Flammable Vapor Ignition Resistant
Water Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Manual 238-51542-00B REV 10/18
Models Covered
by This Manual:
RG130T*(N,X)
RG140T*(N,X)
RG150T(N,X)
LG250H65*(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)
(*) Denotes Warranty Years
Save this manual for future reference
Introduction 3 - - -
Troubleshooting Chart 4 - - -
Inner Door Gasket Removal, Inspection, and Replacement 9 RG-I
Thermocouple/Thermopile Testing and Replacement 12 RG-II
The Bradford White
®
Page Service Procedure
Pilot Assembly Inspection Cleaning and Replacement 15 RG-III
Piezo Igniter, Electrode Testing and Replacement 16 RG-IV
White Rodgers Gas Valve Testing and Replacement 17 RG-V
Honeywell Gas Control Testing, Disassembly, and Replacement 22 RG-VI
Burner Operation Inspection, Adjustment, Cleaning and Replacement 28 RG-VII
Resettable Thermal Switch Testing and Replacement 31 RG-VIII
ScreenLok
®
Flame Arrestor Cleaning
33 RG-IX
DipTube and Anode Inspection and Replacement 34 RG-X
Generic Parts List 36 - - -
2
2
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.
3
3
White Rodgers Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom Probable Cause Corrective action
1.
Pilot will not light.
Pilot will not stay lit
when button is
released.
No incoming gas or too low
gas pressure.
2.
Gas control knob set to
wrong position.
3.
Pilot light button 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
“hot” junction.
4.
Weak or defective
thermocouple.
5.
Open ECO on
combination thermostat/
gas valve.
6.
Defective magnet in
combination thermostat/gas
valve.
7.
Resettable thermal switch
has opened.
1.
Turn on gas supply and/or check
line pressure.
2.
Review lighting instruction. Set
combination/thermostat gas valve
to correct position.
3.
Review lighting instruction. Fully
depress pilot lighting button.
4.
Clean, repair or replace.
5.
Verify correct electrode position.
Replace pilot assembly.
6.
Replace piezo igniter.
1.
Check connection at combination
thermostat/gas valve. Proper
tightness should be finger tight
plus ¼ turn.
2.
Inspect thermocouple to ensure
that it is fully engaged into pilot
bracket.
3.
Adjust tip of thermocouple to be
fully engulfed by pilot flame.
4.
Check thermocouple and replace
if necessary.
5.
Check ECO continuity and replace
combination thermostat/gas valve
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
Service
Procedure
1.
See Service
Procedure RG-V,
Page 12.
2.
See Service
Procedure RG-III,
Page 10.
3.
See Service
Procedure RG-III,
Page 10.
4.
See Service
Procedure RG-IV,
Page 11.
1.
See Service
Procedure RG-II,
Page 8.
2.
See Service
Procedure RG-V,
Page 14.
3.
See Service
Procedure RG-V,
Page 13.
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.
1.
See installation
and operation
manual.
2.
See Service
Procedure RG-V,
Page 12.
3.
See Service
Procedure RG-V,
Page 12.
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.
4
4
White Rodgers Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom Probable Cause Corrective action
Pilot goes out
periodically (after
heating cycles,
once a day, once
a week etc.)
Not enough hot
water.
1.
Insufficient combustion air
supply.
2.
Incorrect, clogged vent
system/vent terminal or
location.
3.
Inconsistent gas supply or
gas pressure.
4.
Combination thermostat/gas
valve set too low for desired
water temperature.
5.
Cold inlet water temperature
is very cold.
6.
High demand periods.
7.
Incorrectly sized water
heater for application.
8.
Combination thermostat/gas
valve is out of calibration/not
functioning.
9.
Out of spec dip tube is
diluting hot water with cold
water.
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
arrestor plate and clean with stiff
bristled brush and/or vacuum to
remove any debris accumulation.
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
incoming water supply.
3.
Adjust high demand usage.
4.
Contact Plumbing professional.
5.
Check combination
thermostat/gas valve for proper
operation, replace if necessary.
6.
Inspect dip tube and replace if
necessary.
Service
Procedure
1.
See Service
Procedure RGVIII, Page 22.
2.
See Service
Procedure RG-V,
Page 14.
1.
See Service
Procedure RG-V,
Page 12.
2.
See Service
Procedure RG-IX,
Page 23.
5
5
g
g
V
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.
Honeywell V1 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
LED Status Control Status Probable Cause Service Procedure
If the pilot will not stay lit
None (LED not
on or flashing)
Pilot assembly is not lit
Gas control is not
powered. Light Pilot.
replace pilot assembly. If
problem persists replace
as control.
1.
One flash and
three second
pause
LED on
continuously
(solid)
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.
Setpoint knob has been recently
turned to the “OFF” position. Wait
until LED goes out before
attemptin
to relight.
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.
Setpoint knob was
turned to “OFF”
position.
Normal operation.
LED will not go out and the
control will function
normally the is lit.
Two flashes
and three
second pause
Three flashes
and three
second pause
6
Weak pilot signal detected.
System will reset when pilot
flame is sufficient.
Insufficient water heating.
System will reset.
1.
Thermopile failure.
2.
Unstable pilot.
3.
Pilot tube block or
restricted.
1.
Thermal sensor out
of calibration.
2.
Faulty gas control.
1.
See service procedure IV
2.
See service procedure II
3.
See service procedure II
Replace gas control.
6
g
y
Observe green LED indicator on Gas Control.
Status flash codes are displayed with a three
second pause before repeating. Check and repair
Honeywell V1 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
the system as noted in the troubleshooting table
below.
LED Status Control Status Probable Cause Service Procedure
Four flashes
three second
pause
Five flashes
and three
second pause
Six flashes
and three
second pause
Seven flashes
and three
second pause
Eight flashes
and three
second pause
Excessive tank temperature.
System must be reset.
Temperature sensor fault.
Water leak detected by
accessory module
Gas control electronic fault
detected.
Standing pilot remains on while
setpoint knob is in “OFF”
position.
1.
Temperature sensor
out of calibration.
2.
Faulty gas control.
1.
Damage to the
temperature sensor.
2.
Temperature sensor
resistance out of
ran
e.
Excessive amount of
water in drain pan/water
dam.
1.
Control needs to be
reset.
2.
Control is wet or
ph
sically damaged.
Pilot valve stuck in
open position.
Replace gas control
Replace gas control
1. Check T&P valve.
2. Check all water fittings.
3. Pressurize and leak test
tank.
1. Reset gas control
2. Replace gas control.
Replace gas control
7
7
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 Service Procedure
If the pilot will not stay lit
replace pilot assembly. If
problem persists, replace
gas control.
Normal operation.
Normal operation.
1. See service procedure
IV.
2. See service procedure II.
3. See service procedure II.
None (LED not on
or flashing)
One flash every
four seconds
(LED green)
One flash every
second
(LED green)
Two flashes
(LED yellow)
Millivolt power is not
present. Light pilot.
Not an error. Indicates
pilot is lit and main
burner is off.
Not an error. Indicates
main valve is open and
main burner is lit.
Low thermopile voltage;
main valve not turned
ON.
Gas valve is functioning normally.
Gas valve is not powered. Light
pilot.
You can now turn the know to a
desired setpoint temperature
None. Control will automatically
shut main burner off when water
temperature reaches the setpoint
temperature.
Check thermopile and its
connections. Check pilot flame.
Check the valves and the water
temperature sensor. Reduce the
Four flashes
(LED red)
Temperature cut-out
limit reached.
water temperature setpoint.
Thoroughly check
out main valve operation and water
Replace gas control
temperature control before walking
away.
Check water temperature sensor
Five flashes
(LED red)
Water temperature
sensor failure.
and its connection for open
circuits, shorts, or differences in
resistance between the two sensor
Replace gas control
elements.
1. Check T&P valve.
Six flashes
(LED red)
Solid ON
(LED red)
8
Tank leakage detected
by accessory module.
Not an error-indicates
that the control is in
OFF mode.
Control recovers after receiving
message from accessory module.
