Bradford-White D80T725 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

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

3.Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)

 

µA

Heating

Flame Current

Status Operational

SELECT

SET

4. Setpoint (Display/Change)

°F setpoint

idle

Status Operational

SELECT

SET

5.°F/°C (Display/Change)

°F °F/C° setpoint

idle

Status Operational

SELECT

SET

6.Differential (Display only - shows the differential of the thermostat)

°F Differential

idle

Status Operational

SELECT

SET

11

7. Software Version (Display only)

Soft

idle

Status Operational

SELECT

SET

8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show a “--“if there are no error codes.

idle

Status Operational

SELECT

SET

To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:

Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.

WARNING

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

°F Max

Setpoint

idle

Status Operational

SELECT

SET

12

Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.

°F Max

Setpoint

idle

Status Operational

SELECT

SET

Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180°F.

"Max Setpoint" continues to flash while making adjustments

°F

Max

 

 

Setpoint

%

idle

 

Status Operational

 

SELECT

SET

Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.

"Max Setpoint" stops flashing

°F Max

Setpoint

idle

Status Operational

SELECT %SET

13

Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.

Max %

Setpoint

idle

Status Operational

&ExitingSELECTServiceSETMode

Display of Water Temperature:

Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water heater display. For water heaters using two temperature sensors in the tank, this will be the average reading between the two sensors. For water heaters using a single sensor, this is the reading for the sensor.

°F Water

Temp

idle

Status Operational

Upper Sensor

SELECT

SET

Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the water heater display.

°F

idle

Status Operational

Upper Sensor

SELECT SET

14

Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display.

°F

idle

Status Operational

Lower Sensor

SELECT SET

To Display Flame Sense Current of the Pilot Flame Sensor:

The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays “Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3: Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value displayed is in microamps (µA).

Flame

Current

µA

Heating

Status Operational

SELECT

SET

To Display and Change Temperature Setpoint:

Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display

°F setpoint

idle

Status Operational

SELECT

SET

15

Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.

°F setpoint

idle

Status Operational

SELECT

SET

Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.

NOTICE

The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint” described previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint Limit…" described previously under “Accessing the Service Mode on the Water Heater Display”.

WARNING

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

°F

setpoint

%

 

idle

 

 

Status Operational

 

 

SELECT

SET

 

Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display.

"Setpoint" Flashes

°F setpoint

idle

Status Operational

SELECT SET

16

Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display.

°F setpoint

idle

Status Operational

SELECT

SET

To Display and Change Temperature Format (°F/°C):

To Change Temperature Format in Display from °F to °C or °C to °F:

Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right portion of the water heater display.

°F °F/C°

idle

Status Operational

SELECT

SET

Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display.

°F °F/C°

idle

Status Operational

SELECT

SET

17

Step 3a: Press “Temperature Up” button to change temperature format to °C

°C

°F/C°

%

 

idle

 

 

Status Operational

 

 

SELECT

SET

 

Step 3b: Press “Temperature Down” button to change temperature format to °F

°F °F/C°

idle

Status Operational

SELECT

SET

Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing

°F °F/C°

idle

Status Operational

SELECT

SET

18

Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately

°F

idle

Status Operational

Lower Sensor

SELECT

SET

Error Codes and Error History Display:

If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located under the Water Heater Display and the following section in this Service Manual explains the error codes with corrective actions to repair the water heater.

Example of Error Code in the Display

idle

Service Needed

SELECT SET

Error Code History:

In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence of service modes) will show an error code history, if there have been any previous operating problems with the water heater. If the display shows --,there is not a current error code.

The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index #1 and the most recent in code index #10.

19

To view previous error codes:

Step 1:

In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current error codes, the display will show -- .

°F

idle

Status Operational

SELECT

SET

Step 2:

Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.

idle

 

%

Status Operational

 

SELECT

SET

Step 3:

Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number. If no number is displayed with only a “--“in the water heater display, then there has not been an error code for error code index 10.

idle

Status Operational

SELECT

SET

20

Step 4:

Press the “Temperature Down” button to change to the previous code index, code #9.

idle

 

%

Status Operational

 

SELECT

SET

Step 5:

Press the “Select” button for code index #9 to view if there are any code numbers.

idle

Status Operational

SELECT

SET

Step 6:

Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10.

Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.

°F setpoint%

idle

Statu Operational s

&ExitingSELECTServiceSETMode

21

ERROR CODE DEFINITIONS

If the water heater has an operating problem, there will be a number in the water heater display with “Service Needed” shown below the error code number. Note the error code and the definition in the chart below. This label appears on the control box under the water heater display. The following sections will provide instructions for servicing each error code.

22

WARNING

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.

If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower right button under “Lockout Reset” shown in the lower right portion of the display. The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition.

Error Code Shown in

Water Heater Display

Status Service needed

SELECT Lockout RESET%

Press for 2 seconds

All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.

Resetting Error Codes in Hard Lockout Condition

Error Code Shown in

Water Heater Display

Status Service Needed

 

%

SELECT

SET

&Step 1: Press for 3 seconds to enter service mode.

Status Service Needed

SELECT Lockout RESET

Step 2: Press for 3 seconds to reset control in service mode.

23

 

SERVICE PROCEDURE PDV24-I

 

Thermostat Circuit Testing

 

CAUTION

DANGER

Be Careful When Making Voltage

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

Connector Pins.

Condition: Water Heater Not Operating Display shows error code “31” (Upper Sensor Readings Faulty) or error code “32” (Lower Sensor Readings Faulty)

Unplug or disconnect electrical power to the water heater

Check continuity of wire harness to affected sensor. Measurement of ohmeter should be close to 0 ohms. Replace wire harness if high resistance is measured (over 0.5 ohms) Check wires for intermittent connections, shorts, frayed insulation. Replace if necessary

If wire harness checks out O.K., check sensor resistance detailed in the section for testing sensor resistance. Replace the upper or lower sensor as indicated by error code number.

Turn power on to water heater.

Run water heater through heating cycle and verify proper operation. Sensor temperature can be viewed when burner shuts off (see section on viewing the display in “Service Mode”.

Measuring upper sensor resistance through wire harness (disconnected at control board).

Checking continuity of upper sensor wire harness.

Condition: Water Heater Not Operating Display shows error code “65”

High Water Temperature (over 200 deg. F)

WARNING

Do not reset the display from the hard lockout state without correcting the cause of the overheating condition

Turn power “OFF”.

Draw water to cool tank below 120 deg. F

Check lower sensor. Is the sensor fully inserted into the well? Sensor is held in place with a clip fastened to the well (see photo ) Check lower sensor wire making sure it is not damaged or has breaks in the wire insulation. Check upper harness wires to upper sensor, if used (some models).

Removing lower sensor from well. Held in place by a clip fastened to well shoulder.

If sensor clip is damaged

N replace clip. Replace lowerSee next page sensor if damaged.

YCheck Sensor Resistance (See Sensor Resistance

Testing, following section)

24

SERVICE PROCEDURE PDV24-I

Thermostat Circuit Testing

WARNING!

Do not operate water heater without verifying that the overheating condition has been corrected.

Condition: Water Heater Not Operating

Display shows error code “65”

High Water Temperature (over 200 deg. F)

Continued

Once cause of overheating condition has been diagnosed and corrected, the control may be reset

Reconnect and switch on power to the water heater.

Enter service mode on the water heater display (see illustration) Press button under “Lockout Reset” and hold for 3 seconds. Set thermostat to the desired setting.

Water heater should start.

Monitor temperatures for one complete heating cycle making

sure the maximum tank temperature remains well below 200 deg. F

25

Conditions: Upper or Lower Sensor Reading Faulty, High Water Temperature, or suspect thermostat is not accurate.

SERVICE PROCEDURE PDV24-I

Thermostat Circuit Testing

Sensor Resistance Testing

Upper Sensor

1.Determine resistance value of upper sensor using an ohmeter. Test across grey wires.

2.Draw quart of water off T&P valve. Using a thermometer, determine water temperature.

3.Use table below to verify correct resistance per water temperature measured.

Lower Sensor:

1. Determine resistance value of lower sensor. Test across center wire (common) to each outside wire. Resistance of both thermistors in the lower sensor should be close to each other. If the resistance values for both thermistors are not close to each other, replace the lower sensor. The dual thermistors are used to provide high limit protection in case the thermostat circuit fails to shut off the water heater.

2.Draw quart of water off Drain Valve. Using a thermometer, determine water temperature.

3.Use table below to verify correct resistance per water temperature measured.

Upper thermister location (applicable models)

Checking resistance of upper sensor

Lower thermister access located inside control box.

Are readings N

Replace

 

correct?

 

thermister

Checking resistance of

Y

 

 

 

 

lower sensor (center and

Check harness

 

Replace

outside pins)

N

 

continuity.

 

 

harness

CAUTION

Continuity okay?

 

 

 

Y

 

 

Be Careful When Making Resistance

 

 

Measurements Not to Damage or

 

 

 

Replace

 

 

Deform Connectors or Connector Pins.

 

 

 

control board

 

Sensor Resistance at Various Temperatures

 

 

Example: If water temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area). NOTE: Sensor resistance increases as the temperature falls.

In Degrees F

 

 

 

 

 

 

 

 

 

 

 

°F

0

1

2

3

4

5

6

7

8

9

40

26109

25400

24712

24045

23399

22771

22163

21573

21000

20445

50

19906

19383

18876

18383

17905

17440

16990

16553

16128

15715

60

15314

14925

14548

14180

13823

13477

13140

12812

12494

12185

70

11884

11592

11308

11032

10763

10502

10248

10000

9760

9526

80

9299

9078

8862

8653

8449

8250

8057

7869

7685

7507

90

7333

7165

7000

6839

6683

6531

6383

6238

6098

5961

100

5827

5697

5570

5446

5326

5208

5094

4982

4873

4767

110

4663

4562

4464

4368

4274

4183

4094

4006

3922

3839

120

3758

3679

3602

3527

3453

3382

3312

3244

3177

3112

130

3048

2986

2925

2866

2808

2752

2697

2643

2590

2538

140

2488

2439

2391

2344

2298

2253

2209

2166

2124

2083

150

2043

2004

1966

1928

1891

1856

1820

1786

1753

1720

160

1688

1656

1625

1595

1566

1537

1509

1481

1454

1427

170

1402

1376

1351

1327

1303

1280

1257

1235

1213

1191

180

1170

1150

1129

1110

1090

1071

1053

1035

1017

999

190

982

965

949

933

917

901

886

871

857

842

200

828

814

801

788

775

762

749

737

725

713

26

 

 

SERVICE PROCEDURE PDV23-II

 

 

 

Pressure Switch Testing

 

 

 

 

 

 

 

 

DANGER

 

CAUTION

 

 

 

 

Be Careful When Making Voltage

 

 

 

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

 

 

 

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

 

 

 

Connector Pins.

