Bradford White PDV Series Service Manual
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Bradford White PDV Series Service Manual

Residential & light duty commercial power direct vent models
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Residential & Light Duty Commercial
Power Direct Vent Models
Manual 238-53795-00A REV 11/19
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RC2PDV50H*(N,X)
LC2PDV50H76*(N,X)
(*) Denotes Warranty Years
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Summary of Contents for Bradford White PDV Series

  • Page 1 Residential & Light Duty Commercial Power Direct Vent Models SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: RC2PDV50H*(N,X) LC2PDV50H76*(N,X) (*) Denotes Warranty Years Manual 238-53795-00A REV 11/19 Save this manual for future reference...

  • Page 2: Table Of Contents

    The Bradford White Condensing PDV Series Through-The-Wall Gas Water Heaters Table of Contents Page PV Service Procedure Introduction........................4 How to Use This Manual ....................5 Tools Required for Service ..................5 Specifications .......................6 Glossary of Terms .......................6 Vent Tables ........................7 Control Timings......................8 Sequence of Operation ....................9...
  • Page 3 Condensing PDV Series WARNING: If the information in these instructions is not followed exactly, a fire or DANGER explosion may result causing property damage, DO NOT store or use gasoline or other personal injury, or death. flammable, combustible, or corrosive vapors...

  • Page 4: Introduction

    Condensing PDV Series Introduction The Bradford White residential condensing water heaters are designed to provide reliable performance with enhanced standard features. New design features include reliable spark to pilot ignition system, enhanced diagnostics, simplified servicing, significantly quiet operation and additional vent lengths.

  • Page 5: How To Use This Manual

    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.

  • Page 6: Glossary Of Terms

    Condensing PDV Series Specifications Power Supply Dedicated 115 VAC, 60 Hz, 15A Minimum 1/2” NPT (schedule 40 black iron pipe recommended) Gas Supply Pipe Approved Gas Natural Gas or L.P., unit must match gas type supplied Type 5.0” w.c. min. for Natural Gas, 11.0” w.c. min. for L.P., 14.0” w.c. maximum (Natural Gas Pressure Gas &...

  • Page 7: Vent Tables

    Condensing PDV Series Vent Tables 2" Diameter (5.1 cm) Vent Connector Lengths # of Maximum Straight Minimum Straight Terminating Elbows Length ft. (m) Length ft. (m) Through the Wall 45 (13.7) 2 (.6) Through the Wall 40 (12.2) 2 (.6) Through the Wall 35 (10.7)

  • Page 8: Control Timings

    Condensing PDV Series Control Timings Ignition State Timing Pre-purge 2 Seconds Trial for Ignition 90 Seconds Flame Stabilization Period 3 Seconds Inter-purge 15 Seconds Flame Failure Response Time 1.5 Seconds (2 second maximum; 1 second minimum.) Post-purge 15 Seconds PS Fault Delay (failed open/close)

  • Page 9: Sequence Of Operation

    Sequence of Condensing PDV Series Operation Power Up Sequence 1. Start Up: Upon power up, the control runs a safe-start check with a typical start-up delay of 5 seconds. 2. Flammable Vapor: To assure no outputs are energized if the Simulated Resistive Device is out of range, the control will test the Simulated Resistive Device for proper operating range.
  • Page 10 Condensing PDV Series Sequence of Operation Normal Heating Sequence (cont.) 7. Steady State Operation: During steady state operation, the control monitors: Thermostat temperature sensor – When the set point temperature is satisfied, the gas valve is shut down and the blower will post purge for 15 seconds. The control LED flashes a short flash once every 4 seconds (idle) status code.
  • Page 11 Sequence of Condensing PDV Series Operation 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 and main valves.
  • Page 12 Condensing PDV Series Sequence of Operation Abnormal Operation (cont.) blower through post purge and flashes 6 times, then, a one time 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).

  • Page 13: Troubleshooting

    Condensing PDV Series Troubleshooting 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. Service Procedure LED Status...
  • Page 14 Condensing PDV Series Troubleshooting Service Procedure LED Status Control Status Probable Cause 1. Unstable pilot. Failed to light 2. Pilot tube blocked or restricted. Six-one flash, pilot. 3. Oxidation build up on pilot electrode. Page 17 three second System auto 4.

  • Page 15: Burner Inspection, Cleaning & Replacement

    Condensing PDV Series Service Procedure I Burner Operation Inspection, Cleaning and Replacement 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 ensure no debris is accumulating.
  • Page 16 Condensing PDV Series Service Procedure I Burner Operation Inspection, Cleaning and Replacement 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.

  • Page 17: Pilot Inspection Testing, Cleaning & Replacement

    Service Procedure II Condensing PDV Series Pilot Inspection, Cleaning, & Replacement 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.

  • Page 18: Pressure Switch Testing & Replacement

    Service Procedure III Condensing PDV Series Pressure Switch Testing and Replacement 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.
  • Page 19 PDV Series Service Procedure III Pressure Switch Testing and Replacement Pressure Switch Replacement WARNING 115 volt potential exposure. Use Step 1. Position the gas control power caution to avoid personal injury. switch to the “OFF” position. Step 2. Identify correct pressure switch for replacement (see photo 3).

  • Page 20: Blower Testing & Replacement

    PDV Series Service Procedure IV Blower Testing and Replacement WARNING Blower Testing & Replacement 115 volt potential exposure. Use caution to avoid personal injury. Step 1. Position gas control power switch to the “ON” position and adjust control to call for heat.
  • Page 21 Condensing PDV Series Service Procedure IV Blower Testing and Replacement 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.

  • Page 22: Blower Temperature Switch Testing & Replacement

    Condensing PDV Series Service Procedure V Blower Temperature Switch Testing & Replacement Blower Temperature Switch Testing WARNING Step 1. Position power switch on gas control to the “OFF” position. 115 volt potential exposure. Use caution to avoid personal injury. Step 2. Locate blower temperature switch (see photo 13).
  • Page 23 Condensing PV Series Service Procedure V Blower Temperature Switch Testing & Replacement WARNING Blower Temperature Switch 115 volt potential exposure. Use Replacement caution to avoid personal injury. Step 1. Position the gas control power switch to the “OFF” position and unplug the water heater from the wall outlet.

  • Page 24: Gas Control Testing & Replacement

    Condensing PDV Series Service Procedure VI Gas Control Testing and Replacement 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).
  • Page 25 Condensing PDV Series Service Procedure VI Gas Control Testing and Replacement 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”...
  • Page 26 Condensing PDV Series Service Procedure VI Gas Control Testing and Replacement 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.
  • Page 27 Condensing PDV Series Service Procedure VI Gas Control Testing and Replacement 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...

  • Page 28: Simulated Resistive Device Testing

    Condensing PDV Series Service Procedure VII Service Procedure VI Simulated Resistive Gas Control Testing and Device Testing Replacement Simulated 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).

  • Page 29: Safety Circuit Voltage Trace

    Condensing PDV Series Service Procedure VIII Safety Circuit Voltage Trace Safety Circuit Voltage Trace NOTE: This procedure assumes a cool tank. Remove three screws (Phillips screwdriver) from the control access cover on the blower and remove the cover (see photo 17).

  • Page 30: 115 Vac Circuit Trace

    Condensing PDV Series Service Procedure IX 115 VAC Circuit Trace 115 VAC Circuit Trace Step 1. Verify 115 VAC and proper polarity at wall WARNING outlet. 115 volt potential exposure. Use caution to avoid personal injury. Step 2. With unit plugged in and control power switch in the “ON”...

  • Page 31: Diptube Inspection & Replacement

    Condensing PDV Series Service Procedure X Diptube Inspection & Replacement Diptube Inspection & Replacement 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. 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.

  • Page 32: Anode Inspection & Replacement

    Condensing PDV Series Service Procedure XI Anode Inspection & Replacement Anode Inspection & Replacement This water heater has 2 anodes installed. Both anodes require inspection. WARNING Water Heater components and stored water may be HOT when performing the following steps in this procedure.

  • Page 33: Flue Baffle Inspection & Replacement

    Condensing PDV Series Service Procedure XII Flue Baffle Inspection & Replacement Flue Baffle Inspection & Replacement Step 1. Position the gas control power switch to Loosen hose clamps the “OFF” position and unplug the with 5/16” nutdriver blower from the wall outlet.
  • Page 34 Service Procedure XII Condensing PDV Series Flue Baffle Inspection & Replacement 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.

  • Page 35: Inner Door/Gasket Removal, Inspection & Replacement

    Condensing PDV Series Service Procedure XIII Service Procedure XII Inner Door/Gasket Removal, Flue Baffle Inspection & Inspection, & Replacement Replacement Inner Door Removal Procedure Position gas control power switch to the “OFF” position. Step 1. Step 2. Remove outer jacket burner access door.
  • Page 36 Service Procedure XIII Condensing PDV Series Inner Door/Gasket Removal, Inspection, & Replacement Installation of Inner Door With Gasket WARNING Stripped fastener connections Step 1. Clean any residual gasket residue or other debris from the may allow for seal breach of combustion chamber surface before installing the inner inner door.
  • Page 37 Service Procedure XIII Condensing PDV Series Inner Door/Gasket Removal, Inspection, & Replacement Installation of Inner Door With Gasket (cont.) Step 4. 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.

  • Page 38: Condensate Trap Removal, Inspection & Replacement

    Service Procedure XIV Condensing PDV Series Condensate Trap Removal, Inspection, & Replacement 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.

  • Page 39: Exhaust Collector Removal, Inspection & Replacement

    Condensing PDV Series Service Procedure XV Condensate Trap Removal, Inspection, & Replacement 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.
  • Page 40 Service Procedure XV Service Procedure XIV Condensing PDV Series Exhaust Collector Removal, Condensate Trap Removal, Inspection, & Replacement Inspection, & Replacement d. Align the gasket flange holes to go over the studs extending through the jacket. After verifying that the studs are through the flange holes and that the gasket is sealed around the secondary flue tubes, return the cover such that the studs extend through the openings.

  • Page 41: Parts Diagram

    Condensing PV Series Parts Diagram Part Name and Description 1. Exhaust Adapter 12. Heat Trap Insert 23. ¾ NPT Plug 34. Burner Assembly 2. Blower 13. Hot Water Outlet 24. T & P Valve 35. Burner 3. Int. Pressure Switch 14.

This manual is also suitable for:

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