Bradford White Condensing PV Series User manual

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Manual 238‐51526‐00B 08/18
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
Through‐The‐Wall Models:
RC2PV50H*(N,X)
LC2PV50H76*(N,X)
(*) Denotes Warranty Years
Through-The-Wall Gas Water Heaters
Condensing PV Series

2
The Bradford White
2
Condensing PV Series
Through-The-Wall Gas Water Heaters
Table of Contents
Page PV Service Procedure
Introduction ................................................................................................................................4 ---
How to Use This Manual..........................................................................................................5 ---
Tools Required for Service .......................................................................................................5 ---
Specifications .............................................................................................................................6 ---
Glossary of Terms .....................................................................................................................6 ---
Vent Tables ................................................................................................................................7 ---
Control Timings.........................................................................................................................9 ---
Sequence of Operation ..............................................................................................................10 ---
Troubleshooting.........................................................................................................................14 ---
Burner Inspection, Cleaning & Replacement .........................................................................16 I
Pilot Inspection Testing, Cleaning & Replacement................................................................18 II
Pressure Switch Testing & Replacement ................................................................................19 III
Blower Testing & Replacement...............................................................................................21 IV
Blower Temperature Switch Testing & Replacement ...........................................................23 V
Gas Control Testing & Replacement.......................................................................................25 VI
Simulated Resistive Device Testing ........................................................................................29 VII
Safety Circuit Voltage Trace ....................................................................................................30 VIII
115 VAC Circuit Trace.............................................................................................................31 IX
Diptube Inspection & Replacement.........................................................................................32 X
Anode Inspection & Replacement ...........................................................................................33 XI
Flue Baffle Inspection & Replacement....................................................................................34 XII
Inner Door/Gasket Removal, Inspection & Replacement .....................................................36 XIII
Condensate Trap Removal, Inspection & Replacement........................................................39 XIV
Exhaust Collector Removal, Inspection & Replacement.......................................................40 XV
Parts List .....................................................................................................................................42 ---
Notes ...........................................................................................................................................43 ---

3
Condensing PV Series
3
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury, or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in the
vicinity of this or any other appliance.
IMPORTANT
Before proceeding, please inspect the
water heater and its components for
possible damage. DO NOT install any
water heater with damaged
components. If damage is evident
then please contact the supplier where
the water heater was purchased or the
manufacturer listed on the rating plate
for replacement parts.
WHAT TO DO IF YOU SMELL GAS!
xDo not try to light any appliance.
xDo not touch any electrical switch; do not use any
phone in your building.
xImmediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
xIf you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
DANGER
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in
the vicinity of this or any other appliance.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
xLiquefied petroleum gases/propane gas and natural gas
have an odorant added by the gas supplier that aids in the
detection of the gas.
xMost people recognize this odor as a “sulfur” or “rotten egg”
smell.
xOther conditions, such as “odorant fade” can cause the
odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
xIf you have a diminished sense of 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, for more information.
CAUTION
Turn off or disconnect the electrical power supply to the water heater
before servicing. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED ¾” X ¾”
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE
THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT
FROM EXCESSIVE TEMPERATURE AND PRESSURES.
WARNING
Water heaters are heat producing appliances. To avoid damage
or injury, do not store materials against the water heater or vent-
air intake system. Use proper care to avoid unnecessary contact
(especially by children) with the water heater and vent-air intake
components. UNDER NO CIRCUMSTANCES MUST
FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT
THINNER BE USED OR STORED IN THE VICINITY OF THIS
WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY
LOCATION FROM WHICH FUMES COULD REACH THE
WATER HEATER OR VENT-AIR INTAKE SYSTEM
WARNING
Hydrogen gas can be produced in an operating water heater that
has not had water drawn from the tank for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable. To prevent the possibility of injury under these
conditions, we recommend the hot water faucet to be open for
several minutes at the kitchen sink before you use any electrical
appliance which is connected to 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 time it is open.
CAUTION
If sweat fittings are to be used DO NOT apply 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
plastic liner.

