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THERMO

C

OU

P

LE RE

P

L

AC

EMENT

Step 1.

Turn off gas supply to water heater. Rotate knob of gas control to “OFF” position.

Step 2.

Remove outer jacket door.

Step 3.

Slide open inner combustion chamber door.

Step 4.

Disconnect thermocouple from gas control. 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. Connect other end of thermocouple to gas control (finger tight + ¼ turn).

Step 6.        Route carefully through the relief opening in the combustion chamber skirt.

Step 7.

To resume operation follow the instructions located on the lighting instruction label or the lighting
instructions located in the installation and operation manual.

Step 8.

Slide inner door closed when finished.

S

ERVI

C

P

RO

C

E

D

URE 

A

G-I

Thermocoup

l

e

 

Testin

and

 

Rep

l

acement

F

or

 M

ode

l

s

 U

sin

White

 

Rod

g

ers

 

or

Robertshaw

 

Gas

 

Contro

l

P

a

g

e

 

6

F

i

g

ure

 

3

F

or

 

White

 

Rod

g

ers

 g

as

contro

l

,

 

depress

 

knob

s

l

i

g

ht

l

y

 

and

 

rotate

c

l

ockwise

 

to

 

the

 

“O

FF

position

.

F

or

 

Robertshaw

 g

as

contro

l

,

 

rotate

 

knob

c

l

ockwise

 

to

 

the

 

“O

FF

position

.

Step 1.

Disconnect thermocouple from gas control.

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. A reading of 20 to 30 millivolts indicates good thermocouple output.

O

P

EN 

C

IR

C

UIT THERMO

C

OU

P

LE TE

S

TING

F

i

g

ure

 4

Thermocoup

l

e

 

position

F

i

g

ure

 

1

F

i

g

ure

 2

NOTE:

I

t

 

wi

ll 

be

 

necessary

 

to

 

ho

l

d

 

the

 g

as

 

contro

l

knob

 

down

 

in

 

the

 

PI

LOT”

 

position

continuous

l

y

 

throu

g

hout

 

this

 

test

.

6

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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