Bradford White RG2F40S*(N, X), RG2F50S*(N Service Manual

High EF

Atmospheric Vent Gas Water Heater

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

RG2F40S*(N,X)
RG2F50S*(N,X)
(*) Denotes Warranty Years

Manual 238-51617-00A

Save this manual for future reference

Table of Contents

Section Page

Introduction ______________________________________________ 5
How to Use this Manual _____________________________________ 6
Tools Required for Service ___________________________________ 6
Specifications _____________________________________________ 7
Sequence of Operation _____________________________________ 9
Power Up Sequence
Normal Heating Sequence
Abnormal Operation
Troubleshooting __________________________________________ 13
Burner Maintenance _______________________________________ 15
Burner Inspection
Burner Cleaning Procedure
Pilot Maintenance_________________________________________ 17
Pilot Inspection, Testing and Replacement
Blower Replacement ______________________________________ 19
Gas Control Testing & Replacement __________________________ 21
Determine Temperature Inside Tank _____________________ 21
Gas Control Removal _________________________________ 22
Flammable Vapor Sensor Testing ____________________________ 23
120 VAC Circuit Trace _____________________________________ 23
Diptube Inspection _______________________________________ 24
Anode Inspection _________________________________________ 25
Blower Removal __________________________________________ 25
Inner Door Removal ______________________________________ 28
Inner Door Gasket Replacement _____________________________ 30
Inner Door Installation ____________________________________ 31
Pressure Switch Testing & Replacement _______________________ 32
Arrestor Cleaning _________________________________________ 34
Common Terms __________________________________________ 35
Parts List _______________________________________________ 36
Notes __________________________________________________ 37

2

Page 2

WARNING

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

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.

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.

CAUTION

Incorrect operation of this water heater may create a hazard to life and property and will
nullify the warranty.

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.

Turn off or disconnect the electrical power supply to the water heater before servicing.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper operation after servicing.

NOTICE

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.

Page 3

3

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store
materials against the water heater or any of its components. Use proper care to avoid
unnecessary contact, especially by children, with the water heater and its components.
Under no circumstances must flammable materials, such as gasoline or paint thinner be
used or stored in the vicinity of this water heater or in any location in which the fumes
could reach the water heater.

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 a 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.

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE
FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas
supplier that aids in the detection of the gas. Most people recognize this odor as a “sulfur”
or “rotten egg” smell. Other conditions, such as “odorant fade” can cause the odorant to
diminish in intensity, or ”fade,” and not be as readily detectable. 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 plumbing professional for more information.

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.

Page 4

4

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.

Introduction

The new Bradford White High EF atmospheric vent gas water heaters are designed to provide
reliable performance with enhanced standard features. New design features include reliable
spark-to-pilot ignition system, enhanced diagnostics, simplified servicing, and the Bradford
White Defender Safety System.

Spark-to-Pilot Ignition System - employing the spark-to-pilot ignition system promotes
reliable and consistent pilot and main burner ignitions to provide hot water on demand.

Integrated Immersion Thermal Well/Gas Control with LED - was developed for ease of
troubleshooting by providing simple diagnostic codes to pinpoint an installation or component
performance issue.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

The gas control maintains water temperature, ignition sequence, and regulates gas flow. If a
situation outside of normal operating parameters exists, the gas control diagnostic LED will
flash a code to positively identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency.
To further promote quicker service times, the gas control can be removed and replaced without
draining the water heater.

Please read the service manual completely before attempting service on this new series of High
EF gas models.

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 holes in the very bottom of the corrosion resistant combustion chamber bottom. The air
then travels up through the flame arrestor louvers, where the velocity of the air is increased and
its direction altered. The air then mixes in a normal manner with supplied gas and is efficiently
combusted, producing low NOx emissions.

In the unlikely event trace amounts of flammable vapors are present in the air flowing into the
combustion chamber, the vapors are harmlessly ignited by the burner. If flammable vapors are

Page 5

5

How to Use this Manual

in sufficient quantity to prevent normal combustion, the flammable vapor sensor recognizes this
and shuts down the pilot and main burner. Should the flammable vapors continue to burn, the
flame arrestor prevents the flames from traveling backwards and igniting vapors outside of the
combustion chamber. And, the resettable thermal switch will open and shut down the pilot and
main burner.

How to Use this Manual

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 High EF atmospheric gas water heaters.
Understanding the sequence of operation section of this manual will contribute greatly to
troubleshooting the water heater.

The Honeywell WV4462 Electronic Gas Control will display status codes in the event of
abnormal operation. Status codes are listed in the troubleshooting chart beginning on page 13 of
this service manual. The troubleshooting chart 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.

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 (magna-helic) 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 reading. 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), torx bits, 1/4" nut
driver, pliers (common & needle nose), socket set, side cutters, wire cutters, wire strippers, wire
crimpers, torpedo level, small shop vac, step ladder, flashlight, and 5 gallon pail.

