powered direct vent series gas-fired commercial water heater

POWERED DIRECT VENT SERIES GAS-FIRED
COMMERCIAL WATER HEATER
(INDEPENDENT PVC VENTING)
WARNING: If the information in
these instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death
-
Do not store or use gasoline or other
flammable 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.
-
For your family’s comfort, safety and
convenience, it is recommended this water
heater be installed and serviced by a
plumbing professional.
INSTALLATION/OPERATION MANUAL
WITH TROUBLESHOOTING GUIDE
PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
238-47707-00A
REV 04/09
SECTION I: IMPORTANT INFORMATION
READ CAREFULLY
This gas-fired water heater is design certified by CSA International under the American National Standard, Z21.10.3
and CAN/CGA 4.3-M (as indicated on the rating plate). These standards are available from CSA Standards
Association, 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA.
This water heater must be installed in accordance with local codes. In the absence of local codes, it must be
installed in compliance with the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA
B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest
Edition).
The following terms are used throughout this manual to bring attention to the presence of hazards at various risk
levels, or to important information concerning product life.
DANGER
CAUTION
Indicates an imminently hazardous situation,
which, if not avoided, will result in death, serious
injury or substantial property damage.
Indicates potentially hazardous situation, which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
WARNING
Indicates a potentially hazardous situation,
which, if not avoided, could result in death,
serious injury or substantial property damage.
Indicates special instructions on installation,
operation or maintenance, which are important
but not related to personal injury hazards.
NOTICE
This water heater has a limited warranty. The warranty for this water heater is valid only if the water heater has
been installed, maintained and operated in accordance with these instructions. The warranty does not cover
damage or injury caused by the use of any energy-saving devices (other than those authorized by the manufacturer)
in conjunction with this water heater. The use of unauthorized energy-saving devices may decrease the life of the
water heater and endanger life and/or property. The manufacturer will not be liable for any damage, injury, or loss of
life resulting from alteration and/or failure to comply with these instructions.
IMPORTANT-Before proceeding, please inspect the water heater and components for possible damage. DO NOT
install damaged components. If damage is evident, please contact the supplier where the water heater was
purchased or the manufacturer listed on the rating plate for replacement parts.
TABLE OF CONTENTS
I
II
III
IV
IMPORTANT INFORMATION……………………2
SPECIFICATIONS..............................................5
GENERAL INFORMATION.................................6
INSTALLATION INSTRUCTIONS.......................8
VIII
IX
X
XI
V
VI
VENTING...........................................................11
WATER CONNECTIONS…………………..……19
XII
XIII
VII
GAS CONNECTIONS........................................21
XIV
2
ELECTRICAL CONNECTIONS......................22
OPERATING INSTRUCTIONS......................25
MAINTENANCE.............................................32
DIAGNOSTIC AND TROUBLESHOOTING
GUIDE............................................................36
PARTS LIST...................................................56
INSTALLATION FOR POTABLE
WATER AND SPACE HEATING....................58
NOTES…………………………………………..59
DANGER
DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of
this or any other appliance.
This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures
required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or
death. The temperature at which injury occurs varies with the person’s age and the time of exposure. The slower
response time of disabled persons increases the hazards to them. NEVER allow small children to use a hot water
tap, or to draw their own bath water. NEVER leave a child or disabled person unattended in a bathtub or shower.
Toxic chemical, such as those used for boiler treatment, must not be introduced into potable water used for space
heating.
This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.
All piping components connected to this water heater for space heating applications must be suitable for use with
potable water.
WARNING
Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal injury or
loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and
understand all instructions, including all those provided with the appliance before installing, starting-up, operating,
maintaining or servicing this appliance. Keep this manual and literature in legible condition with this water heater for
reference by owner and service technician.
This water heater requires regular maintenance and service to operate safely. Follow the instructions contained in
this manual.
Installation, maintenance, and service must be performed only by a qualified, skilled and knowledgeable installer or
service provider.
Installation is not complete unless a temperature and pressure relief valve is installed into the proper location at the
top of this water heater.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are properly
operating when the installation is complete.
DO NOT operate this water heater without first being certain it is filled with water.
DO NOT tamper with or alter the water heater and/or controls.
DO NOT operate water heater with jumpered or absent controls or safety devices.
DO NOT operate water heater if any external part has been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system including gas controls, which has
been under water.
DO NOT attempt to use this water heater with any gas other than the type listed on the rating plate. Do not attempt to
convert this water heater for use with a gas other than the type for which it is equipped. Failure to use the proper gas
can create an unsafe condition resulting in property damage, bodily injury, or death. Consult your local gas supplier
or gas company if there are any questions.
For installations in high altitude regions, this water heater must be ordered from the supplier to the manufacturer’s
specifications for that particular altitude. Contact the company listed on the rating plate when ordering high altitude
constructed water heaters.
Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.
DO NOT operate this water heater if the input rate exceeds the rate shown on the water heater rating plate.
This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to
disconnect any components of this water heater without positively assuring the water is cool and is not under
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this water heater to
prevent scald injuries. Do not rely on the temperature gauges to determine the temperature. Do not touch any
components unless they are cool.
This water heater must be properly vented and connected to an approved vent system in good condition. DO NOT
operate water heater with the absence of an approved vent system. A clean and unobstructed vent system is
necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward
maintaining the water heater’s efficiency.
3
WARNING
This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in
contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber,
burners, and flue tubes and creates a risk of asphyxiation.
Water heater materials of construction, products of combustion and the fuel contain carbon monoxide, nitrogen oxides,
aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to
the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing,
respirators and equipment when servicing or working nearby this water heater.
Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or
adjacent to the water heater. Open containers of flammable material should not be stored or used in the same room
with this water heater.
Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES 90.1b
(latest edition) standards with respect to insulation and standby loss requirements.
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. See following section in this Installation/Operation Manual to change the maximum setpoint limit (max
setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings
being improperly adjusted.
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 connect to the hot water system. If hydrogen is present, there will be
unusual sounds such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame
near the faucet at the time it is open.
WARNING
Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of
leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
• DO NOT try to light any appliance.
• DO NOT touch any electric switch; do not use any telephone in your building.
• Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
To comply with NSF requirements this water heater is to be:
a) Sealed to the floor with sealant, in a smooth and easily cleanable way, or
b) Installed with an optional leg kit that includes legs and/or extensions that provide a minimum clearance of 6”
beneath the water heater.
4
SECTION II: SPECIFICATIONS
Figure 1. Dimensional layout
Model Description
Capacity
Input (BTU/hr)
(Gal)
Nat.
LP
100
199,999 199,999
100
150,000 150,000
100
250,000 225,000
80
250,000 225,000
80
199,999 199,999
80
150,000 150,000
A
(In.)
72.13
72.13
72.13
63.13
63.13
63.13
Dimensions for Figure 1
B
C
D
(In.)
(In.)
(In.)
60.31
77.19
56.81
60.31
77.19
56.81
60.31
82.13
56.81
51.31
68.19
47.81
51.31
68.19
47.81
51.31
68.19
47.81
E
(In.)
74.13
74.13
74.13
65.13
65.13
65.13
Model Description
Capacity
Input (kW/hr)
(Liter)
Nat.
LP
378.5
58.6
58.6
378.5
43.9
43.9
378.5
73.2
65.9
302.8
73.2
65.9
302.8
58.6
58.6
302.8
43.9
43.9
A
(cm)
183.2
183.2
183.2
160.4
160.4
160.4
Dimensions for Figure 1
B
C
D
(cm)
(cm)
(cm)
153.2
196.1
144.3
153.2
196.1
144.3
153.2
208.4
144.3
130.3
173.2
121.4
130.3
173.2
121.4
130.3
173.2
121.4
E
(cm)
188.3
188.3
188.3
165.4
165.4
165.4
5
SECTION III: GENERAL INFORMATION
FEATURES
1. Porcelain enamel lined tank provides corrosion protection with a tough glass lining on the interior of the tank.
2. Magnesium anodes provide an extra measure of protection and extends tank life.
3. Direct Vent design with an induced draft blower. Flue gases are exhausted and combustion air is taken from outside
the building through 3” or 4” PVC, CPVC, or ABS pipe. Maximum venting distance for each pipe of 40 feet with one
elbow for 3” diameter pipe and 55 feet with one elbow for 4” diameter pipe. May be horizontally or vertically vented.
See venting section for complete details.
4. Hand Hole Cleanout allows inspection of tank interior and allows the removal of lime and sediment deposits.
5. Honeywell Integrated Water Heater has the following features:
• Attractive digital water heater display on control panel for precisely setting and displaying the temperature setpoint.
Pressing temperature up and down buttons changes the temperature setpoint. Temperature format may be
displayed in degrees F or degrees C.
• Single control board with plug in wiring controls temperature, ignition, and induced draft 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. Temperature of the tank sensors can be monitored in the Service Mode.
• Water heater display can show up to 10 previous error codes to further aid in servicing the water heater.
WARNING
Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be
hot enough to cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or
materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot
Water Supply Systems, ANS Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve shall be
marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The
combination temperature and pressure relief valve shall also have an hourly rated temperature steam BTU
discharge capacity not less than the hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose
on the water heater.
Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.
Verify that the combination temperature and pressure relief valve complies with local codes. If the combination
temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit
within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical
part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and
pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.
DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches
(10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature
and pressure relief valve.
Do not place a valve between the combination temperature and pressure relief valve and the tank.
6
DISHWASHING MACHINE REQUIREMENTS
All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water
flow pressures between 15 and 25 pounds per square inch. Flow pressures above 25 pounds per square inch, or below
15 pounds per square inch, will result in improperly sanitized dishes.
The National Sanitation Foundation also recommends circulation of 180°F water. Where this is done, the circulation
should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation
should be just enough to provide 180°F water at the point of take-off to the dishwashing machine. Adjust flow by means
of the valve in the circulation line.
7
SECTION IV: INSTALLATION INSTRUCTIONS
WARNING
INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN IN THE FIELD INVOLVED.
PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND
ELECTRICAL WORK ARE REQUIRED.
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 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 telephone in another building.
• Gas detectors are available. Contact your gas supplier or plumbing professional for more information.
Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking
gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any telephone in your building.
• Immediately call your gas supplier from a telephone in another building.
instructions.
• If you cannot reach your gas supplier, call the fire department.
Follow the gas supplier’s
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
This water heater must be located in an area where leakage of the tank, water line connections, or the combination
temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower
floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the
water heater. The drain pan depth must be suitable for draining and collecting water, and have a minimum length
and width of at least four (4) inches (10.0 cm) measured from the jacket of the water heater. The drain pan, as
described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate
drain. The piping must be at least 3/4 inch (2.0 cm) in diameter and pitched for proper drainage. It is recommended
that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and
maintenance of the combination temperature and pressure relief valve.
Water heaters are heat producing appliances. To avoid damage or injury there shall be no materials stored against
the water heater and proper care shall be taken to avoid unnecessary contact (especially by children) with the water
heater components. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE
OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE
SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR
INTAKE SYSTEM.
Failure to adhere to these installation and operating instructions may create a hazard to life and property and will
nullify the warranty.
8
Minimum Clearances
CAUTION
The National Fuel Gas Code (ANSI Z233.1- latest edition) or in Canada The Natural Gas or Propane
Installation Code CAN/CGA (B149.1, B149.2- latest edition), expressly prohibits the following:
a. Installation of a water heater in a bathroom, bedroom, or any occupied room normally kept closed.
b. Installation of a water heater in a garage, unless the unit is installed so that the burner and ignition devices are
at least eighteen (18) inches (45.8 cm) above floor level and protected to avoid damage by a moving vehicle.
If the buildings cold water supply has a back-flow preventer, check valve or water meter with check valve, provisions
for thermal expansion of water in the hot water system must be provided.
The location of this water heater is of the utmost importance. Before installing this water heater, you should read the
Installation section of these instructions. After reading these Installation and Operating Instructions, select a location for
the water heater where the floor is level and is easily accessible to water lines, gas supply (type identified on the rating
plate), an adequate open drain, and within the maximum specified venting distance to an outside wall or roof for the direct
vent terminal. DO NOT locate the water heater where water lines could be subjected to freezing temperatures.
Make sure the cold water pipes are not located directly above the gas control so that condensate during humid
weather does not drip or accumulate on the controls.
This installation must allow access to the front of the water heater and adequate clearance shall be provided for servicing
and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor. If
the water heater is to be installed directly on carpeting, it shall be installed on top of a metal or wood panel (or equivalent)
extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the
appliance is to be installed in an alcove or closet, the entire floor shall be covered by the panel. The minimum clearances
to combustibles for this water heater are given on the following pages. A minimum of 24 inches (61 cm) front clearance
shall be provided for inspection and servicing. Adequate clearances shall be provided for easy access to controls by
service personnel to enable proper cleaning, servicing, and operation of the water heater. Under no circumstances is the
front of the water heater to be placed in a position where the burner tray assembly cannot slide out for removal when
servicing.
This water heater MUST be installed indoors out of the wind and weather.
Note: For California installation this water heater must be braced, anchored, or strapped to avoid falling or
moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained
from DSA Headquarters Office, 1102 Q Street, Suite 5100, Sacramento, California 95811.
Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical
vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents,
refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process
chemicals. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.
NOTICE
DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED
BY THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS OR WILL OCCUR. DO
NOT STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER OR
THE DIRECT VENT TERMINAL.
This water heater may be installed in an alcove on combustible flooring with clearances from combustible materials
as shown in the following clearances illustration of this Installation and Operation Instruction Manual.
UNPACKING
INSPECT SHIPMENT carefully for any signs of damage.
1. All equipment is carefully manufactured, inspected and packed.
2. Any claims for damage or shortage in shipment must be filed immediately with the manufacturer noted on the
rating plate label.
9
LOCATE WATER HEATER in front of final position before removing crate.
1. LOCATE so that venting connections will be short and direct.
2. THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR.
3. Proper venting practices must be considered when selecting a location for this water heater. For exact venting
specifications, please consult the Venting section of these Installation and Operating Instructions.
4. It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water
heater for servicing and maintenance of the combination temperature and pressure relief valve.
MINIMUM CLEARANCES
Figure 2
REMOVE CRATE
1. Remove all banding and pry off crate sides carefully so as not to damage the water heater.
2. Carefully roll/lift the water heater from the crate base.
MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking. Place drain pan underneath water heater
INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not already installed).
This water heater must be located in an area where the general public does not have access to set temperatures.
AIR REQUIREMENTS
1. Do not obstruct the flow of ventilating air.
2. For safe operation, adequate air is needed for combustion and ventilation. Sooting may result in serious damage
to the water heater and risk of fire or explosion. It can also create a risk of asphyxiation. Such a condition often
will result in a yellow, luminous burner flame, causing carboning or sooting of the combustion chamber, burner
and flue tubes.
WARNING
IMPORTANT-The flow of combustion and ventilating air must not be obstructed.
10
SECTION V: VENTING
WARNING
The direct vent system must be properly installed. Failure to properly install the direct vent system could
result in property damage, personal injury, or death.
DO NOT install any damaged venting system 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.
Use only the vent terminals provided or factory authorized for venting this water heater.
NOTICE
For installations in Canada, field supplied plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and
be certified to the Standard For Type BH Gas Venting Systems, ULC S636. Components of this listed system shall
not be interchanged with other vent systems or unlisted pipe/fittings. All plastic components and specified primers
and glues of the certified vent system must be from a single system manufacturer and not intermixed with other
system manufacturer’s vent system parts.
The supplied vent connector and vent termination are certified as part of the water heater.
This water heater is a Powered Direct Vent Gas Water Heater where all air for combustion is obtained from the outside
atmosphere and all flue gases are discharged to the outside atmosphere. The venting system consists of separate PVC
combustion air intake and flue exhaust pipes. Venting may be run horizontally through an outside wall or vertically
through a roof through 3” (7.6 cm) or 4” (10.2 cm) diameter PVC, ABS or CPVC pipe for models with input ratings under
200,000 Btu/hr. Models with input ratings over 200,000 Btu/hr. (check the model nameplate) must use 4” (10.2 cm)
diameter PVC, ABS, or CPVC only. The water heater is supplied with a screened intake and exhaust 90° elbow referred
to as the exhaust vent or combustion air intake terminal (see figure 5). Consult the venting table in this section for the
maximum venting distances with 3” (7.6 cm) and 4” (10.2 cm) PVC pipe.
Note: The combustion air intake must be piped to the outdoors as outlined in the following instructions in order
for this appliance to be a direct vent water heater.
11
Figure 3.
Direct Vent Terminal Clearances
1
Canadian Installations
US Installations
2
A=
Clearance above grade, veranda, porch, deck or balcony
12 inches (30 cm)
12 inches (30 cm)
B=
Clearance to widow or door that may be opened
36 inches (91 cm)
12 inches (30 cm)
C=
Clearance to permanently closed widow
*b
*b
D=
Vertical clearance to ventilated soffit located above the terminal within a
horizontal distance of 2 feet (61 cm) from the center line of the terminal
12 inches (30 cm) *a
12 inches (30 cm) *a
E=
Clearance to unventilated soffit
12 inches (30 cm) *a
12 inches (30 cm) *a
F=
Clearance to outside corner
*b
*b
G=
Clearance to inside corner
*b
*b
H=
Clearance to each side of center line extended above meter/regulator
assembly
3 feet (91 cm) within a
height 15 feet (4.6 m)
above the meter/regulator
assembly
*b
I=
Clearance to service regulator vent outlet or oil tank vent
36 inches (91 cm)
*b
J=
Clearance to non-mechanical air supply inlet to building or the combustion air
inlet to any other appliance
36 inches (91 cm)
12 inches (30 cm)
K=
Clearance to a mechanical air supply inlet
6 feet (1.83 m)
3 feet (91 cm) above if
within 10 feet horizontally
L=
Clearance above paved sidewalk or paved driveway located on public
property
7 feet (2.13 m)†
*b
M=
Clearance under a veranda, porch, deck, or balcony
12 inches (30 cm) ‡
*b
1
In accordance with the current CAN/CGA-B149 Installation Codes.
