Bradford White LC2PV50H76N, RC2PV50HN, RC2PV50HX, LC2PV50H76X, RC2PV50H series Service Manual

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Condensing PV Series

Through-The-Wall Gas Water Heaters

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

Manual 238‐51526‐00A REV 08/18

Save this manual for future reference

The Bradford White

IV



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

Blower Temperature Switch Testing & Replacement ........................................................... 23 V

Gas Control Testing & Replacement ....................................................................................... 25 VI

Simulative 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 ---

2


2

Condensing PV Series

WARNING: If the information in these

instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury, or death.



WHATTODOIFYOUSMELLGAS!

x Donottrytolightanyappliance.
x Donottouchanyelectricalswitch;donotuseany

phoneinyourbuilding.

x Immediatelycallyourgassupplierfromaneighbor'sphone.

Followthegassupplier'sinstructions.

x If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.

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.

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

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

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

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:

x Liquefied petroleum gases/propane gas and natural gas

have an odorant added by the gas supplier that aids in the
detection of the gas.

x Most people recognize this odor as a “sulfur” or “rotten egg”

smell.

x Other conditions, such as “odorant fade” can cause the

odorant to diminish in intensity, or “fade”, and not be as
readily detectable.

x If 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.



3

3

Condensing PV Series



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.

4


4

Condensing 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 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.



5

5

Condensing 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

Gas Pressure

Venting System Power vent through the wall or vertical through the roof.
Approved Vent
Materials
Minimum
Clearance for
Servicing
Water Supply
Pressure
Gas Control
ECO Limit
Residential
Temperature Set
Point Range

Commercial
Temperature Set
Point Range

Blower
Temperature
Switch

Pressure Switch

Natural Gas or Propane, unit must match gas type supplied.

5.0” w.c. min. for Natural Gas, 11.0” w.c. min. for Propane, 14.0” w.c. maximum
(Natural Gas & Propane).

PVC, CPVC or ABS.

18” from top, 24” from front, 4” sides and rear.

150 psi maximum allowable working pressure. Check local codes for supply
pressure.

Residential 188°F (87°C), Commercial 199°F (93°C).

60°F (16°C) to 160°F (71°C) (approximate temperatures).

80°F (27°C) to 180°F (82°C) (approximate temperatures).

Normally closed, opens @ 155°F (68°C), auto reset @ approximately 135°F (57°C).

Normally open
Closes on vacuum increase @ -1.73” w.c.

Blower

6


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

6

Condensing PV Series

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

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

3" Diameter (10.2 cm) Vent Connector Lengths

Terminating

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

1

2

3

4

0

1

2

3

4

# of

Elbows

1

2

3

4

5

0

1

2

3

4

45 (13.7) 2 (.6)

40 (12.2)

35 (10.7) 2 (.6)

30 (9.2) 2 (.6)

50 (15.2) 7 (2.1)

45 (13.7)

40 (12.2) 7 (2.1)

35 (10.7) 7 (2.1)

30 (9.2) 7 (2.1)

Maximum Straight

Length ft. (m)

115 (35.0) 10 (3.1)

110 (33.5) 10 (3.1)

105 (32.0) 10 (3.1)

100 (30.5) 10 (3.1)

95 (29.0) 10 (3.1)

120 (36.6) 15 (4.6)

115 (35.0) 15 (4.6)

110 (33.5) 15 (4.6)

105 (32.0) 15 (4.6)

100 (30.5) 15 (4.6)

Minimum Straight

Length ft. (m)

2 (.6)

7 (2.1)



7

7

Condensing PV Series

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

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

1

2

3

4

5

0

1

2

3

4

180 (54.9) 10 (3.1)

175 (53.3) 10 (3.1)

170 (51.8) 10 (3.1)

165 (50.3) 10 (3.1)

160 (48.8) 10 (3.1)

180 (54.9) 15 (4.6)

175 (53.3) 15 (4.6)

170 (51.8) 15 (4.6)

165 (50.3) 15 (4.6)

160 (48.8) 15 (4.6)

8


8

Condensing PV Series

Control Timings

Ignition State Timing

Pre-purge
Trial for Ignition 90 Seconds

Flame Stabilization Period
Inter-purge
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)

2 Seconds

3 Seconds
15 Seconds



9

9

Condensing PV Series

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 “Simulative 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 insure 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.

10


10

Condensing PV Series

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



11

11

Condensing PV Series

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

12


12

Condensing PV Series

Abnormal Operation (cont.)

blower through post purge and flashes 6 times, then once with a 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.



13

13

Condensing PV Series

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

None, control
LED not on or
flashing

Short flash once
every four
seconds

“Heartbeat”
alternates
bright/dim

Short flash once
per second

Two flash, three
second pause

Three flash,
three second
pause

Four flash, three
second pause

Five flash, three
second pause

No electrical
Power.

