Bradford White PDV Series User manual

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Manual 238-53795-00A REV 11/19
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
RC2PDV50H*(N,X)
LC2PDV50H76*(N,X)
(*) Denotes Warranty Years
Residential & Light Duty Commercial
Power Direct Vent Models

The Bradford White
2
Condensing PDV Series
Through-The-Wall Gas Water Heaters
Table of Contents
Page PV Service Procedure
Introduction...................................................................................................................
4 ---
How to Use This Manual ............................................................................................5 ---
Tools Required for Service .........................................................................................5 ---
Specifications...............................................................................................................6
---
Glossary of Terms .......................................................................................................6 ---
Vent Tables..................................................................................................................7
---
Control Timings............................................................................................................8 ---
Sequence of Operation...............................................................................................9 ---
Troubleshooting...........................................................................................................13 ---
Burner Inspection, Cleaning & Replacement ...........................................................15 I
Pilot Inspection 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
Simulated Resistive Device Testing ..........................................................................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 Inspection & Replacement ......................................................................33 XII
Inner Door/Gasket Removal, Inspection & Replacement .......................................35 XIII
Condensate Trap Removal, Inspection & Replacement .........................................38 XIV
Exhaust Collector Removal, Inspection & Replacement.........................................39 XV
Parts Diagram..............................................................................................................41 ---
Notes ............................................................................................................................42 ---
2

Condensing PDV Series
3
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury, or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in the
vicinity of this or any other appliance.
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.
WHAT TO DO IF YOU SMELL GAS:
xDO NOT try to light any appliance.
xDO NOT touch any electrical switch; do not use any
phone in your building.
xImmediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
xIf you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
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.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
xLiquefied petroleum gases/propane gas and natural gas
have an odorant added by the gas supplier that aids in the
detection of the gas.
xMost people recognize this odor as a “sulfur” or “rotten egg”
smell.
xOther conditions, such as “odorant fade” can cause the
odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
xIf you have a diminished sense of smell, or are in any way
unsure of the presence of gas, immediately contact your gas
supplier from a neighbor’s telephone.
Gas detectors are available. Contact your gas supplier, or plumbing
professional, for more information.
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
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED ¾” X ¾”
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE
THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT
FROM EXCESSIVE TEMPERATURE AND PRESSURES.
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 SHOULD
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
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.
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.
3

Condensing PDV Series
4
Introduction
The Bradford White residential condensing 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 and additional vent lengths.
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 - developed for ease of troubleshooting
by providing simple diagnostic codes to pinpoint an installation or component performance issue.
New Powerful Blower - eliminates 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 achieving 90% Thermal
Efficiency and enhanced Standby Loss performance.
The residential condensing water heaters use a combustion system where the flue gases are pulled at a low
temperature from the water heater directly into the blower. The 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 series of condensing power
vent models.
4

Condensing PDV Series
5
How to Use This Manual
It is intended for this manual to be used by qualified service personnel for the primary purpose of
troubleshooting and repair of the Bradford White Condensing PV Series water heaters. Understanding the
sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.
The Honeywell WV4462A Electronic Gas Control will display error codes in the event of abnormal operation.
Error codes are listed in the troubleshooting chart of this service manual. The troubleshooting chart will also
indicate the probable cause for the error 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
Manometer: 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.
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.
Electronic Probes: 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.
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.
Various Hand Tools: Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12” crescent
wrench, allen wrench set, screw drivers (common & Phillips), 1/4” & 5/16” 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.
5

Condensing PDV Series
6
Specifications
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 L.P., unit must match gas type supplied
Gas Pressure
5.0” w.c. min. for Natural Gas, 11.0” w.c. min. for L.P., 14.0” w.c. maximum (Natural
Gas & Propane)
Venting System
Power 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 @ approximately 135°F (57°C)
Exhaust
Pressure Switch
Normally open
Closes on vacuum increase @ -2.15” w.c.
Intake
Pressure Switch
Normally closed
Opens on vacuum increase @ -0.8” w.c.
Blower
115 VAC, 60 Hz, 3.3 amps, 3000 RPM @ 1.5” w.c.
Glossary of Terms
BTU British Thermal Units psi Pounds per Square Inch
GPM Gallons per Minute RPM Revolutions per minute
Hz Hertz ECO Energy Cut Out
kWhr Kilowatt Hour VAC Volts Alternating Current
LED Light Emitting Diode “w.c. Inches of Water Column
NPT National Pipe Thread ºC Degrees Centigrade
Ohms Ohms of resistance ºF Degrees Fahrenheit
6

Condensing PDV Series
7
Vent Tables
2" Diameter (5.1 cm) Vent Connector Lengths
Terminating
# of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall
1
45 (13.7)
2 (.6)
Through the Wall
2
40 (12.2)
2 (.6)
Through the Wall
3
35 (10.7)
2 (.6)
Through the Wall
4
30 (9.2)
2 (.6)
Through the Roof
0
50 (15.2)
7 (2.1)
Through the Roof
1
45 (13.7)
7 (2.1)
Through the Roof
2
40 (12.2)
7 (2.1)
Through the Roof
3
35 (10.7)
7 (2.1)
Through the Roof
4
30 (9.2)
7 (2.1)
3" Diameter (10.2 cm) Vent Connector Lengths
Terminating
# of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall
1
115 (35.0)
10 (3.1)
Through the Wall
2
110 (33.5)
10 (3.1)
Through the Wall
3
105 (32.0)
10 (3.1)
Through the Wall
4
100 (30.5)
10 (3.1)
Through the Wall
5
95 (29.0)
10 (3.1)
Through the Roof
0
120 (36.6)
15 (4.6)
Through the Roof
1
115 (35.0)
15 (4.6)
Through the Roof
2
110 (33.5)
15 (4.6)
Through the Roof
3
105 (32.0)
15 (4.6)
Through the Roof
4
100 (30.5)
15 (4.6)
4" Diameter (10.2 cm) Vent Connector Lengths
Terminating
# of
Elbows
Maximum Straight
Length ft. (m)
Minimum Straight
Length ft. (m)
Through the Wall
1
180 (54.9)
10 (3.1)
Through the Wall
2
175 (53.3)
10 (3.1)
Through the Wall
3
170 (51.8)
10 (3.1)
Through the Wall
4
165 (50.3)
10 (3.1)
Through the Wall
5
160 (48.8)
10 (3.1)
Through the Roof
0
180 (54.9)
15 (4.6)
Through the Roof
1
175 (53.3)
15 (4.6)
Through the Roof
2
170 (51.8)
15 (4.6)
Through the Roof
3
165 (50.3)
15 (4.6)
Through the Roof
4
160 (48.8)
15 (4.6)
7

Condensing PDV Series
8
Control Timings
Ignition State Timing
Pre-purge
2 Seconds
Trial for Ignition
90 Seconds
Flame Stabilization Period
3 Seconds
Inter-purge
15 Seconds
Flame Failure Response Time
1.5 Seconds (2 second 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 PV SERVICE PROCEDURE VI; page 24)
Verify Resistive Delay
Retry after 2 minutes (repeats 5 times)
Simulated Resistive Load Lockout
Indefinite (cycle power to restart)
Hardware Error Lockout
Indefinite (self clears if fault clears for at least 15 seconds)
8

