Bradford White DV Series User manual

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Manual 238-51636-00C REV 08/19
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RG2DV40S*(N,X)
RG2DV50S*(N,X)
RG2DV50H*(N,X)
LG2DV50H50*(N,X)
(*) Denotes Warranty Years
Direct Vent Water Heaters
Flammable Vapor Ignition Resistant
Water Heaters

2
The Bradford White
DV Series
Direct Vent Water Heaters
Table of Contents
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
Diptube Inspection and Replacement ......................................39 VIII
Anode Inspection and Replacement ........................................40 IX
Glossary of Terms .....................................................................41 ---
Parts Diagram............................................................................42 ---
Notes ..........................................................................................43 ---
2

DV Series
3
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury, or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in the
vicinity of this or any other appliance.
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.
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.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF
YOU ARE NOT CERTAIN OF THE FOLLOWING:
x Liquefied petroleum gases/propane gas and natural
gas have an odorant added by the gas supplier that
aids in the detection of the gas.
x Most people recognize this odor as a “sulfur” or
“rotten egg” smell.
x Other conditions, such as “odorant fade” can cause
the odorant to diminish in intensity, or “fade”, and not
be as readily detectable.
x If you have a diminished sense of smell or are in any
way unsure of the presence of gas, immediately
contact your gas supplier from a neighbor’s
telephone.
Gas detectors are available. Contact your gas supplier, or
plumbing professional, for more information.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED
3/4” X 3/4” TEMPERATURE AND PRESSURE RELIEF
VALVE WILL RELEASE THE MANUFACTURER FROM ANY
CLAIM THAT MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
CAUTION
If sweat fittings are to be used DO NOT apply heat to the
nipples on top of the water heater. Sweat the tubing to the
adapter before fitting the adapter to the water connections. It
is imperative that heat is not applied to the nipples containing
a plastic liner.
WARNING
Hydrogen gas can be produced in an operating water
heater that has not had water drawn from the tank for a
long period of time (generally two weeks or more).
HYDROGEN GAS IS EXTREMELY FLAMMABLE. To
prevent the possibility of injury under these conditions,
we recommend the hot water faucet to be open for
several minutes at the kitchen sink before you use any
electrical appliance which is connected to the hot water
system. If hydrogen is present, there will be an
unusual sound such as air escaping through the pipes
as hot water begins to flow. DO NOT smoke or have
open flame near the faucet at the time it is open.
WARNING
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.
3

DV Series
4
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.
4

DV Series
5
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
Manometer:
A liquid “U” tube type or a digital (magnahelic) type can be
used. This device is used to measure gas and/or air pressure
and vacuum.
Multi-Meter:
A digital type is strongly recommended. This device is used
to measure electrical values. The meter you select must have
the capability to measure volts AC, volts DC, amps,
micro-amps, and ohms.
Electronic Probes:
In some cases, standard multi-meter probes will damage or
simply not be effective to obtain certain voltage and ohm
readings. It will be necessary to have special electronic “pin”
type multi-meter probes. These probes are available at most
electronic wholesale outlets.
Thermometer:
Used to measure water temperature. An accurate
thermometer is recommended.
Water Pressure Gage:
Used to measure water supply pressure. Also used to
determine tank pressure by adapting to the drain valve of the
heater.
Various Hand Tools:
Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”,
1/2”), 12” crescent wrench, allen wrench set, screw drivers
(common & Phillips), 1/4” nut driver, pliers (common & needle
nose), socket set, side cutters, wire cutters, wire strippers,
wire crimpers, torpedo level, small shop vacuum, step ladder,
flashlight, and 5-gallon pail.
5

DV Series
6
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.
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.
Short flash once
per second
Gas control is calling for heat
(no fault).
Tank temperature below
setpoint of thermostat. 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 II
2. See Service Procedure VI
3. See Service Procedure VI
Three flashes
and three second
pause
Insuffcient water heating.
System will reset.
1. Thermal sensor out of
calibration.
2. Faulty gas control.
Replace gas control.
Troubleshooting Gas
Control V1
6

DV Series
7
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.
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.
2. Temperature sensor
resistance out of
range.
Replace gas control.
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.
Troubleshooting Gas
Control V1
7

DV Series
8
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.
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 gas
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 temperature.
Normal operation.
Two flashes
and three
second pause
(LED yellow)
Low thermopile
voltage;
main valve not turned
on.
Check thermopile and its
connections. Check pilot flame.
1. See Service Procedure II
2. See Service Procedure VI
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 to
restart system.
LED will go out and the
control will function normally
once the pilot is lit.
Troubleshooting Gas
Control V2
8

DV Series
9
Troubleshooting Gas Control
White Rodgers Mechanical
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
IV
2. See Service
Procedure
V I
3. See Service
Procedure
V I
4. See Service
Procedure
III
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 II
2. See Service
Procedure IV
3. See Service
Procedure IV
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 IV
3. See Service
Procedure IV
9

DV Series
10
Troubleshooting Gas Control
White Rodgers Mechanical
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 VII
2. See Service
Procedure IV
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 IV
10

DV Series
11
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.
Troubleshooting Gas Control
White Rodgers Electronic
11

DV Series
12
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.
WARNING
If the information in these instructions is not followed
exactly, a fire or explosion may result causing property
damage, personal injury, or death.
Service Procedure I
Inner Door Removal and
Replacement
12

DV Series
13
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.
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
over tighten screws in steps 2, 3 and 4.
Service Procedure I
Inner Door Removal and
Replacement
13

DV Series
14
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.
Service Procedure I
Inner Door Removal and
Replacement
14

DV Series
15
Closed Circuit Thermocouple Testing (White Rodgers Mechanical)
Step 1. Closed circuit testing is the preferred method for testing the thermocouple. Following the
lighting instruction label on the heater, proceed to light the pilot and allow to operate for
three minutes. If the pilot will not stay lit, hold the pilot button (located on the combination
thermostat/gas valve) down during this test.
Step 2. 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.
Step 3. If meter reads 10 millivolts or higher, the thermocouple is O.K.. If reading is below 10
millivolts, replace the thermocouple.
Open Circuit Thermocouple Testing (White Rodgers Mechanical)
Step 1. Disconnect the thermocouple from the combination
thermostat/gas valve.
Step 2. Using a multimeter capable of measuring millivolts,
connect one alligator clip to the end ball or contact
portion of the thermocouple and the other alligator
clip to copper portion of the thermocouple.
Step 3. Following the lighting instruction label on the
heater, proceed to light the pilot and allow to
operate for three minutes. It will be necessary to
hold the pilot button down continuously
throughout this test. A reading of 20 to 30
millivolts indicates good thermocouple output.
Service Procedure II
Thermocouple/Thermopile
Testing and Replacement
Alligator clip to copper
sheath of thermocouple
15

DV Series
16
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.
Step 2. Remove the outer jacket door.
Step 3. Remove the right side of the inner door per Service Procedure I, Steps 3a through
3c.
Step 4. 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.
Step 5. 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).
Step 6. Inspect the inner door gasket per Service Procedure I, Step 4.
Step 7. Install right side inner door per Service Procedure I, “Installation of Inner Door with
Gasket,” Step 6 through 8.
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.
Service Procedure II
Thermocouple/Thermopile
Testing and Replacement
16

DV Series
17
Closed Circuit Thermopile Testing
(White Rodgers Electronic and Honeywell)
Closed circuit thermopile testing is the preferred method for testing the thermopile.
Step 1. 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 (rotate the gas
control knob to the pilot position, push and
hold in) during this test.
Step 2. Using a multimeter capable of measuring
millivolts, place one lead of the multimeter on
the left side of the wire harness and place the
second lead of the multimeter on the right side
of the wire harness.
Step 3. If meter reads 300 millivolts or higher, the
thermopile is O.K.. If reading is below 300
millivolts, replace the pilot assembly per
Service Procedure VI.
Open Circuit Thermopile Testing
(White Rodgers Electronic and Honeywell)
Step 1. Disconnect the red and white pilot wires from the gas control.
Step 2. Using a multimeter capable of measuring millivolts, connect one lead to the red
thermopile wire and one lead to the white thermopile wire.
Step 3. Following the lighting instruction label on
the heater, proceed to light the pilot and
allow the heater to operate for three
minutes. It will be necessary to hold
the gas control knob down in the
“PILOT” position continuously
throughout this test. A reading over
400 millivolts indicates a good thermopile
output.
Step 4. A reading under 400 millivolts indicates a
bad thermopile; replace the pilot
assembly per Service Procedure VI.
Service Procedure II
Thermocouple/Service
Testing and Replacement
17