6

Page 6

Specifications

Power Supply

Gas Supply Pipe

Approved Gas Type

Gas Pressure

Approved Vent Materials

Recommended Minimum

Clearance for Servicing

Water Supply Pressure

ECO Limit

Pressure Switch Setting

(normal altitude)

Temperature Setpoint Range

Dedicated 120VAC, 60 Hz, 15A

Minimum 1/2” (Schedule 40 black iron pipe

recommended)

Natural or Propane; unit must match gas type supplied

5” w.c. minimum for Natural Gas; 11” w.c. for Propane;
14” w.c. maximum for Natural Gas / Propane

Single or Double Wall Metal Vent Pipe

18” from top; 24” from front; 4” from sides and rear

150 psi maximum allowable working pressure; check local
codes for supply pressure

188°F (87°C)

-0.20” w.c. (-0.10” for Hi-Alt.)

60°F (16°C) to 160°F (71°C); approximate temperatures

Page 7

7

Specifications

Control Timings

Ignition State Timing

Pre-purge 15 seconds

Trial for Ignition 90 seconds

Flame Stabilization Period 3 seconds

Interpurge 15 seconds

Flame Failure Response Time

Postpurge 15 seconds

Pressure Switch Fault Delay (failed open/close) Retry after 2 minutes

Soft Lockout Retry after 5 minutes

ECO Limit Lockout Indefinite (See page 21 to reset)

Verify Resistive Delay Retry after 2 minutes (repeats 5 times)

Simulated Resistive Load Lockout Indefinite (cycle power to reset)

Hardware Status Lockout

1.5 seconds (2 second maximum; 1 second mini­mum)

Indefinite (self clears if fault clears for at least 15

seconds)

Wiring Diagram

8

Page 8

Sequence of Operation

Power Up Sequence

1. Start-up: Upon power up, the gas control runs a safe start check with a typical

delay of 5 seconds.

2. Flammable Vapor Verification: The gas control verifies that the Flammable Vapor

Sensor is in the proper operating range prior to energizing any components. If the
sensor is within the proper range, the gas control resumes normal operation. If the
Flammable Vapor Sensor is out of range, the gas control LED immediately flashes
7 times with a 3 second pause.

Normal Heating Sequence

1. Thermostat Calls for Heat: Prior to energizing the blower, the gas control verifies

the safety circuit to see if it is in the correct state. Normal switch positions in the
safety circuit are as follows:

A) Pressure switch normally open;

B) Blower temperature switch normally closed.

If the safety circuit is closed, the gas control LED flashes 2 times with a 3 second
pause. The gas control waits 2 minutes. Then, the blower is energized for 30
seconds. This cycle repeats until the safety circuit opens.

2. Blower Energizes

3. Safety Circuit Check: If the safety circuit does not close within 30 seconds, the

gas control LED flashes 3 times with a 3 second pause. The blower runs for a
maximum of 30 seconds every 2 minutes trying to close the safety circuit. This
cycle repeats as long as there is a call for heat.

4. Blower Pre-Purge (15 seconds)

5. Trial for Pilot Ignition (90 seconds): The gas control lights the pilot by activating

the spark igniter and gas flow to the pilot burner. If flame is not sensed within 90
seconds, the spark igniter and gas flow are deactivated. The blower will postpurge,
and the gas control LED flashes 6 times then 1 time with a 3 second pause.

6. Main Burner Ignition: After pilot flame is sensed, the gas control activates the

main valve for main burner ignition. The gas control will ignore flame signals for 3
seconds to allow for the main burner to stabilize.

Page 9

9

Sequence of Operation

Normal Heating Sequence (cont’d)

7. Steady State Operation: During steady state operation, the gas control monitors:

Temperature Sensor: When the setpoint temperature is satisfied, the gas control is

shutdown, and the blower will postpurge for 15 seconds. The gas control LED
flashes a short flash once every 4 seconds (Idle status code).

Pressure Switch / Blower Temperature Switch: If either switch opens, the pilot and
main valves are shutdown. The blower continues to run for 30 seconds attempting
to close the circuit. The gas control LED flashes 3 times with a 3 second pause.

Flame Sensor: If flame is lost, the pilot and main valves are shutdown. The blower
runs for 15 seconds. The gas control attempts to re-light the pilot 4 times. If
unsuccessful, the blower is shutdown, and the gas control proceeds to a 5 minute
lockout. The gas control re-attempts to light the pilot starting at Normal Heating
Sequence #2.

