Honeywell PDX150SF(BN,SX,CX) User's Manual
Contents
1. temp level 1 Unstable pilot EE 2 Pilot tube block or restricted Monee Short flash once per Weak pilot signal ae seeond aeeoe 3 Oxidation build up on pilot electrode 24 Page 17 4 Wire damage to pilot assembly or bad ce connection at gas valve Pressure switch not 1 Pressure switch tubing kinked or blocked Two flash three second working closed 2 Blocked pressure tap on switch or blower Page 18 pause a position 3 Faulty pressure switch 1 Vent blockage or improper vent configuration iC hee eeatereneiables 2 Pressure switch tubing kinked or blocked Pressure switch or 3 Faulty pressure switch 2 amp 3 Page 18 Three flash three second blower temp 4 Blower not spinning up to speed i 4 Page 20 pause switch not working 5 Blower temp or exhaust temp too high open position 6 Faulty blower temperature switch 5 amp 6 Page 22 7 Intake vent length exceeds exhaust vent length 8 Frozen intake or exhaust vent terminal Se Pagea KCO SIVONEN 1 Thermal well sensor out of calibration 1 Page 24 Four flash three second temperature 2 Faulty gas control pause System must be 2 Replace gas control 3 Plumbing leak reset page 26 Five flash three second pause Undesired false pilot flame present 1 Pilot valve stuck in open position Replace gas control page 26 HEATERS BRADFORD WHITE nS PDX Series Troubleshooting Wire damage t2. injury or death Do not over tighten screws in steps 8 10 and 11 If a fastener connection is stripped contact the manufacturer listed on the water heater rating plate Igniter wire and pilot tube shown in proper position 35 PDX SERVICE PROCEDURE XIII PDX Series Inner Door Gasket Removal Inspection Replacement and Reinstallation a 7 5 Installation of inner door with gasket continued from page 36 Step 10 Firmly place right side inner door flange against the left side inner door flange and secure with two 1 4 drive screws from step 3c DO NOT OVER TIGHTEN SCREWS Step 11 Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted opening Verify seal integrity around combustion opening Secure right side inner door using 1 4 hex drive screws from step 3b DO NOT OVER TIGHTEN SCREWS Verify both left and right sides of the inner door are properly positioned and sealed against the combustion chamber Verify threaded hole alignment with slotted openings in inner door Ne Z Step 12 Replace outer jacket burner access door Step 13 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual 36 EE BRADFORD WHITE WATER HEATERS PDX Series
3. BRADFORD WHITE WATER HEATERS PDX Series Powered Direct Vent Gas Water Heaters SERVICE i MANUAL Troubleshooting Guide and Instructions for Service ay To be performed ONLY by qualified service providers Models Covered by This Manual PDX Series Models PDX140S F BN SX CX PDX150S F BN SX CX PDX440S F BN SX PDX450S F BN SX PDX250T F BN SX CX PDX265T F BN SX CX samc PDX275T F BN SX CX ee XL A PDX50S60F B S C N X PDX65S65F B S C N X PDX75S70F B S C N X Denotes Warranty Years d JA Manual 238 49770 00A Save this manual for future reference Bradford White PDX Series Powered Direct Vent Gas Water Heaters Table of Contents Page PDX Service Procedure Introduction 4 How to use this manual 5 Tool required for service 5 Specifications 6 Control Timings 9 Sequence of Operation 10 Troubleshooting 13 Burner Inspection Cleaning and Replacement 15 I Pilot Testing Cleaning and Replacement 17 II Pressure Switch Testing and Replacement 18 Il Blower Testing and Replacement 20 IV Blower Temperature Switch Testing and Replacement 22 V Gas Control amp Thermal well Testing amp Replacement 24 VI Flammable Vapor Sensor Testing amp Replacement 28 VII Safety Circuit Voltage Trace 29 VII LISVAC Circuit Trace 30 IX Dip Tube inspection and Replacement 31 X Anode Inspection and Replacement 32 XI Flue Baffle Inspection and Replacement 33 XII Inn
4. 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 Replace pilot if damage is found With a multi meter set to the ohms setting check continuity cee Dit a through igniter flame sense wire Replace pilot if no continuity AI orifice A Visually inspect igniter flame sense electrode for deterioration i qaa Replace pilot as necessary Electrode should not be in contact F H with pilot hood If so carefully adjust electrode to a gap _ _ distance of 3 32 09 from pilot hood e Igniter flame sense Igniter flame sense Visually inspect igniter flame sense electrode for oxidation yee A 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 a Remove ferrule nut from bottom of pilot assembly 7 16 wrench b Remove pilot tube and pilot orifice c Inspect pilot tubing and pilot orifice for blockage Clean or replace as necessary Reassemble pilot and install to 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
5. i A E N Observe heater operation If control continues to lockout due to excessive tank temperature proceed to thermal well testing to determine cause i A a Thermal well testing N Position gas control power switch to the OFF position and disconnect thermal well harness from gas C control J CAUTION DO NOT use standard multimeter probes for this test Doing so will damage connector Use special pin type electronic la E probes or small diameter wire pins inserted into connector Using a multi meter set to the ONS SENING eae Using a multi meter set to the ohms setting insert one meter probe see caution E Cea 821 into center wire position of thermal well connector insert the second probe see caution into either of the outside wire positions see photo 20 lt A Alternate the probe on the outside position to the opposite outside wire position see photo 21 y vA Once the thermal well resistance values are known the water temperature must also be known to determine if the resistance N Replace thermal well values are correct See page 25 to obtain water temperature see page 27 Are thermal well resistance values correct F Replace gas control see page 27 24 BRADFORD WHITE PDX SERVICE PROCEDURE VI i Gas Control Thermal Well Testing and PDX Series Replacement a WARNING
6. s vorra Burner port area OO Step 9 Unscrew burner from main burner orifice On cast iron burners loosen air shutter nut and unscrew feedline from burner Main burner orifice Step 10 Remove main burner orifice from feedline 2 wrench on steel burners 3 8 wrench on cast iron inspect orifice clean or replace if necessary L P Main burner orifice Left hand thread Step 11 Reassemble burner and reinstall into water heater Restore gas supply and check for gas leaks Step 12 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual Ga BRADFORD WHITE PDX Series Pilot testing Cleaning and Replacement PDX SERVICE PROCEDURE II P Pilot Inspection Testing and Replacement Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 amp 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 remove inner door per service proceedure XIII on page 35 Ge N a sense wire J Disconnect pilot tube nut 7 16 wrench and feedline nut e eden D 74 wrench from gas control N Ss Pilot tubin g nut
