Flammable Vapor Ignition Resistant Water Heaters 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.
The Bradford White DEFENDER Safety System® Flammable Vapor Ignition Resistant Water Heaters Table of Contents Page 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 ..
WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result in 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. – 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.
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.
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.
White Rodgers Mechanical Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Symptom Pilot will not light Probable Cause 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.
White Rodgers Mechanical Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Symptom Probable Cause 1. Insufficient combustion air supply. Pilot goes out periodically (after 2. Incorrect or clogged vent heating cycles, system/vent terminal, or once a day, once incorrect location. a week etc.) 3. Inconsistent gas supply or gas pressure. Not enough hot water 1. Combination thermostat/gas valve set too low for desired water temperature. 2.
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 None (LED not on or flashing) Indicates control is off. Main and pilot burner are off. Probable Cause Gas valve is functioning normally. Gas valve is not powered. Light pilot.
Honeywell V1 Gas Control Troubleshooting Chart V 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 Service Procedure Pilot assembly is not lit. Gas control is not powered. Light pilot. If the pilot will not stay lit replace pilot assembly.
Honeywell V1 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 Four flashes and three second pause Control Status Probable Cause Excessive tank temperature. System must be reset. 1. Temperature sensor out of calibration. 2. Faulty gas control.
Honeywell V2 Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters 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. LED Status Control Status Probable Cause None (LED not on Millivolt power is not or flashing) present. Light pilot. Gas valve is functioning normally. Gas valve is not powered. Light pilot.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection, and Replacement Inner Door Removal Procedure Step 1. Rotate knob of the combination thermostat/gas valve to the “OFF” position. Step 2. Remove the outer jacket burner access door. Step 3. 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.
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. Step 2. 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.
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. Step 5. 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.
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. Step 2.
SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement 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.
SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement OPEN CIRCUIT THERMOPILE TESTING (Honeywell & White Rodgers Electronic) Step 1. Turn knob to pilot position and depress. Step 2. Continue pressing knob and remove the red (+) wire from resettable thermal door switch. Step 3. Using a multimeter capable of measuring millivolts, connect the positive side of the multimeter to the terminal of the resettable thermal switch.
SERVICE PROCEDURE RG-III Pilot Assembly Inspection, Cleaning and Replacement PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING, AND REPLACEMENT Step 1. Turn off gas supply to water heater. Rotate the knob of gas control/gas valve to the “OFF” position. Step 2. Remove the outer jacket door. Step 3. Remove right side of inner door per Service Procedure RG-I, Steps 3a through 3c. Step 4. Disconnect thermocouple/thermopile, pilot tube, and feedline from gas control/gas valve.
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. Remove the outer jacket door. Step 2. Repeatedly depress the piezo igniter while viewing the pilot through the sight glass. If a spark is present, the circuit is O.K..
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.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers Mechanical) MAGNET ASSEMBLY TESTING (White Rodgers Mechanical Control) 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 the gas valve) down during this test. Step 2.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers Mechanical) COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT Step 1. Rotate the knob of the gas valve to the “OFF” position. Step 2. Turn off gas supply to the water heater. Step 3. Disconnect the gas supply line from the gas valve. Step 4. Turn off water supply and drain the water heater completely. Step 5. Remove the outer jacket burner access door.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers Mechanical) Step 7. Removal of gas valve: a) Disconnect the main burner feedline, pilot tube and thermocouple from the gas valve. Remove the burner from combustion chamber. NOTE: Feed line nut for natural gas control uses right hand threads; L.P. control uses left hand thread. b) Remove piezo bracket with piezo igniter (refer to Service Procedure RG-IV) from gas valve.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers Mechanical) Step 9. Reinstallation of inner door assembly (cont.): b) Clean any gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly. c) Position thermocouple, pilot tube and piezo wire against left side inner door flange gasket. DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (White Rodgers Electronic & Honeywell) 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 presumes a maximum line pressure of 14.0" W.C.) Step 1.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) NOTE: The following procedure applies to the Honeywell gas control ONLY. HONEYWELL COVER REMOVAL CAUTION Step 1. Rotate the knob of the gas control to the “OFF” position. Step 2. Turn off gas supply to the water heater. Step 3. Disconnect the gas supply line from the gas control. Use caution to not bend or damage valve body pins when removing or installing the gas control cover. Step 4.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) HONEYWELL COVER REMOVAL (cont.) Step 7. Disconnect the temperature sensor from the control board and remove the wire from the temperature sensor wire routing clip. Temperature sensor wire routing clip Disconnect temperature sensor Step 8. Remove the piezo igniter from the control cover by releasing the lock tab on the control cover.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL CAUTION Step 1. Disconnect the burner and pilot tubes per Service Procedure RG-II. Step 2. Remove the valve body by removing the screw located at the lower left corner. Unclip the lower right side from the backplate first, followed by the lower left side, using a flat-head screwdriver. Use caution to not bend or damage valve body pins.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) HONEYWELL VALVE BODY REMOVAL AND TEMPERATURE SENSOR REMOVAL (cont.) Step 4. Remove the temperature sensor from the insertion stick by pulling apart as illustrated below. Pull in this direction Temperature sensor Insertion stick Pull in this direction Step 5. To reassemble the gas control, follow the previous steps in reverse order.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) TEMPERATURE SENSOR TESTING (Honeywell) Step 1. If control has gone into lockout due to excessive tank temperature (four flashes, three second pause), reset control by rotating gas control knob to “OFF” position and wait a minimum of five (5) minutes. Then follow lighting instructions and return the gas control knob to a desired setpoint. Step 2. Observe green light indicator.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (Honeywell ONLY) WARNING Stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. DETERMINE WATER TEMPERATURE INSIDE TANK NOTE: It is important to understand once the resistance for the temperature sensor is determined from the previous page, water flow through the water heater should not occur.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & R eplacement (White Rodgers Electronic & Honeywell) ______________________________________________________________________________________________________________________________________ GAS CONTROL REPLACEMENT Step 1. Rotate knob of the gas control to the “OFF” position. Step 2. Turn off gas supply to the water heater. Step 3. Disconnect the gas supply line from gas control. Step 4.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & Replacement (White Rodgers Electronic & Honeywell) GAS CONTROL REPLACEMENT (cont.) Step 8. Install new gas control into water heater (cont.): b) Reattach the main burner feedline, pilot tube, piezo igniter wire, inner door wire (red), and thermopile wire (white) to the gas control. Attach the inner door wire (red) to the positive (+) terminal and the thermopile wire (white) to the negative (-) terminal.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly, & Replacement (White Rodgers Electronic & Honeywell) GAS CONTROL REPLACEMENT (cont.) Step 9. Reinstallation of inner door assembly (cont.): d) 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 6c. DO NOT OVER TIGHTEN SCREWS.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment, Cleaning, and Replacement MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement At periodic intervals (not more than 6 months) a visual inspection should be made of the main burner for proper operation and to ensure no debris accumulation. Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment, Cleaning, and Replacement BURNER CLEANING Step 4. Disconnect the burner plate from main burner orifice and disconnect feedline from burner. Step 5. Remove main burner orifice from feed line. Inspect and clean if necessary. Step 6. Remove pilot assembly, refer to Service Procedure RG-III for cleaning and inspection. Step 7. Using a stiff brush and compressed air, clean the burner plate and feedline, then reassemble all components. Step 8.
SERVICE PROCEDURE RG-VIII Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH CONTINUITY TESTING Step 1. Remove the outer jacket door. Step 2. Disconnect the wire leads from the resettable thermal switch. Step 3. Using a multimeter capable of measuring continuity (ohms), place one probe of meter on one of the brass connection tabs of the resettable thermal switch, and the remaining probe on the other connection tab. Step 4.
SERVICE PROCEDURE RG-VIII Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH REPLACEMENT Step 1. Rotate the knob of combination thermostat/gas valve to the “OFF” position. Step 2. Remove the outer jacket door. Step 3. Disconnect the wire leads from the resettable thermal switch. Step 4. Remove the resettable thermal switch from the inner door (Phillips screwdriver). Step 5. Put new resettable thermal switch in place.
SERVICE PROCEDURE RG-IX ScreenLok® Flame Arrestor Cleaning ScreenLok® Flame Arrestor Cleaning Step 1. Rotate knob of combination thermostat gas valve to the off position. Step 2. Remove the outer jacket door. Step 3. Remove inner door per Service Procedure RG-I, Steps 3a through 3e. Step 4. Disconnect the main burner feed line, pilot tube, and thermocouple/thermopile from combination thermostat gas valve and remove burner assembly from the combustion chamber.
SERVICE PROCEDURE RG-X Diptube and Anode Inspection and Replacement DIPTUBE INSPECTION AND REPLACEMENT WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Rotate the knob of combination thermostat/gas valve to “OFF” position. Step 2. Turn off cold water supply to the water heater. Connect a hose to the drain spigot of the water heater and route to an open drain.
SERVICE PROCEDURE RG-X Diptube and Anode Inspection and Replacement ANODE INSPECTION AND REPLACEMENT WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Turn off water supply to water heater. Rotate knob of combination thermostat/gas valve to “OFF” position. Step 2. Turn off cold water supply to the water heater.
Parts Diagram 1 2 3 4 5 6A 6B 6C 6D 7 8 9 10 11 12 13 14 15 16 Draft Hood Hot Water Outlet/Anode Cold Water Inlet Tube Flue Baffle T&P Relief Valve Gas Control (Honeywell V1) Gas Control (Honeywell V2) Gas Control (White Rodgers Mechanical) Gas Control (White Rodgers Electronic) Piezo Igniter (White Rodgers Mechanical) Brass Drain Valve Screw-#8-18 x 3/4 Hex Washer Head Screw-#10-12 x 3/4 Hex Washer Head Left Side Inner Door with Gasket Complete Right Side Inner Door Resettable Thermal Switch Screw-#6-20
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