Bradford White RG1PV40SN19 User manual

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Manual 238-53838-00B REV 04/22
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RG1PV40S*(N,X)19
RG1PV50S*(N,X)19
RG1PV55H*(N,X)19
LG1PV55H*(N,X)19
RG2PV40S*(N,X)19
RG2PV50S*(N,X)19
RG2PV50H*(N,X)19
LG2PV50H*(N,X)19
RG2PV40T*(N,X)19
RG2PV50T*(N,X)19
RG2PV60T*(N,X)19
RG2PV75H*(N,X)19
LG2PV75H*(N,X)19
* Denotes Warranty Year
PV Series
Through-The-Wall (TTW®)
Gas Water Heaters - 19 Models

2
The Bradford White
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........................................................................................................................... 8
---
Sequence of Operation ................................................................................................................9
---
Troubleshooting .........................................................................................................................13
---
Burner Inspection, Cleaning & Replacement ..........................................................................15
I
Pilot 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
Flammable Vapor Device Testing and Replacement..............................................................31
VII
Safety Circuit Voltage Trace.....................................................................................................32
VIII
115 VAC Circuit Trace .............................................................................................................33
IX
Dip Tube Inspection & Replacement.......................................................................................34
X
Anode Inspection & Replacement............................................................................................35
XI
Flue Baffle Inspection & Replacement ....................................................................................36
XII
Inner Door Removal, Inspection & Replacement...................................................................37
XIII
Glossary of Terms......................................................................................................................41
---
Parts List .....................................................................................................................................42
---
2

3
PV Series
WARNING: If the information in these
instructions is not followed exactly, afire or
explosion may result causing property damage,
personal injury, or death.
WHAT TO DO IF YOU SMELL GAS!
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from aneighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
•
•
Installation and service must be performed by aqualified
installer, service agency or the gas supplier.
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
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.
WARNING
FAILURE TO INSTALL AND MAINTAIN ANEW, LISTED ¾” X¾”
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE
THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT
FROM EXCESSIVE TEMPERATURE AND PRESSURES.
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.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
• Liquefied petroleum gases/propane gas and natural gas
have an odorant added by the gas supplier that aids in the
detection of the gas.
• Most people recognize this odor as a“sulfur” or “rotten egg”
smell.
• Other conditions, such as “odorant fade” can cause the
odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
• If you have adiminished sense of smell, or are in any way
unsure of the presence of gas, immediately contact your gas
supplier from aneighbor’s telephone.
Gas detectors are available. Contact your gas supplier, or plumbing
professional, for more information.
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
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.
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.
3

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PV Series
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.
Concealed Wiring Connections –Provide simple 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

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PV Series
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
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.
Manometer:
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.
Multi-Meter:
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.
Electronic Probes:
Used to measure water temperature. An accurate thermometer is
recommended.
Thermometer:
Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Water Pressure Gage:
Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12”
crescent wrench, allen wrench set, screw drivers (common & T20 Torx),
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.
Various Hand Tools:
5

6
PV Series
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, 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
RG(1,2)PV(40,50)(S,T) Models: Normally closed, opens @ 160F
(71C), auto reset @ approximately 140F (60C)
(L,R)G(1,2)PV(50,55,75)H Models: Normally closed, opens @
155F (68C), auto reset @ approximately 135F (57C)
Pressure Switch
RG(1,2)PV(40,50,60)(S,T) Models: Normally open, closes on
vacuum increase @ -.92” W.C.; Opens on vacuum decrease @
-.87” W.C.
(L,R)G(1,2)PV(50,55)H Models: Normally open, closes on
vacuum increase @ -.88" W.C.; opens on vacuum decrease @
-0.83" W.C.
(L,R)G2PV75H Models: Normally open, closes on vacuum
increase @ -0.96" W.C.; Opens on vacuum decrease @
-.91" W.C.
Blower
RG(1,2)PV(40,50,60)(S,T) Models: 115 VAC, 60 Hz, 2.8 amps,
3000 RPM.
(L,R)G(1,2)PV(50,55,75)H Models: 115 VAC 60 Hz, 3.3 amps,
3300 RPM
6

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PV Series
Vent Tables
Venting Specifications for:
RG1PV40S, RG2PV40T, RG2PV60T
RG1PV50S, RG2PV50T
TABLE 1 - VENT CONNECTOR LENGTHS
FOR 2 in (5.1 cm) DIAMETER VENT PIPE
Terminating
# of
Elbows
(excl. vent
terminals)
Minimum
Straight
Length ft
(m)
Maximum
Straight
Length
ft (m)
Elevation of installation
above sea level ft (m)
0-10100
(0-3079)
0-5400
(0-1646)
5401-7800
(1646-2378)
7801-10100
(2378-3079)
Through the Wall
1
2 (0.6)
45 (13.7)
30 (9.1)
20 (6.1)
Through the Wall
2
2 (0.6)
40 (12.2)
25 (7.6)
15 (4.6)
Through the Wall
3
2 (0.6)
35 (10.7)
20 (6.1)
10 (3.0)
Through the Wall
4
2 (0.6)
30 (9.1)
15 (4.6)
5 (1.5)
Through the Roof
0
7 (2.1)
50 (15.2)
35 (10.7)
25 (7.6)
Through the Roof
1
7 (2.1)
45 (13.7)
30 (9.1)
20 (6.1)
Through the Roof
2
7 (2.1)
40 (12.2)
25 (7.6)
15 (4.6)
Through the Roof
3
7 (2.1)
35 (10.7)
20 (6.1)
10 (3.0)
TABLE 2 –VENT CONNECTOR LENGTHS
FOR 3 in (7.6 cm) DIAMETER VENT PIPE
Terminating
# of Elbows
(excl. vent
terminals)
Minimum
Straight Length
ft (m)
Maximum
Straight Length
ft (m)
Elevation of installation
above sea level ft (m)
0-10100
(0-3079)
0-10100
(0-3079)
Through the Wall
1
10 (3.1)
115 (35.0)
Through the Wall
2
10 (3.1)
110 (33.5)
Through the Wall
3
10 (3.1)
105 (32.0)
Through the Wall
4
10 (3.1)
100 (30.5)
Through the Wall
5
10 (3.1)
95 (29.0)
Through the Roof
0
15 (4.6)
120 (36.6)
Through the Roof
1
15 (4.6)
115 (35.0)
Through the Roof
2
15 (4.6)
110 (33.5)
Through the Roof
3
15 (4.6)
105 (32.0)
Through the Roof
4
15 (4.6)
100 (30.5)
7

8
PV Series
Vent Tables (cont.)
Venting Specifications for:
RG1PV40S, RG2PV40T, RG2PV60T
RG1PV50S, RG2PV50T
TABLE 3 –VENT CONNECTOR LENGTHS
FOR 4 in (10.1 cm) DIAMETER VENT PIPE
Terminating
# of Elbows
(excl. vent
terminals)
Minimum
Straight Length
ft (m)
Maximum
Straight Length
ft (m)
Elevation of installation
above sea level ft (m)
0-10100
(0-3079)
0-2000
(0-610)
2001-10100
(611-3079)
Through the Wall
1
10 (3.1)
195 (59.4)
175 (53.3)
Through the Wall
2
10 (3.1)
190 (57.9)
170 (51.8)
Through the Wall
3
10 (3.1)
185 (56.4)
165 (50.3)
Through the Wall
4
10 (3.1)
180 (54.9)
160 (48.8)
Through the Wall
5
10 (3.1)
175 (53.3)
155 (47.2)
Through the Roof
0
15 (4.6)
200 (61.0)
180 (54.9)
Through the Roof
1
15 (4.6)
195 (59.4)
175 (53.3)
Through the Roof
2
15 (4.6)
190 (57.9)
170 (51.8)
Through the Roof
3
15 (4.6)
185 (56.4)
165 (50.3)
Through the Roof
4
15 (4.6)
180 (54.9)
160 (48.8)
8

9
PV Series
Vent Tables (cont.)
Venting Specifications for:
RG2PV50H, LG2PV50H
RG2PV75H, LG2PV75H
RG1PV55H, LG1PV55H
TABLE 1 - VENT CONNECTOR LENGTHS
FOR 3 in (7.6 cm) DIAMETER VENT PIPE
Terminating
# of
Elbows
(excl. vent
terminals)
Minimum
Straight
Length
ft (m)
Maximum
Straight
Length
ft (m)
Installation elevation above
sea level ft (m)
0-10100
(0-3079)
0-5400
(0-1646)
5401-7800
(1646-2378)
7801-10100
(2378-3079)
Through the Wall
1
2 (0.6)
70 (21.3)
45 (13.7)
20 (6.1)
Through the Wall
2
2 (0.6)
65 (19.8)
40 (12.2)
15 (4.6)
Through the Wall
3
2 (0.6)
60 (18.2)
35 (10.7)
10 (3.0)
Through the Wall
4
2 (0.6)
55 (16.7)
30 (9.1)
5(1.5)
Through the Roof
0
7 (2.1)
75 (22.8)
50 (15.2)
25 (7.6)
Through the Roof
1
7 (2.1)
70 (21.3)
45 (13.7)
20 (6.1)
Through the Roof
2
7 (2.1)
65 (19.8)
40 (12.2)
15 (4.6)
Through the Roof
3
7 (2.1)
60 (18.2)
35 (10.7)
10 (3.0)
TABLE 2 - VENT CONNECTOR LENGTHS
FOR 4 in (10.2 cm) DIAMETER VENT PIPE
Terminating
# of
Elbows
(excl. vent
terminals)
Minimum
Straight
Length
ft (m)
Maximum
Straight
Length
ft (m)
Elevation of installation
above sea level ft (m)
0-10100
(0-3079)
0-7800
(0-2378)
7801-10100
(2378-3079)
Through the Wall
1
10 (3.1)
175 (53.3)
140 (42.7)
Through the Wall
2
10 (3.1)
170 (51.8)
135 (41.2)
Through the Wall
3
10 (3.1)
165 (50.3)
130 (39.6)
Through the Wall
4
10 (3.1)
160 (48.8)
125 (38.1)
Through the Wall
5
10 (3.1)
155 (47.2)
120 (36.6)
Through the Roof
0
15 (4.6)
180 (54.9)
145 (44.2)
Through the Roof
1
15 (4.6)
175 (53.3)
140 (42.7)
Through the Roof
2
15 (4.6)
170 (51.8)
135 (41.2)
Through the Roof
3
15 (4.6)
165 (50.3)
130 (39.6)
Through the Roof
4
15 (4.6)
160 (48.8)
125 (38.1)
HIGH ALTITUDE INSTALLATIONS
This appliance has been certified for installations up to 10,100 ft above sea level without modification.
Installations greater than 10,100 ft above sea level are not intended. Unauthorized modifications may result in
unsafe operation.
WARNING: In order to assure the safe and efficient performance of the water heater, it is necessary to follow
the vent connector length rules shown above. Failure to adhere to these rules can result in the unsafe operation
of the appliance.
9

10
PV Series
Control Timings
Ignition State Timing
Pre-purge
2Seconds
Trial for Ignition
90 Seconds
Flame Stabilization Period
3Seconds
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