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) RG230S*(N,X)

RG140T*(N,X) RG230T*(N,X)

RG150T(N,X) RG240S*(N,X)

RG140S*(N,X) RG240T*(N,X)

RG150L*(N,X) RG250H*(N,X)

RG150S*(N,X) RG250L*(N,X)

LG255H*(N.X) RG250S*(N,X)

LG275H*(N,X) RG250T*(N,X)

LG250H65*(N,X) RG250H*(N,X)

RG2100H*(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	Service
	Procedure
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
Resettable Thermal Switch Testing and Replacement……………………….. .…..37	RG-VIII
ScreenLok® Flame Arrestor Cleaning………………………………………………..39	RG-IX
Diptube and Anode Inspection and Replacement…………………………………..40	RG-X
Parts Diagram……………………………………………………………………….…..42	---
Notes………..………………………………………………………………………… ...43	---

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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

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:

xLiquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas.

xMost people recognize this odor as a “sulfur” or “rotten egg” smell.

xOther conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or “fade”, and not be as readily detectable.

xIf 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 containing a plastic liner.

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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.

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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.

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White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

	Symptom	Probable Cause	Corrective Action	Service
				Procedure
		1.No incoming gas or too low	1.Turn on gas supply and/or check
		gas pressure.		1.See Service
		2.Gas control knob set to	line pressure.
		wrong position.	2.Review lighting instruction. Set gas	Procedure RG-V
		3.Gas control knob not being	control knob to correct position.	2.See Service
	Pilot will not light	fully depressed when	3.Review lighting instruction. Fully	Procedure RG-III
		attempting to light pilot.	depress gas control knob.	3.See Service
		4.Pilot orifice or pilot tube is	4.Clean, repair or replace.	Procedure RG-III
		obstructed or kinked.	5.Verify correct electrode position.	4.See Service
		5.Pilot electrode not sparking to	Replace pilot assembly.	Procedure RG-IV
		pilot.	6.Replace piezo igniter.
		6.Piezo igniter not functioning.
			1.Check connection at combination
		1.Poor thermocouple	thermostat/gas valve. Proper
			tightness should be finger tight
		connection at combination
			+ a 1/4 turn.
		thermostat/gas valve.
			2.Inspect thermocouple to ensure
		2.Thermocouple not fully
			that it is fully engaged into pilot
		engaged in pilot assembly
			bracket.
		bracket.
			3.Clean pilot orifice and verify pilot
		3.Pilot flame is not fully		1.See Service
			tube is clear; check gas supply
		enveloping the thermocouple
			and line pressure.	Procedure RG-II
	Pilot will not stay lit	bulb.
			4.Check thermocouple and replace	2.See Service
	when button is	4.Weak or defective
			if necessary.	Procedure RG-V
	released	thermocouple.
			5.Check ECO continuity and replace	3.See Service
		5.Open ECO in
			combination thermostat/gas valve	Procedure RG-V
		combination thermostat/
			if necessary.
		gas valve.
			6.Check magnet operation and
		6.Defective magnet in
			replace combination
		combination thermostat/gas
			thermostat/gas valve if necessary.
		valve.
			7.Determine cause of switch
		7.Resettable thermal switch
			activation. To reset, depress
		has opened.
			button on resettable thermal
			switch located on inner door.
		1.Combination thermostat/gas	1.Adjust temperature dial on
			combination thermostat/gas
		valve set too low for desired
			valve.	1.See Installation
		water temperature.
			2.Check temperature dial
		2.Combination		and Operation
	Pilot will light but		setting on combination
		thermostat/gas valve		Manual.
			thermostat/gas valve.
	the main burner	temperature is satisfied.		2.See Service
			3.Check gas supply and line
	will not come on	3.Insufficient gas supply or		Procedure RG-V
			pressure.
		low gas pressure.		3.See Service
			4.Check combination
		4.Combination thermostat/gas		Procedure RG-V
			thermostat/gas valve for
		valve has wide differential or
			proper operation, replace if
		is out of calibration.
			necessary.

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White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Symptom		Probable Cause		Corrective Action	Service
					Procedure
			1.	Verify adequate combustion air
				is available to the unit. Check
	1.	Insufficient combustion air		and clear jacket slot openings of
Pilot goes out				any dirt, dust, restrictions or	1. See Service
		supply.		other obstructions. Inspect flame
periodically (after	2. Incorrect or clogged vent			arrestor plate and clean with stiff	Procedure RG-
heating cycles,		system/vent terminal, or		bristled brush and compressed	VIII
once a day, once		incorrect location.		air to remove any debris	2. See Service
a week etc.)	3. Inconsistent gas supply or		2.	accumulation.	Procedure RG-V
		gas pressure.		Check venting for proper sizing
			3.	and proper operation.
				Check gas supply and line
				pressure.
	1.	Combination thermostat/gas	1.	Check dial on combination
		valve set too low for desired	2.	thermostat/gas valve.
	2.	water temperature.		Extremely cold water going into
		Cold inlet water temperature		the heater will decrease the
	3.	is very cold.		amount of hot water produced. It	1. See Service
Not enough hot		High demand periods.		may be necessary to temper
	4. Incorrectly sized water		3.	incoming water supply.	Procedure RG-V
water		heater for application.		Adjust high demand usage.	2. See Service
	5. Combination thermostat/gas		4.	Contact plumbing professional.	Procedure RG-IX
		valve is out of calibration/not	5.	Check combination
		functioning.		thermostat/gas valve for proper
	6. Out of spec dip tube is		6.	operation, replace if necessary.
		diluting hot water with cold		Inspect dip tube and replace if
		water.		necessary.

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White Rodgers ElectronicGas Control Troubleshooting Chart

FlammableVaporIgnitionResistantWaterHeaters

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	Indicates control is off. Main	Gas valve is functioning normally. Gas valve is
	or flashing)	and pilot burner are off.	not powered. Light pilot.
	One flash every	Not an error. Indicates pilot is	Gas valve is powered and waiting for the set
			point knob to be turned to a water temperature
	four seconds	lit and main burner is off.	setting. If the set point knob is at desired setting,
			the thermostat is satisfied.
	One flash every	Not an error. Indicates main	Thermostat is calling for heat. Water heater
		valve is open and main
	second		operating normally and is in heat cycle.
		burner is lit.
	Solid ON	Not an error. Indicates that	Set point knob was recently turned to “OFF”
		the control is in shutdown	position. Wait until LED goes out before
		mode.	attempting to relight.
	Two flashes and	Low thermopile voltage; main	Loose thermopile connections or weak pilot
	three second
		burner not lit.	flame.
	pause
	Four flashes and		Excessive temperatures may have been
		Temperature cut-out limit	reached. Shut off the control and reduce the
	three second
		reached causing shutdown.	water temperature. Thoroughly verify control
	pause
			operation, replace if exceeding setpoint.
	Five flashes and	Electronics, sensor, or gas	Control may be wet or damaged. Verify all
	three second		connections are tight; if problem persists replace
		valve fault detected.
	pause		the control.

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Honeywell V1Gas Control Troubleshooting Chart

FlammableVaporIgnitionResistantWaterHeaters

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
	None (LED not		Gas control is not		If the pilot will not stay lit
		Pilot assembly is not lit.			replace pilot assembly. If
	on or flashing)		powered. Light pilot.		problem persists replace
					gas control.
		1. If setpoint knob is in “PILOT”	1.	Gas control is
		position then pilot flame is		powered and waiting
	One flash and	detected. Turn setpoint knob		for setpoint knob to
		to desired setting.		be turned to a water	Normal operation.
	three second
		2. If the setpoint knob is		temperature setting.
	pause
		already at the desired	2.	Water heater is
		setting, the water heater is		satisfied and
		satisfied.		operating normally.
	LED on	Setpoint knob has been recently	Setpoint knob was		LED will go out and the
		turned to the “OFF” position. Wait
	continuously	until LED goes out before	turned to “OFF”		control will function
	(solid)		position.		normally once the pilot is lit.
		attempting to relight.
	Two flashes	Weak pilot signal detected.	1.	Thermopile failure.	1. See Service Procedure IV
			2.	Unstable pilot.
	and three	System will reset when pilot			2. See Service Procedure II
			3.	Pilot tube blocked or
	second pause	flame is sufficient.			3. See Service Procedure II
				restricted.
	Three flashes	Insufficient water heating.	1.	Thermal sensor out
	and three			of calibration.	Replace gas control.
		System will reset.
	second pause		2.	Faulty gas control.