Stand-by mode,
Waiting for call

for heat (no fault).
Thermostat

calling for heat
(no fault).

Weak pilot signal
on last call for
heat.

Pressure switch
not working­closed position.

Pressure switch
or blower temp.
switch not
working -open
position.

Excessive tank
temperature.
System must be

reset.
Undesired-false
pilot flame
present.

Control power switch in “OFF” position.
Supply voltage interrupted.

Temperature demand is satisfied

Tank temperature below set point of
thermostat.

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.

5. Low gas pressure.

1. Pressure switch tubing kinked or blocked.

2. Blocked pressure tap on switch or blower.

3. Faulty pressure switch.

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. Temperature sensor out of calibration.

2. Faulty gas control.

3. Plumbing leak.

1. Pilot valve stuck in open position.

ServiceProcedure

Turn power on

Normal operation.
Adjust thermostat to

temperature level.
Normal operation.
Adjust thermostat to

temperature level.

Page 18
Procedure II

Page 19
Procedure III

1. Check vent or vent
tables.

2. & 3. Page 19

4. Page 21

5. & 6. Page 23

1. Page 23

2. Replace gas
control, page 27

Replace gas control,
page 27

14


14

Condensing PV Series

LEDStatus ControlStatus ProbableCause

1. Unstable pilot.

Six-one flash,
three second
pause

Six-two flash,
three second
pause

Six-three flash,
three second
pause

Six-four flash,
three second
pause

Seven flash,
three second
pause

Eight-one flash,
three second
pause

Eight-two flash,
three second
pause

Eight-three flash,
three second
pause

Eight-four flash,
three second
pause

Failed to light
pilot.
System auto

resets.

Pressure switch
or blower temp
switch opened
during burner
operation.
System auto

resets.

Pilot flame
extinguished.
System auto

resets.

Undesired-false
pilot flame
sensed.
System auto

resets.
Simulated
Resistive Device
fault detected.
Simulated
Resistive Device
out of
specification.

Temperature
Sensor fault.

Gas valve
electronics fault
detected.

Gas valve fault
detected.

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

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. 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.

Pilot valve stuck in open position.

Simulative resistance device harness out of
specification or disconnected.

Simulated resistive device out of
specification. Possible short

1. Damage to temperature sensor wire.

2. Temperature sensor resistance out of
range.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Control needs to be reset.

2. Control is wet or physically damaged.

ServiceProcedure

Page 18

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

1.-4. Page 18

5. Refer to installation

manual

6. Page 25

Replace gas control,
page 27

Page 29

Page 29

Page 27

1. Interrupt power
supply.

2. Replace gas control,
page 27

1. Interrupt power
supply.

2. Replace gas control,
page 27



15

15

Condensing PV Series

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.

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).

16


16

Condensing PV Series

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.

NOTICE

The feedline nut for natural gas
control uses right hand threads,
LP control uses left hand thread.

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.



17

17

Condensing PV Series

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.

18


18

Condensing PV Series

Y

Y

Y

Y

pag

Y

Y

Pressure Switch Testing & Replacement

WARNING

115 volt potential exposure. Use

Step 1. Position the power switch on the gas

caution to avoid personal injury.

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).

Remove 3 Phillips screws to
remove cover.

1



With steps 1,2 & 3

complete, disconnect wire

leads from pressure switch.

Remove 2 Phillips screws to
pressure switch.

2

Pressure switch wire leads.



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)

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

running?

Switch contacts are OK.

See Safety Circuit Voltage

Trace (page 30).

N



N

Check tubing and

pressure tap on

switch for blockage.

Is there blockage?

Check tubing and pressure
tap on switch for blockage.

Is there blockage?

Clear blockage.

N

Is vent system

blocked?

N

N

Is vent system length

specifications listed on

Replace switch

(see page 19).

within vent table

es 7 & 8?

N

Reconfigure vent

system to be compliant

with vent tables.

See blower testing

(page 21)

Is blower OK?

N

Correct blower

problem.

19

19

Condensing PV Series

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.

3

115 volt potential exposure. Use
caution to avoid personal injury.

4

WARNING

20

20




5



6





Condensing PV Series

Y

(

)

Y

(

)

Y

(Pag

)

Y

Y

y

Y

Y

Y

Y

Y

Blower Testing & Replacement

Step 1. Position gas control power switch to

the “ON” position and adjust control to call for heat.

Step 2. Remove the three screws (Phillip’s screw driver) from control access cover

on blower assembly and remove cover (see photo 7).

Does blower energize

within 2 minutes?

N

Does blower energize after

2 minutes, run for 30

seconds and shut down?

N

Disconnect cord set

shown in photo 10. Is

there 115VAC across

locations 1 & 2 shown in

figure 11?