 

 

Condition: Blower operates, burners not lit. Display shows error code “29” (Pressure Switch Failed to Close).

Connect a digital manometer to the tubing for the pressure switches and determine the average reading. See table at right for pressure switch settings and minimum readings required. Is the pressure switch reading at least 0.20" above the switch reading for the model tested (see chart at right)?

Check intake and exhaust vent terminals outside the building. Is there any blockage from debris (leaves, ice, snow, paper, etc.). If so, clear intake or exhaust vent terminals. Pressure switch should close and the burners should fire.

Check the total equivalent vent length by adding up the total number of elbows and the straight lengths of vent pipe for the intake and exhaust pipe (or coaxial vent pipe for PDV-Tmodel series). See table at right for maximum distances. If the venting distance is excessive, reduce the number of elbows or route the vent terminals to a shorter distance outside the building.

If the venting system and vent terminals are O.K., but the pressure switch reading is still low, check the pressure switch tubing to make sure there are no small holes or kinks. Make sure there are no drops of condensate in the tubing. Check the pressure switch tubing connection fitting and pressure tap to make sure it is not clogged with dirt. Blow through tubing to verify that the pressure taps and tubing are clear and not leaking.

PDV-SMODELS: Check the vent safety thermal switch near the outlet of the blower (see photo at right). Press the red reset button. (See photo on next page). If you feel a slight click, the temperature was excessive and the switch opened. Check to be sure the burner access screws are tight and the gasket is in good condition (see section on servicing the burners)

If the pressure switch readings are at least 0.20" w.c. above the above pressure switch settings for the installed model and the switch does not close, then replace the pressure switch with the same setpoint.

Minimum Differential Dual Tap Pressure Switch Settings:

 

(Contacts open)

PDV80S,100S-150models:

-2.00"w.c.

PDV80S,100S-200models:

-1.20"w.c.

PDV80S,100S-250models:

-2.00"w.c.

PDV80T300 models:

-1.20"w.c.

PDV100T360 models:

-0.60"w.c.

Note: During normal hot running conditions, the pressure switch readings should be at least 0.20" higher than the above readings where the pressure switch will open.

PDV80,100S-150,200Models with 3" PVC vent: Maximum Distance of 40 feet with one 90 deg. elbow for intake or exhaust (subtract 5 feet for each additional elbow).

For venting with 4" PVC vent: Maximum distance of 55 feet with one 90 deg. elbow for intake or exhaust (subtract 5 feet for each additional elbow).

PDV80S,100S-250Models with 4" PVC vent: Maximumdistance of 55 feet with one 90 deg. elbow for intake or

exhaust (subtract 5 feet for each additional elbow).

PDV80T300, PDV100T360 Models with coaxial venting system: Maximum venting distance of 19 feet 6 inches with one 90 deg. elbow. Each additional elbow reduces

the venting distance by 39".

See installation instruction manuals supplied with the water heater for further details on proper venting installations.

Checking pressure switch contacts. Contacts are open if blower is operating and there is 22-26volts measured between the two contacts (as in photos)

27

 

 

 

 

 

SERVICE PROCEDURE PDV24-II

 

 

 

 

 

 

Pressure Switch Testing

 

 

 

 

 

 

 

 

 

 

 

 

DANGER

 

 

CAUTION

 

 

 

 

 

Be Careful When Making Voltage

 

 

120 volt exposure. To avoid personal injury,

 

Measurements or Jumping Terminals

 

 

use caution while performing this procedure.

 

Not to Damage or Deform Connectors or

 

 

 

 

 

 

Connector Pins.

 

 

 

PDV(S & T) Models

 

 

Vent Safety Switch (PDV-SModels Only)

 

Red reset button

Check pressure switch tubing to the pressure switch. Make sure tubing does not have kinks, holes, condensate, or dirt blocking air pressure to the switch. The tubing to the blower tap attaches to the - (minus) tap on the pressure switch.

Vent safety thermal switch on PDV-Sblower. Depress red reset button in center of switch. If a slight click is felt, switch opened. Check for loose or leaking burner access panel (see section on servicing burners)

Induced Draft Models (D80T725 & D65T625):

Induced Draft Models use a single tap pressure switch to measure vacuum in the flue collector. The pressure switch is located inside the control box (see photo to left). Connect a digital manometer to a tee in the pressure switch tubing and measure the vacuum with the blower operating. The vacuum should be in the range of -1.70"to-2.10"w.c. The pressure switchcontacts will open at -1.25" andclose by -1.40" w.c. If the vacuum is below - 1.50", check to make sure the flue damper is fully open when the blower is operating. Make sure the damper and rod are not binding. Make sure there are no restrictions in the venting system and that is at least 8" in diameter. Venting is for vertical gravity venting only. Insure that there is sufficient combustion air to the utility room.

28

 

 

SERVICE PROCEDURE PDV24-II

 

 

 

Pressure Switch Testing

 

 

 

 

 

 

 

DANGER

 

CAUTION

 

 

 

Be Careful When Making Voltage

 

 

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

 

 

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

 

 

Connector Pins.

 

Condition: Blower does not operate, burners not lit. Display shows error code “29” (Pressure Switch Failed to Close ).

With a voltmeter, check to make sure the “line in” connection to the control board has 110-120volts. Make sure the secondary plug from the transformer to the board has 24 volts at the yellow and blue wire pin terminals (see photos to right).

Make sure the water heater control display shows “Heating” in the status window. Raise the setpoint if needed. If there is no call for heat and the setpoint is well above the tank temperature, refer to the thermostat troubleshooting and replacement section.

