Bradford-White D65T625 User Manual

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PDV(S,T) MODEL SERIES AND INDUCED DRAFT (D80T725, D65T625) MODEL SERIES WATER HEATERS WITH HONEYWELL INTEGRATED CONTROL SYSTEM

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

PDV80S150

PDV802200

PDV80S250

PDV100S150

PDV100S200

PDV100S250

PDV80T300

PDV100T360

D80T725

D65T625

(PDV80S Shown)

Manual 48061A

Save this manual for future reference

 

 

Table of Contents

 

Page

PDV Service Procedure

Introduction

4

 

 

- - -

Tool required for service

4

 

- - -

Sequence of Operation

6

 

- - -

Troubleshooting

7

 

- - -

Thermostat Circuit Testing

24

 

 

PDV24-I

Pressure Switch Testing

27

 

 

PDV24-II

Pilot Operation Testing

30

 

 

PDV24-III

Main Burner Operation Testing

33

 

 

PDV24-IV

Main Burner & Pilot Removal & Inspection

35

 

 

PDV24-V

Control Board Replacement

40

 

 

PDV24-VI

Flue Baffle Removal & Inspection

41

 

 

PDV24-VII

Anode Removal & Inspection

42

 

 

PDV24-VIII

Generic Parts List - PDV-S

43

 

- - -

Generic Parts List - PDV-T

46

 

- - -

Generic Parts List - Induced Draft Models

49

 

- - -

Glossary of Terms

52

 

- - -

2

FEATURES OF PDV-SMODEL SERIES

Power vented direct vent design, uses a blower to vent the flue products to the outside and pull combustion air in from outside the building

Independent Venting - Exhausts flue products and supplies combustion air through two separate 3" or 4" PVC, CPVC or ABS pipes. Maximum venting distance of 40 ft. with one 90 degree elbow for each pipe in 3". The 250,000 Btu/hr. model vents with 4" PVC, CPVC, or ABS only. Maximum vent length is 55 feet with one 90 degree elbow in 4" pipe (each pipe) for all models.

Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control system. Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle. Electronic thermostat and LCD Display - Accurately monitors the tank temperature and the setpoint is easily adjusted by using the temperature UP and DOWN buttons on the display on the control box cover.

FEATURES OF PDV-TMODEL SERIES

Power vented direct vent design, uses a blower to vent the flue products to the outside and pull combustion air in from outside the building

Co-axialVenting (pipe inside a pipe) - Combustion air enters from outside the building through an outer pipe and exhausts flue products through the inside pipe. May be vertically or horizontally vented with a maximum venting distance of19'-6"(19 feet, 6 inches) with one 90 degree elbow.

Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control system. Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle. Electronic thermostat and LCD Display - Accurately monitors the tank temperature and the setpoint is easily adjusted by using the temperature UP and DOWN buttons on the display on the control box cover.

FEATURES OF INDUCED DRAFT MODELS

High Capacity power vented design, uses a blower to pull the flue products out the water heater. Designed to vent vertically through 8 inch diameter type B venting system. Uses room air for combustion.

Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control System. Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle. Electronic thermostat and LCD Water Heater Control Display - Accurately monitors the tank temperature and the setpoint and is easily adjusted by using the temperature UP and DOWN buttons on the display on the control box cover.

FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM

Attractive digital water heater display on control panel for setting and displaying the temperature setpoint. Pressing temperature up and down buttons changes the temperature setpoint. Same water heater display used on all models. Temperature format may be displayed in degrees F or degrees C.

Single control board with plug in wiring controls temperature, ignition, and blower operation. Reduced number of parts for servicing and wiring.

Plug in wiring reduces chance of miswiring.

Water heater display will show diagnostic codes in the event the water heater needs servicing. Aids in diagnosing and servicing the water heater.

Water heater display can show previous error code history to further aid in servicing the water heater.

3

Introduction

It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting analysis and repair of the Bradford White PDV & Induced Draft Series Water Heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product.