Condensing PDV Series
9
Sequence of
Operation
Power Up Sequence
1. Start Up:
Upon power up, the control runs a safe-start check with a typical start-up delay of 5
seconds.
2. Flammable Vapor:
To assure no outputs are energized if the Simulated Resistive Device is out of
range, the control will test the Simulated Resistive Device for proper operating
range. If Simulated Resistive Device is out of range, the control LED immediately
flashes 7 times with a 3 second pause.
Normal Heating Sequence
1. Thermostat Calls For Heat:
Prior to energizing the blower, the gas control checks the safety circuit to ensure
that the circuit is open. Normal switch positions in the safety circuit are as follows:
a) Exhaust pressure switch normally open.
b) Intake pressure switch normally closed.
c) Blower temperature switch normally closed.
If the safety circuit is closed, the control waits 4 seconds, then the gas
control LED flashes 2 times with a 3 second pause. The gas control waits 2
minutes and then the blower runs for 30 seconds. This cycle repeats until the
safety circuit opens.
2. Blower energizes.
3. Pressure Switch Proves Blower/Vent System Operation:
If both pressure switches are not closed 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 both pressure switches and temperature switch into a closed state.
This cycle repeats as long as there is a call for heat.
4. Blower pre-purge period (2 seconds).
5. Trial For Pilot Ignition (90 seconds):
a. The gas control lights the pilot by activating the spark igniter and gas flow to
the pilot burner.
b. If the flame is not sensed within 90 seconds, the igniter and gas flow are
deactivated, the blower will post purge and the control LED will flash 6 times
with a 3 second pause.
6. Main Burner Ignition:
After the pilot flame is sensed, the gas control activates the main valve for main
burner ignition. The gas control will ignore the flame and pressure switch signals for
3 seconds allowing for the main burner to stabilize.
9

Condensing PDV Series
10
Sequence of
Operation
Normal Heating Sequence (cont.)
7. Steady State Operation:
During steady state operation, the control monitors:
Thermostat temperature sensor – When the set point temperature is satisfied, the
gas valve is shut down and the blower will post purge for 15 seconds. The control
LED flashes a short flash once every 4 seconds (idle) status code.
Pressure switch / blower temperature switch – If any switch opens, the pilot
valve and the main valve are both shut down. The blower continues to run for 30
seconds attempting to close the circuit. The control LED flashes 3 times with a 3
second pause.
Flame sensor- If the flame is lost, the pilot and main valves are shut down and the
blower runs for 15 seconds. The control attempts to re-light the pilot 4 times. If
unsuccessful, the blower is shut down and the control proceeds to a 5 minute
lockout. The control re-attempts to light pilot starting at normal heating sequence
#2.
8. Thermostat satisfies (Control LED flashing once every 4 seconds).
9. Burner off.
10. Blower post purges (15 seconds).
Abnormal Operation
1. Simulated Resistive Device Fault:
a. If the resistance is greater than 70,000 ohms –The gas control
immediately turns off all outputs. The control waits and monitors the
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
and flashes 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.
b. If the resistance is below 3000 ohms –The gas control immediately turns
off all outputs and proceeds to flash 8 times, then once with a three second
pause. The error self clears if the resistance returns to normal range for at
least 15 seconds.
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 a 3
second pause. The error 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
10

Condensing PDV Series
11
Sequence of
Operation
Abnormal Operation (cont.)
times, then 3 times twice with 3 second pauses. The error 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 the pilot and main valves. It then proceeds to
flash 4 times with a 3 second pause. The blower continues to run until the
gas control is reset. To reset the control, rotate the temperature control knob
to the minimum setting for at least 6 seconds before returning to the desired
temperature setting.
3. Pressure Switch/Blower Temperature Fault:
a. Exhaust pressure switch closed at start of call for heat –The gas control
waits 4 seconds, then proceeds to flash 2 times a with 3 second pause. The
control waits 2 minutes and then turns on the blower for 30 seconds. The
blower turns off after 30 seconds and the control waits for the pressure
switch to open. Any time the pressure switch opens, the blower turns on (or
stays on) and the control proceeds to wait for the pressure switch to close.
b. 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 3 times with a 3 second
pause. The gas control waits 2 minutes before turning on the blower for
another 30 seconds to check if the circuit will close. This cycle repeats as
long as there is a call for heat or until the circuit closes.
c. Pressure switch or blower temperature switch opens during burner
operation –The gas control turns off the pilot and main valve and runs the
blower for 15 seconds (inter-purge), waiting for the 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 has
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 a 3 second pause. The gas control waits 5 minutes before
repeating ignition sequence.
4. Trial for Ignition Fault:
a. Pressure switch opens during trial –The gas control turns off the 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 the flame is not sensed within 90
seconds, the igniter turns off, the pilot valve is closed and the gas control
runs the
11

Condensing PDV Series
12
Sequence of
Operation
Abnormal Operation (cont.)
blower through post purge and flashes 6 times, then, a one time 3 second
pause. The control waits 5 minutes before repeating the ignition sequence.
5. Flame Sensing Fault:
a. Flame lost during run – The gas control turns off the pilot and main valves
and 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 limit has been reached, the gas
control turns off the blower and flashes 6 times, then 3 times with a 3 second
pause. The gas control waits 5 minutes before repeating the ignition
sequence.
b. Flame sensed out of sequence – The gas control only looks for pilot flame
when the blower is running. If the flame is present when the pilot valve is not
open, the gas control proceeds to wait for flame loss and flashes 5 times with
a 3 second pause. This continues until flame signal is lost. Once the flame
signal is lost, the control flashes 6 times, then 4 times with a 3 second pause.
The control waits 5 minutes before repeating the ignition sequence.
12

Condensing PDV Series
13
Troubleshooting
Observe green LED indicator on
electronic gas control. Error flash codes
are displayed with a three second pause
before repeating. Check and repair the
system as noted in the troubleshooting
table below.
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
temperature level.
“Heartbeat”
alternates
bright/dim
Thermostat
calling for heat
(no fault).
Tank temperature below set point of
thermostat.
Normal operation.
Adjust thermostat to
temperature level.
Short flash once
per second
Weak pilot signal
on last call for
heat.
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. Low gas pressure.
Page 17
Procedure II
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
Procedure III
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. Page 22
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
13

Condensing PDV Series
14
Troubleshooting
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.
5. Low gas pressure.
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.
8. Blocked condensate trap.
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
8. Page 38
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
Simulated
Resistive Device
fault detected.
Simulated resistance device harness out of
specification or disconnected. Page 28
Eight-one flash,
three second
pause
Simulated
Resistive Device
out of
specification.
Simulated resistive device out of
specification. Possible short. Page 28
Eight-two flash,
three second
pause
Temperature
sensor fault.
1. Damage to temperature sensor wire.
2. Temperature sensor resistance out of
range.
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
14

Condensing PDV Series
15
Service Procedure I
Burner Operation Inspection,
Cleaning and Replacement
Burner Inspection
At periodic intervals (every 6 months) a visual inspection should be made of the pilot and main
burner for proper operation and to ensure no debris is accumulating.
The pilot flame should be stable. Some causes for an unstable pilot flame are:
a) The water heater vent is less than the allowable vent length.
b) The gas pressure is out of specification.
c) The pilot flame is not fully engulfing the spark/flame sensor.
The main burner should light smoothly from the pilot and burn with a blue flame and a minimum of
yellow tips.
The main burner must be free from any debris accumulation that may affect burner operation (see
burner cleaning procedure on page 16).
15

Condensing PDV Series
16
Service Procedure I
Burner Operation Inspection,
Cleaning and Replacement
Burner Cleaning
Step 1. Position the gas control power
switch to the “OFF” position and
unplug the water heater from wall
outlet.
Step 2. Turn off the gas supply to the water
heater.
Step 3. Remove the outer jacket door and inner door
per Service Procedure XIII on page 35.
Step 4. Disconnect the pilot tube (7/16” wrench) and
feedline (3/4” wrench) from the gas control.
Step 5. Disconnect the igniter/flame sensor wire from the gas control.
Step 6. Remove the burner assembly from the combustion chamber.
Step 7. Thoroughly inspect the burner surface area and burner port area and
remove any loose debris.
Step 8. Unscrew the burner from the main burner orifice.
Step 9. Remove the main burner orifice from
the feedline (1/2” wrench on steel
burners). Inspect the orifice and
clean or replace if necessary.
Step 10. Reassemble the burner and
reinstall into the water heater.
Restore the gas supply and check
for gas leaks.
Step 11. To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the Installation and
Operation Manual.
NOTICE
The feedline nut for natural gas
control uses right hand threads,
L.P. control uses left hand thread.
16

Condensing PDV Series
17
Service Procedure II
Pilot Inspection, Cleaning, &
Replacement
Pilot Inspection, Cleaning & Replacement
Step 1. Position the gas control power
switch to the “OFF” position and
unplug the water heater from wall
outlet.
Step 2. Turn off the gas supply to the water heater.
Step 3. Remove the outer jacket door and inner door
per Service Procedure XIII on page 35.
Step 4. Disconnect the pilot tubing nut (7/16” wrench) and feedline nut (3/4” wrench) from
the gas control.
Step 5. Disconnect the igniter/flame sense wire from the gas control.
Step 6. Remove the burner assembly from the combustion chamber.
Step 7. Remove the pilot assembly from the feedline (1/4” nut driver).
Step 8. Visually inspect the igniter/flame sense wire for damage. Replace the pilot if
damage is found.
Step 9. With a multi-meter set to the ohms setting,
check the continuity through the igniter/flame
sense wire. Replace the pilot if there is no
continuity.
Step 10. Visually inspect the igniter/flame sense
electrode for deterioration. Replace the pilot
as necessary. The electrode should not be in
contact with the pilot hood. If so, carefully
adjust the electrode to a gap distance of 3/32”
(.094”) from the pilot hood.
Step 11. Visually inspect the igniter/flame sense
electrode for oxidation build up. Carefully clean
any oxidation using a very fine emery cloth.
Step 12. Visually inspect the pilot tubing for kinks or
cracks. If damage is found, replace the pilot.
Step 13. Inspect the pilot tubing and pilot orifice for
blockage:
a. Remove the ferrule nut from the bottom of the pilot assembly (7/16”
wrench).
b. Remove the pilot tube and pilot orifice.
c. Inspect the pilot tubing and pilot orifice for blockage. Clean or replace as
necessary.
Step 14. Reassemble pilot and install on feedline. Reinstall burner assembly to water
heater. Restore gas supply and check for gas leaks.
Step 15. To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the Installation and
Operation Manual.
17

Condensing PDV Series
18
Service Procedure III
Pressure Switch Testing and
Replacement
Pressure Switch Testing & Replacement
Step 1. Position the power switch on the gas
control to the “OFF” position.
Step 2. Remove the three screws (Phillips screwdriver) from the control access
cover on the blower assembly and remove the cover. Do not disconnect the
blower harness from the cover (see photo 1).
Step 3. Remove the 2 screws (Phillips screwdriver) and carefully remove the
pressure switch to gain access to the wire lead connections (see photo 2).
co
With steps 1,2 & 3
complete, disconnect wire
leads from either the intake
or exhaust pressure switch.
Use a mutli-meter set to the ohms
setting. With blower
turned
off, check
across pressure switch terminals.
Are switch contacts open?
(no electrical continuity)
N
Y
Position gas valve power switch
to the “ON” position and adjust
thermostat to call for heat, this
will start the blower. Check with
multi-
meter, do the pressure
switch contacts close with blower
running?
Y
N
Y
Check tubing and
pre
ssure tap on
switch for blockage.
Is there blockage?
Check tubing and pressure
tap on switch for blockage.
Is there blockage?
Switch contacts are OK.
See Safety
Circuit
Voltage
Trace (page 29).
Y
N
Replace switch
(see page 17).
N
N
Remove 3 Phillips screws to
remove cover.
Remove 2 Phillips screws to
pressure switch.
Clear blockage.
Is vent system
blocked?
Reconfigure vent
system to be compliant
with vent tables.
Correct blower
problem.
Y
Is vent system length
within vent table
specifications listed on
pages 7 & 8?
See blower testing
(page 20)
Is blower OK?
N
N
Y
Y
1
2
Pressure switch wire leads.
Exhaust
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
Intake
Use a mutli-meter set to the ohms
setting. With blower
turned off, c
heck
across pressure switch terminals.
Are switch contacts closed?
(electrical continuity)
N
Position gas valve power switch
to the “ON” position and adjust
thermostat to call for heat, this
will start the blower. Check with
multi-
meter, do the pressure
switch contacts
remain
closed
with blower running?
Y
N
Y
Switch contacts
are OK.
See Safety
C
ircuit
Voltage
Trace (page 29).
Refer to “Check
tubing and pressure
tap…”
box in flow
chart.
18

PDV Series
19
Service Procedure III
Pressure Switch Testing and
Replacement
Pressure Switch Replacement
Step 1. Position the gas control power
switch to the “OFF” position.
Step 2. Identify correct pressure switch for replacement (see photo 3).
Step 3. Remove three screws (Phillips screwdriver) from the control access cover
on the blower assembly and remove the cover (see photo 4).
Step 4. Remove the screws (Phillips screwdriver) that attach the switch to housing.
Then carefully remove tubing from pressure switch (see photo 5).
Step 5. Disconnect the wire leads from the pressure switch (see photo 6).
Step 6. Reconnect the wires from Step 5 to the new pressure switch.
Step 7. Carefully position the pressure switch into the blower housing and replace the
screws from Step 4.
Step 8. Replace the control access cover from Step 3 and fasten in place with the
three screws.
Step 9. Reconnect the tubing to the new pressure switch.
Step 10. Position the gas control power switch to the “ON” position and verify proper
heater operation.
EXHAUST PRESSURE SWITCH INTAKE PRESSURE SWITCH
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
3
4
5
6
4
6
ES
SURE
SWI
T
TCH
INTAKE PR
T
19

PDV Series
20
Service Procedure IV
Blower Testing and
Replacement
Blower Testing & Replacement
Step 1. Position gas control power switch to
the “ON” position and adjust control to call for heat.
Step 2. Remove the three screws (Phillips screwdriver) from control access cover
on blower assembly and remove cover (see photo 7).
WARNING
115 volt potential exposure. Use
caution to avoid personal injury.
Disconnect pressure switch
tubing from blower.
(see photo 8)
Connect manometer to
pressure tap of blower.
(see photo 8)
Disconnect vent system
from top of blower and
remove vent adapter.
(see photo 9)
See pressure switch
testing.
(Page 19)
Y
N
Disconnect cord set
shown in photo 10. Is
there 115VAC across
locations 1 & 2
shown in
photo 11?
Y
N
Is power cord
damaged?
Replace blower.
Is there
115VAC at wall
outlet?
Incorrect supply
voltage polarity.
With blower running, and exhaust
adapter removed from the top of
blower, is there a negative pressure
of -2.80” to -3.2” w.c.?
Repair or replace
power cord.
Blower OK.
N
N
Y
Replace cord set.
Y
Replace gas
control.
Replace blower.
Is there 115VAC across
the yellow and green
wires?
(see photo 12)
Determine voltage
problem and
correct.
Does cord set have
electrical continuity?
N
Y
N
Y
Y
N
Replace
blower.
N
Y
Does blower energize
within 2 minutes?
N
Y
Does blower energize after
2 minutes, run for 30
seconds and shut down?
7
8
Is there 115VAC
across the locations
2 & 6 shown in
photo
11?
Determine power
source problem
and correct.
Reconnect cord set
shown in photo 10, is
there 115VAC between
yellow
and green wires?
(see photo 12)
N
9
10
11
12
Green wire
Insert the volt meter lead in the back of the connector to
make contact with the yellow wire. Use the ground screw to
make contact with the green wire.
Y
Yellow wire
20