Bradford White LG275H, RG140T, RG150S, LG255H, RG2100H Service Manual

Flammable Vapor Ignition Resistant

Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

RG130T*(N,X)
RG140T*(N,X)
RG150T(N,X)
RG140S*(N,X)
RG150L*(N,X)
RG150S*(N,X)
LG255H*(N.X)
LG275H*(N,X)
LG250H65*(N,X)
RG2100H*(N,X)

(*) 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………..………………………………………………………………………

2

…..35 RG-VII

…..39

…

...43 ---

RG-IX

2

g

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.

3

3

INTRODUCTION

The Bradford White DEFENDER Safety System

The Bradford White DEFENDER Safety System®was designed to resist the ignition of flammable
vapors that can occur outside of the water heater. Use and installation are nearly identical to
previous versions of atmospherically fired and vented water heaters. A number of exclusive
design features are incorporated in the system that will require additional knowledge on the part of
the qualified service provider. 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.

4

4

It is intended for this manual to be used by qualified service personnel for the primary purpose
of troubleshooting and repair of the Bradford White DV Series water heaters.

The Honeywell Icon Gas Control will display status codes in the event of abnormal operation.
Status codes are listed in the troubleshooting charts found in this service manual. The
troubleshooting charts will also indicate the probable cause for the status code and direct the
service professional to a service procedure to properly diagnose the abnormal operation.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent
system to determine the problem.

Contact the Bradford White technical support group immediately if diagnosis cannot be made
using the methods described in this service manual.

Tools Required for Service

Manometer: A liquid “U” tube type or a digital (magnahelic) type can be

used. This device is used to measure gas and/or air pressure
and vacuum.

Multi-Meter: A digital type is strongly recommended. This device is used

to measure electrical values. The meter you select must have
the capability to measure volts AC, volts DC, amps,
micro-amps, and ohms.

Electronic Probes: In some cases, standard multi-meter probes will damage or

simply not be effective to obtain certain voltage and ohm
readings. It will be necessary to have special electronic “pin”
type multi-meter probes. These probes are available at most
electronic wholesale outlets.

Thermometer: Used to measure water temperature. An accurate

thermometer is recommended.

Water Pressure Gage: Used to measure water supply pressure. Also used to

determine tank pressure by adapting to the drain valve of the
heater.

Various Hand Tools: Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”,

1/2”), 12” crescent wrench, allen wrench set, screw drivers
(common & Phillips), 1/4” nut driver, pliers (common & needle
nose), socket set, side cutters, wire cutters, wire strippers,
wire crimpers, torpedo level, small shop vacuum, step ladder,
flashlight, and 5-gallon pail.

5

5

White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Symptom Probable Cause Corrective Action

1.

No incoming gas or too low

1.

Turn on gas supply and/or check
line pressure.

2.

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

3.

Review lighting instruction. Fully
depress gas control knob.

4.

Clean, repair or replace.

5.

Verify correct electrode position.
Replace pilot assembly.

6.

Replace piezo igniter.

1.

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

2.

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

3.

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

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
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.

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.

2.

Gas control knob set to
wrong position.

3.

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

4.

Pilot orifice or pilot tube is
obstructed or kinked.

5.

Pilot electrode not sparking to
pilot.

6.

Piezo igniter not functioning.

1.

Poor thermocouple
connection at combination
thermostat/gas valve.

2.

Thermocouple not fully
engaged in pilot assembly
bracket.

3.

Pilot flame is not fully
enveloping the thermocouple
bulb.

4.

Weak or defective
thermocouple.

5.

Open ECO in
combination thermostat/
gas valve.

6.

Defective magnet in
combination thermostat/gas
valve.

7.

Resettable thermal switch
has opened.

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.

Service

Procedure

1.

See Service
Procedure RG-V

2.

See Service
Procedure RG-III

3.

See Service
Procedure RG-III

4.

See Service
Procedure RG-IV

1.

See Service
Procedure RG-II

2.

See Service
Procedure RG-V

3.

See Service
Procedure RG-V

1.

See Installation
and Operation
Manual.

2.

See Service
Procedure RG-V

3.

See Service
Procedure RG-V

6

6

White Rodgers Mechanical Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Symptom Probable Cause Corrective Action

1.

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.

2.

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

3.

Inconsistent gas supply or
gas pressure.

1.

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

2.

Cold inlet water temperature
is very cold.

3.

High demand periods.

4.

Incorrectly sized water
heater for application.

5.

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

6.

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

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.

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

2.

See Service
Procedure RG-V

1.

See Service
Procedure RG-V

2.

See Service
Procedure RG-IX

7

7

White Rodgers Electronic Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.

LED Status Control Status 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.

8

8

Honeywell V1 Gas Control Troubleshooting Chart

V

Flammable Vapor Ignition Resistant Water Heaters

Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.

LED Status Control Status Probable Cause Service Procedure

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

One flash and
three second
pause

Pilot assembly is not lit.

1.

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

2.

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

Gas control is not
powered. Light pilot.

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.

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.

1.

Thermopile failure.

2.

Unstable pilot.

3.

Pilot tube blocked or
restricted.

1.

Thermal sensor out
of calibration.

2.

Faulty gas control.

9

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

1.

See Service Procedure IV

2.

See Service Procedure II

3.

See Service Procedure II

Replace gas control.

9

Honeywell V1 Gas Control Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

Observe green LED indicator on gas control. Status
flash codes are displayed with a three second pause
before repeating. Check and repair the system as
noted in the troubleshooting table below.

LED Status 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.

1.

Temperature sensor
out of calibration.

2.

Faulty gas control.

1.

Damage to the

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

2.

Faulty gas control.

Excessive amount of
water in drain pan/water
dam.

1.

Control needs to be
reset.

2.

Control is wet or
physically damaged.

Replace gas control.

1.

See Service Procedure VI

2.

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

10

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

Pilot valve stuck in
open position.

10

Replace gas control.

Honeywell V2 Gas Control Troubleshooting Chart

g

y

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.

Normal operation.

1. See Service Procedure IV

2. See Service Procedure II

3. See Service Procedure II

Replace gas control.

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.

11

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

11

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

12

GASKET OVERLAP
MUST BE AS
SHOWN ±1/32"

12

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

13

13

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Step 4. Firmly place right side inner door flange against the left side inner door flange and secure with two

(2) 1 / 4 ” hex drive screws from Step 3c. DO NOT OVER TIGHTEN SCREWS.

Step 5.

Align the right side inner door to combustion chamber and verify that the fastener holes of the
combustion chamber are aligned with the right side inner door slotted opening. Verify seal
integrity around the combustion opening. Secure right side inner door using two (2) 1/4” hex drive
screws from Step 3b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the
inner door are properly positioned and sealed against the combustion chamber.

Step 6. Reconnect the lead wires from combination thermostat/gas valve to resettable thermal switch

(see photo in Step 3).
NOTE: Wire terminations are interchangeable with either resettable thermal switch connections.

Step 7.

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.

14

14

SERVICE PROCEDURE RG-II

p

Thermocouple/Thermopile Testing and

Replacement

CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Mechanical)

Step 1. Closed circuit testing is the preferred method for testing the thermocouple. Following the lighting

instruction label on the heater, proceed to light the pilot and allow to operate for three minutes. If
the pilot will not stay lit, hold the pilot button (located on the combination thermostat/gas valve)
down during this test.

Step 2.

Step 3.

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.

If meter reads 10 millivolts or higher, the thermocouple is O.K.. If reading is below
10 millivolts, re

lace the thermocouple.

Alligator clip to copper
sheath of thermocouple

15

15

SERVICE PROCEDURE RG-II

Thermocouple/Thermopile Testing and

Replacement

OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers Mechanical)

Step 1.

Disconnect the thermocouple from the
combination thermostat/gas valve.

Step 2.

Using a multimeter capable of measuring millivolts,
connect one alligator clip to the end ball or contact
portion of the thermocouple and the other alligator clip
to copper portion of the thermocouple.

Step 3.

Following the lighting instruction label on the heater, proceed to light the pilot and allow to
operate for three minutes. It will be necessary to hold the pilot button down continuously

throughout this test. A reading of 20 to 30 millivolts indicates good thermocouple output.

THERMOCOUPLE REPLACEMENT (White Rodgers Mechanical)

Step 1. Turn off gas supply to the water heater. Rotate the knob of the

combination thermostat/gas valve to “OFF” position.

Depress knob slightly
and rotate clockwise to
the “OFF” position.

Step 2.

Remove the outer jacket door.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Remove the right side of inner door per Service Procedure RG-I, Steps 3a through 3c.

Disconnect the thermocouple from the combination thermostat/gas valve. Locate other end of the
thermocouple inside of the combustion chamber and remove from the pilot bracket. Pull firmly,
pulling away from the pilot assembly.

Install a new thermocouple into the pilot bracket making certain the thermocouple is fully engaged
into the pilot bracket. Position the thermocouple against the left side inner door flange at its original
position. Connect the other end of thermocouple to the combination thermostat/gas valve (finger
tight + a 1/4 turn).

Thermocouple position

Inspect the inner door gasket per Service
Procedure RG-I, Step4.

Install right side inner door per Service Procedure RG-I,
“Installation of Inner Door with Gasket,” Step 6 through Step 8.

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

16

16

OPEN CIRCUIT THERMOPILE TESTING
(Honeywell & White Rodgers Electronic)

SERVICE PROCEDURE RG-II

Thermocouple/Thermopile Testing and

Replacement

Step 1.

Step 2.

Step 3.

Turn knob to pilot position and depress.

Continue pressing knob and remove the 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 switch. Connect the negative side of the multimeter to any
earth ground location (jacket base, screw, etc.). Normal thermopile operation will be between
350mV - 850mV.

Step 4. If reading is less than 350mV, resettable thermal switch must be tested. Refer to Service Process

RG-III. If resettable thermal switch is closed, replacement of pilot assembly is recommended
following Service Procedure RG-III.

Step 5. If thermopile reading is between 350mV - 850mV, reconnect red wire to positive (+) terminal of

the gas control.

Release the gas control knob and turn to desired setting to resume normal operation.Step 6.

17

17

SERVICE PROCEDURE RG-III

Pilot Assembly Inspection, Cleaning

and Replacement

PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING, AND REPLACEMENT

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Turn off gas supply to water heater. Rotate the knob
of gas control/gas valve to the “OFF” position.

Remove the 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, L.P. control uses left hand thread.

Disconnect piezo ignition wire from piezo igniter.

Remove burner assembly from the combustion chamber.

Remove the pilot/electrode assembly from the 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.

Step 9.

Step 10.

Step 11.

Step 12.

Step 13.

Inspect pilot orifice (Honeywell ONLY):

a) Remove 7/16" nut from bottom of pilot assembly.

b) Remove pilot tube and pilot orifice.

c) Inspect pilot orifice for blockage, must be cleaned or

replaced. (Honeywell & White Rodgers Electronic pilot
orifice not replaceable, replace pilot assembly).

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, “Installation of Inner
Door with Gasket.”

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

18

Removal of thermopile from
Honeywell & White Rodgers
Electronic pilot assembly is
NOT recommended but can be
achieved by viewing the pilot
assembly from the top and
pressing the thermopile
towards the right while pulling
to remove.

18

SERVICE PROCEDURE RG-IV

Piezo Igniter, Electrode Testing

and Replacement

PIEZO IGNITER, ELECTRODE TESTING AND REPLACEMENT

With the pilot not in operation (no pilot flame) you can check the piezo and electrode circuit by viewing pilot
through the sight glass located on the inner door and observing the spark action.

Step 1.

Step 2.

Step 3.

Remove the outer jacket door.

Repeatedly depress the piezo igniter while viewing the pilot through the sight glass.
If a spark is present, the circuit is O.K.. If there is no spark, proceed to Step 3.

Remove orange (or white) wire from piezo igniter and install a jumper wire in its place.
Hold the other end of the jumper by the wire insulation or using an insulated tool, next to
an unpainted surface such as the feedline or gas valve and depress the piezo igniter. If
there is a spark, the igniter is O.K., the pilot is not functioning and must be replaced (see
Service Procedure RG-III for pilot replacement). If no spark is present the igniter is not
functioning and must be replaced.

Step 4a.

Step 4b.

Jumper
wire

For White Rodgers Mechanical gas valves: To replace the igniter, disconnect orange wire
from piezo igniter. Use a flat-head screwdriver under piezo bracket and gently pry bracket
from the front of the gas valve and unhook the bracket from rear of the gas valve.

Flat-head screwdriver

For Honeywell gas controls: To replace the igniter, see the Honeywell ONLY information in
Service Procedure RG-VI.

19

19

SERVICE PROCEDURE RG-V

Gas Valve Testing and Replacement (White

Rodgers Mechanical)

GAS VALVE TESTING AND REPLACEMENT (White Rodgers Mechanical)

The gas valve is a non-repairable device. If troubleshooting has determined a problem with the gas valve, it
must be replaced.

If the burner and/or pilot do not function, service checks for gas pressure, thermocouple output, magnet
assembly, and ECO are to be performed. If these check O.K., the gas valve may be faulty.

LINE PRESSURE

The gas valve is designed for a maximum line pressure of 14.0" W.C., and a minimum line pressure based on
the manifold pressure plus 1.0" W.C. (check rating plate for rated manifold pressure). Line pressure must be
checked with burner on and burner off to assure proper readings.

MANIFOLD PRESSURE TESTING

(This procedure assumes a maximum line pressure of 14.0" W.C.)

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Set gas valve to “OFF” position.

Remove the pressure tap plug (3/16” Allen wrench) and install
pressure tap.

Connect the manometer to pressure tap.

Follow the 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.

a. If pressure is O.K., set gas valve to “OFF” remove manometer and pressure tap and replace

pressure tap plug. Check for gas leaks before placing water heater back in operation.

b. If pressure is out of the specification noted above, proceed to Step 6 for proper service

procedure.

The manifold pressure is NOT adjustable. If manifold pressure is outside of the range in
Step 5, the control must be replaced.

20

20

SERVICE PROCEDURE RG-V

Gas Valve Testing and Replacement

(White Rodgers Mechanical)

MAGNET ASSEMBLY TESTING (White Rodgers Mechanical Control)

Step 1.

Step 2.

Step 3.

Step 4.

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.

