Bradford-White Corp PDV80S250 manual

SERVICE MANUAL Troubleshoot ing Guide and Instructions f o r Service (To be per forme d ON LY by qu al ifie d servic e pr ovid ers) Sav e this m anua l for fu ture r efere nce Manu al 4 806 1A PDV 80S150 PDV 802200 PDV 80S250 PDV 100S150 PDV 100S200 PDV 100S250 PDV80T 300 PDV 100T360 D80T725 D65T625 PDV(S,T) MODEL SERIES AND INDUCED DRAFT (D80T725,[...]

Table of Conte nts Page PDV Service Procedure Introduction 4 - - - Tool r equired for service 4 - - - Sequence of Operation 6 - - - Troubleshooting 7 - - - Thermos tat Circuit Testing 24 PDV24-I Pressure Switch Tes ting 27 PDV24-II Pilot Operation Testing 30 PDV24-III Main Burner Oper ation Testing 33 PDV24-IV Main Burner & Pilot Removal & [...]

FEA TURES OF HONEY WELL I NTEG RATED CONT ROLS SY STEM Attr ac ti ve digital wat er heater displ ay on control panel for setting and dis pl aying the tem per at ure set point . P re ssing temper at ure up and down button s changes the temper at ure setp oint . Same water heat er disp lay use d on al l mod els. Temperat ure form at may be displayed [...]

Too ls Re qu ir ed fo r Ser v i c e It is intende d for this manual to be used by qua lified service perso nal for the primar y purp ose of troubl eshooting analysis and repa ir of th e Bradford W hite PDV & Induce d Draft Ser ies Water Hea ters. Un derstanding th e sequ ence of operation sect ion of th is manu al wi ll contribu te greatl y to [...]

Specifica tions Power Supply Current Draw Gas Supply Connec t ion Approv ed G as Type Gas Pr essu re (Nat. & L .P.) Venti ng Syst em Minimum Clear anc e fo r Servicing Maxim um Wat er Suppl y Pres sure Ther m ostat Senso r(s) Control B oar d Control Di splay Transf ormer Pilo t Induced Dr aft Blower Dedicated 120 V A C, 60 Hz., 15 A Less than 5[...]

1 Thermost at calls for heat: . The relay clos es on the control board, sendi ng line volt age ( 115- 120 volts) from “in ducer” term i nals #5 and 3 on the control boar d to the i nduced dr aft blower. 2 The blo wer st arts and when suffici ent vacuum is achi eved, t he pr essure s witch closes a nd com plete s t he 24 vol t circu it bet ween [...]

TRO UBLES HOOTING CAUTION Use Caution Not t o Damage Connect ors wh en makin g Vol tage Measur ements o r J umping T erminals Water Heat er Fault: Wate r hea ter does not oper ate Disp lay Err or Code: Water heat er display does not ope rate - blank display Che ck ma in power supply to wat er heater - fuse , ci rcuit break er, plug rece ptacle, lin[...]

Doe s i ndu ce d dra ft bl owe r oper ate ? Er ror co de #29 on dis pl ay . Me as ur e vo l ta ge at the pi n ter m in al s on th e co ntr ol boa rd b et wee n the b la ck and w hit e wi res t o the bl ower ( ter mi na ls 5 an d 3 on th e “i ndu cer ” outp ut on th e boar d , se e i mage ab ov e). Make s ure th e cont rol di spla y sh ows “he[...]

ACCESSI NG SER VICE MO DE O N THE W ATER HE ATER D ISPLAY (F OR SER VICE P ERSO NNEL ONLY) The dis play has a “serv ic e mo de” for ch angin g the maxim um set point a nd ac ce ssi ng informat ion in aiding serv ic ing of the water heat er. This procedur e is for s er v ic e and ins ta llation per s onn el only. To enter the Serv ic e Mod e, fo[...]

1. Max Setpoint (Di splay/ Change) 2a. Water Temperat ure Aver age (D is plays aver age if t her e ar e two sens or s - sens or temper at ure display ed if single sensor is us ed). SEL E CT SET Status °F id le Water Temp Operational 2b. Water Tempe rature - Upper Sen so r (Dis pl ays if there is an upper se ns or - some model s) SEL ECT S ET St at[...]

