Bradford-White PDX75S70F(B User Manual

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Bradford White

PDX Series

Powered Direct Vent Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

For Bradford White

PDX Series Models:

PDX250T6*F(BN,CX)

PDX265T6*F(BN,CX)

PDX275T6*F(BN,CX)

PDX50S60F(B,C)*(N,X)

PDX65S65F(B,C)*(N,X)

PDX75S70F(B,C)*(N,X)

(*) Denotes Warranty Years

Manual 46925A

Save this manual for future reference

 

 

Bradford White

PDX Series

Powered Direct Vent Gas Water Heaters

Table of Contents

 

 

Page

TTW Service Procedure

Introduction

 

4

 

- - -

How to use this manual

5

- - -

Tool required for service

5

- - -

Specifications

6

- - -

Control Timings

8

- - -

Sequence of Operation

9

- - -

Troubleshooting

12

- - -

Burner Inspection, Cleaning and Replacement

14

 

I

Pilot Testing, Cleaning and Replacement

16

 

II

Pressure Switch Testing and Replacement

17

 

III

Blower Testing and Replacement

21

 

IV

Blower Temperature Switch Testing and Replacement

23

 

V

Gas Control & Thermal well Testing & Replacement

25

 

VI

Flammable Vapor Sensor Testing & Replacement

29

 

VII

Safety Circuit Voltage Trace

30

 

VIII

115VAC Circuit Trace

31

 

IX

Dip Tube inspection and Replacement

32

 

X

Anode Inspection and Replacement

33

 

XI

Flue Baffle Inspection and Replacement

34

 

XII

Inner Door Removal, Inspection & Replacement

35

 

XIII

Glossary of Terms

38

- - -

Parts List

39

- - -

Page 2

2

PDX 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.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

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.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

CAUTION

Incorrect operation of this

appliance may create a hazard to

life and property and will nullify the

warranty.

DANGER

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

IMPORTANT

Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any water heater with damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-airintake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater andvent-airintake components.UNDER NO

CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIRINTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER ORVENT-AIRINTAKE SYSTEM.

CAUTION

If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

Hydrogen gas can be produced in an operating

water heater that has not had water drawn from the

tank for a long period of time (generally two weeks or

more). Hydrogen gas is extremely flammable. To

prevent the possibility of injury under these

conditions, we recommend the hot water faucet to be

open for several minutes at the kitchen sink before

you use any electrical appliance which is connected

to the hot water system. If hydrogen is present,

there will be an unusual sound such as air escaping

through the pipes as hot water begins to flow. Do

not smoke or have open flame near the faucet at the

time it is open.

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas

supplier that aids in the detection of the gas. Most people recognize this odor as a “sulfur” or

“rotten egg” smell.

Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or

”fade”, and not be as readily detectable.

If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a

neighbor's telephone.

Gas detectors are available. Contact your gas supplier, or plumbing professional, for more information.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW,

LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE

RELIEF VALVE WILL RELEASE THE

MANUFACTURER FROM ANY CLAIM THAT MIGHT

RESULT FROM EXCESSIVE TEMPERATURE AND

PRESSURES.

CAUTION

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Page 3

3

PDX Series

Introduction

The new Bradford White PDX2 and PDX 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 certified FVIR technology.

Spark to Pilot Ignition System - employing the spark to pilot ignition system promotes reliable and consistent pilot and main burner ignitions to provide hot water on demand.

Integrated Immersion Thermostat/Gas Control Valve with LED - was developed for ease of troubleshooting by providing simple diagnostic codes to pinpoint an installation or component performance issue.

New Powerful Blower - will eliminate problems with difficult venting situations.

Quieter and Cooler Blower Operation - blower noise is significantly reduced for both interior and exterior environments. Cooler operation increases blower life by reducing bearing wear and noise.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

Increased Vent Lengths - increased venting performance is achieved while maintaining Energy Factor & FHSR performance.

The PDX2 and PDX water heaters use a combustion system were flue gases are combined with dilution air to reduce the flue gas temperature in the blower, combustion air and dilution air are drawn from outside the building. The diluted flue gases are evacuated to the exterior through low temperature vent materials. The gas control maintains water temperature, ignition sequence and regulates gas flow. A safety circuit consisting of a pressure switch and blower temperature switch verifies proper conditions exist for safe and reliable operation. If a situation outside of normal operating parameters exists, the gas control diagnostic LED will flash a code to positively identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency. To further promote quicker service times the new gas valve can be removed and replaced without draining the water heater. A special tool is required and will be provided with each gas valve kit shipped from our Service Parts department.

Please read the service manual completely before attempting service on this new series of power vent models.

How the Safety System Works

During normal operation, air for combustion is drawn into the water heater though the vent pipe from outside your building. The air travels into the closed combustion chamber. The air then mixes with in a normal manner with supplied gas and its efficiently combusted, producing very low NOx emissions.

In the unlikely event trace amounts of flammable vapors are present in the area surrounding the water heater, the sealed combustion system prevents the flammable vapors from reaching the ignition source. In addition the flammable vapors sensor will stop the water heater from operating if a significant amount of flammable vapors are present.

Page 4

4

PDX Series

How to Use This Manual

It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting and repair of the Bradford White TTW Series water heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.

The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation. Error codes are listed in the troubleshooting chart beginning on page 12 of this service manual. The troubleshooting chart will also indicate the probable cause for the error code and direct the service professional to a service procedure to properly diagnose the abnormal operation.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to determine the problem.

Contact the Bradford White technical support group immediately if diagnosis can not be made using the methods described in this service manual.

Tools Required for Service

 

 

 

 

Manometer:

 

A liquid “U” tube type or a digital (magna-helic)type can be used. This

 

 

device is used to measure gas and/or air pressure 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.

Electronic Probes:

In some cases, standard multi-meterprobes will damage or simply

 

 

not be effective to obtain certain voltage and ohm reading. It will be

 

 

necessary to have special electronic “pin” type multi-meterprobes.

 

 

These probes are available at most electronic wholesale outlets.

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.

Gas Control Service Tool: BWC part number 239-45991-00.A specialized tool designed to remove

 

the gas control from gas control thermal well. Available from

 

your Bradford White parts supplier.

Various Hand Tools:

Pipe wrench, channel locks, open end wrenchs (3/8",7/16",½"),

 

12" crescent wrench, Allen wrench set, screw drivers (common &

Phillips), ¼" nut driver, pliers (common & needle nose), socket set, side cutters wire cutters, wire strippers, wire crimpers, torpedo level, small shop vac, step ladder, and flashlight, 5 gallon pail.

Page 5

5

PDX Series

Specifications

Power supply

Dedicated 115VAC, 60 Hz, 15A

 

 

Gas Supply Pipe

Minimum 1/2" NPT (schedule 40 black iron pipe recommended)

 

 

Approved Gas Type

Natural or Propane. Unit must match gas type supplied.

 

 

Gas Pressure

5.0" W.C. min. for Nat gas, 11.0" W.C. min. for L.P. gas, 14.0" W.C. maximum (Nat. & L.P.)

