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: LG250H65*(N,X) RG230S*(N,X) RG230T*(N,X) RG240S*(N,X) RG240T*(N,X) RG250H*(N,X) RG250L*(N,X) RG250S*(N,X) RG250T*(N,X) (*) Denotes Warranty Years Manual 238-51542-00A REV 4/15 Save this manual for future reference
The Bradford White ® Page Service Procedure Introduction 3 --- Troubleshooting Chart 4 --- Inner Door Gasket Removal, Inspection, and Replacement 7 RG-I Thermocouple/Thermopile Testing and Replacement 10 RG-II Pilot Assembly Inspection Cleaning and Replacement 13 RG-III Piezo Igniter, Electrode Testing and Replacement 14 RG-IV White Rodgers Gas Valve Testing and Replacement 15 RG-V Honeywell Gas Control Testing, Disassembly, and Replacement 20 RG-VI Burner Operation Inspection, Adju
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.
White Rodgers Gas Valve Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters SYMPTOM Pilot will not light Pilot will not stay lit when button is released Pilot will light but the main burner will not come on PROBABLE CAUSE 1. No incoming gas or too low gas pressure. 2. Gas control knob set to wrong position. 3. Pilot light button 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.
Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Observe green LED indicator on Gas Control. Error 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 Green LED Indicator Control Status Probable Cause Service Procedure None (LED not on or flashing. Gas control is operating normally. Pilot flame may not be present.
Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Observe green LED indicator on Gas Control. Error 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 Green LED Indicator Control Status Five flashes and three Thermostat/well sensor fault. second pause Probable Cause 1. Damage to the temperature sensor. 2. Temperature sensor resistance out of range. 1.
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 outer jacket burner access door. Step 3. Inner Door Removal. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. a) Disconnect resettable thermal switch wire leads (leading from gas control/gas valve). b) Remove (2) hex drive screws from right side inner door.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection, and Replacement Installation of Inner Door With Gasket Step 7. Step 8. Step 9. 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.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation Step 10. Firmly place right side inner door flange against the left side inner door flange and secure with (2) hex drive screws from step 3c. DO NOT OVER TIGHTEN SCREWS. Step 11. Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted opening. Verify seal integrity around combustion opening.
SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Control) Step 1. Closed circuit testing is the preferred method for testing 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 Gas Valve) Step 1. Disconnect thermocouple from 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 Gas Control) The following test should be performed while the pilot flame is on. Step 1. Turn knob to pilot position and depress. Step 2. Continue pressing knob and remove 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 door 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 knob of gas control/gas valve to “OFF” position. Step 2. Remove 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 thru the sight glass located on the inner door and observing the spark action. Step 1. Remove outer jacket door. Step 2. Repeatedly depress the piezo igniter while viewing the pilot thru the sight glass. If a spark is present, the circuit is OK.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) Gas Valve Testing and Replacement (White Rodgers) The gas valve is a non repairable device. If trouble shooting 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 OK, the gas valve may be faulty.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers) THERMOCOUPLE TESTING See SERVICE PROCEDURE RG-II MAGNET ASSEMBLY TESTING (White Rodgers 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) COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT Step 1. Rotate knob of the gas valve to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from gas valve. Step 4. Turn off water supply and drain water heater completely. Step 5. Remove outer jacket burner access door. Step 6. Right side inner door removal.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers) Step 7. Removal of gas valve. a) Disconnect main burner feedline, pilot tube and thermocouple from gas valve & remove burner from combustion chamber. NOTE: Feed line nut for natural gas control uses right hand threads, LP 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) 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 & Replacement (Honeywell) Honeywell Gas Control Testing, Disassembly, and Replacement The gas control is made up of (5) major components; the control cover, the piezo igniter, the valve body, the temperature sensor, and the back plate. The gas control is designed so that any of these components may be replaced without replacing the entire gas control.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) MANIFOLD PRESSURE TESTING (this procedure presumes a maximum line pressure of 14.0" w.c.) Step 1. Set the gas control to the “OFF” position. Step 2. Remove pressure tap plug and install 1/8" NPT pipe, coupling, & pressure tap. Step 3. Connect manometer to pressure tap. Step 4. Follow instructions located on the lighting instructions label and proceed to light the main burner and observe manometer reading. Step 5.