Bradford White PDV80S150 Service 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)
PDV80S150
PDV802200
PDV80S250
PDV100S150
PDV100S200
PDV100S250
PDV80T300
PDV100T360
D80T725
D65T625
(PDV80S Shown)
Manual 48061A
Save this manual for future reference
Table of Contents
Page
PDV Service Procedure
Introduction
4
---
Tool required for service
4
---
Sequence of Operation
6
---
Troubleshooting
7
---
Thermostat Circuit Testing
24
PDV24-I
Pressure Switch Testing
27
PDV24-II
Pilot Operation Testing
30
PDV24-III
Main Burner Operation Testing
33
PDV24-IV
Main Burner & Pilot Removal & Inspection
35
PDV24-V
Control Board Replacement
40
PDV24-VI
Flue Baffle Removal & Inspection
41
PDV24-VII
Anode Removal & Inspection
42
PDV24-VIII
Generic Parts List - PDV-S
43
---
Generic Parts List - PDV-T
46
---
Generic Parts List - Induced Draft Models
49
---
Glossary of Terms
52
---
2
FEATURES OF PDV-S MODEL SERIES
Power vented direct vent design, uses a blower to vent the flue products to the outside and pull combustion air in
from outside the building
Independent Venting - Exhausts flue products and supplies combustion air through two separate 3" or 4" PVC,
CPVC or ABS pipes. Maximum venting distance of 40 ft. with one 90 degree elbow for each pipe in 3". The
250,000 Btu/hr. model vents with 4" PVC, CPVC, or ABS only. Maximum vent length is 55 feet with one 90
degree elbow in 4" pipe (each pipe) for all models.
Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control system.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermostat and LCD Display - Accurately monitors the tank temperature and the setpoint is easily
adjusted by using the temperature UP and DOWN buttons on the display on the control box cover.
FEATURES OF PDV-T MODEL SERIES
Power vented direct vent design, uses a blower to vent the flue products to the outside and pull combustion air in
from outside the building
Co-axial Venting (pipe inside a pipe) - Combustion air enters from outside the building through an outer pipe and
exhausts flue products through the inside pipe. May be vertically or horizontally vented with a maximum venting
distance of 19'-6" (19 feet, 6 inches) with one 90 degree elbow.
Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control system.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermostat and LCD Display - Accurately monitors the tank temperature and the setpoint is easily
adjusted by using the temperature UP and DOWN buttons on the display on the control box cover.
FEATURES OF INDUCED DRAFT MODELS
High Capacity power vented design, uses a blower to pull the flue products out the water heater. Designed to
vent vertically through 8 inch diameter type B venting system. Uses room air for combustion.
Electronic ignition - Pilot is automatically lit and monitored by the Honeywell Integrated Ignition Control System.
Main burners light from the pilot. Pilot and main burners shut off at the end of each water heating cycle.
Electronic thermostat and LCD Water Heater Control Display - Accurately monitors the tank temperature and the
setpoint and is easily adjusted by using the temperature UP and DOWN buttons on the display on the control box
cover.
FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM
Attractive digital water heater display on control panel for setting and displaying the temperature
setpoint. Pressing temperature up and down buttons changes the temperature setpoint. Same
water heater display used on all models. Temperature format may be displayed in degrees F or
degrees C.
Single control board with plug in wiring controls temperature, ignition, and blower operation.
Reduced number of parts for servicing and wiring.
Plug in wiring reduces chance of miswiring.
Water heater display will show diagnostic codes in the event the water heater needs servicing.
Aids in diagnosing and servicing the water heater.
Water heater display can show previous error code history to further aid in servicing the water
heater.
3
Introduction
It is intended for this manual to be used by qualified service personal for the primary purpose of
troubleshooting analysis and repair of the Bradford White PDV & Induced Draft Series Water
Heaters. Understanding the sequence of operation section of this manual will contribute greatly to
troubleshooting this product.
Troubleshooting begins by noting the error code, if any, on the water heater control display and
finding the section in this service manual for diagnosing the problem for this error code. This step
by step procedure beginning on page 5 will direct the service provider to a series of test
procedures to determine root cause of failure.
Contact Technical support immediately if diagnosis is not determined using the methods described
in this service manual.
Tools Required for Service
Manometer:
Two types available, a liquid “U” tube type or a digital (magna-helic)
type. This device is used to measure gas and/or air pressures and
vacuum.
Multi-Meter:
A digital type is strongly recommended. This device is used to measure
electrical values. The meter you select must have the capability to
measure volts AC, volts DC, Amps, micro-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
Dedicated 120 VAC, 60 Hz., 15 A
Current Draw
Less than 5 Amps
Gas Supply Connection
Approved Gas Type
Gas Pressure (Nat. & L.P.)
PDV-S & PDV-T MODELS: 3/4" NPT Minimum connection to gas valve.
INDUCED DRAFT MODELS: 1" NPT Minimum conncection to gas valve.
Schedule 40 black iron pipe recommended for all models.
Natural or Propane. Gas supply must match the gas type listed on the
water heater rating label.
Manifold Pressure: 4.5" w.c. natural gas, 10.0" w.c. L.P.
Gas Supply Pressure: At least 1" above manifold pressure with water heater
operating, 14" w.c. maximum
PDV-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. models.
Refer to the installation instruction manual for further information on venting
lengths and installation requirements.
Venting System
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 (200mm diam.)
and exhausts flue products through the inside pipe (130mm diam.). Refer to
the installation instruction manual for further information on venting lengths
and installation requirements.
INDUCED DRAFT MODELS:
Connect 8” vent to blower vent collar for venting through a chimney or type
B vent only. Vertical venting only.
Minimum Clearance for Servicing 30" Front Clearance, 16" Top, 2" Sides and Rear
Maximum Water Supply Pressure 150 PSI
Thermostat Sensor(s)
Control Board
Control Display
Transformer
Pilot
Induced Draft Blower
Redundant thermister with 11,900 + or - 0.5% ohms resistance at 70 deg. F.
Sensor inside well for lower sensor. PDV-T model series and Induced Draft
models also use an upper sensor (dual sensors for these models).
Honeywell Integrated Control Board for Temperature Control, Induced Draft
Blower, and Ignition Control Functions. Operates on 24 volts AC current
from transformer. Single sensor boards for PDV-S models and dual sensor
boards for PDV-T models and Induced Draft models.
Honeywell LCD Control Display with Temperature Setpoint, Format, and
Error Code Display in User Mode, Diagnostic Functions in Service Mode.
Communicates with Control Board. 24 volts AC. Same control display used
on all models.
120 VAC Primary, 24 VAC Secondary, 40 VA
Intermittent Pilot with Spark Electrode and Flame Sensor monitored by
Control Board
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
2
3
Thermostat calls for heat:
.
The relay closes on the control board, sending line voltage (115-120 volts) from “inducer” terminals #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
circuit between terminals 1 and 3 on the Control Plug to the the board, allowing the ignition sequence to proceed.
The blower “purges” any remaining combustion products from the previous cycle for 15 seconds before allowing the
pilot to light. This is the pre-purge period of the ignition cycle.
Trial for ignition (three 90 second ignition trials, with 75
second pauses between trials).
Control Board simultaneously sends:
1. 24 volts from control pin terminal #8, to “MV/PV”
terminal of gas valve (common terminal).
2. 24 volts from control pin terminal #2, to “PV”
terminal of gas valve to establish
gas flow at pilot.
3. Low current high voltage from “spark”
terminal, to generate spark at the pilot and
ignite pilot gas flow.
4
5
4. Pilot flame proving signal (measured in
micro-amps). from the “sense” terminal, to
prove pilot flame.
Once pilot flame is proven, sparking will stop.
Once sparking stops, 24 volts is sent from control pin
terminal #5 on control board, to “MV” terminal on gas valve
to establish main burner gas flow. Main burners ignite from
the pilot flame.
The control board constantly monitors pilot flame through
the flame sensor rod. If pilot flame is lost, pilot and main
burners are shut down. After a 75 second inter-purge
period, the control will attempt to re-light the pilot beginning
at sequence 3 above.
7
8
Main burner fires until the thermostat is satisfied. The control
board interrupts 24 volts through the gas valve circuit. Pilot
and main burners are turned off.
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 error code number (62 or 63) with
WIRING DIAGRAM
“Service Needed” in the display window. Refer to error codes in the
diagnostic section of this Service Manual. In a “Soft Lockout” condition,
the control will wait for 60 minutes and then make 2 more attempts to light the pilot and establish the main burners.
Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3 seconds.
If the water heater should reach 200 degrees F, then the high limit control will shut off the burners and the water heater will
go into a “Hard Lockout”. Error code 65 will be shown in the water heater display. The control can only be reset in the
“service mode”, which is detailed in the next section of this Service Manual.
If the exhaust or intake terminals become blocked during operation or if the blower motor fails, the pressure switch will open
and error code 29 will appear in the display. When the condition is corrected, the error code will disappear and the water
heater will resume normal operation. No resetting of the control display is needed for the pressure switch error code.
6
TROUBLESHOOTING
CAUTION
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals
Water Heater Fault: Water heater does not operate
Display Error Code: Water heater display does not operate - blank display
Check main power supply to water
heater - fuse, circuit breaker, plug
receptacle, line cord or wiring to
water heater.
Check to make sure switch on top of
control panel is in the ON position
Checking line voltage to board.
Pins to black and white wires.
Checking primary voltage to
transformer from board. Pins to
black and white wires.
Voltage at primary pins 1&3 should be
110-120. If not, check Line In pins 1&4.
Check line cord with volt meter.
Replace line cord if defective.
Verify Primary and Secondary
voltage at the control board.
If there is not 24 volts at Secondary
pins on the control board, check
transformer. Replace transformer
or wire harness.
Switch on power.
Does water heater display operate?
Does the induced draft blower start
to operate? Increase thermostat
setting if tank is warm.
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.
N
See next page
If no voltage at Display, check wire
harnesses and voltage at E-com
screw terminals on the Control Board.
Replace control display if voltage is
present at back of display pin terminals
(see photo at left). Replace control board if
no voltage is present at E-com terminals
(1&3 and 1&2) to the control display.
7
TROUBLESHOOTING
CAUTION
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals
From previous page
Error code #29 on display. Measure voltage at the pin
terminals on the control board between the black and white
wires to the blower (terminals 5 and 3 on the “inducer”
output on the board, see image 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?
N
Does induced draft blower
operate?
Y
N
Is there pilot flame?
Y
N
Error code #29 on display. Pressure switch did not close. Check for
blocked intake or exhaust vents, damper stuck closed, or excessive
vent length. See section on “Checking Pressure Switch”. If pressure
switch closes, and error code 62 appears on control display, pilot is not
lighting or staying lit during the ignition cycle. Proceed to the section
“Pilot Operation Testing”
N
Does Main Burner operate?
Error code #62 on display. See pilot lights, no flame
signal in the section for “Pilot Operation Testing”
Replace control board if display
shows “heating” and no voltage is
present to the blower harness.
Make sure there are no codes for
the temperature sensors
(following sections) before
replacing control board.
If there is voltage from the
control board to the blower wire
harness? Check the voltage at
the connection to the blower.
Replace wire harness if there is
no voltage to the blower.
Replace blower, if there is
voltage to the blower.
Y
Does burner continue until
thermostat set point is reached?
See setting display in Service Mode
and displaying temperature
sensors.
N
Error code #63 on display. See Main Burner short
cycles in the section under “Main Burner Operation
Testing”
Y
Blower Stops shortly after burners
shut off.
Y
Error Code Shown
in Water Heater Display
System okay
Status Service Needed
SELECT
Lockout RESET
Example of error code shown on control display.
8
ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)
The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the
water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps
illustrated below:
Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the
display.
"Max Setpoint”
next to Temperature
Setpoint value.
Max
Setpoint
idle
Statu Operational
s
SELECT
SET
Step 2: Pressing “Select” button will change display to next mode
°F
Water
Temp
idle
Status Operational
SELECT
SET
The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:
Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.
Error Code Shown
in Water Heater Display
Status Service Needed
SELECT
Lockout RESET
9
1. Max Setpoint (Display/Change)
Max Setpoint value in
Water Heater Display
°F
Max
Setpoint
idle
Status Operational
E
SELECT
SET
2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single
sensor is used).
°F
Water Temp
idle
Status Operational
SELECT
SET
2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models)
°F
idle
Status Operational
Upper Sensor
SELECT
SET
2c. Water Temperature - Lower Sensor (Displays if there are two sensors)
°F
idle
Status Operational
Lower Sensor
SELECT
SET
10
3.
Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)
µA
Heating
Status
Flame Current
Operational
SELECT
SET
4. Setpoint (Display/Change)
°F
setpoint
idle
Status Operational
SELECT
5.
SET
°F/°C (Display/Change)
°F
°F/C°
setpoint
idle
Status Operational
SELECT
6.
SET
Differential (Display only - shows the differential of the thermostat)
°F Differential
idle
Status Operational
SELECT
SET
11
7. Software Version (Display only)
Soft
idle
Status
Operational
SELECT
8.
SET
Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater
Display will show a “--“ if there are no error codes.
idle
Status Operational
SELECT
SET
To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:
Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.
WARNING
Setting the water temperature
to the maximum set point can
result in scalding hot water
delivered to the faucets. It is
highly recommended that the
maximum setpoint be adjusted
to the lowest temperature
possible for the needs of the
installation. Make sure the
water heater control display is
not in a public area that can
re su lt in t h e t emp era t ur e
set ti ngs bei ng improp erly
adjusted.
°F
Max
Setpoint
idle
Status Operational
SELECT
SET
12
Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.
Max
Setpoint
°F
idle
Status Operational
SELECT
SET
Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint
the user can select. Note: The maximum setpoint is approximately 180°F.
"Max Setpoint" continues to flash
while making adjustments
Max
Setpoint
°F
idle
Status Operational
SELECT
SET
D
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
"Max Setpoint" stops flashing
°F
Max
Setpoint
idle
Status Operational
SELECT
D
SET
13
Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max
Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water
Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select”
buttons together for 3 seconds.
Max
Setpoint
idle
Status Operational
E
SELECT
SET
D
Exiting Service Mode
Display of Water Temperature:
Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the
water heater display. For water heaters using two temperature sensors in the tank, this will be the average reading
between the two sensors. For water heaters using a single sensor, this is the reading for the sensor.
°F
Water
Temp
idle
Status Operational
Upper Sensor
SELECT
SET
Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper
Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the
water heater display.
°F
idle
Status Operational
Upper Sensor
SELECT
SET
14
Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor
temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater
display.
°F
idle
Status Operational
Lower Sensor
SELECT
SET
To Display Flame Sense Current of the Pilot Flame Sensor:
The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays
“Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3:
Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value
displayed is in microamps (µA).
Flame
Current
µA
Heating
Status Operational
SELECT
SET
To Display and Change Temperature Setpoint:
Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display
°F
setpoint
idle
Status Operational
SELECT
SET
15
Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.
°F
setpoint
idle
Status Operational
SELECT
SET
Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on
the water heater display.
NOTICE
The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint” described
previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint Limit…"
described previously under “Accessing the Service Mode on the Water Heater Display”.
WARNING
Setting the water temperature
to the maximum set point can
result in scalding hot water
delivered to the faucets. It is
highly recommended that the
maximum setpoint be adjusted
to the lowest temperature
possible for the needs of the
installation. Make sure the
water heater control display is
not in a public area that can
re su lt in t h e t emp era t ur e
set ti ngs bei ng improp erly
adjusted.
°F
setpoint
idle
Status Operational
SELECT
SET
D
Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown
on the water heater display.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational
SELECT
SET
16
Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new
setpoint. “Setpoint” stops flashing in the water heater display.
°F
setpoint
idle
Status Operational
SELECT
SET
To Display and Change Temperature Format (°F/°C):
To Change Temperature Format in Display from °F to °C or °C to °F:
Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right po rtion of the water heater
display.
°F
°F/C°
idle
Status Operational
SELECT
SET
Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will fl ash in the water heater display.
°F
°F/C°
idle
Status Operational
SELECT
SET
17
Step 3a: Press “Temperature Up” button to change temperature format to °C
°C °F/C°
idle
Status Operational
SELECT
SET
D
Step 3b: Press “Temperature Down” button to change temperature format to °F
°F
°F/C°
idle
Status Operational
SELECT
SET
Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing
°F °F/C°
idle
Status Operational
SELECT
SET
18
Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately
°F
idle
Status Operational
Lower Sensor
SELECT
SET
Error Codes and Error History Display:
If there is an operating problem with the water heater, an error code number will appear on the water heater display with
“Service Needed” to the right of the “Status” indicator. The error code label is located under the Water Heater Display
and the following section in this Service Manual explains the error codes with corrective actions to repair the water
heater.
Example of Error Code in the Display
idle
Service Needed
SELECT
SET
Error Code History:
In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence
of service modes) will show an error code history, if there have been any previous operating problems with the water
heater. If the display shows --, there is not a current error code.
The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index
#1 and the most recent in code index #10.
19
To view previous error codes:
Step 1:
In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current
error codes, the display will show -- .
°F
idle
Status Operational
SELECT
SET
Step 2:
Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.
idle
Status Operational
SELECT
SET
D
Step 3:
Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is.
The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the
water heater display, then there has not been an error code for error code index 10.
idle
Status
Operational
SELECT
SET
20
Step 4:
Press the “Temperature Down” button to change to the previous code index, code #9.
idle
Status Operational
SELECT
SET
D
Step 5:
Press the “Select” button for code index #9 to view if there are any code numbers.
idle
Status Operational
SELECT
SET
Step 6:
Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the
error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water
heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in
code index #10.
Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code
display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.
°F
setpoint
idle
Statu Operational
s
E
SELECT
SET
D
Exiting Service Mode
21
ERROR CODE DEFINITIONS
If the water heater has an operating problem, there will be a number in the water heater display with
“Service Needed” shown below the error code number. Note the error code and the definition in the
chart below. This label appears on the control box under the water heater display. The following
sections will provide instructions for servicing each error code.
22
WARNING
The following procedure is for service and installation personnel only. Resetting lockout
conditions without correcting the malfunction can result in a hazardous condition.
If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition”
with the water heater display showing the error code number and “Service Needed” in the status section of the
display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition
recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower
right button under “Lockout Reset” shown in the lower right portion of the display. The control will also go through 3
attempts to relight the burners every hour in the soft lockout condition.
Error Code Shown in
Water Heater Display
Status
Service needed
SELECT
D
Lockout RESET
Press for 2 seconds
All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not
operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described
earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the
lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.
Resetting Error Codes in Hard Lockout Condition
Error Code Shown in
Water Heater Display
Status Service Needed
E
SELECT
SET
D
Status Service Needed
SELECT
Lockout RESET
Step 2: Press for 3 seconds to
reset control in service mode.
Step 1: Press for 3 seconds
to enter service mode.
23
SERVICE PROCEDURE PDV24-I
Thermostat Circuit Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Measuring upper
sensor resistance
through wire
harness
(disconnected at
control board).
Condition: Water Heater Not Operating
Display shows error code “31” (Upper Sensor
Readings Faulty) or error code “32” (Lower Sensor
Readings Faulty)
Unplug or disconnect electrical power to the water heater
Check continuity of wire harness to affected sensor. Measurement
of ohmeter should be close to 0 ohms. Replace wire harness if high
resistance is measured (over 0.5 ohms) Check wires for intermittent
connections, shorts, frayed insulation. Replace if necessary
Checking
continuity of
upper sensor wire
harness.
If wire harness checks out O.K., check sensor resistance detailed in
the section for testing sensor resistance. Replace the upper or
lower sensor as indicated by error code number.
Turn power on to water heater.
Run water heater through heating cycle and verify proper operation.
Sensor temperature can be viewed when burner shuts off (see
section on viewing the display in “Service Mode”.
Removing lower
sensor from well.
Held in place by a
clip fastened to
well shoulder.
Condition: Water Heater Not Operating
Display shows error code “65”
High Water Temperature (over 200 deg. F)
WARNING
Do not reset the display from the hard lockout
state without correcting the cause of the
overheating condition
Turn power “OFF”.
Draw water to cool tank below 120 deg. F
N
Check lower sensor. Is the sensor fully inserted into the well?
Sensor is held in place with a clip fastened to the well (see photo )
Check lower sensor wire making sure it is not damaged or has
breaks in the wire insulation. Check upper harness wires to upper
sensor, if used (some models).
Y
24
If sensor clip is damaged
replace clip. Replace lower
sensor if damaged.
Check Sensor Resistance
(See Sensor Resistance
Testing, following section)
See next page
SERVICE PROCEDURE PDV24-I
Thermostat Circuit Testing
WARNING!
Do not operate water heater without verifying that the overheating condition has been corrected.
Condition: Water Heater Not Operating
Display shows error code “65”
High Water Temperature (over 200 deg. F)
Continued
Once cause of overheating condition has been diagnosed
and corrected, the control may be reset
Reconnect and switch on power to the water heater.
Enter service mode on the water heater display (see illustration)
Press button under “Lockout Reset” and hold for 3 seconds.
Set thermostat to the desired setting.
Water heater should start.
Monitor temperatures for one complete heating cycle making
sure the maximum tank temperature remains well below 200 deg. F
25
SERVICE PROCEDURE PDV24-I
Thermostat Circuit Testing
Conditions: Upper or Lower Sensor Reading
Faulty, High Water Temperature, or suspect
thermostat is not accurate.
Sensor Resistance Testing
Upper Sensor
1. Determine resistance value of upper sensor using an
ohmeter. Test across grey wires.
Upper thermister location
(applicable models)
2. Draw quart of water off T&P valve. Using a thermometer,
determine water temperature.
3. Use table below to verify correct resistance per water
temperature measured.
Lower Sensor:
1. Determine resistance value of lower sensor. Test across
center wire (common) to each outside wire. Resistance of both
thermistors in the lower sensor should be close to each other.
If the resistance values for both thermistors are not close to
each other, replace the lower sensor. The dual thermistors are
used to provide high limit protection in case the thermostat
circuit fails to shut off the water heater.
Checking resistance of
upper sensor
Lower thermister
access located inside
control box.
2. Draw quart of water off Drain Valve. Using a thermometer,
determine water temperature.
3. Use table below to verify correct resistance per water
temperature measured.
Are readings
correct?
N
Replace
thermister
Checking resistance of
lower sensor (center and
outside pins)
Y
Check harness
N
continuity.
Continuity okay?
Replace
harness
CAUTION
Be Careful When Making Resistance
Measurements Not to Damage or
Deform Connectors or Connector Pins.
Y
Replace
control board
Sensor Resistance at Various Temperatures
Example: If water temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area).
NOTE: Sensor resistance increases as the temperature falls.
°F
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
0
26109
19906
15314
11884
9299
7333
5827
4663
3758
3048
2488
2043
1688
1402
1170
982
828
1
25400
19383
14925
11592
9078
7165
5697
4562
3679
2986
2439
2004
1656
1376
1150
965
814
2
24712
18876
14548
11308
8862
7000
5570
4464
3602
2925
2391
1966
1625
1351
1129
949
801
3
24045
18383
14180
11032
8653
6839
5446
4368
3527
2866
2344
1928
1595
1327
1110
933
788
In Degrees
4
23399
17905
13823
10763
8449
6683
5326
4274
3453
2808
2298
1891
1566
1303
1090
917
775
26
F
5
22771
17440
13477
10502
8250
6531
5208
4183
3382
2752
2253
1856
1537
1280
1071
901
762
6
22163
16990
13140
10248
8057
6383
5094
4094
3312
2697
2209
1820
1509
1257
1053
886
749
7
21573
16553
12812
10000
7869
6238
4982
4006
3244
2643
2166
1786
1481
1235
1035
871
737
8
21000
16128
12494
9760
7685
6098
4873
3922
3177
2590
2124
1753
1454
1213
1017
857
725
9
20445
15715
12185
9526
7507
5961
4767
3839
3112
2538
2083
1720
1427
1191
999
842
713
SERVICE PROCEDURE PDV23-II
Pressure Switch Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition: Blower operates, burners not lit.
Display shows error code “29” (Pressure Switch
Failed to Close).
Connect a digital manometer to the tubing for the pressure
switches and determine the average reading. See table at
right for pressure switch settings and minimum readings
required. Is the pressure switch reading at least 0.20"
above the switch reading for the model tested (see chart at
right)?
Check intake and exhaust vent terminals outside the
building. Is there any blockage from debris (leaves, ice,
snow, paper, etc.). If so, clear intake or exhaust vent
terminals. Pressure switch should close and the burners
should fire.
Check the total equivalent vent length by adding up the
total number of elbows and the straight lengths of vent pipe
for the intake and exhaust pipe (or coaxial vent pipe for
PDV-T model series). See table at right for maximum
distances. If the venting distance is excessive, reduce the
number of elbows or route the vent terminals to a shorter
distance outside the building.
If the venting system and vent terminals are O.K., but the
pressure switch reading is still low, check the pressure
switch tubing to make sure there are no small holes or
kinks. Make sure there are no drops of condensate in the
tubing. Check the pressure switch tubing connection fitting
and pressure tap to make sure it is not clogged with dirt.
Blow through tubing to verify that the pressure taps and
tubing are clear and not leaking.
Minimum Differential Dual Tap Pressure Switch Settings:
(Contacts open)
PDV80S,100S-150 models:
-2.00" w.c.
PDV80S,100S-200 models:
-1.20" w.c.
PDV80S,100S-250 models:
-2.00" w.c.
PDV80T300 models:
-1.20" w.c.
PDV100T360 models:
-0.60" w.c.
Note: During normal hot running conditions, the
pressure switch readings should be at least 0.20" higher
than the above readings where the pressure switch will
open.
PDV80,100S-150,200 Models with 3" PVC vent: Maximum
Distance of 40 feet with one 90 deg. elbow for intake or
exhaust (subtract 5 feet for each additional elbow).
For venting with 4" PVC vent: Maximum distance of 55 feet
with one 90 deg. elbow for intake or exhaust (subtract 5
feet for each additional elbow).
PDV80S,100S-250 Models with 4" PVC vent: Maximum
distance of 55 feet with one 90 deg. elbow for intake or
exhaust (subtract 5 feet for each additional elbow).
PDV80T300, PDV100T360 Models with coaxial venting
system: Maximum venting distance of 19 feet 6 inches
with one 90 deg. elbow. Each additional elbow reduces
the venting distance by 39".
See installation instruction manuals supplied with the
water heater for further details on proper venting
installations.
PDV-S MODELS: Check the vent safety thermal switch
near the outlet of the blower (see photo at right). Press the
red reset button. (See photo on next page). If you feel a
slight click, the temperature was excessive and the switch
opened. Check to be sure the burner access screws are
tight and the gasket is in good condition (see section on
servicing the burners)
If the pressure switch readings are at least 0.20" w.c.
above the above pressure switch settings for the installed
model and the switch does not close, then replace the
pressure switch with the same setpoint.
27
Checking pressure switch contacts.
Contacts are open if blower is
operating and there is 22-26 volts
measured between the two contacts
(as in photos)
SERVICE PROCEDURE PDV24-II
Pressure Switch Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
PDV(S & T) Models
Vent Safety Switch (PDV-S Models Only)
Red reset button
Vent safety thermal switch on PDV-S blower. Depress red
reset button in center of switch. If a slight click is felt, switch
opened. Check for loose or leaking burner access panel (see
section on servicing burners)
Check pressure switch tubing to the pressure switch. Make
sure tubing does not have kinks, holes, condensate, or dirt
blocking air pressure to the switch. The tubing to the
blower tap attaches to the - (minus) tap on the pressure
switch.
Induced Draft Models (D80T725 & D65T625):
Induced Draft Models use a single tap pressure switch to
measure vacuum in the flue collector. The pressure
switch is located inside the control box (see photo to left).
Connect a digital manometer to a tee in the pressure
switch tubing and measure the vacuum with the blower
operating. The vacuum should be in the range of -1.70"
to -2.10" w.c. The pressure switch contacts will open at
-1.25" and close by -1.40" w.c. If the vacuum is below 1.50", check to make sure the flue damper is fully open
when the blower is operating. Make sure the damper and
rod are not binding. Make sure there are no restrictions
in the venting system and that is at least 8" in diameter.
Venting is for vertical gravity venting only. Insure that
there is sufficient combustion air to the utility room.
28
SERVICE PROCEDURE PDV24-II
Pressure Switch Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition: Blower does not operate, burners not lit.
Display shows error code “29” (Pressure Switch
Failed to Close ).
With a voltmeter, check to make sure the “line in” connection
to the control board has 110-120 volts. Make sure the
secondary plug from the transformer to the board has 24
volts at the yellow and blue wire pin terminals (see photos to
right).
Make sure the water heater control display shows “Heating”
in the status window. Raise the setpoint if needed. If there
is no call for heat and the setpoint is well above the tank
temperature, refer to the thermostat troubleshooting and
replacement section.
If the water heater control display shows “Heating” and the
blower is off, Error code 29, then check the voltage output at
the blower plug on the board. Should read 110-120 volts
between the black and white wires to the blower (terminals 5
and 3 on the inducer output on the control board, see
illustration to the right).
Checking line voltage to board.
Pins to black and white wires.
Checking secondary
voltage from transformer.
Pins to blue and yellow
wires.
If there is voltage between the black and white wires to the
blower plug on the board, then check the voltage at the
blower connection on the blower (see photo at right). If no
voltage is present, replace the wire harness. If there is 110120 volts, replace the blower.
Condition: Blower does not operate, burners not lit.
Display shows error code “2” (Pressure Switch
Failed to Open - Stuck Closed).
Disconnect power and remove the pressure switch cover
(previous photo-PDV models). Disconnect wires on the
pressure switch. Measure continuity on the pressure switch
terminals with an ohmeter. If there is continuity, the pressure
switch is stuck closed. Make sure pressure switch has not
been bypassed (jumpered). The control will not operate with
a jumpered pressure switch.
Checking line voltage at the
blower wire harness connection
on blower.
If pressure switch contacts are stuck closed, check the
pressure switch tubing for condensate, dirt, or kinks. If the
tubing is O.K., replace the pressure switch with the same
setting.
Reconnect power. Verify
proper operation.
If there is no voltage on the control board to the blower
plug and the control display shows “Heating”, then
replace the control board.
29
SERVICE PROCEDURE PDV24-III
Pilot Operation Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition:
Pilot will not light or stay lit,
Error codes 62, or 63 shown on Water
Heater Display
Reset control by pressing the lower
right button under “reset” on the
display for 3 seconds. Does control
board start ignition sequence and
start sparking (sparking noise at pilot
or at board)
Checking for 24
volts output to
pilot valve
(yellow and red
wire pin
terminals on
control board
“control” plug.
N
Replace control board
Y
N
Is there spark at the pilot?
Check across “MV/PV” & “PV” Wire
leads to gas valve
Check for:
Loose or damaged ignition wire
Grounded pilot electrode
Damaged pilot.
Y
Is there 22-27 volts AC output across
terminal pins 8 & 2 on “Control” plug
of Control Board? Carefully insert
meter probe in wire plug to check pin
terminals. Make sure control is in the
trial for ignition sequence (see
sequence of operation).
(see photo at top of page)
N
Replace control board.
Y
Is there 22-27 volts AC input across
wire leads
“MV/PV” & “PV”
at Gas Valve?
(see photo to the right)
N
Check wire harness for damage or
loose connections. Repair or replace
as needed.
Y
Loosen pilot tubing connection at
the gas valve and soap test.
Is there pilot gas flow out of the
gas valve? See pilot illustration
for pilot inspection.
Y
Check for clogged or kinked pilot
tube, clogged pilot orifice. Clean
or replace as needed.
(see photo below)
N
Flame
Rod
Tighten pilot tube connection at
the gas valve. Check incoming
gas pressure to water heater. if
okay, replace gas valve
Ceramic
Insulators
Turn on power to the water heater
and verify proper operation
Pilot
Orifice
Ignition
Wire
Checking MV
pin terminal to
gas valve wire
harness for 24
volts output to
gas valve during
heating cycle
(pilot must be lit
with no
sparking).
7//16"
ferrule
Nut
Flame Sense
Wire
Aluminum
Pilot Tubing
30
SERVICE PROCEDURE PDV24-III
Pilot Operation Testing
Condition:
Error code 57: Flame Rod Shorted
to Ground
Disconnect power. Shut off gas
supply to water heater. Slide out
burner assembly. See section on
removing pilot and main burner
assembly.
Check to see if pilot shield is touching
pilot flame sensor or flame sensor
touching pilot hood. Bend shield to
prevent interference.
Check pilot flame sense wire for
broken insulation. Replace pilot if
defective
Make sure pilot shield
clears flame sense rod
Reinstall pilot and burner assembly.
Reconnect gas line union, turn on
gas. Reconnect power and verify
proper ignitions.
31
SERVICE PROCEDURE PDV24-III
Pilot Operation Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition:
Pilot lights, no or low flame signal. Control
Display shows “4” or “62” for Error Codes
(Service Needed). Control continues to spark
until system “Lock Out”.
Main burner will not light.
Check for loose or damaged flame sense
lead from pilot to module. (see illustration to
the right). Is flame sense lead okay?
Meter
Probe
Repair wire lead
or replace pilot.
N
Flame rod
Multi-meter set
to check
continuity.
Y
Check for loose or damaged ground wire(s)
from gas valve to control board. Check
continuity of wires with ohmeter. Are ground
wires okay?
Repair ground
wire(s) or replace
as needed.
N
Y
Meter
Probe
Check venting conditions
(vent length & number of elbows)
Is vent system okay?
Correct improper
venting condition.
N
Checking pilot flame sensor wire and flame
rod for continuity.
Y
Is heater condensing causing pilot
interruption?
N
Y
Make sure pilot shield is in
place and not bent or damaged
(refer to section on main burner
and pilot assembly) .
Determine cause for
condensing and correct.
Under sized water heater or
high demand periods
µA
Heating
Status
The microamp output of the pilot may be
checked by entering “Service Mode” on the
water heater display and pressing “Select”
until the flame current is shown. The control
must be in the heating mode with the pilot lit
to display a reading. See section on
accessing service mode on the water heater
display.
NOTE:
Check continuity of flame sense
lead to flame rod. If no
continuity, clean pilot flame rod
or replace pilot. Check pilot
flame appearance - if weak
check for clogged pilot orifice,
bent pilot tubing, or low inlet
gas pressure.
(see above illustration)
Micro-amp readings
0.000 Micro Amp =
1.0 micro amp or less =
Replace control board or pilot if wire is
damaged.
Clean pilot flame rod or replace pilot.
32
Flame Current
Operational
SELECT
SET
Pilot flame sensor microamp output
shown in display using service mode.
Pilot must be lit to get reading.
SERVICE PROCEDURE PDV24-IV
Main Burner Operation Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition:
Main burner will not light,
Display shows “Heating” under temperature
setpoint.
Tank is cold.
Is Pilot lit?
N
See “pilot will not light”
in “Pilot Operation
Testing” section.
Y
Y
Does control board continue to spark with
pilot lit?
See “Pilot lights, no flame signal” in
“Pilot Operation Testing” section.
Checking MV & MV/PV control plug
pins to gas valve for 24 volts output
during heating cycle (pilot must be
lit with no sparking).
N
Disconnect control wire harness from
“Control” plug of control board.
Is there 22-27 volts AC across
pin terminals 5 & 8? Refer to wiring
diagram
(also see photo )
N
Be sure control display is showing “Heating”,
pilot is lit and control is not sparking.
Recheck voltage across control board
pin terminals 5 & 8 ((MV & MV/PV)
Is voltage present?
N
Replace control board.
Y
Y
Reconnect control plug
to control board.
Brown wire disconnected
from “MV” terminal of gas
valve
Disconnect brown wire lead from
“MV” terminal of gas valve.
Is there 22-27 volts AC across
brown wire lead & ground
Y
Check incoming gas
pressure to gas valve. if
okay,
replace gas valve.
N
Check wire harness for damage or loose
connections. Repair or replace as needed.
Checking main valve (MV) voltage to gas valve.
33
Ground lug of
gas valve
SERVICE PROCEDURE PDV24-IV
Main Burner Operation Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition:
Main burner short cycles.
Control Display may show error
code “63, 57, or 4” and be in
“Soft Lockout” state.
Check gas (line) pressure to the
water heater.
Minimum line pressure should be
5.5" W.C.
Is gas pressure within proper
specification? (see photo at right)
Line gas
pressure port
N
Determine cause of
incorrect gas
pressure and correct.
Y
Check venting conditions.
(blocked intake or exhaust
terminal, excessive vent length,
or number of elbows)
Verify pressure switch is not
cycling (see “Pressure Switch
Testing”.
Is vent system okay?
N
Correct improper
venting condition.
Manifold
Pressure Port
Connect hose barb to manifold
pressure port, then connect
monometer to measure gas manifold
pressure.
Y
Is there sufficient combustion air
being supplied to the water
heater?
PDV(S&T) MODELS: Check
intake piping and terminal.
N
Y
INDUCED DRAFT MODELS:
Make sure there is sufficient
air supply to utility room.
Check for unstable pilot flame or oxidized
flame rod on pilot causing weak pilot
signal. Make sure pilot shield is in place
and does not touch pilot flame sensor.
(see “pilot inspection”)
Check burner tubes for scale or
debris build-up. Clean burner(s)
as necessary.
(see “main burner inspection”)
Check tank flues for blockage or
debris build-up causing
restriction.
(see “flue baffle inspection”)
34
SERVICE PROCEDURE PDV24-V
Main Burner & Pilot
Removal and Inspection
WARNING
Water Heater components may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
PDV (S&T) MODELS
PDV-S MODELS
(Hinged Door)
PDV-T MODELS
(Removable Door)
Step 1: Remove burner box cover screws
Step 2: Open Burner Box Cover
Step 3: Disconnect Pilot Fitting from
Burner Box
Step 4: Disconnect gas valve wires and
pilot tube
Step 5: Disconnect and Remove Gas
Valve
Step 6: Remove pipe flange plate from
Burner Box
35
SERVICE PROCEDURE PDV24-V
Main Burner & Pilot
Removal and Inspection
WARNING
Water Heater components may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
PDV (S&T) MODELS
Step 8: Remove manifold from Burners
Step 7: Remove manifold bracket screws
Step 10: Disconnect Pilot Tube Fitting
from inside Burner Box
Step 9: Slide manifold out through side
flange opening in Burner Box
PDV-S MODELS
PDV-T MODELS
Step 12: Disconnect Pilot wires from
control board and remove from Control
Box
Step 11: Remove screw fastening burner
to burner box/burner shroud.
36
SERVICE PROCEDURE PDV24-V
Main Burner & Pilot
Removal and Inspection
WARNING
Water Heater components may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
PDV (S&T) MODELS
Step 13: Pull pilot wires through burner
box
Step 14: Slide out burner assembly
Step 15: To remove pilot, remove pilot
bracket screws
Step 16: Slide pilot assembly to back of
burner rack
Step 17: Pilot removal for servicing.
37
SERVICE PROCEDURE PDV24-V
Main Burner & Pilot
Removal and Inspection
WARNING
Water Heater components may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
INDUCED DRAFT MODELS
Gas Valve
Control Knob
Main Burner Removal
Burner Rack
Mounting
Screw
Gas Valve
Wire Leads
Step 1.
Disconnect (un-plug) water heater from
electrical supply.
Step 2.
Turn “OFF” gas supply to water heater.
Step 3.
Rotate gas valve control knob to the “OFF” position
(see photos at right).
Step 4.
Disconnect Gas supply line from the gas valve.
Step 5.
Disconnect wire leads from gas valve
(see photos at right).
Step 6.
Disconnect white flame sense wire & orange ignition
wire from Control Board (see photos at right).
Pilot Flame Sense
Wire (White)
Step 7.
Remove the two burner rack mounting screws (see photos).
Step 8.
Slide complete burner rack out from water heater
(see photos below).
Step 9.
To install burner, reverse above procedure.
Step 10.
Check for gas leaks and verify proper operation.
Pilot spark wire
(Orange)
Pilot Draft
Shield
Burner Rack
Mounting
Screw
38
SERVICE PROCEDURE PDV24-V
Main Burner & Pilot
Removal and Inspection
PDV (S&T) AND INDUCED DRAFT MODELS
Pilot Shield
Pilot Burner Removal
Step 1.
With burner rack removed from heater, disconnect
pilot tube connection from gas valve
Step 2.
Remove the two pilot burner mounting screws
securing the pilot and pilot shield in place.
Step 3.
Remove pilot shield and pilot from burner rack.
Step 4.
To install pilot burner and pilot shield, reverse above
procedure. Be sure to reconnect green ground wire.
Ground Wire
Location
Pilot & Pilot Shield
Mounting Screws
Pilot Burner Inspection
Step 1.
Inspect pilot for the following:
a) Broken or cracked ceramic insulators. If found,
pilot must be replaced.
Flame
Rod
b) Damaged electrode or flame sense wire. If found,
pilot must be replaced.
Ceramic
Insulators
c) Oxidation build-up on flame rod. Clean flame rod
or replace pilot as necessary.
Step 2.
Pilot
Orifice
Inspect pilot orifice:
Ignition
Wire
a) Remove 7/16" ferrule nut from bottom of pilot.
b) Remove pilot tube and orifice from pilot.
7//16"
ferrule
Nut
Flame Sense
Wire
c) Inspect pilot tube for blockage. Clean or replace
as necessary.
d) Inspect pilot orifice for blockage. Clean or replace
as necessary.
39
Aluminum
Pilot Tubing
SERVICE PROCEDURE PDV24-VI
Control Board Replacement
DANGER
120 volt exposure. To avoid personal injury,
unplug while performing this procedure.
Slots in
control panel
Depress
plastic
tabs
Unhook tabs
from control
panel slots
Control board replacement
Step 2. Tilt control panel to the
right and slide control hook tabs
from slots in control panel.
Step 1. Depress left plastic tabs and
pull out from slots in control panel
Step 3. Unplug wire connections from board and replace.
Wire connections
Remove lower sensor
Remove clip, pull sensor out.
Remove clip
Pull out sensor
40
SERVICE PROCEDURE PDV24-VII
Flue Baffle Removal, Inspection
WARNING
Heater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
Step 1.
Disconnect (unplug) water heater from electrical supply.
Step 2.
Turn “OFF” water supply to water heater.
Step 3.
Open a near by hot water faucet to relieve tank pressure.
Step 4.
Connect hose to drain valve of water heater and route to an open
drain. Open drain valve and drain a minimum of 5 gallons of water
from the water heater. Close drain valve and disconnect drain hose
from water heater.
Step 5.
If required, disconnect top plumbing connection from top of water heater.
Step 6.
Remove screws holding jacket head to top of water heater
and remove jacket head from top of water heater. Note, it may
be necessary to use a screw driver to pry underneath
jacket head.
Step 7.
If required, remove insulation from top of water heater to expose
collector cover.
Step 8.
Remove screws from top (or side) of collector cover. Note, it may be
necessary to chisel away some foam to access screws.
Step 9.
Remove collector cover from water heater.
Step 10.
Remove flue baffles from water heater. Note, it may be necessary
to use pliers to loosen and remove baffles from flue tubes.
Step 11.
Visually inspect flue baffles. Flue baffles may show signs
of oxidation; this is normal. If the oxidation has deteriorated
any portion of the flue baffle, replacement is recommended.
If any restrictors are missing, replacement is recommended.
Step 12.
Upon completion of inspection or subsequent replacement,
reinstall flue baffles into heater.
Step 13.
Reinstall collector cover and insulation (if applicable)
over collector cover.
Step 14.
Reinstall jacket head.
Step 15.
Reconnect plumbing connection to top of water heater
& turn on water supply if required.
Step 16.
Check for leaks and verify proper operation.
Flue Baffle
PDV Models
41
SERVICE PROCEDURE PDV24-VIII
Anode Removal and Inspection
WARNING
Water Heater components may be HOT when performing the following steps in this
procedure. Take necessary precaution to prevent personal injury.
Step 1.
Disconnect (unplug) water heater from electrical supply.
Step 2.
Turn “OFF” water supply to water heater.
Step 3.
Open a near by hot water faucet to relieve tank pressure.
Step 4.
Connect hose to drain valve of water heater and route to an open drain. Open
drain valve and drain a minimum of 5 gallons of water from the water heater.
Close drain valve and disconnect drain hose from water heater.
Step 5.
If required, disconnect top plumbing connection from top of water heater.
Step 6.
Remove screws holding jacket head to top of water heater
and remove jacket head from top of water heater. Note, it may
be necessary to use a screw driver to pry underneath
jacket head (see photos at right).
Replace Anode
Step 7.
Remove insulation from top of water heater to expose collector cover,
if necessary. (see bottom of page for approx. anode locations)
Step 8.
Remove screws from top (or sides) of collector cover. Note, it may be
necessary to chisel away some foam to access screws.
Step 9.
Locate and remove anode rods from top of water heater (1-1/16 hex socket).
Step 10.
Visually inspect anode rod. Anode rod may show signs of depletion;
this is normal. If the anode shows signs of depletion
(approximately 5/8", see photo at right), replacement is recommended. If any of
the steel core of the anode is exposed, replacement is recommended.
Step 11.
Upon completion of inspection or subsequent replacement,
reinstall anode rods into water heater.
Step 12.
Check for leaks.
Step 13.
Reinstall collector cover & insulation over collector cover, if applicable.
Step 14.
Reinstall jacket head.
Step 15.
Reconnect plumbing connection to top of water heater if required.
Step 16.
Restore water supply and power to water heater.
Step 17.
Verify proper operation.
42
Generic Parts List
PDV-S
1A. Vent Kit
2A. Vent Elbow
3A. Intake Terminal
4A. Vent Reducer
5A. PVC Pipe
6A. Blower Vent Adaptor
7A. Blower Receptacle Gasket
8A. Blower
9A. Temperature Switch
10A. Blower Intake Gasket
11A. Blower Mounting Flange
12A. ¼-20 Hex Nut
13A. Collector to Blower Transition
14A. Air Intake Assembly
15A. Utility Cover
16A. Air Intake Pipe
17A. Cover Rear Boot
18A. Combustion Box Boot
19A. Blower Escutcheon
20A. Blower Hose Barb
21A. Air Inlet
22A. Vent Orifice
23A. Air Intake Tee
24A. Cold Water Inlet Dip Tube
25A. Hot Water Outlet Nipple
26A. Pressure Switch Cover
27A. Pressure Switch
28A. Flue Baffle
29A. Hex Head Anode
30A. Pipe Plug
31A. Hole Closure
32A. Hot Water Outlet Nipple
33A. Lower Thermostat Well
34A. Wire Harness Lower Sensor
43
35A. T & P Nipple
36A. T & P Valve
37A. Cold Water Inlet Nipple
38A. Drain Valve
39A. Sight Glass Holder
40A. Sight Glass Gasket
41A. Sight Glass
42A. Combustion Box Gasket
43A. Combustion Box Gasket
44A. Cleanout Gasket
45A. Cleanout Cover (Tank)
46A. 5/16-18 Hex Screw
47A. Cleanout Cover (Jacket)
48A. Lower Thermostat Sensor Clip
49A. ASSE Approved Mixing Valve
50A. Blower Harness
51A. Pressure Switch Harness
Generic Parts List
PDV S
1B. Gas Valve Assembly
2B. Burner Assembly
3B. Burner Rack
4B. Burner Tube
5B. Burner Shroud
6B. Burner Draft Panel
7B. Burner Support
8B. Aluminum Tubing
9B. Pilot Shield
10B. Pilot Orifice
11B. Pilot Assembly
12B. Street Elbow
13B. Gas Valve
14B. Aluminum Tubing
15B. Nipple Close
16B. Union
17B. Nipple
18B. Combustion Box Flange
19B. Flange Gasket
20B. Manifold
21B. Main Burner Orifice
44
Generic Parts List
PDV-S
1C. Control Box Assembly
2C. Control Box Cover Assembly
3C. Honeywell Display
4C. Control Box Cover
5C. Integrated Control Board
6C. Control Box Panel
7C. Power On/Off Switch
8C. Pan Head Screw w/adh.
9C. Pan Head Screw #8-18
10C. Transformer
11C. Strain Relief Bushing ½"
12C. Strain Relief Bushing 7/8"
13C. Snap-In-Bushing 7/8"
14C. Power Cord Wiring Harness
15C. Display Control Wiring Harness
16C. Display Cover Wiring Harness
17C. Primary Transformer Wiring Harness
18C. Secondary Transformer Wiring Harness
19C. Gas Valve Control Wiring Harness
20C. Pan Head Screw #8-18.
21C. Ground Lug
22C. Snap-In-Plug 7/8"
45
Generic Parts List
PDV-T
1A. ASSE Approved Mixing Valve
2A. Vent Clamp
3A. Blower Vent Adapter
4A. Combustion Box Cover
5A. Wire Raceway
7A. Blower Receptacle Gasket
8A. Blower
9A. Temperature Switch
10A. Blower Intake Gasket
11A. Blower Mounting Flange
12A. ¼-20 Hex Nut
13A. Collector to Blower Transition
15A. Utility Cover
16A. Air Intake Pipe
18A. Combustion Box Boot
19A. Blower Escutcheon
20A. Blower Hose Barb
24A. Cold Water Inlet Dip Tube
25A. Hot Water Outlet Nipple
26A. Pressure Switch Cover
27A. Pressure Switch
28A. Flue Baffle
29A. Hex Head Anode
30A. Upper Thermostat Sensor
31A. Upper Sensor Wire Harness
32A. Hot Water Outlet Nipple
33A. Lower Thermostat Sensor
34A. Lower Sensor Wire Harness
46
35A. T & P Nipple
36A. T & P Valve
37A. Cold Water Inlet Dip Tube
38A. Drain Valve
39A. Combustion Box Gasket
40A. Combustion Box Gasket
41A. Cleanout Gasket
42A. Cleanout Cover (Tank)
43A. 5/16-18 Hex Screw
44A. Cleanout Cover (Jacket)
Generic Parts List
PDV T
1B. Burner Assembly
2B. Burner Rack
3B. Burner Tube
4B. Burner Draft Panel
5B. Burner Support
6B. Aluminum Tubing
7B. Pilot Shield
8B. Pilot Orifice
9B. Pilot Assembly
10B. Manifold
11B. Main Burner Orifice
12B. Gas Valve Assembly
13B. Nipple
14B. Street Elbow
15B. Union
16B. Nipple Close
17B. Aluminum Tubing
18B. Gas Valve
47
Generic Parts List
PDV-T
1C. Control Box Assembly
2C. Control Box Cover Assembly
3C. Honeywell Display
4C. Control Box Cover
5C. Integrated Control Board
6C. Control Box Panel
7C. Power On/Off Switch
8C. Pan Head Screw w/adh.
9C. Pan Head Screw #8-18
10C. Transformer
11C. Strain Relief Bushing ½"
12C. Strain Relief Bushing 7/8"
13C. Snap-In-Bushing 7/8"
14C. Power Cord Wiring Harness
15C. Display Control Wiring Harness
16C. Display Cover Wiring Harness
17C. Primary Transformer Wiring Harness
18C. Secondary Transformer Wiring Harness
19C. Gas Valve Control Wiring Harness
20C. Pan Head Screw #8-18.
21C. Ground Lug
22C. Snap-In-Plug 7/8"
23C. Upper Sensor Harness
48
Generic Parts List
INDUCED DRAFT MODELS
1A. Flue Baffle
2A. Hex Head Anode
3A. Pressure Tap Fitting
4A. 1/8" NPT Elbow
5A. Hose Barb
6A. Silicone Hose
7A. Control Box Assembly
8A. ASSE Approved Mixing Valve
9A. Blower Transistion
10A. T & P Nipple
11A. T & P Valve
12A. Hot Water Outlet Nipple
13A. Blower Flange Mount
14A. Vent Adapter
15A. Flange Gasket
16A. Blower
17A. Drain Valve
18A. Cold Water Inlet Dip Tube
19A. Cleanout Gasket
20A. Cleanout Cover (Tank)
21A. 5/16-18 Hex Screw
22A. Cleanout Cover (Jacket)
23A. Upper Thermostat
24A. Lower Thermostat Well
25A. Lower Thermostat Clip
26A. Lower Thermostat Sensor
27A. Utility Cover
28A. Burner Assembly
49
Generic Parts List
INDUCED DRAFT MODELS
1B. Burner Assembly
2B. Burner Panel
3B. Burner Tube
4B. Burner Mounting Bracket
5B. Burner Rack
6B. Dual Gas Valve Assembly
7B. Main Burner Orifice
8B. Manifold
9B. Pilot Assembly
10B. Aluminum Tubing
11B. Pilot Draft Shield
12B. Burner Support
13B. Valve Support Bracket
14B. 1" NPT Street Elbow
15B. 1" NPT X 3-½" Nipple
16B. 1" NPT Elbow
50
Generic Parts List
INDUCED DRAFT MODELS
1C. Control Box Assembly
2C. Control Box Cover Assembly
3C. Pan Head Screw #8-18
4C. Honeywell Display
5C. Control Box Cover
6C. Integrated Control Board
7C. Pan Head Screw #8-18
8C. Transformer
9C. Ground Lug
10C. Pressure Switch
11C. Power On/Off Switch
12C. Control Box Panel
13C. Secondary Transformer Wiring Harness
14C. Primary Transformer Wiring Harness
15C. Strain Relief Bushing ½"
16C, Strain Relief Bushing 7/8"
17C. Snap-In-Plug 7/8"
18C. Pan Head Screw w/adh.
19C. Blower Wiring Harness
20C. Power Cord Wiring Harness
21C. Gas Valve Control Wiring Harness
22C. Upper Sensor Harness
23C. Display Control Wiring Harness
24C. Display Cover Wiring Harness
51
Glossary of Terms
AC
BTU/H
CO
CO2
DC
ECO
GFI
GPM
Hz
LED
NOx
NPT
PSI
VA
VAC
W.C.
°C
°F
µA
Alternating Current
British Thermal Units
Carbon Monoxide
Carbon Dioxide
Direct Current
Energy Cut Off
Ground fault interrupt
Gallons per Minute
Hertz
Light Emitting Diode
Oxides of Nitrogen
National Pipe Thread
Pounds per Square Inch
Volt Amps
Volts Alternating Current
Inches of Water Column
Degrees Centigrade
Degrees Fahrenheit
Micro Amp
NOTES
52