8. Thermostat Satisfies: Gas control LED flashes once every 4 seconds.

9. Burner Off

10. Blower Postpurge (15 seconds)

Abnormal Operation

1. Flammable Vapor Sensor Fault:

A) If the resistance is greater than 70,000 ohms: The gas control immediately turns
off all outputs. The gas control waits and monitors resistance for 30 seconds. If the
resistance is greater than 65,000 ohms after 30 seconds, the gas control proceeds
to verify resistive delay for 2 minutes and flashes 7 times with a 3 second pause.
This process is repeated 5 times until the control either returns to normal operation
or proceeds to flammable vapor lockout.

B) If the resistance is below 240 ohms: The gas control immediately turns off all
outputs and proceeds to flash 8 times then 1 time with a 3 second pause. The
status self clears if the resistance returns to normal range for at least 15 seconds.

10

Page 10

Sequence of Operation

Abnormal Operation (cont’d)

2. Temperature Sensor Fault:

A) Temperature Sensor Open Circuit: The gas control immediately turns off all
outputs and proceeds to flash 8 times then 2 times with a 3 second pause. The
status self clears if the fault clears for at least 15 seconds.

B) Temperature Sensors Not Reading the Same Temperature within ±5°F: The gas
control immediately turns off all outputs and proceeds to flash 8 times then 2 times
with 3 second pause. The status self clears if the fault clears for at least 15
seconds.

C) Water Temperature in excess of ECO (Energy Cut Out) Limit: The gas control
immediately turns off the pilot and main valves. The gas control LED proceeds to
flash 4 times with a 3 second pause.

To reset the gas control, rotate the setpoint knob to the minimum setting for at least
6 seconds before returning to desired temperature setting.

3. Pressure Switch / Blower Temperature Switch (Safety Circuit) Fault:

A) Pressure Switch Closed at Start of Call for Heat: The gas control proceeds to

flash 2 times with a 3 second pause. The gas control waits 2 minutes, and then
turns the blower on for 60 seconds. The blower turns off after 60 seconds, and
the control waits for the pressure switch to open.

B) Pressure Switch Failed to Close: The gas control runs the blower for 60

seconds waiting for the pressure switch to close. If the switch does not close in
60 seconds, the blower turns off, and the control flashes 3 times with a 3 second
pause. The gas control waits two minutes before turning on the blower for
another 60 seconds to see the circuit close. This cycle repeats as long as there
is a call for heat or until the circuit closes.

C) Pressure Switch / Blower Temperature Switch Opens During Burner Operation:

The gas control turns off the pilot and main valve and runs the blower for 15
seconds (inter-purge) waiting for the pressure switch and/or blower temperature
switch to close. If either switch fails to close, the control proceeds as described
in 3B above. If the circuit closes again by the end of the inter-purge, the recycle
counter is incremented. If the recycle count has not reached its limit (4),
another trial for ignition begins. If the recycle count has been reached, the gas
control turns off the blower and flashes 6 times then 2 times with a 3 second
pause. The gas control waits 5 minutes before repeating the ignition sequence.

Page 11

11

Sequence of Operation

Abnormal Operation (cont’d)

4. Trial for Ignition Fault:

A) Pressure Switch / Blower Temperature Switch Opens During Trial: The gas

control stops the trial for ignition. The gas control monitors the pressure switch
until it closes. If the pressure switch closes within 30 seconds, the gas control
will continue with the trial for ignition starting at blower pre-purge.

B) Flame Not Sensed: The gas control energizes the spark igniter attempting to

light the pilot and prove flame. If flame is not sensed within 90 seconds, the
spark igniter turns off, the pilot valve is closed, and the gas control runs the
blower through postpurge. The gas control LED flashes 6 times then 1 time with
3 second pause. The control waits 5 minutes before repeating the ignition
sequence.

5. Flame Sensing Fault:

A) Flame Lost During Run: The gas control turns off pilot and main valves and runs
the blower for 15 seconds (inter-purge). The gas control increments the recycle
count, if the recycle count has not reached its limit (4), another trial for ignition
begins. If the recycle count has been reached, the gas control LED flashes 6 times
then 3 times with a 3 second pause. The gas control waits 5 minutes before
repeating the ignition sequence.

B) Flame Sensed Out of Sequence: The gas control only looks for pilot flame when
the blower is running. If flame is present when the pilot valve is not open, the gas
control continues to wait for flame loss and flashes 5 times with 3 second pause.
This continues until flame is lost. Once the flame signal is lost, the control flashes 6
times then 4 times with a 3 second pause. The control waits 5 minutes before
repeating the ignition sequence.

12

Page 12

LED Status Control S tatus Probable Cause Service Procedure

pply

One short flash

(

)

One short flash

)

p

(

)

Short flash once

g

y p

p

Six flashes, one

g

None (LED not
on or flashing)

every four

every two

Alte rn a tes

brigh t and dim

heartbeat

every second

Two flashes,

three second

Observe the green LED on the water heater gas control. Status
codes are displayed with a 3 second pause before repeating.
Once the status code is known, check and repair the water
heater, as recommended in the table below.

Co ntrol pow e r sw itch in "OFF"
po s ition.
Su

Temperature demand is satisfied
(no ca ll fo r he at)

Temperature on Setback Control is
adjusted down to prevent burner
o

Tank temperature below setpoint of
the rmo st a t

1. Uns ta ble pilo t

2. P ilo t tu be blocke d o r restricte d

3. Oxid a tion build-up o n pilot
electrode

4. W ire da mage to pilo t a s s e mbly o r
bad connection at

1. Pressure switch tubing kinked or
blo cked

2. Blocked pressure tap on switch
or blower

3. Fault

voltage inte rrupted.

eration

as control

ressure switch

Turn Power On

Normal operation

Normal operation

Normal operation

1. See Burner Inspection on page
15
2-4. Se e P ilo t Ins pe ction, Testing
and Replacement on page 17

See Pressure Switch Testing and
Replacement on page 32

second s

second s

pause

Ele ctrical po we r no t

present

Stand-by mode,

Thermostat is

satis fied

Stand-by mode,

Sabbath mode (no

The rmo s tat ca lling

for heat (no fault)

W e a k pilo t s ig nal

on la s t ca ll fo r h e a t

Pressure switch not

w o rkin g - clos e d

no faults

faults

po sitio n

Troubleshooting

Three flashes,

three second

Four flashes,

three second

Five flashes,

three second

flash, three
second pause
(Soft Lockout)

pause

pause

ause

Pressure switch or

temperature sw itch

not working - open

po sitio n

Excessive ta nk

temperature,

syste m mu st b e

reset

Fa ls e p ilo t fla me

present

Faile d to light pilot,

system resets after

(5) min u tes

1. Vent blockage or improper vent
config ura tion

2. Pressure switch tubing kinked or
blo cked

3. Faulty pressure switch

4. Blower not spinning up to speed

5. Da mper (inside blow e r) no t fully
ope nin g

6. Faulty blower temperature switch

1. Temperature sensor out of
calibratio n

2. Faulty gas control

Pilot va lve s tuck in o p e n pos ition Replace gas control

1. Uns ta ble pilo t

2. P ilo t tub e b lo ck or re s tricted

3. Oxid a tion build-up o n pilot
electrode

4. W ire da mage to pilo t a s s e mbly o r
bad connection at

as va lve

1. Ve rify co rd s e ts are fully plug ged
in

2. See Pressure Switch Testing and
Replacement on page 32

1. Test Gas Control & Temperature
Sens o r

2. Replace gas control if necessary

1. See Burner Inspection on page
15
2-4. Se e P ilo t Ins pe ction, Testing
and Replacement on page 17

Page 13

13

g

p

g

p

p

p

Troubleshooting

LED Status Control Status Probable Cause Service Procedure

1. Vent blockage or improper vent
configuratio n

2. Pressure switch tubing kinked or
blo cke d

3. Faulty pressure switch

4. Blower not spinning up to speed

5. Da mpe r (in s id e b lo w e r) no t fully
opening

6. Faulty blower temperature switch

1. Uns table pilot

2. P ilo t tube block o r restricte d

3. O xid a t io n build-up o n pilot
electrode

4. Wire damage to pilot assembly or
bad connection at gas control

5. Insufficient combustion air

6. Insufficient

Pilot valve stuck in open position Replace gas control

1. Flammable vapor present

2. Flammable vapor sensor exposed
to e xce s s ive moistu re

3. Flammable vapor sensor exposed
to extreme ambient temperature

4. Resettable thermal switch open

as pressure

1. See Burner Inspection on
page 15
2-4. See Pressure Switch Testing
and Replacement on page 32

1. See Burner Inspection on
page 15
2-4. See Pilot Inspection, Testing
and Replacement on page 17

5. Refer to Installation &
Operation Manual

See Flammable Vapor Sensor
Testing on page 24

Six flashe s , two

flashes, three
second pause
(Soft Lockout)

Six flas hes, three

flashes, three
second pause
(Soft Lockout)

Six flashes, four

flashes, three

second

Seven flashes,

three second

ause

pause

Pressure switch or

blower temp switch

opened during

burne r o peratio n,

system auto resets

afte r (5) minu t e s

Pilot flame

extinguished,

system auto resets

afte r (5) minu t e s

Undesired false

pilo t flame sensed,

system auto resets

Fla mma b le va p o r

se nsor o r

resettable thermal

switch fa ult

detected, see

warning la b e l

Eight flashes,

one flash, three

second pause

Eight flashes,

tw o fla s he s,

three second

pause

Eight flashes,

three flashes,

three second

pause

Eight flashes,

four fla s hes,

three second

pause

Fla mma b le va p o r

sensor out of

spe cificatio n,

po ssible s hort

Temperature

sensor fault

detected

Gas control

electronics fa u lt

detected

Gas control fault

detected

1. Flammable vapor sensor out of
specification; verify Flammable Vapor
Sens o r (FVS) re s ista nce is not below
25,000 Ohms.

2. P o s sible s hort in flammab le vapor
sensor or resettable thermal switch
w irin

1. Damage to temperature sensor
wire s

2. Temperature sensor resistance
out of range

3. Re

lace temperature sensor

1. Ve rify co ntro l is not w et o r
physically damaged

2. Reset control on/off sw itch

3. Replace gas control if 8-3 error
ersists

1. Ve rify co ntro l is not w et o r

physically damaged

2. Reset control on/off sw itch

3. Replace gas control if 8-4 error
ersists

See Flammable Vapor Sensor
Testing on page 24

See Temperature Sensor Testing
on page 21

See Gas Control Removal on
page 22

1. Replace gas control if wet or
ph ys ically da maged

2. C ycle pow er

3. Replace gas control

Page 14

14

Burner Maintenance

Burner Inspection

At periodic intervals (every 6 months), a visual inspection should be made of the pilot
and main burner for proper operation and to assure no debris is accumulating. The
pilot flame should be stable. Some causes for an unstable pilot flame are:

a) Gas pressure is out of specification.

b) Pilot flame not fully engulfing spark/flame sensor.

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

Steel burner models self adjust air to gas ratio mixture and do not have an adjustable
air shutter. The main burner must be free from any debris accumulation that may
effect burner operation (See Burner Cleaning Procedure below).

Burner Cleaning Procedure

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Turn off the gas supply to the water heater.

Step 4. Remove the outer door.

Outer door

Page 15

15

Burner Maintenance

Burner Cleaning Procedure (cont’d)

Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.

(4) 1/4” hex drive

screws

Step 6. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.

Pilot and main feed-

lines

Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.

Gas control

Spark igniter/flame

sensor wire

Right side

inner door

Step 8. Remove the burner assembly from the combustion
chamber.

Burner assembly

Burner surface area

and burner ports

Step 9. Thoroughly inspect the burner surface area and
burner port area and remove any loose debris.

Step 10. Unscrew the burner from the main burner orifice.

Main feedline

Step 11. Remove the main burner orifice from the main
feedline using a 1/2” wrench. Inspect the orifice and clean or
replace, if necessary.

1/2” wrench

Main burner

orifice

16

Page 16

Pilot Maintenance

Burner Cleaning Procedure (cont’d)

Step 12. Reassemble the burner assembly and reinstall into the water heater.
Restore gas supply and check for gas leaks.

Step 13. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Pilot Inspection, Testing and Replacement

Step 1. Move the gas control power switch to the “OFF”
position

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Turn off the gas supply to the water heater.

Step 4. Remove the outer door.

Outer door

Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.

(4) 1/4” hex drive

screws

Right side

inner door

Step 6. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.

Pilot and main feed-

lines

Page 17

17

Pilot Maintenance

Pilot Inspection, Testing and Replacement (cont’d)

Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.

Gas control

Spark igniter/flame

sensor wire

Step 8. Remove the burner assembly from the combustion
chamber.

Burner assembly

Step 9. Remove the pilot assembly from the main feedline
using a 1/4" nut driver.

Pilot assembly

1/4” nut driver

Step 10. Visually inspect the spark igniter/flame sense wire for damage. Replace
the pilot assembly, if damage is found.

Step 11. With a multi-meter set to the ohms setting, check
continuity through the spark igniter/flame sense wire. Replace
the pilot, if there is no continuity.

Multi-meter

Step 12. Visually inspect the spark igniter/flame sense electrode for deterioration.
Replace the pilot assembly, if necessary. The electrode should not be in contact with
pilot hood. If it is in contact with the pilot hood, carefully adjust electrode to a gap
distance of 3/32" from the pilot hood.

Step 13. Visually inspect the spark igniter/flame sense electrode for oxidation build
up. Carefully clean any oxidation using very fine emery cloth.

18

Page 18

Blower Replacement

Pilot Inspection, Testing and Replacement (cont’d)

Step 14. Visually inspect the pilot tubing for kinks or cracks. If damage is found,
replace the pilot assembly.

Step 15. Inspect the pilot tubing and pilot orifice for blockages:

a) Remove ferrule nut from the bottom of the pilot

assembly using a 7/16" wrench.

b) Remove the pilot tube and pilot orifice.

c) Inspect the pilot tubing and pilot orifice for

blockages. Clean or replace, as necessary.

Step 16. Reassemble the pilot assembly and install it on the main feedline.
Reinstall the burner assembly into the combustion chamber. Restore the gas supply
and check for gas leaks.

Step 17. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Blower Removal & Installation

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Page 19

19

Blower Replacement

Blower Removal & Installation (cont’d)

Step 3. Disconnect the vent system from the draft hood
that is mounted on top of the blower.

