Bradford White PV Series User manual

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Manual 238-51540-00D 4/19
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:
RG1PV40S*(N,X)
RG1PV50S*(N,X)
RG1PV55H*(N,X)
RG2PV40T*(N,X)
RG2PV50H*(N,X)
RG2PV50T*(N,X)
RG2PV75H*(N,X)
RG2PV60T*(N,X)
LG1PV55H78*(N,X)
LG2PV50H65*(N,X)
LG2PV75H76*(N,X)
(*) Denotes Warranty Years
Power Vent Gas Water Heaters
PV Series

The Bradford White
2
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 ---
Control Timings.........................................................................................................................10 ---
Sequence of Operation ..............................................................................................................11 ---
Troubleshooting.........................................................................................................................15 ---
Burner Inspection, Cleaning & Replacement .........................................................................17 I
Pilot Testing, Cleaning & Replacement ..................................................................................19 II
Pressure Switch Testing & Replacement ................................................................................20 III
Blower Testing & Replacement...............................................................................................22 IV
Blower Temperature Switch Testing & Replacement ...........................................................24 V
Gas Control Testing & Replacement.......................................................................................26 VI
Flammable Vapor Device Testing and Replacement.............................................................33 VII
Safety Circuit Voltage Trace ....................................................................................................34 VIII
115 VAC Circuit Trace.............................................................................................................35 IX
Dip Tube Inspection & Replacement ......................................................................................36 X
Anode Inspection & Replacement ...........................................................................................37 XI
Flue Baffle Inspection & Replacement....................................................................................38 XII
Inner Door Removal, Inspection & Replacement ..................................................................39 XIII
Glossary of Terms .....................................................................................................................43 ---
Parts List .....................................................................................................................................44 ---
Power Vent Gas Water Heaters
2

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.
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.
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
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.
3

PV Series
4
Introduction
The new Bradford White RG1PV & RG2PV 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, quiet operation, additional vent lengths, and Bradford White Defender
Safety System
®(not available on all models).
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.
Powerful Blower - will eliminate problems with difficult venting situations.
Quiet and Cool 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 maintaining Energy Factor &
FHR (not available on all models) performance.
The RG1PV & RG2PV water heaters use a combustion system where flue gases are combined with dilution
air to reduce the flue gas temperature in the blower. The diluted 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 power vent
models.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the opening in the jacket.
This air travels down and around the combustion chamber and enters through holes in the very bottom of the
corrosion-resistant combustion chamber. The air then travels up through the oriented flame arrestor plate
louvers, where the velocity of air is increased and its direction altered. The air then mixes in a normal
manner with supplied gas and is efficiently combusted, producing low NOx emissions.
In the unlikely event trace amounts of flammable vapors are present in the air flowing into the combustion
chamber, the vapors are harmlessly ignited by the burner. If flammable vapors are in sufficient quantity to
prevent normal combustion, the flammable vapor sensor recognizes this and shuts down the pilot and main
burner. Should the flammable vapor continue to burn, the flame arrestor plate prevents the flames from
traveling backwards and igniting vapors outside of the combustion chamber. This feature is only on models
with inputs less than or equal to 75,000 BTU/hr.
4

How to Use This Manual
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 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 beginning on page 15 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”
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

Specifications
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
RG1PV(40,50)S, (R,L)G2PV50H Models: Normally open, closes on vacuum increase
@ -.75” W.C.; Opens on vacuum decrease @ -.72” W.C.
RG2PV(40,50,60)T: Normally open, closes on vacuum increase @ -.80” W.C.;
Opens on vacuum decrease @ -.77” W.C.
(R,L)1PV55H Models: Normally open, closes on vacuum increase @ -1.40” W.C.;
Opens on vacuum decrease @ -1.37” W.C.
(R,L)G2PV75H Models: Normally open, closes on vacuum increase @ -1.25” W.C.;
Opens on vacuum decrease @ -1.22” W.C.
Blower 115 VAC, 60 Hz, 3.1 amps, 3000 RPM.
6

