Powered Direct Vent Gas Water Heaters

PDX Series

SERVICE MANUAL
Troubleshooting Guide and Instructions for Service
(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) PDX275T*F(BN,SX,CX) PDX50S60F(B,S,C)*(N,X) PDX65S65F(B,S,C)*(N,X) PDX75S70F(B,S,C)*(N,X) (*) Denotes Warranty Years

Manual 238-49770-00A

Save this manual for future reference

Table of Contents
Page Introduction How to use this manual Tool required for service Specifications Control Timings Sequence of Operation Troubleshooting Burner Inspection, Cleaning and Replacement Pilot Testing, Cleaning and Replacement Pressure Switch Testing and Replacement Blower Testing and Replacement Blower Temperature Switch Testing and Replacement Gas Control & Thermal well Testing & Replacement Flammable Vapor Sensor Testing & Replacement Safety Circuit Voltage Trace 115VAC Circuit Trace Dip Tube inspection and Replacement Anode Inspection and Replacement Flue Baffle Inspection and Replacement Inner Door Removal, Inspection & Replacement Glossary of Terms Parts List 4 5 5 6 9 10 13 15 17 18 20 22 24 28 29 30 31 32 33 34 38 39 PDX Service Procedure --------------I II III IV V VI VII VIII IX X XI XII XIII -----

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PDX Series
WARNING: If the information in these instructions is
not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

CAUTION
Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.

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. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by 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.

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.

WARNING
Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-air intake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater and vent-air intake components. UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENTAIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR INTAKE SYSTEM.

WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING: Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas. Most people recognize this odor as a sulfur or rotten egg smell. Other conditions, such as odorant fade can cause the odorant to diminish in intensity, or fade, and not be as readily detectable. If you have 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
If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING
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 MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.

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
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.

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PDX Series
Introduction
The new Bradford White PDX1, PDX2 and PDX4 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 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 & 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 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. 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.

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How to Use This Manual

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: Multi-Meter: 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. 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. In some cases, standard multi-meter probes will damage or simply 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. Used to measure water temperature. An accurate thermometer is recommended.

Electronic Probes:

Thermometer:

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 & Phillips), " nut driver, pliers (common & needle nose), socket set, side cutters wire cutters, wire strippers, wire crimpers, torpedo level, small shop vac, step ladder, and flashlight, 5 gallon pail.

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Specifications

Power supply Gas Supply Pipe Approved Gas Type Gas Pressure Venting System Approved Vent Materials Minimum Clearance for Servicing Water Supply Pressure Thermal well TCO Limit Residential Temperature Set Point Range Commercial Temperature Set Point Range

Dedicated 115VAC, 60 Hz, 15A Minimum 1/2" NPT (schedule 40 black iron pipe recommended) Natural or Propane. Unit must match gas type supplied. 5.0" W.C. min. for Nat gas, 11.0" W.C. min. for L.P. gas, 14.0" W.C. maximum (Nat. & L.P.) Power direct vent through the wall or vertical through the roof PVC, CPVC or ABS 18" from top, 24" from front, 4" sides and rear. 150 PSI maximum allowable working pressure. Check local codes for supply pressure Residential 188F (87C), Commercial 199F (93C) 60F (16C) to 160F (71C) (Approximate temperatures) 80F (27C) to 180F (82C) (Approximate temperatures)

Blower Temperature Switch Normally closed, opens @ 155F (68C), auto reset @ 128F (54C).

Standard Altitude-Normally open, closes at differential pressure of -.80. Pressure switch High Altitude-Normally open, closes at differential pressure of -.73.

Blower

115VAC, 60Hz, 3.1 amps.

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PDX Series
Venting Specifications for: 48 Gallon 65 Gallon 75 Gallon

Specifications

Vent Tables

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. Terminating Through the Wall Through the Wall Through the Wall Through the Wall Through the Roof Through the Roof Through the Roof Through the Roof # of Elbows 1 2 3 4 0 1 2 3 Maximum Length ft (m) 55 (16.8) 50 (15.2) 45 (13.7) 40 (12.2) 60 (18.3) 55 (16.8) 50 (15.2) 45 (13.7) Minimum Length ft (m) 2 (.6) 2 (.6) 2 (.6) 2 (.6) 7 (2.1) 7 (2.1) 7 (2.1) 7 (2.1) Maximum 75 gal. Maximum Length ft (m) 45 (13.7) 40 (12.2) 35 (10.7) 30 (9.1) 50 (15.2) 45 (13.7) 40 (12.2) 35 (10.7) Minimum Length ft (m) 2 (.6) 2 (.6) 2 (.6) 2 (.6) 7 (2.1) 7 (2.1) 7 (2.1) 7 (2.1)

4" Diameter (10.2 cm) PVC Vent Connector Lengths Maximum 48, 65 gal. Terminating Through the Wall Through the Wall Through the Wall Through the Wall Through the Wall Through the Roof Through the Roof Through the Roof Through the Roof Through the Roof # of Elbows 1 2 3 4 5 0 1 2 3 4 Maximum Length ft (m) 95 (29.0) 90 (27.4) 85 (25.9) 80 (24.4) 75 (22.9) 100 (30.5) 95 (29.0) 90 (27.4) 85 (25.9) 80 (24.4) Minimum Length ft (m) 10 (3.1) 10 (3.1) 10 (3.1) 10 (3.1) 12 (3.6) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6) Maximum 75 gal. Maximum Length ft (m) 85 (25.9) 80 (24.4) 75 (22.9) 70 (21.3) 65 (19.8) 90 (27.4) 85 (25.9) 80 (24.4) 75 (22.9) 70 (21.3) Minimum Length ft (m) 10 (3.1) 10 (3.1) 10 (3.1) 10 (3.1) 12 (3.6) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6)

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Vent Tables
Part II-Venting Specifications for: 40 Gallon 50 Gallon

Specifications

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 Terminating Through the Wall Through the Wall Through the Wall Through the Wall Through the Roof Through the Roof Through the Roof Through the Roof
# of Elbows (excl. vent term.)

Maximum straight Length ft (m) 30 (9.1) 25 (7.6) 20 (6.1) 15 (4.6) 35 (9.1) 30 (9.1) 25 (7.6) 20 (6.1)

Minimum straight Length ft (m) 2 (.6) 2 (.6) 2 (.6) 2 (.6) 7 (2.1) 7 (2.1) 7 (2.1) 7 (2.1)

1 2 3 4 0 1 2 3

VENT CONNECTOR LENGTHS FOR 3" (7.6 cm) DIAMETER VENT PIPE Terminating Through the Wall Through the Wall Through the Wall Through the Wall Through the Roof Through the Roof Through the Roof Through the Roof Through the Roof Through the Roof
# of Elbows (excl. vent term.)

Maximum straight Length ft (m) 80 (24.4) 75 (22.9) 70 (21.3) 65 (19.8) 60 (18.3) 85 (29.9) 80 (24.4) 75 (22.9) 70 (22.3) 65 (19.8)

Maximum straight Length ft (m) 10 (3.1) 10 (3.1) 10 (3.1) 10 (3.1) 10 (3.1) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6) 15 (4.6)

1 2 3 4 5 0 1 2 3 4

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Control Timings
Ignition State Pre-purge Trial for Ignition Flame Stabilization Period Inter-purge Flame Failure Response Time Post-purge PS Fault Delay (failed open/close) Soft Lockout TCO Limit Lockout Verify Resistive Delay Simulated Resistive Load Lockout Hardware Error Lockout 15 Seconds 90 Seconds 3 Seconds 15 Seconds Timing

Specifications

1.5 Seconds (2 second. Maximum; 1 second minimum.) 15 Seconds Retry after 2 Minutes Retry after 5 Minutes Indefinite (cycle power to restart) Retry after 2 Minutes (repeats 5 times) Indefinite (cycle power to restart) Indefinite (self clears if fault clears for at least 15 seconds)

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PDX Series

Sequence of Operation

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 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.

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. Blower pre-purge period (15 seconds) 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.

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 deactivated, blower will post purge and control LED flashes 6 times with 3 second pause.

Main burner Ignition

After pilot flame is sensed, gas control activates main valve for main burner ignition. The gas control will ignore flame and pressure switch signals for 3 seconds allowing for main burner to stabilize.

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PDX Series

Sequence of Operation

Steady state operation.

7

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 & 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. Burner off. Blower post purge (15 seconds).