Vent system

Step 4. Remove the draft hood from the blower and retain
it for use on the new blower.

Draft hood

Blower

Step 5. Unplug the cord sets from the blower.

Cord sets

Step 6. Remove the three blower mounting screws using a
1/4” nut driver and retain for later use.

1/4” nut driver

Blower

Step 7. Remove the blower from the top of the water
heater.

Top of water

heater

Water heater tank flue

Step 8. Clean any debris from the jacket head of the water heater.

Step 9. Set the new blower in place using the water heater tank flue and the
screw holes in the jacket head.

Step 10 Secure the blower in place using the screws from Step 6.

Step 11. Re-install the draft hood from Step 4.

Step 12. Reconnect the vent system to the draft hood.

Page 20

20

Gas Control Testing & Replacement

Blower Removal & Installation (cont’d)

Step 13. Reconnect the cord sets from Step 5.

Step 14. Plug the water heater into the wall outlet.

Step 15. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Determine Water Temperature Inside Tank

Step 1. Move the gas control power switch to the “OFF” position.

Step 2. Draw approximately 4 gallons of water from the drain valve into a
container and discard. Draw an additional gallon and immediately measure the water
temperature using an accurate thermometer. It may be necessary to open a hot water
faucet to allow heater to drain.

Step 3. Compare the measured water temperature with the setting on the gas
control. In most instances, they should not differ by more than approx. 10°F.

WARNING

Stored water may be HOT when performing the following steps in this procedure. Take
necessary precaution to prevent personal injury.

Page 21

21

Gas Control Testing & Replacement

Gas Control Removal

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Drain the water heater to a point below the gas control level.

Step 4. Turn off the gas supply to the water heater and disconnect the gas piping
from the gas control.

Step 4. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.

Pilot and main feed-

lines

Step 5. Disconnect the wire harnesses and spark igniter/
flame sense wire from the gas control.

Gas control

Spark igniter/flame

sensor wire

Wire harnesses

Step 6. Spin the gas control out of the water heater tank.

Page 22

22

120 VAC Circuit Trace

Flammable Vapor Sensor Testing

CAUTION

Do not use standard multi-meter probes for this testing. Doing so will damage the con­nector. Use special pin type electronic probes or small diameter wire pins inserted into
connector.

Step 1. Move the gas control power switch to the “OFF”
position.

Step 2. Disconnect the flammable vapor sensor / resettable thermal switch (FVS/
RTS) harness from the gas control.

Gas control power

switch

FVS/RTS harness

Step 3. Using a multi-meter set to the ohms setting, measure the resistance of
the flammable vapor sensor.

Step 4. Using a multi-meter set to the ohms setting, measure the resistance of
the resettable thermal switch (between the left two pins of the wire harness). The
resistance must be between 3,000 and 48,000 ohms for both the switch and sensor. If
the resistance is out of this range, verify that the resettable thermal switch has not
been tripped. If it hasn’t, replace the thermal switch.

120 VAC Circuit Trace

Step 1. Verify 120VAC and proper polarity are at the wall outlet.

Step 2. With the water heater plugged in and the gas control power switch in the
“ON” position verify LED status.

Page 23

23

Diptube Inspection

Diptube Inspection and Replacement

Step 1. Move the gas control power switch to the “OFF” position

Step 2. Unplug the water heater from the wall outlet.

Step 3. Turn off the cold water supply to the water heater. Connect a hose to the
drain valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of water heater and
allow the water heater to drain to a point below the inlet connection nipple.

Step 4. Disconnect the inlet nipple from the plumbing system.

Step 5. With an appropriate tool, such as a pipe wrench, remove the inlet nipple/
diptube from the water heater. Use caution not to damage pipe threads.

Step 6. Visually inspect the inlet nipple/diptube. The inlet nipple/diptube should
be free of cracks and any blockage. Hydro-jet slots should be open and free of any
blockage. Any damage, such as cracks, restriction due to deformation, or
unintentional holes are not field repairable and the inlet nipple/diptube must be
replaced.

Step 7. Upon completion of the inspection or subsequent replacement, reinstall
the inlet nipple/diptube into the water heater. Ensure pipe dope is used on the nipple’s
threads. Connect the nipple to the plumbing system, resume water supply to the water
heater, refill the water heater and check for leaks.

Step 8. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

24

Page 24

Anode Inspection

Anode Inspection and Replacement

Step 1. Move the gas control power switch to the “OFF” position

Step 2. Unplug the water heater from the wall outlet.

Step 3. Turn off the cold water supply to the water heater. Connect a hose to the
drain valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of water heater and
allow the water heater to drain to a point below the outlet connection nipple.

Step 4. Disconnect the outlet nipple from the plumbing system.

Step 5. With an appropriate tool, such as a pipe wrench, remove the outlet
nipple/anode from the water heater. Use caution not to damage the pipe threads.

Step 6. Visually inspect the outlet nipple/anode. The outlet nipple/anode should
show signs of depletion, which is normal. If depletion is one-half the original anode
diameter (approximately 3/4” diameter), replacement is recommended. If any of the
steel core of the anode is exposed, replacement is recommended.

Step 7. Upon completion of the inspection or subsequent replacement, reinstall

WARNING

Water heater components and stored water may be HOT when performing the following
steps in this procedure. Take necessary precaution to prevent personal injury.

the outlet nipple/anode into the water heater. Ensure pipe dope is used on the
nipple’s threads. Connect the nipple to the plumbing system, resume water supply to
the water heater, refill the water heater, and check for leaks.

Step 8. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Remove the Blower to Gain Access to the Flue Baffle

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Page 25

25

Anode Inspection

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Disconnect the vent system from the draft hood that is mounted on top of
the blower.

Vent system

Draft hood

Blower

Step 4. Unplug the cord sets from the blower.

Cord sets

Step 5. Remove the (3) blower mounting screws using a 1/4” nut driver and
retain for later use.

1/4” nut driver

26

Page 26

Blower Removal

Remove the Blower to Gain Access to the Flue Baffle (cont’d)

Blower

Top of water

heater

Water heater tank flue

Step 6. Remove the blower from the top of the water heater.

Flue baffle

Step 7. Remove the flue baffle from the water heater.

Step 8. Inspect the baffle for deterioration and missing restrictors. Clean any
scale or debris build-up. Replace with a new baffle, as necessary.

Step 9. Reinstall the baffle into the flue. Be sure the baffle hanger tab is inserted
into the notch locations at the top of the flue.

Step 10. Check the burner to ensure no scale has accumulated during operation.
See the Burner Cleaning Procedure on page 15, if accumulation has occurred.

Step 11. Secure the blower in place using the screws from Step 5.

Step 12. Reconnect the vent system to the draft hood.

Step 13. Reconnect the cord sets from Step 4.

Step 14. Plug the water heater into the wall outlet.

Step 15. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Page 27

27

Inner Door Removal

Inner Door Removal Procedure

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Remove the outer door.

Outer door

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

Page 28

(4) 1/4” hex drive

screws

Right side
inner door

28

Inner Door Removal

Inner Door Removal Procedure (cont.)

Step 5. Remove (2) 1/4” drive screws from the left side inner door.

Left side inner door

1/4” hex drive

screws

Step 6. Remove the connectors attached to the resettable thermal switch on the
right side inner door.

Connectors attached to reset-

table thermal switch

Step 7. Inspect both inner doors for any of the following imperfections: tears,
missing material, cracks, dirt or debris, lack of adhesion to the inner door, material left
on combustion chamber, or any other imperfections that will inhibit a proper seal.

If any of the imperfections above are present, replace the inner door gasket following
the Inner Door Gasket Replacement Procedure. If not, replacement of the inner door
gaskets is not necessary.

Page 29

29

Inner Door Gasket Replacement

Inner Door Gasket Replacement Procedure

WARNING

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

Step 1. Completely remove all gasket and adhesive residue from the right and
left side inner doors, as needed.

Gasket Overlap must be as

shown + 1/32

Step 2. Using RTV sealant, apply a 1/8” bead to
secure the inner door gasket to the inner door sections.
Refer to the illustration for proper application. Note the
overlap configuration in the flange area of the inner door.
Set the flange section first, and this will help to achieve the
proper overlap position.

Recommended pattern for RTV sealant

Gasket Overlap must be as

shown + 1/32

Enlarged

view of

flange area

Expanded view

30

Page 30

Inner Door Installation

Inner Door Installation with Gasket

WARNING

Stripped fastener connections may allow for an inner door seal breach. A seal breach may
result in a fire or explosion, causing property damage, personal injury, or death. Do not
over tighten screws. If a fastener connection is stripped, contact the manufacturer listed
on the water heater rating plate.

Step 1. Clean any residual gasket residue or other debris from the combustion
chamber surface before installing the inner door/gasket assembly.

Step 2. Place the left side inner door into position first, being sure to firmly
position the concave channel of the inner door around the feedline.

Step 3. Using the 1/4” hex drive screws removed in Step 5 of the Inner Door
Removal Procedure on page 29, secure the left side inner door in place. Do not over­tighten the screws.

Step 3. Position the pilot tube and spark igniter wire against the left side inner
door flange gasket. Do not route these through the concave channel with the feedline.

Step 4. Firmly place the right side inner door flange against the left side inner
door flange.

Step 5. Using the 1/4” hex drive screws removed in Step 4 of the Inner Door
Removal Procedure on page 29, secure the two flanges together. Do not over-tighten
the screws.

Step 6. Align the right side inner door to the 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 chamber opening.

