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Manual 238-51636-00C REV 08/19

SERVICE

MANUAL

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 Warranty Years

Direct Vent Water Heaters

Flammable Vapor Ignition Resistant

Water Heaters

Содержание RG2DV40S Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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