Bradford White RG1PV Service Manual Download

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Manual 238

‐

51540

‐

00A

REV 08/18

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:

RG1PV40S*(N,X)

RG1PV50S*(N,X)

RG1PV55H*(N,X)

RG2PV40T*(N,X)

RG2PV50H*(N,X)

RG2PV50T*(N,X)

RG2PV75H*(N,X)

LG1PV55H78*(N,X)

LG2PV50H65*(N,X)

LG2PV75H76*(N,X)

(*) Denotes Warranty Years

Power Vent Gas Water Heaters

PV Series

Summary of Contents for RG1PV

Page 1: ...ions for Service To be performed ONLY by qualified service providers Models Covered by This Manual Through The Wall Models RG1PV40S N X RG1PV50S N X RG1PV55H N X RG2PV40T N X RG2PV50H N X RG2PV50T N X RG2PV75H N X LG1PV55H78 N X LG2PV50H65 N X LG2PV75H76 N X Denotes Warranty Years Power Vent Gas Water Heaters PV Series ...

Page 2: ...Replacement 19 II Pressure Switch Testing Replacement 20 III Blower Testing Replacement 22 IV Blower Temperature Switch Testing Replacement 24 V Gas Control Testing Replacement 26 VI Flammable Vapor Device Testing and Replacement 33 VII Safety Circuit Voltage Trace 34 VIII 115 VAC Circuit Trace 35 IX Dip Tube Inspection Replacement 36 X Anode Inspection Replacement 37 XI Flue Baffle Inspection Rep...

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 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 ca...

Page 4: ...ntrol 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 desi...

Page 5: ...red 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 Am...

Page 6: ...s Control ECO Limit Residential 188 F 87 C Commercial 199 F 93 C Residential Temperature Set Point Range 60 F 16 C to 160 F 71 C approximate temperatures Commercial Temperature Set Point Range 80 F 27 C to 180 F 82 C approximate temperatures Blower Temperature Switch Normally closed opens 155 F 68 C auto reset approximately 135 F 57 C Pressure Switch RG1PV 40 50 S R L G2PV50H Models Normally open ...

Page 7: ...of 1 45 16 8 7 2 1 Through the Roof 2 40 15 2 7 2 1 Through the Roof 3 35 10 7 7 2 1 Through the Roof 4 30 9 2 7 2 1 3 Diameter 10 2 cm Vent Connector Lengths Terminating of Elbows Maximum Straight Length ft m Minimum Straight Length ft m Through the Wall 1 115 35 10 3 1 Through the Wall 2 110 33 5 10 3 1 Through the Wall 3 105 32 0 10 3 1 Through the Wall 4 100 30 5 10 3 1 Through the Wall 5 95 2...

Page 8: ...e 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 10 2 cm Vent Connector Lengths Terminating of Elbows Maximum Straight Length ft m Minimum Straight Length ft m Through the Wall 1 175 53 3 10 3 1 Through the Wall 2 170 51 8 10 3 1 Through the Wall 3 165 50 3 10 3 1 Through the Wall 4 160 48 8 10 3 1 Through the Wall 5 155 47 2 10 3 1 Through the Ro...

Page 9: ...hrough the Roof 1 45 13 7 7 2 1 Through the Roof 2 40 12 2 7 2 1 Through the Roof 3 35 10 7 7 2 1 4 Diameter 7 6 cm Vent Connector Lengths Terminating of Elbows Maximum Straight Length ft m Minimum Straight Length ft m Through the Wall 1 175 53 3 10 3 1 Through the Wall 2 170 51 8 10 3 1 Through the Wall 3 165 50 3 10 3 1 Through the Wall 4 160 48 8 10 3 1 Through the Wall 5 155 47 2 10 3 1 Throug...