Step 7. Using the 1/4” hex drive screws removed in Step 4 of the Inner Door
Removal Procedure on page 29, secure the right side inner door. Do not over-tighten
the screws. Verify that both the left and right side inner doors are properly positioned
and sealed against the combustion chamber.

Step 8. Re-install the outer door.

Step 9. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

Page 31

31

Pressure Switch Testing

Pressure Switch Testing & Replacement

Step 1. Move the gas control power switch to the “OFF”
position.

Gas control power

switch

Step 2. Unplug the water heater from the wall outlet.

Blower (water heater)

power cord

Step 3. Unplug the cord sets from the blower.

Cord sets

Slotted screwdriver

Step 4. Using a slotted screwdriver, remove the (3)
screws (one on the backside of the junction box is not shown)
holding the end of the blower junction box on. Retain the
screws for later use.

Blower junction box

Junction box screws

Step 5. Remove the pressure switch tubing from the
pressure switch.

Pressure switch tubing

Step 6. Carefully pull out and lower the blower junction
box cover.

Junction box cover

32

Page 32

Pressure Switch Testing

Pressure Switch Testing & Replacement (cont’d)

Step 7. Using a slotted screwdriver, remove the (2)
screws holding the pressure to the blower junction box. Retain
the screws for later use.

Pressure switch screws

Step 8. Pull the pressure switch out of the junction box.

Pressure switch

Step 9. Using a multi-meter, check the resistance across
the pressure switch terminals. There should be no electrical
continuity, meaning the switch is open.

Multi-meter leads

Step 10. If the switch is open, check the pressure switch
tubing and pressure tap on the switch for a blockage. Clear the
blockage if one is present.

Step 11. If there is not a blockage, replace the pressure switch. Verify the switch
setting of the replacement switch matches the original switch’s setting.

Step 12. Remove both terminals from the pressure switch..

Step 13. Connect both terminals to the new pressure switch.

Step 14. Place the pressure switch into the blower junction box.

Step 15. Align the pressure switch and install the (2) screws removed in Step 7.

Step 16. Re-install the blower junction box cover.

Step 17. Re-install the (3) screws removed in Step 4.

Step 18. Re-install the pressure switch tubing.

Step 19. Reconnect the cord sets from Step 3.

Step 20. Plug the water heater into the wall outlet.

Page 33

33

Arrestor Cleaning

Pressure Switch Testing & Replacement (cont’d)

Step 21. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

ScreenLok® Flame Arrestor Cleaning Procedure

Step 1. Move the gas control power switch to the “OFF” position and unplug the
water heater from the wall outlet.

Step 2. Remove the outer door.

Step 3. Remove the right side inner door per the Inner Door Removal Procedure
on page 32.

Step 4. Disconnect the pilot tube using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas control.

Step 5. Disconnect the spark igniter/flame sensor wire from gas control.

Step 6. Remove the burner assembly from the combustion chamber.

Step 7. Clean the ScreenLok® flame arrestor using a stiff brush, compressed air,
and/or a shop vacuum to remove any scale or other debris accumulation. Using a soft
brush, clear jacket openings from any dirt, dust, restrictions, or other obstructions.

Step 8. Remove any debris from the burner assembly following the Burner
Cleaning Procedure on page 15.

Step 9. Re-install the burner assembly.

Step 10. Reconnect the main and pilot tubing and spark igniter wire to the gas
control.

Step 11. Re-install the inner door per the Inner Door Installation with Gasket
Procedure on page 34.

Step 12. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.

34

Page 34

Common Terms

BTU British Thermal Units
ECO Energy Cut Off
GPM Gallons per Minute
Hz Hertz
KWh Kilowatts per hour
LED Light Emitting Diode
NPT National Pipe Thread
Ohms Ohms of resistance
PSI Pounds per Square Inch
RPM Revolutions per Minute
VAC Volts Alternating Current
W.C. Inches of Water Column

°C Degrees Centigrade
°F Degrees Fahrenheit

Common Terms

Page 35

35

Parts List

36

Page 36

PART NAME AND DESCRIPTION

1. DraŌ Hood 15. Inner Door (Right)

2. Jacket Head Pan 15A. ReseƩable Thermal Switch

3. Jacket 16. Inner Door (LeŌ)

4. Blower 17. Blower Wire Harness

5. Heat Trap—Outlet 18. Feedline

6. Magnesium Anode–Hot Water Outlet 19. Gas Control Valve

7. Heat Trap—Inlet 20. Wire Harness (FVS / RTS)

8. Flue Baŋe Assembly 21. FVS Sensor Clip

9. Dip Tube–Cold Water Inlet 22. Flammable Vapor Sensor (FVS)

10. Temperature and Pressure Relief Valve 23. Outer Door

11. Glass Lined Tank 24. Steel Burner

12. CombusƟon Chamber Assembly 25. OriĮce

13. Jacket Base Pan 26. Pilot Assembly

14. Drain Valve