If the water heater control display shows “Heating” and the blower is off, Error code 29, then check the voltage output at the blower plug on the board. Should read 110-120volts between the black and white wires to the blower (terminals 5 and 3 on the inducer output on the control board, see illustration to the right).

If there is voltage between the black and white wires to the blower plug on the board, then check the voltage at the blower connection on the blower (see photo at right). If no voltage is present, replace the wire harness. If there is 110120 volts, replace the blower.

Condition: Blower does not operate, burners not lit. Display shows error code “2” (Pressure Switch Failed to Open - Stuck Closed).

Disconnect power and remove the pressure switch cover (previous photo-PDVmodels). Disconnect wires on the pressure switch. Measure continuity on the pressure switch terminals with an ohmeter. If there is continuity, the pressure switch is stuck closed. Make sure pressure switch has not been bypassed (jumpered). The control will not operate with a jumpered pressure switch.

If pressure switch contacts are stuck closed, check the pressure switch tubing for condensate, dirt, or kinks. If the tubing is O.K., replace the pressure switch with the same setting.

Checking line voltage to board.

Checking secondary

Pins to black and white wires.

voltage from transformer.

 

Pins to blue and yellow

 

wires.

Checking line voltage at the blower wire harness connection on blower.

Reconnect power. Verify

proper operation. If there is no voltage on the control board to the blower plug and the control display shows “Heating”, then

replace the control board.

29

 

SERVICE PROCEDURE PDV24-III

 

Pilot Operation Testing

 

CAUTION

DANGER

Be Careful When Making Voltage

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

Connector Pins.

Condition:

Pilot will not light or stay lit, Error codes 62, or 63 shown on Water

Heater Display

Reset control by pressing the lower right button under “reset” on the display for 3 seconds. Does control board start ignition sequence and start sparking (sparking noise at pilot or at board)

Y

Is there spark at the pilot?

Y

Is there 22-27volts AC output across terminal pins 8 & 2 on “Control” plug of Control Board? Carefully insert meter probe in wire plug to check pin terminals. Make sure control is in the trial for ignition sequence (see sequence of operation).

(see photo at top of page) Y

Is there 22-27volts AC input acrosswire leads

“MV/PV” & “PV” at Gas Valve?

(see photo to the right)

N

Check wire harness for damage or loose connections. Repair or replace as needed.

Turn on power to the water heater and verify proper operation

N

Replace control board

N

Check for:

Loose or damaged ignition wire

 

 

Grounded pilot electrode

 

Damaged pilot.

N

Replace control board.

 

Checking for 24 volts output to pilot valve (yellow and red wire pin terminals on control board “control” plug.

Check across “MV/PV” & “PV” Wire leads to gas valve

Loosen pilot tubing connection at Y the gas valve and soap test.

Is there pilot gas flow out of the gas valve? See pilot illustration

for pilot inspection.

N

Tighten pilot tube connection at the gas valve. Check incoming gas pressure to water heater. if okay, replace gas valve

Checking MV pin terminal to gas valve wire harness for 24 volts output to gas valve during heating cycle (pilot must be lit with no sparking).

Check for clogged or kinked pilot Y tube, clogged pilot orifice. Clean

or replace as needed. (see photo below)

Flame

Rod

Ceramic Insulators

Pilot

Orifice

Ignition Wire

7//16" ferrule

Nut Flame Sense Wire

Aluminum

Pilot Tubing

30

SERVICE PROCEDURE PDV24-III

Pilot Operation Testing

Condition:

Error code 57: Flame Rod Shorted to Ground

Disconnect power. Shut off gas

 

Check to see if pilot shield is touching

 

 

supply to water heater. Slide out

 

 

Check pilot flame sense wire for

 

pilot flame sensor or flame sensor

 

burner assembly. See section on

 

 

broken insulation. Replace pilot if

 

touching pilot hood. Bend shield to

 

removing pilot and main burner

 

 

defective

 

prevent interference.

 

assembly.

 

 

 

 

 

 

 

Make sure pilot shield clears flame sense rod

Reinstall pilot and burner assembly. Reconnect gas line union, turn on gas. Reconnect power and verify proper ignitions.

31

 

SERVICE PROCEDURE PDV24-III

 

Pilot Operation Testing

 

CAUTION

DANGER

Be Careful When Making Voltage

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

Connector Pins.

Condition:

 

Pilot lights, no or low flame signal. Control

 

Display shows “4” or “62” for Error Codes

 

(Service Needed). Control continues to spark

 

until system “Lock Out”.

 

Main burner will not light.

 

Check for loose or damaged flame sense lead from pilot to module. (see illustration to the right). Is flame sense lead okay?

Y

Check for loose or damaged ground wire(s) from gas valve to control board. Check continuity of wires with ohmeter. Are ground wires okay?

Y

Check venting conditions (vent length & number of elbows)

Is vent system okay?

Y

Is heater condensing causing pilot interruption?

N

The microamp output of the pilot may be checked by entering “Service Mode” on the water heater display and pressing “Select” until the flame current is shown. The control must be in the heating mode with the pilot lit to display a reading. See section on accessing service mode on the water heater display.

Micro-ampreadings

 

 

 

Meter

N

Repair wire lead

 

Probe

Multi-meterset

Flame rod

 

or replace pilot.

 

 

to check

 

 

 

 

 

 

continuity.

 

Repair ground N wire(s) or replace

as needed.