None; wait until LED turns off if
you want to restart system.
2. Check all water fittings.
3. Pressurize and leak test
tank.
LED will go out and the
control will function normally
the pilot is lit.
8
Inner Door Removal Procedure
)
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
Step 1.
Rotate knob of the combination
thermostat/gas valve to the “OFF” position.
Step 2.
Step 3.
Remove outer jacket burner access door.
Inner Door Removal.
a) Disconnect resettable thermal switch wire leads
(leading from gas control/gas valve).
b) Remove (2) hex drive screws from right side inner door.
c) Remove (2) hex drive screws from flange section of inner door.
d) Remove (2) 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:
>Tears
>Missing material
>Cracks
>Other imperfections that will inhibit proper seal
>Gasket adhesion to inner door
>Material left on combustion chamber (around opening)
>Dirt 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
RECOMMENDED
PATTERN FOR RTV
SEALANT
PLACE FLANGE
SECTIONS FIRST
EXPANDED
VIEW
GASKET OVERLAP
MUST BE AS
SHOWN ±1/32"
VIEW WITH
GASKETS IN
PLACE
ENLARGED
VIEW OF
FLANGE AREA
9
9
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
Installation of Inner Door with Gasket
Step 5.
Step 6.
Step 7.
Clean any residual gasket residue or other
debris from combustion chamber surface
before installing the inner door/gasket
assembly.
Place the left side inner door into position
first. Firmly position the radiused channel of
the inner door around the feedline. Using the
(2) hex drive screws from step 3d, secure left
side inner door in place
DO NOT OVER TIGHTEN SCREWS.
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 over tighten screws in
steps 8, 10 and 11.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
10
10
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal, Inspection
Replacement and Reinstallation
Step 8.
Step 9.
Firmly place right side inner door flange against the left side inner door flange and secure with (2)
hex drive screws from step 3c. DO NOT OVER TIGHTEN SCREWS.
Align 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 opening. Verify seal integrity around
combustion opening. Secure right side inner door using (2) 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 10.
Step 11.
Step 12.
Reconnect 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.
Replace outer jacket burner access door.
To resume operation, follow the instructions located on th e lighting instruction label or the lighting
instructions located in the installation and operation manual.
11
11
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Control)
Step 1.
Closed circuit testing is the preferred method for testing 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 mv or higher, the thermocouple is OK. If reading is below 10 mv,
replace the thermocouple.
12
12
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers Gas Valve)
Step 1.
Step 2.
Disconnect thermocouple from combination thermostat/gas valve.
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 Gas Valve)
Step 1.
Step 2.
Step 3.
Step 4
Turn off gas supply to water heater. Rotate knob of combination
thermostat/gas valve to “OFF” position.
Depress knob slightly and rotate
clockwise to the “OFF” position.
Remove outer jacket door.
Remove right side of inner door per SERVICE PROCEDURE RG-I, steps 3a through 3c.
Disconnect thermocouple from combination thermostat/gas valve. Locate other end of
thermocouple inside of combustion chamber and remove from pilot bracket. Pull firmly pulling away
from the pilot assembly.
Step 5.
Step 6.
Step 7.
Step 8.
Install new thermocouple into pilot bracket making certain the thermocouple is fully engaged into
the pilot bracket. Position thermocouple against left side inner door flange at its original position.
Connect other end of thermocouple to combination thermostat/gas valve (finger tight + ¼ turn).
Inspect inner door gasket per
SERVICE PROCEDURE RG-I, Step 4.
Install right side inner door per
SERVICE PROCEDURE RG-I,
Step 10 through 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.
13
13
OPEN CIRCUIT THERMOPILE TESTING (Honeywell Gas Control)
The following test should be performed while the pilot flame is on.
Step 1.
Step 2.
Step 3.
Normal thermopile operation will be between 350mV - 850mV. If reading is less than 350mV, replacement of
pilot assembly is recommended following SERVICE PROCEDURE RG-III.
Step 4.
Step 5.
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
Turn knob to pilot position and depress.
Continue pressing knob and remove red (+) wire from resettable thermal door switch.
Using a multimeter capable of measuring millivolts, connect the positive side of the multimeter to
the terminal of the resettable thermal door switch. Connect the negative side of the multimeter to
any earth ground location (jacket base, screw, etc.).
If thermopile reading is between 350mV - 850mV, remove multimeter and reconnect red wire to
positive (+) terminal of gas control.
Release gas control knob and turn to desired setting to resume normal operation.
14
14
y
PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING AND REPLACEMENT
Step 1.
Step 2.
Step 3.
Step 4
Step 5
Step 6.
Step 7.
Step 8.
Step 9. Inspect pilot orifice:
Step 10.
Step 11.
Step 12.
Step 13.
Turn off gas supply to water heater. Rotate knob
of gas control/gas valve
to “OFF” position.
Remove outer jacket door.
Remove right side of inner door per
SERVICE PROCEDURE RG-I, steps 3a through 3c.
Disconnect thermocouple/thermopile, pilot tube,
and feedline from gas control/gas valve.
NOTE: Feedline nut for natural gas control uses
right hand threads, LP control uses left hand thread.
Disconnect piezo ignition wire from piezo igniter.
Remove burner assembly from combustion chamber.
Remove pilot/electrode assembl
from feedline.
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.
a) Remove ½" 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 pilot orifice not replaceable,
replace pilot assembly)
Install pilot/electrode assembly to feedline, secure with screw from step 7.
Re-Install burner assembly into combustion chamber, connect feedline,
pilot tube and thermocouple/thermopile to gas control/gas valve.
Install inner door per SERVICE PROCEDURE RG-I, step 4 through 13.
To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the installation
and operation manual.
SERVICE PROCEDURE RG-III
Pilot Assembly Inspection, Cleaning
and Replacement
Removal of thermopile from
Honeywell 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.
15
15
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
thru the sight glass located on the inner door and observing the spark action.
Step 1.
Step 2.
Step 3.
Step 4a.
SERVICE PROCEDURE RG-IV
Piezo Igniter, Electrode Testing
and Replacement
Remove outer jacket door.
Repeatedly depress the piezo igniter while viewing the pilot thru the sight glass. If a
spark is present, the circuit is OK. If there is no spark, proceed to 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 OK, 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.
For White Rodgers gas valves: With orange wire disconnected from piezo igniter. Using
a common screw driver, place blade of screw driver under piezo bracket and gently pry
bracket from front of gas valve and unhook bracket from rear of gas valve.
16
Step 4b.
16
For Honeywell gas controls: To replace igniter, see “Gas Control Disassembly
Reassembly” in SERVICE PROCEDURE RG-VI.
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement (White
Rodgers)
Gas Valve Testing and Replacement (White Rodgers)
The gas valve is a non-repairable device. If trouble shooting 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 OK, 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 of 1.0"w.c.
over the water heater rated manifold pressure (check rating plate). 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.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Set gas valve to “OFF” position.
Remove pressure tap plug and install pressure tap.
Connect manometer to pressure tap.
Follow lighting instructions and proceed to light
main burner and observe manometer reading.
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.
If pressure is OK, 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. If pressure is out of the
specification noted in step 5, proceed to step 7 for proper service procedure.
The manifold pressure is not adjustable. If manifold pressure is outside the range in step
5, the control must be replaced.
17
17
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers)
THERMOCOUPLE TESTING
See SERVICE PROCEDURE RG-II
MAGNET ASSEMBLY TESTING (White Rodgers 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.
Step 3.
Step 4.
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.
With a meter reading of 13 millivolts or greater, rotate knob of combination thermostat/gas valve to
the “OFF” position.
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 thermocouple from gas valve.
Step 2.
Using a multimeter capable of measuring Ohms (or continuity),
attach one lead (alligator clip) to the pilot tube. Insert the other
lead (probe) fully into the magnet opening, be sure the probe
makes contact only at the top center of the magnet opening.
Do not allow the probe to make contact with the threaded
sides of the opening.
18
Step 3.
If continuity is indicated, the ECO is OK. If continuity is not indicated, the ECO has opened and the
gas valve must be replaced.
18
SERVICE PROCEDURE RG-V
geg
Gas Valve Testing and Replacement
COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT
(White Rodgers)
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Rotate knob of the gas valve to the “OFF” position.
Turn off gas supply to water heater.
Disconnect gas supply line from gas valve.
For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position.
Turn off water supply and drain water heater completely.
Remove outer jacket burner access door.
Right side inner door removal.
a) Disconnect resettable thermal switch wire leads (leading from gas valve)
and remove wire tie from feedline.
b) Remove (2) hex drive screws from right side inner door.
c) Remove (2) hex drive screws from flange section of inner door.
d) Remove right side inner door and set aside.
Be careful not to dama
asket material on inner door.
19
19
Step 7. Removal of gas valve.
Step 8. Installation of gas valve.
Step 9. Reinstallation of inner door assembly.
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.
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers)
a) Disconnect main burner feedline, pilot tube and thermocouple from
gas valve & remove burner from combustion chamber.
NOTE: Feed line nut for natural gas control uses right hand threads,
LP 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 ½"
NPT pipe threaded into inlet of control.
a) Install new gas valve using a control body wrench or a length
of ½" 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, LP
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.
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
> Tears
> Missing Material
> Cracks
> Dirt or debris
> Gasket adhesion to inner door
> Other imperfections that will inhibit proper seal
> Material left on combustion chamber
20
20
Step 9. Reinstallation of inner door assembly. (cont.)
W
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.
d) Firmly place right side inner door flange against the left side inner door flange and secure with
(2) hex drive screws from step 6c. DO NOT OVER TIGHTEN SCREWS.
SERVICE PROCEDURE RG-V
Gas Valve Testing and Replacement
(White Rodgers)
WARNING
A seal breach may result in a fire or
explosion causing property damage,
personal injury or death.
Step 10.
Step 11.
Step 12.
Step 13.
Step 14.
e) Align right side inner door to combustion chamber and verify the fastener holes of the combustion
chamber is aligned with the right-side inner door slotted openings. Verify seal integrity around
combustion opening. Secure right-side inner door using (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.
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.
Replace outer jacket burner access door.
Reconnect gas supply to gas valve.
Resume water supply to water heater. Be sure tank is full of water.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
21
21
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
MANIFOLD PRESSURE TESTING (this procedure presumes a maximum line pressure of 14.0" w.c.)
Step 1.
Step 2.
Set the gas control to the “OFF” position.
Remove pressure tap plug and install
1/8" NPT pipe, coupling, & pressure tap.
Step 3.
Step 4.
Connect manometer to pressure tap.
Follow instructions located on the lighting
instructions label and proceed to light the 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 LP gas is: 10.0" ±0.5" w.c.
Step 6.
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.
Step 7.
If gas pressure is outside the specification noted
above, refer to “Honeywell gas control Testing,
Disassembly, and Replacement” to replace gas control
22
THERMOPILE TESTING
See SERVICE PROCEDURE RG-II
ECO (Energy Cut Off) TESTING
The Honeywell 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 (5) minutes before relighting following the instructions located on the lighting instruction label or
the lighting instructions located in the installation and operation manual.
22
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
TEMPERATURE SENSOR TESTING
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
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 (5)
minutes. Then follow lighting instructions and
return gas control knob to desired setpoint.
Observe Green LED indicator.
Does status code 4 (four
flashes, three second pause)
Y
Temperature Sensor Testing
Following “Gas Control
Disassembly/Reassembly”
instructions, disassemble gas
control to access temperature
sensor.
With the temperature sensor, still
in the back plate, use a multi-
meter set t o the Ohms setting,
determine the resistance of
temperature sensor
(see caution and photos above)
N
DO NOT use standard multimeter probes for this test.
CAUTION
Doing so will damage connector. Use special pin type
electronic probes or small diameter wire pins inserted
into connector.
Using a multi-meter set to the ohms setting, insert one-meter probe (see
caution) into center wire position of thermal well connector, insert the
second probe (see caution) into either of the outside wire positions (see
photo above).
Alternate the probe on the outside position to the opposite outside wire
position
(see photo above).
Resume normal operation.
Once the temperature sensor resistance values are known, the
resistance values are correct. See next page to obtain water
temperature.
Are temperature sensor resistance values correcting?
Y
Replace gas control
N
Replace temperature
sensor
23
23
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
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.
Step 2.
Step 3.
Set the Gas Control knob to the “OFF” position. Turn
off inlet water supply to water heater.
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 4.
Example:
Using the chart below, determine correct resistance value for the water temperature from step 3.
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
°F012345678 9
40 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445
50 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715
60 15314 14925 14548 14180 13823 13477 13140 12812 12494 12185
70 11884 11592 11308 11032 10763 10502 10248 10000 9760 9526
80 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507
90 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961
100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767
110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839
120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112
130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538
140 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083
150 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720
160 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427
170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191
180 1170 1150 1129 1110 1090 1071 1953 1035 1017 999
190 982 965 949 933 917 901 886 871 857 842
200 828 814 801 788 775 762 749 737 725 713
24
24
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
GAS CONTROL REPLACEMENT
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
Step 1. Rotate knob of the gas control to the “OFF” position.
Step 2. Turn off gas supply to water heater.
Step 3. Disconnect gas supply line from gas control.
Step 4. Turn off water supply and drain water heater completely.
Step 5. Remove outer jacket burner access door.
Step 6. Right side inner door removal.
a) Disconnect red wire leads from resettable thermal
switch.
b) Remove (2) hex drive screws from RIGHT side
inner door.
c) Remove (2) hex drive screws from FLANGE
SECTION of inner door.
d) Remove right side inner door and set aside.
Be careful not to 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
½" NPT pipe threaded into gas inlet of gas control.
Step 8. Install new gas control into water heater.
a) Install new gas control into water heater by rotating clockwise. DO NOT use a wrench on
the gas control body, damage to the gas control may occur. If necessary, use a length of
½" NPT pipe threaded into gas inlet of gas control.
25
25
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
GAS CONTROL REPLACEMENT
Step 8. Install new gas control into water heater (continued).
b) Reattach main burner feedline, pilot tube, piezo igniter wire, inner door wire (red) and thermopile
wire (white) to gas control. Attach inner door wire (red) to the positive (+) terminal and the
thermopile wire (white) to the negative (-) terminal.
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
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.
Use back up wrench on wrench boss
of gas control, never use back up
wrench on body of gas control.
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
> Tears
> Missing Material
> Cracks
> Gasket adhesion to inner door
> Other imperfections that will inhibit proper seal
> Material left on combustion chamber
> Dirt or debris
If the gasket is not effected 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 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.
CAUTION
26
26
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
GAS CONTROL REPLACEMENT
Step 9. Reinstallation of inner door assembly (continued).
d) Firmly place right side inner door flange against the left side inner door flange and
secure with (2) hex drive screws from step 6c. DO NOT OVER TIGHTEN SCREWS.
e) Align 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 combustion opening. Secure right side inner door using
(2) hex drive screws from step 6b.
DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly
SERVICE PROCEDURE RG-VI
Gas Control Testing, Disassembly &
Replacement (Honeywell)
Step 10.
Step 11.
Step 12.
Step 13.
Step 14.
Reconnect (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.
Replace outer jacket burner access door.
Reconnect gas supply to gas control.
Use back up wrench on wrench boss
of gas control, never use back up
wrench on body of gas control.
CAUTION
Resume water supply to water heater. Be sure tank is full of water before resuming operation.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
27
27
SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
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 insure no debris accumulating.
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 32).
DANGER
Under no circumstances shall 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 inactivated. If flammable
vapors are present, a fire or explosion may result causing property damage, personal injury or death.
Upon completion of the cast iron burner adjustment procedure, the inner door must be replaced per
SERVICE PROCEDURE RG-1, steps 4 through 14 to reactivate Bradford White Defender Safety System.
WARNING
Inner door and burner components may be HOT when performing this operation. Take necessary
precaution to prevent personal injury.
Step 1.
Step 2.
With main burner in operation, remove right side inner door per SERVICE PROCEDURE I, steps
3b & 3c. Be sure to maintain wire connection to resettable thermal switch for this adjustment
procedure.
To adjust for proper burning, loosen the air shutter nut, rotate the shutter to close the opening in the
burner, then slowly rotate the shutter until the yellow tips disappear and the flame becomes blue.
Tighten the air shutter nut. Too much air will cause the flame to lift off the burner ports and create
noisy burner operation. Too little air (yellow tips) will result in soot formation.
Place right side inner door into proper position to confirm proper burner flame pattern and correct
air shutter adjustment. It may be necessary to allow the burner to operate for several minutes for
burner flame to stabilize.
28
28
SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement (cont.)
Step 3.
Fully inspect inner gasket per SERVICE PROCEDURE RG-I, step 4. Replace gasket if required
following SERVICE PROCEDURE I, steps 5 & 6.
Step 4.
Be certain that thermocouple, pilot tube and piezo wire are
routed by inner door flange as shown and reinstall inner
door per SERVICE PROCEDURE RG-I, step 10 and 11.
Step 5.
Observe burner operation through sight glass of inner door. Burner should operate as adjusted in
step 2, if not, repeat procedure compensating air shutter position for proper burner operation with
inner door in place.
Step 6.
It may be necessary to clean main burner or main burner orifice to achieve proper burner operation.
If cleaning is required proceed to burner cleaning section in this procedure.
BURNER CLEANING
Step 1.
Step 2.
Remove inner door assembly per SERVICE PROCEDURE RG-I, steps 1 through 3c.
Disconnect 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,
LP control uses left hand thread.
Step 3.
Thoroughly inspect burner surface area and burner ports and remove any loose debris
accumulation.
29
29
SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
BURNER CLEANING (Cont.)
SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Step 10.
Step 11.
Disconnect (unscrew) main burne r from main burner orifice &
disconnect (unscrew) feedline from burner.
Remove main burner orifice from feed line.
Inspect and clean if necessary.
Remove pilot assembly, refer to SERVICE PROCEDURE RG-III for cleaning and inspection.
Reassemble burner.
Inspect combustion chamber area of heater prior to reinstallation of burner assembly. If cleaning is
required, refer to SERVICE PROCEDURE RG-VIII.
Reinstall burner assembly into combustion chamber, reconnect feedline, thermocouple and pilot
tube to the combination thermostat/gas valve.
Reinstall inner door per SERVICE PROCEDURE RG-I, steps 4 through 13.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
30
30
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
RESETTABLE THERMAL SWITCH CONTINUITY TESTING
Step 1.
Remove outer jacket door.
Step 2.
Step 3.
Step 4.
Step 5.
Disconnect wire leads from resettable thermal switch.
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.
If continuity is indicated, the switch is closed, allowing millivolt current to pass.
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 ACTIV ATION
PROBABLE CAUSE CORRECTIVE ACTION
1.
Verify adequate combustion air supply is
available.
2.
Insufficient combustion air
1.
Weak switch or switch
out of calibration.
2.
Incorrect switch.
Clear jacket slot openings of any dirt, dust,
restrictions or other obstructions.
3.
Inspect flame arrestor plate and clean with a
stiff brush, compressed air and/or vacuum
to remove scale deposits and debris.
1.
Replace resettable thermal switch.
2.
Verify switch color code and approximate
temperature.
Resettable thermal switch
color code reference.
Color Code
Blue
Yellow 270°
Red 290°
Approximate switch
activation temperature
(open)
240°
Flammable vapor incident 1. Replace water heater.
31
31
RESETTABLE THERMAL SWITCH REPLACEMENT
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
Step 1. Rotate knob of combination thermostat gas valve to the off position.
Step 2.
Step 3.
Remove outer jacket door.
Disconnect wire leads from resettable thermal switch.
SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
Step 4. Remove resettable thermal switch from inner door (Phillips screw driver).
Step 5.
Place 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 termination are interchangeable with either resettable thermal switch connection.
Step 7.
Step 8.
Replace outer jacket door.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instruction located in the installation and operation manual.
32
32
SERVICE PROCEDURE RG-IX
ScreenLok
®
Flame Arrestor Cleaning
SERVICE PROCEDURE RG-IX
ScreenLok
ScreenLok® Flame Arrestor Cleaning
Step 1. Rotate knob of combination thermostat gas valve to the off position.
Step 2.
Step 3.
Step 4.
Remove outer jacket door.
Remove inner door per SERVICE PROCEDURE RG-I, step 3a through 3e.
Disconnect 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, LP control uses left hand thread.
®
Flame Arrestor Cleaning
Step 5.
Step 6.
Step 7.
Step 8
Step 9.
®
Clean ScreenLok
Flame Arrestor using stiff brush, compressed air and/or shop vacuum to remove
any scale or other debris accumulation. Using a soft brush, clear jacket openings of any dirt, dust,
restrictions or other obstructions.
Remove any debris from burner assembly per SERVICE PROCEDURE RG-V and reinstall burner
assembly into combustion chamber.
Reconnect feedline, thermocouple and pilot tube to the combination thermostat/gas valve.
Reinstall inner door per SERVICE PROCEDURE RG-I, steps 4 through 13.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instruction located in the installation and operation manual.
33
33
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 knob of combination thermostat/gas valve to “OFF” position
SERVICE PROCEDURE RG-X
Diptube and Anode
Inspection and Replacement
Step 2.
Step 3.
Step 4
Step 5.
Step 6.
Step 7.
Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an
open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of
water heater and allow heater to drain to a point below the inlet connection nipple.
Disconnect inlet nipple from plumbing system.
With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to
damage pipe threads.
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. Anti-siphon hole located approximately 6" 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.
Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater.
Ensure pipe dope is used on the nipple’s threads. Connect nipple to plumbing system, resume
water supply and refill heater with water.
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-X
Diptube and Anode
Inspection and Replacement
ANODE INSPECTION AND REPLACEMENT
WARNING
Heater components and stored w ater may be HOT when performing the following steps in
this procedure. Take necessary precaution to prevent personal injury.
SERVICE PROCEDURE RG-X
Diptube and Anode
Inspection and Replacement
Step 1.
Step 2.
Step 3.
Step 4
Step 5.
Step 6.
Turn off water supply to water heater. Rotate knob of combination thermostat/gas valve to
“OFF” position.
Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an
open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of
water heater and allow heater to drain to a point below the outlet connection nipple.
Disconnect outlet nipple from plumbing system.
With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to
damage pipe threads.
Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is
normal. If depletion is ½ 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.
Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater.
Ensure pipe dope is used on the nipple’s threads. Connect nipple to plumbing system, resume
water supply and refill 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.
35
35
Generic Parts List
Generic Parts List
36
Draft Hood
1
2
Hot Water Outlet/Anode
3
Cold Water Inlet Tube
4
Flue Baffle
5
T&P Relief Valve
6A
Gas Control (Honeywell V1)
6B
Gas Control (Honeywell V2)
6C
Gas Valve (White Rodgers)
7
Piezo Igniter (White Rodgers)
8
Brass Drain Valve
9
Screw-#8-18 x 3/4 Hex Washer Head
10
Screw-#10-12 x 3/4 Hex Washer Head
11
Left Side Inner Door with Gasket
12
Complete Right Side Inner Door
14
Resettable Thermal Switch
15
Outer Door
16
Complete N Burner Assembly (Natural) N
17
Burner Only
18
Main Burner Orifice
19
Pilot Assembly
20
Pilot Orifice
21
Thermocouple/Thermopile
22
Complete X Burner Assembly (LP)
23
X Burner Only
24
Main Burner Orifice
25
Pilot Assembly
26
Pilot Orifice
27
Thermocouple/Thermopile
28
ASSE Approved Mixing Valve (Optional)
29
¾ NPT Tank Plug (H Models)
30
Inner Door Gasket Kit
31
Wire Tie
32
Heat Trap (Outlet)
33
Heat Trap (Inlet)
Heat Trap Kit
34
36
373839
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