Flammable Vapor Ignition
Resistant Water Heaters
Gas Water Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
FEATURING
For the Bradford White
Defender Safety System®
Models:
MI30T*F(BN,CX,SX)
MI30S*F(BN, CX,SX)
MI303T*F(BN,CX,SX)
MI40T*F(BN,CX,SX)
MI403S*F(BN,CX,SX)
MI404T*F(BN,CX,SX)
MI503*F(BN,CX,SX)
MI50L*F(BN,CX,SX)
MI504S*F(BN,CX,SX)
MI60T*F(BN,CX,SX)
M430T*F(BN,CX,SX)
M440T*F(BN, CX,SX)
M4403S*F(BN,CX,SX)
M4503*F(BN,CX,SX)
M460T*F(BN,CX,SX)
M1XR403S*F(BN,CX,SX)
M1XR504T*F(BN,CX,SX)
M2XR504T*F(BN,CX,SX)
M2XR65T*F(BN,CX,SX)
M2C504T*F(BN,CX,SX)
C(S,D)W2504T*F(BN,CX,SX) 50T65F(B*N,C*X,S*X)
65T65F(B*N,C*X,S*X)
(*) Denotes Warranty Years
Manual 238-44943-00D
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INTRODUCTION
The Bradford White DEFENDER Safety System®
The Bradford White DEFENDER Safety System® was designed to resist
the ignition of flammable vapors that can occur outside of the water
heater. Use and installation are nearly identical to previous versions of
atmospherically fired and vented water heaters. A number of exclusive
design features are incorporated in the system that will require additional
knowledge on the part of the qualified service provider. The following
information will instruct service professionals on the function, proper
diagnosis and repair of water heaters employing the Bradford White
DEFENDER Safety System.
How the Safety System Works
During normal operation, air for combustion is drawn into the water
heater through the opening in the jacket. This air travels down and around
the combustion chamber and enters through holes in the very bottom of
the corrosion-resistant combustion chamber. The air then travels up
through the oriented flame arrestor plate louvers, where the velocity of the
air is increased and its direction altered. The air then mixes in a normal
manner with the supplied gas and is efficiently combusted, producing very
low NOx emissions.
In the case where trace amounts of flammable vapors are present in the air
flowing into the combustion chamber, the vapors are harmlessly ignited
by the burner / pilot flame. If flammable vapors are in sufficient quantity
to prevent normal combustion, the burner/pilot flame is shut down.
Should the flammable vapors continue to the burner, the flame arrestor
plate prevents the flames from traveling backwards and igniting vapors
outside of the combustion chamber. The calibrated, multipurpose thermal
switch recognizes this and shuts down the pilot and main burner. This
switch also deactivates the burner and pilot in the unlikely event of
restricted airflow caused by severe lint, dust or oil accumulation on the
arrestor plate.
3
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White Rodgers/Robertshaw Gas Valve Troubleshooting Chart
Flammable Vapor Ignition Resistant Water Heaters
SERVICE
PROCEDURE
SYMPTOM
PROBABLE CAUSE
CORRECTIVE ACTION
1. Turn on gas supply and/or check line
pressure.
2. Review lighting instruction. Set
combination/thermostat
gas valve to correct position.
3. Review lighting instruction. Fully depress
pilot lighting button.
1. See Service Procedure
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.
RG-V, Page 12.
4. See Service Procedure
RG-III, Page 10.
Pilot Will Not Light
5. See Service Procedure
RG-III, Page 10.
4. Clean, repair or replace.
5. Verify correct electrode position. Replace
pilot assembly.
5. Pilot electrode not sparking to pilot.
6. Piezo igniter not functioning.
6. See Service Procedure
RG-IV, Page 11.
6. Replace Piezo igniter.
1. Check connection at combination
thermostat/gas valve. Proper tightness
should be finger tight plus ¼ turn.
2. Inspect thermocouple to ensure that it is
fully engaged into pilot bracket.
3. Adjust tip of thermocouple to be fully
engulfed by pilot flame.
4. Check thermocouple and replace if
necessary.
5. Check ECO continuity and replace
combination thermostat/gas valve if
necessary.
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 “hot” junction.
4. Weak or defective thermocouple.
5. Open ECO on combination thermostat/
gas valve.
4. See Service Procedure
RG-II, Page 8
Pilot Will Not
stay lit
when button is
released
5. See Service Procedure
RG-V, Page 14
6. See Service Procedure
RG-V, Page 13
6. Defective magnet in combination
thermostat/gas valve.
7 Resettable thermal switch has opened.
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. Combination thermostat/gas valve set too 1. Adjust temperature dial on combination
2. See Installation &
operation manual.
low for desired water temperature.
2. Combination thermostat/gas valve
temperature is satisfied.
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.
Pilot will light but
the main burner
will not come on
3. See Service Procedure
RG-V, Page 12
3. Insufficient gas supply or low gas
pressure.
4. Combination thermostat/gas valve has
wide differential or is out of calibration.
4. See Service Procedure
RG-V, Page 12
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/or vacuum to remove any debris
accumulation.
2. Check venting for proper sizing and proper
operation
3. Check gas supply and line pressure.
Pilot goes out
periodically (after
heating cycles,
once a day, once
a week etc.)
1. Insufficient combustion air supply.
1. See Service Procedure
RG-VIII, Page 22
2. Incorrect, clogged vent system/ vent
terminal or location.
3. See Service Procedure
RG-V, Page 12
3. Inconsistent gas supply or gas pressure.
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.
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.
5. See Service Procedure
RG-V, Page 12
Not enough hot
water
3. Adjust high demand usage.
4. Contact Plumbing professional.
5. Check combination thermostat/gas valve
for proper operation, replace if
necessary.
6. See Service Procedure
RG-IX, Page 23
6. Inspect dip tube and replace if necessary.
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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
Green LED Indicator
troubleshooting table below.
Service
Procedure
LED Status
Control Status
Probable Cause
1. Gas Control is functioning
normally.
If the pilot will not stay
lit replace pilot
Gas Control is operating normally.
Pilot flame may not be present.
Check for pilot flame through sight
glass and light if necessary.
None (LED not on
or flashing
2. Gas Control is not powered. Light assembly. If problem
pilot.
persists replace Gas
Control.
3. Thermopile failure.
If set point knob is in “PILOT”
position then pilot flame is
detected. Turn set point knob to
desired setting.
Normal operation.
Adjust thermostat to
desired temperature
setting.
One flash and
three second
pause
Gas Control is powered and waiting
for the set point knob to be turned to
a water temperature setting.
Set point knob has been recently
turned to the “OFF” position. Wait
until LED goes out before
attempting to relight
LED will go out and the
LED on
continuously
(Solid)
Set point knob was turned to “OFF” control will function
position.
normally when the pilot
is lit.
1. See service
procedure RG-II
2. See service
procedure RG-III
3. See service
procedure RG-III
4. See service
procedure RG-VIII
1. Thermopile failure
Two flashes and
three second
pause
Weak pilot signal detected. System 2. Unstable pilot
will reset when pilot flame is
sufficient.
3. Pilot tube block or restricted.
4. Resettable thermal switch has
opened
Three flashes and
three second
pause
Insufficient water heating. System
will reset.
1. Temperature sensor out of
calibration
1. See service
procedure RG-VI
1. See service
procedure RG-VI
2. See service
procedure RG-VI
Four flashes and
three second
pause
1. Temperature sensor out of
calibration
2. Faulty Gas Control
Excessive tank temperature.
System must be reset.
5
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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
Green LED Indicator
troubleshooting table below.
Service
Procedure
LED Status
Control Status
Probable Cause
1. Damage to the temperature
sensor.
2. Temperature sensor resistance
out of range.
Five flashes and
three second
pause
1. See service
procedure RG-VI
Thermostat/well sensor fault.
1. Check T&P valve
2. Check all water
fittings.
3. Pressurize and leak
test tank.
Six flashes and
three second
pause
Water leak detected by accessory
module.
Excessive amount of water in drain
pan/water dam.
Seven flashes and
three second
pause
1. Control need to be reset.
2. Control is wet or physically
damaged.
1. Reset Gas Control
2. Replace Gas
Control.
Gas Control electronic fault
detected.
Eight flashes and
three second
pause
Standing pilot remains on while set
point knob is in “OFF” position.
Pilot valve stuck in open position.
Replace Gas Control.
6
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SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal, Inspection
Replacement and Reinstallation
For Honeywell Control, rotate
knob counter-clockwise to the
“OFF” position.
Inner Door Removal Procedure
Step 1.
Rotate knob of the combination
thermostat/gas valve to the “OFF” position.
Step 2.
Step 3.
Remove outer jacket burner access door
Inner Door Removal.
For White Rodgers Control,
For Robertshaw Control,
depress knob slightly and rotate
rotate knob clockwise to
clockwise to the “OFF” position.
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.
c) Remove (2) hex drive screws from flange section of inner door.
d) Remove (2) hex drive screws from left side inner door.
e) Remove inner door and inspect per step 4.
Resettable Thermal Switch
Wire Connection
Hex Drive Screws
Right and Left Side Inner Door.
Hex Drive Screws at
Flange Area of Inner Door
Step 4. Fully inspect inner door gaskets for the following:
>Tears
>Other imperfections that will inhibit proper seal
>Missing Material
>Cracks
>Gasket adhesion to inner door
>Material left on combustion chamber (around opening)
>Dirt or debris
If the gasket is not effected 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.
WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
Step 5.
Step 6.
After inspection of inner door as noted in step 4, completely remove gasket and adhesive residue from right
and left side inner doors as needed.
Use RTV sealant (recommended bead size 1/8") to secure the inner door gasket to the inner door sections
(right & left). Refer to illustration on 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 over lap position.
7
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SERVICE PROCEDURE RG-I
Inner Door/Gasket Removal, Inspection
Replacement and Reinstallation
GASKET
OVERLAP MUST
RECOMMENDED PATTERN
FOR RTV SEALANT
BE AS SHOWN
1/32"
ENLARGED
VIEW OF
FLANGE AREA
PLACE FLANGE
SECTIONS FIRST
VIEW WITH GASKETS
IN PLACE
EXPANDED VIEW
Installation of Inner Door With Gasket.
WARNING
Step 7.
Step 8.
Clean any residual gasket residue or other debris
from combustion chamber surface before
installing the inner door/gasket assembly.
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 8, 10 and 11.
Place the left side inner door into position first.
Firmly position the radiused channel of the inner
door aroundthe feedline. Using the (2) hex drive
screws from step 3d, secure left side inner door in
place. DO NOT OVER TIGHTEN SCREWS.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
Step 9
Position thermocouple, pilot tube and Piezo wire
against left side inner door flange gasket.
DO NOT ROUTE THROUGH RADIUSED
CHANNEL WITH FEEDLINE.
Position thermocouple/thermopile,
pilot tube and piezo wire.
Radiused Channel for
Feedline
8
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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. Secure right side inner door using (2) hex drive screws from step 3b. DO NOT OVER TIGHTEN
SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against
the combustion chamber.
Secure flange with
hex drive screws.
Verify threaded hole
alignment with slotted
openings in inner door.
Step 12. Reconnect lead wires from combination thermostat/gas valve to resettable thermal switch (See photo in step
3). Note, wire terminations are interchangeable with either resettable thermal switch connections.