 

 

Venting System

Power vent through the wall or vertical through the roof

 

 

Approved Vent Materials

PVC, CPVC or ABS

 

 

Minimum Clearance

18" from top, 24" from front, 4" sides and rear.

for Servicing

 

 

 

Water Supply Pressure

150 PSI maximum allowable working pressure. Check local codes for supply pressure

 

 

Thermal well TCO Limit

Residential 188°F (87°C), Commercial 199°F (93°C)

 

 

Residential Temperature

60°F (16°C) to 160°F (71°C) (Approximate temperatures)

Set Point Range

 

Commercial Temperature

80°F (27°C) to 180°F (82°C) (Approximate temperatures)

Set Point Range

 

Blower Temperature

Normally closed, opens @ 165°F (74°C), auto reset @ 130°F (54°C).

Switch

 

 

Exhaust-Normallyopen, closes on vacuum increase @-1.30.

Pressure switch

Intake-Normallyclosed, opens on vacuum increase @-1.15.

 

 

 

Blower

115VAC, 60Hz, 3.1 amps.

 

 

Page 6

6

Vent Tables

PDX Series

Specifications

Venting Specifications for:

48 Gallon

65 Gallon

75 Gallon

This water heater is approved for installation with the following PVC, CPVC or ABS Schedule 40 venting material.

The maximum and minimum vent lengths listed on this label are for the exhaust portion of the vent. The intake portion of the vent must be equal to or less than the length of the exhaust.

3" Diameter (7.6 cm) PVC Vent Connector Lengths

 

# of

 

Maximum 48, 65 gal.

 

 

Maximum 75 gal.

 

Terminating

 

Maximum

 

Minimum

 

Maximum

 

Minimum

 

Elbows

 

 

 

 

 

 

 

Length ft (m)

 

Length ft (m)

 

Length ft (m)

 

Length ft (m)

 

 

1

 

55 (16.8)

 

2

(.6)

 

45

(13.7)

 

2

(.6)

 

Through the Wall

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

2

 

50 (15.2)

 

2

(.6)

 

40

(12.2)

 

2

(.6)

 

Through the Wall

3

 

45 (13.7)

 

2

(.6)

 

35

(10.7)

 

2

(.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

4

 

40 (12.2)

 

2

(.6)

 

30 (9.1)

 

2

(.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

0

 

60 (18.3)

 

7 (2.1)

 

50

(15.2)

 

7 (2.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

1

 

55 (16.8)

 

7 (2.1)

 

45

(13.7)

 

7 (2.1)

 

Through the Roof

2

 

50 (15.2)

 

7 (2.1)

 

40

(12.2)

 

7 (2.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

3

 

45 (13.7)

 

7 (2.1)

 

35

(10.7)

 

7 (2.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4" Diameter (10.2 cm) PVC Vent Connector Lengths

 

 

 

 

 

# of

 

Maximum 48, 65 gal.

 

 

Maximum 75 gal.

 

 

 

 

 

 

Terminating

 

Maximum

 

Minimum

 

Maximum

 

Minimum

 

Elbows

 

 

 

 

 

 

 

Length ft (m)

 

Length ft (m)

 

Length ft (m)

 

Length ft (m)

 

 

1

 

95 (29.0)

 

10

(3.1)

 

85

(25.9)

 

10

(3.1)

 

Through the Wall

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

2

 

90 (27.4)

 

10

(3.1)

 

80

(24.4)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

3

 

85 (25.9)

 

10

(3.1)

 

75

(22.9)

 

10

(3.1)

 

Through the Wall

4

 

80 (24.4)

 

10

(3.1)

 

70

(21.3)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

5

 

75 (22.9)

 

12

(3.6)

 

65

(19.8)

 

12

(3.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

0

 

100 (30.5)

 

15

(4.6)

 

90

(27.4)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

1

 

95 (29.0)

 

15

(4.6)

 

85

(25.9)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

2

 

90 (27.4)

 

15

(4.6)

 

80

(24.4)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

3

 

85 (25.9)

 

15

(4.6)

 

75

(22.9)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

4

 

80 (24.4)

 

15

(4.6)

 

70

(21.3)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 7

7

PDX Series

Specifications

Control Timings

 

Ignition State

 

Timing

 

 

 

 

 

 

Pre-purge

2 Seconds

 

 

Trial for Ignition

90 Seconds

 

 

Flame Stabilization Period

3 Seconds

 

 

Inter-purge

15 Seconds

 

 

Flame Failure Response Time

1.5 Seconds (2 second. Maximum; 1 second minimum.)

 

 

Post-purge

15 Seconds

 

 

PS Fault Delay (failed open/close)

Retry after 2 Minutes

 

 

Soft Lockout

Retry after 5 Minutes

 

 

TCO Limit Lockout

Indefinite (cycle power to restart)

 

 

Verify Resistive Delay

Retry after 2 Minutes (repeats 5 times)

 

 

Simulated Resistive Load Lockout

Indefinite (cycle power to restart)

 

 

Hardware Error Lockout

Indefinite (self clears if fault clears for at least 15 seconds)

 

 

 

 

 

 

Wiring Diagram

Page 8

8

PDX Series

Sequence of Operation

Power up Sequence

1

2

Start Up.

Upon power up, the control runs a safe-startcheck with a typicalstart-updelay of1-5seconds.

Flammable Vapor Check.

To assure no outputs are energized if the “Flammable Vapor Sensor” is out of range, the control will test the the “Flammable Vapor Sensor” for proper operating range. If the “Flammable Vapor Sensor” is within range the

control resumes normal operation with no perceptible delay. If the “Flammable Vapor Sensor” is out of range, the control LED immediately flashes 7 times with 3 second pause.

Normal Heating Sequence

1 Thermostat calls for heat.

Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. Normal switch positions in the safety circuit are as follows:

a)Exhaust pressure switch normally open.

b)Blower temperature switch normally closed.

c)Inlet pressure switch normally closed.

If the safety circuit is closed, the control waits 4 seconds, gas control LED flashes 2 times with 3 second pause. Gas control waits 2 minutes then, blower runs for 30 seconds. This cycle repeats until safety circuit opens.

2Blower energizes.

3Blower pre-purgeperiod (2 seconds)

4Exhaust pressure switch proves blower/vent system operation.

a)If the pressure switch does not close within 30 seconds, the control LED Flashes 3 times with 3 second pause. The blower runs for 30 seconds every 2 minutes trying to get the pressure switch or blower temperature switch to close. This cycle repeats as long as there is a call for heat.

b)The normally closed inlet pressure switch allows the system to work as long as the inlet air is not blocked.

5Trial for pilot ignition (90 seconds).

a)The gas control lights the pilot by activating spark igniter and gas flow to pilot burner.

b)If flame is not sensed within 90 seconds, igniter and gas flow are deactivated, blower will post purge and control LED flashes 6 times with 3 second pause.

6Main burner Ignition

After pilot flame is sensed, gas control activates main valve for main burner ignition. The gas control will ignore flame and pressure switch signals for 3 seconds allowing for main burner to stabilize.

Page 9

9

PDX Series

Sequence of Operation

Normal Heating Sequence (cont.)

Steady state operation.

7During 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 is shut down. The blower continues to runs for 30 seconds attempting to close the circuit. The control LED Flashes3 times with 3 second pause.

Flame Sense- If flame is lost, pilot & main valve are shut down, blower runs for 15 seconds. Control attempts tore-lightpilot 4 times. If unsuccessful, Blower is shut down and control proceeds to 5 minute lockout. Controlre-attemptsto light pilot starting at normal heating sequence #2.

8Thermostat satisfies.

9Burner off.

