Bradford White RG2F40S*(N,X) User manual

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Manual 238-51617-00A
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
Atmospheric Vent Gas Water Heater
High EF

2
Page 2
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

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.
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.
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.
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.
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

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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.

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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 NOxemissions.
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
Introduction

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Page 6
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.
How to Use this Manual

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Power Supply Dedicated 120VAC, 60 Hz, 15A
Gas Supply Pipe
Minimum 1/2” (Schedule 40 black iron pipe
recommended)
Approved Gas Type Natural or Propane; unit must match gas type supplied
Gas Pressure 5” w.c. minimum for Natural Gas; 11” w.c. for Propane;
14” w.c. maximum for Natural Gas / Propane
Approved Vent Materials Single or Double Wall Metal Vent Pipe
Recommended Minimum
Clearance for Servicing 18” from top; 24” from front; 4” from sides and rear
Water Supply Pressure 150 psi maximum allowable working pressure; check local
codes for supply pressure
ECO Limit 188°F (87°C)
Temperature Setpoint Range 60°F (16°C) to 160°F (71°C); approximate temperatures
Pressure Switch Setting
(normal altitude) -0.20” w.c. (-0.10” for Hi-Alt.)
Specifications

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Ignition State Timing
Pre-purge 15 seconds
Trial for Ignition 90 seconds
Flame Stabilization Period 3 seconds
Interpurge 15 seconds
Flame Failure Response Time 1.5 seconds (2 second maximum; 1 second mini-
mum)
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 Indefinite (self clears if fault clears for at least 15
seconds)
Specifications
Wiring Diagram
Control Timings

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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.
Sequence of Operation

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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.
Sequence of Operation

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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.
Sequence of Operation

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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.
Sequence of Operation

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LED Status Control Status Probable Cause Service Procedure
None (LED not
on or flashing)
Electrical po w er no t
present
Control po w er s w itch in "OFF"
position.
Su
pp
l
y
volta
g
e interru
p
ted.
Turn Power On
One short flash
every four
seconds
Stand-by mode,
Thermostat is
satisfied
(
no faults
)
Temperature demand is satisfied
(no call for heat) Normal operation
One short flash
every two
seconds
Stand-by mode,
Sabbath mode (no
faults
)
Temperature on Setback Control is
adjusted down to prevent burner
o
p
eration
Normal operation
Alternates
bright and dim
(
heartbeat
)
Thermostat calling
for heat (no fault)
Tank temperature below setpoint of
th e rmo s t a t Normal operation
Short flash once
every second
W ea k pilot s ignal
on last call for heat
1. Unstable pilot
2. Pilot tube blocked or restricted
3. Oxidation build-up on pilot
electrode
4. W ire damage to pilot assembly or
bad connection at
g
as control
1. See Burner Inspection on page
15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
Two flashes,
three second
pause
Pressure switch not
w orking - clo se d
position
1. Pressure switch tubing kinked or
blocked
2. Blocked pressure tap on switch
or blower
3. Fault
y
p
ressure switch
See Pressure Switch Testing and
Replacement on page 32
Three flashes,
three second
pause
Pressure switch or
temperature switch
not working - open
position
1. Vent blockage or improper vent
configuration
2. Pressure switch tubing kinked or
blocked
3. Faulty pressure switch
4. Blower not spinning up to speed
5. Da mpe r (ins ide blo w er) not fully
opening
6. Faulty blower temperature switch
1. Verify cord sets are fully plugged
in
2. See Pressure Switch Testing and
Replacement on page 32
Four flashes,
three second
pause
Excessive tank
temperature,
s ys te m mu s t b e
reset
1. Temperature sensor out of
calibration
2. Faulty gas control
1. Test Gas Control & Temperature
Sensor
2. Replace gas control if necessary
Five flashes,
three second
p
ause
False pilot flame
present Pilot valve stuck in ope n position Replace gas control
Six flashes, one
flash, three
second pause
(Soft Lockout)
Failed to light pilot,
system resets after
(5) minutes
1. Unstable pilot
2. Pilot tube block or restricted
3. Oxidation build-up on pilot
electrode
4. W ire damage to pilot assembly or
bad connection at
g
as valve
1. See Burner Inspection on page
15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
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.
Troubleshooting

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LED Status Control Status Probable Cause Service Procedure
Six flashes, two
flashes, three
second pause
(Soft Lockout)
Pressure switch or
blower temp switch
opened during
burner operation,
system auto resets
afte r (5) minute s
1. Vent blockage or improper vent
configuration
2. Pressure switch tubing kinked or
blocked
3. Faulty pressure switch
4. Blower not spinning up to speed
5. Damper (inside blow e r) no t fully
opening
6. Faulty blower temperature switch
1. See Burner Inspection on
page 15
2-4. See Pressure Switch Testing
and Replacement on page 32
Six flashes, three
flashes, three
second pause
(Soft Lockout)
Pilot flame
extinguished,
system auto resets
afte r (5) minute s
1. Unstable pilot
2. Pilot tube block or restricted
3. Oxidation build-up on pilot
electrode
4. Wire damage to pilot assembly or
bad connection at gas control
5. Insufficient combustion air
6. Insufficient
g
as
p
ressure
1. See Burner Inspection on
page 15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
5. Refer to Installation &
Operation Manual
Six flashes, four
flashes, three
second
p
ause
Undesired false
pilot flame sensed,
s
y
stem auto resets
Pilot valve stuck in open position Replace gas control
Seven flashes,
three second
pause
Fla mma ble va p or
sensor or
resettable thermal
sw itch fault
detected, see
warning label
1. Flammable vapor present
2. Flammable vapor sensor exposed
to excessive moisture
3. Flammable vapor sensor exposed
to extreme ambient temperature
4. Resettable thermal switch open
See Flammable Vapor Sensor
Testing on page 24
Eight flashes,
one flash, three
second pause
Fla mma ble va p or
sensor out of
specification,
possible short
1. Flammable vapor sensor out of
specification; verify Flammable Vapor
Sensor (FVS) resistance is not below
25,000 Ohms.
2. Possible short in flammable vapor
sensor or resettable thermal switch
w irin
g
See Flammable Vapor Sensor
Testing on page 24
Eight flashes,
tw o flashe s,
three second
pause
Temperature
sensor fault
detected
1. Damage to temperature sensor
wires
2. Temperature sensor resistance
out of range
3. Re
p
lace tem
p
erature sensor
See Temperature Sensor Testing
on page 21
Eight flashes,
three flashes,
three second
pause
Gas control
electronics fault
detected
1. Verify control is not w et or
physically damaged
2. Reset control on/off switch
3. Replace gas control if 8-3 error
p
ersists
See Gas Control Removal on
page 22
Eight flashes,
four flashes,
three second
pause
Gas control fault
detected
1. Verify control is not w et or
physically damaged
2. Reset control on/off switch
3. Replace gas control if 8-4 error
p
ersists
1. Replace gas control if wet or
physically damaged
2. C ycle po w er
3. Replace gas control
Troubleshooting

15
Page 15
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.
Step 2. Unplug the water heater from the wall outlet.
Step 3. Turn off the gas supply to the water heater.
Step 4. Remove the outer door.
Burner Maintenance
Gas control power
switch
Blower (water heater)
power cord
Outer door

16
Page 16
Burner Cleaning Procedure (cont’d)
Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.
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.
Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.
Step 8. Remove the burner assembly from the combustion
chamber.
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.
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.
Burner Maintenance
(4) 1/4” hex drive
screws Right side
inner door
Pilot and main feed-
lines
Spark igniter/flame
sensor wire
Gas control
Burner assembly
Burner surface area
and burner ports
1/2” wrench
Main burner
orifice
Main feedline

17
Page 17
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
Step 2. Unplug the water heater from the wall outlet.
Step 3. Turn off the gas supply to the water heater.
Step 4. Remove the outer door.
Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.
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 Maintenance
(4) 1/4” hex drive
screws Right side
inner door
Gas control power
switch
Blower (water heater)
power cord
Outer door
Pilot and main feed-
lines

18
Page 18
Pilot Inspection, Testing and Replacement (cont’d)
Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.
Step 8. Remove the burner assembly from the combustion
chamber.
Step 9. Remove the pilot assembly from the main feedline
using a 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.
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.
Pilot Maintenance
Burner assembly
Pilot assembly
1/4” nut driver
Multi-meter
Spark igniter/flame
sensor wire
Gas control

19
Page 19
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.
Step 2. Unplug the water heater from the wall outlet.
Blower Replacement
Gas control power
switch
Blower (water heater)
power cord

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Blower Removal & Installation (cont’d)
Step 3. Disconnect the vent system from the draft hood
that is mounted on top of the blower.
Step 4. Remove the draft hood from the blower and retain
it for use on the new blower.
Step 5. Unplug the cord sets from the blower.
Step 6. Remove the three blower mounting screws using a
1/4” nut driver and retain for later use.
Step 7. Remove the blower from the top of the water
heater.
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.
Blower Replacement
Vent system
Draft hood
Blower
Cord sets
1/4” nut driver
Blower
Top of water
heater
Water heater tank flue