Bradford-White Corp C)*(N manual

Bradford White PDX Series Powered Dir ect Vent Gas Water H eaters Save this m anu al for fut ur e refe re nce Ma nua l 46 92 5A ( *) Denotes W arran ty Years SERVICE MANUAL Troubleshoo ting G uide a nd I nstruc tions fo r Ser vic e (To b e pe rfo rme d ONL Y by qua li fied s erv ice p rov ide rs) For Brad fo rd Wh it e P DX Serie s Mo dels: PDX2 50[...]

Bradford White PDX Series Powered Direct V ent Gas W ater Heaters Table of Conte nts Page TTW Service Procedure Introduction 4 - - - How to us e this manual 5 - - - Tool r equired for service 5 - - - Specifications 6 - - - Control T imings 8 - - - Sequence of Operation 9 - - - Troubleshooting 12 - - - Burner Inspec tion, Cl eaning and Re placement [...]

WARNING: If t he in forma tion in th ese i nstructions is not foll owed exactly, a fire or explosion may result c ausing property damage, p ersonal injury, or de ath. 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 yo ur gas supplier from a ne[...]

Pag e 4 Introduc tion The new Bradford White PDX2 and PDX water heaters are designed to provide reliable performance with enhanced s tandard f eatures. N ew design f eatures include re liable spark to pilot igni tion system, enhanced diagnostics, s implified servici ng, significantly quieter operation, additional vent lengths a nd certified FVIR te[...]

Tools Requi red for Service It i s intend ed for this ma nual to be use d by qual ified ser vice perso nal for the p rimar y purpose of trouble shooting and r epair of the Bradfor d White T TW Series w ater h eaters. U nderstanding the sequence of op eration section o f this manual will contr ibute g reatly to tro ubleshooting the water heater . Th[...]

Sp ecificatio ns Therm al well TCO Limit Resi dential 188° F (87°C), Commercial 199° F (93°C) Resi dent ial Tempe rature Set P oi nt R ange 60°F (16° C) to 160°F ( 71°C) (App ro ximate t emperatu re s) Blow er T emper atur e Switch Normall y closed , opens @ 165° F (74°C) , auto rese t @ 130°F (54° C). Blow er 11 5VAC, 60Hz , 3.1 amps. [...]

S p ecificatio ns V enting Specifications for: 48 Gal lon 65 Gal lon 75 Gal lon This water heater is approved for install ation with the following PVC, CPVC or ABS Schedule 40 venting material. The ma ximum and mi nimum vent lengths listed on this label are for the exhaus t portion of the vent. The intake portion of the vent must be equal to or les[...]

Contro l Timin gs Igni t io n S tat e Tim ing P re- pu r ge 2 Seconds Trial f or I gni tion 90 S econds Flame Stabiliz atio n Perio d 3 Seconds Inter- purge 15 Sec onds Flame Failure Res ponse Tim e 1.5 Se conds (2 second. Maximum ; 1 second m inimum.) Post-pur ge 15 Seconds PS Fault Del ay (failed op en/cl ose) Retry aft er 2 Mi nutes S of t Lo ck[...]

Sequen ce of Op eration Ther mostat calls for h eat. Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. Normal switch positions in th e saf ety circ uit are a s f ollows: a) Exhau st pressure switch norm ally open. b) Blo wer t emper ature s wi tch norm ally clos ed. c) Inlet pressu re switch norma lly clos[...]

Steady sta te operati on. Duri ng Steady S tate Operat ion t he Contr ol Monit ors: T hermostat t emperat ure sensor- Wh en set poin t tempera ture is sa tisfied, gas val ve is shut do wn and blower will post pu rge for 15 seconds . Control LE D flashe s a short fla sh once ev ery 4 seconds (idle ) s tatu s c ode. Pres sure sw itch / Blower temp er[...]

Sequen ce of Op eration Abnorm al Ope ration (cont .) 3. Pr essure Switch/B lower Tempera ture Fault: a ) Pressu re switch cl osed at star t of call for h eat - The contr ol waits fo ur sec onds then , proceeds to f lash 2 times wit h 3 second pause . The contr ol waits 2 minut es and then t urns on blower for 30 sec onds. The blower turn s off aft[...]

Short f lash, o nce e very four seconds “Heart beat ”, alter nates brig ht/dim Ther mostat call ing for hea t (no fault). Short f lash once per second Weak pil ot signa l on las t c all f or heat. Two f lash, three second pau se Press ure switch not w orki ng- closed pos ition . Th re e f l as h, t hr ee second pau se Press ure switch or blower[...]

Six-fo ur flash, three second paus e Undesired-f alse pilot fla me sensed. System auto r es et s. Seven fla sh, three second paus e Flammable Vapo r Sensor fault detected Eight -one fl ash, thr ee second paus e Flammable Vapo r Sensor out of s pe ci f ic at ion . Thermal well s en so r d am a ged or un plugge d Eight- three flash, t hree second pau[...]

St ep 1. Wi th ma in bu rn er in op er at io n, r em ov e o ute r j ack et do or re mo ve in ne r d oo r a s d esc ri be d i n t hi s ma nua l, see i nner door re moval , inspe ction an d repla cement secti on (page 35). Step 2. To adj ust fo r pr op er burni ng , lo o sen the ai r sh ut ter nu t, rot at e th e ai r shu tt er to cl ose t he o pe ni[...]

Bur n er Cl ea n in g St ep 1. Po siti on gas co ntrol power s witch t o the “ OFF” p osit ion an d unpl ug he ater fr om wa ll outl et. St ep 2. Tur n off g as sup ply t o wa ter heater. St ep 3. R emov e oute r jack et door and inne r door per ser vice proc edu re XI II on p age 35 . F eedl in e nu t P ilot tub in g nu t Ign ite r/flam e sens[...]

PDX SERVI CE PRO CED URE II Pilot testi ng, Clea ning and R eplacement Pilot Inspection , Testing and Replacement St ep 1. Po siti on gas co ntrol power s witch t o the “ OFF” p osit ion an d unpl ug he ater fr om wa ll outl et. St ep 2. Tur n off g as sup ply t o wa ter heater. St ep 3. R emov e oute r jack et door and rem ove inne r d oor p e[...]

PDX SERVI CE PRO CED URE III Pressure Switch Testing and Replacem ent Exhaust P res sure Swi tch Testing WARNING 120 volt potential exp osu re. Use cau tion making volt age che cks to av oid perso nal injury. St ep 1. Pos iti on pow er swi tch on gas con trol t o t he “ OF F” po sit ion. St ep 2. Rem ove the t hree scre ws (Phill ips scr ew dr [...]

Exhaust P res sure Swi tch Replaceme nt WARNING 120 vol t pote ntial exposu re. Use ca u tion to avoid p ersonal injur y. St ep 7. Reco nnect wi res from s tep 5 to ne w pres sure sw it ch. St ep 8. Reconn ect tu bing to new pr essur e swi t ch. St ep 9. Car eful ly pos iti on press ure sw itch into blowe r hous ing. St ep 10. Reco nnect wi res and[...]

PDX SERVI CE PRO CED URE III Pressure Switch Testing and Replacem ent Inlet Pr essu re S witch Testing WARNING 120 volt potential exp osu re. Use cau tion making volt age che cks to av oid perso nal injury. St ep 1. Pos iti on pow er swi tch on gas con trol t o t he “ OF F” po sit ion. St ep 2. Rem ove the t hree scre ws (Phill ips scr ew dr iv[...]

Inlet Pr essu re S witch Replaceme nt WARNING 120 vol t pote ntial exposu re. Use ca u tion to avoid p ersonal injur y. St ep 7. Reco nnect wi res from s tep 5 to ne w pres sure sw it ch. St ep 8. Reconn ect tu bing to new pr essur e swi t ch. St ep 9. Rep l ace co ntrol acces s c over fro m step 2. St ep 10. Posit ion gas cont rol power swi tch t [...]

PDX SE RVICE P ROCEDURE IV Blower Testing and Rep lacement WARNING 115 volt potential e xp osure. Use caution when making volt age che cks to av oid perso nal injury. Blower Testing Is th ere 1 15VAC acr oss t ermi nals sho w n i n ph ot o 1 7 ? I ncor r ec t s upp ly vol tag e po la r ity Determine pow er so urce prob lem and corre ct. D oes bl ow[...]

PDX SE RVICE P ROCEDURE IV Blower Testing and Rep lacement St ep 1. Pos iti on gas co ntrol power swi tc h to t he “ OFF” p osit i on. Step 2. Unp lu g bl ow er po wer co r d f rom w al l o ut le t. St ep 3. Di scon nect v ent s yst em f r om e xhaust adapt er on top o f blow er. St ep 4. Rem o ve ex haust ad apte r from blower (bl ade s crew d[...]

PDX SERV ICE PR OC EDURE V Blower T emperature Sw itch Testing and R eplacement Blower Temper ature S witch Testing. WARNING 120 volt potential e xp osure. Use caution to avo id person al injury. 1 9 Di sconn ect wi re le ads to swit ch. Us ing a mu lti -mete r s et to the o hms set tin g, is there c ontin uity b etw een the switch te rminal s? Swi[...]

PDX SERV ICE PROCE DURE V Blower T emperature Sw itch Testing and R eplacement Blower Temper ature S witch Replaceme nt. WARNING 120 volt potential exp osu re. Use cau tion to avo id person al injury. St ep 1. Pos iti on gas co ntrol power swi tc h to t he “ OFF” p osit i on and un plug hea ter fr om wal l out let. Step 2. Remo ve t ubin g fr o[...]

PDX SE RVICE P ROCEDURE VI Gas Control/T hermal Well Testing an d Re pl ac e m e nt PDX Ser ies Therma l Well Te sting Ther mal w ell t est ing Pos i tio n ga s co nt rol po w e r s witc h to the “O F F” p os it io n a n d d is con ne ct t her m al wel l h ar ne ss f rom g as con tr o l. N Y Usin g a mult i-mete r set t o the ohms s etti ng, in[...]

° F 0123 456 78 9 40 26109 25400 24712 24045 2 3399 22771 22 163 21573 2100 0 20445 50 19906 19383 18876 18383 1 7905 17440 16 990 16553 1612 8 15715 60 15314 14925 14548 14180 1 3823 13477 13 140 12812 1249 4 12185 70 11884 11592 11308 11032 1 0763 10502 10 248 1000 9760 9526 80 9299 9078 8862 8653 8 449 8250 80 57 7869 768 5 7507 90 7333 7165 70[...]

PDX SE RVICE P ROCEDURE VI Gas Control & Ther mal Well Te sting and R eplacement Gas Cont rol & Ther ma l Well Rem oval Fro m Wate r Hea ter Step 1. Posi tio n ga s va l ve p ow er s witc h t o the “ O FF” pos i ti on a nd Un pl ug H ea t er f rom po w er s up pl y. St ep 2. Drai n heat er to a po int be low t he gas contro l lev el. St[...]

Gas C ontro l As sembly to T he rmal We ll St ep 6. Reco nnect wire harn esses to g as cont r ol pe r th e ill ust r ati on . St ep 7. Reco nnect ga s pipi ng to gas cont rol . Rest ore ga s sup ply an d chec k for ga s le aks. Step 8. To re sum e op er at io n, f ol low t he ins t ruc t io n l oc a ted o n t he l ig ht in g ins tru ction la bel or[...]

PDX SER VICE PR OC EDURE VII Flamm able Vapors Sensor Testing Pag e 29 PDX Ser ies Flamma ble Vapor Sensor Step 1 . Posi tion power s witc h on ga s contro l to t he “O FF” p ositi on. Step 2 . Disco nnect f lam ma ble va por se nsor f rom ga s con tro l. Ste p 3. Usin g a mu lt i-m ete r se t t o t he o hm s set ti ng check r esis tan ce of fl[...]

PDX SERV ICE PROC EDURE VIII Safety Circuit Voltage Trace Safety C ircui t Voltage Trace WARNING 120 volt potential exp osu re. Use cau tion making volt age che cks to av oid perso nal injury. Posi tio n gas co ntrol switch to the “O N” posi t io n an d ad ju st t h erm o st at di al to ca ll f or he at, Is th er e 1 0 to 13 VA C b etw ee n red[...]

PDX SERVI CE PROC EDURE IX 120 V AC Trace WARNING 120 vo lt potential exp osure. Use c au tion makin g voltage ch ecks to avoid personal inj ury. Disc onne ct c ord s et as show n i n ph oto 2 9 L ED status N one, C ont rol LED not on o r fl ashi ng. Step 1. Verify 1 20VAC and pro per polari ty at w all outlet . Step 2. With un it plugged in and co[...]

PDX SERVICE PROCEDURE X Dip Tube Inspectio n and replace ment St ep 1. Posi tion on/o ff sw itch of gas con trol va lve to “OFF ” po sit ion a nd un plug w ater heater fr om wal l outl et. St ep 2. Turn off cold w ater sup ply to wa ter heat er. Con nect hose t o drai n valv e of wate r heat er and rou te to an open drain. O pen a near by hot w[...]

PDX SERVI CE PROC EDURE XI An ode Inspectio n and replace ment St ep 1. Posi tion on/o ff sw itch of gas con trol va lve to the “O FF” p ositi on and unpl ug wat er he ater fr om wa ll outl e t. St ep 2. Turn off cold w ater sup ply to wa ter heat er. Con nect hose t o drai n valv e of wate r heat er and rou te to an open drain. O pen a near by[...]

PDX SE RVICE P ROCEDURE XII Flue Ba ffle Inspectio n and replace ment Step 1. Posi tion gas con trol p ower sw itch to th e “OFF” po siti on a nd unpl ug b low e r f ro m wall ou tl et . Step 2. Disco nnect vent syst em fr om ex haus t a dapte r on t op of bl ower . Step 3. Disco nnect inta ke air pipi ng. S tep 4 . Unp lug c or d s ets f rom b[...]

PDX Ser ies Step 4 . R ight s ide Inne r D oo r Remo va l. a) R em ov e wi re t ie f r om f e ed li ne . b) Re m ov e ( 2) 1 /4 " he x dri ve sc re ws from ri gh t s i de in ner d oor . c ) Remo ve (2) 1 /4" he x drive screws from flange sectio n of inn er do or. d) Re m ov e r ig ht s id e i nne r do or and se t asi de . B e car efu l no[...]

PDX Ser ies Ins tallatio n of Inner Door With Gas ket. WARNING Stripp ed fast ener conn ections ma y allow for sea l breach o f inner door . A seal breach may result in a fire or explo sion c aus ing pr ope rty da mag e, p erson al inj ury or de ath. Do n o t ov er tight en screws in steps 8, 10 and 11. If a fas t ener connect ion is stri pped, con[...]

PDX Ser ies St ep 10. Firm ly pl ace ri ght s ide inner d oor flang e agai nst th e left s ide i nner door f lange and secu re wi th two ¼ ” dr ive screws fr om step 3c. DO NOT OVER TIGHTEN SCR EWS . St ep 11. Align r igh t side inner door t o com busti on cham ber and verify t he fasten er holes of the co mbust i on cha mb e r ar e a l ig ne d [...]

NOTES P ag e 3 8 Glossary of Terms BTU B ritish Thermal Units GPM Gal lons per Minut e Hz Hertz KW/h Killo-watt s per hour LED Light Emitti ng Dio de NPT Na tional Pipe T hread Ohms Ohms of resistance PSI Poun ds per Sq uare Inch RPM R evol utions pe r Min ute TCO Temp erature Cut Off VAC Volts Alte rnatin g Curre nt W.C. I nches of Water Colu mn ?[...]

Parts L ist 1. Bl ower As sembly 2. Blower Temp. Switch 3. Exh aust Pressure Switch 4. Inlet Pressure Swi tch 5. Blower Gasket 6. Tee and Vent Pipe Ass y. 7. Vent Adap ter with Ter m. 8. Intake Te rminal 9. Vent Termi nal Elbow 10. Ex haust Adap ter 11. Con dens ate Ho se Kit 12. F lue Reducer 13. Heat Trap I nsert ( outlet ) 14. Heat Trap I nsert [...]

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