N

Disconnect pressure switch

tubing from blower.

(see photo 8)

See pressure switch

testing.

e 19

Is there 115VAC

across the locations

2 & 6 shown in figure

11?

N

Incorrect supply

voltagepolarit

Determine voltage

Connect manometer to
pressure tap of blower.

(see photo 8)

problem and

correct.

WARNING

115 volt potential exposure. Use
caution to avoid personal injury.



Disconnect vent system

from top of blower and

remove vent adapter.

see photo 9

With blower running, and exhaust

adapter removed from the top of

blower, is there a negative pressure

of -2.15” to -2.30” w.c.?

N

Is there 115VAC across

the yellow and green

N

wires?

see photo 12

10

Blower OK

Replace blower



Is there

115VAC at wall

Is power cord

damaged?

Replace blower.



N

Replace blower

Replace cord set.

Determine power

N

source problem

and correct.

Repair or replace

power cord.

Reconnect cord set

shown in photo 10, is

there 115VAC between

yellow and green wires?

(see photo 12)

N

Does cord set have

N

electrical continuity?

Replace gas

control.

11

Green wire

Yellow wire

12

InserttheVoltmeterleadinthebackoftheconnectorto

makecontactwiththeyellowwire.Usethegroundscrewto

makecontactwiththegreenwire.

21



21

Condensing PV Series

p

Blower Removal

Step 1. Position the gas control power switch to the “OFF” position and adjust the control

to call for heat.

Step 2. Unplug the blower power cord from the wall outlet.
Step 3. Disconnect the vent system from the exhaust adapter on top of the blower.
Step 4. Remove the brass coupling from the exhaust adapter on the blower and retain for

use on the new blower.

Step 5. Unplug the harness from the blower.
Step 6. Remove the drain hose from the

blower housing.

Step 7. Remove the hose from the pressure

switch.

Step 8. Remove the vent pipe from the

blower intake (slotted screwdriver).

Step 9. Remove the two blower mounting

screws (1/4” nut driver).

Step 10. Remove the blower from the water

heater.

Step4.

Step5.





Step6.

Uncliptoremove
wireharness.

Loosenhoseclam



Step10.

Locationholes

Screwlocations





Steps7&8.

Blower Installation

Step 11. Clean any debris from the jacket head of water heater.
Step 12. Set new blower with gasket in place using locating pins on blower flange to line

up with location holes in jacket head.
Step 13. Secure blower in place using mounting screws from step 9.
Step 14. Re-install vent pipe from step 8 into the blower intake and tighten hose clamp.
Step 15. Reconnect the hose into the pressure switch from step 7.
Step 16. Reconnect the drain hose from step 6 into the blower housing.
Step 17. Plug the harness into the mating connection from step 5. Make sure the

connector latches.
Step 18. Reconnect the brass coupling into the exhaust adapter from step 4.
Step 19. Reconnect vent system to exhaust adapter.
Step 20. Plug blower power cord into wall outlet.
Step 21. Position gas control power switch to the “ON” position.
Step 22. Verify proper blower operation.



22


22

Condensing PV Series

p

Y

Y

Y

Y

Blower Temperature Switch Testing

Step 1. Position power switch on gas control to the

“OFF” position.

Step 2. Locate blower temperature switch (see photo

13).

Opens on rise @ approximately 155°F

Auto resets on fall @ approximately 135°F

Switch Setting

Cool switch to

below 130°F.

Disconnect wire leads to switch.

Using multi-meter, set to ohms

setting. Is there continuity

between the switch terminals?

Reconnect wire leads and

observe heater operation. Does

the exhaust gas temperatures

rise to or above 160°F with vent

connected?

N

Replace switch.

(see page 24)

N

Do switch

contacts o

en?

13

WARNING

115 volt potential exposure. Use

caution to avoid personal injury.



Blower temperature switch

Exhaust temperature

is too hot.

N

Do switch

contacts open?

N

Switch OK.

Replace switch.

(see page 24)

Common causes for high exhaust temperatures

Step 1. Vent length is below minimum allowable.

Step 2. Vent diameter not to specification.

Step 3. Missing or deteriorated flue baffle(s).

Step 4. Gas pressure is out of specification.

23



23

Condensing PV Series

Blower Temperature Switch
Replacement

Step 1. Position the gas control power switch to the “OFF” position and unplug the water

heater from the wall outlet.
Step 2. Locate blower temperature switch (see photo 14).
Step 3. Disconnect red and yellow wire leads from switch.
Step 4. Remove the two screws (1/4” nutdriver) that locate and hold the temperature

switch to the blower housing (see photo 14).
Step 5. Remove the temperature switch from the blower housing.
Step 6. Install the new temperature switch. Be sure the temperature switch is properly

seated in the mounting area.
Step 7. Reconnect the red and yellow wires to the

new temperature switch. The wires are

interchangeable with either terminal.
Step 8. Plug the water heater into the wall outlet.
Step 9. Position the gas control power switch

to the “ON” position and verify proper

heater operation.