4
Condensing PV Series
4
Introduction
The new Bradford White residential condensing water heaters are designed to provide reliable performance
with enhanced standard features. New design features include reliable spark to pilot ignition system,
enhanced diagnostics, simplified servicing, significantly quiet operation and additional vent lengths.
Spark to Pilot Ignition System - employing the spark to pilot ignition system promotes reliable and consistent
pilot and main burner ignitions to provide hot water on demand.
Integrated Immersion Thermostat/Gas Control Valve with LED - was developed for ease of troubleshooting
by providing simple diagnostic codes to pinpoint an installation or component performance issue.
New Powerful Blower - will eliminate problems with difficult venting situations.
Quieter and Cooler Blower Operation - blower noise is significantly reduced for both interior and exterior
environments. Cooler operation increases blower life by reducing bearing wear and noise.
Rugged Wiring Connections - receptacle type connections promote error free wiring.
Increased Vent Lengths - increased venting performance is achieved while achieving 90% Thermal
Efficiency and enhanced Standby Loss performance.
The residential condensing water heaters use a combustion system where the flue gases are pulled at a low
temperature from the water heater directly into the blower. The flue gases are evacuated to the exterior
through low temperature vent materials. The gas control maintains water temperature, ignition sequence
and regulates gas flow. A safety circuit consisting of a pressure switch and blower temperature switch
verifies proper conditions exist for safe and reliable operation. If a situation outside of normal operating
parameters exists, the gas control diagnostic LED will flash a code to positively identify an operational issue.
This service manual is designed to facilitate problem diagnosis and enhance service efficiency.
Please read the service manual completely before attempting service on this new series of condensing
power vent models.

5
How to Use This Manual
Condensing PV Series
5
It is intended for this manual to be used by qualified service personnel for the primary purpose of
troubleshooting and repair of the Bradford White Condensing PV Series water heaters. Understanding the
sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.
The Honeywell WV4462A Electronic Gas Control will display error codes in the event of abnormal operation.
Error codes are listed in the troubleshooting chart of this service manual. The troubleshooting chart will also
indicate the probable cause for the error code and direct the service professional to a service procedure to
properly diagnose the abnormal operation.
In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to
determine the problem.
Contact the Bradford White technical support group immediately if diagnosis cannot be made using the
methods described in this service manual.
Tools Required for Service
Manometer:
Multi-Meter:
Electronic Probes:
Thermometer:
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 recommended. This device is used to measure
electrical values. The meter you select must have the capability to
measure volts AC, volts DC, Amps, micro-amps and ohms.
In some cases, standard multi-meter probes will damage or simply not be
effective to obtain certain voltage and ohm readings. It will be necessary to
have special electronic “pin” type multi-meter probes. These probes are
available at most electronic wholesale outlets.
Used to measure water temperature. An accurate thermometer is
recommended.
Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12”
crescent wrench, allen wrench set, screw drivers (common & Phillip’s), 1/4”
& 5/16” nut driver, pliers (common & needle nose), socket set, side cutters,
wire cutters, wire strippers, wire crimpers, torpedo level, small shop vac,
step ladder, flashlight and 5-gallon pail.

6
Specifications
Condensing PV Series
6
Power supply Dedicated 115 VAC, 60 Hz, 15A.
Gas Supply Pipe Minimum 1/2” NPT (schedule 40 black iron pipe recommended).
Approved Gas
Type Natural Gas or Propane, unit must match gas type supplied.
Gas Pressure 5.0” w.c. min. for Natural Gas, 11.0” w.c. min. for Propane, 14.0” w.c. maximum
(Natural Gas & Propane).
Venting System Power vent through the wall or vertical through the roof.
Approved Vent
Materials PVC, CPVC or ABS.
Minimum
Clearance for
Servicing
18” from top, 24” from front, 4” sides and rear.
Water Supply
Pressure
150 psi maximum allowable working pressure. Check local codes for supply
pressure.
Gas Control
ECO Limit Residential 188°F (87°C), Commercial 199°F (93°C).
Residential
Temperature Set
Point Range
60°F (16°C) to 160°F (71°C) (approximate temperatures).
Commercial
Temperature Set
Point Range
80°F (27°C) to 180°F (82°C) (approximate temperatures).
Blower
Temperature
Switch
Normally closed, opens @ 155°F (68°C), auto reset @ approximately 135°F (57°C).
Pressure Switch Normally open
Closes on vacuum increase @ -1.73” w.c.
Blower 115 VAC, 60 Hz, 3.3 amps, 3000 RPM @ 1.5” w.c.
Glossary of Terms
BTU British Thermal Units
GPM Gallons per Minute
Hz Hertz
kWhr 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. Inches of Water Column
ºC Degrees Centigrade
ºF Degrees Fahrenheit

7
Vent Tables
Condensing PV Series
7
Vent Tables
2" Diameter (5.1 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 145 (13.7) 2 (.6)
Through the Wall 240 (12.2) 2 (.6)
Through the Wall 335 (10.7) 2 (.6)
Through the Wall 430 (9.2) 2 (.6)
Through the Roof 050 (15.2) 7 (2.1)
Through the Roof 145 (13.7) 7 (2.1)
Through the Roof 240 (12.2) 7 (2.1)
Through the Roof 335 (10.7) 7 (2.1)
Through the Roof 430 (9.2) 7 (2.1)
3" Diameter (10.2 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 1115 (35.0) 10 (3.1)
Through the Wall 2110 (33.5) 10 (3.1)
Through the Wall 3105 (32.0) 10 (3.1)
Through the Wall 4100 (30.5) 10 (3.1)
Through the Wall 595 (29.0) 10 (3.1)
Through the Roof 0120 (36.6) 15 (4.6)
Through the Roof 1115 (35.0) 15 (4.6)
Through the Roof 2110 (33.5) 15 (4.6)
Through the Roof 3105 (32.0) 15 (4.6)
Through the Roof 4100 (30.5) 15 (4.6)

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Vent Tables
Condensing PV Series
8
Vent Tables
4" Diameter (10.2 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 1180 (54.9) 10 (3.1)
Through the Wall 2175 (53.3) 10 (3.1)
Through the Wall 3170 (51.8) 10 (3.1)
Through the Wall 4165 (50.3) 10 (3.1)
Through the Wall 5160 (48.8) 10 (3.1)
Through the Roof 0180 (54.9) 15 (4.6)
Through the Roof 1175 (53.3) 15 (4.6)
Through the Roof 2170 (51.8) 15 (4.6)
Through the Roof 3165 (50.3) 15 (4.6)
Through the Roof 4160 (48.8) 15 (4.6)

9
Control Timings
Condensing PV Series
9
Control Timings
Ignition State Timing
Pre-purge 2 Seconds
Trial for Ignition 90 Seconds
Flame Stabilization Period 3 Seconds
Inter-purge 15 Seconds
Flame Failure Response Time 1.5 Seconds (2 second maximum; 1 second minimum.)
Post-purge 15 Seconds
PS Fault Delay (failed open/close) Retry after 2 minutes
Soft Lockout Retry after 5 minutes
ECO Limit Lockout Indefinite (see PV SERVICE PROCEDURE VI; page 26)
Verify Resistive Delay Retry after 2 minutes (repeats 5 times)
Simulated Resistive Load Lockout Indefinite (cycle power to restart)
Hardware Error Lockout Indefinite (self clears if fault clears for at least 15 seconds)

10
Sequence of Operation
Condensing PV Series
10
Power Up Sequence
1. Start Up.
Upon power up, the control runs a safe-start check with a typical start-up delay of 5
seconds.
2. Flammable Vapor.
To assure no outputs are energized if the “Simulated Resistive Device” is out of
range, the control will test the “Simulated Resistive Device” for proper operating
range. If “Simulated Resistive Device” is out of range, the control LED immediately
flashes 7 times with a 3 second pause.
Normal Heating Sequence
1. Thermostat calls for heat.
Prior to energizing the blower, the gas control checks the safety circuit to ensure
that the circuit is open. Normal switch positions in the safety circuit are as follows:
a) Pressure switch normally open.
b) Blower temperature switch normally closed.
If the safety circuit is closed, the control waits 4 seconds, then the gas
control LED flashes 2 times with a 3 second pause. The gas control waits 2
minutes and then the blower runs for 30 seconds. This cycle repeats until
the safety circuit opens.
2. Blower energizes.
3. Pressure switch proves blower/vent system operation.
If the pressure switch does not close within 30 seconds, the control LED flashes 3
times with 3 second pause. The blower runs for 30 seconds every 2 minutes trying
to get the pressure switch or blower temperature switch to close. This cycle repeats
as long as there is a call for heat.
4. Blower pre-purge period (2 seconds).
5. Trial for pilot ignition (90 seconds).
a. The gas control lights the pilot by activating the spark igniter and gas flow to
the pilot burner.
b. If the flame is not sensed within 90 seconds, the igniter and gas flow are
deactivated, the blower will post purge and the control LED flashes 6 times
with a 3 second pause.
6. Main burner ignition.
After the pilot flame is sensed, the gas control activates the main valve for main
burner ignition. The gas control will ignore the flame and pressure switch signals
for 3 seconds allowing for the main burner to stabilize.