Bradford White PDV Series User manual

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Manual 238-53795-00A REV 11/19
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RC2PDV50H*(N,X)
LC2PDV50H76*(N,X)
(*) Denotes Warranty Years
Residential & Light Duty Commercial
Power Direct Vent Models

The Bradford White
2
Condensing PDV 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............................................................................................................8 ---
Sequence of Operation...............................................................................................9 ---
Troubleshooting...........................................................................................................13 ---
Burner Inspection, Cleaning & Replacement ...........................................................15 I
Pilot Inspection Testing, Cleaning & Replacement ..................................................17 II
Pressure Switch Testing & Replacement .................................................................18 III
Blower Testing & Replacement .................................................................................20 IV
Blower Temperature Switch Testing & Replacement..............................................22 V
Gas Control Testing & Replacement
.........................................................................24 VI
Simulated Resistive Device Testing ..........................................................................28 VII
Safety Circuit Voltage Trace.......................................................................................29 VIII
115 VAC Circuit Trace ................................................................................................30 IX
Diptube Inspection & Replacement ...........................................................................31 X
Anode Inspection & Replacement .............................................................................32 XI
Flue Baffle Inspection & Replacement ......................................................................33 XII
Inner Door/Gasket Removal, Inspection & Replacement .......................................35 XIII
Condensate Trap Removal, Inspection & Replacement .........................................38 XIV
Exhaust Collector Removal, Inspection & Replacement.........................................39 XV
Parts Diagram..............................................................................................................41 ---
Notes ............................................................................................................................42 ---
2

Condensing PDV Series
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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 SHOULD
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.
3

Condensing PDV Series
4
Introduction
The 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 - developed for ease of troubleshooting
by providing simple diagnostic codes to pinpoint an installation or component performance issue.
New Powerful Blower - eliminates 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 series of condensing power
vent models.
4

Condensing PDV Series
5
How to Use This Manual
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: 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.
Multi-Meter: 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.
Electronic Probes: 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.
Thermometer: Used to measure water temperature. An accurate thermometer is recommended.
Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank pressure by
adapting to the drain valve of the heater.
Various Hand Tools: Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12” crescent
wrench, allen wrench set, screw drivers (common & Phillips), 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.
5

Condensing PDV Series
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Specifications
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 L.P., unit must match gas type supplied
Gas Pressure
5.0” w.c. min. for Natural Gas, 11.0” w.c. min. for L.P., 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)
Exhaust
Pressure Switch
Normally open
Closes on vacuum increase @ -2.15” w.c.
Intake
Pressure Switch
Normally closed
Opens on vacuum increase @ -0.8” w.c.
Blower
115 VAC, 60 Hz, 3.3 amps, 3000 RPM @ 1.5” w.c.
Glossary of Terms
BTU British Thermal Units psi Pounds per Square Inch
GPM Gallons per Minute RPM Revolutions per minute
Hz Hertz ECO Energy Cut Out
kWhr Kilowatt Hour VAC Volts Alternating Current
LED Light Emitting Diode “w.c. Inches of Water Column
NPT National Pipe Thread ºC Degrees Centigrade
Ohms Ohms of resistance ºF Degrees Fahrenheit
6

Condensing PDV Series
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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
1
45 (13.7)
2 (.6)
Through the Wall
2
40 (12.2)
2 (.6)
Through the Wall
3
35 (10.7)
2 (.6)
Through the Wall
4
30 (9.2)
2 (.6)
Through the Roof
0
50 (15.2)
7 (2.1)
Through the Roof
1
45 (13.7)
7 (2.1)
Through the Roof
2
40 (12.2)
7 (2.1)
Through the Roof
3
35 (10.7)
7 (2.1)
Through the Roof
4
30 (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
1
115 (35.0)
10 (3.1)
Through the Wall
2
110 (33.5)
10 (3.1)
Through the Wall
3
105 (32.0)
10 (3.1)
Through the Wall
4
100 (30.5)
10 (3.1)
Through the Wall
5
95 (29.0)
10 (3.1)
Through the Roof
0
120 (36.6)
15 (4.6)
Through the Roof
1
115 (35.0)
15 (4.6)
Through the Roof
2
110 (33.5)
15 (4.6)
Through the Roof
3
105 (32.0)
15 (4.6)
Through the Roof
4
100 (30.5)
15 (4.6)
4" Diameter (10.2 cm) Vent Connector Lengths
Terminating
# of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall
1
180 (54.9)
10 (3.1)
Through the Wall
2
175 (53.3)
10 (3.1)
Through the Wall
3
170 (51.8)
10 (3.1)
Through the Wall
4
165 (50.3)
10 (3.1)
Through the Wall
5
160 (48.8)
10 (3.1)
Through the Roof
0
180 (54.9)
15 (4.6)
Through the Roof
1
175 (53.3)
15 (4.6)
Through the Roof
2
170 (51.8)
15 (4.6)
Through the Roof
3
165 (50.3)
15 (4.6)
Through the Roof
4
160 (48.8)
15 (4.6)
7

Condensing PDV Series
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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 24)
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)
8

Condensing PDV Series
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Sequence of
Operation
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) Exhaust pressure switch normally open.
b) Intake pressure switch normally closed.
c) 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 both pressure switches are not closed 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 both pressure switches and temperature switch into a closed state.
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 will flash 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.
9

Condensing PDV Series
10
Sequence of
Operation
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 any 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 the flame is lost, the pilot and 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
10