10 Blower post purge (15 seconds).

Abnormal Operation

1. Simulated Resistive Device Fault:

a)If the Flammable Vapor Sensor resistance is greater than 70,000 Ohms - the gas control immediately turns off all outputs. Control waits and monitors resistance for 30 seconds. If the resistance is greater than 70,000 ohms after 30 seconds, the gas control proceeds to verify resistive delay for 2 minutes and flashes 7 times with a three second pause. This process is repeated 5 times until the control either returns to normal operation or proceeds to a lockout mode flashing 7 times with a 3 second pause.

b)If the Flammable Vapor Sensor resistance is below 3000 ohms - The gas control immediately turns off all outputs and proceeds to flash 8 times then once with three second pause. The error self clears if the resistance returns to normal range for at least 15 seconds.

2. Temperature Sensor Fault:

a)Temperature sensor detected open circuit - The gas control Immediately turns off all outputs and proceeds to flash8 times then three times with three second pause. The error self clears if the fault clears for at least 15 seconds.

b)Temperature sensors not reading the same temperature within ±5.5 °F - The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause. The error self clears if the fault clears for at least 15 seconds.

c)Water temperature in excess of TCO (Temperature Cut Off) limit - The gas control immediately turns off pilot & main valve and proceeds to flash 4 times with 3 second pause. Blower continues to run until gas control is reset. Power needs to be cycled to remove gas control from TCO lockout.

Page 10

10

PDX Series

Sequence of Operation

Abnormal Operation (cont.)

3. Pressure Switch/Blower Temperature Fault:

a)Pressure switch closed at start of call for heat - The control waits four seconds then, proceeds to flash

2 times with 3 second pause. The control waits 2 minutes and then turns on blower for 30 seconds. The blower turns off after 30 seconds and the control waits for pressure switch to open. Any time the Pressure switch opens, the blower turns on (or stays on) and the control proceeds to waiting for pressure switch to close.

b)Pressure switch or blower temperature switch failed open - The control runs the blower for 30 seconds waiting for the pressure switch and/or blower temperature switch to close. If either switch does not close in 30 seconds, the blower turns off and the control flashes 3 times with 3 second pause. The control waits two

minutes before turning on the blower for another 30 seconds to see the circuit close. This cycle repeats as long as there is a call for heat or until the circuit closes.

c)Pressure switch or blower temperature switch opens during burner operation - The control turns off the pilot and main valve, runs blower for 15 seconds (inter-purge) waiting for pressure switch and/or blower temperature switch to close. If either switch fails to close, the control proceeds as described in 3b above. If the circuit closes again by the end of the inter-purge, the recycle counter is incremented, if the recycle count has not reached its limit (4), another trial for ignition begins. If the recycle count has been reached, the control turns off the blower and flashes 6 times then 2 times with 3 second pause. The control waits 5 minutes before repeating ignition sequence.

d)Normally closed intake pressure switch opens at start of call for heat-the control runs the blower for 30 seconds waiting for the pressure switch to close. If the switch does not close in 30 seconds, the blower turns off and the control flashes 3 times with a 3 second pause. The control waits two minutes before turning on the blower for another 30 seconds to see the circuit close. This cycle repeats as long as there is a call for heat or until the circuit closes.

4.Trial For Ignition Fault:

a)Pressure switch opens during trial - The control turns off igniter and pilot valve. The gas control proceeds

as described in 3b above. If the pressure switch closes within 30 seconds the gas control will continue with trial for ignition starting at blower pre-purge.

b)Flame Not Sensed - The control energizes the spark igniter attempting to light the pilot and prove flame. If flame is not sensed within 90 seconds, the igniter turns off, the pilot valve is closed and the gas control runs the

blower through post purge and flashes 6 times then once with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

5. Flame Sensing Fault:

a)Flame lost during run - The control turns off pilot and main valves, runs blower for 15 seconds (inter purge). The 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 control turns off the blower and flashes6 times then 3 times with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

b)Flame sensed out of sequence - the control only looks for pilot flame when the blower is running. If flame is present when the pilot valve is not open, the control proceeds to wait for flame loss and flashes5 times with 3 second pause. This continues until flame is lost, once the flame signal is lost, the control flashes6 times then 4 times with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

Page 11

11

PDX Series

Troubleshooting

Observe green LED indicator on Electronic gas control. Error flash codes are displayed with a three second pause before repeating. Check and repair the system as noted in the troubleshooting table below.

Green LED

Indicator

LED Status

 

Control

 

 

 

Probable Cause

 

Service

 

 

 

 

 

 

 

 

 

 

 

Status

 

 

 

Procedure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

None, control LED not

No electrical

 

Control power switch in “OFF” position.

Turn power on

on or flashing

power

 

Supply voltage interrupted.

 

 

 

 

 

 

 

 

 

Stand-bymode,

 

 

 

 

 

Normal operation.

Short flash, once every

 

 

 

 

 

Waiting for call for

 

Temperature demand is satisfied

Adjust thermostat to

four seconds

heat (no fault).

 

 

 

 

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Normal operation.

“Heartbeat”, alternates

Thermostat calling

 

Tank temperature below set point of thermostat.

 

Adjust thermostat to

bright/dim

for heat (no fault).

 

 

 

 

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weak pilot signal

 

1.

Unstable pilot.

1. Page 14

 

 

 

 

Short flash once per

 

2.

Pilot tube block or restricted.

 

 

 

 

 

 

on last call for

 

3.

Oxidation build up on pilot electrode.

2-4.Page 16

second

 

heat.

 

4.

Wire damage to pilot assembly or bad

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

connection at gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Two flash, three

Pressure switch

 

1.

Pressure switch tubing kinked or blocked.

Page 17

not working-

 

2.

Blocked pressure tap on switch or blower.

second pause

 

closed position.

 

3.

Faulty pressure switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Vent blockage or improper vent configuration.

1. Check vent or vent tables.

 

 

 

 

 

 

 

 

 

 

Pressure switch

 

2.

Pressure switch tubing kinked or blocked.

 

 

 

 

 

 

 

 

 

Three flash, three

 

3.

Faulty pressure switch.

2 & 3 Page 17

or blower temp.

 

 

4.

Blower not spinning up to speed.

 

 

 

 

 

second pause

switch not working

 

4. Page 21

 

5.

Blower temp or exhaust temp too high

 

 

 

-openposition.

 

6.

Faulty blower temperature switch.

5 & 6 Page 23

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7.

Intake vent length exceeds exhaust vent length.

 

 

 

Excessive tank

 

1.

Thermal well sensor out of calibration.

1. Page 25

Four flash, three

 

temperature.

 

 

2.

Faulty gas control.

 

 

 

 

 

second pause

System must be

 

2. Replace gas control,

 

3.

Plumbing leak

 

 

 

reset.

 

page 27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Undesired-false

 

 

 

 

 

 

 

 

 

 

Five flash, three

 

1.

Pilot valve stuck in open position.

Replace gas control,

pilot flame

 

second pause

 

page 27

present.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 12

12

PDX Series

Troubleshooting

LED Status

 

Control

 

 

Probable Cause

 

Service

 

 

 

 

 

 

 

 

 

 

Status

 

 

Procedure

 

 

 

 

1.

Unstable pilot.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Failed to light

1. Page 14

 

 

 

2.

Pilot tube blocked or restricted.

Six-oneflash, three

pilot.

 

 

 

 

 

3.

Oxidation build up on pilot electrode.

2-4.Page 16

second pause

System auto

4.

Wire damage to pilot assembly or bad

 

 

 

resets.

 

 

 

 

 

 

 

 

 

connection at gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pressure switch

1.

Vent blockage or improper vent configuration.

1. Check vent or vent tables.

 

 

 

 

 

 

 

 

 

 

 

or blower temp

2.

Pressure switch tubing kinked or blocked.

2 & 3 Page 17

Six-twoflash, three

switch opened

3.

Faulty pressure switch.

4. Refer to venting section of

during burner

4.

Vent termination being affected by wind

second pause

installation manual

operation.

5.

Blower not spinning up to speed.

 

 

 

 

 

 

 

 

 

 

 

System auto

6.

Blower temp or exhaust temp too high

5. Page 21

 

 

 

resets.

7.

Faulty blower temperature switch.

6 & 7 Page 23

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Unstable pilot.

 

 

 

 

 

 

 

 

Pilot flame

2.

Pilot tube blocked or restricted.

1. Page 14

 

 

 

3.

Oxidation build up on pilot electrode.

 

 

 

 

 

Six-threeflash, three

extinguished.

2-4.Page 16

4.

Wire damage to pilot assembly or bad

second pause

System auto

 

 

 

 

 

 

connection at gas valve.

5. Refer to installation manual

 

 

 

resets.

 

 

 

 

5.

Insufficient combustion air.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.

Gas pressure is out of specification.

 

 

 

 

 

 

 

 

Undesired-false

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Six-fourflash, three

pilot flame

 

 

 

 

Replace gas control,

sensed.

Pilot valve stuck in open position.

second pause

page 27

System auto

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

resets.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING: EXPLOSION HAZARD

 

 

 

 

 

 

 

 

 

 

 

* Indicates gasoline vapors were detected at potentially

 

 

 

 

 

Seven flash, three

Flammable Vapor

 

explosive levels.

 

 

 

 

 

* Verify no gasoline vapors are still present

Page 29

second pause

Sensor fault

* Reset the control by cycling power to the appliance or

 

 

 

detected

 

by cycling the ON/OFF switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* Replace the Flammable Vapors Sensor element if a

 

 

 

 

 

 

 

 

 

 

 

gasoline spill event occurred.

 

 

 

 

 

 

 

 

 

 

 

* Verify Flammable Vapor Sensor (FVS) resistance is

 

 

 

 

 

Eight-oneflash, three

Flammable Vapor

 

 

 

 

 

Sensor out of

 

not below 25 K Ohms.

Page 29

second pause

* Check wiring to FVS and insure it is not shorted.

specification.

 

 

 

 

 

 

 

 

* Replace control if everything above checks out OK.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermal well

1.

Damage to thermal well wire.

Page 25

 

 

 

sensor damaged

 

 

 

2.

Thermal well sensor resistance out of range.

Eight-threeflash, three

or unplugged

 

 

 

 

 

 

 

 

 

 

 

 

 

 

second pause

Gas valve

1.

Control needs to be reset.

1. Interrupt power supply

 

 

 

electronics fault

2. Replace gas control,

 

 

 

2.

Control is wet or physically damaged.

 

 

 

detected

page 27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Interrupt power supply

Eight-fourflash, three

Gas valve fault

1.

Control needs to be reset.

second pause

detected.

2.

Control is wet or physically damaged.

2. Replace gas control,

page 27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 13

13

PDX Series

PDX SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Inspection and Air Shutter Adjustment.

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.

Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.

Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter. Cast iron burner can have the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner (see cast iron burner adjustment below).

Main burner must be free from any debris accumulation that may effect burner operation (see burner cleaning procedure on page 14).

Cast Iron Burner Air Shutter Adjustment

WARNING

Inner door and burner components may be HOT when performing this operation. Take necessary precaution to prevent personal injury.

Step 1. With main burner in operation, remove outer jacket door remove inner door as described in this manual, see inner door removal, inspection and replacement section (page 35).

Step 2. To adjust for proper burning, loosen the air shutter nut, rotate the air shutter to close the opening in the burner, then slowly rotate the air shutter open until flame becomes as blue as possible with a minimum of yellow tips. Tighten the air shutter nut.

Too much air will cause the flame to lift off the burner ports and create noisy burner operation. Too little air will result in soot formation.

Step 3. Replace inner door as described in this manual, observe burner operation. Burner should operate as adjusted in step 2. If not, repeat air shutter adjustment compensating for proper burner operation with inner door closed.

Air Shutter Nut

Air Shutter

Page 14

14

Igniter/flame sense wire
Main burner orifice
XIII on page 35.

PDX Series

PDX SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Cleaning

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and inner door per service procedure

Step 4. Disconnect pilot tube (7/16 wrench) and feedline (¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sensor wire from gas control. Step 6. Remove burner assembly from combustion chamber.

Step 7. Thoroughly inspect burner surface area and burner port area and remove any loose debris.

Step 8. For cast iron burners, inspect for any debris build up inside burner casting.

Burner surface area

Feedline nut

Pilot tubing nut

Burner port area

Step 9.

Unscrew burner from main burner

 

orifice. On cast iron burners, loosen

 

air shutter nut and unscrew feedline

 

from burner.

Step 10.

Remove main burner orifice from

 

feedline (½" wrench on steel

 

burners, 3/8" wrench on cast iron)

 

inspect orifice, clean or replace if

 

necessary.

Step 11.

Reassemble burner and reinstall into water heater. Restore gas supply

 

and check for gas leaks.

Step 12

To resume operation follow the instruction located on the lighting

 

instruction label or the lighting instruction located in the installation

 

and operating manual.

L.P. Main burner orifice. Left hand thread

Page 15

15

PDX Series

PDX SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and remove inner door per service proceedure XIII on page 35.

Igniter/flame

sense wire

Step 4. Disconnect pilot tube nut (7/16 wrench) and feedline nut (¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sense wire from gas control. Step 6. Remove burner assembly from combustion chamber. Step 7. Remove pilot assembly from feedline (¼" nut driver).

Step 8. Visually inspect igniter/flame sense wire for damage. Replace pilot if damage is found.

Step 9. With a multi-meterset to the ohms setting, check continuity through igniter/flame sense wire. Replace pilot if no continuity.

Step 10. Visually inspect igniter/flame sense electrode for deterioration. Replace pilot as necessary. Electrode should not be in contact with pilot hood, If so, carefully adjust electrode to a gap distance of 3/32" (.09) from pilot hood.

Step 11. Visually inspect igniter/flame sense electrode for oxidation build up. Carefully clean any oxidation using very fine emery cloth.

Feedline nut

Pilot tubing nut

Ferrule

Pilot

Pilot

Pilot

nut

tubing

orifice

hood

Igniter/flame

Igniter/flame

sense wire

sense electrode

Step 12. Visually inspect pilot tubing for kinks or cracks. If damage is found replace pilot.

Step 13. Inspect pilot tubing and pilot orifice for blockage:

a) Remove ferrule nut from bottom of pilot assembly (7/16" wrench). b) Remove pilot tube and pilot orifice.

c) Inspect pilot tubing and pilot orifice for blockage. Clean or replace as necessary.

Step 14. Reassemble pilot and install to feedline. Reinstall burner assembly to water heater. Restore gas supply and check for gas leaks.

Step 15 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual.

Page 16

16

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Exhaust Pressure Switch

WARNING

Testing

120 volt potential exposure. Use caution

Step 1.

Position power switch on gas control

making voltage checks to avoid personal injury.

 

to the “OFF” position.

 

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and

 

remove cover (see photo 1).

 

Step 3.

Remove tubing and wires from inlet pressure switch.

Step 4.

Carefully remove pressure switch from blower housing (see photo 2)

Exhaust

 

pressure switch

1

Inlet pressure switch

Pressure switch wire leads

With steps 1,2,3 & 4 complete,

disconnect wire leads from pressure switch.

Use a multi-meterset to the

 

 

 

 

 

 

 

 

 

 

ohms setting. With blower off,

 

 

 

 

 

Check tubing and pressure

check across pressure

 

N

 

 

 

 

 

 

 

 

tap on switch for blockage.

switch terminals.

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there blockage?

Are switch contacts open?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(no electrical continuity)

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clear blockage

 

 

 

 

 

 

 

 

 

 

 

Position gas valve power

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

switch to the “ON” position

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

and adjust thermostat

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

to call for heat,

 

 

Check tubing and

 

 

 

 

 

 

 

 

Is vent

 

this will start the blower.

N

pressure tap on

N

N

system

Check with multi-meter,do

 

 

switch for blockage.

 

 

 

 

 

 

 

blocked

 

pressure switch contacts

 

 

Is there blockage?

 

 

 

 

 

 

 

 

 

 

close with blower running with the switch in the vertical postition?

Y

Switch contacts are OK. See safety circuit trace (page 30)

2

Pressure Switch

Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

N

Replace switch

 

(see page 18)

Is vent system length

 

 

Y

 

See blower testing

within vent table

Y

(page 21)

specifications

 

 

Is blower OK?

listed on page 7

 

 

 

N

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reconfigure vent

 

Correct blower

system to be

 

compliant with

 

problem.

vent tables.

 

 

 

Page 17

17

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Exhaust Pressure Switch

 

WARNING

Replacement

 

 

120 volt potential exposure. Use caution

Step 1.

Position gas control power switch

 

to avoid personal injury.

 

to “OFF” position.

 

 

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and

 

remove cover (see photo 3).

 

 

Step 3.

Disconnect the tubing and wires from inlet pressure switch.

 

 

 

Pressure Switch

Step 4.

Carefully remove pressure

3

4

 

 

 

switch from blower

 

 

 

housing (see photo 4)

 

 

 

 

 

Slide pressure switch in direction

 

 

 

of arrow while tilting slightly away

 

 

 

from blower housing.

Step 5.

Disconnect tubing from

5

6

 

 

 

pressure switch.

 

 

 

(see photo 5)

 

 

Step 6.

Disconnect yellow wires

 

 

 

from pressure switch

 

 

 

(see photo 6)

 

 

Step 7. Reconnect wires from step 5 to new pressure switch. Step 8. Reconnect tubing to new pressure switch.

Step 9. Carefully position pressure switch into blower housing. Step 10. Reconnect wires and tubing to inlet pressure switch.

Step 11. Position gas control power switch to “ON” position and verify proper heater operation. Step 12. Replace control access cover from step 2.

Page 18

18

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Inlet Pressure Switch

WARNING

Testing 120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Step 1. Position power switch on gas control to the “OFF” position.

Step 2. Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 7).

Step 3. Remove wires from inlet pressure switch.

Exhaust pressure switch

With steps 1,2 & 3 complete.

Use a multi-meterset to the ohms setting. With blower off, check across pressure switch terminals.

Are switch contacts closed?

Y

Position gas valve power switch to the “ON” position and adjust thermostat

to call for heat,

this will start the blower. Check with multi-meter,do pressure switch contacts remain closed with blower running with the switch in

the vertical postition? Y

Switch contacts are OK. See exhaust pressure switch testing (page 17)

7

Inlet pressure switch

Check tubing and pressure N tap on switch for blockage.

Is there blockage?

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clear blockage

 

 

 

Y

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

Check tubing and

 

 

 

 

 

 

 

Is vent

 

N

pressure tap on

N

N

system

 

switch for blockage.

 

 

 

Is there blockage?

blocked

 

N

Replace switch

 

(see page 20)

Is vent system length within vent table Y

specifications listed on page 7

N

Reconfigure vent system to be compliant with vent tables.

Inlet pressure switch wire leads (found inside cover)

Y

See blower testing (page 21)

Is blower OK? N

Correct blower problem.

Page 19

19

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Inlet Pressure Switch

WARNING

Replacement

120 volt potential exposure. Use caution

Step 1.

Position gas control power switch

to avoid personal injury.

 

to “OFF” position.

 

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and

 

remove cover (see photo 8).

 

Step 3.

Disconnect the tubing from the pressure switch (see photo 9).

 

8

9

Step 4. Remove inlet pressure switch from blower access cover. (see photo 10).

Step 5. Disconnect yellow wires from pressure switch (see photo 11).

Step 6. Attach new inlet pressure switch to blower control access cover.

Remove screws

 

 

to remove inlet

10

 

pressure switch

11

 

 

Step 7. Reconnect wires from step 5 to new pressure switch. Step 8. Reconnect tubing to new pressure switch.

Step 9. Replace control access cover from step 2.

Step 10. Position gas control power switch to “ON” position and verify proper heater operation.

Page 20

20

PDX Series

PDX SERVICE PROCEDURE IV

Blower Testing and Replacement

Blower Testing

WARNING

 

115 volt potential exposure. Use caution when

Step 1. Position gas control power switch

making voltage checks to avoid personal injury.

 

to “ON” position and adjust control to call for heat.

12

Step 2. Remove the three screws (Phillips Screw driver) from control access cover on blower assembly and remove cover (see photo 12).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connect

 

Disconnect vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect

 

 

 

 

 

 

system from top of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

manometer to

 

 

 

 

 

Does blower energize

 

 

 

 

 

Y

 

pressure switch

 

 

 

 

 

blower and remove

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

pressure tap of

 

 

 

 

 

 

 

 

Within 2 minutes?

 

 

 

 

 

 

 

tubing from blower.

 

 

 

 

 

 

 

 

 

exhaust vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 13)

 

 

 

 

 

 

 

 

 

adapter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 13)

 

 

 

 

 

 

15

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 15)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove exhaust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adapter

 

 

 

13

 

 

 

 

 

 

 

 

Pressure tap

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With blower running, and exhaust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adapter removed from top of

 

 

Y

 

Blower OK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower, is there a negative

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

pressure of -2.30"to-2.60"W.C.?

 

 

 

 

 

 

 

 

 

 

 

 

Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

switch tubing

 

 

 

 

 

Determine voltage

 

N

 

Is there 115vac across

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blue and green wires

Replace blower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

problem and correct.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 18)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does blower energize after

 

 

 

Y

 

See pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 minutes, run for 30

 

 

 

 

 

 

switch testing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

 

17

 

 

 

 

 

seconds and shut down?

 

 

 

 

 

Page 17 & 19

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect cord set

 

 

 

 

 

 

 

Is there 115VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

shown in photo 9. Is

 

 

Y

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

there 115VAC across

 

 

 

across terminals

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminals shown in

 

 

 

 

 

 

 

shown in photo 17 ?

 

 

 

Reconnect cord set

 

 

 

 

 

 

 

 

 

 

 

photo 16

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

shown in photo 9, is

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

there 115VAC between

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace blower

 

 

 

 

 

 

 

 

 

 

Incorrect supply

 

 

 

 

 

 

 

blue wire and green

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ground wire

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

voltage polarity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 18)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

Green ground

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Determine

Replace

 

 

N

Does cord set

 

 

 

 

 

wire

 

 

 

18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there 115 VAC

N

 

 

 

 

power source

 

 

have electrical

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

cord set

 

 

 

continuity?

 

 

 

 

 

 

 

 

 

 

 

 

 

at wall outlet?

 

 

 

 

 

 

problem and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

correct.

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

Blue wire

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check power cord

Y

 

 

 

 

Repair or replace

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

for damage.

 

 

 

 

 

 

 

 

power cord

 

 

 

 

 

 

 

 

gas control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

Replace blower

Shown with pressure

switch removed.

 

 

Page 21

21

Pin location holes in jacket head
Locating Pins on blower flange
Vertical air intake
Vertical air intake bracket

PDX Series

PDX SERVICE PROCEDURE IV

Blower Testing and Replacement

Blower removal

Step 1. Position gas control power switch to the “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 screw driver) and retain for use on new blower

Step 5. Unplug cord sets from blower. Step 6. Remove vertical air intake bracket.

Step 7. Disconnect vertical air intake from blower.

Step 8. Remove the three blower mounting screws (¼" nut driver).

Step 9. Remove blower with gasket from water heater.

Remove exhaust adapter and retain for use on new blower.

Blower

Cord Sets

Blower Mounting

Screws

Blower Installation

Step 10. Clean any debris from jacket head of water heater.

Step 11. Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head. Be sure not to damage gasket.

Step 12. Secure blower in place using mounting screws from step 8. Step 13. Slide vertical air intake tee onto blower.

Step 14. Re-installvertical air intake bracket. Step 15.Re-installexhaust adapter from step 4.

Step 16. Reconnect vent system to exhaust adapter. Step 17. Reconnect cord sets from step 5.

Step 18. Plug blower power cord into wall outlet.

Step 19. Position gas control power switch to the “ON” position. Step 20. Verify proper blower operation.

Page 22

22

Position power switch on gas control to the “OFF” position.
Remove tubing from inlet pressure tap.
Remove the three screws (Phillips screw driver) from control access cover on blower and remove cover (see photo 19).
Locate blower temperature switch (see photo 19)

PDX Series

PDX SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch

Testing.

Step 1.

Step 2.

Step 3.

Step 4.

WARNING

120 volt potential exposure. Use caution to avoid personal injury.

19

Switch Setting

Opens on rise @ approximately 165°F Auto resets on fall @ approximately 130°F

20

Blower temperature switch location

Cool switch to

Air mixing inlet

below 130°F

 

Disconnect wire leads to

N

 

 

 

 

 

 

 

 

 

 

 

 

switch. Using a multi-meter

 

Replace switch

 

 

 

 

 

 

 

 

 

set to the ohms setting, is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see page 24)

 

 

 

 

 

 

 

 

 

there continuity between

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the switch terminals?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

Common causes for

 

Reconnect wire leads and

 

 

 

 

 

 

 

 

 

 

 

 

 

Exhaust

 

 

high exhaust temperature

observe heater operation.

 

 

 

 

 

1.

 

 

 

Y

 

Do switch

Y

Vent length is below minimum allowable.

Do exhaust gas

 

 

 

temperature is

 

2.

Vent diameter not to specification.

 

 

 

 

contacts open?

 

 

temperatures rise to or

 

 

 

 

 

too hot.

3.

Restricted dilution air inlet.

 

 

 

 

 

 

 

above 165°F?

 

 

 

 

 

 

 

 

4.

Missing or deteriorated flue baffle.

 

N

 

 

 

 

 

 

 

 

5.

Gas pressure is out of specification.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do switch

Y

 

Replace switch

 

 

 

 

 

 

 

 

 

contacts open?

 

 

 

 

 

(see page 23)

 

 

 

 

 

 

 

 

 

N

Switch OK

Page 23

23

PDX Series

PDX SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch

Replacement.

WARNING

120 volt potential exposure. Use caution to avoid personal injury.

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2. Remove tubing from inlet pressure tap.

Step 3. Remove the three screws (Phillips screw driver) from the control access cover on blower and remove cover.

(see photo 20)

Step 4. Locate blower temperature switch (see photo 21) Step 5. Disconnect red and yellow wire leads from switch.

Step 6. With an appropriate tool such as side cutters, snip the retaining lug from the blower housing to allow removal of temperature switch (see photo 22).

Step 7. Remove switch from blower housing.

Step 8. Install new switch. Be sure switch is properly seated in mounting area.

Step 9. Reconnect red and yellows wires to new switch. Wires are interchangeable with either terminal.

Step 10. Position gas control power switch to the “ON” position and verify proper heater operation.

Step 11. Replace control access cover from step 2.

20

21

Blower temperature

 

 

switch location

22

Snip retaining lug

 

 

from blower housing

Page 24

24

PDX Series

PDX SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

Gas Control Testing

See pages 27 & 28 for gas control input & output testing.

Thermal Well Testing

If Control has gone into TCO lockout due to excessive tank temperature (four flash, 3 second pause) reset control by rotating knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting.

Disconnect thermal well wire harness

Observe heater operation. If control continues to lockout due to excessive tank temperature, proceed to thermal well testing to determine cause.

Thermal well testing Position gas control power switch to the “OFF” position and disconnect

thermal well harness from gas control.

Using a multi-meterset to the Ohms setting, determine the resistance of thermal well sensor (see caution photos 23 & 24)

19

20

CAUTION

DO NOT use standard multimeter probes for this test. Doing so will damage connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Using a multi-meterset to the ohms setting, insert one meter probe (see caution) into center wire position of thermal well connector, insert the second probe (see caution) into either of the outside wire positions (see photo 23).

Alternate the probe on the outside position to the opposite outside wire position (see photo 24).

Once the thermal well resistance values are known, the water

 

 

temperature must also be known to determine if the resistance

N

Replace thermal well

values are correct. See page 25 to obtain water temperature.

 

(see page 27)

 

 

 

Are thermal well resistance values correct?

 

 

 

Y

 

 

 

 

 

 

 

 

 

Replace gas control

 

 

(see page 27)

 

 

Page 25

25

PDX Series

PDX SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

WARNING

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

Determine Water Temperature Inside Tank

Note: It is important to understand once the resistance for the thermal well is determined from page 25, water flow through the heater should not occur. Prior to performing the steps below, turn off the cold water supply to the water heater. This will prevent cold water flow into the tank affecting the resistance value of thermal well.

Step 1. Position gas control power switch to “OFF” position.

Step 2. Draw approximately 4 gallons of water from drain valve into a container and discard. Draw an additional gallon and immediately measure water temperature using an accurate thermometer. It may be necessary to open a hot water faucet to allow heater to drain.

Step 3. Using the chart below, determine correct resistance value for the water temperature from step 2.

Example:

If temperature of water is 84°F, then the resistance through the sensor would be

 

8449 (see shaded area). NOTE: Sensor resistance increases as the temperature

 

falls.

 

 

 

 

 

 

 

 

 

 

 

Sensor Resistance at Various Temperatures

 

 

 

 

 

 

 

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

1000

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

1953

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

Page 26

26

Thermal Well

PDX Series

PDX SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control & Thermal Well Removal From Water Heater

Gas Control

Step 1. Position gas valve 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 and burner assembly from gas control.

Step 5. Remove gas control & thermal well by rotating flats of Thermal Well counter clockwise (1-5/16"wrench).

Gas Control Removal From Thermal Well

Follow the steps below allows removal gas control from thermal well without removing thermal well from tank.