Meter

Probe

N

Correct improper

 

venting condition.

Make sure pilot shield is in place and not bent or damaged (refer to section on main burner

Yand pilot assembly) . Determine cause for

condensing and correct. Under sized water heater or high demand periods

NOTE:

Check continuity of flame sense lead to flame rod. If no continuity, clean pilot flame rod or replace pilot. Check pilot flame appearance - if weak check for clogged pilot orifice, bent pilot tubing, or low inlet gas pressure.

(see above illustration)

Checking pilot flame sensor wire and flame rod for continuity.

 

µA

Heating

Flame Current

Status Operational

SELECT

SET

Pilot flame sensor microamp output shown in display using service mode.

Pilot must be lit to get reading.

0.000 Micro Amp =

Replace control board or pilot if wire is

 

damaged.

1.0 micro amp or less =

Clean pilot flame rod or replace pilot.

32

 

SERVICE PROCEDURE PDV24-IV

 

Main Burner Operation Testing

 

CAUTION

DANGER

Be Careful When Making Voltage

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

Connector Pins.

Condition:

Main burner will not light,

Display shows “Heating” under temperature setpoint.

Tank is cold.

Is Pilot lit?

Y

Does control board continue to spark with pilot lit?

See “pilot will not light”

N in “Pilot Operation

Testing” section.

YSee “Pilot lights, no flame signal” in “Pilot Operation Testing” section.

Checking MV & MV/PV control plug pins to gas valve for 24 volts output during heating cycle (pilot must be lit with no sparking).

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect control wire harness from

 

 

Be sure control display is showing “Heating”,

 

 

“Control” plug of control board.

N

N

 

pilot is lit and control is not sparking.

Is there 22-27volts AC across

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Recheck voltage across control board

 

Replace control board.

pin terminals 5 & 8? Refer to wiring

 

 

 

 

 

 

 

pin terminals 5 & 8 ((MV & MV/PV)

 

 

 

 

diagram

 

 

 

 

 

 

 

 

 

 

 

 

Is voltage present?

 

 

 

 

 

(also see photo )

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reconnect control plug

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to control board.

 

 

 

 

 

 

Brown wire disconnected

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from “MV” terminal of gas

 

Ground lug of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

valve

 

gas valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect brown wire lead from

Y

Check incoming gas

 

 

 

“MV” terminal of gas valve.

 

 

 

 

pressure to gas valve. if

 

 

Is there 22-27volts AC across

 

 

 

 

 

 

 

 

okay,

 

 

 

 

brown wire lead & ground

 

 

 

 

 

 

 

 

 

 

 

replace gas valve.

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check wire harness for damage or loose connections. Repair or replace as needed.

Checking main valve (MV) voltage to gas valve.

33

 

SERVICE PROCEDURE PDV24-IV

 

Main Burner Operation Testing

 

CAUTION

DANGER

Be Careful When Making Voltage

120 volt exposure. To avoid personal injury,

Measurements or Jumping Terminals

use caution while performing this procedure.

Not to Damage or Deform Connectors or

 

Connector Pins.

Condition:

Main burner short cycles. Control Display may show error code “63, 57, or 4” and be in “Soft Lockout” state.

Check gas (line) pressure to the water heater.

Minimum line pressure should be 5.5" W.C.

Is gas pressure within proper specification? (see photo at right)

Y

Check venting conditions. (blocked intake or exhaust terminal, excessive vent length, or number of elbows)

Verify pressure switch is not cycling (see “Pressure Switch Testing”.

Is vent system okay?

Y

Is there sufficient combustion air being supplied to the water heater?

Y

Line gas pressure port

N

Determine cause of

incorrect gas

 

 

 

pressure and correct.

NCorrect improper venting condition.

Manifold

Pressure Port

Connect hose barb to manifold pressure port, then connect monometer to measure gas manifold pressure.

PDV(S&T) MODELS: Check intake piping and terminal.

N

INDUCED DRAFT MODELS: Make sure there is sufficient air supply to utility room.

Check for unstable pilot flame or oxidized flame rod on pilot causing weak pilot signal. Make sure pilot shield is in place and does not touch pilot flame sensor. (see “pilot inspection”)

Check burner tubes for scale or debris build-up.Clean burner(s) as necessary.

(see “main burner inspection”)

Check tank flues for blockage or debris build-upcausing restriction.

(see “flue baffle inspection”)

34

SERVICE PROCEDURE PDV24-V

Main Burner & Pilot

Removal and Inspection

WARNING

Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

PDV (S&T) MODELS

 

PDV-SMODELS

 

 

(Hinged Door)

PDV-TMODELS

(Removable Door)

Step 1: Remove burner box cover screws

Step 2: Open Burner Box Cover

Step 3: Disconnect Pilot Fitting from Burner Box

Step 4: Disconnect gas valve wires and pilot tube

Step 5: Disconnect and Remove Gas

Step 6: Remove pipe flange plate from

Valve

Burner Box

35

SERVICE PROCEDURE PDV24-V

Main Burner & Pilot

Removal and Inspection

WARNING

Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

PDV (S&T) MODELS

Step 7: Remove manifold bracket screws

Step 8: Remove manifold from Burners

Step 9: Slide manifold out through side flange opening in Burner Box

PDV-SMODELS

Step 10: Disconnect Pilot Tube Fitting from inside Burner Box

PDV-TMODELS

Step 11: Remove screw fastening burner to burner box/burner shroud.

Step 12: Disconnect Pilot wires from control board and remove from Control Box

36

SERVICE PROCEDURE PDV24-V

Main Burner & Pilot

Removal and Inspection

WARNING

Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

PDV (S&T) MODELS

Step 13: Pull pilot wires through burner

Step 14: Slide out burner assembly

box

 

Step 15: To remove pilot, remove pilot bracket screws

Step 16: Slide pilot assembly to back of burner rack

Step 17: Pilot removal for servicing.

37

SERVICE PROCEDURE PDV24-V

Main Burner & Pilot

Removal and Inspection

WARNING

Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

INDUCED DRAFT MODELS

Gas Valve

Control Knob

Main Burner Removal

Step 1.

Disconnect (un-plug)water heater from

Gas Valve

Wire Leads

 

electrical supply.

 

Step 2.

Turn “OFF” gas supply to water heater.

 

Step 3.

Rotate gas valve control knob to the “OFF” position

 

(see photos at right).

 

Step 4.

Disconnect Gas supply line from the gas valve.

Step 5.

Disconnect wire leads from gas valve

Pilot Flame Sense

 

(see photos at right).

 

Wire (White)

 

 

Step 6.

Disconnect white flame sense wire & orange ignition

 

wire from Control Board (see photos at right).

Step 7.

Remove the two burner rack mounting screws (see photos).

Step 8.

Slide complete burner rack out from water heater

 

(see photos below).

 

Step 9.

To install burner, reverse above procedure.

 

Step 10.

Check for gas leaks and verify proper operation.

Burner Rack

Mounting

Screw

Pilot spark wire (Orange)

Pilot Draft

Burner Rack Shield

Mounting

Screw

38

SERVICE PROCEDURE PDV24-V

Main Burner & Pilot

Removal and Inspection

PDV (S&T) AND INDUCED DRAFT MODELS

Pilot Shield

Pilot Burner Removal

Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve

Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place.

Step 3. Remove pilot shield and pilot from burner rack.

Step 4. To install pilot burner and pilot shield, reverse above procedure. Be sure to reconnect green ground wire.

Pilot Burner Inspection

Step 1. Inspect pilot for the following:

a)Broken or cracked ceramic insulators. If found, pilot must be replaced.

b)Damaged electrode or flame sense wire. If found, pilot must be replaced.

c)Oxidation build-upon flame rod. Clean flame rod or replace pilot as necessary.

Step 2. Inspect pilot orifice:

a)Remove 7/16" ferrule nut from bottom of pilot.

b)Remove pilot tube and orifice from pilot.

c)Inspect pilot tube for blockage. Clean or replace as necessary.

d)Inspect pilot orifice for blockage. Clean or replace as necessary.

Pilot & Pilot Shield

Ground Wire

Location

Mounting Screws

 

Flame

Rod

Ceramic Insulators

Pilot

Orifice

Ignition Wire

7//16" ferrule

Nut Flame Sense Wire

Aluminum

Pilot Tubing

39

SERVICE PROCEDURE PDV24-VI

Control Board Replacement

DANGER

120 volt exposure. To avoid personal injury, unplug while performing this procedure.

Depress plastic tabs

Control board replacement

Step 1. Depress left plastic tabs and pull out from slots in control panel

Slots in control panel

Unhook tabs from control panel slots

Step 2. Tilt control panel to the right and slide control hook tabs from slots in control panel.

Step 3. Unplug wire connections from board and replace.

Wire connections

Remove lower sensor

Remove clip, pull sensor out.

Remove clip

Pull out sensor

40

SERVICE PROCEDURE PDV24-VII

Flue Baffle Removal, Inspection

WARNING

Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Disconnect (unplug) water heater from electrical supply.

Step 2. Turn “OFF” water supply to water heater.

Step 3. Open a near by hot water faucet to relieve tank pressure.

Step 4. Connect hose to drain valve of water heater and route to an open drain. Open drain valve and drain a minimum of 5 gallons of water from the water heater. Close drain valve and disconnect drain hose from water heater.

Step 5. If required, disconnect top plumbing connection from top of water heater.

Step 6. Remove screws holding jacket head to top of water heater and remove jacket head from top of water heater. Note, it may be necessary to use a screw driver to pry underneath

jacket head.

Step 7. If required, remove insulation from top of water heater to expose collector cover.

Step 8. Remove screws from top (or side) of collector cover. Note, it may be necessary to chisel away some foam to access screws.

Step 9. Remove collector cover from water heater.

Step 10. Remove flue baffles from water heater. Note, it may be necessary to use pliers to loosen and remove baffles from flue tubes.

Step 11. Visually inspect flue baffles. Flue baffles may show signs of oxidation; this is normal. If the oxidation has deteriorated any portion of the flue baffle, replacement is recommended. If any restrictors are missing, replacement is recommended.

Step 12. Upon completion of inspection or subsequent replacement, reinstall flue baffles into heater.

Step 13. Reinstall collector cover and insulation (if applicable) over collector cover.

Flue Baffle

PDV Models

Step 14. Reinstall jacket head.

Step 15. Reconnect plumbing connection to top of water heater & turn on water supply if required.

Step 16. Check for leaks and verify proper operation.

41

SERVICE PROCEDURE PDV24-VIII

Anode Removal and Inspection

WARNING

Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Disconnect (unplug) water heater from electrical supply.

Step 2. Turn “OFF” water supply to water heater.

Step 3. Open a near by hot water faucet to relieve tank pressure.

Step 4. Connect hose to drain valve of water heater and route to an open drain. Open drain valve and drain a minimum of 5 gallons of water from the water heater. Close drain valve and disconnect drain hose from water heater.