115 volt potential exposure. Use

caution to avoid personal injury.

WARNING



24


Two screws (1/4” slotted head)

Blower Temperature Switch

14



24

Condensing PV Series

Line Pressure

The gas control is designed for a maximum line pressure of 14.0” w.c. and a minimum
line pressure of 1.0” w.c. over the water heater’s rated manifold pressure (check rating
plate). The line pressure must be checked with the main burner both on AND off to
assure proper readings.

Manifold Pressure Testing

(this procedure presumes a maximum
line pressure of 14.0” w.c.)

Step 1. Set the Gas Control to the “OFF” position.
Step 2. Remove the pressure tap plug and install

1/8” NPT pipe, coupling & pressure tap.
Step 3. Connect a manometer to the pressure tap.
Step 4. Follow instructions located on the lighting

instructions label and proceed to light the

main burner and observe manometer

reading.
Step 5. Proper operating range for Natural Gas is

4.0” ±0.5” w.c. Proper operating range for

Propane gas is 10.0” ±0.5” w.c.
Step 6. If the pressure is within the range specified

in the previous step, set the gas control

knob to the “OFF” position. Remove the

manometer and pressure tap, and replace

the pressure tap plug. Check for gas leaks

prior to placing the water heater back into

operation by following the instructions

located on the lighting label, or the lighting

instructions located in the installation and

operation manual.
Step 7. If the gas pressure is outside the

specification noted above, refer to the Gas

Control Testing & Replacement section on

page 27 to replace the gas control or valve

body.



25

25

Condensing PV Series

ECO (Energy Cut Out)

The Honeywell gas control is designed with an ECO device that will reset.

If the control has gone into lockout due to excessive tank temperature(four flash, three

second pause), reset the control by turning the gas control to the “LOW” position and wait

a minimum of (6) seconds. Then rotate the gas control knob to the desired setpoint (at

least a 45° rotation) and follow the lighting instructions to return to nomal operation.

Observe the Green LED indication.

Does the error code 4 (four flash with a

three second pause) continue?

Y

Confirm that the water temperature inside the tank has cooled.

Draw approximately 4 gallons of water from the drain valve into a

container and discard. Draw an additional gallon and immediately

measure the temperature using an accurate thermometer.

Resume normal operation.

N

If it is confirmed that the water temperature

has cooled down below the setpoint level

and you are still observing an error code 4

as above, replace the gas control.

26


26

Condensing PV Series

Gas Control Removal From The Water Heater

Step 1. Position the gas control power switch to the “OFF” position

and unplug the water heater from the wall outlet.
Step 2. Drain the water heater to a point below the gas control level.
Step 3. Turn off the gas supply to the water heater and disconnect

gas piping from the gas control.
Step 4. Disconnect the wire harnesses from the gas control.
Step 5. Remove the outer jacket burner access door.
Step 6. Right side inner door removal.

a. Remove (2) hex drive screws from RIGHT side inner

door.
b. Remove (2) hex drive screws from FLANGE SECTION of inner door.
c. Remove right side inner door and set aside. Be careful not to damage gasket

material in inner door.

Step 7. Removal of gas control

a. Disconnect main burner feedline and pilot tube.
b. Remove the gas control from water heater by rotating counter clockwise. DO

NOT use a wrench on the gas control body as damage to the gas control may

occur. If necessary, use a length of ½” NPT pipe threaded into the gas inlet of

the gas control.

¼” HEX DRIVE
SCREWS AT FLANGE
AREA OF INNER DOOR
(STEP 6b).

Step 8. Install the new gas control into the water heater.

a. Install new gas control into water heater by rotating clockwise. DO NOT use a

wrench on the gas control body as damage to the gas control may occur. If

necessary, use a length of ½” NPT pipe threaded into the gas inlet of the gas

control.
b. Reattach the main burner feedline , pilot tube and pilot wire. The main burner

feedline end should rest in the support bracket opening inside the combustion

chamber.

¼” HEX DRIVE SCREWS
ON RIGHT SIDE INNER
DOOR (STEP 6a).





