Bradford White RG2PDV40S6N, RG2PDV50S6N, RG2PDV50H6N, RG2PDV75H6N User Manual

PDV Series

Power Direct Vent Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

PDV Series Models: RG2PDV40S*(N,X) RG2PDV50S*(N,X) RG2PDV50H*(N,X) RG2PDV75H*(N,X) LG2PDV50H60*(N,X) LG2PDV75H80*(N,X) (*) Denotes Warranty Years

Manual 238‐51541‐00B 08/18

Save this manual for future reference

The Bradford White

PDV Series

Powered Direct Vent Gas Water Heaters

Table of Contents

Page PDV Service Procedure

Introduction.................................................................................................................................4 ---

How to Use This Manual ..........................................................................................................5 ---

Tools Required for Service........................................................................................................5 ---

Specifications..............................................................................................................................6 ---

Control Timings.........................................................................................................................9 ---

Sequence of Operation ..............................................................................................................10 ---

Troubleshooting .........................................................................................................................14 ---

Burner Inspection, Cleaning & Replacement ..........................................................................16 I

Pilot Testing, Cleaning & Replacement ................................................................................... 17 II

Pressure Switch Testing & Replacement .................................................................................18 III

Blower Testing & Replacement ...............................................................................................20 IV

Blower TemperatureSwitch Testing & Replacement ............................................................22 V

Gas Control Testing & Replacement........................................................................................24 VI

Flammable Vapor Sensor Testing and Replacement ..............................................................28 VII

Safety Circuit Voltage Trace.....................................................................................................29 VIII

115 VAC Circuit Trace .............................................................................................................30 IX

Diptube Inspection & Replacement..........................................................................................31 X

Anode Inspection & Replacement............................................................................................32 XI

Flue Baffle/Core Inspection & Replacement........................................................................... 33 XII

Inner Door Removal, Inspection & Replacement................................................................... 34 XIII

Glossary of Terms......................................................................................................................37 ---

Parts List .....................................................................................................................................38 ---

PDV 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.

Do not touch any electrical switch; do not use any

x

phone in your building.

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

x

Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire

x

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:

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 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

FAI LU RE TO INST ALL 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.

PDV Series

Introduction

The new Bradford White PDV 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, additional vent lengths, and Bradford White Defender Safety System

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.

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 maintaining Energy Factor & FHR (not applicable on all models) performance.

(not available on all models).

The PDV 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 direct vent models.

How the Safety System Works

During normal operation, air for combustion is drawn into the water heater through the vent pipe from outside your building. This air travels into the closed combustion chamber. The air then mixes in a normal manner with supplied gas and it’s efficiently combusted, producing low NOx emissions.

In the unlikely event trace amounts of flammable vapors are present in the area surrounding the water heater, the sealed combustion system prevents the flammable vapors from reaching the ignition source. In addition the flammable vapors sensor will stop the water heater from operating if a significant amount of flammable vapors are present.

PDV 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 PDV 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 status codes in the event of abnormal operation. Status codes are listed in the troubleshooting chart beginning on page 14 of this service manual. The troubleshooting chart will also indicate the probable cause for the status 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.

PDV 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 direct 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

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).

Blower Temperature Switch

Pressure Switch

Blower

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

Normally open, closes on vacuum increase @ -.80” W.C.; Opens on vacuum decrease @ -.73” W.C. 115 VAC, 60 Hz, 3.1 amps, 3000 RPM.

PDV Series

Vent Tables

Venting Specifications for:

RG2PDV(40,50)S

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 Roof

3" Diameter (7.6 cm) Vent Connector Lengths

Terminating

Through the Wall

Through the Roof

# of

Elbows

30 (9.1) 2 (.6)

25 (7.6)

20 (6.1) 2 (.6)

15 (4.6) 2 (.6)

35 (10.7) 7 (2.1)

30 (9.1)

25 (7.6) 7 (2.1)

20 (6.1) 7 (2.1)

Maximum

Straight

Length ft. (m)

80 (24.4) 10 (3.1)

75 (22.9) 10 (3.1)

70 (21.3) 10 (3.1)

65 (19.8) 10 (3.1)

60 (18.3) 10 (3.1)

85 (25.9) 15 (4.6)

80 (24.4) 15 (4.6)

75 (22.9) 15 (4.6)

70 (21.3) 15 (4.6)

65 (19.8) 15 (4.6)

2 (.6)

7 (2.1)

Minimum

Straight

Length ft. (m)

PDV Series

Venting Specifications for:

RG2PDV(50,75)H LG2PDV(50,75)H

3" Diameter (7.6 cm) Vent Connector Lengths

Terminating

# of

Elbows

Maximum Straight

Length ft. (m)

Minimum Straight

Length ft. (m)

Through the Wall

Through the Roof

4" Diameter (7.6 cm) Vent Connector Lengths

Terminating

Through the Wall

Through the Roof

# of

Elbows

55 (16.8) 2 (.6)

50 (15.2)

45 (13.7) 2 (.6)

40 (12.2) 2 (.6)

60 (18.3) 7 (2.1)

55 (16.8)

50 (15.2) 7 (2.1)

45 (13.7) 7 (2.1)

Maximum

Straight

Length ft. (m)

95 (29.0) 10 (3.1)

90 (27.4) 10 (3.1)

85 (25.9) 10 (3.1)

80 (24.4) 10 (3.1)

75 (22.9) 10 (3.1)

100 (30.5) 15 (4.6)

95 (29.0) 15 (4.6)

90 (27.4) 15 (4.6)

85 (25.9) 15 (4.6)

80 (24.4) 15 (4.6)

2 (.6)

7 (2.1)

Minimum

Straight

Length ft. (m)

PDV Series

Control Timings

Ignition State Timing

Pre-purge Trial for Ignition 90 Seconds

Flame Stabilization Period Inter-purge

Flame Failure Response Time

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 25) Verify Resistive Delay Retry after 2 Minutes (repeats 5 times) Flammable Vapor Sensor/Simulated Resistive Load Lockout

Hardware Status Lockout

15 Seconds

3 Seconds 15 Seconds

1.5 Seconds (2 seconds. maximum; 1 second minimum.)

Indefinite (cycle power to restart)

Indefinite (self clears if fault clears for at least 15 seconds)

PDV Series

Power Up Sequence

1. Start Up. Upon Power up, the control runs a safe-start check with a typical start-up delay of 1-5 seconds.

Flammable Vapor. To assure no outputs are energized if the “Flammable Vapor Sensor” is out of range, the control will test the “Flammable Vapor Sensor” or for proper operating range. If the “Flammable Vapor Sensor” is out of range, the control LED immediately flashes 7 times with 3 second pause.

Normal Heating Sequence

Thermostat calls for heat. Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. Normal switch positions in the safety circuit are as follows:

a) Exhaust 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.

Blower energizes.

Blower pre-purge period (15 seconds)

Differential 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.

Trial for pilot ignition (90 seconds).

The gas control lights the pilot by activating spark igniter and gas flow to pilot burner.

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.

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.

PDV Series

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, pilot valve and main valve is 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 valve 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.

Thermostat satisfies. (Control LED flashing once every 4 seconds).

Burner off.

10. Blower post purges (15 seconds).

Abnormal Operation

1. Flammable Vapor Sensor:

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.

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 status self clears if the resistance returns to normal range for at least 15 seconds.

2. Temperature Sensor Fault:

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 status self clears if the fault clears for at least 15 seconds.

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

PDV Series

Abnormal Operation (cont.)

times, then 3 times twice with 3 second pause. The status 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.

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.

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 as 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.

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.

+ 28 hidden pages

Bradford White RG2PDV40S6N, RG2PDV50S6N, RG2PDV50H6N, RG2PDV75H6N User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual