Bradford White RG2DV40S6N, RG2DV50S6N, RG2DV50H6N User Manual

Flammable Vapor Ignition Resistant

Water Heaters

Direct Vent Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Manual 238-51636-00C REV 08/19

Models Covered

by This Manual:

RG2DV40S*(N,X) RG2DV50S*(N,X) RG2DV50H*(N,X) LG2DV50H50*(N,X) (*) Denotes Warranty Years

Save this manual for future reference

The Bradford White

DV Series

Direct Vent Water Heaters

Page SVC Procedure

Introduction ................................................................................4 ---

Tools Required for Service ........................................................5 ---

Troubleshooting Charts .............................................................6 ---

Inner Door Removal and Replacement ....................................12 I

Thermocouple/Thermopile Testing ...........................................15 II

Igniter, Electrode Testing, and Replacement ...........................18 III

Gas Control Testing and Replacement ....................................19 IV

Burner Inspection, Cleaning, and Replacement ......................34 V

Pilot Testing, Cleaning, and Replacement ...............................36 VI

Resettable Thermal Switch Testing and Replacement ...........37 VII

Table of Contents

Diptube Inspection and Replacement ......................................39 VIII

Anode Inspection and Replacement ........................................40 IX

Glossary of Terms .....................................................................41 ---

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

Notes ..........................................................................................43 ---

DV Series

DANGER

DO NOT store or use gasoline or

vicinity of this or any other appliance

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF

plumbing professional, for more information.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED

TEMPERATURE AND PRESSURES.

CAUTION

If sweat fittings are to be used DO NOT apply heat to the

a plastic liner.

WARNING

Hydrogen gas can be produced in an operating water

open flame near the faucet at the time it is open.

WARNING

Water heaters are heat producing appliances. To

SYSTEM.

WARNING: If the information in these

instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

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 neighbor's

phone. Follow the gas supplier's 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.

FOR YOUR SAFETY

other flammable, combustible, or corrosive vapors and liquids in the

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.

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

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

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 neighbor’s

telephone.

Gas detectors are available. Contact your gas supplier, or

3/4” X 3/4” TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE

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

DV Series

Introduction

The new Bradford White DV water heaters are designed to provide reliable performance with enhanced standard features. Design features include reliable standing pilot ignition system, enhanced diagnostics, simplified servicing, and certified FVIR technology.

The DV water heaters use a combustion system where combustion air is drawn from the outside of the building. The gas control maintains water temperature and gas flow. If a situation outside of the normal operating parameters exists, the gas control diagnostic LED will flash a code to identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency.

Please read the service manual completely before attempting service on this series of direct vent water heaters.

How the Safety System Works

During normal operation, air for combustion is drawn into the water heater through the openings in the jacket. This air travels down and around the combustion chamber and enters through the back of the corrosion resistant combustion chamber. The air then mixes in a normal manner with supplied gas and is efficiently combusted, producing very low NOx emissions.

DV Series

Manometer:

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

and vacuum.

Multi-Meter:

A digital type is strongly recommended. This device is used

micro-amps, and ohms.

Electronic Probes:

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

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

heater.

Various Hand Tools:

Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”,

flashlight, and 5-gallon pail.

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 beginning on page 6 of this service manual. The troubleshooting charts on page 6 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

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

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

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

determine tank pressure by adapting to the drain valve of the

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,

DV Series

LED Status

Control Status

Probable Cause

Service Procedure

If the pilot will not stay

control.

If setpoint knob is in

is satisfied.

Setpoint knob has been

out before attempting to relight.

LED will go out and the

lit.

2. See Service Procedure VI

3. See Service Procedure VI

Troubleshooting Gas

Control V1

Observe green LED indicator on electronic 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.

None (LED not on or flashing)

One flash and three second pause

Short flash once per second

LED on continuously (solid)

Two flashes and three second pause

Pilot assembly is not lit.

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

If the setpoint knob is already at setting, the water

Gas control is calling for heat (no fault).

recently turned to the “OFF”

position. Wait until LED goes

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

the desired

heater

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.

Tank temperature below setpoint of thermostat.

Setpoint knob was turned to “OFF” position.

Thermopile failure.

Unstable pilot.

Pilot tube blocked or restricted.

lit replace pilot assembly. If problem persists replace gas

Normal operation.

control will function normally once the pilot is

1. See Service Procedure II

Three flashes and three second pause

Insuffcient water heating. System will reset.

Thermal sensor out of calibration.

Faulty gas control.

Replace gas control.

DV Series

LED Status

Control Status

Probable Cause

Service Procedure

Four flashes

Damage to the

range.

physically damaged.

Eight flashes

Standing pilot remains on while

Troubleshooting Gas

Control V1

and three second pause

Excessive tank temperature. System must be reset.

Temperature sensor out of calibration.

Faulty gas control.

Replace gas control.

Five flashes and three second pause

Seven flashes and three second pause

and three second pause

Temperature sensor fault.

Gas control electronic fault detected.

setpoint knob is in “OFF”

position.

temperature sensor.

Temperature sensor resistance out of

Control needs to be reset.

Control is wet or

Pilot valve stuck in open position.

Replace gas control.

1. Reset gas control.

2. Replace gas control.

Replace gas control.

DV Series

LED Status

Control Status

Probable Cause

Service Procedure

If the pilot will not stay lit

control.

One flash every

None. Control will automatically

setpoint temperature.

Two flashes

(LED yellow)

voltage;

Check the valves and the water

if exceeding setpoint.

Check water temperature

elements.

Not an error–indicates

OFF position.

LED will go out and the

once the pilot is lit.

Troubleshooting Gas

Control V2

Observe colored LED indicator on electronic 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.

None (LED not on or flashing)

four seconds (LED green)

One flash every second (LED green)

and three second pause

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 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.

shut main burner off when water temperature reaches the

Check thermopile and its connections. Check pilot flame.

temperature sensor. Reduce the water temperature setpoint. Verify control operation, replace

sensor and its connection for open circuits, shorts, or differences in resistance between the two sensor

replace pilot assembly. If problem persists replace gas

Normal operation.

1. See Service Procedure II

2. See Service Procedure VI

Replace gas control.

Solid ON (LED red)

that the control is in

None; wait until LED turns off to restart system.

control will function normally

DV Series

Troubleshooting Gas Control

White Rodgers Mechanical

Service Procedure

Piezo igniter not functioning.

gas

switch located on inner door.

the will

necessary.

Symptom Probable Cause Corrective Action

No incoming gas or too low

Turn on gas supply and/or check

pressure.

line

Review lighting instruction. Set control knob to

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

correct position.

Pilot will not light

Pilot will not stay lit when button is released

gas

pressure.

Gas control knob set to

position.

wrong

Gas control knob not being

depressed when

fully attempting to light

Pilot orifice or pilot tube is obstructed

Pilot electrode not sparking to pilot.

Poor thermocouple connection at thermostat/gas valve.

Thermocouple not fully engaged in bracket.

Pilot flame is not fully enveloping the bulb.

Weak or defective thermocouple.

Open ECO in combination gas valve.

Defective magnet in combination valve.

Resettable thermal switch has

opened.

pilot.

or kinked.

combination

pilot assembly

thermocouple

thermostat/

thermostat/gas

See Service

Procedure See Service Procedure See Service Procedure See Service Procedure

See Service Procedure II See Service Procedure IV See Service Procedure IV

III

Pilot will light but

main burner

not come on

Combination thermostat/gas valve set too water temperature.

Combination thermostat/gas valve temperature is satisfied.

Insufficient gas supply or low gas

Combination thermostat/gas valve has is out of calibration.

low for desired

pressure.

wide differential or

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

See Installation and Operation Manual.

See Service Procedure IV

DV Series

Troubleshooting Gas Control

White Rodgers Mechanical

Service Procedure

Symptom Probable Cause Corrective Action

Verify adequate combustion air

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.

is available and clear jacket slot any dirt, dust, restrictions or other obstructions. Inspect flame arrestor bristled brush air to remove any debris accumulation.

Check venting for proper sizing and proper

Check gas supply and line pressure.

Check dial on combination thermostat/gas

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

Adjust high demand usage.

Contact plumbing professional.

