Bradford White Defender RG140T Series User manual

Save this manual for future reference
Manual 238-51542-00C REV 08/19
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)
Flammable Vapor Ignition Resistant
Water Heaters

2
The Bradford White
DEFENDER
Safety System®
Flammable Vapor Ignition Resistant Water Heaters
Table of Contents
Page Service
Procedure
Introduction………………………………………………………………………… …...4 ---
Troubleshooting Charts…………………………………………………………….…...6 ---
Inner Door Gasket Removal, Inspection, and Replacement…………………
…
…..12 RG-I
Thermocouple/Thermopile Testing and Replacement………………………….…..15 RG-II
Pilot Assembly Inspection Cleaning and Replacement……………………………..18 RG-III
Piezo Igniter, Electrode Testing and Replacement……………………………..…..19 RG-IV
White Rodgers Mechanical Gas Valve Testing and Replacement……………
.
…..20 RG-V
Electronic Gas Control Testing, Disassembly, and Replacement……………
…
…..25 RG-VI
Burner Operation Inspection, Adjustment, Cleaning, and Replacement……
…
…..35 RG-VII
Resettable Thermal Switch Testing and Replacement………………………..
…
.…..37 RG-VIII
ScreenLok®Flame Arrestor Cleaning………………………………………………..39 RG-IX
Diptube and Anode Inspection and Replacement………………………………
.
…..40 RG-X
Parts Diagram……………………………………………………………………….…..42 ---
Notes………..………………………………………………………………………
…
...43 ---
…
…
..
..
..
..
2

3
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.
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.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE
IF YOU ARE NOT CERTAIN OF THE FOLLOWING:
xLiquefied petroleum gases/propane gas and
natural gas have an odorant added by the gas
supplier that aids in the detection of the gas.
xMost people recognize this odor as a “sulfur” or
“rotten egg” smell.
xOther conditions, such as “odorant fade” can
cause the odorant to diminish in intensity, or
“fade”, and not be as readily detectable.
xIf you have a diminished sense of smell or are in
any way unsure of the presence of gas,
immediately contact your gas supplier from a
neighborʼs telephone.
Gas detectors are available. Contact your gas
supplier, or plumbing professional, for more
information.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW,
LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE
RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIM THAT MIGHT
RESULT FROM EXCESSIVE TEMPERATURE AND
PRESSURES.
CAUTION
If sweat fittings are to be used DO NOT apply heat to
the nipples on top of the water heater. Sweat the tubing
to the adapter before fitting the adapter to the water
connections. It is imperative that heat is not applied to
the nipples containin
g
a plastic liner.
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.
– WHAT TO DO IF YOU SMELL GAS
xDo not try to light any appliance.
xDo not touch any electrical switch; do not use any
phone in your building.
xImmediately call your gas supplier from a neighborʼs
phone. Follow the gas supplierʼs instructions.
xIf 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.
WARNING: If the information in these instructions is not followed
exactly, a fire or explosion may result in property damage, personal
in
j
ur
y
, 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.
3

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.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the opening in the
jacket. This air travels down and around the combustion chamber and enters through holes in the
very bottom of the corrosion-resistant combustion chamber. The air then travels up through the
oriented flame arrestor plate louvers, where the velocity of the air is increased, and its direction
altered. The air then mixes in a normal manner with the supplied gas and is efficiently combusted,
producing very low NOx emissions.
In the case where trace amounts of flammable vapors are present in the air flowing into the
combustion chamber, the vapors are harmlessly ignited by the burner/pilot flame. If flammable
vapors are in sufficient quantity to prevent normal combustion, the burner/pilot flame is shut down.
Should the flammable vapors continue to the burner, the flame arrestor plate prevents the flames
from traveling backwards and igniting vapors outside of the combustion chamber. The calibrated,
multipurpose thermal switch recognizes this and shuts down the pilot and main burner. This switch
also deactivates the burner and pilot in the unlikely event of restricted airflow caused by severe lint,
dust, or oil accumulation on the arrestor plate.
4

5
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.
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.
5

6
White Rodgers Mechanical Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom Probable Cause Corrective Action Service
Procedure
Pilot will not light
1. No incoming gas or too low
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. 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. See Service
Procedure RG-V
2. See Service
Procedure RG-III
3. See Service
Procedure RG-III
4. See Service
Procedure RG-IV
Pilot will not stay lit
when button is
released
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. 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. See Service
Procedure RG-II
2. See Service
Procedure RG-V
3. See Service
Procedure RG-V
Pilot will light but
the main burner
will not come on
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.
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.
1. See Installation
and Operation
Manual.
2. See Service
Procedure RG-V
3. See Service
Procedure RG-V
6

7
White Rodgers Mechanical Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
Symptom Probable Cause Corrective Action Service
Procedure
Pilot goes out
periodically (after
heating cycles,
once a day, once
a week etc.)
1. Insufficient combustion air
supply.
2. Incorrect or clogged vent
system/vent terminal, or
incorrect location.
3. Inconsistent gas supply or
gas pressure.
1. Verify adequate combustion air
is available to the unit. Check
and clear jacket slot openings of
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. See Service
Procedure RG-
VIII
2. See Service
Procedure RG-V
Not enough hot
water
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.
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.
1. See Service
Procedure RG-V
2. See Service
Procedure RG-IX
7

8
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)
Indicates control is off. Main
and pilot burner are off.
Gas valve is functioning normally. Gas valve is
not powered. Light pilot.
One flash every
four seconds
Not an error. Indicates pilot is
lit and main burner is off.
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.
One flash every
second
Not an error. Indicates main
valve is open and main
burner is lit.
Thermostat is calling for heat. Water heater
operating normally and is in heat cycle.
Solid ON
Not an error. Indicates that
the control is in shutdown
mode.
Set point knob was recently turned to “OFF”
position. Wait until LED goes out before
attempting to relight.
Two flashes and
three second
pause
Low thermopile voltage; main
burner not lit.
Loose thermopile connections or weak pilot
flame.
Four flashes and
three second
pause
Temperature cut-out limit
reached causing shutdown.
Excessive temperatures may have been
reached. Shut off the control and reduce the
water temperature. Thoroughly verify control
operation, replace if exceeding setpoint.
Five flashes and
three second
pause
Electronics, sensor, or gas
valve fault detected.
Control may be wet or damaged. Verify all
connections are tight; if problem persists replace
the control.
8

9
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.
Honeywell V1 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
V
LED Status Control Status Probable Cause Service Procedure
None (LED not
on or flashing) Pilot assembly is not lit. Gas control is not powered. Light pilot.
If the pilot will not stay lit
replace pilot assembly. If
problem persists replace
gas control.
One flash and
three second
pause
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.
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.
Normal operation.
LED on
continuously
(solid)
Setpoint knob has been recently
turned to the “OFF” position. Wait
until LED goes out before
attempting to relight.
Setpoint knob was
turned to “OFF”
position.
LED will go out and the
control will function
normally once the pilot is lit.
Two flashes
and three
second pause
Weak pilot signal detected.
System will reset when pilot
flame is sufficient.
1. Thermopile failure.
2. Unstable pilot.
3. Pilot tube blocked or
restricted.
1. See Service Procedure IV
2. See Service Procedure II
3. See Service Procedure II
Three flashes
and three
second pause
Insufficient water heating.
System will reset.
1. Thermal sensor out
of calibration.
2. Faulty gas control.
Replace gas control.
9

10
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.
Honeywell V1 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
LED Status Control Status Probable Cause Service Procedure
Four flashes
and three
second pause
Excessive tank temperature.
System must be reset.
1. Temperature sensor
out of calibration.
2. Faulty gas control.
Replace gas control.
Five flashes
and three
second pause
Temperature sensor fault.
1. Damage to the
temperature sensor,
resistance is out of
range, or sensor is
unplugged.
2. Faulty gas control.
1. See Service Procedure VI
2. Replace gas control.
Six flashes
and three
second pause
Water leak detected by
accessory module.
Excessive amount of
water in drain pan/water
dam.
1. Check T&P valve.
2. Check all water fittings.
3. Pressurize and leak test
tank.
Seven flashes
and three
second pause
Gas control electronic fault
detected.
1. Control needs to be
reset.
2. Control is wet or
physically damaged.
1. Reset gas control
2. Replace gas control.
Eight flashes
and three
second pause
Standing pilot remains on
while setpoint knob is in
“OFF” position.
Pilot valve stuck in
open position. Replace gas control.
10