10

1. Simulated Resistive Device Fault:

a) If the Flammable Vapor Sensor resistance is greater than 70,000 Ohms - the gas control immediately turns off all outputs. Control waits and monitors resistance for 30 seconds. If the resistance is greater than 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) If the 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 & main valve and proceeds to flash 4 times with 3 second pause. Blower continues to run until gas control is reset. Power needs to be cycled to remove gas control from TCO lockout.
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PDX Series

Sequence of Operation

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 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 minutes 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.

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Troubleshooting

Green LED Indicator

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.
Service Procedure
Turn power on Normal operation. Adjust thermostat to temp level Normal operation. Adjust thermostat to temp level 1. Page 15 2-4. Page 17

LED Status
None, control LED not on or flashing Short flash, once every four seconds Heartbeat, alternates bright/dim

Control Status
No electrical power Stand-by mode, Waiting for call for heat (no fault). Thermostat calling for heat (no fault).

Probable Cause
Control power switch in OFF position. Supply voltage interrupted.

Temperature demand is satisfied

Tank temperature below set point of thermostat.

Short flash once per second

1. Unstable pilot. 2. Pilot tube block or restricted. Weak pilot signal 3. Oxidation build up on pilot electrode. on last call for heat. 4. Wire damage to pilot assembly or bad connection at gas valve. 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. 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. 7. Intake vent length exceeds exhaust vent length. 8. Frozen intake or exhaust vent terminal. 1. Thermal well sensor out of calibration. 2. Faulty gas control. 3. Plumbing leak 1. Pilot valve stuck in open position.

Two flash, three second pause

Page 18

1. Check vent or vent tables. 2 & 3 Page 18 4. Page 20 5 & 6 Page 22 8. Page 37 1. Page 24 2. Replace gas control, page 26 Replace gas control, page 26

Pressure switch or Three flash, three second blower temp. pause switch not working -open position.

Four flash, three second pause

Excessive tank temperature. System must be reset. Undesired-false pilot flame present.

Five flash, three second pause

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LED Status Control Status Probable Cause

Troubleshooting

Service Procedure
1. Page 15 2-4. Page 17

Six-one flash, three second pause

Six-two flash, three second pause

1. Unstable pilot. 2. Pilot tube blocked or restricted. Failed to light pilot. 3. Oxidation build up on pilot electrode. System auto resets. 4. Wire damage to pilot assembly or bad connection at gas valve. 1. Vent blockage or improper vent configuration. Pressure switch 2. Pressure switch tubing kinked or blocked. or blower temp 3. Faulty pressure switch. switch opened 4. Vent termination being affected by wind during burner 5. Blower not spinning up to speed. operation. 6. Blower temp or exhaust temp too high System auto 7. Faulty blower temperature switch. resets. 8. Insufficient combustion air. 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. 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. Refer to installation manual.

Six-three flash, three second pause

Pilot flame extinguished. System auto resets.

1. Page 15 2-4. Page 17 5. Refer to installation manual

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

WARNING: EXPLOSION HAZARD * Indicates gasoline vapors were detected at potentially explosive levels. Flammable Vapor * Verify no gasoline vapors are still present Seven flash, three second Sensor fault pause * Reset the control by cycling power to the appliance or detected 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 Flammable Vapor not below 25 K Ohms. Sensor out of * Check wiring to FVS and insure it is not shorted. specification. * Replace control if everything above checks out OK. Thermal well sensor damaged or unplugged Gas valve electronics fault detected Gas valve fault detected. 1. Damage to thermal well wire. 2. Thermal well sensor resistance out of range. 1. Control needs to be reset. 2. Control is wet or physically damaged. 1. Control needs to be reset. 2. Control is wet or physically damaged.

Page 28

Eight-one flash, three second pause

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Page 24
1. Interrupt power supply 2. Replace gas control, page 26 1. Interrupt power supply 2. Replace gas control, page 26

Eight-three flash, three second pause

Eight-four flash, three second pause

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PDX SERVICE PROCEDURE I Burner Operation Inspection, Adjustment, Cleaning and Replacement

Burner Inspection and Air Shutter Adjustment.

At periodic intervals (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. Step 2. 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). 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 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.

Air Shutter Nut Air Shutter

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PDX Series
Burner Cleaning
Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8.

PDX SERVICE PROCEDURE I Burner Operation Inspection, Adjustment, Cleaning and Replacement

Position gas control power switch to the OFF position and unplug heater from wall outlet. Turn off gas supply to water heater. Remove outer jacket door and inner door per service procedure XIII on page 35. Disconnect pilot tube (7/16 wrench) and feedline ( wrench) from gas control.
Igniter/flame sense wire

Disconnect igniter/flame sensor wire from gas control. Remove burner assembly from combustion chamber. Thoroughly inspect burner surface area and burner port area and remove any loose debris. For cast iron burners, inspect for any debris build up inside burner casting.
Burner surface area

Feedline nut

Pilot tubing nut

Burner port area

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.

Step 11. Step 12

Remove main burner orifice from feedline (" wrench on steel burners, 3/8" wrench on cast iron) inspect orifice, clean or replace if necessary. Reassemble burner and reinstall into water heater. Restore gas supply and check for gas leaks. To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual.

L.P. Main burner orifice. Left hand thread

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PDX SERVICE PROCEDURE II Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1. Step 2. Step 3. 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.
Igniter/flame sense wire

Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10.

Disconnect pilot tube nut (7/16 wrench) and feedline nut ( wrench) from gas control. Disconnect igniter/flame sense wire from gas control. Remove burner assembly from combustion chamber. Remove pilot assembly from feedline (" 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 through igniter/flame sense wire. Replace pilot if no continuity. Visually inspect igniter/flame sense electrode for deterioration. Replace pilot as necessary. Electrode should not be in contact with pilot hood, If so, carefully adjust electrode to a gap distance of 3/32" (.09) from pilot hood. Visually inspect igniter/flame sense electrode for oxidation build up. Carefully clean any oxidation using very fine emery cloth. Visually inspect pilot tubing for kinks or cracks. If damage is found replace pilot. Inspect pilot tubing and pilot orifice for blockage: 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.
Igniter/flame sense wire Ferrule nut Pilot tubing Pilot orifice

Feedline nut

Pilot tubing nut

Pilot hood

Step 11.

Igniter/flame sense electrode

Step 12. Step 13.

Step 14. Step 15

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 and operating manual.
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Pressure Switch Testing
Step 1. Step 2. Step 3. Position power switch on gas control to the OFF position.

PDX SERVICE PROCEDURE III Pressure Switch Testing and Replacement

WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 1). Carefully remove pressure switch from blower housing (see photo 2)
Exhaust pressure switch

1 2

Pressure Switch Pressure switch wire leads With steps 1,2 & 3 complete, disconnect wire leads from pressure switch. 3 Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

Use a multi-meter set to the ohms setting. With blower off, check across pressure switch terminals. Are switch contacts open? (no electrical continuity) Y

``
N Check tubing and pressure tap N on switch for blockage. Is there blockage? Y Replace switch (see page 18)

Clear blockage Position gas valve power switch to the ON position and adjust thermostat to call for heat, this will start the blower. N Check with multi-meter, do pressure switch contacts close with blower running with the switch in the vertical postition? Y Switch contacts are OK. See safety circuit trace (page 30)

Y Check tubing and pressure tap on switch for blockage. Is there blockage? N

Y Is vent system blocked

Is vent system length within vent table specifications listed on page 7 or 8 N

Y See blower testing (page 21) Is blower OK? N

Reconfigure vent system to be compliant with vent tables.

Correct blower problem.

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Exhaust Pressure Switch Replacement
Step 1. Step 2. Position gas control power switch to OFF position.

PDX SERVICE PROCEDURE III Pressure Switch Testing and Replacement

WARNING 120 volt potential exposure. Use caution to avoid personal injury.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 3).
Pressure Switch 4 5

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) Disconnect yellow wires from pressure switch (see photo 6)

Step 5.

Step 6. Step 7. Step 8. Step 9. Step 10.

Reconnect wires from step 5 to new pressure switch. Reconnect tubing to new pressure switch. Carefully position pressure switch into blower housing. Position gas control power switch to ON position and verify proper heater operation. Replace control access cover from step 2.

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Blower Testing
Step 1. Step 2.

PDX SERVICE PROCEDURE IV Blower Testing and Replacement

WARNING 115 volt potential exposure. Use caution when making voltage checks to avoid personal injury.

Position gas control power switch to ON position and adjust control to call for heat.
8

Remove the three screws (Phillips Screw driver) from control access cover on blower assembly and remove cover (see photo 8).

