Honeywell PDX50S60F-B-S-C-N-X, PDX450SF-BN-SX, PDX65S65F-B-S-C-N-X, PDX275TF-BN-SX-CX, PDX150SF-BN-SX-CX User Manual

...

Download

Save this manual for future reference

Manual 238-49770-00A

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

PDX Series Models: PDX140S*F(BN,SX,CX) PDX150S*F(BN,SX,CX) PDX440S*F(BN,SX) PDX450S*F(BN,SX) PDX250T*F(BN,SX,CX) PDX265T*F(BN,SX,CX) PDX275T*F(BN,SX,CX)

PDX50S60F(B,S,C)*(N,X) PDX65S65F(B,S,C)*(N,X) PDX75S70F(B,S,C)*(N,X) (*) Denotes Warranty Years

Powered Direct Vent Gas Water Heaters

PDX Series

Table of Contents

Page PDX Service Procedure

Introduction 4 - - -

How to use this manual 5 - - -

Tool required for service 5 - - -

Specifications 6 - - -

Control Timings 9 - - -

Sequence of Operation 10 - - -

Troubleshooting 13 - - -

Burner Inspection, Cleaning and Replacement 15 I

Pilot Testing, Cleaning and Replacement 17 II

Pressure Switch Testing and Replacement 18 III

Blower Testing and Replacement 20 IV

Blower Temperature Switch Testing and Replacement 22 V

Gas Control & Thermal well Testing & Replacement 24 VI

Flammable Vapor Sensor Testing & Replacement 28 VII

Safety Circuit Voltage Trace 29 VIII

115VAC Circuit Trace 30 IX

Dip Tube inspection and Replacement 31 X

Anode Inspection and Replacement 32 XI

Flue Baffle Inspection and Replacement 33 XII

Inner Door Removal, Inspection & Replacement 34 XIII

Glossary of Terms 38 - - -

Parts List 39 - - -

Page 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.

WARNING

Water heaters are heat producing appliances. To avoid

damage or injury, do not store materials against the

water heater or vent-air intake system. Use proper care

to avoid unnecessary contact (especially by children) with the water heater and vent-air intake components. UNDER

NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS,

SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENTAIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH

FUMES COULD REACH THE WATER HEATER OR VENT-AIR

INTAKE SYSTEM.

CAUTION

If sweat fittings are to be used DO NOTapply 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.

Incorrect operation of this appliance may

CAUTION

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

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

PDX Series

The new Bradford White PDX1, PDX2 and PDX4 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.

Introduction

Increased Vent Lengths - increased venting performance is achieved while maintaining

Energy Factor & FHSR performance.

The PDX1, PDX2, and PDX4 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 non metallic 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

How to Use This Manual

PDX Series

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 PDX 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-amps and ohms.

Electronic Probes:In some cases, standard multi-meter probes 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-meter probes. 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

PDX Series

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 direct vent through the wall or vertical through the roof

Approved Vent Materials PVC, CPVC or ABS

Minimum Clearance 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 Set Point Range

Commercial Temperature Set Point Range

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

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

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

Specifications

Blower Temperature Switch Normally closed, opens @ 155°F (68°C), auto reset @ 128°F (54°C).

Standard Altitude-Normally open, closes at differential pressure of -.80.

Pressure switch

High Altitude-Normally open, closes at differential pressure of -.73.

Blower 115VAC, 60Hz, 3.1 amps.

Page 6

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.

Vent Tables

3" Diameter (7.6 cm) PVC Vent Connector Lengths

Maximum 75 gal.Maximum 48, 65 gal.

Terminating

Through the Wall

Through the Wall 2 50 (15.2) 2 (.6)

Through the Wall 3 45 (13.7) 2 (.6)

Through the Wall 4 40 (12.2) 2 (.6)

Through the Roof 0 60 (18.3) 7 (2.1)

Through the Roof 1 55 (16.8) 7 (2.1)

Through the Roof 2 50 (15.2) 7 (2.1)

Through the Roof 3 45 (13.7) 7 (2.1)

# of

Elbows

Maximum

Length ft (m)

1 55 (16.8) 2 (.6)

Minimum

Maximum

Length ft (m)

Minimum

Length ft (m)

45 (13.7) 2 (.6)

40 (12.2) 2 (.6)

35 (10.7) 2 (.6)

30 (9.1) 2 (.6)

50 (15.2) 7 (2.1)

45 (13.7) 7 (2.1)

40 (12.2) 7 (2.1)

35 (10.7) 7 (2.1)

4" Diameter (10.2 cm) PVC Vent Connector Lengths

Terminating

Through the Wall

# of

Elbows

Maximum

Length ft (m)

Minimum

Length ft (m)

1 95 (29.0) 10 (3.1)

Through the Wall 2 90 (27.4) 10 (3.1)

Through the Wall 3 85 (25.9) 10 (3.1)

Through the Wall 4 80 (24.4) 10 (3.1)

Through the Wall 5 75 (22.9) 12 (3.6)

Through the Roof 0 100 (30.5) 15 (4.6)

Through the Roof 1 95 (29.0) 15 (4.6)

Through the Roof 2 90 (27.4) 15 (4.6)

Through the Roof 3 85 (25.9) 15 (4.6)

Through the Roof 4 80 (24.4) 15 (4.6)

Maximum 75 gal.Maximum 48, 65 gal.

Maximum

Length ft (m)

Minimum

Length ft (m)

85 (25.9) 10 (3.1)

80 (24.4) 10 (3.1)

75 (22.9) 10 (3.1)

70 (21.3) 10 (3.1)

65 (19.8) 12 (3.6)

90 (27.4) 15 (4.6)

85 (25.9) 15 (4.6)

80 (24.4) 15 (4.6)

75 (22.9) 15 (4.6)

70 (21.3) 15 (4.6)

Page 7

PDX Series

Part II-Venting Specifications for:

40 Gallon 50 Gallon

Specifications

Vent Tables

The minimum equivalent length for the exhaust portion of the vent is 7 feet. The maximum equivalent vent length for the exhaust is 35 feet for 2" diameter pipe and 85 feet for 3" diameter pipe. The intake portion of the vent must be equal to or less than the vent length of the exhaust. The tables below are provided for your quick reference, some installations may require a greater number of elbows. When calculating equivalent vent length, one 90° elbow is equivalent to 5 feet.

IMPORTANT

VENT CONNECTOR LENGTHS FOR 2" (5.1 cm) DIAMETER VENT PIPE

# of

Terminating

Through the Wall

Elbows

(excl. vent

term.)

1 30 (9.1)

Through the Wall 2 25 (7.6)

Through the Wall 3

Through the Wall 4 15 (4.6)

Through the Roof 0 35 (9.1)

Through the Roof 1 30 (9.1)

Through the Roof 2 25 (7.6)

Through the Roof 3 20 (6.1)

Maximum

straight

Length ft (m)

20 (6.1)

Minimum

straight

Length ft (m)

2 (.6)

7 (2.1)

VENT CONNECTOR LENGTHS FOR 3" (7.6 cm) DIAMETER VENT PIPE

Terminating

Through the Wall

# of

Elbows

(excl. vent

term.)

1 80 (24.4)

Maximum

straight

Length ft (m)

Through the Wall 2 75 (22.9)

Through the Wall 3

70 (21.3)

Through the Wall 4 65 (19.8)

Through the Roof 5 60 (18.3)

Through the Roof 0 85 (29.9)

Through the Roof 1 80 (24.4)

Through the Roof 2 75 (22.9)

Through the Roof

3 70 (22.3)

65 (19.8)4

Maximum

straight

Length ft (m)

10 (3.1)

15 (4.6)

Page 8

PDX Series

Control Timings

Pre-purge 15 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)

Specifications

Ignition State Timing

Page 9

PDX Series

Start Up.

Upon power up, the control runs a safe-start check with a typical start-up delay of 1-5 seconds.

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.

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. 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.

Sequence of Operation

Blower energizes.

Blower pre-purge period (15 seconds)

Differential 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.

Trial 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.

Main 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 10

PDX Series

Steady state operation.

Thermostat satisfies.

Burner off.

During Steady State Operation the Control Monitors: Thermostat temperature sensor- When set point temperature is satisfied, gas valve is shut down and blower will post purge for 15 seconds. Control LED flashes a short flash once every 4 seconds (idle) status code.

Pressure switch / Blower temperature switch- If either switch opens, pilot valve and main valve is shut down. The blower continues to run for 30 seconds attempting to close the circuit. The control LED Flashes 3 times with 3 second pause.

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

Sequence of Operation

Blower post purge (15 seconds).

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

flash 8 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 11

Sequence of Operation

PDX Series

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

gins. If the recycle count has been reached, the control

not reached its limit (4), another trial for ignition

turns off the blower and flashes 6 times then 2 times with 3 second pause. The control waits 5 minutes before repeating ignition sequence.

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 flashes 6 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 flashes 5 times with 3 second pause. This continues until flame is lost, once the flame signal is lost, the control flashes 6 times then 4 times with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

Page 12

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.

LED Status

None, control LED not on or flashing

Short flash, once every four seconds

“Heartbeat”, alternates bright/dim

Short flash once per

second

Control Status

No electrical power

Stand-by mode, Waiting for call for

heat (no fault).

Thermostat calling for heat (no fault).

Weak pilot signal on last call for heat.

Control power switch in “OFF” position. Supply voltage interrupted.

Temperature demand is satisfied

Tank temperature below set point of thermostat.

1. Unstable pilot.

2. Pilot tube block or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad connection at gas valve.

Probable Cause

Green LED

Indicator

Service

Procedure

Turn power on

Normal operation.

Adjust thermostat to

temp level

Normal operation.

Adjust thermostat to

temp level

1. Page 15

2-4. Page 17

Two flash, three second pause

Three flash, three second pause

Four flash, three second pause

Five flash, three second pause

Pressure switch not working-closed position.

Pressure switch or blower temp. switch not working

-open position.

Excessive tank temperature. System must be reset.

Undesired-false pilot flame present.

1. Pressure switch tubing kinked or blocked.

2. Blocked pressure tap on switch or blower.

3. Faulty pressure switch.

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Blower not spinning up to speed.

5. Blower temp or exhaust temp too high

6. Faulty blower temperature switch.

7. Intake vent length exceeds exhaust vent length.

8. Frozen intake or exhaust vent terminal.

1. Thermal well sensor out of calibration.

2. Faulty gas control.

3. Plumbing leak

1. Pilot valve stuck in open position.

Page 18

1. Check vent or vent tables.

2 & 3 Page 18

4. Page 20

5 & 6 Page 22

8. Page 37

1. Page 24

2. Replace gas control, page 26

Replace gas control, page 26

Page 13

PDX Series

Troubleshooting

LED Status Control Status

Six-one flash, three second pause

Six-two flash, three second pause

Six-three flash, three second pause

Six-four flash, three second pause

Seven flash, three second pause

Failed to light pilot. System auto resets.

Pressure switch or blower temp switch opened during burner operation. System auto resets.

Pilot flame extinguished. System auto resets.

Undesired-false pilot flame sensed. System auto resets.

Flammable Vapor Sensor fault detected

Probable Cause

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad connection at gas valve.

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Vent termination being affected by wind

5. Blower not spinning up to speed.

6. Blower temp or exhaust temp too high

7. Faulty blower temperature switch.

8. Insufficient combustion air.

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad connection at gas valve.

5. Insufficient combustion air.

6. Gas pressure is out of specification.

Pilot valve stuck in open position.

WARNING: EXPLOSION HAZARD

* Indicates gasoline vapors were detected at potentially

explosive levels.

* Verify no gasoline vapors are still present * Reset the control by cycling power to the appliance or

by cycling the ON/OFF switch.

* Replace the Flammable Vapors Sensor element if a

gasoline spill event occurred.

Service

Procedure

1. Page 15

2-4. Page 17

1. Check vent or vent tables. 2 & 3 Page 18

4. Refer to venting section of installation manual

5. Page 20

6 & 7 Page 22

8. Refer to installation

manual.

1. Page 15

2-4. Page 17

5. Refer to installation manual

Replace gas control, page 26

Page 28

Eight-one flash, three second pause

Eight-three flash, three second pause

Eight-four flash, three second pause

Flammable Vapor Sensor out of specification.

Thermal well sensor damaged or unplugged

Gas valve electronics fault detected

Gas valve fault detected.

* Verify Flammable Vapor Sensor (FVS) resistance is

not below 25 K Ohms.

* Check wiring to FVS and insure it is not shorted. * Replace control if everything above checks out OK.

1. Damage to thermal well wire.

2. Thermal well sensor resistance out of range.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Control needs to be reset.

2. Control is wet or physically damaged.

Page 28

Page 24

1. Interrupt power supply

2. Replace gas control, page 26

1. Interrupt power supply

2. Replace gas control, page 26

Page 14

PDX SERVICE PROCEDURE I

PDX Series

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. d) Door was not sealed properly after servicing.

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 15

PDX Series

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 XIII on page 35.

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.

PDX SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Igniter/flame

sense wire

Feedline nut

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

Burner

port area

Step 9. Unscrew burner from main burner

orifice. On cast iron burners, loosen air shutter nut and unscrew feedline from burner.

Pilot tubing nut

Main burner

orifice

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 16

PDX Series

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.

PDX SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

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-meter set 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.

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

found replace pilot.

Ferrule

Pilot

nut

tubing

Igniter/flame sense

wire

Pilot

orifice

Feedline nut

Pilot tubing nut

Pilot

hood

Igniter/flame sense

electrode

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 17

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Testing

WARNING

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 1).

Step 3. Carefully remove pressure switch from blower housing (see photo 2)

Exhaust pressure

switch

Pressure switch

wire leads

With steps 1,2 & 3 complete,

disconnect wire leads from

pressure switch.

Pressure Switch

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

Use a multi-meter set to the

ohms setting. With blower off,

check across pressure

switch terminals.

Are switch contacts open?

(no electrical continuity)

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 close

with blower running with the

switch in the vertical

postition?

Switch contacts are OK.

See safety circuit trace

(page 30)

Check tubing and

pressure tap on

switch for blockage.

Is there blockage?

Check tubing and pressure tap

on switch for blockage.

Is there blockage?

Clear blockage

Is vent system

blocked

Is vent system length

Replace switch

(see page 18)

within vent table

specifications

listed on page 7 or 8

Reconfigure vent

system to be

compliant with

vent tables.

See blower testing

(page 21)

Is blower OK?

Correct blower

problem.

Page 18

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Exhaust Pressure Switch Replacement

120 volt potential exposure. Use caution

WARNING

to avoid personal injury.

Step 1. Position gas control power switch

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).

Pressure Switch

Step 3. Carefully remove pressure

switch from blower housing (see photo 4)

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

Step 4. Disconnect tubing from

6 7

pressure switch. (see photo 5)

Step 5. Disconnect yellow wires

from pressure switch (see photo 6)

Step 6. Reconnect wires from step 5 to new pressure switch.

Step 7. Reconnect tubing to new pressure switch.

Step 8. Carefully position pressure switch into blower housing.

Step 9. Position gas control power switch to “ON” position and verify proper heater operation.

Step 10. Replace control access cover from step 2.

Page 19

PDX Series

PDX SERVICE PROCEDURE IV

Blower Testing and Replacement

Blower Testing

115 volt potential exposure. Use caution when

making voltage checks to avoid personal injury.

Step 1. Position gas control power switch

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

Step 2. Remove the three screws (Phillips Screw driver)

from control access cover on blower assembly and remove cover (see photo 8).

Does blower energize Within 2

minutes?

Does blower energize after 2

minutes, run for 30 seconds

and shut down?

tubing from blower.

Pressure tap

Pressure switch

See pressure switch

Disconnect

pressure switch

(see photo 13)

tubing

testing

Page 18

manometer to

pressure tap of

(see photo 11)

Determine voltage

problem and correct.

Connect

blower.

12 13

Disconnect vent

system from top of

blower and remove

(see photo 15)

With blower running, and exhaust

adapter removed from top of blower,

is there a negative pressure of -2.30"

WARNING

exhaust vent

adapter.

Remove exhaust

to -2.60" W.C.?

Is there 115vac across blue

and green wires

(see photo 14)

adapter

Replace blower

Blower OK

Disconnect cord set

shown in photo 9. Is

there 115VAC across

terminals shown in photo

Is there 115 VAC at

wall outlet?

Check power cord

for damage.

Replace blower

Is there 115VAC across

terminals shown in

photo 13 ?

Incorrect supply

voltage polarity

Determine

power source

problem and

correct.

Repair or replace

power cord

Replace cord set

Reconnect cord set shown

in photo 8, is there

115VAC between blue wire

and green ground wire

(see photo 14)

Does cord set

have electrical

continuity?

Replace gas

control

Replace blower

Green ground

wire

Shown with pressure

switch removed.

Blue wire

Page 20

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).

Vertical air intake

Step 9. Remove blower with gasket from water heater.

Vertical air intake

Remove exhaust adapter

and retain for use on

new blower.

Blower Mounting

Screws

Blower

Cord Sets

bracket

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-install vertical air intake bracket.

Step 15. Re-install exhaust 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.

Locating Pins

on blower flange

Pin location holes in

jacket head

Page 21

PDX Series

PDX SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch Testing.

Step 1. Position power switch on gas control

to the “OFF” position.

Step 2. Remove tubing from inlet pressure tap.

Step 3. Remove the three screws (Phillips screw driver) from

control access cover on blower and remove cover (see photo 15).

Step 4. Locate blower temperature switch (see photo 16)

Opens on rise @ approximately 155°F

Auto resets on fall @ approximately 128°F

Disconnect wire leads to

switch. Using a multi-meter

set to the ohms setting, is

there continuity between the

Switch Setting

Cool switch to

below 125°F

switch terminals?

Replace switch

(see page 24)

120 volt potential exposure. Use caution

WARNING

to avoid personal injury.

Blower temperature

switch location

Air mixing inlet

Reconnect wire leads and

observe heater operation. Do

exhaust gas temperatures rise

to or above 175°F?

Do switch contacts

open?

Switch OK

Replace switch

(see page 23)

Do switch contacts

open?

temperature is too

Exhaust

hot.

Common causes for

high exhaust temperature

1. Vent length is below minimum allowable.

2. Vent diameter not to specification.

3. Restricted dilution air inlet.

4. Missing or deteriorated flue baffle.

5. Gas pressure is out of specification.

6. Excessively high ambient temperatures.

Page 22

PDX Series

PDX SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch Replacement.

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

and unplug heater from wall outlet.

Step 2. Remove the three screws (Phillips screw driver) from the

control access cover on blower and remove cover. (see photo 17)

Step 3. Locate blower temperature switch (see photo 18)

Step 4. Disconnect red and yellow wire leads from switch.

Step 5. With an appropriate tool such as side cutters, snip the

retaining lug from the blower housing to allow removal of temperature switch (see photo 19).

120 volt potential exposure. Use caution

WARNING

to avoid personal injury.

Blower temperature

switch location

Step 6. Remove switch from blower housing.

Step 7. Install new switch. Be sure switch is properly seated in

mounting area.

Step 8. Reconnect red and yellows wires to new switch. Wires are

interchangeable with either terminal.

Step 9. Position gas control power switch to the “ON” position

and verify proper heater operation.

Step 10. Replace control access cover from step 2.

Snip retaining lug

from blower housing

Page 23

PDX Series

Gas Control Testing

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

PDX SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

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.

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-meter set to the

Ohms setting, determine the

resistance of thermal well sensor

(see caution photos 20 & 21)

Disconnect thermal

well wire harness

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-meter set 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 20).

Alternate the probe on the outside position to the opposite outside wire position (see photo 21).

Once the thermal well resistance values are known, the water

temperature must also be known to determine if the resistance

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

Are thermal well resistance values correct?

Replace gas control

(see page 27)

Replace thermal well

(see page 27)

Page 24

PDX Series

Stored water may be HOT when performing the following steps in this procedure.

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.

PDX SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

WARNING

Take necessary precaution to prevent personal injury.

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 012345678 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 25

PDX Series

Gas Control & Thermal Well Removal From Water Heater

PDX SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control

Step 1. Position gas valve power switch to the “OFF”

position and Unplug Heater from power supply.

Thermal Well

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 26

PDX Series

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 22 for proper control alignment.

Step 2. Route wire leads back into relief opening.

(see photo 23)

Step 3. Align slots located on thermal well flange with tabs

located on back of gas control (see photo 22 & 23)

PDX SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

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.

Igniter/sensor

connection

Step 6. Reconnect wire harnesses to gas control

Step 7. Reconnect gas piping to gas control.

Ground Wire

connection

Step 8. To resume operation, follow the

5 pin

blower harness connection

3 pin thermal well connection

Route wires through relief opening

Gas control Tabs

per the illustration.

Restore gas supply and check for gas leaks.

instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Flammable Vapor Sensor

Page 27

PDX Series

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-meter set 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.

PDX SERVICE PROCEDURE VII

Flammable Vapors Sensor Testing

Flammable Vapor Sensor

Multi-meter set to

ohms setting

Electronic

“pin type” Meter Probes

DO NOT use standard multimeter probes for this test. Doing

CAUTION

so will damage connector. Use special electronic “pin type” probes or small diameter wire pins inserted into connector.

Flammable Vapor Sensor

Page 28

PDX Series

PDX SERVICE PROCEDURE VIII

Safety Circuit Voltage Trace

NOTE: This procedure assumes a cool tank.

Step 2. Remove three screws (Phillips Screw driver) from control

access cover on blower and remove cover (see photo 24).

Position gas control switch to the “ON”

position and adjust thermostat dial to call

for heat, Is there 10 to 13 VAC between red

wire leading to blower temperature switch

and green ground wire?

Blower must be running during this

voltage check. (see photo 25)

Is there 10 to 13 VAC between yellow wire

leading from pressure switch and green

ground wire?

(see photo 25)

Is LED on gas valve flashing the

“heartbeat” code (alternating

Verify 120VAC to gas

control (see page 30)

bright/dim)

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

WARNING

No voltage from gas control,

call for technical support.

Is there continuity

through blower

temperature switch?

(see page 21)

Check for loose or

broken wire connection

at switch terminals

Do you hear or can you see

the igniter sparking?

Safety circuit voltage is OK.

If burner does not light,

observe LED flash code on

gas valve and refer to

troubleshooting section on

page 13

Determine cause of blower

Correct igniter/

sensor problem.

Check igniter/sensor

(see page 17)

is igniter/sensor OK?

temperature switch activation

and correct.

Faulty cord set or

gas control.

Green ground wire

Red wire leading to

blower temp. switch

Yellow wire

leading from

pressure switch

Page 29

PDX Series

PDX SERVICE PROCEDURE IX

120 VAC Trace

120 VAC Circuit Trace

120 volt potential exposure. Use caution

WARNING

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

None, Control LED not

on or flashing.

Disconnect cord set as

shown in photo 26

Using a volt meter set to volts AC, is there 120VAC

across terminals shown

in photo 27 ?

Is there 120VAC across

terminals shown in

photo 28 ?

Incorrect supply

voltage polarity

LED status

Short flash, once every

four seconds.

Waiting for

call for heat.

Reconnect cord set shown in photo 26.

Disconnect wire harness

from gas control

(see photo 29).

LED status

“Heartbeat”, alternates

bright/dim.

Thermostat calling

for heat

Check for damage to AC

supply power cord.

Replace Blower

Wire harness

LED status

Various flashing error

codes.

Verify error code as

listed on page 12

Repair damage

Locate black & white wires at connector, It

may be necessary to pull back wire sheath

to identify wire colors.

(see photo 30)

Is there 120VAC across black & white wires as

shown in photo 30?

Call for technical

support.

Replace gas

control.

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 30

PDX Series

Dip Tube Inspection and Replacement

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.

PDX SERVICE PROCEDURE X

Dip Tube

Inspection and replacement

WARNING

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

Hydro-jet slots 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 31

PDX Series

Anode Inspection and Replacement

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.

PDX SERVICE PROCEDURE XI

Anode

Inspection and replacement

WARNING

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.

Page 32

PDX Series

PDX SERVICE PROCEDURE XII

Flue Baffle

Inspection and replacement

Remove blower to gain access to

Disconnect vent system

from exhaust adapter.

flue baffle

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 31).

Step 5. Remove the three blower mounting screws

(¼" nut driver) (see photo 31).

Step 6. Remove blower with gasket from water heater.

Step 7. Remove flue baffle from Heater (see photo 33).

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 34 & 35).

Step 10. Check Burner to insure no scale has accumulated during this

operation. See burner cleaning procedure on page 15.

Blower

Cord Sets

Remove support

bracket

Blower Mounting

Screws

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.

Flue Baffle

34 35

Flue tube

notch

Baffle shown

installed in flue

tube notch.

Page 33

PDX SERVICE PROCEDURE XIII

PDX Series

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 34

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 around the 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 35

PDX SERVICE PROCEDURE XIII

PDX Series

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 36

PDX Series

Frozen intake or exhaust vent terminal

If an intake or exhaust vent terminal is blocked with ice or snow due to severe conditions, the pressure switch and control will not allow the burner to operate. This will result in a three flash error code. Once the blockage is removed (through melting or other means) the controls will let the burner operate. The position of the vent terminals in relation to each other and terminals from other appliances can have an effect on the potential for blockage due to ice or snow. See the installation instructions for recommended positioning of the terminals.

Testing under severe conditions has shown that the optional concentric vent terminal is resistant to ice blockage. Contact Bradford White or the supplier of the water heater for information about ordering the optional concentric vent terminal.

Bradford White has also developed an air intake relief device that can be installed in the air intake near the water heater temporarily enabling the water heater to operate with a frozen intake terminal. Contact Bradford White or the supplier of the water heater for information about the air intake relief device.

Page 37

PDX Series

BTU British Thermal Units GPM Gallons per Minute Hz Hertz

KW/h Killo-watts per 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

Glossary of Terms

NOTES

Page 38

PDX Series

Parts List

1. Blower Assembly

2. Blower Temp. Switch

3. Pressure Switch

4. Blower Gasket

5. Tee and Vent Pipe Assy.

6. Vent Adapter with Term.

7. Intake Terminal

8. Vent Terminal Elbow

9. Exhaust Adapter

10. Condensate Hose Kit

11. Flue Reducer

12. Heat Trap Insert (outlet)

13. Heat Trap Insert (inlet)

14. Hot Water Outlet Anode

15. Cold Water Inlet Diptube

16. Flue Baffle

17. Blower Harness

18. T&P Relief Valve

19. ¾ NPT PLUg

20. Direct Vent Boot

Escutcheon

21. Air Intake Boot

22. Air Intake Boot Gasket

23. Outer Door

24. Right Side Inner Door

25. Left Side Inner Door

26. Screw-#10-12 x ¾ HWH

27. Screw-#8-18 x ¾ HWH

28. Brass Drain Valve

29. Flammable Vapor Sensor

30. Sensor Harness

31. Flammable Vapor Sensor Clip

32. Thermal Well

33. Gas Control Kit

34. Gas Control Service tool

35. Gas Control

6. Gas

37. Gas BN burner (Nat.)

38. Main Burner Orifice (Nat.)

39. Gas Pilot Assembly (Nat.)

40. Gas Pilot Orifice (Nat.)

Burner Assy (Nat.)

41. Gas Feedline (Nat.)

42. Gas Burner Assy (L.P.)

43. Cast Iron Burner (L.P.)

44. Gas Pilot Assy (L.P.)

45. Gas Pilot Orifice (L.P.)

46. Air Shutter (L.P.)

47. LP Gas Feedline (L.P.)

48. Air Shutter Nut (L.P.)

49. Main Burner Orifice (L.P.)

50. Inner Door Gasket

51. Heat Trap Insert kit

52. Mixing Valve

Page 39

Honeywell PDX50S60F-B-S-C-N-X, PDX450SF-BN-SX, PDX65S65F-B-S-C-N-X, PDX275TF-BN-SX-CX, PDX150SF-BN-SX-CX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual