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SERVICE PROCEDURE PDV24-III
Pilot Operation Testing
CAUTION
Be Careful When Making Voltage
Measurements or Jumping Terminals
Not to Damage or Deform Connectors or
Connector Pins.
DANGER
120 volt exposure. To avoid personal injury,
use caution while performing this procedure.
Condition:
Pilot lights, no or low flame signal. Control
Display shows “4” or “62” for Error Codes
(Service Needed). Control continues to spark
until system “Lock Out”.
Main burner will not light.
The microamp output of the pilot may be
checked by entering “Service Mode” on the
water heater display and pressing “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.
1.0 micro amp or less = Clean pilot flame rod or replace pilot.
Check for loose or damaged ground wire(s)
from gas valve to control board. Check
continuity of wires with ohmeter. Are ground
wires okay?
Check for loose or damaged flame sense
lead from pilot to module. (see illustration to
the right). Is flame sense lead okay?
Repair wire lead
or replace pilot.
Repair ground
wire(s) or replace
as needed.
NOTE:
Check continuity of flame sense
lead to flame rod. If no
continuity, clean pilot flame rod
or replace pilot. Check pilot
flame appearance - if weak
check for clogged pilot orifice,
bent pilot tubing, or low inlet
gas pressure.
(see above illustration)
Y
Y
N
N
Check venting conditions
(vent length & number of elbows)
Is vent system okay?
Correct improper
venting condition.
N
Is heater condensing causing pilot
interruption?
Make sure pilot shield is in
place and not bent or damaged
(refer to section on main burner
and pilot assembly) .
Determine cause for
condensing and correct.
Under sized water heater or
high demand periods
Y
Y
N
SELECT
SET
Status
Heating
Operational
Flame Current
µA
Pilot flame sensor microamp output
shown in display using service mode.
Pilot must be lit to get reading.
Multi-meter set
to check
continuity.
Flame rod
Meter
Probe
Meter
Probe
Checking pilot flame sensor wire and flame
rod for continuity.
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