Does blower energize Within 2 minutes? N

Disconnect pressure switch tubing from blower. (see photo 13) 10

Connect manometer to pressure tap of blower. (see photo 11)

Disconnect vent system from top of blower and remove exhaust vent adapter. (see photo 15) Remove exhaust adapter 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 Y

11

Pressure tap

Blower OK

Pressure switch tubing Determine voltage problem and correct. Does blower energize after 2 minutes, run for 30 seconds and shut down? N Y See pressure switch testing Page 18

Is there 115vac across blue and green wires (see photo 14)

Replace blower

12

13

Disconnect cord set shown in photo 9. Is there 115VAC across terminals shown in photo 12 N

Is there 115VAC across terminals shown in photo 13 ? N Incorrect supply voltage polarity

Y Reconnect cord set shown in photo 8, is there Y 115VAC between blue wire and green ground wire (see photo 14) N Does cord set have electrical continuity? Y Blue wire Green ground wire

Replace blower

Is there 115 VAC at wall outlet? Y Check power cord for damage. N Replace blower

Determine power source problem and correct.

Replace cord set

14

Repair or replace power cord

Replace gas control

Shown with pressure switch removed.

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Blower removal
Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Position gas control power switch to the OFF position. Unplug blower power cord from wall outlet. Disconnect vent system from exhaust adapter on top of blower. Remove exhaust adapter from blower (blade screw driver) and retain for use on new blower Unplug cord sets from blower. Remove vertical air intake bracket. Disconnect vertical air intake from blower. Remove the three blower mounting screws (" nut driver).

PDX SERVICE PROCEDURE IV Blower Testing and Replacement

Remove exhaust adapter and retain for use on new blower. Blower Mounting Screws

Blower Cord Sets

Vertical air intake

Remove blower with gasket from water heater.

Vertical air intake bracket

Blower Installation
Step 10. Step 11. 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. Re-install exhaust adapter from step 4. Reconnect vent system to exhaust adapter. Reconnect cord sets from step 5. Plug blower power cord into wall outlet. Position gas control power switch to the ON position. Verify proper blower operation.
Pin location holes in jacket head Locating Pins on blower flange

Step 12. Step 13. Step 14. Step 15. Step 16. Step 17. Step 18. Step 19. Step 20.

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Blower Temperature Switch Testing.
Step 1. Step 2. Step 3. Position power switch on gas control to the OFF position. Remove tubing from inlet pressure tap. Remove the three screws (Phillips screw driver) from control access cover on blower and remove cover (see photo 15). Locate blower temperature switch (see photo 16)

PDX SERVICE PROCEDURE V Blower Temperature Switch Testing and Replacement

WARNING 120 volt potential exposure. Use caution to avoid personal injury.
15

Step 4.

Switch Setting Opens on rise @ approximately 155F Auto resets on fall @ approximately 128F

16

Blower temperature switch location Cool switch to below 125F Air mixing inlet

Disconnect wire leads to switch. Using a multi-meter set to the ohms setting, is there continuity between the switch terminals? Y

N Replace switch (see page 24)

Reconnect wire leads and observe heater operation. Do exhaust gas temperatures rise to or above 175F? N

N Y Do switch contacts open? Y Exhaust temperature is too hot.

Common causes for high exhaust temperature 1. Vent length is below minimum allowable. 2. Vent diameter not to specification. 3. Restricted dilution air inlet. 4. Missing or deteriorated flue baffle. 5. Gas pressure is out of specification. 6. Excessively high ambient temperatures.

Do switch contacts open? N

Replace switch (see page 23)

Switch OK

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Blower Temperature Switch Replacement.

PDX SERVICE PROCEDURE V Blower Temperature Switch Testing and Replacement

WARNING 120 volt potential exposure. Use caution to avoid personal injury.

Step 1. Step 2.

Position gas control power switch to the OFF position and unplug heater from wall outlet. Remove the three screws (Phillips screw driver) from the control access cover on blower and remove cover. (see photo 17)

17

Step 3. Step 4. Step 5.

Locate blower temperature switch (see photo 18) Disconnect red and yellow wire leads from switch. 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). Remove switch from blower housing. Install new switch. Be sure switch is properly seated in mounting area. Reconnect red and yellows wires to new switch. Wires are interchangeable with either terminal. Position gas control power switch to the ON position and verify proper heater operation. Replace control access cover from step 2.

