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)

8
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.

11
Condensing PV Series
11

Normal Heating Sequence (cont.)
7. Steady state operation.
During steady state operation, the control monitors:
Thermostat temperature sensor-when the set point temperature is satisfied, the
gas valve is shut down and the blower will post purge for 15 seconds. The control
LED flashes a short flash once every 4 seconds (idle) status code.
Pressure switch / blower temperature switch-if either switch opens, the pilot
valve and the main valve are both shut down. The blower continues to run for 30
seconds attempting to close the circuit. The control LED flashes 3 times with a 3
second pause.
Flame sensor-if flame is lost, the pilot & main valves are shut down and the blower
runs for 15 seconds. The control attempts to re-light the pilot 4 times. If
unsuccessful, the blower is shut down and the control proceeds to a 5 minute
lockout. The control re-attempts to light pilot starting at normal heating sequence
#2.
8. Thermostat satisfies. (Control LED flashing once every 4 seconds).
9. Burner off.
10.Blower post purges (15 seconds).
Abnormal Operation
1. Simulated Resistive Device Fault:
a. If the resistance is greater than 70,000 Ohms-the gas control immediately
turns off all outputs. The control waits and monitors the resistance for 30
seconds. If the resistance is greater than 65,000 ohms after 30 seconds, the
gas control proceeds to verify resistive delay for 2 minutes and flashes 7
times, then once with a three second pause. This process is repeated 5
times until the control either returns to normal operation or proceeds to
flammable vapor lockout.
b. If the resistance is below 3000 Ohms-The gas control immediately turns
off all outputs and proceeds to flash 8 times, then once with a three second
pause. The error self clears if the resistance returns to normal range for at
least 15 seconds.
2. Temperature Sensor Fault:
a. Temperature sensor detected open circuit–The gas control immediately
turns off all outputs and proceeds to flash 8 times, then 3 times with a 3
second pause. The error self clears if the fault clears for at least 15 seconds.
b. Thermal well sensor not reading the same temperature within ±5.5°F –
The gas control immediately turns off all outputs and proceeds to flash 8

12
Sequence of Operation
Condensing PV Series
12
Abnormal Operation (cont.)
times, then 3 times twice with 3 second pauses. The error self clears if the
fault clears for at least 15 seconds.
c. Water temperature in excess of ECO (Energy Cut Out) limit -The gas
control immediately turns off the pilot & main valves and proceeds to flash 4
times with a 3 second pause. The blower continues to run until the gas
control is reset. To reset the control, rotate the temperature control knob to
the minimum setting for at least 6 seconds before returning to the desired
temperature setting.
3. Pressure Switch/Blower Temperature Fault:
a. Pressure switch closed at start of call for heat-the gas control waits 4
seconds, then proceeds to flash 2 times a with 3 second pause. The control
waits 2 minutes and then turns on the blower for 30 seconds. The blower
turns off after 30 seconds and the control waits for the pressure switch to
open. Any time the pressure switch opens, the blower turns on (or stays on)
and the control proceeds to wait for the pressure switch to close.
b. Pressure switch or blower temperature switch failed to close-the gas
control runs the blower for 30 seconds waiting for the pressure switch and/or
blower temperature switch to close. If either switch does not close in 30
seconds, the blower turns off and the control flashes 3 times with a 3 second
pause. The gas control waits 2 minutes before turning on the blower for
another 30 seconds to check if the circuit will close. This cycle repeats as
long as there is a call for heat or until the circuit closes.
c. Pressure switch or blower temperature switch opens during burner
operation-the gas control turns off the pilot and main valve and runs the
blower for 15 seconds (inter-purge), waiting for the pressure switch and/or
blower temperature switch to close. If either switch fails to close, the control
proceeds as described in 3b above. If the circuit closes again by the end of
the inter-purge, the recycle counter is incremented, if the recycle count has
not reached its limit (4), another trial for ignition begins. If the recycle count
has been reached, the gas control turns off the blower and flashes 6 times,
then 2 times with a 3 second pause. The gas control waits 5 minutes before
repeating ignition sequence.
4. Trial for Ignition Fault:
a. Pressure switch opens during trial-the gas control turns off the igniter and
pilot valve. The gas control proceeds as described in 3b above. If the
pressure switch closes within 30 seconds, the gas control will continue with
trial for ignition starting at blower pre-purge.
b. Flame not sensed-the gas control energizes the spark igniter attempting to
light the pilot and prove flame. If the flame is not sensed within 90 seconds,
the igniter turns off, the pilot valve is closed and the gas control runs the

