Bradford-White PDV80S250, D80T725, PDV802200, PDV80T300, PDV100S150 User Manual
...
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)
Manual 48061A
PDV80S150
PDV802200
PDV80S250
PDV100S150
PDV100S200
PDV100S250
PDV80T300
PDV100T360
D80T725
D65T625
(PDV80S Shown)
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 - - Gloss a ry of Term s 52 - - -
2
FEATURES OF PDV-S MODEL SERIES
Power vented direct vent design, uses a blower to vent the flue produc ts to t he outside and pull combustion air in
from outside the building
Independent Venting - Exhausts flue products and supplies c om bus tion air through two separate 3" or 4" PVC,
CPVC or ABS pipes. Maximum venting distanc e of 40 f t. wi th 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 ignit ion - Pilo t is automatically lit and monitor ed by the Honeywell Integrated Ignit ion Control system.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermos tat and LCD Dis play - Accur ately monitors the tank temperat ur e 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-T MODEL SERIES
Power vented direct vent design, uses a blower to vent the flue produc ts to t he outside and pull combustion air in
from outside the building
Co-axial Venting (pipe inside a pipe) - Combustion air enter s from outs ide the building through an oute r pip e and
exhausts flue product s thr ough the inside pipe. May be vertically or hor iz ontally vented with a maximum venting
distance of 19'-6" (19 feet, 6 inches) with one 90 degree elbow.
Electronic ignit ion - Pilo t is automatically lit and monitor ed by the Honeywell Integrated Ignit ion Control system.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermos tat and LCD Dis play - Accur ately monitors the tank temperat ur e 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 vente d desi gn, uses a blower to pull the flue products out th e water heater. Designed to
vent vertically through 8 inch diameter type B venting system. Uses room air for combustion.
Electronic ignit ion - Pilo t is automatically lit and monitor ed by the Honeywell Integrated Ignit ion Control System.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermos tat and LCD Wat er Heater Control Display - Accurately mon itors the tank temperature and the
setpoint and is easily adj us ted by us ing the temperature UP and DOWN buttons on the dis play on the control box
cover.
FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM
Attractive digital water heater display on control panel for setting and displ ay ing the temperature
setpoint. Pressin g temper ature 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 wir ing controls temperature, ignition, and blower operation.
Reduced number of parts for ser v ic ing and wir ing.
Plug in wiring reduces chance of miswiring.
Water heater display will show diagnostic codes in the event the water heater needs servic ing.
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 Re quired fo r Ser v i ce
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-amps and 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 1-1/16 deep well
socket, wire cutters, wire strippers, wire crimpers, torpedo level, small
shop vac, step ladder, and flashlight.
4
Specifications
Power Supply
Current Draw
Gas Supply Connection
Approved Gas Type
Gas Pressure (Nat. & L.P.)
Venting System
Dedicated 120 VAC, 60 Hz., 15 A
Less than 5 Amps
PDV-S & PDV-T MODELS: 3/4" NPT Minimum connec tion to gas valve.
INDUCED DRAFT MODELS: 1" NPT Minimum conncec tion to gas valve.
Schedule 40 black iron pipe recommended for all models.
Natural or Propane. Gas supply must matc h the gas type listed on the
water heater rating labe l.
Manifold Pressure : 4.5 " w.c . nat ur al gas , 10. 0" w.c. L.P.
Gas Supply Pressure: At least 1" above manifold pressure with water heater
operating, 14" w.c. maxim um
PDV-S MODELS:
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 . m odels .
Refer to the installation instruction manual for further information on venting
lengths and installa tion requirements.
PDV-T MODELS:
Power vented through Co-axial Venting (pipe inside a pipe) - Combustion air
enters from the outside the building through an outer pipe (200m m diam .)
and exhausts flue produ cts through the inside pipe (130mm diam.) . Ref er to
the installation instruction manual for further information on venting lengths
and installation req uir em ents.
Minimum Clearance for Serv ic ing
Maximum Water Supply Pressure
Thermostat Sensor(s)
Control Board
Control Display
Transformer
Pilot
INDUCED DRAFT MODELS:
Connect 8” vent to blower vent col lar 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 se ns or . PDV-T model s er ies and Induced Draft
models also use an upper sensor (dua l sen so rs fo r thes e mod els ) .
Honeywell Integrat ed Control Board for Temperature Control, Induced Draft
Blower, and Ignition Control Functions. Operates on 24 volts AC current
from transformer. Single s ens or boar ds for PD V-S mod els and dual s ens or
boards for PDV-T models and Indu ce d Dra ft model s .
Honeywell LCD Control Display with Temperature Setpoint, Format, and
Error Code Display in User Mode, Diagnostic Functions in Service Mode.
Communicates with Contr ol B oar d. 24 volts AC. Same control display used
on all models.
120 VAC Primary, 24 VAC Secondary, 40 VA
Intermittent Pilot with Spark Electrode and Flame Sensor monitored by
Control Board
Induced Draft Blower
PDV-S MODELS: 115 VAC, 60 Hz., 4.3 Amps.
PDV-T MODELS AND D80T725, D65T625: 115 VAC, 60 Hz., 3. 6 Amps.
5
Sequence of Operation
1 Thermostat calls for heat:
.
The relay closes on the control boar d, sending line voltage (115-120 volts) from “inducer” term inals #5 and 3 on the
control board to the induced draft blower.
The blower starts and when sufficient vacuum is achieved, the pressure switch closes and completes the 24 volt
2
circuit between termi nals 1 and 3 on the Cont r ol Pl ug to t he the board, allowing the ignition s equence to proceed.
The blower “purges” any remaining combustion products from the prev ious c y cle for 15 seconds before allowing the
pilot to light. This is the pre-pur ge per iod of the ignition cycle.
3
Trial for ignitio n (thr ee 90 s ec ond 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 “ sp ar k”
terminal, to generate spark at the pilot and
ignite pilot gas fl o w .
4. Pilot flame proving si gnal ( m eas ur ed in
micro-amps). from the “sense” terminal, to
prove pilot flame.
4
Once pilot flame is proven, sparking will stop.
Once sparking stops, 24 volts is sen t from c ontrol pin
5
terminal #5 on control board, to “M V” te rminal on gas valve
to establish main burner gas flow. Main burners ignite from
the pilot flame.
The control board consta ntly monitors pilot flame thro ugh
the flame sensor rod. If pilot flame is los t, pilot and main
burners are shut down. Afte r a 75 second inter-purge
period, the control will attempt to re-light the pilot beginning
at sequence 3 above.
Main burner fires until th e therm os tat is satisfied. The contro l
7
board interrupts 24 volt s through the gas valve circuit. Pilot
and main burners are turned off.
8
The induced draft blower shuts off 5 seconds after the
gas valve closes. This is the post-purge period.
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 er ror code number (62 or 63) with
“Service Needed” in the display window. Refer to error codes in th e
WIRING DIAGRAM
diagnostic sect ion of this Service Manual. In a “Soft Lock out” c ondition,
the control will wai t for 60 m inutes and then make 2 more attempts to light the pilot and establish the main burner s .
Soft lockout res et is ac co mp lis hed by depr es s ing the lower right button under “Res et” for 3 seconds.
If the water heater should reach 200 degrees F, then the high lim it 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 intak e term inals 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 t he pr es su re switc h er ro r code.
6
CAUTION
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals
Water Heater Fault: Wate r hea ter does not operate
Display Error Code: Water heat er dis play does not operate - blank display
Check main power supply to wat er
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
Checking line voltage to board.
Pins to black and white wires.
Verify Primary and Secondary
voltage at the control board.
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.
TROUBLESHOOTING
Checking primary voltage to
transformer from board. Pins to
black and white wires.
If there is not 24 volts at Secondary
pins on the control board, check
transformer. Replace transformer
or wire harness.
Switch on power.
Does water heater display operate?
Does the induced draft blower start
to operate? Increase thermostat
setting if tank is warm.
N
See next page
Checking secondary voltage from
transformer. Pins to blue and yellow
wires.
N
Check wire connections of
board to display. See
illustration.
Checking transformer voltage, front
terminals are 24 volts, rear terminals
are 120 volts.
With the control cover tilted down,
measure the voltage between red and
black wire pin connections to display.
Voltage should be 24 volts AC
measured at the back of the Control
Display.
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-com terminals
(1&3 and 1&2) to the control display.
7
TROUBLESHOOTING
CAUTION
Use Caution Not to Damage Connectors when making Voltage Measur ements or Jumping Terminals
From previous page
Does induced draft blower
operate?
Y
Is there pilot flame?
Y
Does Main Burner operate?
Y
Does burner continue until
thermostat set point is reached?
See setting display in Service Mode
and disp la yi ng temper at ur e
sensors.
Y
Error code #29 on display. Measure voltage at the pin
terminals on the control board between the black and white
N
wires to the blower (terminals 5 and 3 on the “inducer”
output on the board, see imag e above). Make sure the
control display shows “heating” in the status mode.
Increase the setpoint, if it does not show “heating”. Is there
110-120 volts to the blower harness?
Error code #29 on display. Pressure swi tch did no t close. Check for
N
blocked intake or exhaust ve nts, dampe r stuck clo sed, or excessive
vent l ength. See section on “Checking Pressure Switch”. If pressur e
switch closes, and error code 62 appears on control display, pilot is not
lighting or staying lit during the i gnition cycle. Proceed to the s ection
“Pilot Operation Testing”
N
Error c ode #62 on d is play . Se e pil ot ligh ts, n o flam e
signal in the section for “Pilot Operation Testing”
N
Error code #63 on d isplay. See M ain Burner short
cycles in the section under “Main Burner O peration
Testing”
Replace control board if display
shows “heating” and no voltage is
N
present to the blower harness.
Make sure there are no codes for
the temperatur e sensors
(following sections) before
replac in g control boa r d.
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 b lower.
Replace blower, if there is
voltage to the blower.
Blower Stops shortly after burners
shut off.
Y
Syste m ok ay
Service Needed
Status
SELECT Lockout RESET
Example of error code shown on control display.
8
Error Code Shown
in Water Heater Display
ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)
e
r
The display has a “service mo de” for ch anging the maximum setpoint and acce ssing information in aiding ser v ic ing of the
water heater. This procedur e is for s er v ic e and ins tallation personnel only . To enter the Service Mode, follow the steps
illustrated bel ow:
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
Operational
Statu
s
SELECT SET
Step 2: Pressing “Sel ec t” button will change display to next mode
Wate
°F
Temp
idl
Operational
Status
SELECT SET
The following is the sequence of modes available in “Service Mode” by pressi ng the “Sel ect” button:
Error Code Number (Displ ay /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)
e
e
t
°F
Setpoin
idl
Operational
Stat us
SELECT SET
Max
Max Setpoint val ue in
Water Heater Display
2a. Water Temperature Aver age (D is play s av er age if there are two sensors - sensor temperature displayed if single
&
sensor is used).
Water Temp
°F
idle
Operational
Status
SELECT SET
2b. Water Temperature - Upper Sen so r (Displays if there is an upper sensor - some model s)
°F
idl
Operational
Status
Upper Sensor
SELECT SET
2c. Water Temperature - Lower Sen so r (Displays if there are two sensors)
°F
idle
Operational
Status
Lower Sensor
SELECT SET
10
3. Flame Current of Pilot Flame Sens or (Di sp l ay s only in the Heat ing Cy c le)
e
4. Setpoint (Display/Change)
5. °F/°C (Display/Change)
Operational
µA
Flame Current
Heating
Status
SELECT SET
setpoint
°F
idle
Operational
Status
SELECT SET
setpoint
°F/C°
°F
idle
Oper ational
Status
SELECT SET
6. Differential (Display only - shows the differential of the thermostat)
Differential
°F
idl
Operational
Status
SELECT SET
11
7. Software Version (Display only )
idle
Operational
Status
SELECT SET
Soft
8. Error Code History (Displ ay s if there are present error codes or up to 10 previous er r or code s). Water Heat er
Display will show a “--“ if there are no error codes.
idle
Operational
Status
SELECT SET
To change the Maximum Setpoint Limit ( Ma x Setp oi nt ) for the te mperature setpoint:
Step 1: In service mode press the “Selec t” button until “Max Setpoint” is displayed.
WARNING
Setting the water temperature
to the ma ximum se t point ca n
result in scalding hot water
delivered to t he faucets. It is
highly recommended that the
maximum setpoint be adjusted
Status
idle
Operational
Max
°F
Setpoint
to the lowest temperature
possible for the needs of the
SELECT SET
installation. Make sure the
water heater control displa y is
not in a public ar ea that can
result in the temperature
settings being improperly
adjusted.
12
Step 2: Press “Set” button t o enter s ett ing mode. “Max Setpoint” will flash to indicate setting mode.
Max
°F
Setpoint
idle
Operational
Status
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
Max
°F
Setpoint
idle
Operational
Status
SELECT SET
%
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
Max
°F
Setpoint
idle
Operational
Status
SELECT SET
"Max Setpoint" stops flashi ng
%
13
Step 5: 30 Seconds after the last button pr es s , th e Wate r Heater Dis play will go back to “User Mode”. It will read “Max
e
Setpoint” without sh owing a temperature value if the temper ature setpoint is at the maximum sett ing. 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
Operational
Status
SELECT SET
&
Display of Water Temperature:
Step 1: In Service Mode, Press the “Selec t” button until “Water Temp” is dis play ed in the upper right section of the
water heater display . For water heat er s usi ng two t emp erature 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.
Exiting Service Mode
Water
°F
Temp
idle
Operational
Status
SELECT SET
Upper Sensor
%
Step 2: For water heaters using two t emp er ature sensors, pressing the “Se lec t” button again displays the Upper
Sensor temperature re ading. “Upper Sensor” will be display ed in the lower right side of the status window of the
water heater display.
°F
idl
Operational
Status
SELECT SET
Upper Sensor
14
Step 3: For water heaters using two temperature sensors, press ing the “Select” button again dis play s the Lower Sensor
temperature readi ng. “Lower Se ns or ” wil l be dis play ed in the lower left side of the status window of the water heater
display.
°F
idle
Operational
Status
Lower Sensor
SELECT SET
To Display Flame Sense Current of the Pilot Flame Sensor:
The pilot flame sense current is avai lable only when the burners are in operat ion. 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 wit h “Flam e Cur r ent” to the right of the number. The value
displayed is in microamps (µA).
Flame
Current
Operational
µA
setpoint
°F
Heating
Status
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
idle
Operational
Status
SELECT SET
15
Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will fl as h in the wat er heater display.
TSET
setpoint
°F
idle
Operational
Status
SELECT SET
Step 3: To raise the temperature setpoint, press the “Temperatur e Up” butt on until the desired temperatur e is sho w n 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 prev ious ly under “ Acces s ing the Service Mode on the Water Heater Display ”.
WARNING
Setting the water temperature
to the ma ximum se t point ca n
result in scalding hot water
delivered to t he 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 displa y is
not in a public ar ea that can
result in the temperature
settings being improperly
adjusted.
Step 4: To lower the temperature set point, press the “Temperature Down” button until the desired temper ature is shown
on the water heater display.
setpoint
°F
idle
Operational
Status
SELECT SET
setpoint
°F
%
"Setpoint" Flashes
idle
Operational
Status
SELEC
16
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