18

Blower temperature switch location

Step 6. Step 7. Step 8. Step 9. Step 10.

19

Snip retaining lug from blower housing

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Gas Control Testing
See pages 27 & 28 for gas control input & output testing.

PDX SERVICE PROCEDURE VI Gas Control/Thermal Well Testing and Replacement

Thermal Well Testing

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.

Disconnect thermal well wire harness

Observe heater operation. If control continues to lockout due to excessive tank temperature, proceed to thermal well testing to determine cause.

20

21

Thermal well testing Position gas control power switch to the OFF position and disconnect thermal well harness from gas control.

CAUTION
DO NOT use standard multimeter probes for this test. Doing so will damage connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Using a multi-meter set to the Ohms setting, determine the resistance of thermal well sensor (see caution photos 20 & 21)

Using a multi-meter set to the ohms setting, insert one meter probe (see caution) into center wire position of thermal well connector, insert the second probe (see caution) into either of the outside wire positions (see photo 20). Alternate the probe on the outside position to the opposite outside wire position (see photo 21).

Once the thermal well resistance values are known, the water temperature must also be known to determine if the resistance values are correct. See page 25 to obtain water temperature. Are thermal well resistance values correct? Y

Replace thermal well (see page 27)

Replace gas control (see page 27)

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PDX SERVICE PROCEDURE VI Gas Control/Thermal Well Testing and Replacement

WARNING 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. Step 2.

Position gas control power switch to OFF position. 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. Using the chart below, determine correct resistance value for the water temperature from step 2. If temperature of water is 84F, 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
F 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 0 26109 19906 15314 11884 9299 7333 5827 4663 3758 3048 2488 2043 1688 1402 1170 982 828 1 25400 19383 14925 11592 9078 7165 5697 4562 3679 2986 2439 2004 1656 1376 1150 965 814 2 24712 18876 14548 11308 8862 7000 5570 4464 3602 2925 2391 1966 1625 1351 1129 949 801 3 24045 18383 14180 11032 8653 6839 5446 4368 3527 2866 2344 1928 1595 1327 1110 933 788 In Degrees 4 23399 17905 13823 10763 8449 6683 5326 4274 3453 2808 2298 1891 1566 1303 1090 917 775 F 5 22771 17440 13477 10502 8250 6531 5208 4183 3382 2752 2253 1856 1537 1280 1071 901 762 6 22163 16990 13140 10248 8057 6383 5094 4094 3312 2697 2209 1820 1509 1257 1953 886 749 7 21573 16553 12812 1000 7869 6238 4982 4006 3244 2643 2166 1786 1481 1235 1035 871 737 8 21000 16128 12494 9760 7685 6098 4873 3922 3177 2590 2124 1753 1454 1213 1017 857 725 9 20445 15715 12185 9526 7507 5961 4767 3839 3112 2538 2083 1720 1427 1191 999 842 713

Step 3. Example:

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PDX SERVICE PROCEDURE VI Gas Control & Thermal Well Testing and Replacement

Gas Control & Thermal Well Removal From Water Heater

Gas Control

Step 1. Step 2. Step 3. Step 4. Step 5.

Position gas valve power switch to the OFF position and Unplug Heater from power supply. Drain heater to a point below the gas control level. Turn off gas supply to water heater and disconnect gas piping from gas control. Disconnect wire harnesses and burner assembly from gas control.

Thermal Well

Remove gas control & thermal well by rotating flats of Thermal Well counter clockwise (1-5/16"wrench).

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. Step 2. Step 3. Step 4. Position gas control power switch to the OFF position and unplug water heater from power supply. Turn off gas supply to water heater and disconnect gas piping from gas control. Disconnect wire harnesses & burner assembly from gas control. 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 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. Page 26

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Gas Control Assembly to Thermal Well
Step 1. Install threaded end of thermal well into tank. Be sure thermal well flange is positioned as shown in photo 22 for proper control alignment. Route wire leads back into relief opening. (see photo 23) Align slots located on thermal well flange with tabs located on back of gas control (see photo 22 & 23)

PDX SERVICE PROCEDURE VI Gas Control & Thermal Well Testing and Replacement

22

Step 2. Step 3.

Thermal well flange slots

Route wires through relief opening

Step 4.

Carefully push control back onto thermal well flange as far as possible towards water heater. Slide control down to lock into position. Install burner and connect pilot tubing and feedline nut to gas control.

23

Step 5.

Gas control Tabs

Igniter/sensor connection

Step 6. Step 7.

Reconnect wire harnesses to gas control per the illustration. Reconnect gas piping to gas control. Restore gas supply and check for gas leaks. To resume operation, follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Ground Wire connection

Step 8.
5 pin blower harness connection 3 pin thermal well connection

Flammable Vapor Sensor

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PDX SERVICE PROCEDURE VII Flammable Vapors Sensor Testing

Flammable Vapor Device Testing

Step 1. Step 2. Step 3. Position power switch on gas control to the OFF position. Disconnect flammable vapor sensor from gas control. 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.

Flammable Vapor Sensor

Multi-meter set to ohms setting

Electronic pin type Meter Probes

CAUTION
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

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Safety Circuit Voltage Trace
NOTE: This procedure assumes a cool tank.

PDX SERVICE PROCEDURE VIII Safety Circuit Voltage Trace

WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury.
24

Step 2.

Remove three screws (Phillips Screw driver) from control access cover on blower and remove cover (see photo 24).

Position gas control switch to the ON 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? Blower must be running during this voltage check. (see photo 25) Y

Is LED on gas valve flashing the heartbeat code (alternating bright/dim) N

No voltage from gas control, call for technical support.

Verify 120VAC to gas control (see page 30)

Is there 10 to 13 VAC between yellow wire leading from pressure switch and green ground wire? (see photo 25) Y

Is there continuity through blower temperature switch? (see page 21) N

Check for loose or broken wire connection at switch terminals

Correct igniter/ sensor problem.

Determine cause of blower temperature switch activation and correct.

Do you hear or can you see the igniter sparking? Y

Check igniter/sensor (see page 17) is igniter/sensor OK?

Faulty cord set or gas control. Green ground wire

Safety circuit voltage is OK.

25 Red wire leading to blower temp. switch

If burner does not light, observe LED flash code on gas valve and refer to troubleshooting section on page 13

Yellow wire leading from pressure switch

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120 VAC Circuit Trace

PDX SERVICE PROCEDURE IX 120 VAC 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 None, Control LED not on or flashing. LED status Short flash, once every four seconds. LED status Heartbeat, alternates bright/dim. LED status Various flashing error codes.

Waiting for call for heat.

Thermostat calling for heat

Verify error code as listed on page 12

26 Disconnect cord set as shown in photo 26

27

28

Using a volt meter set to volts AC, is there 120VAC N across terminals shown in photo 27 ? Y Is there 120VAC across terminals shown in photo 28 ? N Incorrect supply voltage polarity Disconnect wire harness from gas control (see photo 29). Y Reconnect cord set shown in photo 26.

Check for damage to AC supply power cord. N Replace Blower

Repair damage

29

Wire harness

Locate black & white wires at connector, It may be necessary to pull back wire sheath to identify wire colors. (see photo 30)

30

Wire sheath pulled back to identify wire colors Is there 120VAC across black & white wires as shown in photo 30? N

Replace gas control.

Check for 120VAC between black & white wires. -NOTEElectronic meter probes required. Use care not to damage connector during this check.

Call for technical support. Page 30

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PDX SERVICE PROCEDURE X Dip Tube Inspection and replacement

Dip Tube Inspection and Replacement

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. Step 2.

Position on/off switch of gas control valve to OFF position and unplug water heater from wall outlet. 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. Disconnect inlet nipple from plumbing system. 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. Visually inspect inlet nipple/dip tube. Inlet nipple/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 3. Step 4 Step 5.

Step 6. Step 7.

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. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

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PDX SERVICE PROCEDURE XI Anode Inspection and replacement

Anode Inspection and Replacement

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. Step 2. Position on/off switch of gas control valve to the OFF position and unplug water heater from wall outlet. 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. Disconnect outlet nipple from plumbing system. With an appropriate tool such as a pipe wrench, remove outlet nipple/anode from the water heater. Use caution not to damage pipe threads. Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal. If depletion is of the original anode diameter (approximately diameter), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended. 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. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

Step 3. Step 4 Step 5.

Step 6. Step 7.

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Remove blower to gain access to flue baffle
Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8.

PDX SERVICE PROCEDURE XII Flue Baffle Inspection and replacement

Disconnect vent system from exhaust adapter. 31 Blower Mounting Screws

Position gas control power switch to the OFF position and unplug blower from wall outlet. Disconnect vent system from exhaust adapter on top of blower. Disconnect intake air piping. Unplug cord sets from blower. (see photo 31). Remove the three blower mounting screws (" nut driver) (see photo 31). Remove blower with gasket from water heater. Remove flue baffle from Heater (see photo 33). Inspect baffle for deterioration, missing restrictors. Clean any scale or debris build up. Replace with new baffle as necessary. 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 & 35). Check Burner to insure no scale has accumulated during this operation. See burner cleaning procedure on page 15. Reinstall blower on water heater. Connect vent system and cords set to blower. Plug water heater into wall outlet. 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 Blower Cord Sets 32

Step 9.

Remove support bracket

Step 10. Step 11.

Step 12.

33

34

35 Baffle shown installed in flue tube notch.

Flue tube notch

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Inner Door Removal Procedure.

PDX SERVICE PROCEDURE XIII Inner Door/Gasket Removal, Inspection Replacement and Reinstallation

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 on 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: >Tears >Other imperfection that will inhibit proper seal >Missing Material >Gasket adhesion to inner door >Cracks >Material left on combustion chamber (around opening) >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.

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. Step 6. 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. Use RTV sealant (recommended bead size is 1/8") to secure the inner door gasket to the inner door sections (right & 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.
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PDX SERVICE PROCEDURE XIII Inner Door/Gasket Removal, Inspection Replacement and Reinstallation

Installation of Inner Door With Gasket.

Step 7. 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. Step 9 Position thermocouple, pilot tube and Piezo wire against left side inner door flange gasket. DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.

Step 8. hex drive

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 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.

Radiused Channel for Feedline

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PDX SERVICE PROCEDURE XIII Inner Door/Gasket Removal, Inspection Replacement and Reinstallation

Installation of inner door with gasket (continued from page 36).

Step 10. Step 11. Firmly place right side inner door flange against the left side inner door flange and secure with two drive screws from step 3c. DO NOT OVER TIGHTEN SCREWS.

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.

Step 12. Step 13.

Replace outer jacket burner access door. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

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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.

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Glossary of Terms

BTU GPM Hz KW/h LED NPT Ohms PSI RPM TCO VAC W.C. C F

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 Temperature Cut Off Volts Alternating Current Inches of Water Column Degrees Centigrade Degrees Fahrenheit

NOTES

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Parts List

1. Blower Assembly 2. Blower Temp. Switch 3. Pressure Switch 4. Blower Gasket 5. Tee and Vent Pipe Assy. 6. Vent Adapter with Term. 7. Intake Terminal 8. Vent Terminal Elbow 9. Exhaust Adapter 10. Condensate Hose Kit 11. Flue Reducer 12. Heat Trap Insert (outlet) 13. Heat Trap Insert (inlet) 14. Hot Water Outlet Anode

15. Cold Water Inlet Diptube 16. Flue Baffle 17. Blower Harness 18. T&P Relief Valve 19. NPT PLUg 20. Direct Vent Boot Escutcheon 21. Air Intake Boot 22. Air Intake Boot Gasket 23. Outer Door 24. Right Side Inner Door 25. Left Side Inner Door 26. Screw-#10-12 x HWH 27. Screw-#8-18 x HWH

28. Brass Drain Valve 29. Flammable Vapor Sensor 30. Sensor Harness 31. Flammable Vapor Sensor Clip 32. Thermal Well 33. Gas Control Kit 34. Gas Control Service tool 35. Gas Control 36. Gas Burner Assy (Nat.) 37. Gas BN burner (Nat.) 38. Main Burner Orifice (Nat.) 39. Gas Pilot Assembly (Nat.) 40. Gas Pilot Orifice (Nat.)

41. Gas Feedline (Nat.) 42. Gas Burner Assy (L.P.) 43. Cast Iron Burner (L.P.) 44. Gas Pilot Assy (L.P.) 45. Gas Pilot Orifice (L.P.) 46. Air Shutter (L.P.) 47. LP Gas Feedline (L.P.) 48. Air Shutter Nut (L.P.) 49. Main Burner Orifice (L.P.) 50. Inner Door Gasket 51. Heat Trap Insert kit 52. Mixing Valve

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