11
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.
Honeywell V2 Gas Control Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
LED Status Control Status Probable Cause Service Procedure
None (LED not on
or flashing)
Millivolt power is not
present. Light pilot.
Gas valve is functioning
normally. Gas valve is not
powered. Light pilot.
If the pilot will not stay lit
replace pilot assembly. If
problem persists, replace
g
as control.
One flash every
four seconds
(LED green)
Not an error. Indicates
pilot is lit and main
burner is off.
The knob can be turned to a
desired setpoint temperature. Normal operation.
One flash every
second
(LED green)
Not an error. Indicates
main valve is open and
main burner is lit.
None. Control will automatically
shut main burner off when water
temperature reaches the setpoint
tem
p
erature.
Normal operation.
Two flashes and
three second
pause (LED
y
ellow)
Low thermopile voltage;
main valve not turned on.
Check thermopile and its
connections. Check pilot flame.
1. See Service Procedure IV
2. See Service Procedure II
3. See Service Procedure II
Four flashes and
three second
pause (LED red)
Temperature cut-out
limit reached, causing
shutdown.
Check the valves and the water
temperature sensor. Reduce the
water temperature setpoint.
Verify control operation, replace
if exceeding setpoint.
Replace gas control.
Five flashes and
three second
pause (LED red)
Electronics, sensor, or
gas valve fault detected.
Check water temperature sensor
and its connection for open
circuits, shorts, or differences in
resistance between the two
sensor elements.
Replace gas control.
Solid ON
(LED red)
Not an error–indicates
that the control is in OFF
position.
None; wait until LED turns off if
you want to restart system.
LED will go out and the
control will function normally
once the pilot is lit.
11

12
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
ƔTears
ƔMissing material
ƔCracks
ƔDirt or debris
ƔGasket adhesion to inner door
ƔMaterial left on combustion chamber (around opening)
ƔOther imperfections that will inhibit proper seal
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
GASKET OVERLAP
MUST BE AS
SHOWN ±1/32"
RECOMMENDED
PATTERN FOR RTV
SEALANT
ENLARGED
VIEW OF
FLANGE AREA
PLACE FLANGE
SECTIONS FIRST VIEW WITH
GASKETS IN
PLACE
EXPANDED
VIEW
Fully inspect inner door gaskets for the following:
Step 4.
Inner Door Removal Procedure
Rotate knob of the combination thermostat/gas valve
to the “OFF” position.
Step 1.
Step 2.
Step 3.
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.
12

13
SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal,
Inspection, and Replacement
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.
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
wire against left side inner door flange gasket.
DO NOT ROUTE THROUGH RADIUSED
CHANNEL WITH FEEDLINE.
Step 2.
Step 3.
WARNING
Stripped fastener connections may allow
for seal breach of inner door. A seal
breach may result in a fire or explosion
causing property damage, personal injury
or death. DO NOT overtighten screws in
Steps 2, 4, and 5.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
Radiused channel for
feedline
13

14
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.
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 5.
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.
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 O
p
eration Manual.
Step 7.
Step 8.
14

15
SERVICE PROCEDURE RG-II
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.
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
p
lace the thermocou
p
le.
Step 2.
Step 3.
Alligator clip to copper
sheath of thermocouple
15

16
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers Mechanical)
Step 1.
Step 2.
Disconnect the thermocouple from the
combination thermostat/gas valve.
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.
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.
Step 3.
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.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Remove the outer jacket door.
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).
Inspect the inner door gasket per Service
Procedure RG-I, Ste
p
4.
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.
Thermocouple position
16

17
SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOPILE TESTING
(Honeywell & White Rodgers Electronic)
Step 1.
Step 2.
Step 3.
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.
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.
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.
17

18
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
Step 1.
Step 2.
Step 3.
Step 4.
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.
Step 5.
Step 6.
Step 7.
Step 8. 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. 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).
Step 10.
Step 11.
Step 12.
Step 13.
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.
PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING, AND REPLACEMENT
SERVICE PROCEDURE RG-III
Pilot Assembly Inspection, Cleaning
and Replacement
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

19
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.
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.
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. 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.
Step 4b. For Honeywell gas controls: To replace the igniter, see the Honeywell ONLY information in
Service Procedure RG-VI.
Flat-head screwdriver
Jumper
wire
19

20
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.
Step 1.
Step 2.
Step 3.
Step 4.
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.
Step 5.
Step 6.
Set gas valve to “OFF” position.
Remove the pressure tap plug (3/16” Allen wrench) and install
pressure tap.
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.)
20