In accordance with the current ANSI Z223.1-(Latest edition)/NFPA 54 National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single-family dwellings and serves both
dwellings.
‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
*a) A minimum clearance value determined by testing in accordance with section 2.20.
*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.
2
12
The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of
the National Fuel Gas Code, ANSI Z223.1.73.4e and 7.8a, b as follows:
1. Do not terminate near soffit vents or crawl space or other area where condensate or vapor could create a nuisance or
hazard or cause property damage.
2. Do not terminate the exhaust vent terminal where condensate or vapor could cause damage or could be detrimental
to the operation of regulators, relief valves, or other equipment.
3. Do not terminate the exhaust vent terminal over public area or walkways where condensate or vapor can cause
nuisance or hazard.
4. The vent shall terminate a minimum of 12 inches above expected snowfall level to prevent blockage of vent
termination.
Vent pipes serving power vented appliances are classified by building codes as “vent connectors”. Required clearances
from combustible materials must be provided in accordance with information in this manual under LOCATION OF
WATER HEATER and CLEARANCES, and with National Fuel Gas Code and local codes.
Note: Provide protection of the building materials from degradation by flue gases from the exhaust vent terminal.
Horizontal And Vertical Direct Vent Lengths for 199,999 and 150,000 Btu/hr. Input Models
Reference the Venting Component Tables listed in the Installation (Direct Vent System Installation) for the maximum vent
lengths using 3” (7.6 cm) diameter PVC, ABS or CPVC piping. If longer venting distances are required than shown for 3”
(7.6 cm) diameter pipe, then 4” (10.2 cm) diameter pipe may be used. The distances shown in the tables are for each
separate pipe (air intake and exhaust vent).
Do not exceed the maximum allowed exhaust vent or combustion air pipe distances for the number of elbows
listed. Refer to the venting distances listed in tables 1-4 in this installation and operating instruction manual.
Note: The supplied exhaust vent and combustion air intake terminals may be used to vent through outside walls
of any thickness as long as the maximum allowed venting distances are not exceeded.
Maximum Venting Distances
(Horizontal, Vertical, or Combined for models under 200,000 Btu/hr. input ratings only)
TABLE 1 – EXHAUST VENT AND COMBUSTION AIR INTAKE PIPE LENGTHS FOR 3” (7.6 cm) PVC
Number of 90° Elbows (Excluding vent terminals)
Maximum distance of straight pipe (excluding
vent terminal) to exterior wall or roof.
1
40 ft. (12.19 m)
2
35 ft. (10.67 m)
3
30 ft. (9.14 m)
4
25 ft. (7.62 m)
TABLE 2 – EXHAUST VENT AND COMBUSTION AIR INTAKE PIPE LENGTHS FOR 4” (10.2 cm) PVC
(For distances longer than 3” (7.6 cm) PVC)
Number of 90° Elbows (Excluding vent terminals)
Maximum distance of straight pipe (excluding
vent terminal) to exterior wall or roof.
1
55 ft. (16.8 m)
2
50 ft. (15.2 m)
3
45 ft. (13.7 m)
4
40 ft. (12.2 m)
Note: Each 90° elbow reduces the maximum venting distance by 5 ft. (1.52 m). Two 45° elbows are equal to one
90° elbow. Do not use 4” (10.2 cm) diameter PVC for venting distances less than 40 ft. (12.19 m) (with 1 elbow).
Use 3” (7.6 cm) PVC for venting distances of 40 (12.19 m) feet or less.
The total combined distances of vertical and horizontal pipe with equivalent elbow lengths cannot exceed the
maximum distance of straight pipe listed in the tables 1-4.
NOTICE
IMPORTANT - Do not exceed the venting distances or the number of elbows listed. Exceeding the maximum
venting distances may cause the water heater to malfunction or cause an unsafe condition.
The exhaust vent adaptor and gasket with mounting bolts are located inside the cardboard carton with the vent
terminal. The exhaust vent adaptor and gasket must be installed on the blower outlet flange before attempting to
connect the 3” (7.6 cm) diameter plastic vent pipe to the water heater.
13
Direct Vent System Installation (199,999 and 150,000 Btu/hr. input models)
WARNING
The direct vent system must be properly installed. Failure to properly install the direct vent system could result in
property damage, personal injury or death.
The water heater requires its own separate venting system. Do not connect the exhaust vent into an existing
vent pipe or chimney.
CAUTION
Do not install any damaged direct vent system components. Contact the manufacturer of the water heater for
replacement parts. Use only the vent terminals provided or factory authorized for venting this water heater.
The flow of combustion air must not be restricted. Keep the direct vent terminal openings clear of objects,
shrubs, snow and debris.
This water heater is a power direct vent appliance and is designed to vent both its products of combustion and provide the
combustion air supply through 3” (7.6 cm) or 4” (10.2 cm) diameter Schedule 40 PVC, ABS or CPVC pipe to the outdoors.
This water heater may be vented either through the wall or vertically through the roof. The blower outlet adaptor provided
in the vent kit carton and combustion air inlet connection are designed to fit 3” (7.6 cm) diameter schedule 40 plastic pipe.
Remove the plastic exhaust vent adaptor and gasket from the vent kit carton. Line up the gasket screw clearance holes
with the vent adaptor flange and place on top of the blower outlet flange. Assemble the adaptor with the gasket to the
blower outlet using the four (4) nuts, bolts, and washers provided in the kit.
If 4” (10.2 cm) diameter pipe is used, a bell reducer must be used at the blower outlet and air intake connections. Seal
the joint between the PVC pipe and the blower outlet collar with silicone sealant (not supplied) (See figure 4). Table 1
lists the maximum vent lengths for this water heater using 3” (7.6 cm) PVC. If possible, locate the water heater so that the
venting length and number of elbows are kept to the minimum distance necessary to reach the outside. Use the 3” (7.6
cm) vent and intake air terminals supplied with the water heater to terminate on the outside of the building. When using 4”
(10.2 cm) diameter pipe, optional 4” (10.2 cm) diameter vent terminals must be used and are available from your dealer.
Refer to the venting illustrations on the following pages. Make sure the exhaust vent pipe terminal rear edge is at least 6”
(2.5 cm) away from the edge of the wall (see figure 5).
Figure 4
14
CAUTION
IMPORTANT - All of the Exhaust Venting connections must be leak checked with a soap solution upon initial start
up of the water heater. Any leaks must be repaired before continuing operation of the water heater.
NOTE: ABS or CPVC pipes may be substituted for PVC pipe.
Through the Wall Venting:
Cut two 3 1/2 in. (8.9 cm) diameter holes (for 3” (7.6 cm) diameter pipe) or 4 ½” (11.4 cm) diameter holes (for 4” (10.2 cm)
diameter pipe) in the wall with the centerline hole distances at least 6” (15.2 cm) apart, but not more than 24” (61 cm)
apart in the location where the exhaust vent and air intake terminals will exit the outside wall. Use the proper PVC
cement to secure the 90° exhaust vent and air intake terminals provided with the water heater to the plastic pipes. The
distance between the back edge of the 90° exhaust vent terminal and the exterior wall (see Figure 5) must be 5 inches
(12.7 cm) more for the exhaust vent terminal than the air intake terminal. Use the proper cement and assembly
procedures to secure the vent connector joints between the terminal and the blower outlet. Provide support brackets for
every 3 feet (.91 m) of horizontal vent.
Figure 5
Through the Roof Venting: (Vertical Venting)
Cut the necessary holes through the roof and ceiling and install the exhaust vent and air intake plastic pipes as shown in
Figure 6. Make sure that the installation meets the local codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest
Edition) or CGA/CAN B149 Propane or Natural gas Installation Code.
All vertical exhaust vent runs or horizontal runs more than 15 feet in length may accumulate condensate in the exhaust
vent pipe and exhaust blower and will require the installation of a drain tee and condensate trap. A drain tee and
condensate trap are available from your installer or the manufacturer of the water heater and must be installed in the
horizontal exhaust vent as close as practical to the blower vent connection (See Figures 7B and 7C). When using the
condensate tee, the exhaust vent piping must slope with a ¼” (6.35 mm) per foot pitch toward the condensate tee. For
short horizontal runs (less than 15 feet (4.57 m)) without the condensate tee, slope the exhaust vent piping toward the
outside vent terminal so that any condensate will drain out the vent terminal (see figure 7A). Venting arrangements
required for low ground clearance (figure 8) will require a condensate tee with the pipe sloped toward the tee.
Connect 3/8” (15.9 mm) plastic tubing from the barbed fitting on the condensate tee and form a loop using wire ties or
tape as shown in figures 7B and 7C before running to a drain or condensate pump. The loop forms a drain trap so that
flue gases do not escape into the room.
CAUTION
A drain loop must be installed in the drain tubing to serve as a condensate trap to prevent flue gases from
escaping into the room. Refer to figures 7B, 7C, and the instructions discussing the condensate drain tee
and trap under the vertical venting section.
15
Figure 6
Figure 7A
Figure 7B
16
Figure 7C
Through the Wall Venting With Low Ground Clearance:
When venting cannot exit through the wall at a height greater than or equal to 12” (30.5 cm) (and above expected snow
level) from the ground, then the installation must be modified as shown below (see Figure 8). Refer to Tables 3 or 4 for
maximum venting lengths using 3” (7.6 cm) or 4” (10.2 cm) diameter plastic pipe.
Figure 8
TABLE 3
3” (7.6 cm) PVC EXHAUST VENT OR COMBUSTION AIR INTAKE PIPE LENGTHS FROM INSIDE
WALL FOR LOW GROUND CLEARANCE INSTALLATIONS
Termination
# of Elbows
Maximum Length
1
30 ft (9.1 m)
(2) 90° Elbows with (1) 90° Elbow
2
25 ft (7.6 m)
(2) 90° Elbows with (1) 90° Elbow
3
20 ft (6.1 m)
(2) 90° Elbows with (1) 90° Elbow
4
15 ft (4.6 m)
(2) 90° Elbows with (1) 90° Elbow
TABLE 4
4” (10.2 cm) PVC EXHAUST VENT OR COMBUSTION AIR INTAKE PIPE LENGTHS FROM INSIDE
WALL FOR LOW GROUND CLEARANCE INSTALLATIONS
Termination
# of Elbows
Maximum Length
1
45 ft (13.7 m)
(2) 90° Elbows with (1) 90° Elbow
2
40 ft (12.2 m)
(2) 90° Elbows with (1) 90° Elbow
3
35 ft (10.7 m)
(2) 90° Elbows with (1) 90° Elbow
4
30 ft (9.1 m)
(2) 90° Elbows with (1) 90° Elbow
17
Direct Vent System Installation for Models with Input Ratings Over 200,000 Btu/Hr.
Models with input ratings over 200,000 Btu/hr. must use 4” (10.2 cm) diameter PVC, ABS, or CPVC pipe. Install
the blower adaptor exhaust vent assembly and gasket supplied in the vent kit carton on the exhaust blower outlet flange
as described in the previous section. Connect the 4” (10.2 cm) pipe to the 4” (10.2 cm) reducers attached to the
combustion air intake pipe and blower exhaust outlet. The supplied 4” (10.2 cm) exhaust vent and combustion air intake
terminals must also be used. Follow the venting system installation instructions for installing 4” (10.2 cm) diameter pipe
detailed on pages 14-17 and figures 4-8 and follow the venting tables 5 and 6 for the maximum venting distances.
Maximum Venting Distances (Horizontal, Vertical, or Combined)
TABLE 5
EXHAUST VENT OR COMBUSTION AIR INTAKE PIPE LENGTHS FOR 4” (10.2 cm) PVC
Maximum distance of straight pipe (excluding
Number of 90° Elbows (Excluding vent
vent or air intake terminal) to exterior wall or
terminals)
roof.
1
55 ft. (16.8 m)
2
50 ft. (15.2 m)
3
45 ft. (13.7 m)
4
40 ft. (12.2 m)
TABLE 6
4” (10.2 cm) PVC EXHAUST VENT OR COMBUSTION AIR INTAKE PIPE LENGTHS FROM
INSIDE WALL FOR LOW GROUND CLEARANCE INSTALLATIONS
Terminating
# of Elbows
Maximum Length
1
45 ft (13.7 m)
(2) 90° Elbows with (1) 90° Elbow
2
40 ft (12.2 m)
(2) 90° Elbows with (1) 90° Elbow
3
35 ft (10.7 m)
(2) 90° Elbows with (1) 90° Elbow
4
30 ft (9.1 m)
(2) 90° Elbows with (1) 90° Elbow
18
SECTION VI: WATER CONNECTIONS
NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.
After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking
out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the
faucet. The COLD water inlet and HOT water outlet are identified on the top and front of the water heater. Make sure the
diptube is in place before making the cold water connection. Make the proper plumbing connections between the water
heater and the plumbing system to the house. Install a shut-off valve in the cold water supply line.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples on top or side 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.
Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge
may be hot enough to cause scald injury. The water is under pressure and may splash.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE RELIEF VALVE
WILL RELEASE THE MANUFACTURER FROM ANY CLAIM, WHICH MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
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.
NOTICE
If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the
cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in a
closed system without provisions for controlling thermal expansion. Warranties do not cover damages from thermal
expansions such as pressure bulges and/or deformities. Your water supplier or local plumbing inspector should be
contacted on how to control this situation.
After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is
filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows
through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER
HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER.
19
WARNING
Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be
hot enough to cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install temperature and pressure protective equipment
required by local codes, but not less than a combination temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or
materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot
Water Supply Systems, ANS Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve shall be
marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The
combination temperature and pressure relief valve shall also have an hourly rated temperature steam BTU
discharge capacity not less than the hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose
on the water heater.
Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.
Verify that the combination temperature and pressure relief valve complies with local codes. If the combination
temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit
within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical
part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and
pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.
DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches
(10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature
and pressure relief valve.
Do not place a valve between the combination temperature and pressure relief valve and the tank.
This water heater can deliver scalding temperature
water at any faucet in the system. Be careful
whenever using hot water to avoid scalding injury.
Certain appliances such as dishwashers and automatic
clothes washers may require increased temperature
water. By setting the thermostat on this water heater to
obtain the increased temperature water required by
these appliances, you may create the potential for
scald injury. To protect against injury, you should
install an ASSE approved mixing valve in the water
system. This valve will reduce point of discharge
temperature by mixing cold and hot water in branch
supply lines. Such valves are available from the
manufacturer of this water heater or a local plumbing
supplier. Please consult with a plumbing professional. For information regarding space-heating water connections and
plumbing arrangements, refer to the section, “Installation Instructions for Potable Water and Space Heating” in this
Installation and Operating Instruction Manual.
APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
120°F (49°C)
More than 5 minutes
125°F (52°C)
1½ to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1½ seconds
155°F (68°C)
About 1 second
20
SECTION VII: GAS CONNECTIONS
The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in
Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code
(Latest Edition).
The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (0.25 kPa) water
column above the operating manifold pressure. See the rating plate and gas valve for the manifold pressure and gas
type. The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for natural gas and
liquefied petroleum gases/propane gas.
1. Connect this water heater only to the type of gas (Natural or Propane gas) as shown on the rating plate. Use clean
black iron pipe or equivalent material approved by local codes and ordinances. (Dirt and scale from the pipe can
enter the gas valve and cause it to malfunction). The inlet gas line must have a minimum length of three (3) inches
(7.6 cm) drip leg (sediment trap) installed as close to the water heater’s gas valve as possible. A ground joint union
must be installed as close to the water heater as possible in the gas supply line feeding the water heater to permit
servicing of the water heater. Compounds used on the threaded joints of the gas piping must be resistant to the
action of liquefied petroleum gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make certain
that no pipe dope has become lodged in the inlet screen of the gas valve. Extreme care must be taken to ensure
no pipe dope enters the gas valve. Avoid excessive torque when tightening the gas supply line to the gas valve.
Excessive torque may result in cracking of the gas valve housing and could create a gas leak. The suggested
maximum torque is 31.5 ft. lbs. (4.4 kg-m).
WARNING
The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas
inlet as a result of excessive torque.
2. This water heater and its gas connection must be leak tested before placing the water heater in operation. Check for
gas leaks with a soap and water solution and a brush or a commercial leak detector fluid. NEVER USE A MATCH OR
OPEN FLAME FOR TESTING!
CAUTION
The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated
from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply
system at test pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be capped when not
connected to the water heater.
3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the
control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to
operate the water heater.
WARNING
Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field
involved. Plumbing, air supply, venting, gas supply and electrical work are required.
Light the unit in accordance with the operating instructions label attached to the water heater.
Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate. Over
firing could result in damage or sooting of the water heater.
If the unit is exposed to the following, do not operate water heater until all corrective steps have been made by a
factory authorized independent service contractor or qualified service professional.
1. Flooding to or above the level of the burner or controls
2. External firing
3. Damage
4. Firing without water
5. Sooting
21
SECTION IX: ELECTRICAL CONNECTIONS
WARNING
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.
All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes,
the National Electrical Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code.
The water heater must be wired to a 115 volt, 60
Hz, AC power supply. The water heater should be
wired on a separate circuit and breaker. If a
flexible line cord and plug is permitted by local
code, then provide a three wire grounding type
receptacle within reach of the line cord provided on
the control box. Do not plug the line cord into a
receptacle that can have the power supply
interrupted by a switch that is used to control lights
or another appliance.
If wiring in conduit is required, cut the line cord
close to the control board and make the
appropriate wiring connections.
CAUTION
This water heater must be wired on a separate
circuit. Failure to wire on a separate circuit may
cause improper operation or failure of the
electrical components of the water heater.
Refer to the “Electrical Connections” section of
the Installation and Operating Instructions
Manual for complete instructions on electrical
wiring and connections to the water heater.
Do not energize the electric circuit before the
water heater tank is filled with water.
Wiring Diagram (to the right)
22
TYPICAL INSTALLATION
Notes: The heat trap shown above is not part of the water heater, only a piping suggestion to reduce the standby heat
loss. The drain pan may be purchased from your water heater supplier.
WARNING
Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against
the water heater or direct vent system, and proper care must be taken to avoid unnecessary contact (especially by
children) with the water heater and direct vent system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS
WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.
