Visio-48061A PDV service manual.vsd


Reduced number of parts for servicing and wiring. ... Water heater display can show previous error code history to further aid in servicing the water heater. ... Electronic thermostat and LCD Display - Accurately monitors the tank ... PDV-S & PDV-T MODELS: 3/4" NPT Minimum connection to gas valve. ...... Gallons per Minute.

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

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Table of Contents

Page

PDV Service Procedure

Introduction

4

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Tool required for service

4

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Sequence of Operation

6

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Troubleshooting

7

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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

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Generic Parts List - PDV-T

46

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Generic Parts List - Induced Draft Models

49

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Glossary of Terms

52

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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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