Using a multimeter capable of measuring millivolts, connect one lead using an alligator clip to the
copper sheath of the thermocouple. Use the second lead of the multimeter to probe the top
terminal located at the back of the gas valve.

Alligator clip to copper
sheath of thermocouple

With a meter reading of 13 millivolts or greater, rotate the knob of the 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.

Step 2.

Step 3.

Disconnect the thermocouple from the

gas valve.

Using a multimeter capable of measuring ohms (or

continuity), attach one lead using an alligator clip to the

pilot tube. Insert the other lead fully into the magnet

opening, be sure the lead makes contact only at the top

center of the magnet opening.

DO NOT allow the lead to make contact with the

threaded sides of the opening.

If continuity is indicated, the ECO is O.K.. If continuity is not indicated, the ECO has opened, and
the gas valve must be replaced.

21

21

SERVICE PROCEDURE RG-V

g

Gas Valve Testing and Replacement

(White Rodgers Mechanical)

COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

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

Turn off gas supply to the water heater.

Disconnect the

as supplyline from the gas valve.

Turn off water supply and drain the water heater completely.

Remove the outer jacket burner access door.

For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position

.

Right side inner door removal:

a) Disconnect resettable thermal switch wire leads (leading from gas valve)

and remove the wire tie from the feedline.

b) Remove two (2) 1/4” hex drive screws from the right side inner door.

c) Remove two (2) 1/4” hex drive screws from the flange section of inner door.
d) Remove the right side inner door and set aside. Be careful to not damage

the gasket material on the inner door.

22

22

SERVICE PROCEDURE RG-V

Gas Valve Testing and Replacement

(White Rodgers Mechanical)

Step 7.

Step 8.

Removal of gas valve:

a) Disconnect the main burner feedline, pilot tube and thermocouple

from the gas valve. Remove the burner from combustion chamber.

NOTE: Feed line nut for natural gas control uses right hand threads;

L.P. control uses left hand thread.

b) Remove piezo bracket with piezo igniter

(refer to Service Procedure RG-IV) from gas valve.

c) Remove gas valve from water heater, rotating counter clockwise

using a control body wrench or a length of 1/2" NPT pipe threaded
into inlet of control.

Installation of gas valve:

a) Install new gas valve using a control body wrench or a length

of 1/2" NPT pipe threaded into inlet of control. DO NOT OVER
TIGHTEN. Use caution not to damage cast aluminum body of
gas valve. Be certain not to damage the bundled wire leads.

NOTE: Gas valve must be installed in proper upright position to assure the

feedline will align properly at the inner door flange. DO NOT OVER TIGHTEN.
If control is turned past proper alignment, DO NOT reverse direction to align.

b) Reattach piezo bracket with piezo igniter to gas valve.
c) Reattach main burner feedline, pilot tube and thermocouple to gas valve.

Step 9.

NOTE: Feedline nut for natural gas control uses right hand threads;

L.P. control uses left hand thread.

d) Gather wire leads of gas valve and piezo igniter and secure alongside of

feedline using new wire tie provided.

e) Connect gas supply piping to inlet of control. Use back up wrench on

wrench boss of control, NEVER use back up wrench on body of control.

Reinstallation of inner door assembly:
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:

Ɣ Tears
Ɣ Missing material
Ɣ Cracks

Ɣ Gasket adhesion to inner door
Ɣ Other imperfections that will inhibit proper seal
Ɣ Material left on combustion chamber

Ɣ Dirt or debris

If the gasket is not affected by any of the above, gasket replacement will not be required.
If replacement is required, replace using new gasket kit following the provided instructions.

23

23

Step 9. Reinstallation of inner door assembly (cont.):

b) Clean any gasket residue or other debris from combustion chamber surface before installing

the inner door/gasket assembly.

c) Position thermocouple, pilot tube and piezo wire against left side inner door flange gasket. DO NOT

ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that thermocouple and pilot
tube are not in position to interfere with outer jacket burner access door when reinstalled.

SERVICE PROCEDURE RG-V

Gas Valve Testing and Replacement

(White Rodgers Mechanical)

WARNING

A seal breach may result in a

fire or explosion causing

property damage, personal

injury or death.

d) Firmly place the right side inner door flange against the left side inner door flange and secure

with two (2) hex drive screws from Step 6c. DO NOT OVER TIGHTEN SCREWS.

e) Align the right side inner door to combustion chamber and verify the fastener holes of the combustion

chamber are aligned with the right-side inner door slotted openings. Verify seal integrity around the
combustion opening. Secure right-side inner door using two (2) hex drive screws from Step 6b.

DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly
positioned and sealed against the combustions chamber.

Step 10. Reconnect wire leads from gas valve to resettable thermal switch (see photo in Step 6).

NOTE: Wire terminations are interchangeable with either resettable thermal switch connection.

Step 11.

Step 12.

Replace the outer jacket burner access door.

Reconnect the gas supply to the gas valve.

24

Step 13.

Step 14.

Resume water supply to the water heater. Be sure the 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.

24

SERVICE PROCEDURE RG-VI

p

Gas Control Testing, Disassembly, &Replacement

(White Rodgers Electronic & Honeywell)

LINE PRESSURE

The gas valve is designed for a maximum line pressure of 14.0" W.C., and a minimum
line pressure based on the manifold pressure plus 1.0" W.C. (check rating plate for rated
manifold pressure). Line pressure must be checked with burner on and burner off to
assure proper readings.

MANIFOLD PRESSURE TESTING

(This procedure presumes a maximum line pressure of 14.0" W.C.)

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Set the gas control to the “OFF” position.

Remove pressure tap plug (3/16” allen wrench) and install 1/8"
NPT pipe, coupling, and pressure tap.

Connect manometer to pressure tap.

Follow instructions located on the lighting instructions
label and proceed to light the main burner and

3/16” allen wrench

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.

a) If pressure is within the range specified in the

previous step, set gas control knob to the “OFF”
position, remove manometer and pressure tap,
and replace pressure tap plug. Check for gas
leaks prior to placing water heater back into
operation by following the instructions located on
the lighting instruction label or the lighting
instructions located in the Installation and Operation
Manual.

b) If gas pressure is outside the specification noted above,

refer to the following Honeywell ONLY information, or
“Gas Control Replacement” to replace gas control or
valve body.

The manifold pressure is NOT adjustable. If manifold
pressure is outside of the range in Step 5, the control
must be re

laced.

Gas controls
shown in the

“OFF” position

Pressure tap

shown installed

ECO (ENERGY CUT OFF) TESTING

The Honeywell and White Rodgers Electronic gas control is designed with an ECO device that will reset.

To reset the gas control after a status code 4, turn the gas control knob to the “OFF” position and wait a
minimum of five (5) minutes before relighting following the instructions located on the lighting instruction label
or the lighting instructions located in the Installation and Operation Manual.

25

25

Valvebod

NOTE: The following procedure applies
to the Honeywell gas control ONLY.

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

HONEYWELL COVER REMOVAL

Step 1. Rotate the knob of the gas control to the “OFF” position.

Step 2. Turn off gas supply to the water heater.

Step 3. Disconnect the gas supply line from the gas control.

Step 4. Disconnect the piezo igniter wire.

Step 5. Remove the gas control cover screw using flat-head

screwdriver.

CAUTION

Use caution to not bend or damage
valve body pins when removing or
installing the gas control cover.

Rotate knob counter-clockwise to
the “OFF” position

Gas control

cover screw

Step 6. Depress both tabs on the top of the gas control cover and pull straight out to remove.

pins

26

y

26

HONEYWELL COVER REMOVAL (cont.)

Step 7. Disconnect the temperature sensor from the control board and remove the wire from the

temperature sensor wire routing clip.

Disconnect

temperature sensor

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

Temperature sensor

wire routing clip

Step 8. Remove the piezo igniter from the control cover by releasing the lock tab on the control cover.

Release lock tab

27

27

SERVICE PROCEDURE RG-VI

side second

y

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL

Step 1. Disconnect the burner and pilot tubes per Service Procedure RG-II.
Step 2. Remove the valve body by removing the screw located at the lower left

corner. Unclip the lower right side from the backplate first, followed by
the lower left side, using a flat-head screwdriver.

Unclip lower left

Valve body screw

CAUTION

Use caution to not
bend or damage valve

pins.

bod

Unclip lower right

side first

Step 3. Remove the temperature sensor and insertion stick from the backplate by first removing the

wire from the temperature sensor wire routing clips. Make note of the insertion stickʼs
orientation, as the insertion stick can only be installed in one way.

Temperature sensor

wire routing clips

When reinstalling

CAUTION

temperature sensor
and insertion stick,
make sure the
assembly is inserted
FULLY into the
backplate and the
wires are routed
through the wire
routing clips. Failure
to do so will not
allow the valve body
to be reinstalled
properly and may

Insertion stick fully

inserted into backplate

28

damage temperature
sensor wires.

28

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL (cont.)

Step 4. Remove the temperature sensor from the insertion stick by pulling apart as illustrated below.

Pull in this direction

Pull in this direction

Temperature sensor

Insertion stick

Step 5. To reassemble the gas control, follow the previous steps in reverse order. Once the gas control is

reassembled, the burner assembly is reinstalled, and the gas supply line is reconnected,
resume water supply to the water heater. Be sure the tank is full of water before relighting.

Step 6. To resume operation, follow the instructions located on the lighting instruction label, or the lighting

instructions located in the Installation and Operation Manual.

29

29

TEMPERATURE SENSOR TESTING (Honeywell)

Step 1. If control has gone into lockout due to

excessive tank temperature (four
flashes, three second pause), reset
control by rotating gas control knob to
“OFF” position and wait a minimum of
five (5) minutes. Then follow lighting
instructions and return the gas control
knob to a desired setpoint.

Step 2. Observe green light indicator. Does

status code 4 (four flashes, three
second pause) appear?
a) If no, resume normal operation.
b) If yes, continue with Step 3.

DO NOT use standard multimeter probes

connector. Use special pin type electronic

NOTE: Using a multi-meter set to the ohms setting,
insert one-meter probe into center wire position of
thermal well connector, insert the second probe into
either of the outside wire positions (see photo).

Alternate the probe on the outside position to the
opposite outside wire position (see photo).

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

CAUTION

for this test. Doing so will damage

probes or small diameter wire pins

inserted into connector.

Step 3. Following “Honeywell Cover Removal,”

“Honeywell Valve Body Removal and
Temperature Sensor Removal”
instructions, disassemble gas control to
access the temperature sensor.

Step 4. With the temperature sensor still in the back plate, use a multimeter set to the ohms

setting, determine the resistance of the temperature sensor (see photo).

Step 5. See next page to obtain water temperature. Are temperature sensor resistance values

correct?
a) If no, replace the temperature sensor.
b) If yes, replace the gas control.

30

30

y

DETERMINE WATER TEMPERATURE

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(Honeywell ONLY)

WARNING

Stored water may be HOT when performing the following steps in this
procedure.

Take necessar

precaution to prevent personal injury.

NOTE:

Step 1.

Step 2.

Step 3.

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.

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.

Using the chart below, determine correct resistance value for the water temperature from Step 2.

Example: If temperature of water is 84°F, then the resistance through

the sensor would be 8449 (see shaded area).

NOTE: Sensor resistance increases as the temperature decreases.

Sensor Resistance at Various Temperatures

In Degrees F

°F0123456789
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 1053 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

31

31

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, &Replacement

(White Rodgers Electronic & Honeywell)

_________________________________________________________________________________________ _____________________________________________

GAS CONTROL REPLACEMENT

Step 1. Rotate knob of the gas control to the “OFF” position.

Step 2. Turn off gas supply to the water heater.

Step 3. Disconnect the gas supply line from gas control.

Step 4. Turn off the water supply and drain the water heater completely.

Step 5. Remove the outer jacket burner access door.

Step 6. Right side inner door removal:

a) Disconnect the red wire leads from the resettable

thermal switch.

b) Remove two (2) 1/4” hex drive screws from RIGHT side

inner door.

c) Remove two (2) 1/4” hex drive screws from FLANGE

SECTION of inner door.

d) Remove the right side inner door and set aside. Be

careful to not damage gasket material on inner door.

Step 7. Removal of gas control:

a) Disconnect main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and

thermopile wire (white) from gas control.

b) Remove gas control from water heater by rotating counter clockwise. DO NOT use a wrench

on the gas control body, damage to the gas control may occur. If necessary, use a length of
1/2" NPT pipe threaded into gas inlet of gas control.

Step 8. Install new gas control into water heater:

a) Install a new gas control into water heater by rotating clockwise. DO NOT use a wrench

on the gas control body, as damage to the gas control may occur. If necessary, use a
length of 1/2" NPT pipe threaded into gas inlet of gas control.

32

32

GAS CONTROL REPLACEMENT (cont.)

Step 8. Install new gas control into water heater (cont.):

b) Reattach the main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and

thermopile wire (white) to the gas control. Attach the inner door wire (red) to the positive (+)
terminal and the thermopile wire (white) to the negative (-) terminal.

CAUTION

Use back up wrench on wrench boss of gas control,

NEVER use back up wrench on body of gas control.

c) Gather piezo igniter wire, thermopile wire (white), inner door wire (red), and pilot alongside

of feedline using new wire tie provided.

d) Reconnect gas supply piping to inlet of gas control.

Step 9. Reinstallation of inner door assembly:

a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:

Ɣ Tears
Ɣ Missing material
Ɣ Cracks
Ɣ Dirt or debris

If the gasket is not affected by any of the above, gasket replacement will not be required.
If replacement is required, replace using new gasket kit following the instructions provided
with kit.

b)Clean any gasket residue or other debris from combustion chamber surface before

installing the inner door/gasket assembly.

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, & Replacement

(White Rodgers Electronic & Honeywell)

Ɣ Gasket adhesion to inner door
Ɣ Material left on combustion chamber
Ɣ Other imperfections that will inhibitproper seal

c) Position thermopile wire, pilot tube, and piezo wire against left side inner door flange gasket.

DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that the
thermopile and pilot tube are not in position to interfere with outer jacket burner access door
when reinstalled.

WARNING

A seal breach may result in a fire or

explosion causing property damage,

personal injury or death.

33

33

GAS CONTROL REPLACEMENT (cont.)

SERVICE PROCEDURE RG-VI

Gas Control Testing, Disassembly, & Replacement

(White Rodgers Electronic & Honeywell)

Step 9.

