Bradford White LG2PDV50H60N User manual

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Manual 238‐51541‐00C 6/21
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
PDV Series Models:
RG2PDV40S*(N,X)
RG2PDV50S*(N,X)
RG2PDV50H*(N,X)
RG2PDV75H*(N,X)
LG2PDV50H60*(N,X)
LG2PDV75H80*(N,X)
(*) Denotes Warranty Years
Power Direct Vent Gas Water Heaters
PDV Series

2
The Bradford White
PDV Series
Powered Direct Vent Gas Water Heaters
Table of Contents
Page
PDV Service Procedure
Introduction.................................................................................................................................4
---
How to Use This Manual ..........................................................................................................5
---
Tools Required for Service........................................................................................................5
---
Specifications..............................................................................................................................6
---
Control Timings.........................................................................................................................9
---
Sequence of Operation ..............................................................................................................10
---
Troubleshooting .........................................................................................................................14
---
Burner Inspection, Cleaning & Replacement ..........................................................................16
I
Pilot Testing, Cleaning & Replacement ...................................................................................17
II
Pressure Switch Testing & Replacement .................................................................................18
III
Blower Testing & Replacement ...............................................................................................20
IV
Blower Temperature Switch Testing & Replacement ............................................................22
V
Gas Control Testing & Replacement........................................................................................24
VI
Flammable Vapor Sensor Testing and Replacement ..............................................................28
VII
Safety Circuit Voltage Trace.....................................................................................................29
VIII
115 VAC Circuit Trace .............................................................................................................30
IX
Diptube Inspection & Replacement..........................................................................................31
X
Anode Inspection & Replacement............................................................................................32
XI
Flue Baffle/Core Inspection & Replacement ...........................................................................33
XII
Inner Door Removal, Inspection & Replacement...................................................................34
XIII
Glossary of Terms......................................................................................................................37
---
Parts List .....................................................................................................................................38
---
2
2

3
PDV Series
WARNING: If the information in these
instructions is not followed exactly, afire or
explosion may result causing property damage,
personal injury, or death.
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 your gas supplier from aneighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
•
•
Installation and service must be performed by aqualified
installer, service agency or the gas supplier.
3
CAUTION
Turn off or disconnect the electrical power supply to the water heater
before servicing. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
WARNING
Hydrogen gas can be produced in an operating water heater that
has not had water drawn from the tank for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable. To prevent the possibility of injury under these
conditions, we recommend the hot water faucet to be open for
several minutes at the kitchen sink before you use any electrical
appliance which is connected to the hot water system. If
hydrogen is present, there will be an unusual sound such as air
escaping through the pipes as hot water begins to flow. Do not
smoke or have open flame near the faucet at the time it is open.
WARNING
FAILURE TO INSTALL AND MAINTAIN ANEW, LISTED ¾” X¾”
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE
THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT
FROM EXCESSIVE TEMPERATURE AND PRESSURES.
CAUTION
If sweat fittings are to be used DO NOT apply heat to the nipples
on top of the water heater. Sweat the tubing to the adapter
before fitting the adapter to the water connections. It is
imperative that heat is not applied to the nipples containing a
plastic liner.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
• Liquefied petroleum gases/propane gas and natural gas
have an odorant added by the gas supplier that aids in the
detection of the gas.
• Most people recognize this odor as a“sulfur” or “rotten egg”
smell.
• Other conditions, such as “odorant fade” can cause the
odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
• If you have adiminished sense of smell, or are in any way
unsure of the presence of gas, immediately contact your gas
supplier from aneighbor’s telephone.
Gas detectors are available. Contact your gas supplier, or plumbing
professional, for more information.
WARNING
Water heaters are heat producing appliances. To avoid damage
or injury, do not store materials against the water heater or vent-
air intake system. Use proper care to avoid unnecessary contact
(especially by children) with the water heater and vent-air intake
components. UNDER NO CIRCUMSTANCES MUST
FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT
THINNER BE USED OR STORED IN THE VICINITY OF THIS
WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY
LOCATION FROM WHICH FUMES COULD REACH THE
WATER HEATER OR VENT-AIR INTAKE SYSTEM
IMPORTANT
Before proceeding, please inspect the
water heater and its components for
possible damage. DO NOT install any
water heater with damaged
components. If damage is evident
then please contact the supplier where
the water heater was purchased or the
manufacturer listed on the rating plate
for replacement parts.
DANGER
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in
the vicinity of this or any other appliance.
3

4
PDV Series
Introduction
The new Bradford White PDV water heaters are designed to provide reliable performance with enhanced
standard features. New design features include reliable spark to pilot ignition system, enhanced diagnostics,
simplified servicing, significantly quiet operation, additional vent lengths, and Bradford White Defender
Safety System® (not available on all models).
Spark to Pilot Ignition System - employing the spark to pilot ignition system promotes reliable and consistent
pilot and main burner ignitions to provide hot water on demand.
Integrated Immersion Thermostat/Gas Control Valve with LED - was developed for ease of troubleshooting
by providing simple diagnostic codes to pinpoint an installation or component performance issue.
Powerful Blower - will eliminate problems with difficult venting situations.
Quieter and Cooler Blower Operation - blower noise is significantly reduced for both interior and exterior
environments. Cooler operation increases blower life by reducing bearing wear and noise.
Rugged Wiring Connections - receptacle type connections promote error free wiring.
Increased Vent Lengths - increased venting performance is achieved while maintaining Energy Factor &
FHR (not applicable on all models) performance.
The PDV water heaters use a combustion system where flue gases are combined with dilution air to reduce
the flue gas temperature in the blower. The diluted flue gases are evacuated to the exterior through low
temperature vent materials. The gas control maintains water temperature, ignition sequence and regulates
gas flow. A safety circuit consisting of a pressure switch and blower temperature switch verifies proper
conditions exist for safe and reliable operation. If a situation outside of normal operating parameters exists,
the gas control diagnostic LED will flash a code to positively identify an operational issue.
This service manual is designed to facilitate problem diagnosis and enhance service efficiency.
Please read the service manual completely before attempting service on this new series of power direct vent
models.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the vent pipe from outside
your building. This air travels into the closed combustion chamber. The air then mixes in a normal manner
with supplied gas and it’s efficiently combusted, producing low NOx emissions.
In the unlikely event trace amounts of flammable vapors are present in the area surrounding the water
heater, the sealed combustion system prevents the flammable vapors from reaching the ignition source. In
addition the flammable vapors sensor will stop the water heater from operating if a significant amount of
flammable vapors are present.
4
4

5
PDV Series
It is intended for this manual to be used by qualified service personnel for the primary purpose of
troubl
eshooting and repair of the Bradford White PDV Series water heaters. Understanding the sequence of
operation section of this manual will contribute greatly to troubleshooting the water heater.
The ICON System WV4462A Electronic Gas Control will display status codes in the event of abnormal
operation.
Status codes are listed in the troubleshooting chart beginning on page 14 of this service manual.
The
troubleshooting chart will also indicate the probable cause for the status code and direct the service
professional to a service procedure to properly diagnose the abnormal operation.
In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to
determine the problem.
Contact the Bradford White technical support group immediately if diagnosis cannot be made using the
methods described in this service manual.
Tools Required for Service
A liquid “U” tube type or a digital (magnahelic) type can be used. This
device is used to measure gas and/or air pressure and vacuum.
Manometer:
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.
Multi-Meter:
In some cases, standard multi-meter probes will damage or simply not be
effective to obtain certain voltage and ohm readings. It will be necessary to
have special electronic “pin” type multi-meter probes. These probes are
available at most electronic wholesale outlets.
Electronic Probes:
Used to measure water temperature. An accurate thermometer is
recommended.
Thermometer:
Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Water Pressure Gage:
Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12”
crescent wrench, allen wrench set, screw drivers (common & Phillip’s), 1/4”
nut driver, pliers (common & needle nose), socket set, side cutters, wire
cutters, wire strippers, wire crimpers, torpedo level, small shop vac, step
ladder, flashlight and 5 gallon pail.
Various Hand Tools:
5
5

6
PDV Series
6
Power supply
Dedicated 115 VAC, 60 Hz, 15A.
Gas Supply Pipe
Minimum 1/2” NPT (schedule 40 black iron pipe recommended).
Approved Gas
Type
Natural Gas or Propane, unit must match gas type supplied.
Gas Pressure
5.0” W.C. min. for Natural Gas, 11.0” W.C. min. for Propane, 14.0” W.C. maximum
(Natural Gas &Propane).
Venting System
Power direct vent through the wall or vertical through the roof.
Approved Vent
Materials
PVC, CPVC or ABS.
Minimum
Clearance for
Servicing
18” from top, 24” from front, 4” sides and rear.
Water Supply
Pressure
150 PSI maximum allowable working pressure. Check local codes for supply
pressure.
Gas Control
ECO Limit
Residential 188°F (87°C), Commercial 199°F (93°C).
Residential
Temperature Set
Point Range
60°F (16°C) to 160°F (71°C) (approximate temperatures).
Commercial
Temperature Set
Point Range
80°F (27°C) to 180°F (82°C) (approximate temperatures).
Blower
Temperature
Switch
Normally closed, opens @155°F (68°C), auto reset @ 135°F (57°C).
Pressure Switch
Normally open, closes on vacuum increase @ -.80” W.C.;
Opens on vacuum decrease @ -.73” W.C.
Blower
115 VAC, 60 Hz, 3.1 amps, 3000 RPM.
6

7
PDV Series
Vent Tables
Venting Specifications for:
RG2PDV(40,50)S
7
3" Diameter (7.6 cm) Vent Connector Lengths
Terminating #of
Elbows
Maximum
Straight
Length ft. (m)
Minimum
Straight
Length ft. (m)
Through the Wall 180 (24.4) 10 (3.1)
Through the Wall 275 (22.9) 10 (3.1)
Through the Wall 370 (21.3) 10 (3.1)
Through the Wall
4
65 (19.8)
10 (3.1)
Through the Wall
5
60 (18.3)
10 (3.1)
Through the Roof
0
85 (25.9)
15 (4.6)
Through the Roof
1
80 (24.4)
15 (4.6)
Through the Roof
2
75 (22.9)
15 (4.6)
Through the Roof
3
70 (21.3)
15 (4.6)
Through the Roof
4
65 (19.8)
15 (4.6)
2" Diameter (5.1 cm) Vent Connector Lengths
Terminating
#of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 130 (9.1) 2 (.6)
Through the Wall 225 (7.6) 2(.6)
Through the Wall 320 (6.1) 2 (.6)
Through the Wall
4
15 (4.6)
2(.6)
Through the Roof
0
35 (10.7)
7 (2.1)
Through the Roof
1
30 (9.1)
7 (2.1)
Through the Roof
2
25 (7.6)
7 (2.1)
Through the Roof
3
20 (6.1)
7 (2.1)
7

8
PDV Series
Venting Specifications for:
RG2PDV(50,75)H
LG2PDV(50,75)H
8
4" Diameter (7.6 cm) Vent Connector Lengths
Terminating #of
Elbows
Maximum
Straight
Length ft. (m)
Minimum
Straight
Length ft. (m)
Through the Wall 195 (29.0) 10 (3.1)
Through the Wall 290 (27.4) 10 (3.1)
Through the Wall 385 (25.9) 10 (3.1)
Through the Wall
4
80 (24.4)
10 (3.1)
Through the Wall
5
75 (22.9)
10 (3.1)
Through the Roof
0
100 (30.5)
15 (4.6)
Through the Roof
1
95 (29.0)
15 (4.6)
Through the Roof
2
90 (27.4)
15 (4.6)
Through the Roof
3
85 (25.9)
15 (4.6)
Through the Roof
4
80 (24.4)
15 (4.6)
3" Diameter (7.6 cm) Vent Connector Lengths
Terminating
#of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall 155 (16.8) 2 (.6)
Through the Wall 250 (15.2) 2(.6)
Through the Wall 345 (13.7) 2 (.6)
Through the Wall
4
40 (12.2)
2 (.6)
Through the Roof
0
60 (18.3)
7 (2.1)
Through the Roof
1
55 (16.8)
7 (2.1)
Through the Roof
2
50 (15.2)
7 (2.1)
Through the Roof
3
45 (13.7)
7 (2.1)
8

9
PDV Series
Control Timings
9
Ignition State Timing
Pre-purge
15 Seconds
Trial for Ignition
90 Seconds
Flame Stabilization Period
3Seconds
Inter-purge
15 Seconds
Flame Failure Response Time
1.5 Seconds (2 seconds. maximum; 1 second
minimum.)
Post-purge
15 Seconds
PS Fault Delay (failed open/close)
Retry after 2 Minutes
Soft Lockout
Retry after 5 Minutes
ECO Limit Lockout
Indefinite (see page 25)
Verify Resistive Delay
Retry after 2 Minutes (repeats 5 times)
Flammable Vapor Sensor/Simulated Resistive Load
Lockout
Indefinite (cycle power to restart)
Hardware Status Lockout
Indefinite (self clears if fault clears for at least 15
seconds)
9

10
PDV Series
Power Up Sequence
1.
Start Up.
Upon Power up, the control runs a safe-start check with a typical start-up delay of
1-5 seconds.
Flammable Vapor.
To assure no outputs are energized if the “Flammable Vapor Sensor” is out of
range, the control will test the “Flammable Vapor Sensor” or for proper operating
range. If the “Flammable Vapor Sensor” is out of range, the control LED
immediately flashes 7 times with 3 second pause.
2.
Normal Heating Sequence
Thermostat calls for heat.
Prior to energizing blower, gas control checks safety circuit to insure the circuit is
open. Normal switch positions in the safety circuit are as follows:
a) Exhaust pressure switch normally open.
b) Blower temperature switch normally closed.
If the safety circuit is closed, the control waits 4 seconds, gas control LED
flashes 2 times with 3 second pause. Gas control waits 2minutes then,
blower runs for 30 seconds. This cycle repeats until safety circuit opens.
Blower energizes.
Blower pre-purge period (15 seconds)
Differential pressure switch proves blower/vent system operation.
If the pressure switch does not close within 30 seconds, the control LED flashes 3
times with 3 second pause. The blower runs for 30 seconds every 2 minutes trying
to get the pressure switch or blower temperature switch to close. This cycle repeats
as long as there is acall for heat.
Trial for pilot ignition (90 seconds).
a. The gas control lights the pilot by activating sparkigniter and gas flow to pilot
burner.
b. If flame is not sensed within 90 seconds, igniter and gas flow are
deactivated, blower will post purge and control LED flashes 6 times with 3
second pause.
Main burner ignition.
After pilot flame is sensed, gas control activates main valve for main burner ignition.
The gas control will ignore flame and pressure switch signals for 3 seconds allowing
for main burner to stabilize.
1.
2.
3.
4.
5.
6.
10
10

11
PDV Series
Normal Heating Sequence (cont.)
7.
Steady state operation.
During steady state operation, the control monitors:
Thermostat temperature sensor-when set point temperature is satisfied, gas
valve is shut down and blower will post purge for 15 seconds. Control LED flashes
ashort flash once every 4seconds (idle) status code.
Pressure switch / blower temperature switch-if either switch opens, pilot valve
and main valve is shut down. The blower continues to run for 30 seconds
attempting to close the circuit. The control LED flashes 3times with 3second
pause.
Flame sensor-if flame is lost, pilot & main valve are shut down, blower runs for 15
seconds. Control attempts to re-light pilot 4 times. If unsuccessful, blower is shut
down and control proceeds to 5 minute lockout. Control re-attempts to light pilot
starting at normal heating sequence #2.
Thermostat satisfies. (Control LED flashing once every 4 seconds).
Burner off.
8.
9.
10. Blower post purges (15 seconds).
Abnormal Operation
1.
Flammable Vapor Sensor:
a.
If the resistance is greaterthan 70,000 Ohms-the gas control immediately
turns off all outputs. Control waits and monitors resistance for 30 seconds.
If the resistance is greater than 65,000 ohms after 30 seconds, the gas
control proceeds to verify resistive delay for 2 minutes andflashes 7 times
then once with a three second pause. This process is repeated 5 times until
the control either returns to normal operation or proceeds to flammable vapor
lockout.
If the resistance is below 3000 Ohms-The gas control immediately turns
off all outputs and proceeds to flash 8 times then once with three second
pause. The status self clears if the resistance returns to normal range for at
least 15 seconds.
b.
2.
Temperature Sensor Fault:
a. Temperature sensor detected open circuit–The gas control immediately
turns off all outputs and proceeds to flash 8 times then, 3 times with 3
second pause. The status self clears if the fault clears for at least 15
seconds.
b. Thermal well sensor not reading the same temperature within ±5.5°F –
The gas control immediately turns off all outputs and proceeds to flash 8
11
11

12
PDV Series
Abnormal Operation (cont.)
times, then 3times twice with 3 second pause. The status self clears if the
fault clears for at least 15 seconds.
c. Water temperature in excess of ECO (energy cut out) limit -The gas
control immediately turns off pilot &main valves and proceeds to flash 4
times with 3 second pause. Blower continues to run until gas control is reset.
To reset control, rotate knob of temperature control to the minimum setting
for at least 6 seconds before returning to desired temperature setting.
3.
Pressure Switch/Blower Temperature Fault:
a.
Pressure switch closed at start of call for heat-the gas control waits 4
seconds then, proceeds to flash 2 times with 3 second pause. The control
waits 2 minutes and then turns on blower for 30 seconds. The blower turns
off after 30 seconds and the control waits for pressure switch to open. Any
time the pressure switch opens, the blower turns on (or stays on) and the
control proceeds to wait for pressure switch to close.
Pressure switch or blower temperature switch failed to close-the gas
control runs the blower for 30 seconds waiting for the pressure switch and/or
blower temperature switch to close. If either switch does not close in 30
seconds, the blower turns off and the control flashes 3times with 3second
pause. The gas control waits 2 minutes before turning on the blower for
another 30 seconds to see the circuit close. This cycle repeats as long as
there is a call for heat or until the circuit closes.
Pressure switch or blower temperature switch opens during burner
operation-the gas control turns off the pilot and main valve, runs blower for
15 seconds (inter-purge) waiting for pressure switch and/or blower
temperature switch to close. If either switch fails to close, the control
proceeds as described in 3b above, if the circuit closes again by the end of
the inter-purge, the recycle counter is incremented, if the recycle count as
not reached its limit (4), another trial for ignition begins. If the recycle count
has been reached, the gas control turns off the blower and flashes 6 times
then, 2 times with 3 second pause. The gas control waits 5 minutes before
repeating ignition sequence.
b.
c.
4.
Trail for Ignition Fault:
a. Pressure switch opens during trial-the gas control turns off igniter and
pilot valve. The gas control proceeds as described in 3b above. If the
pressure switch closes within 30 seconds the gas control will continue with
trial for ignition starting at blower pre-purge.
b. Flame not sensed-the gas control energizes the spark igniter attempting to
light the pilot and prove flame. If flame is not sensed within 90 seconds, the
igniter turns off, the pilot valve is closed and the gas control runs the blower
through post purge and flashes 6 times then, once with 3 second pause.
The control waits 5 minutes before repeating the ignition sequence.
12
12

13
PDV Series
Abnormal Operation (cont.)
5.
Flame sensing fault:
a.
Flame lost during run-the gas control turns off pilot and main valves, runs
blower for 15 seconds (inter-purge). The gas control increments the recycle
count, if the recycle count has not reached its limit (4), another trial for
ignition begins. If the recycle count has beenreached, the gas control turns
off the blower and flashes 6 times then, 3 times with 3 second pause. The
gas control waits 5 minutes before repeating the ignition sequence.
Flame sensed out of sequence-the gas control only looks for pilot flame
when the blower is running. If flame is present when the pilot valve is not
open, the gas control proceeds to wait for flame loss and flashes 5 times with
3second pause. This continues until flame is lost. Once the flame signal is
b.
lost, the control flashes 6 times then, 4times with 3 second pause.
control waits 5 minutes before repeating the ignition sequence.
The
13
13

14
PDV Series
Observe green LED indicator on
Electronic gas control. Status flash
codes are displayed with a three second
pause before repeating. Check and
repair the system as noted in the
troubleshooting table below
14
LED Status Control Status Probable Cause
Service
Procedure
None, control
LED not on or
flashing
No electrical
power
Control power switch in “OFF” position.
Supply voltage interrupted.
Turn power on
Short flash, once
every four
seconds
Stand-by mode,
Waiting for call
for heat (no fault).
Temperature demand is satisfied.
Normal operation.
Adjust thermostat to
temp level
“Heartbeat”,
alternates
bright/dim
Thermostat
calling
for heat (no fault).
Tank temperature below set point of
thermostat.
Normal operation.
Adjust thermostat to
temp level
Short flash once
per second
Weak pilot signal
on last call for
heat.
1. Unstable pilot.
2. Pilot tube block or restricted.
3. Oxidation builds up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
Page 17
Two flash, three
second pause
Pressure switch
not working-
closed position.
1. Pressure switch tubing kinked or blocked.
2. Blocked pressure tap on switch or blower.
3. Faulty pressure switch.
Page 18
Three flash,
three second
pause
Pressure switch
or blower temp.
switch not
working -open
position.
1. Vent blockage or improper vent
configuration.
2. Pressure switch tubing kinked or blocked.
3. Faulty pressure switch.
4. Blower not spinning up to speed.
5. Blower temp or exhaust temp too high.
6. Faulty blower temperature switch.
1. Check vent or vent
tables.
2 & 3 Page 18
4. Page 20
5 & 6 Page 22
Four flash, three
second pause
Excessive tank
temperature.
System must be
reset.
1. Temperature sensor out of calibration.
2. Faulty gas control.
3. Plumbing leak.
1 & 2. Replace gas
control, page 26
Five flash, three
second pause
Undesired-false
pilot flame
present.
1. Pilot valve stuck in open position.
Replace gas control,
page 26
14

15
PDV Series
15
LED Status Control Status Probable Cause
Service
Procedure
Six-one
flash, three
second
pause
Failed to light
pilot.
System auto
resets.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
Page 17
Six-two flash,
three second
pause
Pressure switch
or blower temp
switch opened
during burner
operation.
System auto
resets.
1. Vent blockage or improper vent configuration.
2. Pressure switch tubing kinked or blocked.
3. Faulty pressure switch.
4. Vent termination being affected by wind.
5. Blower not spinning up to speed.
6. Blower temp or exhaust temp too high.
7. Faulty blower temperature switch.
1. Check vent or vent tables.
2 & 3 Page 18
4. Refer to venting section of
installation manual
5. Page 20
6 & 7 Page 22
Six-three
flash, three
second
pause
Pilot flame
extinguished.
System auto
resets.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
5. Insufficient combustion air.
6. Gas pressure is out of specification..
1-4. Page 17
5. Refer to installation
manual
6. Page 24
Six-four
flash, three
second
pause
Undesired-false
pilot flame
sensed.
System auto
resets.
Pilot valve stuck in open position.
Replace gas control,
page 26
Seven flash,
three second
pause
Flammable vapor
sensor fault
detected.
Flammable vapor sensor or simulative resistance
device out of specification.
Page 28
Eight-one
flash, three
second
pause
Flammable vapor
sensor out of
specification.
Flammable vapor sensor or Simulated resistive
device out of specification.
Page 28
Eight-two
flash, three
second
pause
Temperature
Sensor fault.
1. Damage to temperature sensor wire.
2. Temperature sensor resistance out of range.
Replace gas control,
page 26.
Eight-three
flash, three
second
pause
Gas valve
electronics fault
detected.
1. Control needs to be reset.
2. Control is wet or physically damaged.
1. Interrupt power supply
2. Replace gas control,
page 26
Eight-four
flash, three
second
pause
Gas valve fault
detected.
1. Control needs to be reset.
2. Control is wet or physically damaged.
1. Interrupt power supply
2. Replace gas control,
page 26
15

16
PDV Series
Burner Inspection
At
periodic intervals (every 6months) avisual inspection should be made of the pilot and main
burner
for proper operation and to assure no debris is accumulating.
Pilot flame should be stable, some causes for an unstable pilot flame are:
a)
b)
c)
Water heater vent is less than the allowable vent length.
Gas pressure is out of specification.
Pilot flame not fully engulfing spark/flame sensor.
Main burner should light smoothly from pilot and burn with ablue flame with aminimum of yellow
tips.
Main
burner must be free from any debris accumulation that may affect burner operation (see
burner
cleaning procedure on page 16).
Burner Cleaning
Step 1.
Position gas control power switch to the
“OFF” position and unplug heater from
wall outlet.
Turn off gas supply to water heater.
Remove outer jacket door and inner door
per service procedure XIII on page 34.
Disconnect pilot tube (7/16” wrench) and
feedline (3/4” wrench) from gas control.
Disconnect igniter/flame sensor wire from
gas control.
Remove burner assembly from
combustion chamber.
Thoroughly inspect burner surface area
and burner port area and remove any
loose debris.
Unscrew burner from main burner orifice.
Remove main burner orifice from feedline
(1/2” wrench on steel burners) inspect
orifice, clean or replace if necessary.
Reassemble burner and reinstall into
water heater. Restore gas supply and
check for gas leaks.
To resume operation, follow the
instruction located on the lighting
instruction labelor the lighting instruction
located in the installation and operation
manual.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Step 10.
Step 11.
16
16

17
PDV Series
Pilot Testing and Replacement
Step 1.
Position gas control power
switch to the “OFF” position
and unplug heater from wall
outlet.
Turn off gas supply to water
heater.
Remove outer jacket door and inner door per
service procedure XIII on page 34.
Disconnect pilot tubing nut (7/16” wrench) and
feedline nut (3/4” wrench) from gas control.
Disconnect igniter/flame sense wire from gas control.
Remove burner assembly from combustion chamber.
Remove pilot assembly from feedline (1/4” nut driver).
Visually inspect igniter/flame sense wire for damage.
found.
With a multi-meter set to ohms setting, check
continuity through igniter/flame sense wire. Replace
pilot if no continuity.
Visually inspect igniter/flame sense
electrode for deterioration. Replace pilot as
necessary. Electrode should not be in
contact with pilot hood, if so, carefully adjust
electrode to agap of distance of 3/32” (.09)
from pilot hood.
Visually inspect igniter/flame sense
electrode for oxidation build up. Carefully
clean any oxidation using very fine emery
cloth.
Visually inspect pilot tubing for kinks or
cracks. If damage is found, replace pilot.
Inspect pilot tubing and pilot orifice for
blockage:
Remove ferrule nut from bottom of pilot
assembly (7/16” wrench).
Remove pilot tube and pilot orifice.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Replace pilot if damage is
Step 9.
Step 10.
Step 11.
Step 12.
Step 13.
a.
b.
c.
Step 14.
Inspect pilot tubing and pilot orifice for blockage. Clean or replace as necessary.
Reassemble pilot and install on feedline. Reinstall burner assembly to water
heater. Restore gas supply and check for gas leaks.
To resume operation, follow the instruction located on the lighting
instruction label or the lighting instruction located in the installation and
operation manual.
Step 15.
17
17

18
PDV Series
Pressure Switch Testing
Step 1.
Position power switch on gas
control to the “OFF” position.
Step 2.
Remove the three screws (Phillips screw driver) from control access cover
on blower assembly and remove cover (see photo 1).
Carefully remove pressure switch from blower housing (see photo 2).
Step 3.
18
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
18

19
PDV Series
Pressure Switch Replacement
Step 1.
Position gas control power
switch to “OFF” position.
Remove the three screws
(Phillip’s screw driver) from
control access cover on blower
assembly and remove cover
(see photo 3).
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Carefully remove pressure switch from blower housing (see photo 4).
Disconnect tubing from pressure switch. (see photo 5).
Disconnect yellow wires from pressure switch (see photo 6).
Reconnect wires from step 6to new pressure switch.
Reconnect tubing to new pressure switch.
Carefully position pressure switch into blower housing.
Position gas control power switch to “ON” position and verify proper heater
operation.
Replace control access cover from step 2.
Step 10.
19
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
19

20
PDV Series
Blower Testing
Step 1.
Position gas control
power switch to “ON”
position and adjust control
to call for heat.
Remove the three screws
(Phillip’s screw driver) from
Step 2.
control access cover on blower
assembly and remove cover (see
photo 7).
20
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
20