residual gasket residue or other
debris from combustion chamber surface
before installing the inner door/gasket
assembly.
Step 2.
Place the left side inner door into position
first. Firmly position the radiused channel of
the inner door around the feedline. Using the
two (2) hex drive screws from Step 3d,
secure left side inner door in place. DO NOT
OVER TIGHTEN SCREWS.
Step 3.
Position thermocouple, pilot tube and piezo
wire against left side inner door flange gasket.
DO NOT ROUTE THROUGH RADIUSED
CHANNEL WITH FEEDLINE.
WARNING
Stripped fastener connections may allow
for seal breach of inner door. A seal
breach may result in a fire or explosion
causing property damage, personal injury
or death. DO NOT overtighten screws in
Step s 2, 4, and 5.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
Radiused channel for
feedline
13
13
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal, Inspection
Replacement and Reinstallation
Step 4.
Firmly place right side inner door flange against the left side inner door flange and secure with two
(2) 1 / 4 ” hex drive screws from Step 3c. DO NOT OVER TIGHTEN SCREWS.
Step 5.
Align the right side inner door to combustion chamber and verify that the fastener holes of the
combustion chamber are aligned with the right side inner door slotted opening. Verify seal
integrity around the combustion opening. Secure right side inner door using two (2) 1/4” hex drive
screws from Step 3b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the
inner door are properly positioned and sealed against the combustion chamber.
Step 6.
Reconnect the lead wires from combination thermostat/gas valve to resettable thermal switch
(see photo in Step 3).
NOTE: Wire terminations are interchangeable with either resettable thermal switch connections.
Step 7.
Replace the outer jacket burner access door.
Step 8.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
14
14
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Mechanical)
Step 1.
Closed circuit testing is the preferred method for testing the thermocouple. Following the lighting
instruction label on the heater, proceed to light the pilot and allow to operate for three minutes. If
the pilot will not stay lit, hold the pilot button (located on the combination thermostat/gas valve)
down during this test.
Step 2.
Using a multimeter capable of measuring millivolts, connect one lead using an alligator clip to the
copper sheath of the thermocouple. Use the second lead of the multimeter to probe the top
terminal located at the back of the combination thermostat/gas valve.
Step 3.
If meter reads 10 millivolts or higher, the thermocouple is O.K.. If reading is below
10 millivolts, replace the thermocouple.
Alligator clip to copper
sheath of thermocouple
15
15
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers Mechanical)
Step 1. Disconnect the thermocouple from the
combination thermostat/gas valve.
Step 2. Using a multimeter capable of measuring millivolts,
connect one alligator clip to the end ball or contact
portion of the thermocouple and the other alligator clip
to copper portion of the thermocouple.
Step 3. Following the lighting instruction label on the heater, proceed to light the pilot and allow to
operate for three minutes. It will be necessary to hold the pilot button down continuously
throughout this test. A reading of 20 to 30 millivolts indicates good thermocouple output.
THERMOCOUPLE REPLACEMENT (White Rodgers Mechanical)
Step 1. Turn off gas supply to the water heater. Rotate the knob of the
combination thermostat/gas valve to “OFF” position.
Depress knob slightly
and rotate clockwise to
the “OFF” position.
Step 2. Remove the outer jacket door.
Step 3. Remove the right side of inner door per Service Procedure RG-I, Steps 3a through 3c.
Step 4. Disconnect the thermocouple from the combination thermostat/gas valve. Locate other end of the
thermocouple inside of the combustion chamber and remove from the pilot bracket. Pull firmly,
pulling away from the pilot assembly.
Step 5. Install a new thermocouple into the pilot bracket making certain the thermocouple is fully engaged
into the pilot bracket. Position the thermocouple against the left side inner door flange at its original
position. Connect the other end of thermocouple to the combination thermostat/gas valve (finger
tight + a 1/4 turn).
Thermocouple position
Step 6. Inspect the inner door gasket per Service
Procedure RG-I, Step 4.
Step 7. Install right side inner door per Service Procedure RG-I,
“Installation of Inner Door with Gasket,” Step 6 through Step 8.
Step 8. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
16
16
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOPILE TESTING
(Honeywell & White Rodgers Electronic)
Step 1.
Turn knob to pilot position and depress.
Step 2.
Continue pressing knob and remove the red (+) wire from resettable thermal door switch.
Step 3.
Using a multimeter capable of measuring millivolts, connect the positive side of the multimeter to
the terminal of the resettable thermal switch. Connect the negative side of the multimeter to any
earth ground location (jacket base, screw, etc.). Normal thermopile operation will be between
350mV - 850mV.
Step 4.
If reading is less than 350mV, resettable thermal switch must be tested. Refer to Service Process
RG-III. If resettable thermal switch is closed, replacement of pilot assembly is recommended
following Service Procedure RG-III.
If thermopile reading is between 350mV - 850mV, reconnect red wire to positive (+) terminal of
the gas control.
Step 5.
Step 6.
Release the gas control knob and turn to desired setting to resume normal operation.
17
17
SERVICE PROCEDURE RG-III
Pilot Assembly Inspection, Cleaning
and Replacement
PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING, AND REPLACEMENT
Step 1. Turn off gas supply to water heater. Rotate the knob
of gas control/gas valve to the “OFF” position.
Step 2. Remove the outer jacket door.
Step 3. Remove right side of inner door per
Service Procedure RG-I, Steps 3a through 3c.
Step 4. Disconnect thermocouple/thermopile, pilot tube,
and feedline from gas control/gas valve.
NOTE: Feedline nut for natural gas control uses
right hand threads, L.P. control uses left hand thread.
Step 5. Disconnect piezo ignition wire from piezo igniter.
Step 6. Remove burner assembly from the combustion chamber.
Step 7. Remove the pilot/electrode assembly from the feedline.
Step 8. Inspect pilot for the following:
a) Primary air openings for blockage. Must be free from any
debris (dirt, lint, etc.).
b) Kinks or cracks in the pilot tube. If found,
the pilot must be replaced.
Step 9. Inspect pilot orifice (Honeywell ONLY):
a) Remove 7/16" nut from bottom of pilot assembly.
b) Remove pilot tube and pilot orifice.
c) Inspect pilot orifice for blockage, must be cleaned or
replaced. (Honeywell & White Rodgers Electronic pilot
orifice not replaceable, replace pilot assembly).
Step 10. Install pilot/electrode assembly to feedline, secure with screw from Step 7.
Step 11. Re-install burner assembly into combustion chamber, connect feedline,
pilot tube and thermocouple/thermopile to gas control/gas valve.
Step 12. Install inner door per Service Procedure RG-I, “Installation of Inner
Door with Gasket.”
Step 13. To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the Installation
and Operation Manual.
18
18
Removal of thermopile from
Honeywell & White Rodgers
Electronic pilot assembly is
NOT recommended but can be
achieved by viewing the pilot
assembly from the top and
pressing the thermopile
towards the right while pulling
to remove.
SERVICE PROCEDURE RG-IV
Piezo Igniter, Electrode Testing
and Replacement
PIEZO IGNITER, ELECTRODE TESTING AND REPLACEMENT
With the pilot not in operation (no pilot flame) you can check the piezo and electrode circuit by viewing pilot
through the sight glass located on the inner door and observing the spark action.
Step 1.
Remove the outer jacket door.
Step 2.
Repeatedly depress the piezo igniter while viewing the pilot through the sight glass.
If a spark is present, the circuit is O.K.. If there is no spark, proceed to Step 3.
Step 3.
Remove orange (or white) wire from piezo igniter and install a jumper wire in its place.
Hold the other end of the jumper by the wire insulation or using an insulated tool, next to
an unpainted surface such as the feedline or gas valve and depress the piezo igniter. If
there is a spark, the igniter is O.K., the pilot is not functioning and must be replaced (see
Service Procedure RG-III for pilot replacement). If no spark is present the igniter is not
functioning and must be replaced.
Jumper
wire
Step 4a. For White Rodgers Mechanical gas valves: To replace the igniter, disconnect orange wire
from piezo igniter. Use a flat-head screwdriver under piezo bracket and gently pry bracket
from the front of the gas valve and unhook the bracket from rear of the gas valve.
Flat-head screwdriver
Step 4b. For Honeywell gas controls: To replace the igniter, see the Honeywell ONLY information in
Service Procedure RG-VI.
19
19
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement (White
Rodgers Mechanical)
GAS VALVE TESTING AND REPLACEMENT (White Rodgers Mechanical)
The gas valve is a non-repairable device. If troubleshooting has determined a problem with the gas valve, it
must be replaced.
If the burner and/or pilot do not function, service checks for gas pressure, thermocouple output, magnet
assembly, and ECO are to be performed. If these check O.K., the gas valve may be faulty.
LINE PRESSURE
The gas valve is designed for a maximum line pressure of 14.0" W.C., and a minimum line pressure based on
the manifold pressure plus 1.0" W.C. (check rating plate for rated manifold pressure). Line pressure must be
checked with burner on and burner off to assure proper readings.
MANIFOLD PRESSURE TESTING
(This procedure assumes a maximum line pressure of 14.0" W.C.)
Step 1.
Set gas valve to “OFF” position.
Step 2.
Remove the pressure tap plug (3/16” Allen wrench) and install
pressure tap.
Step 3.
Connect the manometer to pressure tap.
Step 4.
Follow the lighting instructions and proceed to light main
burner and observe manometer reading.
Step 5.
Proper operating range for natural gas is 4.0 ±0.5" W.C.
Proper operating range for L.P. gas is 10.0 ±0.5" W.C.
a. If pressure is O.K., set gas valve to “OFF” remove manometer and pressure tap and replace
pressure tap plug. Check for gas leaks before placing water heater back in operation.
b. If pressure is out of the specification noted above, proceed to Step 6 for proper service
procedure.
Step 6.
The manifold pressure is NOT adjustable. If manifold pressure is outside of the range in
Step 5, the control must be replaced.
20
20
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers Mechanical)
MAGNET ASSEMBLY TESTING (White Rodgers Mechanical Control)
Step 1.
Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate
for three minutes. If the pilot will not stay lit, hold the pilot button (located on the gas valve) down
during this test.
Step 2.
Using a multimeter capable of measuring millivolts, connect one lead using an alligator clip to the
copper sheath of the thermocouple. Use the second lead of the multimeter to probe the top
terminal located at the back of the gas valve.
Alligator clip to copper
sheath of thermocouple
Step 3.
With a meter reading of 13 millivolts or greater, rotate the knob of the combination thermostat/gas
valve to the “OFF” position.
Step 4.
The magnet should remain closed for a drop of at least 6 millivolts. You will hear a “snap” or “click”
sound when the magnet opens; if you hear this sound prior to a drop of 6 millivolts, the magnet is
out of specification and the gas valve should be replaced.
ECO (ENERGY CUT OFF) TESTING
Step 1. Disconnect the thermocouple from the
gas valve.
Step 2. Using a multimeter capable of measuring ohms (or
continuity), attach one lead using an alligator clip to the
pilot tube. Insert the other lead fully into the magnet
opening, be sure the lead makes contact only at the top
center of the magnet opening.
DO NOT allow the lead to make contact with the
threaded sides of the opening.
Step 3. If continuity is indicated, the ECO is O.K.. If continuity is not indicated, the ECO has opened, and
the gas valve must be replaced.
21
21
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers Mechanical)
COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT
Step 1. Rotate the knob of the gas valve to the “OFF” position.
Step 2. Turn off gas supply to the water heater.
Step 3. Disconnect the gas supply line from the gas valve.
Step 4. Turn off water supply and drain the water heater completely.
Step 5. Remove the outer jacket burner access door.
For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position.
Step 6. Right side inner door removal:
a) Disconnect resettable thermal switch wire leads (leading from gas valve)
and remove the wire tie from the feedline.
b) Remove two (2) 1/4” hex drive screws from the right side inner door.
c) Remove two (2) 1/4” hex drive screws from the flange section of inner door.
d) Remove the right side inner door and set aside. Be careful to not damage
the gasket material on the inner door.
22
22
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers Mechanical)
Step 7.
Removal of gas valve:
a) Disconnect the main burner feedline, pilot tube and thermocouple
from the gas valve. Remove the burner from combustion chamber.
NOTE: Feed line nut for natural gas control uses right hand threads;
L.P. control uses left hand thread.
b) Remove piezo bracket with piezo igniter
(refer to Service Procedure RG-IV) from gas valve.
c) Remove gas valve from water heater, rotating counter clockwise
using a control body wrench or a length of 1/2" NPT pipe threaded
into inlet of control.
Step 8.
Installation of gas valve:
a) Install new gas valve using a control body wrench or a length
of 1/2" NPT pipe threaded into inlet of control. DO NOT OVER
TIGHTEN. Use caution not to damage cast aluminum body of
gas valve. Be certain not to damage the bundled wire leads.
NOTE: Gas valve must be installed in proper upright position to assure the
feedline will align properly at the inner door flange. DO NOT OVER TIGHTEN.
If control is turned past proper alignment, DO NOT reverse direction to align.
b) Reattach piezo bracket with piezo igniter to gas valve.
c) Reattach main burner feedline, pilot tube and thermocouple to gas valve.
NOTE: Feedline nut for natural gas control uses right hand threads;
L.P. control uses left hand thread.
d) Gather wire leads of gas valve and piezo igniter and secure alongside of
feedline using new wire tie provided.
e) Connect gas supply piping to inlet of control. Use back up wrench on
wrench boss of control, NEVER use back up wrench on body of control.
Step 9. Reinstallation of inner door assembly:
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
Ɣ Tears
Ɣ Gasket adhesion to inner door
Ɣ Missing material
Ɣ Other imperfections that will inhibit proper seal
Ɣ Cracks
Ɣ Material left on combustion chamber
Ɣ Dirt or debris
If the gasket is not affected by any of the above, gasket replacement will not be required.
If replacement is required, replace using new gasket kit following the provided instructions.
23
23
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers Mechanical)
Step 9.