Step 13. Replace outer jacket burner access door.
Step 14. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
9
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SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Control)
Step 1.
Step 2.
Step 3.
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 minuets. If the pilot will not stay
lit, hold the pilot button (located on the combination thermostat/gas valve) down during this test
Using a multimeter capable of measuring millivolts, connect one lead
using an alligator clip to the copper sheath of the thermocouple, use the second lead of the multi meter to
probe the top terminal located at the back of the combination thermostat/gas valve.
If meter reads 10 millivolts or higher, the thermocouple is OK. If reading is below 10 millivolts,
replace the thermocouple.
Probe top terminal on
back of combination
thermostat/gas valve
Alligator clip to copper
sheath of thermocouple
CLOSED CIRCUIT THERMOCOUPLE TESTING (Robertshaw Control)
Step 1.
Step 2.
Disconnect thermocouple from combination thermostat/gas valve.
Connect a thermocouple adaptor
(BWC P/N 239-44642-00, Robertshaw P/N 75036) at the
thermocouple location in the combination thermostat/gas valve.
Step 3.
Step 4
Reconnect thermocouple to adaptor. Make certain all
connections are tight (finger tight plus ¼ turn)
Using a multimeter capable of measuring millivolts, connect
one alligator clip to the set screw of the adaptor, and the other
alligator clip to copper portion of the thermocouple.
Step 5.
Step 6.
Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for
three minuets. If the pilot will not stay lit, hold the red reset button (located on the combination
thermostat/gas valve) down during this test
If meter reads 13 millivolts or higher, the thermocouple is OK. If reading is below 13 millivolts
replace the thermocouple.
10
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SERVICE PROCEDURE RG-II
Thermocouple/Thermopile Testing and
Replacement
OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers/Robertshaw 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.
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.
THERMOCOUPLE REPLACEMENT (White Rodgers/Robertshaw Gas Valve)
Step 1.
Turn off gas supply to water heater. Rotate knob of combination
thermostat/gas valve to “OFF” position.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position.
Step 2.
Step 3.
Step 4
Remove outer jacket door.
Remove right side of inner door per SERVICE PROCEDURE RG-I, steps 3a through 3c.
Disconnect thermocouple from combination thermostat/gas valve. Locate other end of
thermocouple inside of combustion chamber and remove from pilot bracket. Pull firmly pulling away
from the pilot assembly.
Step 5.
Install new thermocouple into pilot bracket making certain the thermocouple is fully engaged into the pilot
bracket. Position thermocouple against left side inner door flange at its original position. Connect other end of
thermocouple to combination thermostat/gas valve (finger tight + ¼ turn).
Step 6.
Step 7.
Inspect inner door gasket per
SERVICE PROCEDURE RG-I, Step 4.
Thermocouple position
Install right side inner door per
SERVICE PROCEDURE RG-I,
Step 10 through Step 13
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.
11
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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.
Step 2.
Step 3.
Turn knob to pilot position and depress.
Continue pressing knob and remove red (+) wire from resettable thermal door switch.
Using a multimeter capable of measuring millivolts, connect the positive side of the multimeter to the
terminal of the resettable thermal door switch. Connect the negative side of the multimeter to any earth
ground location (jacket base, screw, etc.).
Resettable Thermal Door
Switch Terminal (+)
Jacket Base Screw (-)
Normal thermopile operation will be between 350mV - 850mV. If reading is less than 350mV, replacement of pilot
assembly is recommended following SERVICE PROCEDURE RG-III.
Step 4.
Step 5.
If thermopile reading is between 350mV - 850mV, remove multimeter and reconnect red wire to positive (+)
terminal of Gas Control.
Release Gas Control knob and turn to desired setting to resume normal operation.
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SERVICE PROCEDURE RG-III
Pilot Assembly Inspection, Cleaning
and Replacement
For Honeywell Control, rotate
knob counter-clockwise to the
“OFF” position.
PILOT/ELECTRODE ASSEMBLY INSPECTION,
CLEANING AND REPLACEMENT
Step 1.
Turn off gas supply to water heater. Rotate knob
of gas control/gas valve
For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position.
to “OFF” position.
Step 2.
Step 3.
Remove outer jacket door.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
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.
NOTE: Feedline nut for natural gas control
uses right hand threads, LP control uses left hand thread.
Disconnect piezo ignition wire from piezo igniter.
Remove burner assembly from combustion chamber.
Remove pilot/electrode assembly from feedline
Inspect pilot for the following:
Step 5
Step 6.
Step 7.
Step 8.
Feedline Nut
a) Primary air openings for blockage. Must be free from any
debris (dirt, lint, etc).
Primary Air
Opening
b) Kinks or cracks in the pilot tube. If found,
the pilot must be replaced.
Step 9.
Inspect pilot orifice:
a) Remove ½" nut from bottom of pilot assembly.
b) Remove pilot tube and pilot orifice.
Pilot Orifice
c) Inspect pilot orifice for blockage, must be cleaned or replaced.
(Honeywell pilot orifice not replaceable, replace pilot assembly)
Removal of thermopile from
Honeywell pilot assembly is not
recommended, but can be
Step 10. Install pilot/electrode assembly to feedline, secure with screw from step 7.
achieved by viewing the pilot
assembly from the top and
Step 11. Re-Install burner assembly into combustion chamber, connect feedline,
pilot tube and thermocouple/thermopile to gas conrol/gas valve.
pressing the thermopile towards
the right while pulling to remove.
Step 12. Install inner door per SERVICE PROCEDURE RG-I, step 4 through 13.
Step 13. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
13
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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.
Step 2.
Remove outer jacket door.
Repeatedly depress the Piezo igniter while viewing the pilot thru the sight glass. If a spark is
present, the circuit is OK. If there is no spark, proceed to step 3.
View spark
Action through
Sight glass
Repeatedly
Depress Piezo
Igniter
Step 3
Remove orange (or white) wire from Piezo igniter and install a jumper wire in its place. Hold the
other end of the jumper by the wire insulation or using an insulated tool, next to an unpainted
surface such as the feedline or gas valve and depress the Piezo igniter. If there is a spark, the igniter
is OK, the pilot is not functioning and must be replaced, see SERVICE PROCEDURE RG-III for
pilot replacement. If no spark is present the igniter is not functioning and must be replaced.
Step 4a. For White Rodgers/Robertshaw gas valves: With orange wire disconnected from piezo igniter.
Using a common screw driver, place blade of screw driver under piezo bracket and gently pry
bracket from front of gas valve and unhook bracket from rear of gas valve.
Common Screw
Driver
Step 4b. For Honeywell gas controls: To replace igniter, see “Gas Control Disassembly/Reassembly” in
SERVICE PROCEDURE RG-VI.
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SERVICE PROCEDURE RG-V
Gas Valve
Testing and Replacement (White Rodgers/Robertshaw)
Gas Valve Testing and Replacement (White Rodgers/Robertshaw)
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.
LINE PRESSURE
The gas valve is designed for a maximum line pressure of 14.0" w.c. and a minimum line pressure of 1.0"w.c. over the
water heater rated manifold pressure (check rating plate). Line pressure must be checked with burner on and burner off to
assure proper readings.
MANIFOLD PRESSURE TESTING (this procedure assumes a maximum line pressure of 14.0" w.c.)
Step 1.
Set gas valve to “OFF” position.
Step 2.
Remove pressure tap plug and install pressure tap.
Step 3.
Step 4
Connect manometer to pressure tap.
Pressure Tap
Shown Installed
Follow lighting instructions and proceed to light
main burner and observe manometer reading.
Step 5
Step 6
Proper operating range for natural gas is 4.0 0.3" W.C.
Proper operating range for L.P. gas is 10.0 0.5" W.C.
If pressure is OK, set gas valve to “OFF”
remove manometer and pressure tap and replace pressure tap plug. Check for gas leaks before placing water
heater back in operation. If pressure is out of the specification noted in step 5, proceed to step 7 or 8 for proper
service procedure.
Step 7
For White Rodgers control, the manifold pressure is not adjustable. If manifold pressure is outside the range
in step 5, the control must be replaced.
Step 8
Step 9
For Robertshaw control, the manifold pressure is adjustable, proceed to step 9 for adjustment procedure
While burner is in operation, remove regulator access cap to expose the regulator adjusting screw. With small
screw driver, rotate adjusting screw clockwise to increase pressure and counter clockwise to decrease pressure.
Step 10 Replace regulator access cap, set gas valve to “OFF”. Remove manometer and
pressure tap and replace pressure tap plug. Check for gas leaks before placing water heater back in operation.
15
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SERVICE PROCEDURE RG-V
Gas Valve
Testing and Replacement (White Rodgers/Robertshaw)
THERMOCOUPLE TESTING
See SERVICE PROCEDURE RG-II
MAGNET ASSEMBLY TESTING (White Rodgers Control)
Step 1.
Step 2.
Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for
three minuets. If the pilot will not stay lit, hold the pilot button (located on the gas valve) down during this test.
Using a multimeter capable of measuring millivolts, connect one lead
using an alligator clip to the copper sheath of the thermocouple, use the second lead of the multi meter to
probe the top terminal located at the back of the gas valve.
Probe top terminal on
back of combination
thermostat/gas valve
Alligator clip to copper
sheath of thermocouple
Step 6.
Step 7.
With a meter reading of 13 millivolts or greater, rotate knob of combination thermostat/gas valve to the
“OFF” position.
The magnet should remain closed for a drop of at least 6 millivolts. You will here 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.
MAGNET ASSEMBLY TESTING (Robertshaw Control)
Step 1.
Step 2.
Disconnect thermocouple from gas valve.
Connect a thermocouple adaptor
(BWC P/N 239-44642-00, Robertshaw P/N 75036) at the
thermocouple location in the gas valve.
Step 3.
Step 4
Reconnect thermocouple to adaptor. Make certain all connections
are tight (finger tight plus ¼ turn).
Using a multimeter capable of measuring millivolts, connect one
alligator clip to the set screw of the adaptor and the other alligator
clip to copper portion of the thermocouple.
Step 5.
Step 6.
Step 7.
Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for
three minuets.
With a meter reading of 13 millivolts or greater, rotate knob of gas valve to the
“OFF” position.
The magnet should remain closed for a drop of at least 6 millivolts. You will here 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.
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SERVICE PROCEDURE RG-V
Gas Valve
Testing and Replacement (White Rodgers/Robertshaw)
ECO (Energy Cut Off) TESTING
Step 1.
Disconnect thermocouple from gas valve.
Step 2.
Using a multimeter capable of measuring Ohms (or continuity),
attach one lead (alligator clip) to the pilot tube. Insert the other lead
(probe) fully into the magnet opening, Be sure the probe makes
contact only at the top center of the magnet opening. Do not allow
the probe to make contact with the threaded sides of the opening.
Step 3.
If continuity is indicated, the ECO is OK. If continuity is not indicated, the ECO has opened and the
gas valve must be replaced.
COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT
For White Rodgers Control,
depress knob slightly and rotate
clockwise to the “OFF” position.
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.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
Step 6. Right side inner door removal.
a) Disconnect resettable thermal switch wire leads (leading from gas valve)
and remove wire tie from feedline.
b) Remove (2) hex drive screws from right side inner door.
c) Remove (2) hex drive screws from flange section of inner door.
d) Remove right side inner door and set aside. Be careful not to damage gasket material on inner door.
Resettable Thermal Switch
Wire Connection
Remove
Wire Tie
Hex Drive Screws shown on
Right Side Inner Door.
Hex Drive Screws at
Flange section of Inner Door
17
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SERVICE PROCEDURE RG-V
Gas Valve
Testing and Replacement (White Rodgers/Robertshaw)
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.
c) Remove gas valve from water heater,
Wrench Boss
rotating counter clockwise using a control body wrench or a
length of ½" NPT pipe threaded into inlet of control.
To remove or install control, insert
only ½" NPT threaded pipe into inlet
and use to loosen or tighten control.
Step 8. Installation of gas valve.
a) Install new gas valve using a control body wrench or a length of ½" NPT
pipe threaded into inlet of control. DO NOT OVER TIGHTEN. Use caution not to damage cast
aluminum body of gas valve. Be certain not to damage the bundled wire leads.
Note: Gas valve must be installed in proper upright position to
assure the feedline will align properly at the inner door flange.
DO NOT OVER TIGHTEN. If control is turned past proper alignment, do not
reverse direction to align.
b) Reattach Piezo bracket with Piezo igniter to gas valve.
c) Reattach main burner feedline, pilot tube and thermocouple to gas valve.
NOTE: Feedline nut for natural gas control uses right hand threads,
LP control uses left hand thread.
d) Gather wire leads of gas valve and Piezo igniter and secure along side of
feedline using new wire tie provided.
e) Connect gas supply piping to inlet of control. Use back up wrench on wrench boss of control, never
use back up wrench on body of control.
Step 9. Reinstallation of inner door assembly.
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
> Tears
> Gasket Adhesion to inner door
> Missing Material > Other imperfections that will inhibit proper seal
> Cracks
> Dirt or debris
> Material left on combustion chamber
If the gasket is not effected by any of the above, gasket replacement will not be required. If replacement is
required, replace using new gasket kit following the instructions provided with kit.
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SERVICE PROCEDURE RG-V
Gas Valve
Testing and Replacement (White Rodgers/Robertshaw)
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. Be sure that thermocouple and pilot tube are not
in position to interfere with outer jacket burner access door when reinstalled.
WARNING
A seal breach may result in a fire or
explosion causing property damage,
personal injury or death.
Position thermocouple,
pilot tube and Piezo wire.
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. Verify seal integrity around combustion
opening. Secure right side inner door using (2) hex drive screws from step 6b. DO NOT OVER TIGHTEN
SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against
the combustion chamber.
Secure flange with
¼" drive screws.
Verify threaded hole
alignment with slotted
openings in inner door.
Step 10. Reconnect wire leads from gas valve to resettable thermal switch (See photo in step 6). Note: wire
terminations are interchangeable with either resettable thermal switch connection.
Step 11. Replace outer jacket burner access door.
Step 12. Reconnect gas supply to gas valve.
Step 13. Resume water supply to water heater. Be sure tank is full of water.
Step 14. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
19
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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.
Valve Body
Backplate
Gas Control
Cover
Gas Control
Cover Screw
Temperature
Piezo Igniter
Sensor
Valve Body
Screw
Insertion Stick
LINE PRESSURE
The Gas Control is designed for a maximum line pressure of 14.0" w.c. and a minimum line pressure of 1.0" w.c. over the
water heater’s rated manifold pressure (check rating plate). Line pressure must be checked with the main burner on and
off to assure proper readings.
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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.
Step 2.
Set the Gas Control to the “OFF” position.
Remove pressure tap plug and install
1/8" NPT pipe, coupling, & pressure tap.
Gas Control shown in the “OFF” position
Step 3.
Step 4.
Connect manometer to pressure tap.
Follow instructions located on the lighting
instructions label and proceed to light the main
burner and observe manometer reading.
Step 5.
Step 6.
Proper operating range for natural gas is: 4.0" 0.5" w.c.
Proper operating range for LP gas is: 10.0" 0.5" w.c.
If pressure is within the range specified in the previous
step, set Gas Control knob to the “OFF” position,
remove manometer and pressure tap, and replace
pressure tap plug. Check for gas leaks prior to placing
water heater back into operation by following the
instructions located on the lighting instruction label or the
lighting instructions located in the installation and
operation manual.
Step 7.
If gas pressure is outside the specification noted above,
refer to “Honeywell Gas Control Testing, Disassembly,
and Replacement” to replace Gas Control or valve body.
Pressure Tap
Shown Installed
THERMOPILE TESTING
See SERVICE PROCEDURE RG-II
ECO (Energy Cut Off) TESTING
The Honeywell Gas Control is designed with an ECO device that will reset.
To reset the Gas Control after an error code (4), turn the Gas Control knob to the “OFF” position and wait a minimum
of (5) minutes before relighting following the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
21
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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. Then
follow lighting instructions and return gas control
knob to desired setpoint.
Observe Green LED indicator.
N
Does error code 4 (four flash, three
second pause) continue?
Y
Using a multi-meter set to the ohms setting, insert one meter probe (see caution)
into center wire position of thermal well connector, insert the second probe (see
caution) into either of the outside wire positions (see photo on left).
Temperature Sensor Testing
Following “Gas Control
Disassembly/Reassembly”
instructions, disassemble Gas
Control to access temperature
sensor.
Alternate the probe on the outside position to the opposite outside wire position
(see photo on right).
With the temperature sensor still
in the back plate, use a multi-
meter set to the Ohms setting,
determine the resistance of
temperature sensor
Resume normal operation.
(see caution and photos above)
Once the temperature sensor resistance values are known, the
water temperature must also be known to determine if the
resistance values are correct. See next page to obtain water
temperature.
N
Replace temperature
sensor
Are temperature sensor resistance values correct?
