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 steps in t

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ake necessary precaution to

prevent personal injury

SE

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Step 1. Turn the gas control  to the “OFF” position and

disconnect the thermowell harness from the gas control.

Step 2. Using a multimeter set to measure Ohms determine the resistance of the thermowell sensor (See

caution on this page).

Step 3. Hold one probe in the center pin and measure the outside positions pins (see figure 29 & 30, page 16).

Step 4. Draw approximately 1 quart of water from the drain valve and immediately measure the water

temperature using an accurate thermometer.  It may be necessary to open a hot water faucet to allow
the heater to drain.

Step 5. Refer to Table 1 below to determine the correct resistance value for the water heater tank temperature.

Example: If the temperature of the water is 84°F, then the resistance through the sensor would be 8449 (see

     shaded area). NOTE: Sensor resistance increases as the temperature falls.

°F

0

1

2

3

4

5

6

7

8

9

40

26109

25400

24712

24045

23399

22771

22163

21573

21000

20445

50

19906

19383

18876

18383

17905

17440

16990

16553

16128

15715

60

15314

14925

14548

14180

13823

13477

13140

12812

12494

12185

70

11884

11592

11308

11032

10763

10502

10248

1000

9760

9526

80

9299

9078

8862

8653

8449

8250

8057

7869

7685

7507

90

7333

7165

7000

6839

6683

6531

6383

6238

6098

5961

100

5827

5697

5570

5446

5326

5208

5094

4982

4873

4767

110

4663

4562

4464

4368

4274

4183

4094

4006

3922

3839

120

3758

3679

3602

3527

3453

3382

3312

3244

3177

3112

130

3048

2986

2925

2866

2808

2752

2697

2643

2590

2538

140

2488

2439

2391

2344

2298

2253

2209

2166

2124

2083

150

2043

2004

1966

1928

1891

1856

1820

1786

1753

1720

160

1688

1656

1625

1595

1566

1537

1509

1481

1454

1427

170

1402

1376

1351

1327

1303

1280

1257

1235

1213

1191

180

1170

1150

1129

1110

1090

1071

1953

1035

1017

999

190

982

965

949

933

917

901

886

871

857

842

200

828

814

801

788

775

762

749

737

725

713

I

n

 

De

g

rees

 F

P

a

g

e

 

17

Sensor 

R

esistance at Various 

T

emperatures

(T

able 1

)

C

AU

T

I

ON

DO

 

NOT

 use standard multimeter

probes to test. 

D

oin

g

 so 

w

ill dama

g

e

connector. Use special pin type
electronic probes or small diameter

w

ire pins inserted into connector

 

17

Summary of Contents for 25X78B N Series

Page 1: ...lified service providers Models Covered by This Manual GX225S BN GX155S BN 25X78B N 55X80B N M1XR65T BN CX SX MI75S BN CX SX M2XR75S BN CX SX MI100T BN CX SX 65T65 BN CX SX 75T80 BN CX SX C S D W275T...

Page 2: ...Cleaning and Replacement White Rodgers and Robertshaw Gas Control 9 AG II Pilot Assembly Inspection Cleaning and Replacement Honeywell Gas Control 10 AG II Gas Control Testing and Replacement White R...

Page 3: ...lly depress pilot lighting button 4 Clean repair or replace 1 Check connection at gas control Proper tightness should be finger tight plus turn 2 Inspect thermocouple to ensure that it is fully engage...

Page 4: ...as control is powered and waiting for the set point knob to be turned to a water temperature setting Gas control was turned to the OFF position 1 Thermopile failure 2 Unstable pilot 3 Pilot tube block...

Page 5: ...s control is wet or physically damaged See Service Procedure AG III Page 16 Lite pilot per the instructions located on the lighting instructions label or the lighting instructions located in the insta...

Page 6: ...peration manual Step 8 Slide inner door closed when finished SERVICE PROCEDURE AG I Thermocouple Testing and Replacement For Models Using White Rodgers or Robertshaw Gas Control Page 6 Figure 3 For Wh...

Page 7: ...control to operate for three minutes Step 2 Using a multimeter capable of measuring millivolts measure across thermopile connections at the gas control see Figure 6 CLOSED CIRCUIT THERMOPILE TESTING T...

Page 8: ...t using a 7 16 open end wrench Step 6 Install the new thermopile into the pilot bracket and tighten the threads using care not to damage the thermopile lead wires Route new wires through the appropria...

Page 9: ...bly b Remove pilot tube and pilot orifice c inspect pilot orifice for blockage must be cleaned or replaced SERVICE PROCEDURE AG II Pilot Assembly Inspection Cleaning and Replacement For Models Using W...

Page 10: ...pect pilot orifice a Remove 7 16 nut from the bottom of the pilot assembly b Remove pilot tube and pilot orifice c Inspect pilot orifice for blockage must be free from any debris dirt lint dust etc d...

Page 11: ...ombustion chamber door Step 4 Depress the igniter button repeatedly while viewing the spark through the open door of the combustion chamber If there is no spark proceed to Step 5 If there is a spark t...

Page 12: ...efore 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 p...

Page 13: ...trol Step 1 Disconnect thermocouple from gas control Step 2 Connect a thermocouple adaptor BWC P N 239 44642 00 Robertshaw P N 75036 at the thermocouple location in the gas control Step 3 Reconnect th...

Page 14: ...n Step 1 Disconnect thermocouple from gas control 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 i...

Page 15: ...ntrol is turned past proper alignment do not reverse direction to align b Reattach main burner feedline pilot tube and thermocouple to gas control NOTE Feedline nut for natural gas control uses right...

Page 16: ...position and disconnect the thermowell harness from the gas control Step 4 Using a multimeter set to measure Ohms determine the resistance of the thermowell sensor See caution on this page Step 5 Hol...

Page 17: ...er heater tank temperature Example If the temperature of the water is 84 F then the resistance through the sensor would be 8449 see shaded area NOTE Sensor resistance increases as the temperature fall...

Page 18: ...the thermowell from the tank Step 1 Turn the gas control knob to the OFF position Step 2 Turn off and disconnect gas supply piping to the gas control Step 3 Disconnect wire harnesses and burner assem...

Page 19: ...nge with tabs located on the back of the gas control see Figure 36 Figure 36 Gas control tabs Step 4 Carefully push the gas control back onto the thermowell flange Step 5 Install burner assembly and r...

Page 20: ...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 C...

Page 21: ...r Operation Inspection Adjustment Cleaning and Replacement Position thermocouple or thermopile and pilot tube BURNER CLEANING Steel Cast Iron Step 1 Slide open or remove inner combustion chamber door...

Page 22: ...llation of burner assembly Step 10 Reinstall burner assembly into combustion chamber reconnect feedline thermocouple or thermopile pilot tube and igniter wire for applicable models to the gas control...

Page 23: ...uld 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 Upon completi...

Page 24: ...ent is recommended Step 6 Upon completion of inspection or subsequent replacement reinstall outlet nipple anode into water heater Reconnect plumbing system to outlet nipple anode resume water supply a...

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