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Manual 238

‐

51541

‐

00A 3/15

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

Power Direct Vent Gas Water Heaters

PDV Series

Summary of Contents for RG2PDV40SN

Page 1: ...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 LG2PDV50...

Page 2: ...acement 17 II Pressure Switch Testing Replacement 18 III Blower Testing Replacement 20 IV Blower Temperature Switch Testing Replacement 22 V Gas Control Testing Replacement 24 VI Flammable Vapor Senso...

Page 3: ...al for more information WARNING FAILURE TO INSTALL AND MAINTAIN A NEW LISTED X TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE TEMPE...

Page 4: ...e 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...

Page 5: ...uired 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 measur...

Page 6: ...m Clearance for Servicing 18 from top 24 from front 4 sides and rear Water Supply Pressure 150 PSI maximum allowable working pressure Check local codes for supply pressure Gas Control ECO Limit Reside...

Page 7: ...the Roof 1 30 9 1 7 2 1 Through the Roof 2 25 7 6 7 2 1 Through the Roof 3 20 6 1 7 2 1 3 Diameter 7 6 cm Vent Connector Lengths Terminating of Elbows Maximum Straight Length ft m Minimum Straight Le...

Page 8: ...gh the Roof 1 55 16 8 7 2 1 Through the Roof 2 50 15 2 7 2 1 Through the Roof 3 45 13 7 7 2 1 4 Diameter 7 6 cm Vent Connector Lengths Terminating of Elbows Maximum Straight Length ft m Minimum Straig...

Page 9: ...aximum 1 second minimum Post purge 15 Seconds PS Fault Delay failed open close Retry after 2 Minutes Soft Lockout Retry after 5 Minutes ECO Limit Lockout Indefinite see page 25 Verify Resistive Delay...

Page 10: ...ause Gas control waits 2 minutes then blower runs for 30 seconds This cycle repeats until safety circuit opens 2 Blower energizes 3 Blower pre purge period 15 seconds 4 Differential pressure switch pr...

Page 11: ...seconds Abnormal Operation 1 Flammable Vapor Sensor a If the resistance is greater than 70 000 Ohms the gas control immediately turns off all outputs Control waits and monitors resistance for 30 secon...

Page 12: ...before turning on the blower for another 30 seconds to see the circuit close This cycle repeats as long as there is a call for heat or until the circuit closes c Pressure switch or blower temperature...

Page 13: ...e blower and flashes 6 times then 3 times with 3 second pause The gas control waits 5 minutes before repeating the ignition sequence b Flame sensed out of sequence the gas control only looks for pilot...

Page 14: ...ilot tube block or restricted 3 Oxidation builds up on pilot electrode 4 Wire damage to pilot assembly or bad connection at gas valve Page 17 Two flash three second pause Pressure switch not working c...

Page 15: ...amage to pilot assembly or bad connection at gas valve 5 Insufficient combustion air 6 Gas pressure is out of specification 1 4 Page 17 5 Refer to installation manual 6 Page 24 Six four flash three se...

Page 16: ...the OFF position and unplug heater from wall outlet Step 2 Turn off gas supply to water heater Step 3 Remove outer jacket door and inner door per service procedure XIII on page 34 Step 4 Disconnect pi...

Page 17: ...gniter flame sense electrode for deterioration Replace pilot as necessary Electrode should not be in contact with pilot hood if so carefully adjust electrode to a gap of distance of 3 32 09 from pilot...

Page 18: ...the OFF position Step 2 Remove the three screws Phillips screw driver from control access cover on blower assembly and remove cover see photo 1 Step 3 Carefully remove pressure switch from blower hous...

Page 19: ...Step 4 Disconnect tubing from pressure switch see photo 5 Step 5 Disconnect yellow wires from pressure switch see photo 6 Step 6 Reconnect wires from step 6 to new pressure switch Step 7 Reconnect tub...

Page 20: ...wer switch to 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 WARNING 11...

Page 21: ...e three blower mounting screws 1 4 nut driver Step 9 Remove blower with gasket from water heater Blower Installation Step 10 Clean any debris from jacket head of water heater Step 11 Set new blower wi...

Page 22: ...he gas control to the OFF position Step 1 Remove the three screws Phillip s screw driver from control access cover on blower and remove cover see photo 14 Step 2 Locate blower temperature switch see p...

Page 23: ...tep 5 With an appropriate tool such as side cutters snip the retaining lug from the blower housing to allow removal of temperature switch see photo 18 Step 6 Remove switch from blower housing Step 7 I...

Page 24: ...llow 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 oper...

Page 25: ...erature Inside Tank Step 1 Position gas control power switch to OFF position Step 2 Draw approximately 4 gallons of water from drain valve into a container and discard Draw an additional gallon and im...

Page 26: ...r 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 Gas Control from water heater by rot...

Page 27: ...installed g Firmly place right side inner door flange against the left side inner door flange and secure with 2 hex drive screws from step 6c DO NOT OVER TIGHTEN SCREWS h Align right side inner door t...

Page 28: ...sing a multi meter set to the ohms setting check resistance of flammable vapor sensor Resistance must be within 3 000 ohms and 48 000 ohms If outside of this range replace Flammable Vapor Sensor CAUTI...

Page 29: ...oltage Trace NOTE This procedure assumes a cool tank Remove Three screws Phillips Screw driver from control access cover on blower and remove cover see photo 21 WARNING 115 volt potential exposure Use...

Page 30: ...uit 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 WARNING 115 volt potential exposure Use cau...

Page 31: ...t nipple dip tube Inlet nipple dip tube should be free of cracks and any blockage Hydrojet slots should be open and free of any blockage Any damage such as cracks restriction due to deformation or uni...

Page 32: ...p 5 Visually inspect outlet nipple anode Outlet nipple anode should show signs of depletion this is normal If depletion is of the original anode diameter approximately diameter replacement is recommen...

Page 33: ...r core for deterioration missing restrictors Clean any scale or debris build up Replace with new baffle or core as necessary Step 9 Reinstall baffle or core into flue tube Be sure hanger tabs are inse...

Page 34: ...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...

Page 35: ...er door around the feedline Using the hex drive screws from step 6 secure left side inner door in place DO NOT OVER TIGHTEN SCREWS Step 13 Position pilot tube and igniter sensor wire against left side...

Page 36: ...amber are aligned with right side inner door slotted opening Verify seal integrity around combustion opening Secure right side inner door using hex drive screws from step 4 DO NOT OVER TIGHTEN SCREWS...

Page 37: ...he optional concentric vent terminal is resistant to ice blockage Contact Bradford White or the supplier of the water heater for information about ordering the optional concentric vent terminal Bradfo...

Page 38: ...t Trap Inlet 16 Inlet Dip Tube 17 Wire Harness 18 T P Valve 19 NPT Plug 20 Direct Vent boot escutcheon 21 Air intake boot 22 Air intake boot gasket 23 Outer Door 24 Right side inner door 25 Left side...

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