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Honeywell V1Gas Control Troubleshooting Chart

FlammableVaporIgnitionResistantWaterHeaters

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	Excessive tank temperature.	1. Temperature sensor	Replace gas control.
	and three	System must be reset.	out of calibration.
	second pause		2. Faulty gas control.
			1. Damage to the
	Five flashes		temperature sensor,
			resistance is out of	1.See Service Procedure VI
	and three	Temperature sensor fault.
			range, or sensor is	2.Replace gas control.
	second pause
			unplugged.
			2. Faulty gas control.
	Six flashes		Excessive amount of	1. Check T&P valve.
		Water leak detected by		2. Check all water fittings.
	and three		water in drain pan/water
		accessory module.		3. Pressurize and leak test
	second pause		dam.	tank.
	Seven flashes		1. Control needs to be
		Gas control electronic fault	reset.	1. Reset gas control
	and three
		detected.	2. Control is wet or	2. Replace gas control.
	second pause
			physically damaged.
	Eight flashes	Standing pilot remains on	Pilot valve stuck in
	and three	while setpoint knob is in		Replace gas control.
			open position.
	second pause	“OFF” position.

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Honeywell V2 Gas Control Troubleshooting Chart

FlammableVaporIgnitionResistantWaterHeaters

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
	None (LED not on	Millivolt power is not	Gas valve is functioning	If the pilot will not stay lit
				replace pilot assembly. If
			normally. Gas valve is not
	or flashing)	present. Light pilot.		problem persists, replace
			powered. Light pilot.
				gas control.
	One flash every	Not an error. Indicates	The knob can be turned to a	Normal operation.
	four seconds	pilot is lit and main	desired setpoint temperature.
	(LED green)	burner is off.
	One flash every	Not an error. Indicates	None. Control will automatically
	second	main valve is open and	shut main burner off when water	Normal operation.
			temperature reaches the setpoint
	(LED green)	main burner is lit.	temperature.
	Two flashes and		Check thermopile and its	1. See Service Procedure IV
	three second	Low thermopile voltage;
				2. See Service Procedure II
	pause (LED	main valve not turned on.	connections. Check pilot flame.
				3. See Service Procedure II
	yellow)
	Four flashes and	Temperature cut-out	Check the valves and the water
			temperature sensor. Reduce the	Replace gas control.
	three second	limit reached, causing	water temperature setpoint.
	pause (LED red)	shutdown.	Verify control operation, replace
			if exceeding setpoint.
	Five flashes and		Check water temperature sensor
		Electronics, sensor, or	and its connection for open	Replace gas control.
	three second		circuits, shorts, or differences in
	pause (LED red)	gas valve fault detected.	resistance between the two
			sensor elements.
	Solid ON	Not an error–indicates	None; wait until LED turns off if	LED will go out and the
	(LED red)	that the control is in OFF	you want to restart system.	control will function normally
		position.		once the pilot is lit.

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SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal,

Inspection, and Replacement

InnerDoor 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:

ƔTears	ƔGasket adhesion to inner door
ƔMissing material	ƔMaterial left on combustion chamber (around opening)
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 InnerDoorGasketReplacement Procedure.

InnerDoor GasketReplacementProcedure

RECOMMENDED	GASKET OVERLAP
	MUST BE AS	ENLARGED
PATTERN FOR RTV	SHOWN ±1/32"	VIEW OF
SEALANT		FLANGE AREA

PLACE FLANGE	VIEW WITH
SECTIONS FIRST
EXPANDED	GASKETS IN
	PLACE
VIEW

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SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal,

Inspection, and Replacement

Installation of Inner Door with Gasket

Step 1. Clean anyresidualgasket residue or other debrisfrom combustionchambersurface before installing the innerdoor/gasket assembly.

Step 2. Place the left side inner door into position first. Firmlyposition the radiused channelof the innerdooraroundthe feedline. Usingthe two (2)hexdrive screwsfrom Step 3d, secure left side innerdoorin place. DO NOT

OVER TIGHTEN SCREWS.

Step 3. Position thermocouple,pilot tube and piezo wire against left side innerdoorflange 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 Steps 2, 4, and 5.

If a fastener connection is stripped, contact the manufacturer listed on the water heater rating plate.

Radiused channel for feedline

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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. DONOTOVERTIGHTENSCREWS.

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 NOTOVERTIGHTENSCREWS.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.

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