3. Flame Current of Pilot Flame Sens or (Di splays only in the Heat ing Cy c le) SELECT SET Stat us Heatin g Operati onal Flame Cu rrent µA 4. Setpoint (Dis pla y/Chan ge) SELECT SET Status °F idle setpoint Operational 5. °F/° C (Displ ay/Change) SEL ECT SET St at us °F/C° idle O per at io n al °F set point 6. Diffe re nti al (Display only -[...]

7. Software Ve r si on (Di s play only ) SELECT SET Stat us idle Operat ional Soft 8. Error Code Hist ory (Displ ay s if there are present erro r codes or up to 10 previous er r or code s). Water Heat er Display will show a “--“ if t here are no error codes. SELECT SET St at us id le Operational To change the Maximu m Setp oi nt Limit (Max Setp[...]

Step 2: Press “ Se t” butt on t o en ter s etting mode. “Max Setpoin t” will flas h to ind icate setti ng mode. SELECT SET Status °F idle Ope rat io nal Ma x Setpoint Step 3: Press the “UP ” or “DOWN” but to ns to change th e maximum setpoi nt value . This will li mit the maximum setpoin t the user can se lec t. Note: The maximum s[...]

Step 5: 30 Seconds aft er the last b utt on pr es s , th e Wate r Heat er Dis play will go back to “User Mode” . It will re ad “Max Setpoint ” without sh owing a te mperature value if the temper at ure setpoi nt is at th e maxim um sett ing. The Water Heater Display can be set back to the “Us er Mode” immediat ely by pre s sing b oth t [...]

Step 3: For water heate rs using two temper at ure sensor s , pr es s ing th e “Sele ct” butt on agai n displays the Low er Sensor tempera ture readi ng. “Lower Se ns or ” wil l be di s play ed in t he lower left side of the stat us window of the wat er heater displa y. SEL ECT SE T Sta tu s °F idle O per a ti o nal Lower Se ns or To Di sp[...]

Step 2: Press the “Set ” butt on to ent er the set ting mode . “Setpoint ” will flas h in the wat er heater disp lay . SELECT SET Status °F idle set poi nt O per ati onal Step 3: To raise the temper at ure setpo int , press the “Temper at ure Up” butt on unt il the desir ed temper at ure is sho wn on the wat er heater d isplay. SELECT [...]

Step 5: When the desired s et point is reache d on the water heater dis pl ay, press the “Se t” but ton to confirm the new setpoi nt . “ S etpoin t” stops flas hing in th e water heater dis play . SELECT SET Status °F idle set poi nt O per ati onal To D is play an d Cha nge T empe ra ture F orma t ( °F/ °C): To Change Temperat u re Forma[...]

Step 3a: Pres s “Tem peratur e Up” bu tton to chang e tem peratur e format to ° C SELECT SET Status idle Operat iona l °C % °F/ C° Step 3b: Press “ Temperature Down ” butt on to change temperat ure f ormat t o °F SELECT S ET St atus id le Ope rat io nal °F °F/C° Step 4: Press “ Se t” butt on t o conf ir m °F or °C forma t. °F[...]

Step 5: Pr essing “Se lec t” but ton will return display to setpo int in format selec t ed (°F or °C) immediat ely SELECT SET Stat us °F idle Op e rat ional Low er Sens or Error Co des an d Error Histor y Disp lay: If there is an oper at ing probl em with the water heater , an err or cod e numb er will appear on th e water heater dis play wi[...]

To vi ew previ ous er ror co des: Step 1: In “ Service M ode pres s the “Selec t” bu tton until the ne xt display af ter th e “Sof tware Ver sion”. I f ther e are no curr ent error code s, the displ ay will show -- . SEL ECT S ET St atus °F idle Operati onal Step 2: Pres s the “Tem per at ure Down” butt on to sele ct the error code i[...]

Step 4: Press the “Tempe r ature Down ” button to change t o the previou s code index, code #9. SELECT SET Status idle Opera t ional % Step 5: Press the “Select ” button for code inde x #9 to view if the re are any code num ber s . SELECT SET Status idle Op eratio nal Step 6: Continue press ing t he “Temper ature Down” button to chan ge[...]

ERROR CODE DEF I N ITIONS If t he wat er heate r has an oper ating probl em, th ere will be a number in t he wat er he ater displ ay wi th “Service Need ed” shown below th e e rro r code number. Note the error co de and the def ini ti on in the chart belo w. T his labe l a ppear s on the cont rol box under the wat er heater disp lay . The follo[...]

WARNING The f ollowing p rocedure is for service an d inst allation per sonnel on ly. Resetti ng lockout condi tions witho ut corre cting the m alfunc tion can r esult in a hazardou s conditio n . If an err or cod e is displ ayed (excep t fo r #4, low fla me sense current), the water heat er will be in a “lockou t condit ion ” with th e wa ter [...]

SERV ICE PROCEDURE PDV24- I The rmostat Circ uit Tes ting CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . WARNING Do not rese t the display fro m the[...]

SER VICE P ROCEDURE PDV24-I Thermostat Circuit Testing Condit io n: Water Heat e r Not Operatin g Displ ay sho ws erro r cod e “65 ” High Water Temper at ure (over 200 deg. F) Co ntin ued WARNING! Do not oper ate water heat er without ver if ying tha t the overhe ating condit ion has been cor r ec ted . On ce cau se of o verh eating condit ion [...]

° F 012345678 9 40 26109 25 400 24712 24 045 23399 227 71 22163 2157 3 21000 20445 50 19906 19 383 18876 18 383 17905 174 40 16990 1655 3 16128 15715 60 15314 14 925 14548 14 180 13823 134 77 13140 1281 2 12494 12185 70 11884 11 592 11308 11 032 10763 105 02 10248 1000 0 9760 9526 80 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507 90 7333 7165 7[...]

SERVI CE PROCE DURE PDV 23-II Pressure Switc h Testing D ANGER 120 vo lt exposure. To avoid personal in jury, use cau tion wh ile per forming this proce d u re. CAUTION Be Care ful When Making Vo ltage Mea sur eme nts or Ju mp i ng Te r minal s Not to Damage or Deform Connectors or Connecto r Pins. Cond ition: Bl ower operates, burners not lit. Dis[...]

SERVI CE PRO CEDURE PDV24-II Press ure Swit ch Tes ting DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. Vent saf ety thermal sw itch on PDV-S blow er[...]

SERVI CE PRO CEDURE PDV24-II Press ure Swit ch Tes ting DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. Con d ition : Bl owe r do e s no t op e r a t[...]

SER VICE P ROCEDURE PDV24-III Pilot Ope ration Tes ting CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . Cond ition: Pilot wil l no t light or sta y l[...]

Cond ition: Error c ode 5 7: Fla me R od S hort ed t o Grou nd Di sconn ect p ow er. Shut off gas sup ply to wa ter he ater. Slid e out bur ner as sembl y . See sec ti on on remo vi ng pil ot and ma in bu rn er as sembl y. SERVICE PROCEDURE PDV24-III Pilot Operation Testing Ch eck to see if pilo t shi eld is to uching pil ot flam e sens or or fla m[...]

SER VICE P ROCEDURE PDV24-III Pilot Ope ration Tes ting CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . Con dition: Pil ot li gh ts, n o or low f lam[...]

SERV ICE PROCEDURE PDV24- IV Main Burner Operation Tes ting CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . Cond ition: Ma in b urn er will n ot li g[...]

SERV ICE PROCEDURE PDV24- IV Main Burner Operation Tes ting CAUTION Be Carefu l When Mak in g Voltage Meas ureme nts or J umpi ng Ter min als Not to Dama ge or D e form Co nn ect ors or Con nect or Pi ns. DANGER 120 vo lt exposure. T o avoid personal injury, use ca u ti on while performing this p rocedure . Co ndition : Ma in burn er s hor t cy cle[...]

SER VICE PR OCEDURE PDV24-V Main B urner & Pilot Removal and I nspe ction WARNING Wat er He ater co mpone nts may be HOT w he n per form ing the fol lowin g step s in thi s proc edure. Tak e n e cessary p recaut ion to pr event p erson al injury. Step 1: Remove burne r box cover screws Step 2: Open Bur ner Box Cover Step 3: Discon nect Pilot Fi[...]

SERV ICE PROCEDURE PDV24- V Main B urner & Pilot Removal and Inspection WARNING Water Heate r component s may b e HOT when per forming the fo llowing steps in this pro cedure. T ake necess ar y precau tion to p revent personal in jury. Step 7: Remove manif old bracket scr ews Step 8: Rem ov e ma nif old from Burner s Step 9: Sl ide m anif old o[...]

SERV ICE PROCEDURE PDV24- V Main B urner & Pilot Removal and Inspection WARNING Water Heate r component s may b e HOT when per forming the fo llowing steps in this pro cedure. T ake necess ar y precau tion to p revent personal in jury. Step 13: Pull pilo t wires throu gh burner box Step 14: Slide out burner as s em bly Step 15: T o remove pilo [...]

38 SERVICE PROCEDURE PDV24- V Main Burner & Pilot Removal and Inspection WARNING Water H eater c omponen ts may b e HOT when perform ing th e follo wing steps i n this procedur e. Take n ecessar y precau tion to p revent personal i n ju ry. Main Burn er Remo val Step 1 . Di sconnect (un-pl ug) water heat er from ele ct r ic al s u ppl y . Step [...]

SER VICE PR OCEDURE PDV24-V Main B urner & Pilot Removal and I nspe ction P ilot Bu rner R emo val Step 1. Wi th burner rack removed fr om heat er, disconn ect pilot t ube connect ion from gas val ve Step 2. Remov e the two pilot burner mou nti ng screws securi ng t he p ilot a nd pilot shield in pla ce . Step 3. Remove pilot shield and pi lot [...]

SERV ICE PROCEDURE P DV24-VI Control Board Replacement Co nt r o l bo ard re pl a c em e n t Step 1. Depr es s left pl as tic ta bs and pull out from sl ots in c ont rol panel Step 2. Ti lt control panel to the ri ght and slide con trol hoo k tabs fr om slo ts in co ntrol panel. Depres s plas tic tabs Slot s in control panel Unhook tabs from co nt [...]

SERVICE PROCEDURE PDV24- VII Flue Ba ffle Removal, Inspection WARNING Heat er componen ts may b e HOT when perf orming the f ollowing st ep s in this pro cedure. Take ne cessa ry precau tion to preve nt person al injur y. Step 1. D isconnec t (unp lug) water hea ter fr om elec t rical supply . Step 2. T ur n “ OFF” water supply to water heater [...]

SERVICE PROCEDUR E PDV24-VIII Anode Removal and I nspe ction WARNING Wat er He ater co mpone nts may be HOT w he n per form ing the fol lowin g step s in thi s proc edure. Tak e n e cessary p recaut ion to pr event p erson al injury. Step 1. Disc onne ct (unplug ) water heat er from elec tr ic al supply. Step 2. Turn “OFF” water supp ly t o wat[...]

Generic Part s List PD V-S 1A. V ent Kit 2A. V ent Elbow 3A. In take Te r mi n a l 4A. V ent Reducer 5A. P VC P ipe 6A. B lower Vent Adaptor 7A. B lower Receptacl e Gas ket 8A. B lower 9A. T emperat ure Swi tch 10A. B lower Intak e Gasket 11A. B lower Mountin g Flang e 12A. ¼-20 Hex Nut 13A. C ollect or to Blower Transit ion 14A. Air Inta ke Ass e[...]

Generic Part s List PDV S 12B. S treet Elbow 13 B . Ga s V a lv e 14B. A lumin um Tubing 15B. Ni pple Close 16B. Un ion 17B. Ni pple 18B. Co mbustion Box Flange 19B. F lang e Gasket 20B. M anifol d 21B. M ain Bur ner Orifice 1B. Ga s Val ve Ass embly 2B. B urner Assembl y 3B. B urner Rack 4B. B urner Tube 5B. B urner Shroud 6B. Burner Dr aft Pa nel[...]

Generic Part s List PD V-S 1C. Co ntrol Box Assembly 2C. Co ntrol Box Cover As sembly 3C. Honeywe ll Display 4C. Cont r ol Box Cover 5C. In tegrated Cont r ol B oar d 6C. Cont r ol Box Panel 7C. Pow er O n/O ff S wi tc h 8C. Pan Head S crew w/ adh. 9C. Pan Head S crew #8-18 10C . T ran sf orm er 11C. Strai n Relief Bush ing ½" 12C. Str ain Re[...]

Generic Parts List PDV -T 1A. ASSE Approved Mixing Valve 2A. V ent Clamp 3A. B lower Vent Adapter 4A. Combus tio n Box Cover 5A. Wire Racewa y 7A. B lower Receptacl e Gas ket 8A. B lower 9A. T emperat ure Swi tch 10A. B lower Intak e Gasket 11A. B lower Mountin g Flang e 12A. ¼-20 Hex Nut 13A. C ollect or to Blower Transit ion 15A. U tility Cover [...]

Generic Parts List PDV T 12B. Gas Valve A ssembl y 13B. Nipple 14B. Stree t E l bow 15B. Union 16B. Nipple Clos e 17B. Aluminum Tub ing 18B . Ga s Va l v e 1B. Burner Assem bly 2B. Burner Rac k 3B. Burner Tube 4B. B urner D raft Pane l 5B. Burner Sup por t 6B. Aluminum Tubi ng 7B. Pilot Shi eld 8B. Pilot Orif ice 9B. Pilot Assem bly 10B. Manif old [...]

Generi c Par ts List PDV -T 1C. Cont r ol Box Assembly 2C. Cont r ol Box Cover Assembly 3C. Honey wel l Display 4C. Cont rol Box Cover 5C. Int egr at ed Control B oar d 6C. Cont rol Box Panel 7C. Pow er On/O ff S wi tc h 8C. P an Head Screw w/ adh. 9C. P an Head Screw #8- 18 10C. Tran sformer 11C. Strai n Relief Bushi ng ½" 12C. Str ain Reli [...]

Generic Parts List INDUCED DRA FT MODELS 49 1A. Fl u e Ba ff le 2A . He x H ead A n ode 3A . P r e s s u re T a p F i t tin g 4A. 1/8" NP T Elbow 5A . Ho s e Ba r b 6A. S ilicone Hose 7A. Control Box Asse mbly 8A. ASSE Approve d Mixin g Valve 9A. B lower Transis tion 10A. T & P Nippl e 11A. T & P Valv e 12A. Hot W ate r Ou tlet N ip pl[...]

Generic Parts List INDUCED DRA FT MODELS 50 1B. B urner Assembl y 2B. B urner Panel 3B. B urner Tube 4B. Burner Mo unt ing Bracket 5B. B urner Rack 6B. Dual Gas Valv e Assembly 7B. Main Burner Orifice 8B. M anifold 9B . Pil ot Ass emb ly 10B. Aluminum Tubi ng 11B. P ilot D raft Shi eld 12B. Burner Sup por t 13B. Valve Su ppor t Brac k et 14B. 1&quo[...]

Generic Parts List INDUCED DRA FT MODELS 51 1C. C ontro l Box Assembly 2C. Cont rol Box Cover Assemb ly 3C. Pan Hea d Screw #8-18 4C. H oneywell Disp lay 5C. C ontro l Box Cover 6C. Int egr at ed Control Bo ar d 7C. Pan Hea d Screw #8-18 8C. T ransf ormer 9C. G round Lug 10C. Press ur e S wit ch 11 C. P ower On/Of f Sw itch 12C. Cont r ol Box Panel[...]

NOTES AC Altern ating Curren t BTU/H British Thermal Units CO Car bon Monoxide CO2 Car bon Dioxide DC Direct Current ECO Ener gy Cut Off GFI Ground fault interru pt GPM Gallo ns per Minute Hz Hertz LED Lig ht Emitting Diod e NOx Oxide s of Nitro gen NPT Natio nal Pipe Thread PSI Poun ds per Sq uare Inch VA Volt Am ps VA C Volts A ltern ating Cur re[...]