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Manual 238-51617-00A

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

RG2F40S*(N,X)

RG2F50S*(N,X)

(*) Denotes Warranty Years

Atmospheric Vent Gas Water Heater

High EF

Summary of Contents for RG2F40S*(N,X)

Page 1: ...51617 00A SERVICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual RG2F40S N X RG2F50S N X Denotes Warranty...

Page 2: ...Replacement __________________________ 21 Determine Temperature Inside Tank _____________________ 21 Gas Control Removal _________________________________ 22 Flammable Vapor Sensor Testing __________...

Page 3: ...heat to the nipples on top of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections It is imperative that heat is not applied to the nipples containing a...

Page 4: ...the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the tim...

Page 5: ...tic codes to pinpoint an installation or component performance issue Rugged Wiring Connections receptacle type connections promote error free wiring The gas control maintains water temperature ignitio...

Page 6: ...technical support group immediately if diagnosis cannot be made using the methods described in this service manual Tools Required for Service Manometer A liquid U tube type or a digital magna helic t...

Page 7: ...mum for Natural Gas Propane Approved Vent Materials Single or Double Wall Metal Vent Pipe Recommended Minimum Clearance for Servicing 18 from top 24 from front 4 from sides and rear Water Supply Press...

Page 8: ...e 15 seconds Pressure Switch Fault Delay failed open close Retry after 2 minutes Soft Lockout Retry after 5 minutes ECO Limit Lockout Indefinite See page 21 to reset Verify Resistive Delay Retry after...

Page 9: ...es with a 3 second pause The gas control waits 2 minutes Then the blower is energized for 30 seconds This cycle repeats until the safety circuit opens 2 Blower Energizes 3 Safety Circuit Check If the...

Page 10: ...ceeds to a 5 minute lockout The gas control re attempts to light the pilot starting at Normal Heating Sequence 2 8 Thermostat Satisfies Gas control LED flashes once every 4 seconds 9 Burner Off 10 Blo...

Page 11: ...urns the blower on for 60 seconds The blower turns off after 60 seconds and the control waits for the pressure switch to open B Pressure Switch Failed to Close The gas control runs the blower for 60 s...

Page 12: ...ing the ignition sequence 5 Flame Sensing Fault A Flame Lost During Run The gas control turns off pilot and main valves and runs the blower for 15 seconds inter purge The gas control increments the re...

Page 13: ...Switch Testing and Replacement on page 32 Three flashes three second pause Pressure switch or temperature switch not working open position 1 Vent blockage or improper vent configuration 2 Pressure swi...

Page 14: ...or sensor or resettable thermal switch fault detected see warning label 1 Flammable vapor present 2 Flammable vapor sensor exposed to excessive moisture 3 Flammable vapor sensor exposed to extreme amb...

Page 15: ...om the pilot and burn with a blue flame with a minimum of yellow tips Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter The main burner must be free fr...

Page 16: ...y from the combustion chamber Step 9 Thoroughly inspect the burner surface area and burner port area and remove any loose debris Step 10 Unscrew the burner from the main burner orifice Step 11 Remove...

Page 17: ...n Testing and Replacement Step 1 Move the gas control power switch to the OFF position Step 2 Unplug the water heater from the wall outlet Step 3 Turn off the gas supply to the water heater Step 4 Rem...

Page 18: ...nuity through the spark igniter flame sense wire Replace the pilot if there is no continuity Step 12 Visually inspect the spark igniter flame sense electrode for deterioration Replace the pilot assemb...

Page 19: ...r replace as necessary Step 16 Reassemble the pilot assembly and install it on the main feedline Reinstall the burner assembly into the combustion chamber Restore the gas supply and check for gas leak...

Page 20: ...d retain for later use Step 7 Remove the blower from the top of the water heater Step 8 Clean any debris from the jacket head of the water heater Step 9 Set the new blower in place using the water hea...

Page 21: ...switch 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 the water temperature using...

Page 22: ...the gas piping from the gas control Step 4 Disconnect the pilot tube using a 7 16 wrench and the main burner feedline with a 3 4 wrench from the gas control Step 5 Disconnect the wire harnesses and sp...

Page 23: ...resistance must be between 3 000 and 48 000 ohms for both the switch and sensor If the resistance is out of this range verify that the resettable thermal switch has not been tripped If it hasn t repla...

Page 24: ...t to damage pipe threads Step 6 Visually inspect the inlet nipple diptube The inlet nipple diptube should be free of cracks and any blockage Hydro jet slots should be open and free of any blockage Any...

Page 25: ...rmal If depletion is one half the original anode diameter approximately 3 4 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 7 Upon...

Page 26: ...from the draft hood that is mounted on top of the blower Step 4 Unplug the cord sets from the blower Step 5 Remove the 3 blower mounting screws using a 1 4 nut driver and retain for later use Blower...

Page 27: ...e flue Step 10 Check the burner to ensure no scale has accumulated during operation See the Burner Cleaning Procedure on page 15 if accumulation has occurred Step 11 Secure the blower in place using t...

Page 28: ...F position Step 2 Unplug the water heater from the wall outlet Step 3 Remove the outer door Step 4 Remove 4 1 4 hex drive screws from the right side inner door Gas control power switch Blower water he...

Page 29: ...tears missing material cracks dirt or debris lack of adhesion to the inner door material left on combustion chamber or any other imperfections that will inhibit a proper seal If any of the imperfecti...

Page 30: ...lication Note the overlap configuration in the flange area of the inner door Set the flange section first and this will help to achieve the proper overlap position Gasket Overlap must be as shown 1 32...

Page 31: ...ver tighten the screws Step 6 Align the right side inner door to the combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted openi...

Page 32: ...s one on the backside of the junction box is not shown holding the end of the blower junction box on Retain the screws for later use Step 5 Remove the pressure switch tubing from the pressure switch S...

Page 33: ...present Step 11 If there is not a blockage replace the pressure switch Verify the switch setting of the replacement switch matches the original switch s setting Step 12 Remove both terminals from the...

Page 34: ...flame sensor wire from gas control Step 6 Remove the burner assembly from the combustion chamber Step 7 Clean the ScreenLok flame arrestor using a stiff brush compressed air and or a shop vacuum to r...

Page 35: ...er Minute Hz Hertz KWh Kilowatts per hour LED Light Emitting Diode NPT National Pipe Thread Ohms Ohms of resistance PSI Pounds per Square Inch RPM Revolutions per Minute VAC Volts Alternating Current...

Page 36: ...edline 6 Magnesium Anode Hot Water Outlet 19 Gas Control Valve 7 Heat Trap Inlet 20 Wire Harness FVS RTS 8 Flue Ba e Assembly 21 FVS Sensor Clip 9 Dip Tube Cold Water Inlet 22 Flammable Vapor Sensor F...

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