Reinstallation of inner door assembly (cont.):
b) Clean any gasket residue or other debris from combustion chamber surface before installing
the inner door/gasket assembly.
c) Position thermocouple, pilot tube and piezo wire against left side inner door flange gasket. DO NOT
ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that thermocouple and pilot
tube are not in position to interfere with outer jacket burner access door when reinstalled.
WARNING
A seal breach may result in a
fire or explosion causing
property damage, personal
injury or death.
d) Firmly place the right side inner door flange against the left side inner door flange and secure
with two (2) hex drive screws from Step 6c. DO NOT OVER TIGHTEN SCREWS.
e) Align the right side inner door to combustion chamber and verify the fastener holes of the combustion
chamber are aligned with the right-side inner door slotted openings. Verify seal integrity around the
combustion opening. Secure right-side inner door using two (2) hex drive screws from Step 6b.
DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly
positioned and sealed against the combustions chamber.
Step 10. Reconnect wire leads from gas valve to resettable thermal switch (see photo in Step 6).
NOTE: Wire terminations are interchangeable with either resettable thermal switch connection.
Step 11. Replace the outer jacket burner access door.
Step 12. Reconnect the gas supply to the gas valve.
Step 13. Resume water supply to the water heater. Be sure the tank is full of water.
Step 14. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
24
24
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(White Rodgers Electronic & Honeywell)
LINE PRESSURE
The gas valve is designed for a maximum line pressure of 14.0" W.C., and a minimum
line pressure based on the manifold pressure plus 1.0" W.C. (check rating plate for rated
manifold pressure). Line pressure must be checked with burner on and burner off to
assure proper readings.
MANIFOLD PRESSURE TESTING
(This procedure presumes a maximum line pressure of 14.0" W.C.)
Step 1. Set the gas control to the “OFF” position.
Gas controls
shown in the
“OFF” position
Step 2. Remove pressure tap plug (3/16” allen wrench) and install 1/8"
NPT pipe, coupling, and pressure tap.
Step 3. Connect manometer to pressure tap.
Step 4. Follow instructions located on the lighting instructions
label and proceed to light the main burner and
observe manometer reading.
3/16” allen wrench
Step 5. Proper operating range for natural gas is:
4.0" ±0.5" W.C.
Proper operating range for L.P. gas is:
10.0" ±0.5" W.C.
a) If pressure is within the range specified in the
previous step, set gas control knob to the “OFF”
position, remove manometer and pressure tap,
and replace pressure tap plug. Check for gas
leaks prior to placing water heater back into
operation by following the instructions located on
the lighting instruction label or the lighting
instructions located in the Installation and Operation
Manual.
b) If gas pressure is outside the specification noted above,
refer to the following Honeywell ONLY information, or
“Gas Control Replacement” to replace gas control or
valve body.
Step 6. The manifold pressure is NOT adjustable. If manifold
pressure is outside of the range in Step 5, the control
must be replaced.
Pressure tap
shown installed
ECO (ENERGY CUT OFF) TESTING
The Honeywell and White Rodgers Electronic gas control is designed with an ECO device that will reset.
To reset the gas control after a status code 4, turn the gas control knob to the “OFF” position and wait a
minimum of five (5) minutes before relighting following the instructions located on the lighting instruction label
or the lighting instructions located in the Installation and Operation Manual.
25
25
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
NOTE: The following procedure applies
to the Honeywell gas control ONLY.
HONEYWELL COVER REMOVAL
CAUTION
Step 1. Rotate the knob of the gas control to the “OFF” position.
Step 2. Turn off gas supply to the water heater.
Step 3. Disconnect the gas supply line from the gas control.
Use caution to not bend or damage
valve body pins when removing or
installing the gas control cover.
Step 4. Disconnect the piezo igniter wire.
Step 5. Remove the gas control cover screw using flat-head
screwdriver.
Rotate knob counter-clockwise to
the “OFF” position
Gas control
cover screw
Step 6. Depress both tabs on the top of the gas control cover and pull straight out to remove.
Valve body
pins
26
26
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
HONEYWELL COVER REMOVAL (cont.)
Step 7. Disconnect the temperature sensor from the control board and remove the wire from the
temperature sensor wire routing clip.
Temperature sensor
wire routing clip
Disconnect
temperature sensor
Step 8. Remove the piezo igniter from the control cover by releasing the lock tab on the control cover.
Release lock tab
27
27
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL
CAUTION
Step 1. Disconnect the burner and pilot tubes per Service Procedure RG-II.
Step 2. Remove the valve body by removing the screw located at the lower left
corner. Unclip the lower right side from the backplate first, followed by
the lower left side, using a flat-head screwdriver.
Use caution to not
bend or damage valve
body pins.
Unclip lower right
side first
Unclip lower left
side second
Valve body screw
Step 3. Remove the temperature sensor and insertion stick from the backplate by first removing the
wire from the temperature sensor wire routing clips. Make note of the insertion stickʼs
orientation, as the insertion stick can only be installed in one way.
Temperature sensor
wire routing clips
Insertion stick fully
inserted into backplate
28
28
CAUTION
When reinstalling
temperature sensor
and insertion stick,
make sure the
assembly is inserted
FULLY into the
backplate and the
wires are routed
through the wire
routing clips. Failure
to do so will not
allow the valve body
to be reinstalled
properly and may
damage temperature
sensor wires.
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL (cont.)
Step 4. Remove the temperature sensor from the insertion stick by pulling apart as illustrated below.
Pull in this direction
Temperature sensor
Insertion stick
Pull in this direction
Step 5. To reassemble the gas control, follow the previous steps in reverse order. Once the gas control is
reassembled, the burner assembly is reinstalled, and the gas supply line is reconnected,
resume water supply to the water heater. Be sure the tank is full of water before relighting.
Step 6. To resume operation, follow the instructions located on the lighting instruction label, or the lighting
instructions located in the Installation and Operation Manual.
29
29
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
TEMPERATURE SENSOR TESTING (Honeywell)
Step 1. If control has gone into lockout due to
excessive tank temperature (four
flashes, three second pause), reset
control by rotating gas control knob to
“OFF” position and wait a minimum of
five (5) minutes. Then follow lighting
instructions and return the gas control
knob to a desired setpoint.
Step 2. Observe green light indicator. Does
status code 4 (four flashes, three
second pause) appear?
a) If no, resume normal operation.
b) If yes, continue with Step 3.
CAUTION
DO NOT use standard multimeter probes
for this test. Doing so will damage
connector. Use special pin type electronic
probes or small diameter wire pins
inserted into connector.
NOTE: Using a multi-meter set to the ohms setting,
insert one-meter probe into center wire position of
thermal well connector, insert the second probe into
either of the outside wire positions (see photo).
Alternate the probe on the outside position to the
opposite outside wire position (see photo).
Step 3. Following “Honeywell Cover Removal,”
“Honeywell Valve Body Removal and
Temperature Sensor Removal”
instructions, disassemble gas control to
access the temperature sensor.
Step 4. With the temperature sensor still in the back plate, use a multimeter set to the ohms
setting, determine the resistance of the temperature sensor (see photo).
Step 5. See next page to obtain water temperature. Are temperature sensor resistance values
correct?
a) If no, replace the temperature sensor.
b) If yes, replace the gas control.
30
30
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(Honeywell ONLY)
WARNING
Stored water may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
DETERMINE WATER TEMPERATURE
INSIDE TANK
NOTE: It is important to understand once the resistance for the temperature sensor is determined from
the previous page, water flow through the water heater should not occur. Prior to drawing
water from drain valve, turn off the cold-water supply to the water heater. This will prevent cold
water flow into the tank, affecting the resistance value of the temperature sensor.
Step 1. Set the gas control knob to the “OFF” position. Turn off inlet water supply to water heater.
Step 2. Draw approximately 4 gallons of water from drain valve into a container, or suitable drain, and
discard. Draw an additional gallon and immediately measure water temperature using an accurate
thermometer. It may be necessary to open a hot water faucet to allow water heater to drain.
Step 3. Using the chart below, determine correct resistance value for the water temperature from Step 2.
Example: If temperature of water is 84°F, then the resistance through
the sensor would be 8449 (see shaded area).
NOTE: Sensor resistance increases as the temperature decreases.
Sensor Resistance at Various Temperatures
In Degrees F
°F
40
50
60
70
0
26109
19906
15314
11884
1
25400
19383
14925
11592
2
24712
18876
14548
11308
3
24045
18383
14180
11032
4
23399
17905
13823
10763
5
22771
17440
13477
10502
6
22163
16990
13140
10248
7
21573
16553
12812
10000
8
21000
16128
12494
9760
9
20445
15715
12185
9526
80
9299
9078
8862
8653
8449
8250
8057
7869
7685
7507
90
100
110
120
130
140
150
160
170
180
190
200
7333
5827
4663
3758
3048
2488
2043
1688
1402
1170
982
828
7165
5697
4562
3679
2986
2439
2004
1656
1376
1150
965
814
7000
5570
4464
3602
2925
2391
1966
1625
1351
1129
949
801
6839
5446
4368
3527
2866
2344
1928
1595
1327
1110
933
788
6683
5326
4274
3453
2808
2298
1891
1566
1303
1090
917
775
6531
5208
4183
3382
2752
2253
1856
1537
1280
1071
901
762
6383
5094
4094
3312
2697
2209
1820
1509
1257
1053
886
749
6238
4982
4006
3244
2643
2166
1786
1481
1235
1035
871
737
6098
4873
3922
3177
2590
2124
1753
1454
1213
1017
857
725
5961
4767
3839
3112
2538
2083
1720
1427
1191
999
842
713
31
31
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & R eplacement
(White Rodgers Electronic & Honeywell)
______________________________________________________________________________________________________________________________________
GAS CONTROL REPLACEMENT
Step 1. Rotate knob of the gas control to the “OFF” position.