Step 5. If required, disconnect top plumbing connection from top of water heater.

Step 6. Remove screws holding jacket head to top of water heater

and remove jacket head from top of water heater. Note, it may

be necessary to use a screw driver to pry underneath Replace Anode jacket head (see photos at right).

Step 7. Remove insulation from top of water heater to expose collector cover, if necessary. (see bottom of page for approx. anode locations)

Step 8. Remove screws from top (or sides) of collector cover. Note, it may be necessary to chisel away some foam to access screws.

Step 9. Locate and remove anode rods from top of water heater (1-1/16hex socket).

Step 10. Visually inspect anode rod. Anode rod may show signs of depletion; this is normal. If the anode shows signs of depletion

(approximately 5/8", see photo at right), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 11. Upon completion of inspection or subsequent replacement, reinstall anode rods into water heater.

Step 12. Check for leaks.

Step 13. Reinstall collector cover & insulation over collector cover, if applicable.

Step 14. Reinstall jacket head.

Step 15. Reconnect plumbing connection to top of water heater if required.

Step 16. Restore water supply and power to water heater.

Step 17. Verify proper operation.

42

Generic Parts List

PDV-S

1A.

Vent Kit

18A.

Combustion Box Boot

35A.

T & P Nipple

2A.

Vent Elbow

19A.

Blower Escutcheon

36A.

T & P Valve

3A.

Intake Terminal

20A.

Blower Hose Barb

37A.

Cold Water Inlet Nipple

4A.

Vent Reducer

21A.

Air Inlet

38A.

Drain Valve

5A.

PVC Pipe

22A.

Vent Orifice

39A.

Sight Glass Holder

6A.

Blower Vent Adaptor

23A.

Air Intake Tee

40A.

Sight Glass Gasket

7A.

Blower Receptacle Gasket

24A.

Cold Water Inlet Dip Tube

41A.

Sight Glass

8A.

Blower

25A.

Hot Water Outlet Nipple

42A.

Combustion Box Gasket

9A.

Temperature Switch

26A.

Pressure Switch Cover

43A.

Combustion Box Gasket

10A.

Blower Intake Gasket

27A.

Pressure Switch

44A.

Cleanout Gasket

11A.

Blower Mounting Flange

28A.

Flue Baffle

45A.

Cleanout Cover (Tank)

12A.

¼-20Hex Nut

29A. Hex Head Anode

46A.

5/16-18Hex Screw

13A.

Collector to Blower Transition

30A.

Pipe Plug

47A.

Cleanout Cover (Jacket)

14A.

Air Intake Assembly

31A.

Hole Closure

48A.

Lower Thermostat Sensor Clip

15A.

Utility Cover

32A.

Hot Water Outlet Nipple

49A.

ASSE Approved Mixing Valve

16A.

Air Intake Pipe

33A.

Lower Thermostat Well

50A.

Blower Harness

17A.

Cover Rear Boot

34A.

Wire Harness Lower Sensor

51A.

Pressure Switch Harness

43

Generic Parts List

PDV S

1B.

Gas Valve Assembly

12B.

Street Elbow

2B.

Burner Assembly

13B.

Gas Valve

3B.

Burner Rack

14B.

Aluminum Tubing

4B.

Burner Tube

15B.

Nipple Close

5B.

Burner Shroud

16B.

Union

6B.

Burner Draft Panel

17B.

Nipple

7B.

Burner Support

18B.

Combustion Box Flange

8B.

Aluminum Tubing

19B.

Flange Gasket

9B.

Pilot Shield

20B.

Manifold

10B. Pilot Orifice

21B.

Main Burner Orifice

11B. Pilot Assembly

 

 

44

Generic Parts List

PDV-S

1C.

Control Box Assembly

12C.

Strain Relief Bushing 7/8"

2C.

Control Box Cover Assembly

13C.

Snap-In-Bushing7/8"

3C.

Honeywell Display

14C.

Power Cord Wiring Harness

4C.

Control Box Cover

15C.

Display Control Wiring Harness

5C.

Integrated Control Board

16C.

Display Cover Wiring Harness

6C.

Control Box Panel

17C.

Primary Transformer Wiring Harness

7C.

Power On/Off Switch

18C.

Secondary Transformer Wiring Harness

8C.

Pan Head Screw w/adh.

19C.

Gas Valve Control Wiring Harness

9C. Pan Head Screw #8-18

20C.

Pan Head Screw #8-18.

10C. Transformer

21C.

Ground Lug

11C. Strain Relief Bushing ½"

22C.

Snap-In-Plug7/8"

45

Generic Parts List

PDV-T

1A.

ASSE Approved Mixing Valve

18A.

Combustion Box Boot

 

 

 

35A.

T & P Nipple

2A.

Vent Clamp

19A.

Blower Escutcheon

36A.

T & P Valve

3A.

Blower Vent Adapter

20A.

Blower Hose Barb

37A.

Cold Water Inlet Dip Tube

4A.

Combustion Box Cover

24A.

Cold Water Inlet Dip Tube

38A.

Drain Valve

5A.

Wire Raceway

25A.

Hot Water Outlet Nipple

39A.

Combustion Box Gasket

7A.

Blower Receptacle Gasket

26A.

Pressure Switch Cover

40A.

Combustion Box Gasket

8A.

Blower

27A.

Pressure Switch

41A.

Cleanout Gasket

9A.

Temperature Switch

28A.