27

27

Condensing PV Series

Reinstallation of Inner Door Assembly

c. Prior to reinstallation of inner door, fully inspect for the following:

-Tears -Other imperfections that will inhibit proper seal

-Missing material -Gasket adhesion to inner door

-Cracks -Material left on combustion chamber (around opening)

-Dirt or debris

If the gasket is not affected by any of the above, the gasket replacement
may not be required. If a replacement is required, replace using the new
gasket kit, following the instructions provided with it.

d. Clean any gasket residue or other debris from the combustion chamber

surface before installing the inner door/gasket assembly.

e. Position the spark igniter wire and pilot tube against the left side inner door

flange gasket. DO NOT ROUTE THE IGNITER WIRE AND PILOT TUBE
THROUGH THE RADIUSED CHANNEL WITH THE FEEDLINE. Be sure
that the spark igniter wire and pilot tube are not in a position to interfere with
the outer jacket burner access door when reinstalled.

f. Firmly place right side inner door flange against the left side inner door

flange and secure with (2) hex drive screws from step 6b. DO NOT OVER
TIGHTEN SCREWS.

g. Align right side inner door to the combustion chamber and verify the

fastener holes of the combustion chamber are aligned with the right side
inner door slotted openings. Verify seal integrity around combustion
chamber opening. Secure right side inner door using (2) hex drive screws
from step 6a. DO NOT OVER TIGHTEN SCREWS. Verify both left and
right sides of the inner door are properly positioned and sealed against the
combustion chamber.

CAUTION

A seal breach may result in a fire or explosion causing

property damage, personal injury or death.

Step 9. Reinstall the outer jacket burner access door.
Step 10. Reconnect the gas supply to the gas control.
Step 11. Resume water supply to the water heater. Be sure the tank is full of water

before resuming operation.

Step 12. To resume operation, follow the instructions located on the lighting instruction

label or the lighting instructions located in the installation and operation manual.

28


28

Condensing PV Series

Simulative Resistive Device Testing

Step 1. Position the power switch on the gas

control to the “OFF” position.

Step 2. Disconnect flammable vapor sensor

or simulated resistive device from
the gas control (model dependant).

Step 3. Using a multi-meter set to the ohms

setting, check resistance of the
flammable vapor sensor or simulated
resistive device. Resistance must be
between 3,000 ohms and 48,000
ohms. If outside of this range,
replace replace the simulated
resistive device.

CAUTION

DO NOT use a standard multi-meter probe for this

test. Doing so will damage connector. Use

special pin type electronic probes or small

diameter wire pins inserted into connector.





29

29

Condensing PV Series

g

Y

Y

Y

Y

Y

Y

Safety Circuit Voltage Trace

NOTE: This procedure assumes a cool tank.
Remove three screws (Phillips Screw driver)

from the control access cover on the blower
and remove the cover (see photo 17).

WARNING

115 volt potential exposure. Use

caution to avoid personal injury.







17

Position the gas control switch to the “ON”

position and adjust the thermostat dial to call for

heat. Is there 10 to 13 VAC between the

temperature switch terminal and the green ground

screw? The blower must be running during this

voltage check. (see photo 18)

Is there 10 to 13 VAC between the

pressure switch terminal and the green

ground screw?

(see photo 18)

Do you hear or can you

see the ignitor sparking?

N

N

N

Is the LED on the gas control

flashing a “heartbeat” code

(alternating bright/dim)?

N

Verify 115VAC to

the gas control

(see page 31)

Correct ignitor/sensor problem.

N

Check ignitor/sensor

(see page 18).

nitor/sensor OK?

Is the i

No voltage from gas control.

Call for technical support.

Check for loose or broken wire
connection at switch terminals.

Is there continuity through the

blower temperature switch

(see page 23)?

N

Determine cause of blower

temperature switch activation

and correct(see page 24).

Faulty cord set or gas control.

Safety circuit voltage is OK.

If burner does not light, observe the

LED flash code on the gas control

and refer to the troubleshooting

section(see page 14).

30


30

18

PressureSwitch

Terminals

GroundScrew

Temperature

SwitchTerminals



Condensing PV Series

Y

Y

Y

Y

115 VAC Circuit Trace

Step 1. Verify 115 VAC and proper polarity at wall

outlet.

Step 2. With unit plugged in and control power

switch in the “ON” position verify LED
status.



LED Status

None, Control LED

not on or flashing.

Disconnect cord set

as shown in photo 19.

Using a volt meter set to

volts AC, and referring to

photo 22, is there 115VAC

across pins 1 & 2?

Repair damage.

N

Check for damage to AC

power supply cord.

N

Replace Blower.

LED Status

Short Flash, once

every four seconds.

Waiting for call to

heat

WARNING

115 volt potential exposure. Use
caution to avoid personal injury.

LED Status

“Heartbeat”,

alternates bright/dim.

Thermostat

calling for heat.

19

LED Status

Other error codes

flashing.

Verify error code as

listed on page 14.



Is there 115VAC

across pins 2 & 6?

N

Incorrect supply
voltage polarity.

Locate black & white wires at

connector, it may be

necessary to pull back wire

sheath to identify wire colors

(see photo 22).

Is there 115VAC across

black & white wires as

shown in photo 22?

N

Call for technical

support.

Reconnect cord set

shown in photo 19.

