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Manual 238

‐

51637

‐

00A 10/15

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

RG1D30T*(N,X)
RG1D40S*(N,X)
RG1D40T*(N,X)
RG1D50T*(N,X)
RG2D40S*(N,X)
RG2D50S*(N,X)
(*) Denotes Warranty Years

Gas Water Heaters

Residential D Series

Summary of Contents for RG1D30T*(N,X)

Page 1: ...MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual RG1D30T N X RG1D40S N X RG1D40T N X RG1D50T N X RG2D40S N X...

Page 2: ...ng Replacement 15 D II Damper Removal Installation 16 D III Gas Control Testing Replacement 17 D IV Flammable Vapor Device Testing and Replacement 20 D V Diptube Inspection Replacement 21 D VI Anode I...

Page 3: ...nal for more information WARNING FAILURE TO INSTALL AND MAINTAIN A NEW LISTED X TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE TEMP...

Page 4: ...operational issue Please read the service manual completely before attempting service on this new series of damper models How the Safety System Works During normal operation air for combustion is dra...

Page 5: ...eter Water Pressure Gage Various Hand Tools A liquid U tube type or a digital magnahelic type can be used This device is used to measure gas and or air pressure and vacuum A digital type is strongly r...

Page 6: ...for Natural Gas 11 0 w c min for Propane 14 0 w c maximum Natural Gas Propane Venting System Single or Double Wall Metal Vent Pipe Minimum Clearance for Servicing 18 from top 24 from front 4 sides and...

Page 7: ...2 second maximum 1 second minimum Adjust Damper Position and Verify Closed Position 15 Seconds Damper Blade Position Fault failed open close Retry after 2 minutes Soft Lockout Retry after 5 minutes EC...

Page 8: ...ing damper gas control verifies the damper safety circuit to ensure it is in the correct state If the safety circuit is closed the gas control LED flashes 2 times with a 3 second pause The gas control...

Page 9: ...Powered Closed 15 seconds Abnormal Operation 1 Flammable Vapor Sensor Fault a If the resistance is greater than 70 000 Ohms the gas control immediately turns off all outputs The gas control waits and...

Page 10: ...ries to open the damper again b Flame not sensed The gas control energizes the spark igniter attempting to light the pilot and prove flame If flame is not sensed within 90 seconds the spark igniter tu...

Page 11: ...n build up on pilot electrode 4 Wire damage to pilot assembly or bad connection at gas valve 1 See burner inspection on Page 13 2 4 See Pilot Inspection Testing and Replacement on page 15 Two flash th...

Page 12: ...fer to Installation Operation Manual Six four flash three second pause Undesired false pilot flame sensed System auto resets Pilot valve stuck in open position Replace gas control Page 19 Seven flash...

Page 13: ...e some causes for an unstable pilot flame are a Water heater vent is less than the allowable vent length b Gas pressure is out of specification c Pilot flame not fully engulfing spark flame sensor Mai...

Page 14: ...tion chamber Step 7 Thoroughly inspect burner surface area and burner port area and remove any loose debris Step 8 Unscrew burner from main burner orifice Step 9 Remove main burner orifice from feedli...

Page 15: ...Replace pilot as necessary Electrode should not be in contact with pilot hood if so carefully adjust electrode to a gap of distance of 3 32 09 from pilot hood Step 11 Visually inspect igniter flame se...

Page 16: ...he damper from the top of the water heater Step 7 Clean any debris from the jacket head of the water heater Step 8 Set the new damper in place using the water heater tank flue and the screw holes in t...

Page 17: ...ep 4 Follow instructions located on the lighting instructions label and proceed to light the main burner and observe manometer reading Step 5 Proper operating range for Natural Gas is 4 0 0 5 W C Prop...

Page 18: ...ure Inside Tank Step 1 Position gas control power switch to OFF position Step 2 Draw approximately 4 gallons of water from the drain valve into a container and discard Draw an additional gallon and im...

Page 19: ...the Gas Control body damage to the Gas Control may occur If necessary use a length of NPT pipe threaded into the gas inlet of Gas Control Step 9 Install a new gas control into the water heater by rota...

Page 20: ...sing a multi meter set to the ohms setting check resistance of flammable vapor sensor Resistance must be between 3 000 ohms and 48 000 ohms If outside of this range replace Flammable Vapor Sensor CAUT...

Page 21: ...o damage the pipe threads Step 5 Visually inspect the inlet nipple diptube The inlet nipple diptube should be free of cracks and any blockage The Hydrojet slots should be open and free of any blockage...

Page 22: ...Use caution not to damage the pipe threads Step 5 Visually inspect the outlet nipple anode The outlet nipple anode should show signs of depletion this is normal If depletion is of the original anode d...

Page 23: ...he water heater from the wall outlet Step 2 Disconnect the vent system from the draft hood that is mounted on top of the damper Step 3 Remove the draft hood from the damper and retain it for later use...

Page 24: ...he Burner Cleaning Procedure on page 14 if accumulation has occurred Step 11 Clean any debris from the jacket head of the water heater Step 12 Set the new damper in place using the water heater tank f...

Page 25: ...ions that will inhibit proper seal Missing Material Gasket adhesion to inner door Cracks Material left on combustion chamber around opening Dirt or debris If the gasket is not affected by any of the a...

Page 26: ...urface before installing the inner door gasket assembly Step 11 Place the left side inner door into position first Firmly position the radiused channel of the inner door around the feedline Using the...

Page 27: ...on chamber are aligned with right side inner door slotted opening Verify seal integrity around combustion opening Secure right side inner door using hex drive screws from step 3 DO NOT OVER TIGHTEN SC...

Page 28: ...cuit Trace Step 1 Verify 115 VAC and proper polarity at wall outlet Step 2 With unit plugged in and control power switch in the ON position verify LED status WARNING 115 volt potential exposure Use ca...

Page 29: ...from the wall outlet Step 2 Disconnect the vent system from the draft hood that is mounted on top of the damper Step 3 Remove the draft hood from the damper and retain it for use later Step 4 Unplug t...

Page 30: ...in the damper housing from its location Connect the Blue female connector on the relay harness in its place Step 11 Remove the White wire in the damper housing from its location Connect the White fema...

Page 31: ...17 Reconnect the vent system to the draft hood Step 18 Reconnect the cord sets from step 4 Step 19 Plug the water heater into the wall outlet Step 20 Move the gas control power switch in to the ON po...

Page 32: ...tures depending on the 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 heat...

Page 33: ...h in place Be sure the contact surface of resettable thermal switch and the inner door are free of any debris Secure the resettable thermal switch into place using screws from step 4 DO NOT OVER TIGHT...

Page 34: ...d air and or shop vacuum to remove any scale or other debris accumulation Using a soft brush clear jacket openings from any dirt dust restrictions or other obstructions Step 6 Remove any debris from t...

Page 35: ...Minute Hz Hertz kWh Kilowatt hour LED Light Emitting Diode NPT National Pipe Thread Ohms Ohms of resistance psi Pounds per Square Inch RPM Revolutions per minute ECO Energy Cut Out VAC Volts Alternati...

Page 36: ...ure relief valve 10 Brass Drain Valve 11 Right side inner door ass y 12 Resettable thermal switch 13 Outer door 14 Left side inner door ass y 15 FV sensor clip 16 FV sensor 17 FV wire harness 18 Gas v...

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