DV Series
18
Igniter, Electrode Testing and Replacement
Step 1. Remove the outer jacket door.
Step 2. Repeatedly depress the igniter button while viewing the pilot through the flame viewing
window. If a spark is present, the circuit is O.K.. If there is no spark, proceed to Step 3.
Step 3. Remove the white (or orange) wire from the gas control’s igniter wire. Hold the igniter
lead from the gas control to an unpainted surface such as the feedline and depress the
igniter. If there is a spark, the igniter is O.K.. Otherwise, the igniter is not functioning and
the pilot assembly must be replaced. See Service Procedure VI.
Step 4a. For White Rodgers Mechanical: to replace the igniter, disconnect the white (orange)
wire from the igniter. Use a flat-head screwdriver under the igniter and gently pry
bracket from the front of the gas calce and unhook the bracket from rear of the gas
valve.
Step 4b. For Honeywell: to replace the igniter, see the Honeywell ONLY information in Service
Procedure IV.
Jumper
wire
Flat-
head screwdriver
Service Procedure III
Igniter, Electrode Testing,
and Replacement
18

DV Series
19
ECO (Energy Cut Out) Testing
The Honeywell and White Rodgers Electronic gas
control is designed with an ECO device that will reset.
To reset the gas control after a status code 4, turn the
gas control knob to the “OFF” position and wait a
minimum of five (5) minutes before relighting, following
the instructions located on the lighting instruction label
or the lighting instructions located in the Installation and
Operation Manual.
Line Pressure
The gas control is designed for a maximum line pressure of 14.0” W.C.
and a minimum line pressure of the water heater’s rated manifold
pressure plus 1.0” W.C. (check rating plate). Line pressure must be
checked with the main burner on AND off to assure proper readings.
Manifold Pressure Testing
(This procedure presumes a maximum
line pressure of 14.0” W.C.)
Step 1. Position the gas control knob in the “OFF” position.
Step 2. Remove the pressure tap plug (3/16” allen wrench) and
install a 1/8” NPT pipe, coupling, and pressure tap.
Step 3. Connect a manometer to the pressure tap.
Step 4. Follow instructions located on the lighting
instruction label and proceed to light the main
burner. Observe the manometer readings.
Step 5. Proper operating range for natural gas is 4.0”
±0.5” W.C.; L.P. is 10.0” ±0.5” W.C..
a. If pressure is within the range specified in
the previous step, set the gas control knob to
the “OFF” position, remove manometer and
pressure tap, and replace pressure tap plug.
b. If the gas pressure is outside of the
specification noted above, refer to the
following Honeywell ONLY instructions or
“Gas Control Removal from Water Heater.”
Step 6. The manifold pressure is NOT adjustable. If
manifold pressure is outside of the range in
Step 5, the control must be replaced.
Service Procedure IV
Gas Control Testing and
Replacement
White Rodgers
Mechanical
19

DV Series
20
Gas Valve Testing and Replacement (White Rodgers Mechanical)
The gas valve on the White Rodgers Mechanical 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 fuction, 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.
Magnet Assembly Testing (White Rodgers Mechanical)
Step 1. 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 gas
valve) down during this test.
Step 2. Using a multimeter capable of measuring millivolts, connect one lead using an alligator clip
to the copper sheath of the thermocouple. Use the second lead of the multimeter to probe
the top terminal located at the back of the gas valve.
Step 3. With a meter reading of 13 millivolts or greater, rotate the knob of the combination
thermostat/gas valve to the “OFF” position.
Step 4. The magnet should remain closed for a drop of at least 6 millivolts. You will hear a “snap”
or “click” sound when the magnet opens; if you hear this sound prior to a drop of 6
millivolts, the magnet is out of specification and the gas valve should be replaced.
Energy Cut Off (ECO) Testing
Step 1. Disconnect the thermocouple from the gas valve.
Step 2. Using a multimeter capable of measuring ohms (or
continuity), attach one lead using an alligator clip to the
pilot tube. Insert the other lead fully into the magnet
opening. Be sure the lead makes contact only at the top
center of the magnet opening. DO NOT allow the lead to
make contact with the threaded sides of the opening.
Step 3. If continuity is indicated, the ECO is O.K.. If continuity is not
indicated, the ECO has opened, and the gas valve must be replaced.
Alligator clip to copper
sheath of thermocouple
Service Procedure IV
Gas Control Testing and
Replacement
20