Check combination thermostat/gas valve operation, replace if

Inspect dip tube and replace if necessary.

to the unit. Check

plate and clean with stiff

and compressed

operation.

valve.

will decrease the

openings of

produced. It

for proper

necessary.

See Service Procedure VII

See Service Procedure IV

DV Series

Observe green LED indicator on gas

LED Status

Control Status

Probable Cause

Indicates control is off.

off.

Gas valve is powered and waiting for the set

setting, the thermostat is satisfied.

Not an error. Indicates main

Not an error. Indicates that

Two flashes and

pause

Excessive temperatures may have been

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.

Troubleshooting Gas Control

White Rodgers Electronic

None (LED not on or flashing)

One flash every four seconds

One flash every second

Solid ON

three second

Four flashes and three second pause

Five flashes and three second pause

Main and pilot burner are

Not an error. Indicates pilot is lit and main burner is off.

valve is open and main burner is lit.

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.

point knob to be turned to a water temperature setting. If the set point knob is at desired

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.

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.

DV Series

WARNING

If the information in these instructions is not followed

damage, personal injury, or death.

Service Procedure I

Inner Door Removal and

Replacement

Inner Door Removal Procedure

Step 1. Rotate the gas control knob to the

“OFF” position.

Step 2. Remove the outer jacket burner access

door.

Step 3. Remove the wire clip from the feedline

(if present).

Step 4. Remove two (2) 1/4” hex drive screws from the

right side inner door.

Step 5. Remove two (2) 1/4” drive screws from the

flange area of the inner door.

Step 6. Remove two (2) 1/4” drive screws from the left

side inner door.

Step 7. Remove the inner doors and inspect per Step 4.

Step 8. Fully inspect inner door gaskets for the following:

●Tears ●Other imperfections that will inhibit proper seal

●Missing material ●Gasket adhesion to inner door

●Cracks ●Material left on combustion chamber (around opening)

●Dirt or debris

If the gasket is not affected by any of the above, gasket replacement is not required. If replacement is required, proceed to Inner Door Gasket Replacement Procedure.

Inner Door Gasket Replacement Procedure

Step 1. After inspection of inner door as noted in Step 8 of “Inner Door Removal Procedure,"

completely remove gasket and adhesive residue from right and left side inner doors as needed.

exactly, a fire or explosion may result causing property

WARNING

Stripped fastener connections may allow for

over tighten screws in steps 2, 3 and 4.

Service Procedure I

Inner Door Removal and

Replacement

DV Series

Inner Door Gasket Replacement Procedure (cont.)

Step 2. Use RTV sealant (recommended bead size 1/8”) to secure the inner door gasket to the

inner door sections (right & left). Refer to the illustrations on the next page for proper application. Note the overlap configuration in the flange area of the inner door. Set the flange section first, this will help to achieve the proper overlap position.

Installation of Inner Door with Gasket

Step 1. Clean any residual gasket residue or other debris from combustion

chamber surface before installing the inner door/gasket assembly.

Step 2. Place the left side inner door and burner

assembly into position first. Using the three (3) 1/4” hex drive screws from Step 6 of “Inner Door Removal Procedure,” secure left side inner door in place. DO NOT OVER TIGHTEN SCREWS

Step 3. Position pilot tube and igniter/sensor wire against

left side inner door flange gasket.

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 5 of

“Inner Door Removal Procedure”. DO NOT OVER TIGHTEN SCREWS.

seal breach of inner door. A seal breach may result in a fire or explosion causing property damage, personal injury or death. DO NOT

Service Procedure I

Inner Door Removal and

Replacement

DV Series

Installation of Inner Door with Gasket (cont.)

Step 5. Align right side inner door to combustion chamber and verify the fastener holes of

the combustion chamber are aligned with right side inner door slotted opening. Verify seal integrity around combustion opening. Secure right side inner door using 1/4” hex drive screws from Step 4 of “Inner Door Removal Procedure”. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of inner door are properly positioned and sealed against the combustion chamber.

Step 6. Replace outer jacket burner access door.

Step 7. To resume operation follow the instructions located on the lighting instruction label or

the lighting instructions located in the installation and operation manual.

+ 30 hidden pages

Bradford White RG2DV40S6N, RG2DV50S6N, RG2DV50H6N User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual