Vanguard Heating POWERMAX PM400 User's Manual
Contents
1. 222 x zif 12 Apel boned erf 4 4444 JRA 3 POSE OF CONDENS ILLUSTRATION 2 SIDE WALL VENTING INSTALLATION see illustration 2 Install wall thimble into wall observing the aforementioned rules and or local building codes Select the point of wall penetration where the minimum 7 74 foot of slope 6 4 mm per 305 mm be maintained The pipe can be located between joists spaced 16 400 mm centre The pipe be mortared in directly without using a wall thimble if the wall is non combustible Penetrating a combustible wall requires the use of a wall thimble A framed opening is required to insert the thimble halves The thimble is adjustable for different wall thicknesses Caulk around outside edge of plates as necessary and fasten to wall using suitable screws or nails The vent pipe must be sealed at wall thimble as per code regarding continuous vapor barrier The system can now be assembled through the thimble attach the termination first note UP arrow and then back to the appliance as per illustration using JOINT PROCEDURE as described on page 3 A gear clamp or locking band must be installed around the pipe in position so that the system cannot be removed in or out of wall This applies to both combustible and non combustible walls 22 Appendix 3 system m2. commercial dishwashing machines Specific performance depends upon the exact water flow and supply water temperature See table 200 Performance Data Temperature rise Gallons per Minute Gallons per Hour 40 F 8 7 520 50 F 7 0 420 60 F 5 8 348 70 F 5 0 300 140 F 2 5 7 5 for 15 sec Per minute 150 After the necessary power water gas and vent connections are completed correctly and all air is purged from gas and water piping the unit is started by turning on the power switch located on the top front of the left side panel The combustion air fan will start and run continuously and the digital temperature display will light showing the water temperature in the accumulator tank If the tank temperature sensor detects water temperature below the set point it will turn on the internal circulating pump prove water flow combustion air flow and hi limit compliance and activate the hot surface igniter Following a 3 second warm up for the igniter the gas valve opens and the burner ignites If the burner flame is not proved within a few seconds the gas valve automatically closes This cycle will repeat 3 times If ignition flame is not proved the control will go into automatic lock out requiring a re set Re set is accomplished by turning power switch to off for 10 seconds and then turning back on When the tank water temperature exceeds the thermostat set point the burner will shut off until the next call for heat
3. SVSERWC0403 SVSR0404 5 FOOT PIPE SVEPWC0305 SVEPWC0405 FLAT FLASHING SVSSCS03 SVSSCS04 4 FOOT PIPE SVEPWC0304 SVEPWC0404 LOCKING BAND SVSLBX03 SVSLBX04 3 FOOT PIPE SVEPWC0303 SVEPWC0403 FIRESTOP SUPPORT SVSFSS03 SVSFSS04 2 FOOT PIPE SVEPWC0302 SVEPWC0402 FTRESTOP SPACER SVSFSX03 SVSFSX04 1 FOOT PIPE SVEPWC0301 SVEPWC0401 TERMINATION TEE SVSTTX03 SVSTTX04 6 INCH PIPE SVEPWC03 5 SVEPWCO4 5 TERMINATION BOX SVSRTX03 SVSRTX04 90 ELBOW SVEEWC0390 SVEEWC0490 RAIN CAP SVSRCX03 SVSRCX04 45 ELBOW SVEEWC0345 SVEEWC0345 TOP SUPPORT SVSLSX03 SVSLSX04 HORJZ DRAIN TEE SVEDWC03 SVEDWC04 STORM COLLAR SVSSCX03 SVSSCX04 VERTICAL DRAIN TEE SVEVWC03 SVEVWC04 Z VENT SEALANT GE106X WALL THIMBLE SVSWTX03 SVSWTX04 WM TERM COUPLING SVSTPX03 WM GV STARTER SVEWMG03 AMETEK FAN CONN SVSACA03 DRAIN TUBE KIT SVEDTK WM CGI STARTER SVEWMFA03 Z FLEX recommends that the installation be performed by an experienced professional who works with venting systems on a regular basis These instructions are intended as a guide to assist a professional installer When the Z VENT system is installed the following should be observed A venting system that exits the structure through a sidewall or the like shall terminate not less than 12 inches 254 mm above the ground see illustration 2 page 4 2 The termination of a system shall be located above the snow line in geographical areas where snow accumulates The termination area should be kept clear of snow
4. The heater must be isolated from the gas supply piping by closing its individual manual shut off valve during any pressure testing of the gas supply piping at test pressures equal to or less than 1 2 p s i g 3 5 kPa The heater and its individual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 p s i g 3 5 kPa Dissipate test pressure from the gas supply line before re connecting the heater and its manual shut off valve to the gas supply line CAUTION Failure to follow this procedure may damage the gas valve and cause a dangerous condition Over pressured gas valve damage is not covered under warranty NOTE Do not use Teflon tape on gas line threads Use only a flexible thread sealant approved for use with fuel gases Pressure test tap Figure 5 WATER REQUIREMENTS Local water conditions vary greatly between even near by locations and can greatly affect the performance and maintenance requirements of warewashing equipment including your booster heater Proper water conditions will provide lower chemical costs improved cleaning performance reduced spotting and longer equipment life as well as more efficient labor use and reduced damage to dishware and utensils Proper water treatment for effective and efficient performance of this equipment will vary depending upon the make up of the local water supply Recommended water hardness is 4 6 gr