Troubleshooting begins by noting the error code, if any, on the water heater control display and finding the section in this service manual for diagnosing the problem for this error code. This step by step procedure beginning on page 5 will direct the service provider to a series of test procedures to determine root cause of failure.

Contact Technical support immediately if diagnosis is not determined using the methods described in this service manual.

Tools Required for Service

 

 

 

 

Manometer:

 

Two types available, a liquid “U” tube type or a digital (magna-helic)

 

 

type. This device is used to measure gas and/or air pressures and

 

 

vacuum.

Multi-Meter:

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-ampsand ohms.

Thermometer:

Used to measure water temperature. An accurate thermometer is

 

 

recommended.

Water Pressure Gage:

Used to measure water supply pressure. Also used to determine tank

 

 

pressure by adapting to the drain valve of the heater.

Jumper Leads:

A length of wire (12" min.) with alligator clip at both ends.

Various Hand Tools:

Pipe wrench, channel locks, open end wrench set, 12" crescent wrench,

 

 

Allen wrench set, torx bit set, screw drivers (common & phillips), long

 

 

reach (12") magnetic tip phillips head screw driver #2 tip, ¼" nut driver,

 

 

pliers (common & needle nose), socket set including a 1-1/16deep well

 

 

socket, wire cutters, wire strippers, wire crimpers, torpedo level, small

 

 

shop vac, step ladder, and flashlight.

4

 

 

 

Specifications

Power Supply

Dedicated 120 VAC, 60 Hz., 15 A

Current Draw

Less than 5 Amps

Gas Supply Connection

PDV-S&PDV-TMODELS: 3/4" NPT Minimum connection to gas valve.

 

 

 

INDUCED DRAFT MODELS: 1" NPT Minimum conncection to gas valve.

 

 

 

 

Schedule 40 black iron pipe recommended for all models.

Approved Gas Type

Gas Pressure (Nat. & L.P.)

Venting System

Minimum Clearance for Servicing

Maximum Water Supply Pressure

Thermostat Sensor(s)

Control Board

Control Display

Natural or Propane. Gas supply must match the gas type listed on the water heater rating label.

Manifold Pressure: 4.5" w.c. natural gas, 10.0" w.c. L.P.

Gas Supply Pressure: At least 1" above manifold pressure with water heater operating, 14" w.c. maximum

PDV-SMODELS:

Power vented through either 3" or 4" diameter PVC, CPVC, or ABS pipe for 150,000 or 199,999 Btu/hr. models, 4" only for 250,000 Btu/hr. models. Refer to the installation instruction manual for further information on venting lengths and installation requirements.

PDV-TMODELS:

Power vented through Co-axialVenting (pipe inside a pipe) - Combustion air enters from the outside the building through an outer pipe (200mm diam.) and exhausts flue products through the inside pipe (130mm diam.). Refer to the installation instruction manual for further information on venting lengths and installation requirements.

INDUCED DRAFT MODELS:

Connect 8” vent to blower vent collar for venting through a chimney or type B vent only. Vertical venting only.

30" Front Clearance, 16" Top, 2" Sides and Rear

150 PSI

Redundant thermister with 11,900 + or - 0.5% ohms resistance at 70 deg. F. Sensor inside well for lower sensor. PDV-Tmodel series and Induced Draft models also use an upper sensor (dual sensors for these models).

Honeywell Integrated Control Board for Temperature Control, Induced Draft Blower, and Ignition Control Functions. Operates on 24 volts AC current from transformer. Single sensor boards for PDV-Smodels and dual sensor boards forPDV-Tmodels and Induced Draft models.

Honeywell LCD Control Display with Temperature Setpoint, Format, and Error Code Display in User Mode, Diagnostic Functions in Service Mode. Communicates with Control Board. 24 volts AC. Same control display used on all models.

Transformer

Pilot

Induced Draft Blower

120 VAC Primary, 24 VAC Secondary, 40 VA

Intermittent Pilot with Spark Electrode and Flame Sensor monitored by Control Board

PDV-SMODELS: 115 VAC, 60 Hz., 4.3 Amps.

PDV-TMODELS AND D80T725, D65T625: 115 VAC, 60 Hz., 3.6 Amps.

5

WIRING DIAGRAM

Sequence of Operation

1Thermostat calls for heat:

.

The relay closes on the control board, sending line voltage (115-120volts) from “inducer” terminals #5 and 3 on the control board to the induced draft blower.

2The blower starts and when sufficient vacuum is achieved, the pressure switch closes and completes the 24 volt circuit between terminals 1 and 3 on the Control Plug to the the board, allowing the ignition sequence to proceed. The blower “purges” any remaining combustion products from the previous cycle for 15 seconds before allowing the pilot to light. This is the pre-purgeperiod of the ignition cycle.

3Trial for ignition (three 90 second ignition trials, with 75 second pauses between trials).

Control Board simultaneously sends:

1.24 volts from control pin terminal #8, to “MV/PV” terminal of gas valve (common terminal).

2.24 volts from control pin terminal #2, to “PV” terminal of gas valve to establish

gas flow at pilot.

3.Low current high voltage from “spark” terminal, to generate spark at the pilot and ignite pilot gas flow.

4.Pilot flame proving signal (measured in micro-amps).from the “sense” terminal, to prove pilot flame.

4Once pilot flame is proven, sparking will stop.

Once sparking stops, 24 volts is sent from control pin

5terminal #5 on control board, to “MV” terminal on gas valve to establish main burner gas flow. Main burners ignite from the pilot flame.

The control board constantly monitors pilot flame through the flame sensor rod. If pilot flame is lost, pilot and main burners are shut down. After a 75 second inter-purgeperiod, the control will attempt tore-lightthe pilot beginning at sequence 3 above.

Main burner fires until the thermostat is satisfied. The control

7board interrupts 24 volts through the gas valve circuit. Pilot and main burners are turned off.

8The induced draft blower shuts off 5 seconds after the gas valve closes. This is the post-purgeperiod.

LOCKOUT CONDITION

Control board will go into “Soft Lockout” if the pilot cannot be lit after 3 ignition trials. The water heater display indicates a lockout condition by showing an error code number (62 or 63) with “Service Needed” in the display window. Refer to error codes in the

diagnostic section of this Service Manual. In a “Soft Lockout” condition,

the control will wait for 60 minutes and then make 2 more attempts to light the pilot and establish the main burners.

Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3 seconds.

If the water heater should reach 200 degrees F, then the high limit control will shut off the burners and the water heater will go into a “Hard Lockout”. Error code 65 will be shown in the water heater display. The control can only be reset in the “service mode”, which is detailed in the next section of this Service Manual.

If the exhaust or intake terminals become blocked during operation or if the blower motor fails, the pressure switch will open and error code 29 will appear in the display. When the condition is corrected, the error code will disappear and the water heater will resume normal operation. No resetting of the control display is needed for the pressure switch error code.

6

TROUBLESHOOTING

CAUTION

Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals

Water Heater Fault: Water heater does not operate

Display Error Code: Water heater display does not operate - blank display

Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater.

Check to make sure switch on top of control panel is in the ON position

Verify Primary and Secondary

voltage at the control board.

If there is not 24 volts at Secondary pins on the control board, check transformer. Replace transformer or wire harness.

Checking line voltage to board. Pins to black and white wires.

Voltage at primary pins 1&3 should be 110-120.If not, check Line In pins 1&4.

Check line cord with volt meter. Replace line cord if defective.

Checking primary voltage to transformer from board. Pins to black and white wires.

Switch on power.

 

Checking secondary voltage from

Checking transformer voltage, front

 

 

 

 

 

 

 

 

transformer. Pins to blue and yellow

terminals are 24 volts, rear terminals

 

 

 

 

wires.

are 120 volts.

Does water heater display operate?