Y
Replace Gas Control
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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. Prior to drawing water from drain
valve, turn off the cold water supply to the water heater. This will prevent cold water flow into the tank
affecting the resistance value of the temperature sensor.
Step 1.
Step 2.
Step 3.
Set the Gas Control knob to the “OFF” position.
Turn off inlet water supply to water heater.
Draw approximately 4 gallons of water from drain valve into a container, or suitable drain, and discard.
Draw an additional gallon and immediately measure water temperature using an accurate thermometer.
It may be necessary to open a hot water faucet to allow water heater to drain.
Step 4.
Using the chart below, determine correct resistance value for the water temperature from step 3.
Example:
If temperature of water is 84°F, then the resistance through the sensor would be
8449 (see shaded area). NOTE: Sensor resistance increases as the temperature
decreases.
Sensor Resistance at Various Temperatures
In Degrees F
°F
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
0
1
2
3
4
5
6
7
8
9
26109
19906
15314
11884
9299
7333
5827
4663
3758
3048
2488
2043
1688
1402
1170
982
25400
19383
14925
11592
9078
7165
5697
4562
3679
2986
2439
2004
1656
1376
1150
965
24712
18876
14548
11308
8862
7000
5570
4464
3602
2925
2391
1966
1625
1351
1129
949
24045
18383
14180
11032
8653
6839
5446
4368
3527
2866
2344
1928
1595
1327
1110
933
23399
17905
13823
10763
8449
6683
5326
4274
3453
2808
2298
1891
1566
1303
1090
917
22771
17440
13477
10502
8250
6531
5208
4183
3382
2752
2253
1856
1537
1280
1071
901
22163
16990
13140
10248
8057
6383
5094
4094
3312
2697
2209
1820
1509
1257
1953
886
21573
16553
12812
10000
7869
6238
4982
4006
3244
2643
2166
1786
1481
1235
1035
871
21000
16128
12494
9760
7685
6098
4873
3922
3177
2590
2124
1753
1454
1213
1017
857
20445
15715
12185
9526
7507
5961
4767
3839
3112
2538
2083
1720
1427
1191
999
842
713
828
814
801
788
775
762
749
737
725
23
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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.
Step 4. Disconnect piezo igniter wire.
Rotate knob counter-clockwise
to the “OFF” posistion.
Step 5. Remove inner door assembly following SERVICE PROCEDURE RG-I, steps 1 through 3c.
Step 6. Remove Gas Control cover screw.
Gas Control
cover screw
Step 7. Depress both tabs on the top of the Gas Control cover and pull to remove.
CAUTION
Use caution not to bend or damage valve body pins
when removing or installing Gas Control cover.
Valve body pins
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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.
Release lock tab
25
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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. Remove temperature sensor and insertion stick from backplate by first removing wire from the temperature sensor
wire routing clips located on the backplate. Note the orientation of insertion stick, insertion stick can only be
installed in one way.
Temperature sensor
wire routing clips
CAUTION
When reinstalling temperature sensor and insertion stick,
make sure the assembly is inserted FULLY into the
backplate and the wires are routed through the wire
routing clips. Failure to do so will not allow valve body to
be reinstalled properly and may damage temperature
Insertion stick fully
sensor wires.
inserted into backplate
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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.
Temperature sensor
Pull in this direction
Insertion stick
Pull in this direction
Step 13. To reassemble Gas Control, follow the previous steps in reverse order. Once Gas Control is reassembled, burner
assembly is reinstalled, and the gas supply line is reconnected, resume water supply to water heater. Be sure tank
is full of water before relighting.
Step 14. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
27
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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.
a) Disconnect red wire leads from resettable thermal switch.
b) Remove (2) hex drive screws from RIGHT side inner door.
c) Remove (2) hex drive screws from FLANGE SECTION of inner door.
d) Remove right side inner door and set aside. Be careful not to damage gasket material on inner door.
Resettable Thermal Switch
Remove
Wire Tie
Wire Connection
Hex Drive Screws
Right and Left Side Inner Door.
Hex Drive Screws at
Flange Area of Inner Door
Step 7. Removal of Gas Control.
a) Disconnect main burner feedline, pilot tube, piezo igniter wire, inner door wire (red) and thermopile wire
(white) from Gas Control.
b) Remove Gas Control from water heater by rotating counter clockwise. DO NOT use a wrench on the
Gas Control body, damage to the Gas Control may occur. If necessary, use a length of ½" NPT pipe
threaded into gas inlet of Gas Control.
Step 8. Install new Gas Control into water heater.
a) Install new Gas Control into water heater by rotating clockwise. DO NOT use a wrench on the Gas
Control body, damage to the Gas Control may occur. If necessary, use a length of ½" NPT pipe threaded
into gas inlet of Gas Control.
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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 thermopile wire
(white) to Gas Control. Attach inner door wire (red) to the positive (+) terminal and the thermopile wire
(white) to the negative (-) terminal.
Positive (+) Terminal
Negative (-) Terminal
(red wire)
(white wire)
c) Gather piezo igniter wire, thermopile wire (white), inner door wire (red), and pilot tube and secure along
side of feedline using new wire tie provided.
CAUTION
d) Reconnect gas supply piping to inlet of Gas Control.
Step 9. Reinstallation of inner door assembly.
Use back up wrench on wrench boss
of Gas Control, never use back up
wrench on body of Gas Control.
a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:
> Tears > Gasket Adhesion to inner door
> Missing Material > Other imperfections that will inhibit proper seal
> Cracks
> Dirt or debris
> Material left on combustion chamber
If the gasket is not effected by any of the above, gasket replacement will not be required. If replacement is
required, replace using new gasket kit following the instructions provided with kit.
b) Clean any gasket residue or other debris from combustion chamber surface before installing
the inner door/gasket assembly.
c) Position thermopile wire, pilot tube and Piezo wire against left side inner door flange gasket. DO NOT ROUTE
THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that thermopile and pilot tube are not
in position to interfere with outer jacket burner access door when reinstalled.
WARNING
A seal breach may result in a fire or
explosion causing property damage,
personal injury or death.
Position thermopile, pilot
tube and Piezo wire.
29
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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. Verify seal integrity around combustion
opening. Secure right side inner door using (2) hex drive screws from step 6b. DO NOT OVER TIGHTEN
SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against
the combustion chamber.
Secure flange with
hex drive screws.
Verify threaded hole
alignment with slotted
openings in inner door.
Step 10. Reconnect (2) red wire leads from pilot assembly and Gas Control to resettable thermal switch. Note: wire
terminations are interchangeable with either resettable thermal switch connection.
Step 11. Replace outer jacket burner access door.
Step 12. Reconnect gas supply to Gas Control.
CAUTION
Use back up wrench on wrench boss
of Gas Control, never use back up
wrench on body of Gas Control.
Step 13. Resume water supply to water heater. Be sure tank is full of water before resuming operation.
Step 14. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
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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 debris is not 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. Cast iron burner can have
the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner (see step 2
below).
Main burner must be free from any debris accumulation that may effect burner operation (see burner cleaning procedure
on page 17).
CAST IRON BURNER ADJUSTMENT
DANGER
Under no circumstances shall flammable materials be used or stored in the vicinity of the water heater.
With the inner door removed the Bradford White Defender Safety System will be inactivated. If flammable
vapors are present, a fire or explosion may result causing property damage, personal injury or death.
Upon completion of the cast iron burner adjustment procedure, the inner door must be replaced per
SERVICE PROCEDURE RG-1, steps 4 through 14 to reactivate Bradford White Defender Safety System.
WARNING
Inner door and burner components may be HOT when performing this operation. Take necessary
precaution to prevent personal injury.
Step 1.
Step 2.
With main burner in operation, remove right side inner door per SERVICE PROCEDURE I, steps 3b & 3c.
Be sure to maintain wire connection to resettable thermal switch for this adjustment procedure.
To adjust for proper burning, loosen the air shutter nut, rotate the shutter to close the opening in the burner,
then slowly rotate the shutter until the yellow tips disappear and the flame becomes blue. Tighten the air
shutter nut. Too much air will cause the flame to lift off the burner ports and create noisy burner operation.
Too little air (yellow tips) will result in soot formation.
Place right side inner door into proper position to confirm proper burner flame pattern and correct air shutter
adjustment. It may be necessary to allow the burner to operate for several minutes for burner flame to stabilize.
Air Shutter Nut
31
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SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
MAIN BURNER: Inspection, Adjustment,
Cleaning and Replacement (cont.)
Step 3.
Step 4.
Fully inspect inner gasket per SERVICE PROCEDURE RG-I, step 4. Replace gasket if required following
SERVICE PROCEDURE I, steps 5 & 6.
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.
Position thermocouple/thermopile,
pilot tube and Piezo wire.
Step 5.
Step 6.
Observe burner operation through sight glass of inner door. Burner should operate as adjusted in step 2, if not,
repeat procedure compensating air shutter position for proper burner operation with inner door in place.
It may be necessary to clean main burner or main burner orifice to achieve proper burner operation. If
cleaning is required proceed to burner cleaning section in this procedure.
BURNER CLEANING (Steel & Cast Iron)
Step 1.
Step 2.
Remove inner door assembly per SERVICE PROCEDURE RG-I, steps 1 through 3c.
Disconnect main burner feed line, pilot tube and thermocouple/thermopile
from combination thermostat gas valve and remove burner assembly from combustion chamber.
NOTE: Feedline nut for natural gas control uses right hand threads,
LP control uses left hand thread.
Step 3.
Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation.
Burner Surface Area
Burner Port Area
Burner Venturi
Step 4.
On cast iron burners, inspect
Opening
for any debris build up inside
burner venturi. If found,
disconnect feedline from burner
and remove debris build up.
Feedline
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SERVICE PROCEDURE RG-VII
Burner Operation Inspection, Adjustment
Cleaning and Replacement
BURNER CLEANING (Cont.)
Step 5.
Disconnect (unscrew) Main burner (steel) from main
burner orifice or on cast iron burners (“C” burner), loosen air shutter &
disconnect (unscrew) feedline from burner.
Step 6.
Remove main burner orifice from feed line. Inspect and clean if necessary.
Step 7.
Step 8.
Step 9.
Remove pilot assembly, refer to SERVICE PROCEDURE RG-III for cleaning and inspection.
Reassemble burner.
Inspect combustion chamber area of heater prior to reinstallation of burner assembly. If cleaning is required,
refer to SERVICE PROCEDURE RG-VIII.
Step 10. Reinstall burner assembly into combustion chamber, reconnect feedline, thermocouple and pilot tube to
the combination thermostat/gas valve.
Step 11. Reinstall inner door per SERVICE PROCEDURE RG-I, steps 4 through 13.
Step 12. To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
33
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SERVICE PROCEDURE RG-VIII
Resettable Thermal Switch
Testing and Replacement
RESETTABLE THERMAL SWITCH CONTINUITY TESTING
Step 1.
Step 2.
Remove outer jacket door.
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.
Step 5.
If continuity is indicated, the switch is closed, allowing millivolt current to pass.
If continuity is not indicated, the switch is open, possibly due to an over heating condition. The switch is
designed to open at predetermined temperatures depending on model. An open switch can be reset by
depressing the red colored button located at the center of the switch. The overheating condition must be
determined prior to putting the heater back in service.
PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH ACTIVATION
Resettable thermal switch
color code reference.
PROBABLE CAUSE
CORRECTIVE ACTION
Approximate switch
activation temperature
(open)
1. Verify adequate combustion air supply is
available.
Color Code
Blue
240°
270°
2. Clear jacket slot openings of any dirt, dust,
restrictions or other obstructions.
Insufficient combustion air
Yellow
3. inspect flame arrestor plate and clean with
stiff brush and/or vacuum to remove scale
deposits and debris.
Red
290°
1. Weak switch or switch
out of calibration.
1. Replace resettable thermal switch
2. Verify switch color code and approximate
temperature.
2. Incorrect switch.
Flammable vapor incident
1. Replace water heater.
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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.
Step 3.
Remove outer jacket door.
Disconnect wire leads from resettable thermal switch.
Step 4.
Remove resettable thermal switch from inner door (Phillips screw driver)
Step 5.
Step 6.
Place new resettable thermal switch in place. Be sure contact surface of resettable thermal switch and inner
door are free of any debris. Secure resettable thermal switch into place using screws from step 4. DO NOT
OVER TIGHTEN SCREWS.
Reconnect wire leads from combination thermostat/gas valve to resettable thermal switch.
Note: Wire termination are interchangeable with either resettable thermal switch connection.
Replace outer jacket door
Step 7.
Step 8.
To resume operation follow the instructions located on the lighting instruction label or the lighting instruction
located in the installation and operation manual.
35
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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.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
Step 2.
Step 3.
Remove outer jacket door.
Remove inner door per SERVICE PROCEDURE RG-I, step 3a through 3e.
Step 4.
Disconnect main burner feed line, pilot tube and thermocouple/thermopile
from combination thermostat gas valve and remove burner assembly
from combustion chamber.
Feedline
Nut
NOTE: Feedline nut for natural gas control uses right hand threads,
LP control uses left hand thread.
Step 5. Clean ScreenLok® Flame Arrestor using stiff brush, compressed air and/or shop vacuum to remove any scale or
other debris accumulation. Using a soft brush, clear jacket openings of any dirt, dust, restrictions or other obstructions.
Step 6.
Remove any debris from burner assembly per SERVICE PROCEDURE RG-V and reinstall burner assembly
into combustion chamber.
Step 7.
Step 8
Step 9.
Reconnect feedline, thermocouple and pilot tube to the combination thermostat/gas valve.
Reinstall inner door per SERVICE PROCEDURE RG-I, steps 4 through 13.
To resume operation follow the instructions located on the lighting instruction label or the lighting instruction
located in the installation and operation manual.
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SERVICE PROCEDURE RG-X
Dip Tube and Anode
Inspection and Replacement
DIP TUBE 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.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
Step 2.
Turn off cold water supply to heater. Connect hose to drain valve of water heater and route to an open drain.
Open a nearby hot water faucet to vent heater for draining. Open drain valve of water heater and allow
heater to drain to a point below the inlet connection nipple.
Step 3.
Step 4
Disconnect inlet nipple from plumbing system.
With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage
pipe threads.
Step 5.
Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage.
Hydro-jets located near the bottom of the dip tube should be open and free of any blockage.
Anti-siphon hole located approximately 6" from the bottom of nipple, should be free of any blockage.
Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable
and the inlet nipple/dip tube must be replaced.
Step 6.
Step 7.
Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Connect
nipple to plumbing system, resume water supply and refill heater with water.
To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
37
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SERVICE PROCEDURE RG-X
Dip Tube 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.
For Honeywell Control, rotate
knob counter-clockwise to the
“OFF” position.
For Robertshaw Control, rotate
knob clockwise to the “OFF”
position.
Step 2.
Turn off cold water supply to heater. Connect hose to drain valve of water heater and route to an open drain.
Open a nearby hot water faucet to vent heater for draining. Open drain valve of water heater and allow
heater to drain to a point below the outlet connection nipple.
Step 3.
Step 4
Disconnect outlet nipple from plumbing system.
With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage
pipe threads.
Step 5.
Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.
If depletion is ½ of the original anode diameter (approximately 5/8” diameter), replacement is recommended.
If any of thesteel core of the anode is exposed, replacement is recommended.
Step 6.
Step 7.
Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Connect
nipple to plumbing system, resume water supply and refill heater with water.
To resume operation, follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.
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Generic Parts List
16
1
34
32
2
33
3
17
4
18
21
19
20
5
28
6A
6B
6C
30
7
23
8
24
27
25
11
26
1
2
3
4
5
Draft Hood
16 Complete BN Burner Assembly (Natural)
17 BN Burner Only
Hot Water Outlet/Anode
Cold Water Inlet Tube
Flue Baffle
18 Main Burner Orifice
19 Pilot Assembly
T&P Relief Valve
20 Pilot Orifice
6A Gas Control (Honeywell)
6B Gas Valve (Robertshaw)
6C Gas Valve (White Rodgers)
21 Thermocouple/Thermopile
22 Complete SX Burner Assembly (LP)
23 SX Burner Only
7
8
9
Piezo Igniter (White Rodgers/Robertshaw)
Brass Drain Valve
24 Main Burner Orifice
25 Pilot Assembly
Screw-#8-18 x 3/4 Hex Washer Head
26 Pilot Orifice
10 Screw-#10-12 x 3/4 Hex Washer Head
11 Left Side Inner Door with Gasket
12 Complete Right Side Inner Door
14 Resettable Thermal Switch
15 Outer Door
27 Thermocouple/Thermopile
28 ASSE Approved Mixing Valve (Optional)
29 ¾ NPT Tank Plug (XR Models)
30 Inner Door Gasket Kit
31 Wire Tie
32 Heat Trap (Outlet)
33 Heat Trap (Inlet)
34 Heat Trap Kit
39
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