UPV Series Through-The-Wall (TTW®) Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: URG1PV40S*N URG1PV50S*N URG2PV40T*N URG2PV50T*N URG2PV50H*N ULG2PV50H56*N (*) Denotes Warranty Years Manual 238‐51548‐00D 12/20 Save this manual for future reference
The Bradford White UPV Series Through-The-Wall Gas Water Heaters Table of Contents Page Introduction.................................................................................................................. 4 --- How to Use This Manual ............................................................................................ 5 --- Tools Required for Service ........................................................................................ 5 --- Specifications ........................
UPV 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! • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department.
Introduction The new Bradford White URG1PV & URG2PV 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 quieter operation, additional vent lengths, and ® Bradford White Defender Safety System (not available on all models).
UPV Series How to Use This Manual 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 UPV Series water heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater. The Resideo WV4462A Electronic Gas Control will display status codes in the event of abnormal operation.
UPV Series Power Supply Gas Supply Pipe Approved Gas Type Gas Pressure Venting System 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 Blower 6 6 Dedicated 115 VAC, 60 Hz, 15A. Minimum 1/2” NPT (schedule 40 black iron pipe recommended). Natural Gas, unit must match gas type supplied. 6.0” W.C. min. for Natural Gas, 14.0” W.C. maximum.
UPV Series Vent Tables Venting Specifications for: URG1PV40S, URG2PV40T URG1PV50S, URG2PV50T 2" Diameter (5.1 cm) Vent Connector Lengths # of Maximum Straight Minimum Straight Terminating Elbows Length ft. (m) Length ft. (m) Through the Wall 1 45 (13.7) 2 (.6) Through the Wall 2 40 (12.2) 2 (.6) Through the Wall 3 35 (10.7) 2 (.6) Through the Wall 4 30 (9.1) 2 (.6) 0 1 2 3 4 50 (15.2) 45 (13.7) 40 (12.2) 35 (10.7) 30 (9.2) 7 (2.
UPV Series Vent Tables Venting Specifications for: URG2PV50H ULG2PV50H 3" Diameter (7.6 cm) Vent Connector Lengths # of Maximum Straight Minimum Straight Terminating Elbows Length ft. (m) Length ft. (m) Through the Wall 1 55 (16.8) 2 (.6) Through the Wall 2 50 (15.2) 2 (.6) Through the Wall 3 45 (13.7) 2 (.6) Through the Wall 4 40 (12.2) 2 (.6) Through the Roof Through the Roof Through the Roof Through the Roof 0 1 2 3 60 (18.3) 55 (16.8) 50 (15.2) 45 (13.7) 7 (2.1) 7 (2.1) 7 (2.1) 7 (2.
UPV Series Control Timings Ignition State Pre-purge Trial for Ignition Flame Stabilization Period Inter-purge Flame Failure Response Time Post-purge PS Fault Delay (failed open/close) Soft Lockout ECO Limit Lockout Verify Resistive Delay Flammable Vapor Sensor/Simulated Resistive Load Lockout Hardware Status Lockout Timing 15 Seconds 90 Seconds 3 Seconds 15 Seconds 1.
UPV 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 “Flammable Vapor Sensor” is out of range, the control will test the “Flammable Vapor Sensor” or “Simulated Resistive Device” for proper operating range. If the “Flammable Vapor Sensor” or “Simulative Resistive Device” is out of range, the control LED immediately flashes 7 times with 3 second pause.
UPV 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 shut down.
UPV Series Abnormal Operation (cont.) 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.
UPV Series Abnormal Operation (cont.) 5. Flame sensing fault: a. Flame lost during run-the gas control turns off pilot and main valves, 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 has been reached, the gas control turns off the blower and flashes 6 times then, 3 times with 3 second pause.
UPV Series Observe green LED indicator on electronic gas control. Status 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 None, control LED not on or flashing Short flash, once every four seconds “Heartbeat” alternates bright/dim Control Status No electrical power Stand-by mode, waiting for call for heat (no fault). Thermostat calling for heat (no fault).
UPV Series LED Status Control Status Six-one flash, three second pause Failed to light pilot. System auto resets. Probable Cause 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. 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.
UPV 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. Pilot flame should be stable, 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.
UPV Series Burner Cleaning (cont.) Step 9. Remove manifold mount from burner inner door by removing (2) ¼” hex drive screws. Step 10. Use a stiff brush, compressed air and/or a vacuum to remove any debris build up from the manifold mount. Step 11. Thoroughly inspect burner surface area and burner port area and remove any loose debris using compressed air and/or a vacuum. Step 12. Thoroughly inspect burner screen and burner venturi and remove any loose debris accumulation.