Disconnect wire

harness from gas

control

(see photo 21).

Replace Gas

control.

20

21



Checkfor115VACbetweenblack&whitewires.

ͲNOTEͲ

Electronicmeterproesrequired.Usecarenotto

damageconnectorduringthischeck.

WireHarness



22



31

31

Condensing PV Series

Diptube Inspection & Replacement





Water heater components and stored water may be HOT when performing the following

steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Position the on/off switch of the gas control valve to the “OFF” position and

unplug the water heater from the wall outlet.

Step 2. Turn off the cold water supply to the water heater. Connect a hose to the drain

valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of the water
heater and allow the water heater to drain to a point below the inlet connection

nipple.
Step 3. Disconnect the inlet nipple from the plumbing system.
Step 4. With an appropriate tool such as a pipe wrench, remove the inlet nipple/diptube

from the water heater. Use caution not to damage the pipe threads.
Step 5. Visually inspect the inlet nipple/diptube. The inlet nipple/diptube should be free

of cracks and any blockage. The HydroJet slots should be open and free of any

blockage. Any damage such as cracks, restriction due to deformation or

unintentional holes are not field repairable and the inlet nipple/diptube must be

replaced.
Step 6. Upon completion of inspection or subsequent replacement, reinstall the inlet

nipple/diptube into the water heater. Apply Teflon tape or pipe dope to the

threads and connect the nipple to the plumbing system, resume the water

supply and refill with water.
Step 7. To resume water heater operation, plug the water heater back into the wall

outlet and follow the instructions located on the lighting instruction label or the

lighting instructions located in the Installation and Operation manual.



WARNING

32


32

Condensing PV Series

Anode Inspection & Replacement

This water hater has 2 anodes installed. Both anodes require inspection.











Step 1. Position the on/off switch of the gas control valve to the “OFF” position and

unplug the water heater from the wall outlet.

Step 2. Turn off the cold water supply to the water heater. Connect a hose to the drain

valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of the water
heater and allow the water heater to drain to a point below the outlet
connection nipple.

Step 3. Remove the caps with a slotted

screwdriver or similar tool.

Step 4. Remove the insulation to gain

access to the hex head anode.

Step 5. The hex head anode is approximately 4-1/4” below the

jacket head. An extension and a deep 1-1/16” socket is

necessary to loosen the anode.
Step 6. Remove the anode and visually inspect the anode.
Step 7. If the anode does show signs of depletion, this is normal.

a. If depletion is ½ of the original anode diameter

(approximately ¾” diameter), replacement is
recommended.

b. If any of the steel core of the anode is exposed,

replacement is recommended.

Step 8. Upon completion of inspection or subsequent replacement, apply Teflon tape

to the threads and reinstall the hex head anode into the water heater. Put in

place the insulation as best as possible to reduce heat loss and reapply the

hole closure.
Step 9. Repeat steps 4 through 8 for the second anode.
Step 10. Resume the water supply and refill with water.
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.

Anodesarelocatedundercaps.



WARNING

Water Heater components and stored water may

be HOT when performing the following steps in

this procedure. Take necessary precaution to

prevent personal injury.









33

33

Condensing PV Series

Flue Baffle Inspection & Replacement

Step 1. Position the gas control power switch to

the “OFF” position and unplug the
blower from the wall outlet.

Loosenhoseclamps
with5/16”nutdriver

Step 2. Use a slotted screwdriver or 5/16” nutdriver to loosen the

hose clamps connecting the venting to both the top and back
of the blower. Disconnect tubing and both sets of venting

from the blower.
Step 3. Disconnect the blower harness from the blower.
Step 4. Remove the two blower mounting screws with a

1/4” nut driver.
Step 5. Remove the blower from the water heater.
Step 6. Remove the two blower mounting screws with a

1/4” nut driver.
Step 7. Remove the blower from the water heater.
Step 8. Remove the jacket head screws with a ¼”

nutdriver. Remove the jacket head. This may

require assistance with a slotted screwdriver as

shown below.

Disconnect
blowerharness

Unscrew2blowermounting
screwswitha¼”nutdriver.





Insertingslottedendofa
screwdriverandapplyingforce



Removeall¼”hexhead

screwsaroundthejacket

headflange.



upwardcanassistinremovingthe
jackethead.

Step 9. With the jacket head removed, cut the perimeter of the

top piece of fiberglass insulation to peel back or remove

and gain access to the flue collector.
Step 10. Remove the 11 screws

sealing the top lid of the flue

collector with a ¼” nutdriver.

Remove the flue collector lid

to gain access to the flue

core and baffles.

34


Withthefiberglassinsulation



perimetercut,itcanbepulled
backortakenofftoprovideaccess
to¼”screwsonthefluecollector.

34

Condensing PV Series

Step 11. Remove the flue baffles and flue core from the

water heater.

Step 12. Inspect the baffles and flue core for deterioration.

Clean any scale or debris build up. Replace with
new baffles or flue core as necessary.

Step 13. Reinstall the flue core into the water heater. Be

sure that when reinstalling the baffles, they are
oriented as shown below such that the top flat
portion will form a small arc if connected. A slight
reduction in efficiency will result otherwise.

Flatsectionsofbaffles

orientedtoprovideanarc
whenreinstalledproperly.





Step 14. Review the seals around the flues to verify that the flue collector is in good

working order.

Step 15. Place the flue collector lid back on and screw in securely all 11 of the ¼” head

head screws. Refer to Step 9.

Step 16. Return the insulation above the flue collector and apply the jacket head. Secure

the jacket head in place by screwing in the ¼” screws removed in Step 7.

Step 17. Reinstall the blower on the jacket head. There are holes in the jacket head to

accept locating pins on the underside of the blower housing. Screw the blower

securely in place with the 2 screws removed in Step 5.
Step 18. Connect the blower harness to the blower connector.
Step 19. Connect the vertical vent pipe assembly to the side of the blower, securing it in

place by tightening the hose clamp with a 5/16” nutdriver.
Step 20. Connect the exhaust venting to the blower top, securing it in plce by tightening

the hose clamp with a 5/16” nutdriver.
Step 21. Connect the tubing from the vertical vent pipe to the blower.
Step 22. Verify all hose clamp connections are secure and tubing is connected.
Step 23. Plug the water heater into the wall outlet.
Step 24. To resume operation follow the lighting instruction located on the lighting

instruction label or the lighting instruction located in the Installation & Operation

manual.

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35

35

Condensing PV Series

Inner Door Removal Procedure

Step 1. Position gas control power switch to the “OFF” position.
Step 2. Remove outer jacket burner access door.
Step 3. Inner Door removal.

a. Remove (2) ¼” hex drive screws from right side inner door.
b. Remove (2) ¼” drive screws from flange section of inner door.
c. Remove (2) ¼” drive screws from left side inner door.
d. Remove inner door and inspect per step 4.









¼” HEX DRIVE
SCREWS AT FLANGE



AREA OF INNER DOOR
(STEP 3b).



¼” HEX DRIVE SCREWS
ON RIGHT AND LEFT
SIDE INNER DOOR
(STEPS 3a & 3c).



Step 4. Fully inspect inner door gaskets for the following:

-Tears -Other imperfections that will inhibit proper seal

-Missing Material -Gasket adhesion to inner door

-Cracks -Material left on combustion chamber (around opening)

-Dirt or debris

If the gasket is not affected by any of the above, gasket replacement is not required. If replacement
is required, proceed to Inner Door Gasket Replacement Procedure.

Inner Door Gasket Replacement Procedure

WARNING

If the information in these instructions is not followed exactly, a fire or

explosion may result causing property damage, personal injury or death.

Step 5. After inspection of the inner door as noted in step 4, completely remove the gasket and

adhesive residue from the right and left side inner doors as needed.

Step 6. Use RTV sealant (recommended bead size 1/8”) to secure the inner door gasket to the inner

door sections (right & left). Refer to illustration on the next page for proper application. Note
the overlap configuration in the flange area of the inner door. Set the flange section first. This
will help to achieve the proper overlap position.

36
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36

Condensing PV Series

Installation of Inner Door With Gasket

Stripped fastener connections

Step 7. Clean any residual gasket residue or other debris from the

combustion chamber surface before installing the inner
door/gasket assembly.

Step 8. Place the left side inner door into position first. Firmly

position the radiused channel of the inner door around the
feedline. Using the ¼” hex drive screws from step 3c,
secure the left side inner door in place. DO NOT OVER

TIGHTEN SCREWS.

Step 9. Position pilot tube and igniter/sensor wire against left side inner door flange gasket. DO

NOT ROUTE PILOT TUBE AND IGNITER/SENSOR WIRE THROUGH RADIUSED
CHANNEL WITH THE FEEDLINE.

may allow for seal breach of

inner door. A seal breach may

result in a fire or explosion

causing property damage,

personal injury or death. Do

not over tighten screws in

steps 8, 10 and 11.

WARNING



37

37

Condensing PV Series

Installation of Inner Door With Gasket (cont.)

Step 10. Firmly place right side inner door flange against the left side inner door flange and

secure with (2) ¼” hex drive screws from step 3b. DO NOT OVER TIGHTEN
SCREWS.

Step 11. Align right side inner door to combustion chamber and verify the fastener

holes of the combustion chamber are aligned with right side inner door slotted
opening. Verify seal integrity around combustion opening. Secure right side
inner door using ¼” hex drive screws from step 3a. DO NOT OVER
TIGHTEN SCREWS. Verify both left and right sides of inner door are

properly positioned and sealed against the combustion chamber.
Step 12. Replace outer jacket burner access door.
Step 13. To resume operation follow the instructions located on the lighting instruction

label or the lighting instructions located in the Installation & Operation manual.

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38
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38

Condensing PV Series

Condensate Trap Removal, Inspection & Replacement

The condensate trap has a self-priming trap that safely removes condensate from the water
heater. If the condensate is not removed from the water heater, it will accumulate and
eventually produce an error code. This condensate trap is field serviceable and can be
removed for inspection if this condition exists.

Step 1. Disconnect the clear tube that allows the

condensate to come into the condensate tee
from the exhaust and blower assembly.

Step 2. Disconnect the mate to the condensate trap

discharge. Note if water can flow through
the condensate line attached to the
condensate tee. If water cannot flow through
line, remove obstruction.

Step 3. Loosen the hose clamps connecting the

condensate tee to the back cover and the
vertical vent pipe.

Step 4. Remove the condensate tee. Be aware that condensate is in the tee and take appropriate

measures.

Step 5. Remove the bottom cap of the condensate tee and verify that there is no obstruction in the

trap.
Step 6. Return the trap into service. Secure the bottom cap by screwing it in place.
Step 7. Position the condensate back in place, securing the hose clamps on the cover neck and

the vertical vent pipe assembly.
Step 8. Connect the condensate discharge to the trap.
Step 9. Connect the clear tube from the exhaust and

blower assembly to the condensate trap.
Step 10. Return the water heater into operation, following

the instructions located on the lighting instruction

label or the lighting instructions located in the

Installation and Operation manual.

Hoseclamps

Cleartubefromblower

Condensatetrapdischarge

BlowerCondensate



Chamber



CondensateDischarge

Chamber

Verifynodebrisisobstructing

condensatefromentering

CondensateDischargeChamber

39

39

Condensing PV Series

Exhaust Collector Removal, Inspection & Replacement

The Exhaust Collector Gasket seals around the secondary flue tubes and between the jacket
and the collector cover. This seal allows the exhaust to be concentrated into a single
exhaust port and allows a passageway for the condensate to flow into the trap.

If the condensate is dripping from the seal or if a measured reduction in blower pressure is
observed, the gasket may need inspection. To do this, follow the steps listed below.

1. Loosen the hose clamp connecting the condensate tee to the exhaust cover.

2. Remove the ¼” clear hose from the port on the exhaust cover.

3. With a 5/16” socket, loosen the 8 screws sealing the cover to the gasket.

4. Remove the cover and inspect the seal bead on the gasket flange as well as the seal around
the secondary flue tubes. Inspect the gasket to make sure there are no cuts or openings in
the balance of the gasket body.

5. If the gasket is necessary to be removed and replaced, follow the steps below.

a. Pull the gasket off the studs extending beyond the jacket. The gasket flange should be

aligned such that the studs extend through the flange holes.
b. Pull the gasket off the secondary flue tubes.
c. Replace the gasket with the new

gasket by first pushing the gasket

over the secondary flue tubes. This

can be done by hand and should be

pushed over the secondary flue

discharge such that the neck of the

opening should be flush with the end

of the secondary flue tube.
d. Align the gasket flange holes to go

over the studs extending through the

jacket.
e. Place the cover back on the exhaust collector and begin screwing in the flange nuts

that were removed in step 3. This process should be done following the diagram

below. Each flange nut should be tightened until snug or 25 in*lbs.

SecondaryFlueTubes

Studs

40



40

Condensing PV Series

6. Once all the flange nuts are back in place,
reconnect the ¼” clear tubing onto the port
on the cover.

7. Connect the condensate tee and coupler to
the neck provided on the cover and secure
by tightening the hose clamp.



41

41

Condensing PV Series















































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





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1. Exhaust Adapter

2. Blower

3. Pressure Switch

4. Blower Temp. Switch

5. Jacket Head

6. Surround

7. Jacket Head Insulation

8. Collector Screw

9. Flue Collector Cover

10. Collector Insulation

11. Heat Trap Insert

12. Hot Water Outlet

13. Inlet Diptube

14. Flue Baffle

15. Hex Head Anode

16. Vertical Vent Pipe

17. Flue Core

18. ¾ NPT Plug

19. T & P Valve

20. Screw

21. Washer

22. Exhaust Cover

23. Condensate Tee

24. Exhaust Gasket

25. Right Side Inner Door

26. Left Side Inner Door

27. Outer Door

28. Drain Valve

29. Gas Valve

30. Burner Assembly

31. Burner

32. Orifice

33. Pilot

34. Screw

35. Feedline

36. Inner Door Gasket

37. Heat Trap Kit

38. ASSE Approved Mixing
Valve

42


42

43