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) TEMPERATURE SENSOR TESTING CAUTION DO NOT use standard multimeter probes for this test. Doing so will damage connector. Use special pin type electronic probes or small diameter wire pins inserted into connector. If control has gone into lockout due to excessive tank temperature (four flash, three second pause) reset control by rotating gas control knob to “OFF” position and wait a minimum of (5) minutes.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) 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 & Replacement (Honeywell) GAS CONTROL DISASSEMBLY/REASSEMBLY Step 1.Rotate knob of the gas control to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from gas control. Rotate knob counter-clockwise to the “OFF” posistion. Step 4. Disconnect piezo igniter wire. Step 5. Remove inner door assembly following SERVICE PROCEDURE RG-I, steps 1 through 3c. Step 6. Remove gas control cover screw.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) GAS CONTROL DISASSEMBLY/REASSEMBLY Step 8. Disconnect temperature sensor from control board and remove wire from the temperature sensor wire routing clip. Temperature sensor wire routing clip Disconnect temperature sensor Step 9. 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 & Replacement (Honeywell) GAS CONTROL DISASSEMBLY/REASSEMBLY Step 10. Remove the valve body by removing screw located at the lower left corner then unclipping the lower right side from the backplate first, followed by the lower left side using a flat head screwdriver. CAUTION Use caution not to bend or damage valve body pins. Unclip lower right side first Unclip lower left side second Valve body screw Step 11.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) GAS CONTROL DISASSEMBLY/REASSEMBLY Step 12. Remove temperature sensor from insertion stick by pulling apart as illustrated below. Pull in this direction Temperature sensor Insertion stick Pull in this direction Step 13. To reassemble gas control, follow the previous steps in reverse order.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) GAS CONTROL REPLACEMENT Rotate knob counter-clockwise to the “OFF” position. Step 1.Rotate knob of the gas control to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from gas control. Step 4. Turn off water supply and drain water heater completely. Step 5. Remove outer jacket burner access door. Step 6. Right side inner door removal.
SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) GAS CONTROL REPLACEMENT Step 8. Install new gas control into water heater (contintued). b) Reattach main burner feedline, pilot tube, piezo igniter wire, inner door wire (red) and thermopil wire (white) to gas control. Attach 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 (Honeywell) GAS CONTROL REPLACEMENT Step 9. Reinstallation of inner door assembly (continued). d) Firmly place right side inner door flange against the left side inner door flange and secure with (2) hex drive screws from step 6c. DO NOT OVER TIGHTEN SCREWS. e) Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted openings.
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 insure no debris accumulating. Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips. Steel burner models have a self adjusting air mixture and do not have an adjustable air shutter.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment Cleaning and Replacement MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement (cont.) Step 3. Fully inspect inner gasket per SERVICE PROCEDURE RG-I, step 4. Replace gasket if required following SERVICE PROCEDURE I, steps 5 & 6. Step 4. Be certain that thermocouple, pilot tube and piezo wire are routed by inner door flange as shown and reinstall inner door per SERVICE PROCEDURE RG-I, step 10 and 11.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment Cleaning and Replacement BURNER CLEANING (Cont.) Step 4. Disconnect (unscrew) main burner from main burner orifice & disconnect (unscrew) 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. Reassemble burner. Step 8.
SERVICE PROCEDURE RG-VIII Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH CONTINUITY TESTING Step 1. Remove outer jacket door. Step 2. Disconnect wire leads from 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 knob of combination thermostat gas valve to the off position. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. For Robertshaw Control, rotate knob clockwise to the “OFF” position. Step 2. Remove outer jacket door. Step 3.
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. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. Step 2. Remove outer jacket door. Step 3. Remove inner door per SERVICE PROCEDURE RG-I, step 3a through 3e. Step 4.
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 knob of combination thermostat/gas valve to “OFF” position For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position.
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. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position.
Generic Parts List 16 1 34 32 33 2 17 3 4 18 19 21 20 5 28 6A 6B 30 7 23 8 24 25 11 1 2 3 4 5 6A 6B 7 8 9 10 11 12 14 15 16 17 27 26 Draft Hood Hot Water Outlet/Anode Cold Water Inlet Tube Flue Baffle T&P Relief Valve Gas Control (Honeywell) Gas Valve (White Rodgers) Piezo Igniter (White Rodgers/Robertshaw) 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 Outer