UPV Series Pilot Inspection, Testing and Replacement Pilot Inspection, Testing, and Replacement Step 1. Visually inspect igniter/flame sense electrode for oxidation build up. Carefully clean any oxidation using very fine emery cloth. Step 2. Remove pilot assembly from the burner assembly (¼” nut driver). Step 3. Visually inspect igniter/flame sense wire for damage. Replace pilot if damage is found. Step 4. With a multi-meter set to ohms setting, check continuity through igniter/flame sense wire.
UPV Series Pressure Switch Testing Step 1. Position power switch on gas control to the “OFF” position. WARNING 115 volt potential exposure. Use caution to avoid personal injury. Step 2. Remove the three screws (Phillips screwdriver) 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).
UPV Series Pressure Switch Pressure SwitchReplacement Replacement 115 volt potential exposure. Use caution to avoid personal injury. Step 1. Position gas control power switch to “OFF” position. Step 2. Remove the three screws (Phillips screwdriver) from control access cover on blower assembly and remove cover (see photo 3). Step 3. Remove pressure switch from blower housing by removing the two T10 screws (see photo 4a).
UPV Series Blower Testing Step 1. Position gas control power switch to “ON” position and adjust control to call for heat. Blower Testing and Replacement WARNING 115 volt potential exposure. Use caution to avoid personal injury. Step 2. Remove the three screws (Phillips screwdriver) from control access cover on blower assembly and remove cover (see photo 7).
UPV Series Blower Testing and Replacement Blower Removal Step 1. Position gas control power switch to “OFF” position. Step 2. Unplug blower power cord from wall outlet. Step 3. Disconnect vent system from exhaust adapter on top of blower. Step 4. Remove exhaust adapter from blower (blade screwdriver) and retain for use on new blower. Step 5. Unplug cord sets from blower. Step 6. Remove the three blower mounting screws (¼” nut driver). Step 7. Remove blower with gasket from water heater.
UPV Series Blower Temperature Switch Testing Step 1. Position power switch on gas control to the “OFF” position. Step 2. Remove the three screws (Phillips screwdriver) from control access cover on blower and remove cover (see photo 14). WARNING 115 volt potential exposure. Use caution to avoid personal injury. Step 3. Locate blower temperature switch (see photo 15).
UPV Series Blower Temperature Switch Testing and Replacement Blower Temperature Switch Replacement Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet. Step 2. Remove the three screws (Phillips screwdriver) from the control access cover on blower and remove cover (see photo 16). Step 3. Locate blower temperature switch (see photo 17). Step 4. Disconnect red and yellow wire leads from switch. Step 5.
UPV 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). Line pressure must be checked with the main burner 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.
UPV Series ECO (Energy Cut Out) TESTING The ICON System gas control is designed with an ECO device that will reset. To reset the gas control after a status code (4), turn the gas control knob to the “OFF” position and wait a minimum of (5) minutes before relighting following the instructions located on the lighting instruction label or the lighting instructions located in the Installation and Operation Manual.
UPV Series Gas Control Removal from Water Heater Step 1. Position gas control power switch to the “OFF” position and unplug heater from power supply. Step 2. Drain heater to a point below the gas control level. Step 3. Turn off gas supply to water heater and disconnect gas piping from gas control. Step 4. Disconnect wire harnesses from gas control. Step 5. Remove outer jacket burner access door. Step 6. Disconnect main burner feedline, swing counter-clockwise away from gas control. Step 7.
UPV Series Flammable Vapor/Simulative Resistance Device Testing Flammable Vapor Sensor Testing Step 1. Position power switch on gas control to the “OFF” position. Step 2. Disconnect flammable vapor sensor from gas control. Step 3. Using 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. CAUTION DO NOT use a standard multi-meter probe for this test.
UPV Series Safety Circuit Voltage Trace NOTE: This procedure assumes a cool tank. WARNING 115 volt potential exposure. Use caution to avoid personal injury. Remove three screws (Phillips screwdriver) from control access cover on blower and remove cover (see photo 21).
UPV Series 115 VAC Circuit Trace 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. 30 30 WARNING 115 volt potential exposure. Use caution to avoid personal injury.
UPV Series Diptube Inspection and 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 on/off switch of gas control valve to “OFF” position and unplug water heater from wall outlet. Step 2. Turn off cold water supply to water heater. Connect hose to drain valve of water heater and route to an open drain.
