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DV Series 

30 

 

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. 

Determine Water Temperature Inside Tank 

 

 

 

 

Step 1. 

Position the gas control knob to the “OFF” position.

 

Step 2. Draw approximately 4 gallons of water from the drain valve into a container 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 3. Using the chart below, determine the correct resistance value for the water temperature 

from Step 2. Example: If water temperature is 84 F, then the resistance through the sensor 

would be 8449. 

 

  Note: Sensor resistance increases as the temperature decreases 

 

Sensor Resistance at Various Temperature 

 

 

 

 

 

In Degrees F

 

°F 

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  10000 

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 

1053 

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 

Service Procedure IV 

Gas Control Testing and 

Replacement 

30

Summary of Contents for RG2DV40S Series

Page 1: ...Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual RG2DV40S N X RG2DV50S N X RG2DV50H N X LG2DV50H50 N X Denotes Warra...

Page 2: ...rmocouple Thermopile Testing 15 II Igniter Electrode Testing and Replacement 18 III Gas Control Testing and Replacement 19 IV Burner Inspection Cleaning and Replacement 34 V Pilot Testing Cleaning and...

Page 3: ...f smell or are in any way unsure of the presence of gas immediately contact your gas supplier from a neighbor s telephone Gas detectors are available Contact your gas supplier or plumbing professional...

Page 4: ...rameters exists the gas control diagnostic LED will flash a code to identify an operational issue This service manual is designed to facilitate problem diagnosis and enhance service efficiency Please...

Page 5: ...helic type can be used This device is used to measure gas and or air pressure and vacuum Multi Meter A digital type is strongly recommended This device is used to measure electrical values The meter y...

Page 6: ...urned to a water temperature setting 2 Water heater is satisfied and operating normally Normal operation Short flash once per second Gas control is calling for heat no fault Tank temperature below set...

Page 7: ...alibration 2 Faulty gas control Replace gas control Five flashes and three second pause Temperature sensor fault 1 Damage to the temperature sensor 2 Temperature sensor resistance out of range Replace...

Page 8: ...urner off when water temperature reaches the setpoint temperature Normal operation Two flashes and three second pause LED yellow Low thermopile voltage main valve not turned on Check thermopile and it...

Page 9: ...s valve 7 Resettable thermal switch has opened 1 Check connection at combination thermostat gas valve Proper tightness should be finger tight a 1 4 turn 2 Inspect thermocouple to ensure that it is ful...

Page 10: ...r operation 3 Check gas supply and line pressure 1 See Service Procedure VII 2 See Service Procedure IV Not enough hot water 1 Combination thermostat gas valve set too low for desired water temperatur...

Page 11: ...lve is open and main burner is lit Thermostat is calling for heat Water heater operating normally and is in heat cycle Solid ON Not an error Indicates that the control is in shutdown mode Set point kn...

Page 12: ...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 13: ...he left side inner door and burner assembly into position first Using the three 3 1 4 hex drive screws from Step 6 of Inner Door Removal Procedure secure left side inner door in place DO NOT OVER TIGH...

Page 14: ...er door using 1 4 hex drive screws from Step 4 of Inner Door Removal Procedure DO NOT OVER TIGHTEN SCREWS Verify both left and right sides of inner door are properly positioned and sealed against the...

Page 15: ...3 If meter reads 10 millivolts or higher the thermocouple is O K If reading is below 10 millivolts replace the thermocouple Open Circuit Thermocouple Testing White Rodgers Mechanical Step 1 Disconnec...

Page 16: ...5 Install a new thermocouple into the pilot bracket making certain the thermocouple is fully engaged into the pilot bracket Position the thermocouple against the left side inner door flange at its ori...

Page 17: ...the thermopile is O K If reading is below 300 millivolts replace the pilot assembly per Service Procedure VI Open Circuit Thermopile Testing White Rodgers Electronic and Honeywell Step 1 Disconnect th...

Page 18: ...and depress the igniter If there is a spark the igniter is O K Otherwise the igniter is not functioning and the pilot assembly must be replaced See Service Procedure VI Step 4a For White Rodgers Mech...

Page 19: ...f 14 0 W C Step 1 Position the gas control knob in the OFF position Step 2 Remove the pressure tap plug 3 16 allen wrench and install a 1 8 NPT pipe coupling and pressure tap Step 3 Connect a manomete...