Step 1. Position gas control power switch to the “OFF” position and unplug water heater from power supply. Step 2. Turn off gas supply to water heater and disconnect gas piping from gas control.

Step 3. Disconnect wire harnesses & burner assembly from gas control.

Step 4. Using gas control service tool (239-45991-00)available from your BWC parts supplier, Insert tool into back of gas control (see photos below)

View from back of control for clarity

Insert tool from

back of control Service tool shown inserted in to back

of control

Step 5. Pivot tool towards heater as far as possible (see photo below). Lift straight up on gas control. The control should move about 1/8". Hold control in position and remove tool. Lift straight up on control to remove completely from Thermal Well.

With service tool inserted, pivot tool back towards water heater as far as possible. Lift straight up on control, control will move 1/8". Remove tool and continue to lift straight up on control to remove from Thermal Well.

Page 27

27

PDX Series

PDX SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control Assembly to Thermal Well

Step 1. Install threaded end of thermal well into tank. Be sure thermal well flange is positioned as shown in photo 24 for proper control alignment.

Step 2. Route wire leads back into relief opening. (see photo 24)

Step 3. Align slots located on thermal well flange with tabs located on back of gas control (see photo 24 & 25)

Thermal well flange slots

Step 4. Carefully push control back onto thermal well flange as far as possible towards water heater. Slide control down to lock into position.

Step 5. Install burner and connect pilot tubing and feedline nut to gas control.

24

25

Route wires through relief opening

Igniter/sensor

Step 6.

connection

 

Step 7.

Ground Wire connection

Step 8.

5 pin

blower harness connection 3 pin

thermal well connection

Gas control Tabs

Reconnect wire harnesses to gas control per the illustration.

Reconnect gas piping to gas control. Restore gas supply and check for gas leaks.

To resume operation, follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Flammable Vapor

Sensor

Page 28

28

PDX Series

PDX SERVICE PROCEDURE VII

Flammable Vapors Sensor Testing

Flammable Vapor Device 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-meterset to the ohms setting check resistance of flammable vapor sensor. (see caution below)

Resistance must be within 3,000 ohms and 48,000 ohms. If outside of this range replace flammable vapor sensor.

Flammable Vapor

Sensor

Multi-meterset to

ohms setting

Electronic “pin type” Meter Probes

CAUTION

DO NOT use standard multimeter probes for this test.

Doing so will damage connector. Use special electronic

“pin type” probes or small diameter wire pins inserted

into connector.

Flammable Vapor

Sensor

Page 29

29

PDX Series

PDX SERVICE PROCEDURE VIII

Safety Circuit Voltage Trace

Safety Circuit Voltage

Trace

NOTE: This procedure assumes a cool tank.

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

27

Step 2. Remove three screws (Phillips Screw driver) from control access cover on blower and remove cover (see photo 26).

Position gas control switch to the “ON”

 

 

 

position and adjust thermostat dial to call

 

 

 

for heat, Is there 10 to 13 VAC between

Is LED on gas valve flashing

 

red wire leading to blower temperature N

Y

 

 

 

the “heartbeat” code

 

switch and green ground wire?

 

(alternating bright/dim)

 

Blower must be running during this

 

 

 

 

voltage check.

 

N

 

 

 

(see photo 28)

 

 

 

 

 

 

Y

Verify 120VAC to gas

 

 

 

 

 

 

 

 

 

 

control (see page 30)

 

 

 

 

 

 

 

No voltage from gas control, call for technical support.

Is there 10 to 13 VAC between yellow

Is there continuity

 

Check for loose or

wire leading from pressure switch and N

through blower

Y

broken wire

green ground wire?

 

temperature switch?

 

connection at switch

(see photo 28)

(see page 21)

 

terminals

 

Y

 

N

 

 

 

 

 

 

 

 

 

Determine cause of blower

 

 

 

Correct igniter/

temperature switch

 

 

 

 

sensor problem.

activation and correct.

 

 

 

 

 

 

 

 

 

Do you hear or can you N see the igniter sparking?

Y

Safety circuit voltage is OK.

If burner does not light, observe LED flash code on gas valve and refer to troubleshooting section on page 12

Check igniter/sensor

Y

Faulty cord set or

(see page 16)

 

gas control.

is igniter/sensor OK?

 

 

Green ground wire

 

 

28

 

 

 

 

Red wire leading to

 

 

blower temp. switch

Yellow wire leading from pressure switch

Page 30

30

PDX Series

PDX SERVICE PROCEDURE IX

120 VAC Trace

120 VAC Circuit Trace

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Step 1. Verify 120VAC and proper polarity at wall outlet.

Step 2. With unit plugged in and control power switch in the “ON” position verify LED status.

LED status

LED status

None, Control LED not

Short flash, once every

on or flashing.

four seconds.

 

 

 

 

 

 

 

 

 

Waiting for

 

 

call for heat.

 

 

29

Disconnect cord set as

 

 

shown in photo 29

 

 

Using a volt meter set

 

 

 

to volts AC, is there

N

 

 

120VAC across

 

 

 

 

 

terminals shown in

 

 

 

photo 30 ?

 

 

 

 

Y

 

 

 

 

 

 

 

Is there 120VAC

Y

Reconnect cord set

across terminals

 

shown in photo 29.

shown in photo 31 ?

 

 

 

 

 

N

 

 

 

 

 

 

 

 

Disconnect wire harness

 

 

 

Incorrect supply

 

 

from gas control

voltage polarity

 

(see photo 32).

Locate black & white wires at connector, It may be necessary to pull back wire sheath to identify wire colors. (see photo 33)

Is there 120VAC

 

across black & white Y

Replace gas

wires as shown in

 

control.

photo 33?

 

 

N

 

 

 

 

 

 

Call for technical

 

support.

 

LED status

LED status

“Heartbeat”, alternates

Various flashing error

bright/dim.

codes.

 

 

 

 

 

 

 

Thermostat calling

Verify error code as

for heat

listed on page 12

30

31

Check for damage to Y

Repair damage

AC supply power cord.

 

 

 

N

 

 

 

Replace Blower

 

32

Wire harness

33

Wire sheath pulled back to identify wire colors

Check for 120VAC between black & white wires. -NOTE-

Electronic meter probes required. Use care not to damage connector during this check.

Page 31

31

PDX Series

PDX SERVICE PROCEDURE X

Dip Tube Inspection and replacement

Dip Tube Inspection and 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. Open a nearby hot water faucet to vent heater for draining. Open drain valve of water heater and allow heater to drain to a point below the inlet connection nipple.

Step 3. Disconnect inlet nipple from plumbing system.

Step 4 With an appropriate tool such as a pipe wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage pipe threads.

Step 5. Visually inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage. Hydro-jetslots should be open and free of any blockage.

Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable and the inlet nipple/dip tube must be replaced.

Step 6. Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into water heater. Connect nipple to plumbing system, resume water supply and refill with water.

Step 7. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

Page 32

32

PDX Series

PDX SERVICE PROCEDURE XI

Anode Inspection and replacement

Anode Inspection and 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. Open a nearby hot water faucet to vent water heater for draining. Open drain valve of water heater and allow water heater to drain to a point below the outlet connection nipple.

Step 3. Disconnect outlet nipple from plumbing system.

Step 4 With an appropriate tool such as a pipe wrench, remove outlet nipple/anode from the water heater. Use caution not to damage pipe threads.

Step 5. Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal. If depletion is ½ of the original anode diameter (approximately ¾” diameter), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 6. Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into water heater. Connect nipple to plumbing system, resume water supply and refill with water.

Step 7. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

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33

PDX Series

PDX SERVICE PROCEDURE XII

Flue Baffle Inspection and replacement

 

Remove blower to gain access to

 

Disconnect vent

 

 

system from exhaust

flue baffle

adapter.

34

 

 

 

 

 

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.

Disconnect intake air piping.

 

Step 4.

Unplug cord sets from blower. (see photo 34).

 

Step 5.

Remove the three blower mounting screws

Blower

 

 

(¼" nut driver) (see photo 34).

 

 

Cord Sets

Step 6.

Remove blower with gasket from water heater.

35

Step 7.

Remove flue baffle from Heater (see photo 36).

 

Step 8.

Inspect baffle for deterioration, missing restrictors.

 

 

 

Clean any scale or debris build up. Replace with new baffle as

 

 

necessary.

 

Step 9.

Reinstall baffle into flue tube. Be sure baffle

 

 

 

hanger tabs are inserted into notch location at the

 

 

 

top of the flue tube (see photos 36 & 37).

Remove support

Step 10.

 

 

 

bracket

Check Burner to insure no scale has accumulated during this

 

 

operation. See burner cleaning procedure on page 15.

 

Step 11.

Reinstall blower on water heater. Connect vent

 

 

 

system and cords set to blower. Plug water heater

 

 

 

into wall outlet.

 

Step 12.

To resume operation follow the lighting instruction

 

 

 

located on the lighting instruction label or the lighting instruction

 

 

located in the installation and operation

 

 

 

manual.

 

36

 

 

 

 

 

 

 

Flue Baffle

 

 

 

37

 

38

Blower Mounting

Screws

Baffle shown installed in flue tube notch.

Flue tube notch

Page 34

34

PDX Series

PDX SERVICE PROCEDURE XIII

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Inner Door Removal Procedure.

Step 1. Slide switch of the Electronic Gas Control to the “OFF” position and unplug from wall. Step 2. Remove outer jacket burner access door.

Step 3. Disconnect wire connections from Electronic Gas Control.

Step 4. Right side Inner Door Removal. a) Remove wire tie from feedline.

b) Remove (2) 1/4" hex drive screws from right side inner door.

c) Remove (2) 1/4" hex drive screws from flange section of inner door.

d) Remove right side inner door and set aside. Be careful not to damage gasket material on inner door.

¼" Hex Drive Screws shown on Right Side Inner Door.

¼" Hex Drive Screws at Flange section of Inner Door

Step 4. Fully inspect inner door gaskets for the following:

>Tears

>Other imperfection that will inhibit proper seal

>Missing Material

>Gasket adhesion to inner door

>Cracks

>Material left on combustion chamber (around opening)

>Dirt or debris

 

If the gasket is not effected by any of the above, gasket replacement is not required. If replacement is required, proceed to Inner Door Gasket Replacement Procedure.

Inner Door Gasket Replacement Procedure.

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 5. After inspection of inner door as noted in step 4, completely remove gasket and adhesive residue from right and left side inner doors as needed.

Step 6. Use RTV sealant (recommended bead size is 1/8") to secure the inner door gasket to the inner door sections (right & left). Refer to illustration below for proper application. Note the overlap configuration in the flange area of the inner door. Set the flange section first, this will help to achieve the proper over lap position.

Page 35

35

PDX Series

PDX SERVICE PROCEDURE XIII

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Installation of Inner Door With Gasket.

Step 7. Clean any residual gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly.

Step 8. Place the left side inner door into position first. Firmly position the radiused channel of the inner door aroundthe feedline. Using the 1/4” hex drive screws from step 3d, secure left side inner door in place. DO NOT OVER TIGHTEN SCREWS.

Step 9 Position thermocouple, pilot tube and Piezo wire against left side inner door flange gasket. DO

NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.

WARNING

Stripped fastener connections may allow for seal breach of inner door. A seal breach may result in a fire or explosion causing property damage, personal injury or death. Do not over tighten screws in steps 8, 10 and 11.

If a fastener connection is stripped, contact the manufacturer listed on the water heater rating plate.

Igniter wire and pilot tube shown in proper position.

Radiused Channel

for Feedline

Page 36

36

PDX Series

PDX SERVICE PROCEDURE XIII

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Installation of inner door with gasket (continued from page 36).

Step 10. Firmly place right side inner door flange against the left side inner door flange and secure with two ¼” drive screws from step 3c. DO NOT OVER TIGHTEN SCREWS.

Step 11. Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted opening. Verify seal integrity around combustion

opening. Secure right side inner door using 1/4” hex drive screws from step 3b. DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against the combustion chamber

Verify threaded hole alignment with slotted openings in inner door.

Step 12. Replace outer jacket burner access door.

Step 13. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

Page 37

37

PDX Series

Glossary of Terms

BTU

British Thermal Units

GPM

Gallons per Minute

Hz

Hertz

KW/h

Killo-wattsper hour

LED

Light Emitting Diode

NPT

National Pipe Thread

Ohms

Ohms of resistance

PSI

Pounds per Square Inch

RPM

Revolutions per Minute

TCO

Temperature Cut Off

VAC

Volts Alternating Current

W.C.

Inches of Water Column

°C

Degrees Centigrade

°F

Degrees Fahrenheit

NOTES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 38

38

PDX Series

Parts List

1.

Blower Assembly

15.

Hot Water Outlet Anode

28.

Screw-#8-18x ¾ HWH

41.

Gas Pilot Orifice (Nat.)

2.

Blower Temp. Switch

16.

Cold Water Inlet Diptube

29.

Brass Drain Valve

42.

Gas Feedline (Nat.)

3.

Exhaust Pressure Switch

17.

Flue Baffle

30.

Flammable Vapor Sensor

43.

Gas Burner Assy (L.P.)

4.

Inlet Pressure Switch

18.

Blower Harness

31.

Sensor Harness

44.

Cast Iron Burner (L.P.)

5.

Blower Gasket

19.

T&P Relief Valve

32.

Flammable Vapor Sensor

45.

Gas Pilot Assy (L.P.)

6.

Tee and Vent Pipe Assy.

20.

¾ NPT PLUg

 

Clip

46.

Gas Pilot Orifice (L.P.)

7.

Vent Adapter with Term.

21.

Direct Vent Boot

33.

Thermal Well

47.

Air Shutter (L.P.)

8.

Intake Terminal

 

Escutcheon

34.

Gas Control Kit

48.

LP Gas Feedline (L.P.)

9.

Vent Terminal Elbow

22.

Air Intake Boot

35.

Gas Control Service tool

49.

Air Shutter Nut (L.P.)

10.

Exhaust Adapter

23.

Air Intake Boot Gasket

36.

Gas Control

50.

Main Burner Orifice (L.P.)

11.

Condensate Hose Kit

24.

Outer Door

37.

Gas Burner Assy (Nat.)

51.

Inner Door Gasket

12.

Flue Reducer

25.

Right Side Inner Door

38.

Gas BN burner (Nat.)

52.

Heat Trap Insert kit

13.

Heat Trap Insert (outlet)

26.

Left Side Inner Door

39.

Main Burner Orifice (Nat.)

53.

Mixing Valve

14.

Heat Trap Insert (inlet)

27.

Screw-#10-12x ¾ HWH

40.

Gas Pilot Assembly (Nat.)

 

 

Page 39

39

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