7. Frozen intake or exhaust vent terminal If an intake or exhaust vent terminal is blocked with ice or snow due to severe conditions the pressure switch and control will not allow the burner to operate This will result in a three flash error code Once the blockage is removed through melting or other means the controls will let the burner operate The position of the vent terminals in relation to each other and terminals from other appliances can have an effect on the potential for blockage due to ice or snow See the installation instructions for recommended positioning of the terminals Testing under severe conditions has shown that the optional concentric vent terminal is resistant to ice blockage Contact Bradford White or the supplier of the water heater for information about ordering the optional concentric vent terminal Bradford White has also developed an air intake relief device that can be installed in the air intake near the water heater temporarily enabling the water heater to operate with a frozen intake terminal Contact Bradford White or the supplier of the water heater for information about the air intake relief device amp BRADFORD WHITE ne PDX Series BTU GPM Hz KW h LED NPT Ohms PSI RPM TCO VAC W C G F NOTES British Thermal Units Gallons per Minute Hertz Killo watts per hour Light Emitting Diode National Pipe Thread Ohms of resistance Pounds per Square Inch Revolutions per Minute Temperatu
8. Stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Determine Water Temperature Inside Tank Note It is important to understand once the resistance for the thermal well is determined from page 25 water flow through the heater should not occur Prior to performing the steps below turn off the cold water supply to the water heater This will prevent cold water flow into the tank affecting the resistance value of thermal well Step 1 Position gas control power switch to OFF position Step2 Draw approximately 4 gallons of water from drain valve into a container and discard Draw an additional gallon and immediately measure water temperature using an accurate thermometer It may be necessary to open a hot water faucet to allow heater to drain Step 3 Using the chart below determine correct resistance value for the water temperature from step 2 Example If temperature of water is 84 F then the resistance through the sensor would be 8449 see shaded area NOTE Sensor resistance increases as the temperature falls sensor Resistance at Various Temperatures In Degrees F F 0 1 2 3 40 26109 25400 24712 24045 50 19906 19383 18876 18383 60 15314 14925 14548 14180 5 6 I 8 9 22 71 22163 21573 21000 20445 17440 16990 16553 16128 15715 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10502 10248 1000 9760 9
9. the gas control immediately turns off all outputs Control waits and monitors resistance for 30 seconds If the resistance is greater than 70 000 ohms after 30 seconds the gas control proceeds to verify resistive delay for 2 minutes and flashes 7 times with a three second pause This process is repeated 5 times until the control either returns to normal operation or proceeds to a lockout mode flashing 7 times with a 3 second pause b Ifthe Flammable Vapor Sensor 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 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 three times with three second pause The error self clears if the fault clears for at least 15 seconds b Temperature sensors not reading the same temperature within 5 5 F The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause The error self clears if the fault clears for at least 15 seconds c Water temperature in excess of TCO Temperature Cut Off limit The gas control immediately turns off pilot amp main valve and proceeds to flash 4 times with 3 second pause Blower continues to run until gas control is reset Power n
10. 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 control turns off the blower and flashes 6 times then 2 times with 3 second pause The control waits 5 minutes before repeating ignition sequence 4 Trial For Ignition Fault a Pressure switch opens during trial The 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 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 5 Flame Sensing Fault a Flame lost during run The control turns off pilot and main valves runs blower for 15 seconds inter purge The 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 been reached the control turns off the blower and flashes 6 times then 3 times with 3 second pause The control waits 5 minu
11. Specifications Vent Tables Part Il Venting Specifications for 40 Gallon 50 Gallon IMPORTANT The minimum equivalent length for the exhaust portion of the vent is 7 feet The maximum equivalent vent length for the exhaust is 35 feet for 2 diameter pipe and 85 feet for 3 diameter pipe The intake portion of the vent must be equal to or less than the vent length of the exhaust The tables below are provided for your quick reference some installations may require a greater number of elbows When calculating equivalent vent length one 90 elbow is equivalent to 5 feet VENT CONNECTOR LENGTHS FOR 2 5 1 cm DIAMETER VENT PIPE of E oam Maximum Minimum Terminating eveni straight straight term Length ft m Length ft m Through the Wall 1 30 9 1 2 6 Through the Wall 2 25 7 6 2 6 Through the Wall 3 20 6 1 2 6 Through the Wall 4 15 4 6 2 6 Through the Roof 0 35 9 1 7 2 1 Through the Roof 1 30 9 1 T 2 1 Through the Roof 2 25 7 6 T 2 1 Through the Roof 3 20 6 1 7 2 1 VENT CONNECTOR LENGTHS FOR 3 7 6 cm DIAMETER VENT PIPE o Ea Maximum Maximum Terminating jueni straight straight term Length ft m Length ft m Through the Wall 1 80 24 4 10 3 1 Through the Wall 2 75 22 9 10 3 1 Through the Wall 3 70 21 3 10 3 1 Through the Wall 4 65 19 8 10 3 1 Through the Roof 5 60
12. Upon completion of inspection or subsequent replacement reinstall inlet nipple dip tube into water heater Connect nipple to plumbing system resume water supply and refill with water Step 7 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE eee ee eee ee eee C PDX SERVICE PROCEDURE XI PDX Series Anode Inspection and replacement ko A Anode Inspection and Replacement A WARNING Water Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Position on off switch of gas control valve to the OFF position and unplug water heater from wall outlet Step 2 Turn off cold water supply to water heater Connect hose to drain valve of water heater and route to an open drain Open a nearby hot water faucet to vent water heater for draining Open drain valve of water heater and allow water heater to drain to a point below the outlet connection nipple Step 3 Disconnect outlet nipple from plumbing system Step 4 With an appropriate tool such as a pipe wrench remove outlet nipple anode from the water heater Use caution not to damage pipe threads Step 5 Visually inspect outlet nipple anode Outlet nipple anode should show signs of depletion this is normal If depleti
