Bradford White RG2DV40S Series Service Manual Download Page 42

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DV Series

1. Venting Package Complete 11. Inlet Diptube

21. Feedline Clip

2. Venting Protection Screen 12. T&P Valve

22. Right Side Inner Door

3. Plenum

13.

3/4 NPT plug (“H” Models

only) 23. Left Side Inner Door

4. 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 Burner

27. Inner Door Gasket Kit

8. Anode Outlet Device

18. Main Burner Orifice

28. Kit-Heat Trap Insert

9. Flue Baffle

19. Pilot Assy.

29. ASSE Approved Mixing Valve

10. Heat Trap Inlet

20. Feedline

Parts Diagram

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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Bradford White RG2DV40S Series, Service Manual

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