13
Sequence of Operation
Condensing PV Series
13
Abnormal Operation (cont.)
blower through post purge and flashes 6 times, then, a one time 3 second
pause. The control waits 5 minutes before repeating the ignition sequence.
5. Flame sensing fault:
a. Flame lost during run-the gas control turns off the pilot and main valves
and runs blower for 15 seconds (inter-purge). The gas control increments
the recycle count. If the recycle count has not reached its limit (4), another
trial for ignition begins. If the recycle count limit has been reached, the gas
control turns off the blower and flashes 6 times, then 3 times with a 3 second
pause. The gas control waits 5 minutes before repeating the ignition
sequence.
b. Flame sensed out of sequence-the gas control only looks for pilot flame
when the blower is running. If the flame is present when the pilot valve is not
open, the gas control proceeds to wait for flame loss and flashes 5 times with
a 3 second pause. This continues until flame signal is lost. Once the flame
signal is lost, the control flashes 6 times, then 4 times with a 3 second pause.
The control waits 5 minutes before repeating the ignition sequence.

14
Troubleshooting
Condensing PV Series
14
Observe green LED indicator on
electronic gas control. Error flash codes
are displayed with a three second pause
before repeating. Check and repair the
system as noted in the troubleshooting
table below.
LED Status Control Status Probable Cause Service Procedure
None, control
LED not on or
flashing
No electrical
Power.
Control power switch in “OFF” position.
Supply voltage interrupted. Turn power on
Short flash once
every four
seconds
Stand-by mode,
waiting for call for
heat (no fault).
Temperature demand is satisfied.
Normal operation.
Adjust thermostat to
temperature level.
“Heartbeat”
alternates
bright/dim
Thermostat
calling for heat
(no fault).
Tank temperature below set point of
thermostat.
Normal operation.
Adjust thermostat to
temperature level.
Short flash once
per second
Weak pilot signal
on last call for
heat.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
5. Low gas pressure.
Page 18
Procedure II
Two flash, three
second pause
Pressure switch
not working-
closed position.
1. Pressure switch tubing kinked or blocked.
2. Blocked pressure tap on switch or blower.
3. Faulty pressure switch.
Page 19
Procedure III
Three flash,
three second
pause
Pressure switch
or blower temp.
switch not
working -open
position.
1. Vent blockage or improper vent
configuration.
2. Pressure switch tubing kinked or blocked.
3. Faulty pressure switch.
4. Blower not spinning up to speed.
5. Blower temp or exhaust temp too high.
6. Faulty blower temperature switch.
1. Check vent or vent
tables.
2. & 3. Page 19
4. Page 21
5. & 6. Page 23
Four flash, three
second pause
Excessive tank
temperature.
System must be
reset.
1. Temperature sensor out of calibration.
2. Faulty gas control.
3. Plumbing leak.
1. Page 23
2. Replace gas
control, page 27
Five flash, three
second pause
Undesired-false
pilot flame
present.
1. Pilot valve stuck in open position. Replace gas control,
page 27

15
Troubleshooting
Condensing PV Series
15
LED Status Control Status Probable Cause Service Procedure
Six-one flash,
three second
pause
Failed to light
pilot.
System auto
resets.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
5. Low gas pressure.
Page 18
Six-two flash,
three second
pause
Pressure switch
or blower temp
switch opened
during burner
operation.
System auto
resets.
1. Vent blockage or improper vent
configuration.
2. Pressure switch tubing kinked or blocked.
3. Faulty pressure switch.
4. Vent termination being affected by wind.
5. Blower not spinning up to speed.
6. Blower temp or exhaust temp too high.
7. Faulty blower temperature switch.
8. Blocked condensate trap.
1. Check vent or vent
tables.
2. & 3. Page 19
4. Refer to venting
section of
installation manual.
5. Page 21
6. & 7. Page 23
8. Page 39
Six-three flash,
three second
pause
Pilot flame
extinguished.
System auto
resets.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
5. Insufficient combustion air.
6. Gas pressure is out of specification.
1.-4. Page 18
5. Refer to installation
manual
6. Page 25
Six-four flash,
three second
pause
Undesired-false
pilot flame
sensed.
System auto
resets.
Pilot valve stuck in open position. Replace gas control,
page 27
Seven flash,
three second
pause
Simulated
Resistive Device
fault detected.
Simulated resistance device harness out of
specification or disconnected. Page 29
Eight-one flash,
three second
pause
Simulated
Resistive Device
out of
specification.
Simulated resistive device out of
specification. Possible short. Page 29
Eight-two flash,
three second
pause
Temperature
sensor fault.
1. Damage to temperature sensor wire.
2. Temperature sensor resistance out of
range.
Page 27
Eight-three flash,
three second
pause
Gas valve
electronics fault
detected.
1. Control needs to be reset.
2. Control is wet or physically damaged.
1. Interrupt power
supply.
2. Replace gas control,
page 27
Eight-four flash,
three second
pause
Gas valve fault
detected.
1. Control needs to be reset.
2. Control is wet or physically damaged.
1. Interrupt power
supply.
2. Replace gas control,
page 27

16
PV SERVICE PROCEDURE I
Burner Inspection,
Cleaning & Replacement
Condensing PV Series
16
Burner Inspection
At periodic intervals (every 6 months) a visual inspection should be made of the pilot and main
burner for proper operation and to ensure no debris is accumulating.
The pilot flame should be stable. Some causes for an unstable pilot flame are:
a) The water heater vent is less than the allowable vent length.
b) The gas pressure is out of specification.
c) The pilot flame is not fully engulfing the spark/flame sensor.
The main burner should light smoothly from the pilot and burn with a blue flame and a minimum of
yellow tips.
The main burner must be free from any debris accumulation that may affect burner operation (see
burner cleaning procedure on page 17).

17
PV SERVICE PROCEDURE I
Burner Inspection,
Cleaning & Replacement
Condensing PV Series
17
Burner Cleaning
Step 1. Position the gas control power
switch to the “OFF” position and
unplug the water heater from wall
outlet.
Step 2. Turn off the gas supply to the water
heater.
Step 3. Remove the outer jacket door and inner door
per Service Procedure XIII on page 36.
Step 4. Disconnect the pilot tube (7/16” wrench) and
feedline (3/4” wrench) from the gas control.
Step 5. Disconnect the igniter/flame sensor wire from the gas control.
Step 6. Remove the burner assembly from the combustion chamber.
Step 7. Thoroughly inspect the burner surface area and burner port area and
remove any loose debris.
Step 8. Unscrew the burner from the main burner orifice.
Step 9. Remove the main burner orifice from
the feedline (1/2” wrench on steel
burners). Inspect the orifice and
clean or replace if necessary.
Step 10. Reassemble the burner and
reinstall into the water heater.
Restore the gas supply and check
for gas leaks.
Step 11. To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the Installation and
Operation manual.
NOTICE
The feedline nut for natural gas
control uses right hand threads,
LP control uses left hand thread.

18
PV SERVICE PROCEDURE II
Pilot Inspection, Cleaning & Replacement
Condensing PV Series
18
Pilot Inspection, Cleaning & Replacement
Step 1. Position the gas control power
switch to the “OFF” position and
unplug the water heater from wall
outlet.
Step 2. Turn off the gas supply to the water heater.
Step 3. Remove the outer jacket door and inner door
per Service Procedure XIII on page 36.
Step 4. Disconnect the pilot tubing nut (7/16” wrench) and feedline nut (3/4” wrench) from
the gas control.
Step 5. Disconnect the igniter/flame sense wire from the gas control.
Step 6. Remove the burner assembly from the combustion chamber.
Step 7. Remove the pilot assembly from the feedline (1/4” nut driver).
Step 8. Visually inspect the igniter/flame sense wire for damage. Replace the pilot if
damage is found.
Step 9. With a multi-meter set to the ohms setting,
check the continuity through the igniter/flame
sense wire. Replace the pilot if there is no
continuity.
Step 10. Visually inspect the igniter/flame sense
electrode for deterioration. Replace the pilot
as necessary. The electrode should not be in
contact with the pilot hood. If so, carefully
adjust the electrode to a gap distance of 3/32”
(.094”) from the pilot hood.
Step 11. Visually inspect the igniter/flame sense
electrode for oxidation build up. Carefully clean
any oxidation using a very fine emery cloth.
Step 12. Visually inspect the pilot tubing for kinks or
cracks. If damage is found, replace the pilot.
Step 13. Inspect the pilot tubing and pilot orifice for
blockage:
a. Remove the ferrule nut from the bottom of the pilot assembly (7/16” wrench).
b. Remove the pilot tube and pilot orifice.
c. Inspect the pilot tubing and pilot orifice for blockage. Clean or replace as
necessary.
Step 14. Reassemble pilot and install on feedline. Reinstall burner assembly to water
heater. Restore gas supply and check for gas leaks.
Step 15. To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the installation and
operation manual.

19
PV SERVICE PROCEDURE III
Pressure Switch Testing & Replacement
Condensing PV Series
19
Pressure Switch Testing & Replacement
Step 1. Position the power switch on the gas
control to the “OFF” position.
Step 2. Remove the three screws (Phillips screw driver) from the control access
cover on the blower assembly and remove the cover. Do not disconnect the
blower harness from the cover (see photo 1).
Step 3. Remove the 2 screws (Phillips screw driver) and carefully remove the
pressure switch to gain access to the wire lead connections (see photo 2).
With steps 1,2 & 3
complete, disconnect wire
leads from
p
ressure switch.
Use a mutli-meter set to the ohms
setting. With blower turned off, check
across pressure switch terminals.
Are switch contacts open?
(no electrical continuity)
N
Y
Position gas valve power switch
to the “ON” position and adjust
thermostat to call for heat, this
will start the blower. Check with
multi-meter, do the pressure
switch contacts close with blower
runnin
g
?
Y
Switch contacts are OK.
See Safety Circuit Voltage
Trace (page 30).
N
Y
Check tubing and
pressure tap on
switch for blockage.
Is there blockage?
Check tubing and pressure
tap on switch for blockage.
Is there blockage?
Y
N
Replace switch
(see page 19).
N
N
Clear blockage.
Is vent system
blocked?
YIs vent system length
within vent table
specifications listed on
p
a
g
es 7 & 8?
See blower testing
(page 21)
Is blower OK?
Reconfigure vent
system to be compliant
with vent tables.
Correct blower
problem.
N
NY
Y
1 2
Remove 3 Phillips screws to
remove cover.
Remove 2 Phillips screws to
pressure switch.
ps screws to
R
R
p
s
screws
to
R
p
Pressure switch wire leads.
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.

20
PV SERVICE PROCEDURE III
Pressure Switch Testing & Replacement
Condensing PV Series
20
Pressure Switch Replacement
Step 1. Position the gas control power
switch to the “OFF” position.
Step 2. Disconnect the tubing from the pressure switch (see photo 3).
Step 3. Remove three screws (Phillip’s screw driver) from the control access cover
on the blower assembly and remove the cover (see photo 4).
Step 4. Remove two screws (Phillips screw driver) from the blower housing and
carefully remove the pressure switch (see photo 5).
Step 5. Disconnect the wire leads from the pressure switch (see photo 6).
Step 6. Reconnect the wires from Step 5 to the new pressure switch.
Step 7. Carefully position the pressure switch into the blower housing and replace the
screws from Step 4.
Step 8. Replace the control access cover from Step 3 and fasten in place with the
three screws.
Step 9. Reconnect the tubing to the new pressure switch.
Step 10. Position the gas control power switch to the “ON” position and verify proper
heater operation.
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
3 4
56