Page 10: ...maximum 1 second minimum Post purge 15 Seconds PS Fault Delay failed open close Retry after 2 minutes Soft Lockout Retry after 5 minutes ECO Limit Lockout Indefinite see page 27 Verify Resistive Delay Retry after 2 minutes repeats 5 times Flammable Vapor Sensor Simulated Resistive Load Lockout Indefinite cycle power to restart Hardware Error Lockout Indefinite self clears if fault clears for at le...

Page 11: ...s 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 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 s...

Page 12: ...bnormal Operation 1 Flammable Vapor Sensor or Simulated Resistive Device Fault 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 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...

Page 13: ... 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 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...

Page 14: ...he 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 flame when the blower is running If flame is present when the pilot valve is not open the gas control proceeds to wait for flame loss and flashes 5 times with 3 second pause This continues until fla...

Page 15: ... tube block or restricted 3 Oxidation build up on pilot electrode 4 Wire damage to pilot assembly or bad connection at gas valve Page 19 Two flash three second pause Pressure switch not working closed position 1 Pressure switch tubing kinked or blocked 2 Blocked pressure tap on switch or blower 3 Faulty pressure switch Page 20 Three flash three second pause Pressure switch or blower temp switch no...

Page 16: ...de 4 Wire damage to pilot assembly or bad connection at gas valve 5 Insufficient combustion air 6 Gas pressure is out of specification 1 4 Page 19 5 Refer to installation manual 6 Page 26 Six four flash three second pause Undesired false pilot flame sensed System auto resets Pilot valve stuck in open position Replace gas control page 31 Seven flash three second pause Flammable vapor sensor fault d...

Page 17: ... some causes for an unstable pilot flame are a Water heater vent is less than the allowable vent length b Gas pressure is out of specification c Pilot flame not fully engulfing spark flame sensor Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips Main burner must be free from any debris accumulation that may affect burner operation see burner clea...

Page 18: ...n chamber Step 7 Thoroughly inspect burner surface area and burner port area and remove any loose debris Step 8 Unscrew burner from main burner orifice Step 9 Remove main burner orifice from feedline 1 2 wrench on steel burners inspect orifice clean or replace if necessary Step 10 Reassemble burner and reinstall into water heater Restore gas supply and check for gas leaks Step 11 To resume operati...

Page 19: ... through igniter flame sense wire Replace pilot if no continuity Step 10 Visually inspect igniter 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 hood Step 11 Visually inspect igniter flame sense electrode for oxidation build up Carefully clean any oxida...

Page 20: ...eration manual Pressure Switch Testing Step 1 Position power switch on gas control to 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 housing see photo 2 WARNING 115 volt potential exposure Use caution to avoid personal injury ...

Page 21: ... 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 tubing to new pressure switch Step 8 Carefully position pressure switch into blower housing Step 9 Position gas control power switch to ON position and verify proper heater operation Step 10 Replace con...

Page 22: ...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 115 volt potential exposure Use caution to avoid personal injury ...

Page 23: ...r Step 7 Remove blower with gasket from water heater Blower Installation Step 8 Clean any debris from jacket head of water heater Step 9 Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head Be sure not to damage gasket Step 10 Secure blower in place using mounting screws from step 6 Step 11 Re install exhaust adapter from step 4 Ste...

Page 24: ...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 photo 15 WARNING 115 volt potential exposure Use caution to avoid personal injury ...

Page 25: ...Step 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 Install new switch Be sure switch is properly seated in mounting area Step 8 Reconnect red and yellow wires to new switch Wires are interchangeable with either terminal Step 9 Position gas control pow...

Page 26: ...ocated 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 is10 0 0 5 W C Step 6 If pressure is within the range specified in the previous step set Gas Control knob to the OFF position remove manometer and pressure tap and replace pressure tap plug C...

Page 27: ...ed on the lighting instruction label or the lighting instructions located in the installation and operation manual Gas Control Disassembly Reassembly Step 1 Set the gas control to the OFF position Step 2 Turn off gas supply to water heater Step 3 Disconnect gas supply line from gas control Step 4 Disconnect igniter flame sensor wire Step 5 Remove outer jacket door Step 6 Remove gas control cover s...