Step 2. Turn off gas supply to the water heater.
Step 3. Disconnect the gas supply line from gas control.
Step 4. Turn off the water supply and drain the water heater completely.
Step 5. Remove the outer jacket burner access door.
Step 6. Right side inner door removal:
a) Disconnect the red wire leads from the resettable
thermal switch.
b) Remove two (2) 1/4” hex drive screws from RIGHT side
inner door.
c) Remove two (2) 1/4” hex drive screws from FLANGE
SECTION of inner door.
d) Remove the right side inner door and set aside. Be
careful to not damage gasket material on inner door.
Step 7. Removal of gas control:
a) Disconnect main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and
thermopile wire (white) from gas control.
b) Remove gas control from water heater by rotating counter clockwise. DO NOT use a wrench
on the gas control body, damage to the gas control may occur. If necessary, use a length of
1/2" NPT pipe threaded into gas inlet of gas control.
Step 8. Install new gas control into water heater:
a) Install a new gas control into water heater by rotating clockwise. DO NOT use a wrench
on the gas control body, as damage to the gas control may occur. If necessary, use a
length of 1/2" NPT pipe threaded into gas inlet of gas control.
32
32
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & Replacement
(White Rodgers Electronic & Honeywell)
GAS CONTROL REPLACEMENT (cont.)
Step 8. Install new gas control into water heater (cont.):
b) Reattach the main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and
thermopile wire (white) to the gas control. Attach the inner door wire (red) to the positive (+)
terminal and the thermopile wire (white) to the negative (-) terminal.
CAUTION
Use back up wrench on wrench boss of gas control,
NEVER use back up wrench on body of gas control.
c) Gather piezo igniter wire, thermopile wire (white), inner door wire (red), and pilot alongside
of feedline using new wire tie provided.
d) Reconnect gas supply piping to inlet of gas control.
Step 9. Reinstallation of inner door assembly:
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
Ɣ Tears
Ɣ Gasket adhesion to inner door
Ɣ Missing material
Ɣ Material left on combustion chamber
Ɣ Cracks
Ɣ Other imperfections that will inhibit proper seal
Ɣ Dirt or debris
If the gasket is not affected by any of the above, gasket replacement will not be required.
If replacement is required, replace using new gasket kit following the instructions provided
with kit.
b) Clean any gasket residue or other debris from combustion chamber surface before
installing the inner door/gasket assembly.
c) Position thermopile wire, pilot tube, and piezo wire against left side inner door flange gasket.
DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that the
thermopile and pilot tube are not in position to interfere with outer jacket burner access door
when reinstalled.
WARNING
A seal breach may result in a fire or
explosion causing property damage,
personal injury or death.
33
33
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly, & Replacement
(White Rodgers Electronic & Honeywell)
GAS CONTROL REPLACEMENT (cont.)
Step 9. Reinstallation of inner door assembly (cont.):
d) Firmly place right side inner door flange against the left side inner door flange and secure with two (2)
1/4” hex drive screws from Step 6c. DO NOT OVER TIGHTEN SCREWS.
e) Align the right side inner door to combustion chamber and verify the fastener holes of the
combustion chamber are aligned with the right side inner door slotted openings. Verify seal integrity
around the combustion opening. Secure right side inner door using two (2) 1/4” hex drive screws
from Step 6b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner
door are properly positioned and sealed against the combustion chamber.
CAUTION
Use back up wrench on
wrench boss of gas control,
NEVER use back up wrench
on body of gas control.
Step 10. Reconnect two (2) red wire leads from pilot assembly and gas control to resettable thermal
switch.
NOTE: wire terminations are interchangeable with either resettable thermal switch connection.
Step 11. Replace the outer jacket burner access door.
Step 12. Reconnect the gas supply to gas control.
Step 13. Resume water supply to the water heater. Be sure the tank is full of water before resuming
operation.
Step 14. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
34
34
SERVICE PROCEDURE RG-VII
Burner Operation Inspection,
Adjustment, Cleaning, and Replacement
MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement
At periodic intervals (not more than 6 months) a visual inspection should be made of the main burner for
proper operation and to ensure no debris accumulation.
Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.
Steel burner models have a self-adjusting air mixture and do not have an adjustable air shutter.
Main burner must be free from any debris accumulation that may affect burner operation (see burner cleaning
procedure on page 36).
DANGER
Under NO circumstances should flammable materials be used or stored in the vicinity of the water
heater. With the inner door removed the Bradford White Defender Safety System will be
deactivated. If flammable vapors are present, a fire or explosion may result causing property
damage, personal injury, or death.
WARNING
Inner door and burner components may be HOT when performing this
operation. Take necessary precaution to prevent personal injury.
BURNER REMOVAL
Step 1. Remove inner door assembly per Service Procedure RG-I, Steps 1 through 3c.
Step 2. Disconnect the main burner feed line, pilot tube and thermocouple/thermopile from combination
thermostat gas valve and remove burner assembly from combustion chamber.
NOTE: Feedline nut for natural gas control uses right hand threads;
L.P. control uses left hand thread.
Step 3. Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation.
35
35
SERVICE PROCEDURE RG-VII
Burner Operation Inspection,
Adjustment, Cleaning, and Replacement
BURNER CLEANING
Step 4. Disconnect the burner plate from main burner orifice
and disconnect feedline from burner.
Step 5. Remove main burner orifice from feed line.
Inspect and clean if necessary.
Step 6. Remove pilot assembly, refer to Service Procedure RG-III for cleaning and inspection.
Step 7. Using a stiff brush and compressed air, clean the burner plate and feedline, then reassemble
all components.
Step 8. Inspect combustion chamber area of heater prior to reinstallation of burner assembly. If cleaning is
required, refer to Service Procedure RG-VIII.
Step 9. Reinstall burner assembly into combustion chamber, reconnect feedline, thermocouple and pilot
tube to the combination thermostat/gas valve.
Step 10. Reinstall inner door per Service Procedure RG-I.
Step 11. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
36
36
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
RESETTABLE THERMAL SWITCH CONTINUITY TESTING
Step 1. Remove the outer jacket door.
Step 2. Disconnect the wire leads from the resettable thermal switch.
Step 3. Using a multimeter capable of measuring continuity (ohms),
place one probe of meter on one of the brass connection
tabs of the resettable thermal switch, and the remaining
probe on the other connection tab.
Step 4. If continuity is indicated, the switch is closed, allowing millivolt current to pass.
Step 5. If continuity is not indicated, the switch is open, possibly due to an overheating condition. The
switch is designed to open at predetermined temperatures depending on model. An open switch
can be reset by depressing the red colored button located at the center of the switch. The
overheating condition must be determined prior to putting the heater back in service.
PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH
ACTIVATION
PROBABLE CAUSE
PROBABLE CAUSE
1. Verify adequate
combustion air supply is
available.
2. Clear jacket slot openings
Insufficient combustion air
of any dirt, dust,
restrictions or other
obstructions.
3. Inspect flame arrestor plate
and clean with a stiff brush,
compressed air to remove
scale deposits and debris.
1. Weak switch or switch out
of calibration.
2. Incorrect switch.
Flammable vapor incident
1. Replace resettable thermal
switch.
Resettable thermal switch color
code reference
Approximate
switch
Color code
activation
temperature
(open)
Blue
Û
Yellow
Û
Red
Û
2. Verify switch color code
and approximate
temperature.
1. Replace water heater.
37
37
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
RESETTABLE THERMAL SWITCH REPLACEMENT
Step 1.
Rotate the knob of combination thermostat/gas valve to the “OFF” position.
Step 2. Remove the outer jacket door.
Step 3. Disconnect the wire leads from the resettable
thermal switch.
Step 4. Remove the resettable thermal switch from the
inner door (Phillips screwdriver).
Step 5. Put new resettable thermal switch in place. Be sure contact surface of resettable thermal switch
and inner door are free of any debris. Secure resettable thermal switch into place using screws
from Step 4. DO NOT OVER TIGHTEN SCREWS.
Step 6. Reconnect wire leads from combination thermostat/gas valve to resettable thermal switch.
NOTE: Wire terminations are interchangeable with either resettable thermal switch connection.
Step 7. Replace the outer jacket door.
Step 8. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instruction located in the Installation and Operation Manual.
38
38
SERVICE PROCEDURE RG-IX
ScreenLok® Flame Arrestor Cleaning
ScreenLok® Flame Arrestor Cleaning
Step 1.
Rotate knob of combination thermostat gas valve to the off position.
Step 2. Remove the outer jacket door.
Step 3. Remove inner door per Service Procedure RG-I, Steps 3a through 3e.
Step 4. Disconnect the main burner feed line, pilot tube, and
thermocouple/thermopile from combination thermostat gas valve and
remove burner assembly from the combustion chamber.
NOTE: Feedline nut for natural gas control uses right hand threads;
L.P. control uses left hand thread.
®
Step 5. Clean ScreenLok Flame Arrestor using stiff brush and compressed air to remove any scale or
other debris accumulation. Using a soft brush, clear jacket openings of any dirt, dust, restrictions, or
other obstructions.
Step 6. Remove any debris from burner assembly per Service Procedure RG-V and reinstall burner
assembly into combustion chamber.
Step 7. Reconnect feedline, thermocouple, and pilot tube to the combination thermostat/gas valve.
Step 8
Reinstall inner door per Service Procedure RG-I.
Step 9. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instruction located in the Installation and Operation Manual.
39
39
SERVICE PROCEDURE RG-X
Diptube and Anode
Inspection and Replacement
DIPTUBE INSPECTION AND REPLACEMENT
WARNING
Heater components and stored water may be HOT when performing the following
steps in this procedure. Take necessary precaution to prevent personal injury.
Step 1.
Rotate the knob of combination thermostat/gas valve to “OFF” position.
Step 2. Turn off cold water supply to the water heater. Connect a hose to the drain spigot of the water
heater and route to an open drain. Open a nearby hot water faucet to vent the heater for draining.
Open drain spigot of the water heater and allow the heater to drain to a point below the inlet
connection nipple.
Step 3. Disconnect the inlet nipple from plumbing system.
Step 4
With an appropriate wrench, remove the inlet nipple/dip tube from the water heater. Use caution to
not damage pipe threads.
Step 5. Visually inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any
blockage. Hydro-jets located near the bottom of the dip tube should be open and free of any
blockage. The anti-siphon hole, located approximately 6 in from the bottom of nipple, should be
free of any blockage.
Any damage such as cracks, restriction due to deformation or unintentional holes are not field
repairable and the inlet nipple/dip tube must be replaced.
Step 6. Upon completion of inspection or subsequent replacement, reinstall the inlet nipple/dip tube into the
heater. Ensure pipe dope is used on the nippleʼs threads. Connect the nipple to the plumbing
system, resume the water supply, and refill the heater with water.
Step 7. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
40
40
SERVICE PROCEDURE RG-X
Diptube and Anode
Inspection and Replacement
ANODE INSPECTION AND REPLACEMENT
WARNING
Heater components and stored water may be HOT when performing the following
steps in this procedure. Take necessary precaution to prevent personal injury.
Step 1. Turn off water supply to water heater. Rotate knob of combination thermostat/gas valve to
“OFF” position.
Step 2. Turn off cold water supply to the water heater. Connect a hose to the drain spigot of the water
heater and route to an open drain. Open a nearby hot water faucet to vent the heater for
draining. Open the drain spigot of the water heater and allow the heater to drain to a point below
the outlet connection nipple.
Step 3. Disconnect the outlet nipple from the plumbing system.
Step 4. With an appropriate wrench, remove the outlet nipple/anode from the water heater. Use caution to
not damage pipe threads.
Step 5. Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion; this is
normal. If depletion is 1/2 of the original anode diameter (approximately 5/8” diameter), replacement
is recommended. If any of the steel core of the anode is exposed, replacement is recommended.
Step 6. Upon completion of inspection or subsequent replacement, reinstall the outlet nipple/anode into the
heater. Ensure pipe dope is used on the nippleʼs threads. Connect the nipple to the plumbing
system, resume water supply, and refill the heater with water.
Step 7. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the Installation and Operation Manual.
41
41
Parts Diagram
1
2
3
4
5
6A
6B
6C
6D
7
8
9
10
11
12
13
14
15
16
Draft Hood
Hot Water Outlet/Anode
Cold Water Inlet Tube
Flue Baffle
T&P Relief Valve
Gas Control (Honeywell V1)
Gas Control (Honeywell V2)
Gas Control (White Rodgers Mechanical)
Gas Control (White Rodgers Electronic)
Piezo Igniter (White Rodgers Mechanical)
Brass Drain Valve
Screw-#8-18 x 3/4 Hex Washer Head
Screw-#10-12 x 3/4 Hex Washer Head
Left Side Inner Door with Gasket
Complete Right Side Inner Door
Resettable Thermal Switch
Screw-#6-20 x 3/8 PHCR
Outer Door
Complete Burner Assembly (Natural)
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
42
42
Burner Only
Main Burner Orifice
Pilot Assembly
Pilot Orifice
Thermocouple/Thermopile
Complete Burner Assembly (LP)
Burner Only (LP)
Main Burner Orifice (LP)
Pilot Assembly (LP)
Pilot Orifice(LP)
Thermocouple/Thermopile (LP)
ASSE Approved Mixing Valve (Optional)
3/4 NPT Tank Plug (H Models)
Inner Door Gasket Kit
Wire Tie
Heat Trap (Outlet)
Heat Trap (Inlet)
Heat Trap Kit
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