Bradford White D65T625 User manual

SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by qualified service 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 DRAFT (D80T725,
D65T625) MODEL SERIES WATER HEATERS WITH
HONEYWELL INTEGRATED CONTROL SYSTEM
(PDV80S Shown)

Table of Contents
Page PDV Service Procedure
Introduction 4 - - -
Tool required for service 4 - - -
Sequence of Operation 6 - - -
Troubleshooting 7 - - -
Thermostat Circuit Testing 24 PDV24-I
Pressure Switch Testing 27 PDV24-II
Pilot Operation Testing 30 PDV24-III
Main Burner Operation Testing 33 PDV24-IV
Main Burner & Pilot Removal & Inspection 35 PDV24-V
Control Board Replacement 40 PDV24-VI
Flue Baffle Removal & Inspection 41 PDV24-VII
Anode Removal & Inspection 42 PDV24-VIII
Generic Parts List - PDV-S 43 - - -
Generic Parts List - PDV-T 46 - - -
Generic Parts List - Induced Draft Models 49 - - -
Glossary of Terms 52 - - -
2

FEATURES OF 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.
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.
3

Tools Required for Service
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.
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.
Introduction
4

Specifications
Power Supply
Current Draw
Gas Supply Connection
Approved Gas Type
Gas Pressure (Nat. & L.P.)
Venting System
Minimum Clearance for Servicing
Maximum Water Supply Pressure
Thermostat Sensor(s)
Control Board
Control Display
Transformer
Pilot
Induced Draft Blower
Dedicated 120 VAC, 60 Hz., 15 A
Less than 5 Amps
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.
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.
30" Front Clearance, 16" Top, 2" Sides and Rear
150 PSI
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

1Thermostat 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.
2The 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.
3
4Once pilot flame is proven, sparking will stop.
Sequence of Operation
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. Pilot flame proving signal (measured in
micro-amps). from the “sense” terminal, to
prove pilot flame.
5Once 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.
7Main 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.
8The induced draft blower shuts off 5 seconds after the
gas valve closes. This is the post-purge period.
WIRING DIAGRAM
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
“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
Verify Primary and Secondary
voltage at the control board.
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.
If there is not 24 volts at Secondary
pins on the control board, check
transformer. Replace transformer
or wire harness.
Does water heater display operate?
Does 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 voltage between red and
black wire pin connections to display.
Voltage should be 24 volts AC
measured at the back of the Control
Display.
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.
N
N
See next page
Switch on power.
Checking primary voltage to
transformer from board. Pins to
black and white wires.
Checking line voltage to board.
Pins to black and white wires.
Checking secondary voltage from
transformer. Pins to blue and yellow
wires.
Checking transformer voltage, front
terminals are 24 volts, rear terminals
are 120 volts.
7

Does induced draft blower
operate?
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?
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.
Is there pilot flame?
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”
Does Main Burner operate? Error code #62 on display. See pilot lights, no flame
signal in the section for “Pilot Operation Testing”
Does burner continue until
thermostat set point is reached?
See setting display in Service Mode
and displaying temperature
sensors.
Error code #63 on display. See Main Burner short
cycles in the section under “Main Burner Operation
Testing”
Blower Stops shortly after burners
shut off.
System okay
TROUBLESHOOTING
CAUTION
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals
N
Y
N
N
N
Y
Y
Y
Y
From previous page
Example of error code shown on control display.
SELECT Lockout RESET
Status Service Needed
Error Code Shown
in Water Heater Display
N
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.
Step 2: Pressing “Select” button will change display to next mode
SELECT SET
Status
°F
idl
e
Operational
Wate
r
Temp
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”.
"Max Setpoint”
SELECT SET
Statu
s
idle Operational
next to Temperature
Setpoint value.
Max
Setpoint
SELECT Lockout RESET
Status Service Needed
Error Code Shown
in Water Heater Display
9

1. Max Setpoint (Display/Change)
2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single
sensor is used).
SELECT SET
Status
°F
idle
Water Temp
Operational
2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models)
SELECT SET
Status
°F
idl
e
Operational
Upper Sensor
2c. Water Temperature - Lower Sensor (Displays if there are two sensors)
SELECT SET
Status
°F
idle Operational
Lower Sensor
SELECT SET
Status
°F
idl
e
Operational
Max Setpoint value in
Water Heater Display
Max
Setpoin
t
&
10