Page 20: ...inal located at the back of the gas valve Step 3 With a meter reading of 13 millivolts or greater rotate the knob of the combination thermostat gas valve to the OFF position Step 4 The magnet should r...

Page 21: ...or c Remove two 2 1 4 hex drive screws from the flange section of the inner door d Remove the right side inner door and set aside Be careful to not damage the gasket material on the inner door Step 7...

Page 22: ...e to gas valve NOTE Feedline nut for natural gas control uses right hand threads L P control uses left hand thread d Gather wire leads of gas valve and piezo igniter and secure alongside of feedline u...

Page 23: ...ngs Verify seal integrity around the combustion opening Secure right side inner door using two 2 hex drive screws from Step 6b DO NOT OVER TIGHTEN SCREWS Verify both left and right sides of the inner...

Page 24: ...ontrol cover screw using a flat head screwdriver a For Honeywell V2 remove 4 gas control cover screws using a flat head screwdriver CAUTION Use caution to not bend or damage valve body pins when remov...

Page 25: ...the gas control cover Honeywell V1 only and pull straight out to remove Step 7 Disconnect the temperature sensor from the control board and remove the wire from the temperature sensor wire routing cl...

Page 26: ...re routing clip Disconnect temperature sensor Honeywell Cover Removal cont Step 8 Remove the piezo igniter from the control cover by releasing the lock tab on the control cover Service Procedure IV Ga...

Page 27: ...te by first removing the wire from the temperature sensor wire routing clips Make note of the insertion stick s orientation as the insertion stick can only be installed in one way CAUTION Use caution...

Page 28: ...rol follow the previous steps in reverse order Once the gas control is reassembled the burner assembly is reinstalled and the gas supply line is reconnected resume water supply to the water heater Be...

Page 29: ...Does status code 4 four flashes three second pause appear a If no resume normal operation b If yes continue with Step 3 Step 3 Following Honeywell Cover Removal Honeywell Valve Body Removal and Tempe...

Page 30: ...be 8449 Note Sensor resistance increases as the temperature decreases Sensor Resistance at Various Temperature In Degrees F F 0 1 2 3 4 5 6 7 8 9 40 26109 25400 24712 24045 23399 22771 22163 21573 21...

Page 31: ...inner door and set aside Be careful to not damage gasket material on the inner door Step 7 Removal of gas control a Disconnect the main burner feedline pilot tube igniter wire innder door wire red an...

Page 32: ...ing material Cracks Dirt or debris If the gasket is not affected by any of the above gasket replacement will not be required If replacement is required replace using a new gasket kit following the ins...

Page 33: ...positioned and sealed against the combustion chamber Step 10 Reconnect two 2 red wire leads from pilot assembly and gas control to resettable thermal switch NOTE Wire terminations are interchangeable...

Page 34: ...ay affect burner operation see burner cleaning procedure below Burner Removal Step 1 Position the gas control knob in the OFF position Step 2 Turn off the gas supply to the water heater Step 3 Remove...

Page 35: ...ain burner orifice from feed line Inspect and clean if necessary Step 5 Inspect the orifice clean or replace if necessary Step 6 Reassemble the burner and reinstall into the water heater Step 7 Restor...

Page 36: ...tubing for kinks or cracks If damage is found replace the pilot assembly Step 7 Inspect the pilot tubing and the pilot orifice for blockage a Remove the ferrule nut from the bottom of the pilot assem...

Page 37: ...d button located at the center of the switch The overheating condition must be determined prior to putting the heater back in service Service Procedure VII Resettable Thermal Switch Testing and Replac...

Page 38: ...al 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 Step 6 Reconnect wire leads from combination thermostat...

Page 39: ...ube should be free of cracks and any blockage Hydrojet slots should be open and free of any blockage Any damage such as cracks restriction due to deformation or unintentional holes are NOT field repai...

Page 40: ...he outlet nipple anode should show signs of depletion this is normal If the depletion is 1 2 of the original anode diameter approximately 3 4 diameter replacement is recommended If any of the steel co...

Page 41: ...z 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 alternating current W C...

Page 42: ...Plenum Gasket 14 Air Intake Boot 24 Outer Door 5 Rear Air Intake Tube 15 Air Intake Boot Gasket 25 Brass Drain Valve 6 Flue Reducer 16 Burner Assy Complete 26 Gas Control 7 Heat Trap Outlet 17 Main Bu...

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