13. 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 Thermal well TCO 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 128 F 54 C Pressure switch Standard Altitude Normally open closes at differential pressure of 80 High Altitude Normally open closes at differential pressure of 73 Blower 115VAC 60Hz 3 1 amps WATER HEATERS PDX Series Venting Specifications for 48 Gallon 65 Gallon 75 Gallon Vent Tables f Specifications This water heater is approved for installation with the following PVC CPVC or ABS Schedule 40 venting material The maximum and minimum vent lengths listed on this label are for the exhaust portion of the vent The intake portion of the vent must be equal to or less than the length of the exhaust 3 Diameter 7 6 cm PVC Vent Connector Lengths Maximum 48 65 gal Maximum 75 gal i H
14. test the the Flammable Vapor Sensor for proper operating range If the Flammable Vapor Sensor is within range the control resumes normal operation with no perceptible delay If the Flammable Vapor Sensor is out of range the control LED immediately flashes 7 times with 3 second pause Normal Heating Sequence G 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 2 minutes then blower runs for 30 seconds This cycle repeats until safety circuit opens Blower energizes G Blower pre purge period 15 seconds C Differential pressure switch proves blower vent system operation a 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 a call for heat G Trial for pilot ignition 90 seconds a The gas control lights the pilot by activating spark igniter and gas flow to pilot burner b If flame is not sensed within 90 seconds igniter and gas flow are deactiv
15. until flame becomes as blue as possible with a minimum of yellow tips Tighten the air shutter nut Too much air will cause the flame to lift off the burner ports and create noisy burner operation Too little air will result in soot formation Step 3 Replace inner door as described in this manual observe burner operation Burner should operate as adjusted in step 2 If not repeat air shutter adjustment compensating for proper burner operation with inner door closed of Air Shutter Nut Air Shutter BRADFORD WHITE Se eee ee eee eee PDX SERVICE PROCEDURE I Burner Operation Inspection PDX Series Adjustment Cleaning and Replacement Burner Cleaning Step 1 Position gas control power switch to the OFF position and unplug heater from wall outlet Step 2 Turn off gas supply to water heater Step 3 Remove outer jacket door and inner door per service procedure XIII on page 35 Igniter flame Step 4 Disconnect pilot tube 7 16 wrench and sense wire feedline 4 wrench from gas control y Step 5 Disconnect igniter flame sensor wire from gas control oa 2 Step 6 Remove burner assembly from combustion chamber EEM iubineiit Step 7 Thoroughly inspect burner surface area and burner port area and remove any loose debris Step 8 For cast iron burners inspect for any debris build up inside burner casting Burner surface area
16. 18 3 10 3 1 Through the Roof 0 85 29 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 22 3 15 4 6 Through the Roof 4 65 19 8 15 4 6 E BRADFORD WHITE WATER HEATERS PDX Series Control Timings Specifications Ignition State Timin Pre purge 15 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 TCO Limit Lockout Indefinite cycle power to restart 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 BLOWER WIRING DIAGRAM BLOWER TEMPERATURE SWITCH SWITCH NO WATER TEMPERATURE SENSOR BRADFORD WHITE E f Sequence of Operation PDX Series Power up Sequence G Start Up Upon power up the control runs a safe start check with a typical start up delay of 1 5 seconds Flammable Vapor Check To assure no outputs are energized if the Flammable Vapor Sensor is out of range the control will
17. 526 80 9299 9078 8862 8653 8250 8057 7869 7685 7507 90 1333 7165 7000 6839 6683 6531 6383 6238 6098 5961 100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112 130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538 140 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083 150 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720 160 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427 170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191 180 1170 1150 1129 1110 1090 1071 1953 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 ges 762 749 T37 725 713 BRADFORD WHITE me ee ee eee O PDX SERVICE PROCEDURE VI PDX Series Gas Control amp Thermal Well Testing and Replacement A Gas Control amp Thermal Well Removal From Water Heater Gas Control Step 1 Position gas valve power switch to the OFF va Thermal position and Unplug Heater from power supply Well oa Step 2 Drain heater to a point below the gas vA control level er Fam Step 3 Turn off gas supply to water heater and disconnect gas piping from gas control p c Sa Step 4 Disconnect wire harnesses and burner assembly from gas control Step 5 Remove gas control amp thermal well by rotating flats of Thermal Well counter clockwise 1 5 16 wr
18. P Inner Door Gasket Heat Trap Insert kit Mixing Valve BRADFORD WHITE Se ee eee eee ee eee O HEATERS BRADFORD WHITE WATER HEATERS Ambler PA For U S and Canada field service contact your professional installer or local Bradford White sales representative Sales 800 523 2931 Fax 215 641 1670 Parts Fax 215 641 2180 Technical Support 800 334 3393 Fax 269 795 1089 Warranty 800 531 2111 Fax 269 795 1089 International Telephone 215 641 9400 Telefax 215 641 9750 ts BRADFORD WHITE CANADA INC Mississauga ON Sales 866 690 0961 905 238 0100 Fax 905 238 0105 Technical Support 800 334 3393 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com
19. Terminating oo Maximum Minimum Maximum Minimum Length ft m Length ft m Length ft m Length ft m Through the Wall 1 55 16 8 2 6 45 13 7 2 6 Through the Wall 2 50 15 2 2 6 40 12 2 2 6 Through the Wall 3 45 13 7 2 6 35 10 7 2 6 Through the Wall 4 40 12 2 2 6 30 9 1 2 6 Through the Roof 0 60 18 3 7 2 1 50 15 2 7 2 1 Through the Roof 1 55 16 8 7 2 1 45 13 7 7 2 1 Through the Roof 2 50 15 2 T 2 1 40 12 2 T 2 1 Through the Roof 3 45 13 7 T 2 1 35 10 7 T 2 1 4 Diameter 10 2 cm PVC Vent Connector Lengths Maximum 48 65 gal Maximum 75 gal Terminating nie Maximum Minimum Maximum Minimum Length ft m Length ft m Length ft m Length ft m Through the Wall 1 95 29 0 10 3 1 85 25 9 10 3 1 Through the Wall 2 90 27 4 10 3 1 80 24 4 10 3 1 Through the Wall 3 85 25 9 10 3 1 75 22 9 10 3 1 Through the Wall 4 80 24 4 10 3 1 70 21 3 10 3 1 Through the Wall 5 75 22 9 12 3 6 65 19 8 12 3 6 Through the Roof 0 100 30 5 15 4 6 90 27 4 15 4 6 Through the Roof il 95 29 0 15 4 6 85 25 9 15 4 6 Through the Roof 2 90 27 4 15 4 6 80 24 4 15 4 6 Through the Roof 3 85 25 9 15 4 6 75 22 9 15 4 6 Through the Roof 4 80 24 4 15 4 6 70 21 3 15 4 6 amp BRADFORD WHITE T WATER HEATERS 7 8 PDX Series
20. X SERVICE PROCEDURE IX PDX Series 120 VAC Trace Pi 120 VAC Circuit Trace WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury Step 1 Verify 120VAC and proper polarity at wall outlet Step 2 With unit plugged in and control power switch in the ON position verify LED status LED status LED status LED status LED status None Control LED not Short flash once every Heartbeat alternates Various flashing error on or flashing four TS enem E vat for Thermostat calling Verify error code as call for heat for heat listed on page 12 y Disconnect cord set as shown in photo 26 ye Using a volt meter set to volts AC is there 120VAC N Check for damage to AC Y supply power cord C n Replace Blower Is there 120VAC across Reconnect cord set terminals shown in hoarimohoioat p 28 i wire harness Incorrect a gas control voltage polarity see photo 29 Locate black amp white wires at connector It may be necessary to pull back wire sheath to identify wire colors see photo 30 Repair damage across terminals shown in photo 27 Wire sheath pulled back to identify wire colors ia Is there 120VAC across y Repl N black amp white wires as SP ne a Check for 120VAC between black amp whit
21. and operating manual BRADFORD WHITE eee ee ee ee eee eee PDX SERVICE PROCEDURE III PDX Series Pressure Switch Testing and Replacement Pressure Switch Testing A WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury 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 Step 3 Carefully remove pressure switch from blower housing see photo 2 Exhaust pressure switch Pressure Switch Pressure switch wire leads Slide pressure switch in direction of arrow while tilting slightly away from blower housing With steps 1 2 amp 3 complete disconnect wire leads from pressure switch Use a multi meter set to the ohms setting With blower off check across pressure N switch terminals Are switch contacts open no electrical continuity T Check tubing and pressure tap on switch for blockage Is there blockage Replace switch see page 18 a Pi Y Clear blockage Position gas valve power N switch to the ON position and adjust thermostat Y y y to call for heat Check tubing and Is vent system length ae Is vent ae See blower testing this will start
22. as control page 26 Seven flash three second Flammable Vapor WARNING EXPLOSION HAZARD Indicates gasoline vapors were detected at potentially explosive levels Verify no gasoline vapors are still present pause vias Reset the control by cycling power to the appliance or Papera by cycling the ON OFF switch Replace the Flammable Vapors Sensor element if a gasoline spill event occurred Verify Flammable Vapor Sensor FVS resistance is l Flammable Vapor Eight one flash three Seaport not below 25 K Ohms Pave 28 second pause see A Check wiring to FVS and insure it is not shorted 8 P l Replace control if everything above checks out OK mena WON 1 Damage to thermal well wire sensor damaged i Page 24 2 Thermal well sensor resistance out of range Eight three flash three Or unplugged second pause j a ae 1 Control needs to be reset pent DY power DULY electronics fault gt Conr caeron a cadam 2 Replace gas control detected Pay y gee 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 h IEEE BRADFORD WHITE PDX SERVICE PROCEDURE I PDX Series Burner Operation Inspection Adjustment Cleaning and Replacement Me A Burner Inspection and Air Shutter Adjustment At periodic intervals
23. ated blower will post purge and control LED flashes 6 times with 3 second pause C 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 aa BRADFORD WHITE PDX Series l Sequence of Operation Normal Heating Sequence cont Steady state operation CG 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 a short flash once every 4 seconds 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 3 times with 3 second pause Flame Sense If flame is lost pilot amp 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 G Burner off 10 Blower post purge 15 seconds Abnormal Operation 1 Simulated Resistive Device Fault a Ifthe Flammable Vapor Sensor resistance is greater than 70 000 Ohms
24. blower and remove cover see photo 24 Position gas control switch to the ON b position and adjust thermostat dial to call for heat Is there 10 to 13 VAC between red wire leading to blower temperature switch N and green ground wire Is LED on gas valve flashing the No voltage from gas control heartbeat code alternating 6 6 call for technical support Blower must be running during this brienendima voltage check N see photo 25 p Y Verify 120VAC to gas control see page 30 y Is there 10 to 13 VAC between yellow wire Is there continuity checctoroneii leading from pressure switch and green N through blower y l l broken wire connection ground wire temperature switch E A cael see photo 25 see page 21 y Determine cause of blower Correct igniter temperature switch activation sensor problem and correct y f Check igniter sensor Do you hear or can you see N Y Faulty cord set or ane see page 17 2 the igniter sparking eioniter cneon 0E gas control ij Safety circuit voltage is OK If burner does not light observe LED flash code on gas valve and refer to troubleshooting section on page 13 Green ground wire Red wire leading to blower temp switch Yellow wire leading from pressure switch amp BRADFORD WHITE WATER HEATERS 29 PD
25. e wires shown in photo 30 ikii NOTE Electronic meter probes required Use care not to k ere damage connector during this check A Call for technical support 30 EE BRADFORD WHITE C N PDX SERVICE PROCEDURE X PDX Series Dip Tube Inspection and replacement S wy Dip Tube Inspection and Replacement A WARNING Water Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Position on off switch of gas control valve to OFF position and unplug water heater from wall outlet Step 2 Turn off cold water supply to water heater Connect hose to drain valve of water heater and route to an open drain Open a nearby hot water faucet to vent heater for draining Open drain valve of water heater and allow heater to drain to a point below the inlet connection nipple Step 3 Disconnect inlet nipple from plumbing system Step 4 With an appropriate tool such as a pipe wrench remove inlet nipple dip tube from the water heater Use caution not to damage pipe threads Step 5 Visually inspect inlet nipple dip tube Inlet ntpple dip tube should be free of cracks and any blockage Hydro jet slots should be open and free of any blockage Any damage such as cracks restriction due to deformation or unintentional holes are not field repairable and the inlet nipple dip tube must be replaced Step 6