Reinstallation of inner door assembly (cont.):

d) Firmly place right side inner door flange against the left side inner door flange and secure with two (2)

1/4” hex drive screws from Step 6c. DO NOT OVER TIGHTEN SCREWS.

e) Align the right side inner door to combustion chamber and verify the fastener holes of the

combustion chamber are aligned with the right side inner door slotted openings. Verify seal integrity
around the combustion opening. Secure right side inner door using two (2) 1/4” hex drive screws
from Step 6b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner
door are properly positioned and sealed against the combustion chamber.

CAUTION

Use back up wrench on
wrench boss of gas control,

NEVER use back up wrench

on body of gas control.

Step 10. Reconnect two (2) red wire leads from pilot assembly and gas control to resettable thermal

switch.
NOTE: wire terminations are interchangeable with either resettable thermal switch connection.

Step 11.

Step 12.

Step 13.

Replace the outer jacket burner access door.

Reconnect the gas supply to gas control.

Resume water supply to the water heater. Be sure the tank is full of water before resuming
operation.

Step 14.

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

34

34

SERVICE PROCEDURE RG-VII

ge,p

Burner Operation Inspection,

Adjustment, Cleaning, and Replacement

MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement

At periodic intervals (not more than 6 months) a visual inspection should be made of the main burner for
proper operation and to ensure no debris accumulation.

Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.

Steel burner models have a self-adjusting air mixture and do not have an adjustable air shutter.

Main burner must be free from any debris accumulation that may affect burner operation (see burner cleaning
procedure on page 36).

DANGER

Under NO circumstances should flammable materials be used or stored in the vicinity of the water
heater. With the inner door removed the Bradford White Defender Safety System will be
deactivated. If flammable vapors are present, a fire or explosion may result causing property
dama

ersonal injury, or death.

WARNING

Inner door and burner components may be HOT when performing this

operation. Take necessary precaution to prevent personal injury.

BURNER REMOVAL

Step 1.

Step 2.

Step 3.

Remove inner door assembly per Service Procedure RG-I, Steps 1 through 3c.

Disconnect the main burner feed line, pilot tube and thermocouple/thermopile from combination
thermostat gas valve and remove burner assembly from combustion chamber.

NOTE: Feedline nut for natural gas control uses right hand threads;

L.P. control uses left hand thread.

Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation.

35

35

BURNER CLEANING

SERVICE PROCEDURE RG-VII

Burner Operation Inspection,

Adjustment, Cleaning, and Replacement

Step 4.

Step 5.

Disconnect the burner plate from main burner orifice
and disconnect feedline from burner.

Remove main burner orifice from feed line.
Inspect and clean if necessary.

Step 6.

Step 7.

Step 8.

Step 9.

Step 10.

Step 11.

Remove pilot assembly, refer to Service Procedure RG-III for cleaning and inspection.

Using a stiff brush and compressed air, clean the burner plate and feedline, then reassemble
all components.

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.

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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SERVICE PROCEDURE RG-VIII

RESETTABLE THERMAL SWITCH CONTINUITY TESTING

Resettable Thermal Switch

Testing and Replacement

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Remove the outer jacket door.

Disconnect the wire leads from the 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

PROBABLE CAUSE PROBABLE CAUSE

Insufficient combustion air

1.

Weak switch or switch out

of calibration.

2.

Incorrect switch.

Flammable vapor incident 1. Replace water heater.

ACTIVATION

2.

3.

1.

2.

1.

Verify adequate

combustion air supply is

available.

Clear jacket slot openings

of any dirt, dust,

restrictions or other

obstructions.

Inspect flame arrestor plate

and clean with a stiff brush,

compressed air to remove

scale deposits and debris.

Replace resettable thermal

Verify switch color code

and approximate

temperature.

switch.

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Resettable thermal switch color

code reference

Approximate

switch

Color code

activation

temperature

(open)

Blue Û

Yellow Û

Red Û

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SERVICE PROCEDURE RG-VIII

RESETTABLE THERMAL SWITCH REPLACEMENT

Step 1. Rotate the knob of combination thermostat/gas valve to the “OFF”position.

Resettable Thermal Switch

Testing and Replacement

Step 2.

Step 3.

Step 4.

Step 5.

Remove the outer jacket door.

Disconnect the wire leads from the resettable
thermal switch.

Remove the resettable thermal switch from the
inner door (Phillips screwdriver).

Put new resettable thermal switch in place. Be sure contact surface of resettable thermal switch
and inner door are free of any debris. Secure resettable thermal switch into place using screws
from Step 4. DO NOT OVER TIGHTEN SCREWS.

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Step 6.

Step 7.

Step 8.

Reconnect wire leads from combination thermostat/gas valve to resettable thermal switch.

NOTE: Wire terminations are interchangeable with either resettable thermal switch connection.

Replace the 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.

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SERVICE PROCEDURE RG-IX

ScreenLok

ScreenLok® Flame Arrestor Cleaning

Step 1. Rotate knob of combination thermostat gas valve to the off position.

®

Flame Arrestor Cleaning

Step 2.

Step 3.

Remove the outer jacket door.

Remove inner door per Service Procedure RG-I, Steps 3a through 3e.

Step 4. Disconnect the main burner feed line, pilot tube, and

thermocouple/thermopile from combination thermostat gas valve and
remove burner assembly from the combustion chamber.

NOTE: Feedline nut for natural gas control uses right hand threads;

L.P. control uses left hand thread.

Step 5.

Clean ScreenLok®Flame Arrestor using stiff brush and compressed air to remove any scale or
other debris accumulation. Using a soft brush, clear jacket openings of any dirt, dust, restrictions, or
other obstructions.

Step 6.

Remove any debris from burner assembly per Service Procedure RG-V and reinstall burner
assembly into combustion chamber.

Step 7.

Step 8

Step 9.

Reconnect feedline, thermocouple, and pilot tube to the combination thermostat/gas valve.

Reinstall inner door per Service Procedure RG-I.

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

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DIPTUBE INSPECTION AND REPLACEMENT

WARNING

Heater components and stored water may be HOT when performing the following
steps in this procedure. Take necessaryprecaution to prevent personal injury.

SERVICE PROCEDURE RG-X

Diptube and Anode

Inspection and Replacement

Step 1.

Step 2.

Step 3.

Step 4

Step 5.

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

Turn off cold water supply to the water heater. Connect a hose to the drain spigot of the water
heater and route to an open drain. Open a nearby hot water faucet to vent the heater for draining.
Open drain spigot of the water heater and allow the heater to drain to a point below the inlet
connection nipple.

Disconnect the inlet nipple from plumbing system.

With an appropriate wrench, remove the inlet nipple/dip tube from the water heater. Use caution to
not 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. The anti-siphon hole, located approximately 6 in from the bottom of nipple, should be
free of any blockage.

Step 6.

Step 7.

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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 the inlet nipple/dip tube into the
heater. Ensure pipe dope is used on the nippleʼs threads. Connect the nipple to the plumbing
system, resume the water supply, and refill the heater with water.

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

40

SERVICE PROCEDURE RG-X

Diptube and Anode

Inspection and Replacement

ANODE INSPECTION AND REPLACEMENT

WARNING

Heater components and stored water may be HOT when performing the following
steps in this procedure. Take necessaryprecaution to prevent personal injury.

Step 1. Turn off water supply to water heater. Rotate knob of combination thermostat/gas valve to

“OFF” position.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Turn off cold water supply to the water heater. Connect a hose to the drain spigot of the water
heater and route to an open drain. Open a nearby hot water faucet to vent the heater for
draining. Open the drain spigot of the water heater and allow the heater to drain to a point below
the outlet connection nipple.

Disconnect the outlet nipple from the plumbing system.

With an appropriate wrench, remove the outlet nipple/anode from the water heater. Use caution to
not damage pipe threads.

Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion; this is
normal. If depletion is 1/2 of the original anode diameter (approximately 5/8” diameter), replacement
is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Upon completion of inspection or subsequent replacement, reinstall the outlet nipple/anode into the
heater. Ensure pipe dope is used on the nippleʼs threads. Connect the nipple to the plumbing
system, resume water supply, and refill the heater with water.

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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Parts Diagram

y

y

1 Draft Hood 17 Burner Onl
2 Hot Water Outlet/Anode 18 Main Burner Orifice
3 Cold Water Inlet Tube 19 Pilot Assembl
4 Flue Baffle 20 Pilot Orifice
5 T&P Relief Valve 21 Thermocouple/Thermopile
6A Gas Control (Honeywell V1) 22 Complete Burner Assembly (LP)
6B Gas Control (Honeywell V2) 23 Burner Only (LP)
6C Gas Control (White Rodgers Mechanical) 24 Main Burner Orifice (LP)
6D Gas Control (White Rodgers Electronic) 25 Pilot Assembly(LP)
7 Piezo Igniter (White Rodgers Mechanical) 26 Pilot Orifice(LP)
8 Brass Drain Valve 27 Thermocouple/Thermopile (LP)
9 Screw-#8-18 x 3/4 Hex Washer Head 28 ASSE Approved Mixing Valve (Optional)
10 Screw-#10-12 x 3/4 Hex Washer Head 29 3/4 NPT Tank Plug (H Models)
11 Left Side Inner Door with Gasket 30 Inner Door Gasket Kit
12 Complete Right Side Inner Door 31 Wire Tie
13 Resettable Thermal Switch 32 Heat Trap (Outlet)
14 Screw-#6-20 x 3/8 PHCR 33 Heat Trap (Inlet)
15 Outer Door 34 Heat Trap Kit
16 Complete Burner Assembly (Natural)

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