 

 

 

 

 

 

Does the induced draft blower start

N

Check wire connections of

With the control cover tilted down,

to operate? Increase thermostat

measure the voltage between red and

 

setting if tank is warm.

 

board to display. See

 

black wire pin connections to display.

 

 

 

 

 

 

illustration.

Voltage should be 24 volts AC

 

 

 

 

 

 

measured at the

back of the Control

 

 

N

 

 

 

Display.

 

 

 

 

 

 

 

See next page

 

 

 

If no voltage at Display, check wire

 

 

 

 

 

 

 

 

 

 

 

 

harnesses and voltage at E-com

 

 

 

 

 

 

screw terminals on the Control Board.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace control display if voltage is

 

 

 

 

 

 

present at back of display pin terminals

 

 

 

 

 

 

(see photo at left). Replace control board if

 

 

 

 

 

 

no voltage is present at E-comterminals

 

 

 

 

 

 

(1&3 and 1&2) to the control display.

7

TROUBLESHOOTING

CAUTION

Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals

From previous page

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Error code #29 on display. Measure voltage at the pin

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

terminals on the control board between the black and white

N

Does induced draft blower

 

wires to the blower (terminals 5 and 3 on the “inducer”

 

 

 

output on the board, see image above). Make sure the

 

 

operate?

 

 

 

 

 

 

 

control display shows “heating” in the status mode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Increase the setpoint, if it does not show “heating”. Is there

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

110-120volts to the blower harness?

 

 

 

 

 

 

 

 

 

 

 

N

Error code #29 on display. Pressure switch did not close. Check for

 

 

 

 

blocked intake or exhaust vents, damper stuck closed, or excessive

Is there pilot flame?

 

 

 

vent length. See section on “Checking Pressure Switch”. If pressure

 

 

 

switch closes, and error code 62 appears on control display, pilot is not

 

 

 

 

 

 

 

 

lighting or staying lit during the ignition cycle. Proceed to the section

 

Y

 

 

 

“Pilot Operation Testing”

 

 

 

 

 

 

 

 

Does Main Burner operate?

 

 

 

N

 

Error code #62 on display. See pilot lights, no flame

 

 

 

 

 

 

 

 

 

 

 

signal in the section for “Pilot Operation Testing”

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does burner continue until

 

 

 

Error code #63 on display. See Main Burner short

 

thermostat set point is reached?

 

N

 

 

See setting display in Service Mode

 

 

 

 

cycles in the section under “Main Burner Operation

 

 

 

 

 

 

and displaying temperature

 

 

 

Testing”

 

sensors. Y

Blower Stops shortly after burners shut off.

Replace control board if display shows “heating” and no voltage is present to the blower harness. Make sure there are no codes for the temperature sensors (following sections) before replacing control board.

If there is voltage from the control board to the blower wire harness? Check the voltage at the connection to the blower. Replace wire harness if there is no voltage to the blower. Replace blower, if there is voltage to the blower.

 

Y

 

 

 

Error Code Shown

 

 

System okay

in Water Heater Display

Status Service Needed

SELECT Lockout RESET

Example of error code shown on control display.

8

ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)

The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below:

Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the

display.

"Max Setpoint”

 

next to Temperature

 

Setpoint value.

Max

Setpoint

idle

Statu Operational s

SELECT SET

Step 2: Pressing “Select” button will change display to next mode

°F Water

Temp

idle

Status Operational

SELECT SET

The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:

Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.

Error Code Shown

in Water Heater Display

Status Service Needed

SELECT Lockout RESET

9

1. Max Setpoint (Display/Change)

Max Setpoint value in

 

Water Heater Display

°F

Max

 

Setpoint

idle

Status Operational

&SELECT SET

2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single sensor is used).

°F Water Temp

idle

Status Operational

SELECT

SET

2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models)

°F

idle

Status Operational

Upper Sensor

SELECT SET

2c. Water Temperature - Lower Sensor (Displays if there are two sensors)

°F

idle

Status Operational

Lower Sensor

SELECT

SET

10