Page 28: ...rner assembly is reinstalled and the gas supply line is reconnected resume water supply to water heater Be sure tank is full of water before relighting Step 10 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual CAUTION Use care not to bend or damage valve body pins when removing or inst...

Page 29: ...nector insert the second probe see caution into either of the outside wire positions see photo 19 Alternate the probe on the outside position to the opposite outside wire position see photo 20 CAUTION Do not use standard multi meter probes for this test Doing so will damage connector Use special pin type electronic probes or small diameter wire pins inserted into connector ...

Page 30: ...etermine Water Temperature Inside Tank Step 1 Position gas control power switch to OFF position Step 2 Draw approximately 4 gallons of water from the drain valve into a container and discard Draw an additional gallon and immediately measure water temperature using an accurate thermometer It may be necessary to open a hot water faucet to allow heater to drain Step 3 Using the chart below determine ...

Page 31: ...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 Gas Control from water heater by rotating counter clockwise DO NOT use a wrench on the Gas Control body damage to the Gas Control may occur If necessary use a length of NPT pipe threaded into the ga...

Page 32: ...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 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 ...

Page 33: ... a multi meter set to the ohms setting check resistance of flammable vapor sensor Resistance must be between 3 000 ohms and 48 000 ohms If outside of this range replace Flammable Vapor Sensor or 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 conn...

Page 34: ...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 19 WARNING 115 volt potential exposure Use caution to avoid personal injury ...

Page 35: ...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 caution to avoid personal injury ...

Page 36: ...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 unintentional holes are not field repairable and the inlet nipple dip tube must be replaced Step 6 Upon completion of inspection or subsequent replacement reinstall inlet nipple dip tube into water heate...

Page 37: ...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 recommended If any of the steel core of the anode is exposed replacement is recommended Step 6 Upon completion of inspection or subsequent replacement reinstall outlet nipple anode into water heater Ensure pi...

Page 38: ...fle or core for deterioration missing restrictors Clean any scale or debris build up Replace with new baffle or core as necessary Step 8 Reinstall baffle or core into flue tube Be sure hanger tabs are inserted into notch location at the top of the flue tube see photos 28 29 Step 9 Check burner to insure no scale has accumulated during this operation See burner cleaning procedure on page 18 Step 10...

Page 39: ...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 Step 5 After inspection of inner door as noted in step 4 completely remove gasket and adhesive residue from right and left side inner doors as needed Step 6 Use RTV sealant recommended bead size 1 8 to se...

Page 40: ...er door around the feedline Using the hex drive screws from step 3c secure 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 THROUGH RADIUSED CHANNEL WITH FEEDLINE WARNING Stripped fastener connections may allow for seal breach of inner door A seal breach may result in a fire or explos...

Page 41: ...hamber 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 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 th...

Page 42: ...cuum to remove any scale or other debris accumulation Using a soft brush clear jacket openings from any dirt dust restrictions or other obstructions Step 6 Remove any debris from burner assembly per PROCEDURE I and reinstall burner assembly into combustion chamber Step 7 Reconnect feedline pilot tube and igniter flame sensor wire to the gas control Step 8 Reinstall outer jacket door and inner door...

Page 43: ...nt terminals in relation to each other and terminals from other appliances can have an effect on the potential for blockage due to ice or snow See the installation instructions for recommended positioning of the terminals 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 Pound...

Page 44: ...15 Wire Harness 16 T P Valve 17 NPT Plug H Models only 18 Burner Assy 19 Main Burner 20 Main Burner Orifice 21 Pilot Assy 22 Pilot Orifice 23 Feedline 24 Outer Door 25 Right side Inner Door 26 Screw 8 15 x 27 Left Side Inner Door 28 Screw 10 12 x 29 Brass Drain Valve 30 FV Sensor Clip 31 FV Sensor 32 Sensor Harness except 75 gal 33 Polymer Gas Control 34 Simulative Resistive Device 75 gal only 35 ...

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