26. eeds to be cycled to remove gas control from TCO lockout BRADFORD WHITE ee ee eee ee eee eee eee eee f Sequence of Operation PDX Series Abnormal Operation cont 3 Pressure Switch Blower Temperature Fault a Pressure switch closed at start of call for heat The control waits four 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 waiting for pressure switch to close b Pressure switch or blower temperature switch failed open The 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 3 second pause The control waits two 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 c Pressure switch or blower temperature switch opens during burner operation The 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
27. ench Gas Control Removal From Thermal Well Follow the steps below allows removal gas control from thermal well without removing thermal well from tank Step 1 Position gas control power switch to the OFF position and unplug water heater from power supply Step 2 Turn off gas supply to water heater and disconnect gas piping from gas control Step 3 Disconnect wire harnesses amp burner assembly from gas control Step 4 Using gas control service tool 239 45991 00 available from your BWC parts supplier Insert tool into back of gas control see photos below View from back of control for clarity j a Y Insert tool from back of control Service tool shown inserted in to back of control Step 5 Pivot tool towards heater as far as possible see photo below Lift straight up on gas control The control should move about 1 8 Hold control in position and remove tool Lift straight up on control to remove completely from Thermal Well With service tool inserted pivot tool back towards water heater as far as possible Lift straight up on control control will move 1 8 Remove tool and continue to lift straight up on control to remove from Thermal Well BRADFORD WHITE WATER HEATERS 26 PDX Series PDX SERVICE PROCEDURE VI Gas Control amp Thermal Well Testing and Replacement oe Gas Control Assembly to Thermal Well Step 1 Ins
28. er Door Removal Inspection amp Replacement 34 XII Glossary of Terms 38 Parts List 39 2 E BRADFORD WHITE PDX Series WARNING If the information in these instructions is A CAUTION not followed exactly a fire or explosion may result Incorrect operation of this appliance may causing property damage personal injury or death create a hazard to life and property and will nullify the warranty FOR YOUR SAFETY A DANGER Do not store or use gasoline or other flammable Do not store or use gasoline or other combustible or corrosive vapors and liquids in the flammable combustible or corrosive vicinity of this or any other appliance vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any IMPORTANT phone in your building Before proceeding please inspect the e Immediately call your gas supplier from a neighbor s phone water heater and its components for possible damage DO NOT install any water heater with damaged components If damage is evident then please contact Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire ee b f di lified the supplier where the water heater was Installation and service must be performed by a qualifie purchased or the manufacturer listed on installer service agency or the gas s
29. every 6 months a visual 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 Water heater vent is less than the allowable vent length b Gas pressure is out of specification c Pilot flame not fully engulfing spark flame sensor d Door was not sealed properly after servicing Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter Cast iron burner can have the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner see cast iron burner adjustment below Main burner must be free from any debris accumulation that may effect burner operation see burner cleaning procedure on page 14 Cast Iron Burner Air Shutter Adjustment WARNING Inner door and burner components may be HOT when performing this operation Take necessary precaution to prevent personal injury Step 1 With main burner in operation remove outer jacket door remove inner door as described in this manual see inner door removal inspection and replacement section page 35 Step 2 To adjust for proper burning loosen the air shutter nut rotate the air shutter to close the opening in the burner then slowly rotate the air shutter open
30. exhaust vent adapter see photo 11 E see photo 15 p With blower running and exhaust adapter removed from top of blower is there a negative pressure of 2 30 to 2 60 W C N Remove exhaust adapter Determine voltage N Y roblem and correct Is there 115vac across blue and green wires see photo 14 Replace blower 7 Replace cord set p Reconnect cord set shown 115VAC between blue wire in photo 8 is there and green ground wire see photo 14 A Does cord set have electrical continuity Blue wire Replace gas control Shown with pressure switch removed WATER HEATERS PDX Series Blower Testing and Replacement Blower removal Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Blower Installation Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Step 19 Step 20 amp BRADFORD WHITE eee es PDX SERVICE PROCEDURE IV P Remove exhaust adapter and retain for use on Position gas control power switch to the OFF position new blower Unplug blower power cord from wall outlet Blower Mounting Screws Disconnect vent system from exhaust adapter on top of blower Remove exhaust adapter from blower blade screw driver and
31. ffle as necessary Step 9 Reinstall baffle into flue tube Be sure baffle hanger tabs are inserted into notch location at the top of the flue tube see photos 34 amp 35 Remove support bracket Step 10 Check Burner to insure no scale has accumulated during this operation See burner cleaning procedure on page 15 Step 11 Reinstall blower on water heater Connect vent system and cords set to blower Plug water heater into wall outlet Step 12 To resume operation follow the lighting instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual Flue Baffle Baffle shown installed in flue tube notch Flue tube notch BRADFORD WHITE Se ee eee ee eee eee eee C k PDX SERVICE PROCEDURE XIII PDX Series Inner Door Gasket Removal Inspection Replacement and Reinstallation F Inner Door Removal Procedure Step 1 Slide switch of the Electronic Gas Control to the OFF position and unplug from wall Step 2 Remove outer jacket burner access door Step 3 Disconnect wire connections from Electronic Gas Control Step 4 Right side Inner Door Removal a Remove wire tie from feedline b Remove 2 1 4 hex drive screws from right side inner door c Remove 2 1 4 hex drive screws from flange section of inner door d Remove right side inner door and set aside Be careful not to damage gasket material o
32. llation of Inner Door With Gasket Step 7 Step 8 hex drive Step 9 Cc C RECOMMENDED PATTERN FOR RTV SEALANT ge i BP RB Ain ana S ane BSC 1 aoe Sa T j 0 N A ar Ae i ne PLACE FLANG CO SECTIONS FIRST EXPANDED VIEW Clean any residual gasket residue or other debris from combustion chamber surface before installing the inner door gasket assembly Place the left side inner door into position first Firmly position the radiused channel of the inner door around the feedline Using the 1 4 screws from step 3d secure left side inner door in place DO NOT OVER TIGHTEN SCREWS Position thermocouple pilot tube and Piezo wire against left side inner door flange gasket DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE Ji j Radiused Channel for M Feedline BRADFORD WHITE WATER HEATERS GASKET OVERLAP MUST BE AS SHOWN 1 32 ENLARG EW OF VIEW WITH GASKETS IN PLACE A WARNING Stripped fastener connections may allow for seal breach of inner door A seal breach may result in a fire or explosion causing property damage personal
33. mply not be effective to obtain certain voltage and ohm reading 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 Gas Control Service Tool BWC part number 239 45991 00 A specialized tool designed to remove the gas control from gas control thermal well Available from your Bradford White parts supplier Various Hand Tools Pipe wrench channel locks open end wrenchs 3 8 7 16 12 crescent wrench Allen wrench set screw drivers common amp Phillips nut driver pliers common amp needle nose socket set side cutters wire cutters wire strippers wire crimpers torpedo level small shop vac step ladder and flashlight 5 gallon pail BRADFORD WHITE E 5 PDX Series Specifications Power supply Dedicated 115VAC 60 Hz 15A Gas Supply Pipe Minimum 1 2 NPT schedule 40 black iron pipe recommended Approved Gas Type Natural or Propane Unit must match gas type supplied Gas Pressure 5 0 W C min for Nat gas 11 0 W C min for L P gas 14 0 W C maximum Nat amp L P Venting System Power direct vent through the wall or vertical through the
34. n inner door Hex Drive Screws shown on Right Side Inner Door Hex Drive Screws at Flange section of Inner Door Step 4 Fully inspect inner door gaskets for the following gt Tears gt Other imperfection that will inhibit proper seal gt Missing Material gt Gasket adhesion to inner door gt Cracks gt Material left on combustion chamber around opening gt Dirt or debris If the gasket is not effected by any of the above gasket replacement is not required If replacement is required proceed to Inner Door Gasket Replacement Procedure Inner Door Gasket Replacement Procedure A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Step 5 After inspection of inner door as noted in step 4 completely remove gasket and adhesive residue from right and left side inner doors as needed Step 6 Use RTV sealant recommended bead size is 1 8 to secure the inner door gasket to the inner door sections right amp left Refer to illustration below for proper application Note the overlap configuration in the flange area of the inner door Set the flange section first this will help to achieve the proper over lap position n aa amp WATER HEATERS PDX Series g N PDX SERVICE PROCEDURE XIII Inner Door Gasket Removal Inspection Replacement and Reinstallation Zz Insta
35. o pilot assembly or bad connection at gas valve Service LED Status Control Status Probable Cause sa a as Procedure 1 Unstable pilot 2 Pilot tube blocked or restricted meedeert gt Six one flash three Failed to light pilot a Odar Dudun onn ol aiecode second pause System auto resets 4 p p i 2 4 Page 17 Presses nih 1 Vent blockage or improper vent configuration 2 Pressure switch tubing kinked or blocked lee nerie VED OP VENADIEN or blower temp i 2 amp 3 Page 18 switch opened 3 Faulty pressure switch 4 Refer to venting section of Six two flash three l 4 Vent termination being affected by wind installation manual during burner ae second pause paora o 5 Blower not spinning up to speed 5 Page 20 p 6 Blower temp or exhaust temp too high eee System auto 8 Refer to installation 7 Faulty blower temperature switch resets l manuzi 8 Insufficient combustion air 1 Unstable pilot 2 Pilot tube blocked or restricted 1 Page 15 Pilot flame ape l l ed 3 Oxidation build up on pilot electrode Six three flash three extinguished l 2 4 Page 17 4 Wire damage to pilot assembly or bad second pause System auto connection at gas valve 5 Refer to installation manual resets ae 5 Insufficient combustion air 6 Gas pressure is out of specification Six four flash three second pause Undesired false pilot flame sensed System auto resets Pilot valve stuck in open position Replace g
36. on is 1 2 of the original anode diameter approximately 34 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 6 Upon completion of inspection or subsequent replacement reinstall outlet nipple anode into water heater Connect nipple to plumbing system resume water supply and refill with water Step 7 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual 32 M BRADFORD WHITE a N PDX SERVICE PROCEDURE XII PDX Series Flue Baffle Inspection and replacement XY A Remove blower to gain access to Disconnect vent system rom exhaust adapter flue baffle gt f a j i Ti Blower Mounting Step 1 Position gas control power switch to the OFF position and oY nen unplug blower from wall outlet 7 Al Step2 Disconnect vent system from exhaust adapter on top of blower Step 3 Disconnect intake air piping Step 4 Unplug cord sets from blower see photo 31 lee ae Step 5 Remove the three blower mounting screws E 14 nut driver see photo 31 Cord Sets Step 6 Remove blower with gasket from water heater Step 7 Remove flue baffle from Heater see photo 33 Step 8 Inspect baffle for deterioration missing restrictors Clean any scale or debris build up Replace with new ba
37. ontrol access cover on blower and remove cover see photo 15 Step 4 Locate blower temperature switch see photo 16 Switch Settin Opens on rise approximately 155 F Auto resets on fall approximately 128 F Blower temperature switch location Cool switch to below 125 F 4 S Disconnect wire leads to switch Using a multi meter Sa Replace switch set to the ohms setting is cat see page 24 there continuity between the switch terminals Me E I N Reconnect wire leads and y Exhaust observe heater operation Do Do switch contacts temperature is to exhaust gas temperatures rise open Kat to or above 175 F 1 Vent length is below minimum allowable O 2 Vent diameter not to specification 3 Restricted dilution air inlet Do switch contacts Replace switch open see page 23 Switch OK g Common causes for N high exhaust temperature 4 Missing or deteriorated flue baffle 5 Gas pressure is out of specification 6 Excessively high ambient temperatures WATER HEATERS PDX SERVICE PROCEDURE V PDX Series Blower Temperature Switch Testing and Replacement Pi Blower Temperature Switch A WARNING Replacement 120 volt potential exposure Use caution to avoid personal injury Step 1 Position gas control power switch to the OFF position and unplug heater from wall ou
38. pter before fitting the adapter to the water connections It is imperative that heat is not applied to A the nipples containing a plastic liner WARNING FAILURE TO INSTALL AND MAINTAIN A NEW LISTED 3 4 X 3 4 TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT A MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND WARNING PRESSURES 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 A CAUTION recommend the hot water faucet to be open for several Turn off or disconnect the electrical power supply to the NULE A the kitchen sink before you use any electrical water heater before servicing Label all wires prior to appliance which is connected to the hot water system If disconnection when servicing controls Wiring errors can hydrogen is Aa ites will be a tan aril rs cause improper and dangerous operation Verify proper as air escaping through the pipes as hot water begins to operation after servicing flow Do not smoke or have open flame near the faucet at the time it is open BRADFORD WHITE qe 3 WATER HEATERS PDX Series Introduction The new Bradford White PDX1 PDX2 and PDX4 water heaters are designed to provide reliable performance with enhanced
39. r switch to ON position and verify proper heater operation Step 10 Replace control access cover from step 2 BRADFORD WHITE eee ee eee eee ee ee eee O PDX Series 3 PDX SERVICE PROCEDURE IV Blower Testing and Replacement A Blower Testing Step 1 Position gas control power switch to ON position and adjust control to call for heat Step2 Remove the three screws Phillips Screw driver from control access cover on blower assembly and remove cover see photo 8 Disconnect pressure switch tubing from blower see photo 13 Does blower energize Within2 Y minutes Pressure switch k tubing Does blower energize after 2 See pressure switch minutes run for 30 seconds testing and shut down Page 18 N G Disconnect cord set shown in photo 9 Is y Is there 115VAC across there 115VAC across terminals shown in terminals shown in photo photo 13 12 N N Incorrect supply voltage polarity y Determine Is there 115 VAC at power source wall outlet problem and correct Check DA cord Repair or replace for os power cord Replace blower 20 BRADFORD WHITE WARNING 115 volt potential exposure Use caution when making voltage checks to avoid personal injury Connect manometer to pressure tap of blower r Eea vent N system from top of blower and remove
40. re Cut Off Volts Alternating Current Inches of Water Column Degrees Centigrade Degrees Fahrenheit Glossary of Terms 38 m BRADFORD WHITE WATER HEATERS PDX Series Blower Assembly Blower Temp Switch Pressure Switch Blower Gasket Tee and Vent Pipe Assy Vent Adapter with Term Intake Terminal Vent Terminal Elbow Exhaust Adapter 10 Condensate Hose Kit 11 Flue Reducer 12 Heat Trap Insert outlet 13 Heat Trap Insert inlet 14 Hot Water Outlet Anode OONADAOARWN 2s Cold Water Inlet Diptube 28 Flue Baffle 29 Blower Harness 30 T amp P Relief Valve g1 NPT PLUg Direct Vent Boot 32 Escutcheon 33 Air Intake Boot 34 Air Intake Boot Gasket 35 Outer Door 36 Right Side Inner Door oF Left Side Inner Door 38 Screw 10 12 x HWH 39 Screw 8 18 x 4HWH 40 Brass Drain Valve Flammable Vapor Sensor Sensor Harness Flammable Vapor Sensor Clip Thermal Well Gas Control Kit Gas Control Service tool Gas Control Gas Burner Assy Nat Gas BN burner Nat Main Burner Orifice Nat Gas Pilot Assembly Nat Gas Pilot Orifice Nat Parts List Gas Feedline Nat Gas Burner Assy L P Cast Iron Burner L P Gas Pilot Assy L P Gas Pilot Orifice L P Air Shutter L P LP Gas Feedline L P Air Shutter Nut L P Main Burner Orifice L
41. retain for use on new blower Unplug cord sets from blower Remove vertical air intake bracket Blower Cord Sets Disconnect vertical air intake from blower Remove the three blower mounting screws 4 nut driver Vertical air intake Remove blower with gasket from water heater Vertical air intake bracket Clean any debris from jacket head of water heater Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head Be sure not to damage gasket Secure blower in place using mounting screws from step 8 Slide vertical air intake tee onto blower Re install vertical air intake bracket Locating Pins on blower flange Re install exhaust adapter from step 4 Reconnect vent system to exhaust adapter Reconnect cord sets from step 5 Pin location holes in jacket head Plug blower power cord into wall outlet Position gas control power switch to the ON position Verify proper blower operation WATER HEATERS PDX SERVICE PROCEDURE V PDX Se ries Blower Temperature Switch Testing and Replacement p Blower Temperature Switch WARNING Testing 120 volt potential exposure Use caution to avoid personal injury Step 1 Position power switch on gas control P daid to the OFF position Step2 Remove tubing from inlet pressure tap Step 3 Remove the three screws Phillips screw driver from c
42. sition power switch on gas control to the Disconnect flammable vapor sensor from Step 1 OFF position Step 2 gas control Step 3 Using a multi meter set to the ohms setting check resistance of flammable vapor sensor see caution below Resistance must be within 3 000 ohms and 48 000 ohms If outside of this range replace flammable vapor sensor ohms setting Multi meter set PDX SERVICE PROCEDURE VII Flammable Vapors Sensor Testing a ae Flammable Vapor OOF Sensor se oN Q vO N Aal Electronic A CAUTION oin type Meter Probes DO NOT use standard multimeter probes for this test Doing so will damage connector Use special electronic pin type probes or small diameter wire pins inserted into connector Flammable Vapor sensor WATER HEATERS a o PDX SERVICE PROCEDURE VIII PDX Series Safety Circuit Voltage Trace Safety Circuit Voltage A WARNING Trace 120 volt potential exposure Use caution making voltage checks to avoid personal injury NOTE This procedure assumes a cool tank Step2 Remove three screws Phillips Screw driver from control access cover on
43. standard features New design features include reliable spark to pilot ignition system enhanced diagnostics simplified servicing significantly quieter operation additional vent lengths and certified FVIR technology 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 New 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 amp FHSR performance The PDX1 PDX2 and PDX4 water heaters use a combustion system were flue gases are combined with dilution air to reduce the flue gas temperature in the blower combustion air and dilution air are drawn from outside the building The diluted flue gases are evacuated to the exterior through non metallic vent materials The gas control maintains water temperature ignition sequence and reg
44. tall threaded end of thermal well into tank Be sure thermal well flange is positioned as shown in photo 22 for proper control alignment 22 r aE Step2 Route wire leads back into relief opening see photo 23 Step 3 Align slots located on thermal well flange with tabs located on back of gas control see photo 22 amp 23 Thermal well flange Route wires slots through relief opening Step 4 Carefully push control back onto thermal well flange 23 A as far as possible towards water heater Slide control down to lock into position Step 5 Install burner and connect pilot tubing and feedline nut to gas control J r Ho oas control Tabs Ge eso aman Te Step 6 Reconnect wire harnesses to gas control COONELUON L 6 per the illustration L J Step 7 Reconnect gas piping to gas control amna i Restore gas supply and check for gas connection leaks Step 8 To resume operation follow the 5 pin blower harness connection f pin i thermal well connection instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual o Flammable Vapor eo Sensor E07 amp BRADFORD WHITE WATER HEATERS 21 PDX Series Flammable Vapor Device Testing Po
45. tes before repeating the ignition sequence b Flame sensed out of sequence the control only looks for pilot flame when the blower is running If flame is present when the pilot valve is not open the control proceeds to wait for flame loss and flashes 5 times with 3 second pause This continues until flame is lost once the flame signal is lost the control flashes 6 times then 4 times with 3 second pause The control waits 5 minutes before repeating the ignition sequence PDX Series Troubleshooting me _ Observe green LED indicator on Electronic gas ont control Error flash codes are displayed with a bg three second pause before repeating Check Ro and repair the system as noted in the J troubleshooting table below i e l lef 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
46. the blower N pressure tap on within vent table Y l system a page 21 Check with multi meter do switch for blockage specifications f blocked Is blower OK pressure switch contacts close Is there blockage listed on page 7 or 8 with blower running with the N N switch in the vertical a postition J Y Reconfigure vent system to be Correct blower i A roblem Switch contacts are OK poao p See safety circuit trace vent tables page 30 _ x xx Ey BRADFORD WHITE WATER HEATERS PDX Se ries Pressure Switch Testing and Exhaust Pressure Switch PDX SERVICE PROCEDURE m Replacement Ei WARNING Replacement 120 volt potential exposure Use caution to avoid personal injury Step 1 Position gas control power switch to OFF position Step2 Remove the three screws Phillips screw driver from control access cover on blower assembly and remove cover see photo 3 Pressure Switch Step 3 Carefully remove pressure switch from blower housing see photo 4 Slide pressure switch in direction of arrow while tilting slightly away from blower housing Step 4 Disconnect tubing from pressure switch see photo 5 Step 5 Disconnect yellow wires from pressure switch see photo 6 Step 6 Reconnect wires from step 5 to new pressure switch Step 7 Reconnect tubing to new pressure switch Step 8 Carefully position pressure switch into blower housing Step 9 Position gas control powe
47. tlet Step2 Remove the three screws Phillips screw driver from the control access cover on blower and remove cover see photo 17 Step 3 Locate blower temperature switch see photo 18 Blower temperature Step 4 Disconnect red and yellow wire leads from switch switch location Step 5 With an appropriate tool such as side cutters snip the retaining lug from the blower housing to allow removal of temperature switch see photo 19 Step 6 Remove switch from blower housing Snip retaining lug 8 S tan blower housin Step7 Install new switch Be sure switch is properly seated in mounting area Step 8 Reconnect red and yellows wires to new switch Wires are interchangeable with either terminal Step 9 Position gas control power switch to the ON position and verify proper heater operation Step 10 Replace control access cover from step 2 BRADFORD WHITE EK PDX SERVICE PROCEDURE VI i Gas Control Thermal Well Testing and PDX Series Replacement p Gas Control Testing See pages 27 amp 28 for gas control input amp output testing Thermal Well Testing Well Testin Disconnect thermal well wire harness a b If Control has gone into TCO lockout due to excessive tank temperature four flash 3 second pause reset control by rotating knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting
48. to Use This Manual PDX Series It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting and repair of the Bradford White PDX Series water heaters Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation Error codes are listed in the troubleshooting chart beginning on page 12 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 can not be made using the methods described in this service manual Tools Required for Service Manometer A liquid U tube type or a digital magna helic 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 si
49. ulates gas flow A safety circuit consisting of a pressure switch and blower temperature switch verifies proper conditions exist for safe and reliable operation Ifa 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 To further promote quicker service times the new gas valve can be removed and replaced without draining the water heater A special tool is required and will be provided with each gas valve kit shipped from our Service Parts department Please read the service manual completely before attempting service on this new series of power vent models How the Safety System Works During normal operation air for combustion is drawn into the water heater though the vent pipe from outside your building The air travels into the closed combustion chamber The air then mixes with in a normal manner with supplied gas and its efficiently combusted producing very 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 E BRADFORD WHITE How
50. upplier the rating plate for replacement parts A WARNING WARNING Water heaters are heat producing appliances To avoid DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE damage or injury do not store materials against the NOT CERTAIN OF THE FOLLOWING water heater or vent air intake system Use proper care e Liquefied petroleum gases propane gas and natural gas to avoid unnecessary contact especially by children with have an odorant added by the gas supplier that aids in the water heater and vent air intake components UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR the detection of the gas e Most people recognize this odor as a sulfur or rotten STORED IN THE VICINITY OF THIS WATER HEATER VENT egg smell l AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH e Other conditions such as odorant fade can cause the FUMES COULD REACH THE WATER HEATER OR VENT AIR odorant to diminish in intensity or fade and not be as INTAKE SYSTEM readily detectable e Ifyou 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 A CAUTION plumbing professional for more information 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 ada
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