Bradford White D65T625 Service Manual
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Bradford White D65T625 Service Manual

Bradford White D65T625 Service Manual

Water heaters with honeywell integrated control system
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PDV(S,T) MODEL SERIES AND INDUCED DRAFT (D80T725,
D65T625) MODEL SERIES WATER HEATERS WITH
HONEYWELL INTEGRATED CONTROL SYSTEM
SERVICE
MANUAL

Troubleshooting Guide

and Instructions for Service
(To be performed ONLY by qualified service providers)
PDV80S150
PDV802200
PDV80S250
PDV100S150
PDV100S200
PDV100S250
PDV80T300
PDV100T360
D80T725
D65T625
(PDV80S Shown)
Manual 48061A
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Summary of Contents for Bradford White D65T625

  • Page 1: Troubleshooting Guide

    PDV(S,T) MODEL SERIES AND INDUCED DRAFT (D80T725, D65T625) MODEL SERIES WATER HEATERS WITH HONEYWELL INTEGRATED CONTROL SYSTEM SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) PDV80S150 PDV802200 PDV80S250 PDV100S150 PDV100S200 PDV100S250 PDV80T300...

  • Page 2: Table Of Contents

    Introduction Tool required for service Sequence of Operation Troubleshooting Thermostat Circuit Testing Pressure Switch Testing Pilot Operation Testing Main Burner Operation Testing Main Burner & Pilot Removal & Inspection Control Board Replacement Flue Baffle Removal & Inspection Anode Removal & Inspection Generic Parts List - PDV-S Generic Parts List - PDV-T Generic Parts List - Induced Draft Models...
  • Page 3 UP and DOWN buttons on the display on the control box cover. FEATURES OF INDUCED DRAFT MODELS High Capacity power vented design, uses a blower to pull the flue products out the water heater. Designed to vent vertically through 8 inch diameter type B venting system. Uses room air for combustion.

  • Page 4: Introduction

    Heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product. Troubleshooting begins by noting the error code, if any, on the water heater control display and finding the section in this service manual for diagnosing the problem for this error code. This step by step procedure beginning on page 5 will direct the service provider to a series of test procedures to determine root cause of failure.
  • Page 5 120 VAC Primary, 24 VAC Secondary, 40 VA Intermittent Pilot with Spark Electrode and Flame Sensor monitored by Control Board PDV-S MODELS: 115 VAC, 60 Hz., 4.3 Amps. PDV-T MODELS AND D80T725, D65T625: 115 VAC, 60 Hz., 3.6 Amps. Specifications...

  • Page 6: Sequence Of Operation

    Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3 seconds. If the water heater should reach 200 degrees F, then the high limit control will shut off the burners and the water heater will go into a “Hard Lockout”.

  • Page 7: Troubleshooting

    Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals Water Heater Fault: Water heater does not operate Display Error Code: Water heater display does not operate - blank display Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater.
  • Page 8 Check the voltage at the connection to the blower. Replace wire harness if there is no voltage to the blower. Replace blower, if there is voltage to the blower. Error Code Shown in Water Heater Display...
  • Page 9 The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below: Step 1: Press “Select”...
  • Page 10 2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models) 2c. Water Temperature - Lower Sensor (Displays if there are two sensors) Max Setpoint value in Water Heater Display °F Setpoint idle...
  • Page 11 Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) 4. Setpoint (Display/Change) °F/°C (Display/Change) Differential (Display only - shows the differential of the thermostat) µA Heating Flame Current Operational Status SELECT setpoint °F idle Status Operational SELECT setpoint °F °F/C°...
  • Page 12 7. Software Version (Display only) Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show a “--“ if there are no error codes. To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint: Step 1: In service mode press the “Select”...
  • Page 13 Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180°F. Step 4: Press “Set”...
  • Page 14 Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode”...
  • Page 15 Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display. To Display Flame Sense Current of the Pilot Flame Sensor: The pilot flame sense current is available only when the burners are in operation.
  • Page 16 Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display. Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.
  • Page 17 To Display and Change Temperature Format (°F/°C): To Change Temperature Format in Display from °F to °C or °C to °F: Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right portion of the water heater display.
  • Page 18 Step 3a: Press “Temperature Up” button to change temperature format to °C Step 3b: Press “Temperature Down” button to change temperature format to °F Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing °C °F/C° idle Operational Status...
  • Page 19 Error Codes and Error History Display: If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located under the Water Heater Display and the following section in this Service Manual explains the error codes with corrective actions to repair the water heater.
  • Page 20 Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the water heater display, then there has not been an error code for error code index 10.
  • Page 21 #10. Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.
  • Page 22 ERROR CODE DEFINITIONS If the water heater has an operating problem, there will be a number in the water heater display with “Service Needed” shown below the error code number. Note the error code and the definition in the chart below. This label appears on the control box under the water heater display. The following...
  • Page 23 If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window.

  • Page 24: Thermostat Circuit Testing

    Turn power on to water heater. Run water heater through heating cycle and verify proper operation. Sensor temperature can be viewed when burner shuts off (see section on viewing the display in “Service Mode”.
  • Page 25 SERVICE PROCEDURE PDV24-I Thermostat Circuit Testing WARNING! Do not operate water heater without verifying that the overheating condition has been corrected. Condition: Water Heater Not Operating Display shows error code “65” High Water Temperature (over 200 deg. F) Continued Once cause of overheating condition has been diagnosed and corrected, the control may be reset Reconnect and switch on power to the water heater.
  • Page 26 The dual thermistors are used to provide high limit protection in case the thermostat circuit fails to shut off the water heater. 2. Draw quart of water off Drain Valve. Using a thermometer, determine water temperature.

  • Page 27: Pressure Switch Testing

    90 deg. elbow. Each additional elbow reduces the venting distance by 39". See installation instruction manuals supplied with the water heater for further details on proper venting installations. Checking pressure switch contacts. Contacts are open if blower is...
  • Page 28 The tubing to the blower tap attaches to the - (minus) tap on the pressure switch. Induced Draft Models (D80T725 & D65T625): SERVICE PROCEDURE PDV24-II Pressure Switch Testing CAUTION...
  • Page 29 If the water heater control display shows “Heating” and the blower is off, Error code 29, then check the voltage output at the blower plug on the board. Should read 110-120 volts...

  • Page 30: Pilot Operation Testing

    (see photo to the right) Check wire harness for damage or loose connections. Repair or replace as needed. Turn on power to the water heater and verify proper operation Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or...
  • Page 31 Condition: Error code 57: Flame Rod Shorted to Ground Disconnect power. Shut off gas supply to water heater. Slide out burner assembly. See section on removing pilot and main burner assembly. Make sure pilot shield clears flame sense rod SERVICE PROCEDURE PDV24-III...
  • Page 32 “Select” until the flame current is shown. The control must be in the heating mode with the pilot lit to display a reading. See section on accessing service mode on the water heater display. Micro-amp readings 0.000 Micro Amp = Replace control board or pilot if wire is damaged.

  • Page 33: Main Burner Operation Testing

    DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Condition: Main burner will not light, Display shows “Heating” under temperature setpoint. Tank is cold. Is Pilot lit? Does control board continue to spark with pilot lit? Disconnect control wire harness from “Control”...
  • Page 34 Control Display may show error code “63, 57, or 4” and be in “Soft Lockout” state. Check gas (line) pressure to the water heater. Minimum line pressure should be 5.5" W.C. Is gas pressure within proper specification? (see photo at right) Check venting conditions.

  • Page 35: Main Burner & Pilot Removal & Inspection

    Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1: Remove burner box cover screws Step 3: Disconnect Pilot Fitting from Burner Box Step 5: Disconnect and Remove Gas...
  • Page 36 Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 7: Remove manifold bracket screws Step 9: Slide manifold out through side flange opening in Burner Box PDV-T MODELS Step 11: Remove screw fastening burner to burner box/burner shroud.
  • Page 37 Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 13: Pull pilot wires through burner Step 15: To remove pilot, remove pilot bracket screws Step 17: Pilot removal for servicing.
  • Page 38 Water Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Main Burner Removal Step 1. Disconnect (un-plug) water heater from electrical supply. Step 2. Turn “OFF” gas supply to water heater.
  • Page 39 PDV (S&T) AND INDUCED DRAFT MODELS Pilot Burner Removal Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place. Step 3.

  • Page 40: Control Board Replacement

    120 volt exposure. To avoid personal injury, unplug while performing this procedure. Depress plastic tabs Control board replacement Step 1. Depress left plastic tabs and pull out from slots in control panel SERVICE PROCEDURE PDV24-VI DANGER Slots in control panel Unhook tabs from control panel slots...

  • Page 41: Flue Baffle Removal, Inspection

    Open a near by hot water faucet to relieve tank pressure. Step 4. Connect hose to drain valve of water heater and route to an open drain. Open drain valve and drain a minimum of 5 gallons of water from the water heater. Close drain valve and disconnect drain hose from water heater.

  • Page 42: Anode Removal & Inspection

    Open a near by hot water faucet to relieve tank pressure. Step 4. Connect hose to drain valve of water heater and route to an open drain. Open drain valve and drain a minimum of 5 gallons of water from the water heater.

  • Page 43: Generic Parts List Pdv-S

    1A. Vent Kit 2A. Vent Elbow 3A. Intake Terminal 4A. Vent Reducer 5A. PVC Pipe 6A. Blower Vent Adaptor 7A. Blower Receptacle Gasket 8A. Blower 9A. Temperature Switch 10A. Blower Intake Gasket 11A. Blower Mounting Flange 12A. ¼-20 Hex Nut 13A.
  • Page 44 1B. Gas Valve Assembly 12B. Street Elbow 2B. Burner Assembly 13B. Gas Valve 3B. Burner Rack 14B. Aluminum Tubing 4B. Burner Tube 15B. Nipple Close 5B. Burner Shroud 16B. Union 6B. Burner Draft Panel 17B. Nipple 7B. Burner Support 18B. Combustion Box Flange 8B.
  • Page 45 1C. Control Box Assembly 2C. Control Box Cover Assembly 3C. Honeywell Display 4C. Control Box Cover 5C. Integrated Control Board 6C. Control Box Panel 7C. Power On/Off Switch 8C. Pan Head Screw w/adh. 9C. Pan Head Screw #8-18 10C. Transformer 11C.

  • Page 46: Generic Parts List Pdv-T

    1A. ASSE Approved Mixing Valve 2A. Vent Clamp 3A. Blower Vent Adapter 4A. Combustion Box Cover 5A. Wire Raceway 7A. Blower Receptacle Gasket 8A. Blower 9A. Temperature Switch 10A. Blower Intake Gasket 11A. Blower Mounting Flange 12A. ¼-20 Hex Nut 13A.
  • Page 47 1B. Burner Assembly 12B. Gas Valve Assembly 2B. Burner Rack 13B. Nipple 3B. Burner Tube 14B. Street Elbow 4B. Burner Draft Panel 15B. Union 5B. Burner Support 16B. Nipple Close 6B. Aluminum Tubing 17B. Aluminum Tubing 7B. Pilot Shield 18B. Gas Valve 8B.
  • Page 48 1C. Control Box Assembly 2C. Control Box Cover Assembly 3C. Honeywell Display 4C. Control Box Cover 5C. Integrated Control Board 6C. Control Box Panel 7C. Power On/Off Switch 8C. Pan Head Screw w/adh. 9C. Pan Head Screw #8-18 10C. Transformer 11C.

  • Page 49: Generic Parts List - Induced Draft Models

    1A. Flue Baffle 2A. Hex Head Anode 3A. Pressure Tap Fitting 4A. 1/8" NPT Elbow 5A. Hose Barb 6A. Silicone Hose 7A. Control Box Assembly 8A. ASSE Approved Mixing Valve 9A. Blower Transistion 10A. T & P Nipple 11A. T & P Valve 12A.
  • Page 50 1B. Burner Assembly 2B. Burner Panel 3B. Burner Tube 4B. Burner Mounting Bracket 5B. Burner Rack 6B. Dual Gas Valve Assembly 7B. Main Burner Orifice 8B. Manifold Generic Parts List INDUCED DRAFT MODELS 9B. Pilot Assembly 10B. Aluminum Tubing 11B. Pilot Draft Shield 12B.
  • Page 51 1C. Control Box Assembly 2C. Control Box Cover Assembly 3C. Pan Head Screw #8-18 4C. Honeywell Display 5C. Control Box Cover 6C. Integrated Control Board 7C. Pan Head Screw #8-18 8C. Transformer 9C. Ground Lug 10C. Pressure Switch 11C. Power On/Off Switch 12C.

  • Page 52: Glossary Of Terms

    Alternating Current BTU/H British Thermal Units Carbon Monoxide Carbon Dioxide Direct Current Energy Cut Off Ground fault interrupt Gallons per Minute Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread Pounds per Square Inch Volt Amps Volts Alternating Current W.C.

This manual is also suitable for:

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