Flue Baffle

42A.

Cleanout Cover (Tank)

10A.

Blower Intake Gasket

29A.

Hex Head Anode

43A.

5/16-18Hex Screw

11A.

Blower Mounting Flange

30A.

Upper Thermostat Sensor

44A.

Cleanout Cover (Jacket)

12A.

¼-20Hex Nut

31A.

Upper Sensor Wire Harness

 

 

 

13A.

Collector to Blower Transition

32A.

Hot Water Outlet Nipple

 

 

 

15A.

Utility Cover

33A.

Lower Thermostat Sensor

 

 

 

16A.

Air Intake Pipe

34A.

Lower Sensor Wire Harness

 

 

 

46

Generic Parts List

PDV T

1B.

Burner Assembly

12B.

Gas Valve Assembly

2B.

Burner Rack

13B.

Nipple

3B.

Burner Tube

14B.

Street Elbow

4B.

Burner Draft Panel

15B.

Union

5B.

Burner Support

16B.

Nipple Close

6B.

Aluminum Tubing

17B.

Aluminum Tubing

7B.

Pilot Shield

18B.

Gas Valve

8B.

Pilot Orifice

 

 

9B.

Pilot Assembly

 

 

10B. Manifold

11B. Main Burner Orifice

47

Generic Parts List

PDV-T

1C.

Control Box Assembly

12C.

Strain Relief Bushing 7/8"

2C.

Control Box Cover Assembly

13C.

Snap-In-Bushing7/8"

3C.

Honeywell Display

14C.

Power Cord Wiring Harness

4C.

Control Box Cover

15C.

Display Control Wiring Harness

5C.

Integrated Control Board

16C.

Display Cover Wiring Harness

6C.

Control Box Panel

17C.

Primary Transformer Wiring Harness

7C.

Power On/Off Switch

18C.

Secondary Transformer Wiring Harness

8C.

Pan Head Screw w/adh.

19C.

Gas Valve Control Wiring Harness

9C. Pan Head Screw #8-18

20C. Pan Head Screw #8-18.

10C. Transformer

21C.

Ground Lug

11C. Strain Relief Bushing ½"

22C.

Snap-In-Plug7/8"

 

 

23C.

Upper Sensor Harness

48

Generic Parts List

INDUCED DRAFT MODELS

1A.

Flue Baffle

15A.

Flange Gasket

2A. Hex Head Anode

16A. Blower

3A.

Pressure Tap Fitting

17A.

Drain Valve

4A.

1/8" NPT Elbow

18A.

Cold Water Inlet Dip Tube

5A.

Hose Barb

19A.

Cleanout Gasket

6A.

Silicone Hose

20A.

Cleanout Cover (Tank)

7A.

Control Box Assembly

21A.

5/16-18Hex Screw

8A.

ASSE Approved Mixing Valve

22A.

Cleanout Cover (Jacket)

9A.

Blower Transistion

23A.

Upper Thermostat

10A.

T & P Nipple

24A.

Lower Thermostat Well

11A.

T & P Valve

25A.

Lower Thermostat Clip

12A.

Hot Water Outlet Nipple

26A.

Lower Thermostat Sensor

13A.

Blower Flange Mount

27A.

Utility Cover

14A.

Vent Adapter

28A.

Burner Assembly

49

Generic Parts List

INDUCED DRAFT MODELS

1B.

Burner Assembly

9B. Pilot Assembly

2B.

Burner Panel

10B.

Aluminum Tubing

3B.

Burner Tube

11B.

Pilot Draft Shield

4B.

Burner Mounting Bracket

12B.

Burner Support

5B.

Burner Rack

13B.

Valve Support Bracket

6B.

Dual Gas Valve Assembly

14B.

1" NPT Street Elbow

7B.

Main Burner Orifice

15B.

1" NPT X 3-½"Nipple

8B.

Manifold

16B.

1" NPT Elbow

50

Generic Parts List

INDUCED DRAFT MODELS

1C.

Control Box Assembly

13C.

Secondary Transformer Wiring Harness

2C.

Control Box Cover Assembly

14C.

Primary Transformer Wiring Harness

3C.

Pan Head Screw #8-18

15C.

Strain Relief Bushing ½"

4C.

Honeywell Display

16C, Strain Relief Bushing 7/8"

5C.

Control Box Cover

17C.

Snap-In-Plug7/8"

6C.

Integrated Control Board

18C.

Pan Head Screw w/adh.

7C.

Pan Head Screw #8-18

19C.

Blower Wiring Harness

8C.

Transformer

20C.

Power Cord Wiring Harness

9C.

Ground Lug

21C.

Gas Valve Control Wiring Harness

10C.

Pressure Switch

22C.

Upper Sensor Harness

11C.

Power On/Off Switch

23C.

Display Control Wiring Harness

12C.

Control Box Panel

24C.

Display Cover Wiring Harness

51

Glossary of Terms

AC

Alternating Current

BTU/H

British Thermal Units

CO

Carbon Monoxide

CO2

Carbon Dioxide

DC

Direct Current

ECO

Energy Cut Off

GFI

Ground fault interrupt

GPM

Gallons per Minute

Hz

Hertz

LED

Light Emitting Diode

NOx

Oxides of Nitrogen

NPT

National Pipe Thread

PSI

Pounds per Square Inch

VA

Volt Amps

VAC

Volts Alternating Current

W.C.

Inches of Water Column

°C

Degrees Centigrade

°F

Degrees Fahrenheit

µA

Micro Amp

NOTES

52