UPV Series Anode Inspection and Replacement Anode 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 on/off switch of gas control valve to the “OFF” position and unplug water heater from wall outlet. Step 2. Turn OFF cold water supply to water heater. Connect hose to drain valve of water heater and route to an open drain.
UPV Series Flue Baffle Inspection and Replacement Flue Baffle Inspection and Replacement Step 1. Position gas control power switch to the “OFF” position and unplug blower from wall outlet. Step 2. Disconnect vent system from exhaust adapter on top of blower. Step 3. Unplug cord sets from blower (see photo 28). Step 4. Remove the three blower mounting screws (1/4” nut driver) (see photo 28). Step 5. Remove blower with gasket from water heater. Step 6. Remove flue baffle from heater (see photo 29). Step 7.
UPV Series Inner Door/Gasket Removal, Inspection & Replacement Inner Door Removal Procedure Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Position gas control power switch to the “OFF” position. Remove outer jacket burner access door. Disconnect main burner feedline (3 / 4 ” wrench), pilot tube (7/16” wrench) and white igniter/flame sense wire from the gas valve. Remove (4) ¼” hex drive screws from right side inner door. Remove (3) ¼” drive screws from left side burner door.
UPV Series Inner Door/Gasket Removal, Inspection & Replacement 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 10. After inspection of inner door as noted in step 9, completely remove gasket and adhesive residue from right and left side inner doors as needed. Step 11.
UPV Series Inner Door/Gasket Removal, Inspection & Replacement Installation of Inner Door With Gasket (cont.) Step 5. Step 6. Step 7. 36 36 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. DO NOT OVER TIGHTEN SCREWS.
UPV Series Resettable Thermal Switch Testing and Replacement Resettable Thermal Switch Continuity Testing Step 1. Step 2. Step 3. Step 4. Step 5. Remove outer jacket door. Disconnect black wire leads from the resettable thermal switch. Using a multimeter capable of measuring continuity (Ohms), place one probe of the meter on one of the brass connection tabs of the resettable thermal switch, and the remaining probe on the other connection tab.
UPV Series Resettable Thermal Switch Testing and Replacement Resettable Thermal Switch Replacement Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Rotate gas control knob to the “OFF” position. Remove outer jacket door. Disconnect the black wire leads from resettable thermal switch. Remove (2) ¼” hex drive screws from the manifold mount. Remove resettable thermal switch from manifold mount (Phillips screwdriver). Place new resettable thermal switch in place.
UPV Series ScreenLok® Flame Arrestor Cleaning NOTICE Some models are not equipped with the ® ScreenLok Flame Arrestor. Step 1. Position gas control power switch to the “OFF” position. Step 2. Remove outer door. Step 3. Remove outer jacket door and inner door per service procedure XIII on page 34. Step 4. Disconnect main burner feedline (3/4” wrench), pilot tube (7/16” wrench) and igniter/flame sensor wire from gas control and remove burner assembly from combustion chamber. Step 5.
UPV Series Frozen Exhaust Vent Terminal If an exhaust vent terminal is blocked with ice or snow due to severe conditions, the pressure switch and control will not allow the burner to operate. This will result in a three flash status code. Once the blockage is removed (through melting or other means) the controls will let the burner operate. The position of the vent 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.
UPV Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Blower Complete Air Mixing Inlet Cover Pressure Switch Blower Temp. Switch Blower Gasket Blower Power Cord Dilution Air Clip Flue Reducer (URG2PV50H Only) Heat Trap Outlet Hot Water Outlet Anode Flue Baffle Heat Trap Inlet 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Inlet Dip Tube Wire Harness T&P Valve ¾ NPT Plug Burner Assy. Pilot Assembly Pilot Orifice Pilot Assy. Main Burner Resettable Thermal Switch 23. Main Burner Mount 24. FV sensor mount plate 25.
United States Sales Technical Support Email Warranty Email Service Parts Email 800-523-2931 800-334-3393 techserv@bradfordwhite.com 800-531-2111 warranty@bradfordwhite.com 800-538-2020 parts@bradfordwhite.com Canada Sales & Technical Support Fax Warranty Technical Support Service Parts Orders 866-690-0961 905-203-0600 905-636-0666 bwccwarranty@bradfordwhite.com bwcctech@bradfordwhite.com orders@bradfordwhitecanada.com ca.orders@bradfordwhite.com For U.S.
