Bradford White RG130T6N, RG230T6N, RG230S6N, RG140T6N, RG240T6N User 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)

(*) Denotes Warranty Years

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)

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…………………

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

…

…..12 RG-I

Service

Procedure

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……

Resettable Thermal Switch Testing and Replacement………………………..….…..37 RG-VIII

ScreenLok®Flame Arrestor Cleaning……………………………………………

Diptube and Anode Inspection and Replacement……………………………….…..40 RG-X

Parts Diagram……………………………………………………………………….…..42 ---

Notes………..………………………………………………………………………

…..35 RG-VII

…..39

…

...43 ---

RG-IX

WARNING:

jury

If the information in these instructions is not followed exactly, a fire or explosion may result in property damage, personal in

, 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

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

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.

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 containin

a plastic liner.

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. Th e 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 p revent 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.

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.

White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Symptom Probable Cause Corrective Action

No incoming gas or too low

Turn on gas supply and/or check line pressure.

Review lighting instruction. Set gas control knob to correct position.

Review lighting instruction. Fully depress gas control knob.

Clean, repair or replace.

Verify correct electrode position. Replace pilot assembly.

Replace piezo igniter.

Check connection at combination thermostat/gas valve. Proper tightness should be finger tight + a 1/4 turn.

Inspect thermocouple to ensure that it is fully engaged into pilot bracket.

Clean pilot orifice and verify pilot tube is clear; check gas supply and line pressure.

Check thermocouple and replace if necessary.

Check ECO continuity and replace combination thermostat/gas valve if necessary.

Check magnet operation and replace combination thermostat/gas valve if necessary.

Determine cause of switch activation. To reset, depress button on resettable thermal switch located on inner door.

Adjust temperature dial on combination thermostat/gas valve.

Check temperature dial setting on combination thermostat/gas valve.

Check gas supply and line pressure.

Check combination thermostat/gas valve for proper operation, replace if necessary.

Pilot will not light

Pilot will not stay lit when button is released

Pilot will light but the main burner will not come on

gas pressure.

Gas control knob set to wrong position.

Gas control knob not being fully depressed when attempting to light pilot.

Pilot orifice or pilot tube is obstructed or kinked.

Pilot electrode not sparking to pilot.

Piezo igniter not functioning.

Poor thermocouple connection at combination thermostat/gas valve.

Thermocouple not fully engaged in pilot assembly bracket.

Pilot flame is not fully enveloping the thermocouple bulb.

Weak or defective thermocouple.

Open ECO in combination thermostat/ gas valve.

Defective magnet in combination thermostat/gas valve.

Resettable thermal switch has opened.

Combination thermostat/gas valve set too low for desired water temperature.

Combination thermostat/gas valve temperature is satisfied.

Insufficient gas supply or low gas pressure.

Combination thermostat/gas valve has wide differential or is out of calibration.

Service

Procedure

See Service Procedure RG-V

See Service Procedure RG-III

See Service Procedure RG-IV

See Service Procedure RG-II

See Service Procedure RG-V

See Installation and Operation Manual.

See Service Procedure RG-V

White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Symptom Probable Cause Corrective Action

Verify adequate combustion air is available to the unit. Check and clear jacket slot openings of

1. Pilot goes out periodically (after heating cycles, once a day, once a week etc.)

Not enough hot water

Insufficient combustion air supply.

Incorrect or clogged vent system/vent terminal, or incorrect location.

Inconsistent gas supply or gas pressure.

Combination thermostat/gas valve set too low for desired water temperature.

Cold inlet water temperature is very cold.

High demand periods.

Incorrectly sized water heater for application.

Combination thermostat/gas valve is out of calibration/not functioning.

Out of spec dip tube is diluting hot water with cold water.

any dirt, dust, restrictions or other obstructions. Inspect flame arrestor plate and clean with stiff bristled brush and compressed air to remove any debris accumulation.

Check venting for proper sizing and proper operation.

Check gas supply and line pressure.

Check dial on combination thermostat/gas valve.

Extremely cold water going into the heater will decrease the amount of hot water produced. It may be necessary to temper incoming water supply.

Adjust high demand usage.

Contact plumbing professional.

Check combination thermostat/gas valve for proper operation, replace if necessary.

Inspect dip tube and replace if necessary.

Service

Procedure

See Service Procedure RGVIII

See Service Procedure RG-V

See Service Procedure RG-IX

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 Probable Cause

None (LED not on or flashing)

One flash every four seconds

One flash every second

Solid ON

Two flashes and three second pause

Four flashes and three second pause

Five flashes and three second pause

Indicates control is off. Main

and pilot burner are off.

