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Table of Contents

Page

PDV Service Procedure

Introduction

- - -

Tool required for service

- - -

Sequence of Operation

- - -

Troubleshooting

- - -

Thermostat Circuit Testing

PDV24-I

Pressure Switch Testing

PDV24-II

Pilot Operation Testing

PDV24-III

Main Burner Operation Testing

PDV24-IV

Main Burner & Pilot Removal & Inspection

PDV24-V

Control Board Replacement

PDV24-VI

Flue Baffle Removal & Inspection

PDV24-VII

Anode Removal & Inspection

PDV24-VIII

Generic Parts List - PDV-S

- - -

Generic Parts List - PDV-T

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Generic Parts List - Induced Draft Models

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Glossary of Terms

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Содержание D65T625

Страница 1: ...vice providers Save this manual for future reference Manual 48061A PDV80S150 PDV802200 PDV80S250 PDV100S150 PDV100S200 PDV100S250 PDV80T300 PDV100T360 D80T725 D65T625 PDV S T MODEL SERIES AND INDUCED...

Страница 2: ...ting 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 Remova...

Страница 3: ...tat 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...

Страница 4: ...able 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 mea...

Страница 5: ...e 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 in...

Страница 6: ...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 Main burner fires until the thermostat is satisfied The c...

Страница 7: ...s the induced draft blower start to operate Increase thermostat setting if tank is warm Check wire connections of board to display See illustration With the control cover tilted down measure the volta...

Страница 8: ...9 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...

Страница 9: ...buttons together and hold for 3 seconds until Max Setpoint is shown in the display Step 2 Pressing Select button will change display to next mode SELECT SET Status F idle Operational Water Temp The fo...

Страница 10: ...idle Water Temp Operational 2b Water Temperature Upper Sensor Displays if there is an upper sensor some models SELECT SET Status F idle Operational Upper Sensor 2c Water Temperature Lower Sensor Displ...

Страница 11: ...ng Operational Flame Current A 4 Setpoint Display Change SELECT SET Status F idle setpoint Operational 5 F C Display Change SELECT SET Status F C idle Operational F setpoint 6 Differential Display onl...

Страница 12: ...e setpoint Step 1 In service mode press the Select button until Max Setpoint is displayed SELECT SET Status F idle Max Operational Setpoint WARNING Setting the water temperature to the maximum set poi...

Страница 13: ...aximum setpoint value This will limit the maximum setpoint the user can select Note The maximum setpoint is approximately 180 F Step 4 Press Set button to confirm new Max Setpoint value and stop setti...

Страница 14: ...n 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...

Страница 15: ...lable 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...

Страница 16: ...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 th...

Страница 17: ...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 porti...

Страница 18: ...ELECT SET Status idle Operational C F C Step 3b Press Temperature Down button to change temperature format to F SELECT SET Status idle Operational F F C Step 4 Press Set button to confirm F or C forma...

Страница 19: ...ction in this Service Manual explains the error codes with corrective actions to repair the water heater SELECT SET idle Service Needed Example of Error Code in the Display Error Code History In Servi...

Страница 20: ...elect the error code index starting with the most recent error code 10 SELECT SET Status idle Operational Step 3 Press the Select button to view the error code for code 10 If there is a number display...

Страница 21: ...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 cod...

Страница 22: ...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...

Страница 23: ...ol will also go through 3 attempts to relight the burners every hour in the soft lockout condition All other error codes will put the water heater into a Hard Lockout condition in which the water heat...

Страница 24: ...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 insulatio...

Страница 25: ...orrected 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...

Страница 26: ...Testing Upper thermister location applicable models Lower thermister access located inside control box Sensor Resistance Testing Upper Sensor 1 Determine resistance value of upper sensor using an ohm...

Страница 27: ...rough tubing to verify that the pressure taps and tubing are clear and not leaking If the pressure switch readings are at least 0 20 w c above the above pressure switch settings for the installed mode...

Страница 28: ...he pressure switch 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 digit...

Страница 29: ...ake 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 Reconnect power Verify proper operation Make sure the water hea...

Страница 30: ...eck for clogged or kinked pilot tube clogged pilot orifice Clean or replace as needed see photo below Is there 22 27 volts AC input across wire leads MV PV PV at Gas Valve see photo to the right Check...

Страница 31: ...24 III Pilot Operation Testing 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 brok...

Страница 32: ...d Check continuity of wires with ohmeter Are ground wires okay Check for loose or damaged flame sense lead from pilot to module see illustration to the right Is flame sense lead okay Repair wire lead...

Страница 33: ...here 22 27 volts AC across pin terminals 5 8 Refer to wiring diagram also see photo Disconnect brown wire lead from MV terminal of gas valve Is there 22 27 volts AC across brown wire lead ground Repla...

Страница 34: ...umber of elbows Verify pressure switch is not cycling see Pressure Switch Testing Is vent system okay Correct improper venting condition N Is there sufficient combustion air being supplied to the wate...

Страница 35: ...necessary precaution to prevent personal injury 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...

Страница 36: ...sonal injury Step 7 Remove manifold bracket screws Step 8 Remove manifold from Burners Step 9 Slide manifold out through side flange opening in Burner Box Step 10 Disconnect Pilot Tube Fitting from in...

Страница 37: ...the following steps in this procedure Take necessary precaution to prevent personal injury Step 13 Pull pilot wires through burner box Step 14 Slide out burner assembly Step 15 To remove pilot remove...

Страница 38: ...nect 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 r...

Страница 39: ...ire Location Pilot Burner Inspection Step 1 Inspect pilot for the following a Broken or cracked ceramic insulators If found pilot must be replaced b Damaged electrode or flame sense wire If found pilo...

Страница 40: ...e right and slide control hook tabs from slots in control panel Depress plastic tabs Slots in control panel Unhook tabs from control panel slots Remove lower sensor Remove clip pull sensor out Step 3...

Страница 41: ...nderneath 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 chise...

Страница 42: ...h jacket head see photos at right 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 o...

Страница 43: ...3A 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 Wate...

Страница 44: ...ion 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...

Страница 45: ...rew w adh 9C Pan Head Screw 8 18 10C Transformer 11C Strain Relief Bushing 12C Strain Relief Bushing 7 8 13C Snap In Bushing 7 8 14C Power Cord Wiring Harness 15C Display Control Wiring Harness 16C Di...

Страница 46: ...oot 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 Ther...

Страница 47: ...t 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 Pilo...

Страница 48: ...Pan Head Screw 8 18 10C Transformer 11C Strain Relief Bushing 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...

Страница 49: ...ansistion 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 Gask...

Страница 50: ...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...

Страница 51: ...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 16C Strain Relief Bushin...

Страница 52: ...nergy Cut Off GFI Ground fault interrupt GPM Gallons per Minute Hz Hertz LED Light Emitting Diode NOx Oxides of Nitrogen NPT National Pipe Thread PSI Pounds per Square Inch VA Volt Amps VAC Volts Alte...

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