Specifications
PV Series
7
Vent Tables
Venting Specifications for:
RG1PV40S, RG2PV40T
RG1PV50S, RG2PV50T
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 (16.8) 2 (.6)
Through the Wall 240 (15.2) 2 (.6)
Through the Wall 335 (13.7) 2 (.6)
Through the Wall 430 (12.2) 2 (.6)
Through the Roof 050 (18.3) 7 (2.1)
Through the Roof 145 (16.8) 7 (2.1)
Through the Roof 240 (15.2) 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) 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) 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)
7

Specifications
PV Series
8
Vent Tables
Venting Specifications for:
RG2PV50H
LG2PV50H
3" Diameter (7.6 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 155 (16.8) 2 (.6)
Through the Wall 250 (15.2) 2 (.6)
Through the Wall 345 (13.7) 2 (.6)
Through the Wall 440 (12.2) 2 (.6)
Through the Roof 060 (18.3) 7 (2.1)
Through the Roof 155 (16.8) 7 (2.1)
Through the Roof 250 (15.2) 7 (2.1)
Through the Roof 345 (13.7) 7 (2.1)
4" Diameter (10.2 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 1175 (53.3) 10 (3.1)
Through the Wall 2170 (51.8) 10 (3.1)
Through the Wall 3165 (50.3) 10 (3.1)
Through the Wall 4160 (48.8) 10 (3.1)
Through the Wall 5155 (47.2) 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)
8

Specifications
PV Series
9
Vent Tables
Venting Specifications for:
RG1PV55H
RG2PV75H
LG1PV55H
LG2PV75H
3" Diameter (7.6 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 (9.1) 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)
4" Diameter (7.6 cm) Vent Connector Lengths
Terminating # of
Elbows
Maximum
Straight
Length ft. (m)
Minimum
Straight
Length ft. (m)
Through the Wall 1175 (53.3) 10 (3.1)
Through the Wall 2170 (51.8) 10 (3.1)
Through the Wall 3165 (50.3) 10 (3.1)
Through the Wall 4160 (48.8) 10 (3.1)
Through the Wall 5155 (47.2) 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

Specifications
PV Series
10
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 page 27)
Verify Resistive Delay Retry after 2 minutes (repeats 5 times)
Flammable Vapor Sensor/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
PV Series
11
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 “Flammable Vapor Sensor” (for
RG1PV40S, RG1PV50S, RG2PV40T, RG2PV50T, RG2PV 60T, RG2PV50H) or
“Simulated Resistive Device” (for RG1PV55H and RG2PV75H) is out of range, the
control will test the “Flammable Vapor Sensor” or “Simulated Resistive Device” for
proper operating range. If the “Flammable Vapor Sensor” or “Simulative Resistive
Device” is out of range, the control LED immediately flashes 7 times with 3 second
pause.
Normal Heating Sequence
1. Thermostat calls for heat.
Prior to energizing blower, gas control checks safety circuit to ensure 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, gas control LED
flashes 2 times with 3 second pause. Gas control waits 2 minutes then,
blower runs for 30 seconds. This cycle repeats until 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 spark igniter and gas flow to pilot
burner.
b. If flame is not sensed within 90 seconds, igniter and gas flow are
deactivated, blower will post purge and control LED flashes 6 times with 3
second pause.
6. Main burner ignition.
After pilot flame is sensed, gas control activates main valve for main burner ignition.
The gas control will ignore flame and pressure switch signals for 3 seconds allowing
for main burner to stabilize.
11

Sequence of Operation
PV Series
12
Normal Heating Sequence (cont.)
7. Steady state operation.
During steady state operation, the control monitors:
Thermostat temperature sensor-when set point temperature is satisfied, gas
valve is shut down and blower will post purge for 15 seconds. 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 3
second pause.
Flame sensor-if flame is lost, pilot & main valves are shut down, blower runs for 15
seconds. Control attempts to re-light pilot 4 times. If unsuccessful, blower is shut
down and control proceeds to 5 minute lockout. 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. Flammable Vapor Sensor or Simulated Resistive Device Fault:
a. If the resistance is greater than 70,000 Ohms-the gas control immediately
turns off all outputs. Control waits and monitors 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 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 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
PV Series
13
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 pilot & main valves and proceeds to flash 4
times with 3 second pause. Blower continues to run until gas control is reset.
To reset control, rotate knob of temperature control to the minimum setting
for at least 6 seconds before returning to 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 with 3 second pause. The control
waits 2 minutes and then turns on blower for 30 seconds. The blower turns
off after 30 seconds and the control waits for pressure switch to open. Any
time the pressure switch opens, the blower turns on (or stays on) and the
control proceeds to wait for 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 3 second
pause. The gas control waits 2 minutes before turning on the blower for
another 30 seconds to see the circuit 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, runs blower for
15 seconds (inter-purge) waiting for 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 3 second pause. The gas control waits 5 minutes before
repeating ignition sequence.
4. Trail for Ignition Fault:
a. Pressure switch opens during trial-the gas control turns off 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 flame is not sensed within 90 seconds, the
igniter turns off, the pilot valve is closed and the gas control runs the blower
through post purge and flashes 6 times then, once with 3 second pause.
The control waits 5 minutes before repeating the ignition sequence.
13

Sequence of Operation
PV Series
14
Abnormal Operation (cont.)
5. Flame sensing fault:
a. Flame lost during run-the gas control turns off pilot and main valves, 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 has been reached, the gas control turns
off the blower and flashes 6 times then, 3 times with 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 flame is present when the pilot valve is not
open, the gas control proceeds to wait for flame loss and flashes 5 times with
3 second pause. This continues until flame is lost. Once the flame signal is
lost, the control flashes 6 times then, 4 times with 3 second pause. The
control waits 5 minutes before repeating the ignition sequence.
14

Troubleshooting
PV Series
15
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
temp level.
“Heartbeat”
alternates
bright/dim
Thermostat
calling
for heat (no fault).
Tank temperature below set point of
thermostat.
Normal operation.
Adjust thermostat to
temp level.
Short flash once
per second
Weak pilot signal
on last call for
heat.
1. Unstable pilot.
2. Pilot tube block or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
Page 19
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 20
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 20
4. Page 22
5 & 6 Page 24
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 25
2. Replace gas control,
page 31
Five flash, three
second pause
Undesired-false
pilot flame
present.
1. Pilot valve stuck in open position.
Replace gas control,
page 31
Troubleshooting
PV Series
15
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
temp level.
“Heartbeat”
alternates
bright/dim
Thermostat
calling
for heat (no fault).
Tank temperature below set point of
thermostat.
Normal operation.
Adjust thermostat to
temp level.
Short flash once
per second
Weak pilot signal
on last call for
heat.
1. Unstable pilot.
2. Pilot tube block or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
Page 19
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 20
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 20
4. Page 22
5 & 6 Page 24
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 25
2. Replace gas control,
page 31
Five flash, three
second pause
Undesired-false
pilot flame
present.
1. Pilot valve stuck in open position.
Replace gas control,
page 31
15

Troubleshooting
PV Series
16
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.
Page 19
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.
1. Check vent or vent tables.
2 & 3 Page 20
4. Refer to venting section of
installation manual
5. Page 22
6 & 7 Pa
g
e 24
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 19
5. Refer to installation
manual
6. Page 26
Six-four
flash, three
second
pause
Undesired-false
pilot flame
sensed.
System auto
resets.
Pilot valve stuck in open position.
Replace gas control,
page 31
Seven flash,
three second
pause
Flammable vapor
sensor fault
detected.
Flammable vapor sensor or simulative resistance
device out of specification. Page 33
Eight-one
flash, three
second
pause
Flammable vapor
sensor out of
specification.
Flammable vapor sensor or simulated resistive
device out of specification. Page 33
Eight-two
flash, three
second
pause
Temperature
Sensor fault.
1. Damage to temperature sensor wire.
2. Temperature sensor resistance out of range. Page 29
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 31
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 31
16

PV SERVICE PROCEDURE I
Burner Operation Inspection,
Cleaning and Replacement
PV Series
17
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 assure no debris is accumulating.
Pilot flame should be stable, some causes for an unstable pilot flame are:
a) Water heater vent is less than the allowable vent length.
b) Gas pressure is out of specification.
c) Pilot flame not fully engulfing spark/flame sensor.
Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow
tips.
Main burner must be free from any debris accumulation that may affect burner operation (see
burner cleaning procedure on page 18).
17

PV SERVICE PROCEDURE I
Burner Operation Inspection,
Cleaning and Replacement
PV Series
18
Burner Cleaning
Step 1. Position gas control power
switch to the “OFF” position and
unplug heater from wall outlet.
Step 2. Turn off gas supply to water
heater.
Step 3. Remove outer jacket door and
inner door per service
procedure XIII on page 39.
Step 4. Disconnect pilot tube (7/16” wrench)
and feedline (3/4” wrench) from gas
control.
Step 5. Disconnect igniter/flame sensor wire from gas control.
Step 6. Remove burner assembly from combustion chamber.
Step 7. Thoroughly inspect burner surface area and burner port area and remove
any loose debris.
Step 8. Unscrew burner from main burner orifice.
Step 9. Remove main burner orifice from
feedline (1/2” wrench on steel
burners) inspect orifice, clean or
replace if necessary.
Step 10. Reassemble burner and reinstall
into water heater. Restore gas
supply and check for gas leaks.
Step 11. To resume operation, follow the instruction located on the lighting
instruction label or the lighting instruction located in the installation and
operation manual.
NOTICE
Feedline nut for natural gas control
uses right hand threads, LP control
uses left hand thread.
18

PV SERVICE PROCEDURE II
Pilot Inspection, Testing and Replacement
PV Series
19
Pilot Inspection, Testing and
Replacement
Step 1. Position gas control power
switch to the “OFF” position
and unplug heater from wall
outlet.
Step 2. Turn off gas supply to water
heater.
Step 3. Remove outer jacket door and inner door per
service procedure XIII on page 39.
Step 4. Disconnect pilot tubing nut (7/16” wrench) and
feedline nut (3/4” wrench) from gas control.
Step 5. Disconnect igniter/flame sense wire from gas control.
Step 6. Remove burner assembly from combustion chamber.
Step 7. Remove pilot assembly from feedline (1/4” nut driver).
Step 8. Visually inspect igniter/flame sense wire for damage. Replace pilot if damage
is found.
Step 9. With a multi-meter set to ohms setting,
check continuity through igniter/flame
sense wire. Replace pilot if no continuity.
Step 10. Visually inspect igniter/flame sense
electrode for deterioration. Replace pilot
as necessary. Electrode should not be in
contact with pilot hood, if so, carefully
adjust electrode to a gap of distance of
3/32” (.09) from pilot hood.
Step 11. Visually inspect igniter/flame sense
electrode for oxidation build up. Carefully
clean any oxidation using very fine emery
cloth.
Step 12. Visually inspect pilot tubing for kinks or
cracks. If damage is found, replace pilot.
Step 13. Inspect pilot tubing and pilot orifice for
blockage:
a. Remove ferrule nut from bottom of pilot
assembly (7/16” wrench).
b. Remove pilot tube and pilot orifice.
c. Inspect 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.
19

PV SERVICE PROCEDURE III
Pressure Switch Testing and Replacement
PV Series
20
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.
Pressure Switch Testing
Step 1. Position power switch on gas
control to the “OFF” position.
Step 2. Remove the three screws (Phillips screw driver) from control access cover
on blower assembly and remove cover (see photo 1).
Step 3. Remove pressure switch from blower housing by removing the two T10
screws (see photo 2a). If it does not have 2 screws, carefully remove it from
the housing (see photo 2b).
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
20