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.

Not an error. Indicates that

the control is in shutdown

mode.

Low thermopile voltage; main burner not lit.

Temperature cut-out limit

reached causing shutdown.

Electronics, sensor, or gas

valve fault detected.

Gas valve is functioning normally. Gas valve is not powered. Light pilot.

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.

Thermostat is calling for heat. Water heater

operating normally and is in heat cycle.

Set point knob was recently turned to “OFF”

position. Wait until LED goes out before

attempting to relight.

Loose thermopile connections or weak pilot

flame.

Excessive temperatures may have been reached. Shut off the control and reduce the water temperature. Thoroughly verify control

operation, replace if exceeding setpoint.

Control may be wet or damaged. Verify all

connections are tight; if problem persists replace

the control.

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 Control Status Probable Cause Service Procedure

If the pilot will not stay lit None (LED not on or flashing)

One flash and three second pause

Pilot assembly is not lit.

If setpoint knob is in “PILOT” position then pilot flame is detected. Turn setpoint knob to desired setting.

If the setpoint knob is already at the desired setting, the water heater is satisfied.

Gas control is not powered. Light pilot.

Gas control is powered and waiting for setpoint knob to be turned to a water temperature setting.

Water heater is satisfied and operating normally.

replace pilot assembly. If

problem persists replace

gas control.

Normal operation.

LED on continuously (solid)

Two flashes and three second pause

Three flashes and three second pause

Setpoint knob has been recently turned to the “OFF” position. Wait until LED goes out before attempting to relight.

Weak pilot signal detected. System will reset when pilot flame is sufficient.

Insufficient water heating. System will reset.

Setpoint knob was turned to “OFF” position.

Thermopile failure.

Unstable pilot.

Pilot tube blocked or restricted.

Thermal sensor out of calibration.

Faulty gas control.

LED will go out and the control will function normally once the pilot is lit.

See Service Procedure IV

See Service Procedure II

Replace gas control.

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 Control Status Probable Cause Service Procedure

Four flashes and three second pause

Five flashes and three second pause

Six flashes and three second pause

Seven 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.

Temperature sensor out of calibration.

Faulty gas control.

Damage to the

temperature sensor, resistance is out of range, or sensor is unplugged.

Faulty gas control.

Excessive amount of water in drain pan/water dam.

Control needs to be reset.

Control is wet or physically damaged.

Replace gas control.

See Service Procedure VI

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.

Eight flashes and three second pause

Standing pilot remains on while setpoint knob is in “OFF” position.

Pilot valve stuck in open position.

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 Service Procedure

If the pilot will not stay lit replace pilot assembly. If problem persists, replace

as control.

Normal operation.

1. See Service Procedure IV

2. See Service Procedure II

3. See Service Procedure II

Replace gas control.

None (LED not on or flashing)

One flash every four seconds (LED green)

One flash every second (LED green)

Two flashes and three second pause (LED

ellow)

Four flashes and three second pause (LED red)

Five flashes and three second pause (LED red)

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

Temperature cut-out limit reached, causing shutdown.

Electronics, sensor, or gas valve fault detected.

Gas valve is functioning normally. Gas valve is not powered. Light pilot.

The knob can be turned 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 water temperature setpoint. Verify control operation, replace if exceeding setpoint.

Check water temperature sensor and its connection for open circuits, shorts, or differences in resistance between the two sensor elements.

Solid ON (LED red)

Not an error–indicates that the control is in OFF position.

None; wait until LED turns off if you want to restart system.

LED will go out and the control will function normally once the pilot is lit.

Inner Door Removal Procedure

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal,

Inspection, and Replacement

Step 1.

Step 2.

Step 3.

Step 4.

Rotate knob of the combination thermostat/gas valve to the “OFF” position.

Remove the outer jacket burner access door.

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.

Fully inspect inner door gaskets for the following:

ƔTears ƔMissing material ƔCracks

ƔGasket adhesion to inner door ƔMaterial left on combustion chamber (around opening) 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 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

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal,

Inspection, and Replacement

Installation of Inner Door with Gasket

Step 1.

Step 2.

Step 3.

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 two (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

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

Steps

2, 4, and 5.

If a fastener connection is stripped,

contact the manufacturer listed on the

water heater rating plate.

wire against left side inner door flange gasket.

DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.

Radiused channel for

feedline

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.

Step 8.

Replace the outer jacket burner access door.

To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the Installation and Operation Manual.

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