23
Lighting And Shutdown Instructions
Temperature down
CAUTION
Do not use this appliance if any part has been under water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the control system including gas controls, which has
been under water.
24
SECTION X: OPERATING INSTRUCTIONS
TEMPERATURE ADJUSTMENT
APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
120°F (49°C)
More than 5 minutes
125°F (52°C)
1½ to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1½ seconds
155°F (68°C)
About 1 second
DANGER
Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting
of 140°F (60°C). To protect against hot water injury, install an ASSE approved mixing valve in the water system.
This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed
plumbing professional or local plumbing authority should be consulted.
This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or
the gas supply fail to shut off, turn off the manual gas control valve to the appliance and call a qualified service
technician.
CAUTION
This water heater, when set at a lower temperature setting, is not capable of producing hot water of
sufficient temperature for sanitizing purposes.
NOTICE
Whenever the water heater is filled with cold water, condensate will form on the cool tank surface and drops of water
will fall on the hot burner and combustion chamber surfaces producing a “sizzling” noise. Condensation is normal
and does not indicate a leak. It will disappear when the tank becomes heated.
The lower the temperature setting, the greater the energy efficiency, both to heat the water and to maintain the
storage temperature during standby periods. Lower water temperatures also extend tank life. Remember, no water
heating system will provide exact temperatures at all times. Allow a few days of operation at this setting to
determine the correct temperature setting consistent with the requirements for the installation.
The water heater temperature setting is adjusted by using the control display mounted to the front of the control panel of
the water heater. The water heater thermostat is set at the lowest setpoint of 70°F when shipped from the factory. The
control display shows the temperature setpoint in degrees Fahrenheit (°F) or degrees Celsius (°C), and the status of the
water heater (“Idle” or “Heating”). If the water heater is functioning normally, the display will also show “Operational”.
For energy efficient operation of your water heater, the suggested initial temperature setting is 120°F (49°C). During the
winter season, or any cold period, you may desire a higher temperature setting to adjust for the colder incoming water.
This adjustment, however, may cause additional condensation to form on the cooler tank surface. This does not mean
the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your
water heater and reduce the amount of condensation developed.
Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are proven to be
condensation. To avoid unnecessary expense and inconvenience, make sure the tank is leaking before calling a service
person.
25
Water Heater Display and Control Buttons
Shown flashing
in display only when
temp is adjusted
Sequence of
operation Indicator
Reads "Idle” or “Heating"
Status Indicator
Read "Operational"
or "Service Needed"
Temperature
Up Button
°F
setpoint
idle
Status Operational
SELECT
SET
Temperature Setpoint
in Degrees F or Degrees C
Range 70 - Max °F
Range 21 - Max °C
Temperature
Down Button
Set button
Select button
WARNING
If the water heater display does not show “Operational” in the “Status” indicator, there may be an operating
malfunction with the water heater. If this is the case, a numeric code will be displayed. Refer to the label next to the
display for the definition of the error code and call your plumbing professional or service agent to service the water
heater. Do not try to reset the water heater without having a qualified service person to diagnose and correct the
problem. If the display is blank or does not show an error code, make sure there is power to the water heater.
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. See following section to change the maximum setpoint limit (max setpoint). Make sure the water
heater control display is not in a public area that can result in the temperature settings being improperly adjusted.
See previous warning on scalds and an ASSE approved mixing valve.
NOTICE
When the maximum setpoint is reached, the display will show “Max Setpoint” without the setpoint value. The
maximum setting is equal to approximately 180˚F (82˚C).
The default temperature setpoint from the factory is 70˚F (21˚C).
26
TO INCREASE SETPOINT TEMPERATURE
Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display.
°F
idle
Status Operational
SELECT
SET
%
Step 1
Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button.
"Setpoint"
flashes
°F
setpoint
idle
Status Operational
SELECT
SET
%
Step 2
Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” will stop flashing. If the “SET” button is
not pressed, the new temperature setting will take effect in approximately 10 seconds.
"Setpoint" flashes
for 10 seconds
°F
setpoint
idle
Status Operational
%
SELECT
SET
Step 3
27
Press SET Button for setting to
to take effect immediately
To Decrease Setpoint Temperature
Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display.
°F
idle
Status Operational
SELECT
SET
%
Step 1
Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button.
"Setpoint"
flashes
°F
setpoint
idle
Status Operational
SELECT
SET
%
Step 2
Step 3: Press “SET” button for new setting to take effect immediately. The setpoint will stop flashing. If the “SET” button
is not pressed, the new temperature setting will take effect in approximately 10 seconds.
"Setpoint" flashes
for 10 seconds
°F
setpoint
idle
Status Operational
%
SELECT
SET
Step 3
28
Press SET for setting to
take effect immediately
To Change Temperature Format in Display from °F to °C or ˚C to ˚F:
Step 1: Press “SELECT” button until °F/°C is displayed.
°F
°F/°C
idle
Status Operational
&
SELECT
Press select
SET
Step 1
Step 2: Press “SET” button to change temperature format. Symbol °F/°C will flash.
°F
°F/°C
idle
Status Operational
SELECT
%
%
SET
°F/°C Flashes
Step 2
Step 3a: Press “Temperature Up” button to change temperature format to °C.
Changes to "°C"
°C
idle
Status Operational
SELECT
°F/°C
SET
°F/°C Flashes
Step 3a
29
Step 3b: Press “Temperature Down” button to change temperature format to °F.
Changes to "°F"
°F/°C Flashes
°F
°F/°C
idle
Status Operational
SELECT
SET
%
Step 3b
Step 4: Press “SET” button to confirm ˚F or ˚C format. °F/°C will stop flashing. Setpoint display will appear in the format
selected (˚F or ˚C) in 10 seconds.
Symbol "°F/°C" Stops Flashing
°F
°F/°C
idle
Status Operational
%
SELECT
SET
Press Set
Step 4
Step 5: Pressing “SELECT” button will return display to setpoint in format selected (˚F or ˚C) immediately.
Setpoint shown in °F
°F
idle
Status Operational
&
SELECT
SET
Press select
Step 5
30
An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply
to the burner and pilot if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water
temperature should be reduced to approximately 120°F (49°C) and follow Lighting Instructions to place the water heater
in operation. The water heater must have the problem corrected by a qualified service person before putting the water
heater back in operation. It is recommended that all service work be performed by a qualified service agency.
If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off, the water
heater and piping should be fully drained (See “To Drain the Water Heater”) and the drain valve should be left fully open.
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.
31
SECTION X: MAINTENANCE
Burner Flame Check
At the time of installation and at periodic intervals (about every 3 months), a visual check of the pilot and burner flames
should be made to determine if they are burning properly. No adjustment to the air shutter should be required for this
heater. The burner flames should be blue with yellow tips. A blue-orange flame is characteristic of operation on liquefied
petroleum (LP) gas. If the burner flame does not appear as described, an air shutter adjustment may be required. The
burner tube flames should light smoothly from the pilot.
NOTICE
IMPORTANT- In the event of an emergency, turn off the gas and electric (if applicable) to the appliance.
IMPORTANT- The water heater should be inspected at a minimum annually by a qualified service technician for
damaged components and/or joints not sealed. DO NOT operate this water heater if any part is found damaged or if
any joint is found not sealed.
Figure 9
Note: Actual burner may not appear as shown in Figure 9.
TO FILL THE WATER HEATER
1. Close the water heater drain valve by turning the knob or valve stem clockwise. If alternative water connections are
provided but not used, make certain they are plugged (i.e. rear connections).
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for
water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold
water connections.
5. To restore operation of the water heater, refer to operating instruction label on the water heater.
TO DRAIN THE WATER HEATER
Should it become necessary to completely drain the water heater, make sure you follow the steps below:
1. Reduce the thermostat to the lowest setting. Depress the control panel rocker switch on the top of the control box to
the “OFF” position. Disconnect power to the water heater.
2. Rotate and partially depress gas control knob clockwise to the “OFF” position.
3. Shut off the gas supply to the water heater.
4. Close the cold water supply shut-off valve.
5. Open the drain valve or valve stem on the water heater by turning the knob counter-clockwise. The drain valve has
threads on the end that will allow the connection of a standard hose coupling.
6. Open a hot water faucet to allow air to enter the system.
To refill the water heater, refer to “To Fill the Water Heater.”
32
A qualified service technician should perform the following maintenance at the minimum periodic intervals suggested
below. In some installations, the maintenance interval may be more frequent depending on the amount of use and the
operating conditions of the water heater. Regular inspection and maintenance of the water heater will help to insure safe
and reliable operation.
1. Annual checks of the ignition systems, temperature controls and any other water heater controls are necessary to
ensure proper operation. Also, all safety shut-off valves must be checked to verify proper operation and tightness.
2. The entire combustion system must be sealed for this water heater to function properly. Make sure the burner access
panel is kept tightly sealed. The combustion air supply pipe at the rear of the water heater must be tightly sealed to
the dilution air tee and combustion air boot. Replace any damaged parts. The entire venting system and combustion
air supply parts must be inspected at least annually for integrity of all joints.
3. The flow of combustion and ventilation air MUST NOT be restricted. Keep the direct vent terminal openings clear of
objects, shrubs, snow, and debris. Check to make sure the vent terminal is not damaged.
4. At all times keep the water heater area clear and free from combustible materials, gasoline and other flammable
vapors and liquids.
5. Annually conduct a visual check of the pilot and burner flames to determine that they are burning properly. See
“Burner Flame Check” section for an illustration of the proper burner flame pattern.
6. At annual intervals check the flue baffles for deterioration and scale or carbon deposits. Clean if necessary and brush
the flue tubes if excessive scale or deposits are found on the baffles. Replace any baffles that have become
excessively warped or deteriorated. Check the flue collector gasket for integrity and replace if necessary. Cleaning
of the flue baffles and flue tubes should be done prior to cleaning the burners, since deposits may fall on the burners
during cleaning or checking the baffles.
7. Annually remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign
material. Inspect the burner ports for obstructions or debris and clean with a wire brush, vacuum, or use a mild
detergent solution to clean as needed. Inspect the pilot. Carefully clean the electrode and flame sense rod with
emery cloth. The spark electrode (rod closest to the pilot hood) gap should be 1/8” (3.2 mm). NOTE: It is imperative
for proper operation of the water heater that the main burner rack be replaced in the original location.
To remove the burner rack assembly, follow the procedure outlined below:
a) Shut off the gas and electrical supply to the water heater.
b) Remove the pilot tube fittings at the gas valve and combustion box.
c) Disconnect wires to gas valve. Open control box and disconnect pilot spark and flame sense wires.
d) Disconnect the gas pipe union below the gas valve.
e) Remove the three screws securing the gasketed manifold pipe flange on the left side of the combustion box.
f) Remove the burner access panel screws and lower the hinged panel.
g) Carefully remove and push the pilot wire grommet into the combustion box with the pilot wires.
h) Disconnect the pilot tube fitting on the inside bulkhead fitting of the combustion box.
i) Unthread the gas pipe assembly from the manifold inside the combustion box.
j) Remove the screw securing the curved burner shroud on the top center securing the burner assembly to the tank
skirt.
k) Slide out the burner rack assembly.
l) To remove the individual burners from the rack, the burner assembly shroud assembly must be removed from the
burner rack by removing the four (4) screws securing the shroud to the rack. The shroud must be reattached
to the burner rack after reinstalling the burners back in the rack.
33
To reinstall the burner rack, reverse the above procedure.
Alternate method for removing the burner rack, when there is at least 20” (50.8 cm) clearance on the left front
side:
a) Shut off the gas and electrical supply to the water heater.
b) Disconnect both pilot tube fittings at the combustion box bulkhead fitting.
c) Disconnect wires to gas valve. Open control box and disconnect pilot spark and flame sense wires.
d) Disconnect the gas pipe union either above or below the gas valve.
e) Remove the three screws securing the gasketed manifold flange on the left side of the combustion box.
f) Remove the burner access panel from the front of the combustion box.
g) Carefully remove and push the pilot wire grommet into the combustion box with the pilot wires.
h) Remove the four screws securing the manifold to the burner rack.
i) Carefully remove the manifold through the left side opening in the combustion box.
j) Remove the screw securing the curved burner shroud on the top center securing the burner assembly to the tank
skirt.
k) Slide out the burner rack assembly.
l) To remove the individual burners from the rack, the burner assembly shroud assembly must be removed from the
burner rack by removing the four (4) screws securing the shroud to the rack. The shroud must be reattached
to the burner rack after reinstalling the burners back in the rack.
To reinstall the burner rack, reverse the above procedure.
8. At least once a year, check the combination temperature and pressure relief valve to insure that the valve has not
become encrusted with lime.
Lift the lever at the top of the valve several times until the valve seats properly without leaking and operates freely.
WARNING
When lifting lever of the combination temperature and pressure relief valve, hot water will be released under
pressure. Be careful that any released water does not result in bodily injury or property damage.
Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge
may be hot enough to cause scald injury. The water is under pressure and may splash.
9. Monthly drain off a gallon of water to remove silt and sediment.
WARNING
THIS WATER MAY BE HOT!
10. If the combination temperature and pressure relief valve on the appliance discharges periodically, this may be due to
thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to
correct this situation. Do not plug the combination temperature and pressure relief valve outlet.
11. All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom. If this
water heater operates under hard water conditions, the following should be performed at least every 3 months: Drain
the water heater. Remove the cleanout jacket cover and tank cover. When cleaning the tank, care must be taken to
avoid trying to break deposits loose as this could damage the glass lining and shorten the life of the water heater.
After cleaning, replace the cleanout tank cover and jacket cover, and refill with water. Refer to the section, “General
Operation” in this Installation and Operating Instruction manual for the procedures for filling and draining the water
heater.
12. Four sacrificial anode rods have been installed in the tank head to extend tank life. The anode rods should be
inspected annually for corrosion and replaced when necessary to prolong tank life. Water conditions in your area will
influence the time interval for inspection and replacement of the anode rod. The use of a water softener may increase
the speed of anode consumption. More frequent inspection of the anode is needed when using softened (or
phosphate treated) water. Contact the plumbing professional who installed the water heater or the manufacturer
listed on the rating plate for anode replacement information.
34
13. The induced draft blower motor used in this model series has sealed bearings and does not have provisions for oiling
the bearings.
14. The vent system must be inspected at least once a year to ensure against leakage of exhaust products.
CAUTION
FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS
PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN.
Contact your supplier, plumbing professional or contact the company at the address given on the rating plate of the water
heater for replacement parts.
Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER
HEATER ARE WARRANTED.
Manufactured under one or more of the following U.S. Patents: RE.34,534; B1 5,341,770; 4,416,222; 4,628,184;
4,669,448; 4,672,919; 4,808,356; 4,829,983; 4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696;
5,092,519; 5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952; 5,660,165; 5,682,666;
5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,142,216; 6,684,821; 7,063,132; 6,395,280; 7,007,748
Other U.S. and Foreign patent applications pending. Current Canadian Patents: 1,272,914; 1,280,043;
1,289,832; 2,045,862; 2,092,105; 2,107,012; 2,108,186; 2,112,515
Complete the following information and retain for future reference:
Model No: ________________________________________________________________________
Serial No: ________________________________________________________________________
Service Phone
Days:
Nights: ___________________________________________
Address: _________________________________________________________________________
Supplier: _________________________________________________________________________
Supplier Phone No: ________________________________________________________________
35
SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE
DIAGNOSTIC GUIDE FOR HONEYWELL INTEGRATED CONTROL SYSTEM
SEQUENCE OF OPERATION FOR PDV AND INDUCED DRAFT MODELS
1. When the tank temperature drops below the temperature setpoint on the display, the control sends power to the
induced draft blower to start the ignition sequence.
2. When blower reaches the full operating speed, the pressure switch closes, completing the 24 volt circuit to the
safety circuit of the control. If the exhaust vent becomes blocked or the blower fails, the pressure switch will
open, the gas valves close, and the blower stops after a 5 second post-purge. The blower will restart and
continue to operate in the lockout condition until the blockage is removed or the venting problem is corrected.
Error code 29 will appear on the water heater display.
3. The control will continue to operate the blower for 15 seconds to “prepurge” any flue products remaining before
starting the ignition sequence.
4. After the prepurge period, the control sends 24 volt power to the pilot valve “PV” terminals on the gas valve
allowing pilot gas to flow to the pilot. The control also sends high voltage through the pilot electrode to spark to
the pilot hood and ignite the pilot gas. If the pilot does not ignite within 90 seconds, the pilot valve is denergized
and the sparking stops for 75 seconds. The control will attempt to ignite the pilot two more times. If the pilot does
not light on the 3rd attempt, the control will go into “soft lockout” for 1 hour and then will repeat the 3 ignition
attempts. The blower is off during the “soft lockout” period.
5. When the pilot is lit, the flame is sensed by the flame sense rod. The flame sense signal received by the control
board causes the sparking to stop and the main gas valve to open. The main burners ignite from the pilot flame.
The pilot is continually monitored by the flame sensing circuit. If for any reason, the pilot flame is not sensed by
the flame sensing circuit, the gas valves close. After a 75 second delay, the pilot valve opens and the pilot
electrode sparks to relight the pilot. The same sequence will occur in the event of a power supply or gas supply
interruption.
6. The main burners continue to operate until the water temperature in the tank increases past the control setpoint,
which will cause the gas valve to close. The blower stops operating 5 seconds after the gas valve closes. The
water heater remains in the standby mode until the temperature drops below the setpoint and initiates another
heating cycle.
7. If for some reason, the tank temperature should reach or exceed 200˚F, then the control closes the gas valve and
goes into a “hard lockout” state and will not operate until reset by a qualified service person. The display will read
“error code 65”, which indicates the tank high limit temperature has been exceeded. No attempt should be made
to reset the control until a service person has corrected the cause of the high limit condition. Refer to the
diagnostic service section at the end of this Installation and Operating Instructions Manual.
36
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:
WARNING
The following procedure is for service and installation personnel only. Resetting lockout conditions without
correcting the malfunction can result in a hazardous condition.
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
Status Operational
&
SELECT
SET
%
NOTICE
30 Seconds after the last button press, the display will automatically return to the “User Mode”. Simultaneously
pressing the “Select” and “Temperature Up” buttons will switch the display immediately to the “User Mode”.
Step 2: Pressing “Select” button will change display to next mode
°F
Water
Temp
idle
Status Operational
&
SELECT
SET
37
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
1. Max Setpoint (Display/Change)
Max Setpoint value
Water Heater Display
°F
Max
Setpoint
idle
Status Operational
&
SELECT
SET
2a. Water Temperature Average (Displays average if there are two sensors – sensor temperature displayed if single
sensor is used).
°F Water Temp
idle
Status Operational
&
SELECT
SET
38
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
3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)
µA
Heating
Flame Current
Status Operational
&
SELECT
SET
39
4. Setpoint (Display/Change)
°F
setpoint
idle
Status Operational
&
SELECT
SET
5. ˚F/˚C (Display/Change)
°F
°F/C°
idle
Status Operational
&
SELECT
SET
6. Differential (Display only – shows the differential of the thermostat)
°F Differential
idle
Status Operational
&
SELECT
SET
40
7. Software Version (Display only)
Soft
idle
Status Operational
&
SELECT
SET
8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display
will show -- if there are no error codes.
No current error codes
idle
Status Operational
&
SELECT
SET
To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:
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. See following section to change the maximum setpoint limit (max setpoint). Make sure the water
heater control display is not in a public area that can result in the temperature settings being improperly adjusted.
See previous warning on scalds and an ASSE approved mixing valve.
Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.
°F
Max
Setpoint
idle
Status Operational
&
SELECT
SET
41
Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.
"Max Setpoint" Flashes
°F
Max
Setpoint
idle
Status Operational
%
SELECT
SET
Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint
the user can select. Note: The maximum setpoint is approximately 180˚F.
"Max Setpoint" continues to flash
while making adjustments
°F
Max
Setpoint
idle
Status Operational
SELECT
SET
%
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
"Max Setpoint" stops flashing
°F
Max
Setpoint
idle
Status Operational
%
SELECT
SET
42
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
&
SELECT
SET
%
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
&
SELECT
SET
43
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
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
44
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
Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.
"Setpoint" Flashes
°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
Note: 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”.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational
SELECT
SET
45
%
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
%
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.
"Setpoint" Stops Flashing
°F
setpoint
idle
Status Operational
%
SELECT
SET
To Display and Change Temperature Format (˚F/˚C):
To Change Temperature Format in Display from ˚F to ˚C or ˚C to ˚F:
Step 1: While in “Service Mode”, press “Select” button until “˚F/˚C” is shown in the upper right portion of the water heater
display.
°F
°F/C°
idle
Status Operational
&
SELECT
SET
46
Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display.
"°F/°C" Flashes
°F
°F/C°
idle
Status Operational
%
SELECT
SET
Step 3a: Press “Temperature Up” button to change temperature format to ˚C
Changes to "°C"
"°F/°C" Flashes
°C °F/C°
idle
Status Operational
SELECT
SET
%
Step 3b: Press “Temperature Down” button to change temperature format to ˚F.
Changes to "°F"
"°F/°C" Flashes
°F
°F/C°
idle
Status Operational
SELECT
SET
47
%
Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing.
"°F/°C" Symbol Stops Flashing
°F
°F/C°
idle
Status Operational
%
SELECT
SET
Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately.
Setpoint shown in °F
°F
idle
Status Operational
&
Lower
SELECT
SET
48
How to reset the control from Lockout Conditions:
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.
Resetting Error Codes in Soft Lockout Condition
Error Code Shown in
Water Heater Display
Status
Service needed
SELECT
%
Lockout RESET
Press for 2 seconds
All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate
and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by
pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right
button under “Lockout Reset” in the water heater display and hold for 3 seconds.
Resetting Error Codes in Hard Lockout Condition
Error Code Shown in
Water Heater Display
Status Service Needed
&
SELECT
SET
%
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.
49
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 below the water heater display and
the following section in this Installation and Operating Instruction 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 (if there are 10 error codes).
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 -- .
No Current Error Code
°F
idle
Status Operational
&
SELECT
SET
50
Step 2:
Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.
Error Code Index
idle
Status Operational
SELECT
SET
%
Step 3:
Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is.
The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the
water heater display, then there has not been an error code for error code index 10.
No Error Code Shown
for Code Index 10
idle
Status Operational
&
SELECT
SET
51
Step 4:
Press the “Temperature Down” button to change to the previous code index, code #9.
Error Code Index
idle
Status Operational
SELECT
SET
%
Step 5:
Press the “Select” button for code index #9 to view if there are any code numbers.
Stored Error Code
For Code Index #9
idle
Status Operational
&
SELECT
SET
52
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
Status Operational
&
SELECT
SET
%
Exiting Service Mode
DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR HONEYWELL INTEGRATED
CONTROLS (PDV AND INDUCED DRAFT MODEL SERIES)
Error
Code
Definition of Code
4
Low Flame Sense
Current
2
Pressure Switch
Failed to Open (Stuck
Closed)
29
Pressure Switch
Failed to Close
6
Flame Sensed Out of
Normal Sequence
(Before Opening Gas
Valve or After Closing
Gas Valve)
Cause of Problem and Actions Taken to Correct
Determine flame sense current in the Service Mode with the water heater
operating. If less than 1.0 microamps, check pilot flame sense rod and wire.
Clean flame sense rod with emery cloth. If problem is not solved, replace pilot.
The pressure switch contacts did not return back to the normally open position at
the end of the last heating cycle. The control checks to make sure the pressure
switch is in the normally open position before allowing the blower to start the
ignition sequence. Check to make sure the pressure switch tubing is not blocked.
If the pressure switch tubing is clear, replace the pressure switch.
The pressure switch contacts did not close after the blower was energized. Check
to make sure the blower is energized at the beginning of the heating cycle. If the
blower did not start, check to make sure there is power to the motor. Replace
blower or control board if defective. Check to make sure the venting system is not
blocked. Make sure the vent length does not exceed the specified limits. Make
sure the vent terminal is not blocked. Check to make sure the pressure switch
tubing is clear. Replace the pressure switch if the venting system has checked out
O.K. Control will reset once problem is corrected.
Check to make sure gas valve has closed. No voltage should be present at the
gas valve before or after ignition cycle. Make sure wire positions on the wire
harness are correct. If gas valve is stuck open, replace.
53
Error
Code
Definition of Code
23
Flame Detected
Before Ignition
24
31
32
57
58
59
Flame Detected After
Heating Cycle
Completes
Upper Sensor
Readings Faulty
Lower Sensor
Readings Faulty
Flame Rod Shorted
to Ground
AC Line Frequency
Error – Signal Too
Noisy or Frequency
Incorrect
Line Voltage Too Low
or High
61
DC Output Voltage
Unstable
62
Maximum Number of
Retries Detected
63
Maximum Number of
Ignition Recycles
Detected
64
Electronics Failure
65
High Water
Temperature (Over
200˚F)
Cause of Problem and Actions Taken to Correct
Check to make sure gas valve has closed. No voltage should be present at the
gas valve before the ignition cycle. Make sure wire positions on the wire harness
are correct. If gas valve is stuck open, replace.
Check to make sure gas valve has closed. No voltage should be present at the
gas valve before the ignition cycle. Make sure wire positions on the wire harness
are correct. If gas valve is stuck open, replace.
Resistance of upper sensor out of operating range. Check continuity of wire
harness to upper sensor, and if O.K., replace upper sensor.
Resistance of lower sensor out of operating range. Check continuity of wire
harness to lower sensor, and if O.K., replace lower sensor.
Pilot flame sensor rod is shorted to ground. Check to see if flame sensor wire has
bare spots touching metal parts of if flame sensor rod is touching the pilot shield or
other metal parts. Replace pilot if flame sense wire is damaged or flame rod is
bent. Make sure pilot shield is not touching the pilot flame sensor.
Check line voltage frequency to the water heater. Determine if there are wide
fluctuations. Call an electrician if the problem persists. The water heater should
be on a separate line.
Check line voltage to the water heater. Determine cause of low or high voltage.
Call an electrician or your utility. The water heater should be on a separate line.
Check line voltage to the water heater for erratic readings. Also check wiring to
make sure there are no shorts. If power supply and wiring are O.K., replace
control board.
Pilot is either not lighting or not staying lit during ignition cycle. Check inlet gas
pressure for minimum pressure on rating label. Is pilot electrode sparking? Check
gas valve wire harness for broken wires or shorts. If 24 volts is present between
PV and PV/MV terminals at the gas valve, replace gas valve. Check for voltage
output to the yellow and red gas valve wires on the control board pins. If during
the ignition trial period, there is no voltage present at the control board pin terminal
for the red and yellow wires leading to the gas valve, then replace the control
board. Replace pilot if wires are damaged or electrode is damaged.
Pilot flame is lost during run cycle, then restablished on ignition cycle. Check inlet
gas pressure. Is gas pressure dropping below the minimum operating pressure on
the rating label after the main gas valve opens? Is the gas pipe size to the water
heater adequate? Check the pilot shield position and condition of the burners.
Clean or replace as needed. Check the pilot flame and observe the microamp
output on the run cycle. Check the pilot tubing to the pilot and replace if crimped
or damaged. Replace pilot if wires, flame sensor, or electrode is damaged.
Replace control board.
Water temperature in tank has exceeded 200˚F. Check lower sensor. Make sure
sensor is fully inserted into the well (clip on sensor wire secures sensor in place).
Check lower and upper (where used) sensor readings. If not within specifications,
replace sensor. If sensor and wire harnesses check O.K., replace control board.
54
Procedure for Checking Thermostat Sensors
Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1)
complete cycle. Make sure system operates as desired.
To check the upper sensor or lower sensor assembly, compare the resistance of the sensor terminals (blue leads for
upper sensor, yellow and black lead for lower sensor) as measured by an ohmmeter to the water temperature as
measured by an accurate thermometer. Thermistor resistance increases as the temperature decreases. The tables
below show the correct sensor resistance at various temperatures. Replace the sensor if the ohm reading in the chart
does not approximate the reading from the sensor at the temperature measured in the tank.
°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 F
4
5
23399
22771
17905
17440
13823
13477
10763
10502
8449
8250
6683
6531
5326
5208
4274
4183
3453
3382
2808
2752
2298
2253
1891
1856
1566
1567
1303
1280
1090
1071
917
901
775
762
6
22163
16990
13140
10248
8057
6383
5094
4094
3312
3697
2209
1820
1509
1257
1053
886
749
7
21573
16553
12812
10000
7869
6238
4982
4006
3244
3643
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
°C
0
10
20
30
40
50
60
70
80
90
0
32648
19898
12492
8057
5327
3602
2488
1752
1256
916
1
31026
18968
11942
7722
5117
3468
2400
1693
1216
888
2
29495
18088
11419
7403
4917
3340
2316
1637
1177
861
3
28049
17253
10922
7099
4726
3217
2235
1582
1140
835
In Degrees C
4
5
26682
25389
16461
15710
10450
10000
6808
8532
4543
4368
3099
2986
2157
2083
1530
1480
1105
1070
810
786
6
24166
14998
9572
6268
4201
2878
2011
1432
1037
763
7
23010
14322
9165
6016
4042
2774
1942
1385
1005
741
8
21915
13680
8778
5775
3889
2675
1876
1340
974
719
9
20879
13071
8409
5546
3742
2579
1813
1297
944
698
55
SECTION XII: PARTS LIST
PART NAME AND DESCRIPTION
1. Induced Draft Blower Assembly
2. Diptube
3. Pressure Switch
4. T&P Valve
5. Flue Baffle
6. Cleanout Access (Jacket) Cover
7. Drain Valve
8a. Cleanout Cover
8b. Cleanout Cover O-Ring (under cover – not
shown)
9. Main Burner Tubes
10. Pilot Assembly
11. Pilot Supply Tube (Control Side)
12. Pilot Supply Tube (Burner Side)
13. Main Burner Manifold
14. Gas Valve
15. Main Burner Orifice
16. Transformer
17. Ignition Module
18. Anode Rods (4) (Not shown–top of tank)
19. On-Off Switch
20. Integrated Control Board
21. Utility Cover
22. Outlet Nipple
23. Temperature Display
24. Power Cord
25. Secondary T’former Wire Assy
26. Primary T’former Wire Assy
27. Lower Sensor Retainer Clip
28. Lower Thermostat Well
29. Lower Sensor
30. Pressure Switch Tubing (Not Shown–2
pcs)
31. Flue Collector Head
32. Jacket Head
33. Pilot Shield
34. Pressure Switch Cover
35. Collector Nipple Gaskets (2)
36. Flue Collector
37. Flue Collector Gasket (Top Edge)
38. Burner Access Cover Gasket
39. Sight Glass Gasket
40. Sight Glass
41. Tank (Not shown)
42. Manifold Flange
43. Burner Access Cover
44. Blower Outlet Connection
45. Blower Outlet Flange Gasket
46. Collector to Blower Transition
47. Blower Mounting Flange w/ Pressure Tap
48. Front Combustion Box Assy
49. Combustion Air Tube
50. Combustion Air Inlet Boot
51. Combustion Air Orifice (Inside Dilution Air
Tee)
52. Gas Valve Wire Harness
53. Vent Safety Switch (Not Shown–Located
Below Blower Outlet Flange)
54. Dilution Air Tee
55. Dilution Air Inlet
56. Dilution Air Pressure Tap
57. Escutcheon–Rear Boot
58. Blower Escutcheon
59. Blower Wiring Harness
60. Pressure Switch Harness
REPLACEMENT PARTS LIST FOR POWERED DIRECT VENT MODELS
Contact your supplier, plumbing professional or the company listed on the rating
plate of the water heater for replacement parts.
Provide the part name as well as the model and serial number(s) of the water
heater(s) when ordering parts. When applicable, the following information shall
be provided: type of gas, voltage and amperage, item number (from the following
list) and description (from the following list).
56
VENT KIT COMPONENTS AND OPTIONAL CONDENSATE TEE
150,00 AND 199,999 BTU/HR. MODELS: 3” VENT KIT
MODELS OVER 200,000 BTU/HR.: 4” VENT KIT
COMMON: 3” AND 4” VENT KIT
3” OR 4” EXHAUST TERMINAL
3” OR 4” INTAKE TERMINAL
57
SECTION XIII: INSTALLATION FOR POTABLE WATER AND SPACE HEATING
THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:
GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING
1. All piping components connected to this water heater for space-heating applications must be suitable for use with
potable water. In Massachusetts, space heating piping must not exceed 50 feet.
2. Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space
heating.
3. This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.
4. When the system requires water for space heating at temperatures higher than required for other uses, such as an
ASSE approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard
potential.
Please refer to the illustrations below and on the following pages for suggested piping arrangements.
Suggested Piping Arrangement For Side Connections
Suggested Piping Arrangement For Top and Side Connections
Suggested Piping Arrangement For Top Connections
58
60
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
&
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.
°F
Max
Setpoint
idle
Status Operational
SELECT
SET
Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint
the user can select. Note: The maximum setpoint is approximately 180°F.
"Max Setpoint" continues to flash
while making adjustments
Max
Setpoint
°F
idle
Status Operational
SELECT
SET
%
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
"Max Setpoint" stops flashing
°F
Max
Setpoint
idle
Status Operational
SELECT
%
SET
13
Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max
Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water
Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select”
buttons together for 3 seconds.
Max
Setpoint
idle
Status Operational
&
SELECT
SET
%
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
%
Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown
on the water heater display.
"Setpoint" Flashes
°F
setpoint
idle
Status Operational
SELECT
SET
16
Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new
setpoint. “Setpoint” stops flashing in the water heater display.
°F
setpoint
idle
Status Operational
SELECT
SET
To Display and Change Temperature Format (°F/°C):
To Change Temperature Format in Display from °F to °C or °C to °F:
Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right portion of the water heater
display.
°F
°F/C°
idle
Status Operational
SELECT
SET
Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display.
°F
°F/C°
idle
Status Operational
SELECT
SET
17
Step 3a: Press “Temperature Up” button to change temperature format to °C
°C °F/C°
idle
Status Operational
SELECT
SET
%
Step 3b: Press “Temperature Down” button to change temperature format to °F
°F °F/C°
idle
Status Operational
SELECT
SET
Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing
°F °F/C°
idle
Status Operational
SELECT
SET
18
Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately
°F
idle
Status Operational
Lower Sensor
SELECT
SET
Error Codes and Error History Display:
If there is an operating problem with the water heater, an error code number will appear on the water heater display with
“Service Needed” to the right of the “Status” indicator. The error code label is located under the Water Heater Display
and the following section in this Service Manual explains the error codes with corrective actions to repair the water
heater.
Example of Error Code in the Display
idle
Service Needed
SELECT
SET
Error Code History:
In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence
of service modes) will show an error code history, if there have been any previous operating problems with the water
heater. If the display shows --, there is not a current error code.
The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index
#1 and the most recent in code index #10.
19
To view previous error codes:
Step 1:
In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current
error codes, the display will show -- .
°F
idle
Status Operational
SELECT
SET
Step 2:
Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.
idle
Status Operational
SELECT
SET
%
Step 3:
Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is.
The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the
water heater display, then there has not been an error code for error code index 10.
idle
Status
Operational
SELECT
SET
20
Step 4:
Press the “Temperature Down” button to change to the previous code index, code #9.
idle
Status Operational
SELECT
SET
%
Step 5:
Press the “Select” button for code index #9 to view if there are any code numbers.
idle
Status Operational
SELECT
SET
Step 6:
Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the
error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water
heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in
code index #10.
Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code
display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.
°F
setpoint
idle
Statu Operational
s
&
SELECT
SET
%
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
%
Lockout RESET
Press for 2 seconds
All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not
operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described
earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the
lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.
Resetting Error Codes in Hard Lockout Condition
Error Code Shown in
Water Heater Display
Status Service Needed
&
SELECT
SET
%
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
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
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
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
12B. Gas Valve Assembly
13B. Nipple
14B. Street Elbow
15B. Union
16B. Nipple Close
17B. Aluminum Tubing
18B. Gas Valve
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
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
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