5. The internal circulating pump will operate whenever the thermostat is calling for heat The combustion air blower operates continuously whenever the on off switch is on The operating temperature control is factory set and is not to be user adjusted If temperature rise is not satisfactory call your service agency and or call the factory 12 POWERMAX START UP PROCEDURE For your safety read completely before operating CAUTION DO NOT turn Power Switch on until the booster has been filled with water and all air has been purged from the water lines and accumulator tank FILL THE BOOSTER HEATER Open the water supply valve at the Booster Heater water supply inlet and fill Booster Heater Manually open the temperature pressure relief valve on the left side of the cabinet to vent air from water piping Cycle dishwasher to ensure that all air is purged from the system and to flush out any contaminants left from piping process CHECK ELECTRIC CONTROLS Do this procedure with the manual gas valve CLOSED gas supply off With water supply valve open water side under pressure and with manual gas supply valve in CLOSED position no gas flow to unit push power supply rocker switch on left top side of cabinet to ON position Combustion air fan should start digital temperature readout should illuminate and indicate water temperature in accumulator tank and LED indicators in readout panel should illuminate If water temperature i
6. vent Mfg By Z Flex U S Saf T Vent Mfg By Heat Fab Inc or StaR 34 By Flex L International All are constructed of AL29 4Ctm Stainless Steel auxiliary power vent is being used is it installed with an indirect connection per drawing DODDO Power Vent Exhaust If used is power vent installed and operating correctly YES NO Circle One Q Must come on with burner and continue for 4 minutes after burner shutdown Q Verify electrical connection to unit is correct and to NEC code Q Verify size volume pressure and type of gas supply amp that they are in accordance with manufacturers specification 3 25 w c NG or 8 w c LP Check at test port on gas valve Verify gas supply pipe size dia Q Verify pipe size flow pressure and volume of water supply to unit according to manufacturers specifications Water supply pipe size dia Q Does dishwasher have pressure regulating valve and gauge Flow rinse pressure must be 18 20 p s i YES NO Circle one Q Verify that pipe length from booster accumulator outlet or circulating loop to rinse valve does not exceed 5 feet NSF maximum and is correct diameter both supply and return Q Verify that unit has been flushed properly both water amp gas piping Check all gas connections for leaks Q Check all water connections for leaks D 24 2 Vanguard Technology Inc Factory Authorized Start Up Verif
7. exhaust system is not providing adequate ventilation to the area c The total BTU input rating of all the unvented gas appliances installed divided by the total cubic foot volume of the room area including any adjacent areas that cannot be physically closed off from the installation area does not exceed 20 BTU s per hour per cubic foot of space For sidewall venting the booster heater should be located as close as possible to the wall being used The minimum and maximum wall thickness is determined by the wall thimble available from the vent manufacturer Refer to the vent manufacturer s installation instructions All horizontal runs of vent pipe must have a minimum rise of 1 4 inch per foot of length and must be supported every 5 feet or less 3 feet in Canada and at every elbow For horizontal venting The total length of approved 4 inch diameter vent pipe can be a maximum of 40 feet including two 90 degree elbows and one termination vent For each elbow above two reduce the total allowable vent length by ten feet Minimum horizontal vent length is 2 feet For vertical venting The maximum length of approved 4 inch diameter vent pipe is the same as above the same requirements for elbows and termination vent apply the minimum length for vertical venting is 5 feet An auxiliary power vent kit is available for installations where the vent length must exceed these lengths Call the factory for assistance Additional requirements when venting thr
8. feet the optional circulation return kit must be installed to maintain proper temperature at the dishwasher rinse valve POWERMAX be installed up to 150 feet from the dishwasher when using the circulation kit Call factory for details INSTALLATION CLEARANCES Minimum clearances from combustible or non combustible construction 8 fire 2 service 8 Left side 2 Right side 6 Back 0 Top 24 Front minimum for service The four 6 adjustable legs allow the unit to be leveled on uneven floors by screwing the feet up or down as needed COMBUSTION AIR VENTILATION POWERMAX must be provided with an adequate supply of air for proper combustion and ventilation as required by the National Fuel Gas Code ANSI Z 223 1 or any local codes that supercede the National Code Do not obstruct the combustion and or ventilation air supply openings CAUTION Combustion air must not be contaminated by corrosive vapors or fumes i e salt chlorine refrigerant gases detergents paints cleaners etc Any damage caused by insufficient or contaminated combustion air or improper venting will not be covered under the warranty EXHAUST VENTING The POWERMAX Booster Heater is classified as a category IV appliance positive flue pressure flue gas temperature of approximately 190 degrees Fahrenheit possible condensate Vent piping must be one of the types detailed in this manual or a factory approved in writing
9. light any appliance DO NOT touch any electric 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 and or 911 Use only your hand to push and turn the gas control knob NEVER use tools If the knob will not turn by hand do not try to repair it Call a qualified service technician Using force or attempting to repair may result in a fire or explosion D Do not operate this heater if any part has been under water Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control that has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Turn off electrical power to appliance at switch on upper left side panel Remove front access panel by lifting on handle until bottom of panel is released tilt bottom of panel away from unit and remove 4 This appliance is equipped with an ignition device which automatically lights the burner s DO NOT try to light the burner s by hand Turn the gas control 7 knob clockwise to the OFF position Fig 7 Wait 5 minutes to clear out any gas If you smell gas stop and follow the instructions under WHAT DO IF YOU SMELL GAS ABOVE If you do not smell gas proceed to the next step 7 Tur
10. of combustion air which can lead to malfunction and internal damage Damage caused by a blocked or clogged filter is not covered under the warranty 16 CAUTION TROUBLE SHOOTING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing operating burner s NOT on PROBLEM CAUSE REMEDY 3 On Off switch a No power to heater a Check circuit breaker powered Unit does b Manual reset Hi limit b Manually reset hi not operate tripped limit Determine c Vent fan interlock not cause If hi limit trips proving if auxiliary again call service power vent or E Z Turn on fan check Vent system is switch being used Unit energized a Fan defective a Check replace fan blower not operating b Fan relay defective b Check correct pump not operating or wiring c Check clean air filter burner s not on disconnected Unit energized a Igniter Defective a Replace igniter or blower and pump b Water flow switch call Service operating burner s not proving b Check replace flow are NOT on ignition Air flow flue swich control LED flashing blockage switch not c Clear flue Repair or 4 replace switch ay s d Call Service e Control sensor s e Call Service f f Call Service defective f Control board g Call Service defective h Check replace flame g Igniti
11. periodic adjustment or lubrication Consult power vent manual Vent System Check the vent system annually for damage and or obstruction Any deformation of the vent system should be examined carefully to determine the cause of the deformation The problem MUST be rectified and any damage to the vent system MUST be repaired Check Burner Flame Condition When the burner is operating properly the flame will appear to have a light orange base with a blue tint as you look through the burner observation window and across the burner surface fig 8 Inspect the burner periodically through the observation window If areas of the burner appear different or if the observation window is obscured contact your authorized service agency to have the burner inspected for proper operation If the burner is burning bright orange red or white it is too hot and will burn up igniters at an excessive rate Call factory and or authorized service company to adjust air shutter Piping and General Condition Periodically inspect the booster heater for any signs of water leakage combustion by product leakage soot etc or wiring damage electrical arcing insulation damage Contact your authorized service agency to correct any damage or improper operation that is discovered Check Air Filter Regularly remove and inspect externally mounted air filter on the left side of booster Filter is easily cleaned with soap and water A clogged filter will restrict flow
12. remote or consequential damage of any nature no matter how arising or from any cause whatsoever or any amounts in excess of the selling price of the product Vanguard Technology s policy of constant Quality Improvement means that prices specifications and policies are subject to change at any time and without notice VANGUARD TECHNOLOGY INC 29495 Airport Road Eugene OR 97402 541 461 6020 FAX 541 461 6023 800 624 4809 R12 03 19 APPENDIX TYPICAL SPECIAL STAINLESS STEEL VENTING For use with Category Il Ill IV appliances Contact Local Building or Fire Officials About Restrictions and Installation Inspections in your area as well as National codes USA National fuel gas code 51 7223 CANADA CAN CGA B 149 1 or 2 Fuel Burning Installation Code Please refer to appliance manufacturers instructions to determine proper sizing and connection of venting system to appliance including maximum horizontal length maximum height and installation clearances air spaces The proper operation of the vent system and appliance requires parts specified by Z FLEX with no deletions or substitutions NOTE Co venting with other appliances is prohibited PARTS LIST COMPONENT 3 SYSTEM CAT 4 SYSTEM CAT COMPONENT 3 SYSTEM CAT 4 SYSTEM 1 10 FOOT PIPE SVEPWC0310 SVEPWC041I0 ADJUST FLASHING SVSADJ03 SYSADJ04 8 FOOT PIPE SVEPWC0308 SVEPWC0408 REDUCER 4 TO 3
13. 07501 PART 20000 00303 20000 00302 20000 00031 20000 00030 20021 20001 75220 9001 1 75220 26099 10080 00025 10050 00042 10550 00141 19010 70001 159 19010 70001 250 10080 19101 10070 00110 10080 00071 10570 00103 10070 00104 DESCRIPTION Orifice LP PM Orifice NG PM Orifice Pilot PM LP Orifice Pilot PM NG Pilot Hood Assm w Ign Plate gasket Pump Grundfos W O Housing 26 99F Pump Grundfos 26 99BF complete Relay Power Sensor Flame 18 Lead Wire Sensor Temp PM 41 Solonoid Hi Lo Gas LP Solonoid Hi Lo Gas NG Switch Air Switch Water Flow 1 Switch Sq Rocker Transformer 120V 24V Transformer 120V 12v 596 Tube Vent Pipe Drain Tube Air Switch Valve T amp P 3 4 18 LIMITED WARRANTY Products manufactured by Vanguard Technology Inc are warranted to be free from defects in material and workmanship when installed and maintained in accordance with Vanguard s instructions in normal use and service for the time periods terms and conditions as set forth below 1 Foraperiod of One Year from date of installation but no longer than 18 months from factory shipment Vanguard will at its sole discretion repair or replace defective parts assemblies or entire units including labor costs of its authorized service agency Travel expense of Vanguard s authorized service agent will be paid for the first ninety 90 days of this period not to exceed sixty 60 miles
14. INSTALLATION amp OPERATION MANUAL DO NOT DISCARD THIS MANUAL POWERMAX GAS INFRA RED WATER BOOSTER HEATERS Model PM200 and PM400 IMPORTANT FOR YOUR SAFETY WARNING IF THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH Do not store or use gasoline or any other flammable liquids or vapors 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 the area Immediately call your gas supplier from another location Follow gas suppliers instructions If you cannot reach the gas supplier call the local fire dept or 911 If overheating should occur the automatic gas valve fails to operate properly turn off the manual gas valve on the gas supply piping to the appliance Installation and service of this equipment must be performed by a qualified installer service agency or the gas supplier 29495 Airport Road Eugene OR 97402 l 541 461 6020 FAX 541 461 6023 www vanguardtechnologyinc com Tested to ANSI Z21 10 3 1998 800 624 4809 CAN CGA 1 4 3 M98 NSF Std 5 1992 TABLE CONTENTS General Information Installation Codes Unpacking Locating Combustion Air Ventilation Exhaust Venting Gas Piping Water Requirements Water Piping Electrical Wiring Diagrams Operati
15. ains of hardness per gallon Chlorides must exceed 50 parts per million Water hardness above 6 grains per gallon should be treated with a proper water conditioner water softener or in line treatment Water hardness below 4 grains per gallon also requires water treatment to reduce its corrosive effects Sediment silica chlorides or other dissolved solids may require particulate filtration or reverse osmosis treatment Proper water treatment has been shown to reduce machine cleaning mineral build up detergent usage and corrosion of metal surfaces in booster heaters and dishwashers Damage caused by water conditions is not covered under warranty WATER PIPING WARNING All piping and plumbing connections must comply with applicable sanitary safety and plumbing codes CAUTION All piping and any components connected to this appliance for the purpose of space heating shall be suitable for use with potable water Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used for space heating This appliance when used to supply potable water shall not be connected to any heating system or component s previously used with a non potable water heating appliance or system The inlet and outlet water connections are 1 inch NPT inlet is 1 female pipe outlet is 1 male pipe An inlet and outlet union adaptor is provided with your POWERMAX Booster Heater The inlet water supplied to the boos
16. alternate and must be installed according to the vent pipe manufacturers instructions All joints must be properly sealed and secured to maintain joint integrity All vent piping must slope toward the appliance a minimum of 1 4 inch per foot of length The National Fuel Gas Code ANSI 2223 1 requires that the booster heater be vented in one of the following three ways 1 Into the dishwasher exhaust system See fig 1 The vent pipe must not penetrate any grease filter but should terminate within the hood capture zone In cases of a pantleg type of vent see fig 2 the vent pipe may terminate below an approved eyebrow penetration of the duct When vented into the dishwasher exhaust system an electrical interlock must be provided by others to prevent the appliance from firing if the exhaust system is not providing sufficient draft for any reason 2 Through the ceiling roof see fig 3 or through a sidewall see fig 4 B 1 vent pipe inch min diameter may be used when venting vertically through the roof provided a one inch minimum clearance to combustible material is maintained throughout and the vent terminates into a listed wind cap above the roof 3 Vented freely into the room or space where it is installed provided that a A Mechanical exhaust system is present in the space where the booster heater is installed b An electrical interlock is provided by others so that the booster will not fire if the
17. and ice at all times 3 The vent shall not terminate less than 7 ft 2 13 above a paved sidewalk or driveway 4 The termination shall be 6 ft 1 8 m or more from the combustion air intake of any appliance 5 The system shall terminate more than 3 ft 91 m from any other building opening gas utility meter service regulator or the like 6 Exterior mounted venting systems should be enclosed below the roof line with a chase to limit condensation and protect against mechanical failure NOTES A The Z FLEX SPECIAL STAINLESS VENT SYSTEM is for use only with appliances having a positive vent pressure of 3 of water column or less B Except for installation in one and two family dwellings a venting system that extends through any zone above that on which the connected appliance is located shall be provided with an enclosure having a fire resistance rating equal to or greater than that of the floor or roof assemblies through which it passes C Do not place any type of insulation in any required air spaces surrounding the venting system D A termination must be used on all installations to assure proper operation and to prevent debris from entering the venting system 20 JOINT PROCEDURE see illustration 1 below 1 The outside of male end and inside of female end of pipe must be cleaned before applying silicone bead Remove dirt grease and moisture from surface to be sealed Dry surface or allow to dry tho
18. ccordance with state and local codes or in the absence of local codes with the following National Fuel Code ANSI 2223 1 latest edition the National Electric Code NEC ANSI NFPA 70 latest edition Canada CAN CGA B149 1 B149 2 and CSA 22 2 No 1 latest edition UNPACKING Immediately after unpacking check thoroughly for any possible shipping damage If the POWERMAX is found to be damaged contact the carrier immediately 15 days maximum Be sure to save all the packaging materials for shipper s inspection LOCATING THE POWERMAX BOOSTER HEATER Locate the POWERMAX so that all required clearances are maintained The appliance must be located in an area that is clear and free from combustible materials including gasoline and other flammable or corrosive liquids and vapors The booster heater should not be located in an area where water leakage could cause damage to adjacent areas or areas below the unit If this is not possible the booster heater should be installed in an adequate catch pan preferably stainless steel that is properly drained If appliance is installed on carpeting it must be installed on a wood or metal panel extending beyond the full width and depth of the appliance by at least 3 inches 76 2mm in each direction The booster heater should be installed with no more than five feet of pipe between the 180 degree outlet and the dishwasher rinse valve as specified by NSF 5 If the piping exceeds five
19. fficient water supply stray current or voltage conducted through water piping or unauthorized alteration shall in no way be covered under this warranty Cleaning of filters pumps valves burners fans or electrical connections tightening of threaded connections and or adjustment or calibration of controls is considered a part of normal installation and or maintenance and is not covered under this warranty Hot surface igniters are considered a consumable item similar to a spark plug and are not generally considered a warranty item Accessory components sold but not installed by Vanguard are covered by a one year parts only warranty Warranty on replaced parts or assemblies shall be the lesser of 90 days or the unexpired portion of the original warranty Factory reconditioned and tested parts may be used to satisfy claims under this warranty Warranty work shall be done only by Vanguard Technology s authorized service agency during normal working hours Overtime labor will not be paid under this warranty There are no other expressed or implied warranties of any kind including but not limited to any implied warranty of merchantability or fitness for any particular purpose or usage The remedies under this warranty as set forth here in are at the exclusion of all others and Vanguard Technology Inc neither assumes nor authorizes anyone to assume for it any other obligations In no event shall Vanguard Technology Inc be liable for any
20. ication Worksheet continued Bleed air from accumulator and heat exchanger through temperature pressure relief valve Turn power switch on Burner s will activate until accumulator temperature setting is reached Output temperature sensor should reduce burner to low flame shortly before burner shuts off Q When unit is at temperature flush approx 25 gal of hot water through the unit before shutting off Q Check flame color and condition through view window Burner should have a light orange base with a blue tint Air shutter may be adjusted to achieve this flame FOR CIRCULATOR OPTION In addition to above Q Verify circulator pump is operating amp pumping in right direction Pump should be located in return side of circulator loop and pumping toward booster Verify pipe is sized properly complete loop should be 3 4 I D minimum for 1 dishwasher and 1 I D for 2 dishwashers or dishwashers with both rinse and fill valves filling through booster and insulated to minimum R 4 throughout the loop Call factory if booster is being used to heat Dishwasher wash tanks Comments and Recommendations Service Agency Address Please make 2 copies and send to Facility Manager amp Vanguard Technology Inc For any assistance please call factory at 1 800 624 4809 Technician Signature Technician Name please print Date 25 SLED Pane 4 Volt Water Flow Swich Tank Te
21. in Cap 02VRSRCX03 02VRSRCX04 Bedford NH 03110 Termination Box 02SVSRTX 3 02SVSRTX 4 Flex L International Inc StaR 34 AL 29 4C Termination Tee SRTT03 SRTT04 6385 Kennedy Rd Stainless Steel Wall Thimble SRWT153 SRWT154 Mississauga ON L5T2W4 GAS PIPING The gas inlet pipe size is 3 4 inch NPT male thread located at the lower right front corner of the appliance The gas supply piping must be sized to adequately provide the input BTU hr rate for the appliance at the specified flowing pressure see table 1 The maximum inlet gas pressure must not exceed the maximum value shown in table 1 minimum gas pressure shown in Table 1 is for purposes of input adjustment The FLOWING Gas Pressure Requirement not static Inches W C Water Column Natural Gas LP Incoming Line Pressure Manifold Minimum Maximum Pressure PM200 4 5 NG 10 LP_ 10 5 NG 14 LP 3 5 NG 7 5 LP PM400 4 5 NG 10 LP_ 10 5 147 3 5 NG 7 5 LP TABLE 1 The gas valve is provided with a pressure tap to measure gas pressure downstream which is also the manifold pressure fig 5 The gas piping must have a sediment trap ahead of the heater gas controls and an approved manual shut off valve provided by others located outside the jacket and easily accessible The heater and its gas connections must be leak tested before placing the appliance in operation DO NOT use an open flame for leak testing
22. mp F 7 Sonsor a iJ A Proving FRET a2 F gpk Control 1 i pa Orifice 5 0 5 5 Bronze 4 g Elega l Pump i i 1 Output Temp Sensor A Secondary _ Gas Valve Primary Gas Control Valve Regulator DPST Le Switch A il 1 G LED Panel TAL i Tra nsformer aka Pump ignition j A 4 Fan Gas valra Electronic a Ignition control 26
23. n gas control knob counterclockwise x N to the ON position oF 8 electrical power to the appliance Be careful not to contact any live electrical connections when access panel is open 9 If appliance does not ignite there may be air in the gas supply system Repeat the cycle several times to remove air 10 If the appliance will not operate follow the instructions under TURN OFF GAS TO APPLIANCE following and call your service technician or gas supplier 11 Replace front access panel 14 TO TURN OFF GAS APPLIANCE Turn off all electric power to the booster heater if service is to be performed Turn off manual gas valve in gas supply piping Remove front access panel by lifting panel to release bottom tilting panel away from unit and removing panel Push in and turn gas control knob clockwise So the OFF position Replace front access panel Fig 7 WARNING IF OVERHEATING OCCURS OR THE GAS SUPPLY FAILS TO SHUT OFF CORRECTLY DO NOT TURN OFF OR DISCONNECT ELECTRIC SUPPLY TO THE PUMP SHUT OFF GAS SUPPLY AT THE MANUAL GAS VALVE IN GAS SUPPLY PIPING IF WATER IS LEAKING FROM UNIT AFTER TURNING OFF GAS LET BURNER COOL THEN TURN OFF POWER AND SHUT OFF WATER SUPPLY VALVE 15 MAINTENANCE Lubrication The water pump motor and the combustion air blower are permanently lubricated and require no periodic maintenance Auxiliary power vent motor depending upon model may or may not need
24. ng Sequence Start up Procedure Operating Instructions To Turn Off Gas Appliance Maintenance Troubleshooting Replacement Parts List Limited Warranty Appendix A Sample Start Up Checklist Interior View Parts Breakdown ii Page 10 12 13 14 15 16 17 18 19 20 24 26 POWERMAX gas fired infra red water booster heater provides 180 degree sanitizing rinse water for commercial dishwashing machines Dishware and utensils used in the preparation and serving of food are required by Health Codes and the National Sanitation Foundation NSF to be sanitized by hot min 180 degrees Fahrenheit water or a chemical sanitizing solution to destroy bacteria and parasitical organisms The POWERMAX booster heater operates as a semi instantaneous water heater As 180 degree rinse water is drawn from the unit incoming supply water flow activates the burner and pump to circulate the water through a high efficiency finned copper coil heat exchanger Heat is provided by an advanced infra red ceramic fabric power burner which heats and maintains a constant supply of 180 degree rinse water When the dishwasher is not in use the POWERMAX continues operating for a few minutes before going into a stand by mode operating only as needed to maintain a small approx 4 5 gallon reservoir of 180 degree water for the next dishwashing rinse demand INSTALLATION CODES Installation must be performed in a
25. on control sensor defective h Burner flame not proving Unit energized a Pump defective a Call Service blower on pump not b Relay defective b Call Service Note For service and or parts call your authorized service agency or the factory 1 800 624 4809 17 REPLACEMENT PARTS LIST When ordering parts always refer to the Model number and Serial Number The data plate is mounted on the electrical panel face behind the front cover panel NOTE Part numbers may change without notification To obtain the most recent part numbers contact the Factory or your authorized Vanguard service agency Model PM200 199 900 BTU Hr amp Model PM400 399 800 BTU Hr PART 19052 01612 10050 00039 10592 20000 10050 00043 32200 34209 10051 02383 19052 20075 19020 70200 19020 70201 19020 70202 10080 02466 10080 02602 75220 90051 10080 02465 40000 40004 50304 20001 50303 20001 50603 20001 10080 02601 20000 00304 DESCRIPTION Blower Board Temp Control Control Panel Complete Display Digital Temp ECO Hi Limit PM ECO Hi Limit Manual Reset Filter Air FF 5 Flex Tube Gas 1 18 Flex Tube Gas 7 8x 12 Flex Tube Gas 1 40DX18 Gas Control Valve Honeywell Gasket Igniter Plate Gasket Pump Flange Ignition Control Fenwal Legs Black Manifold Cold Lower 200 Manifold Cold Upper 200 Manifold Hot 200 19025 70015 Mini Igniter 120V 250 19025 70012 Orifice Hi altitude NG LP PM 13053
26. once annually to ensure that it is functioning properly Be careful when operating the relief valve Follow instructions on the tag located on the Temperature and Pressure Relief valve to avoid contact with hot water discharge and to prevent water damage from operation of the valve Repair or alteration of the Temperature and Pressure Relief valve in any way is prohibited by National Safety Standards and local codes DO NOT PLUG THE RELIEF VALVE OR INSTALL A SHUT OFF VALVE OR ANY OTHER RESTRICTION IN THE DISCHARGE DRAIN LINE The booster heater should be located as close to the dishwasher rinse valve as possible If the booster heater is installed more than 5 feet from the dishwasher rinse valve an optional rinse water re circulation kit is available from Vanguard Technology and must be used to insure a consistent water temperature of 180 degrees at the rinse valve Fig 6 NOTE All water supply piping to the booster heater must be completely flushed of all debris and flux residue before connection to the booster heater Damage caused by debris or aggressive flux residue will not be covered under warranty If booster heater is installed a closed water supply system such as one having backflow preventer in the water supply line means shall be provided to control thermal expansion Contact the water supplier or local plumbing inspector on how to control this situation or call the factory circulation pump ball valve Incaming
27. or two 2 hours 2 Foran additional Four Years Vanguard warrants the fin tube heat exchanger in the PowerMax Gas Booster to be free from defects in material or workmanship At Vanguard Technology s sole discretion and in accordance with this warranty defective heat exchangers will be replaced on a pro rated and parts only basis i e Owner will pay a percentage of the current list price of a replacement heat exchanger as follows Failure within first year no charge within second year 20 within third year within fourth year 60 within fifth year 80 3 stainless steel accumulator is covered by a limited lifetime warranty and is warranted to be free from leaks for this time Any attached gauges controls or other parts are subject to the standard one year parts and labor warranty This warranty is limited to the foregoing and does not apply to defect or malfunction resulting from or caused by installation operation or maintenance not in accordance with manufacturer s instructions damage related to shipping accident abuse fire flood or other acts of God units operated in corrosive or other damaging atmospheres or at temperatures outside specified operating range Damage caused by freezing improper water conditions excessively acidic or alkaline water excessive pressure chemica contamination sediment build up etc incorrect electrical supply or connection insufficient combustion air or negative draft insu
28. ote booster installation is used it is wired separately from the booster heater through the provided lighted switch box CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing au ese eet eas ee NOTE IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH APPLIANCE MUST BE REPLACED T MIET RE REPLACED WITH OTC WIRE ITS SENSOR HI LO TEMP TAMA TLAP 12 CONTROL CIRCUIT TRANFORMER Edw le notice Specificatons subject to chang 10 Fleld Hox OPE RAT LMG SENSOR 41 L0_ TEMP SENSOR Tonition Contra W Ghd BR i k 4 H wo a 4 BK we rake zaag GR ae R BKR Sa 1 ozo 365 z ane 7 ae WH aaa Soecifications subject to change without notice Pay WER 4 TEU 225 FAA 341 401 080 11 OPERATING SEQUENCE The booster heater is designed to produce 180 190 degree sanitizing rinse water for
29. ough a sidewall The vent terminal shall be located at least three feet above any forced air inlet located within ten feet at least four feet below and four feet horizontally from or one foot above 4 any door opening window or gravity air inlet into any building It shall also minimum horizontal clearance of four feet from any electric meter gas meter regulator relief valve or other equipment The vent terminal shall be located not less than seven feet above grade when it is adjacent to public walkways The bottom of the vent terminal shall be located at least twelve inches above grade or ground or the normally expected snow accumulation level The snow level may be higher on walls exposed to prevailing winds Avoid areas where local experience indicates that condensate drippage may cause problems such as above planters patios public walkways or areas where condensate or vapor could cause a nuisance or hazard or where its discharge could be detrimental to the operation of regulators relief valves or other equipment Examples of ACCEPTABLE VENT PIPING See Appendix A MANUFACTURER MODEL MATERIAL 4 SPECIFICATION Part Name Part Part Number Heat Fab Inc Saf T Vent AL 29 4C Tee 7390TEE 7490TEE 38 Haywood St Stainless Steel Rain Cap 5300 1 5400 1 Greenfield 01301 Mitre Straight 7390GC Z Flex US Inc Z Vent AL 29 4C Tee O02SVSTTX 3 O2SVSTTX 4 20 Commerce Park North Stainless Steel Ra
30. roughly 2 Apply high temperature silicone approximately one half inch from end around male end of pipe and along both sides of seam for one inch in an even 1 4 bead as per illustration 1 3 Pipes can now be pushed together as far as they will go The seams on pipes should be aligned and oriented upwards in all horizontal applications Apply another bead of silicone around this joint and smooth out Tighten gear clamps 15 N LB MAX Check all joints and seams for tightness prior to using vent system Allow the sealant to cure for one hour before operating the appliance Length of time required for full cure depends upon thickness of application and other factors such as weather ambient temperature humidity etc All sealants must be used within the time limitations marked ao 1 oes 2 26 6 CLEARANCE COMBUSTIBLES SYSTEM CLEARANCE CLEARANCE SEALANT OPERATING ENCLOSED UNENCLOSED REQUIRED HORIZONTAL VERTICAL HORIZONTAL VERTICAL GE 108 DOW CORNING 732 300 F 149 C 8 200 mm 4 100 mm 1 25 mm 1 25 mm 222 SEALANT G E 106 Z FLEX 7 480 F 249 C 8 200 mm 4 100 mm 1 25 mm N A 2 Note Flexible elbows parts SVEFEX03 AND SVEFEX04 must not be enclosed 21 IDE WALL VENTING INSTALLATION LEVEL NE PIECE TERMI JAT LZR
31. s below control set point circulating pump will start air flow water flow and hi limit E C O s will prove and ignition system will be powered Red LED on ignition control will illuminate briefly confirming internal self check Following 2 3 seconds igniter warm up observe igniter through viewing window to verify an audible click will be heard from the gas valve opening With gas supply off ignition will not occur and flame proving sensor will shut off gas valve This process will repeat for 3 cycles after which the ignition system will automatically lock out requiring a manual re set The combustion fan will remain on low speed providing a continuous purge of the combustion chamber Manual re set is accomplished by turning off power switch on booster left side panel for 10 seconds then turning back on 13 FOR YOUR SAFETY READ BEFORE OPERATING WARNING IF YOU DON T FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH A This appliance DOES NOT have a standing pilot ignition system It is equipped with a hot surface ignition device that automatically lights the burner DO NOT attempt to light the burner by hand B Before starting the appliance smell all around the appliance area for gas odor Be sure to smell next to the floor because some gases are heavier than air and will collect on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to
32. tal vertical distance of the vent system from appliance flue collar to the rain cap termination and the maximum length of offsets shall not exceed that specified in the appliance manufacturer s installation instructions No continuous vertical run shall be longer than sixty feet 18 3 m All horizontal sections must observe the rules for HORIZONTAL VENTING The clearance to combustibles inside a chase shall be no less than 4 100 mm 1 Prior to beginning the installation loosely assemble all parts required to make sure all parts are present 2 Locate position for venting system and proceed to cut holes for firestop support and firestop spacers All vertical installations require the use of a support Frame the opening of the floor using lumber which is dimensionally consistent with the structural members Insert the support from beneath the framed opening and secure with nails or screws as required Refer to JOINT PROCEDURE before assembling system 23 NGUARD T E C HN OL OG Y 29495 Airport Road Eugene OR 97402 Tel 541 461 6020 Fax 541 461 6023 Toll Free 1 800 624 4809 Factory Authorized PowerMax Start Up Verification Worksheet Job Name Job Location Dealer Name Serial Verify incoming water temperature to booster heater is 110E to 140E Verify size of vent piping ___ dia Is there any horizontal vent piping YES NO Circle one How much ft Is vent pipe correct pipe for application Z
33. ter heater should be a minimum of 110 degrees Fahrenheit except in the case of single rack door type dishwashers and some water saver conveyor machines in which case incoming water can be as low as 45 degrees Fahrenheit DO NOT connect the POWERMAX Booster Heater to a cold water supply pipe if it is to be used with a full flow conveyor dishwasher Recommended flowing water pressure to the booster heater is 45 p s i Flowing water pressure at the dishwasher rinse valve should be 20 p s i An optional pressure regulating valve and pressure gauge for the booster heater outlet is available from Vanguard Technology if the dishwasher is not equipped with these items The supply water inlet to the booster heater does not require a pressure regulating valve unless the supply water pressure exceeds 50 p s i A full flow shut off valve must be provided in the water supply piping to the booster heater Installation of a suitable water hammer arrester is recommended between the booster heater and the dishwasher rinse valve A drain valve assembly is provided for installation on the lower outlet at the back of the booster heater The Temperature and Pressure Relief valve is installed at the left side of the booster heater Install suitable 3 4 i d drainpipe from the discharge of the Temperature and Pressure Relief valve to a suitable drain or catch pan with drain The Temperature and Pressure Relief valve should be manually test operated at least
34. ust be supported along its horizontal length at all elbow locations and joints every forty eight inches or less using straps around pipes maintaining clearance to combustibles as per table Any horizontally installed portion of a venting system shall have a slope upwards for Category Il III or IV appliances or upwards for Category Ill or IV appliances not less than 1 4 6 4 mm every 12 inches 305 mm to prevent collection of condensate at any location in the assembly The components of the system must not be penetrated by fasteners either when joining pipes and fittings or using support straps The lengths of pipe may be cut on non expanded end using aviation snips or a hacksaw 24 tpi The cut end must be filed or sanded smooth before joining When installing the condensate tube be sure to form a trap by means of a 3 76 2 mm loop filled with water This tube must be 3 8 ID high temperature silicone for at least the first 6 inches 152 mm and attached with a gear clamp or hose clamp The effluent must be disposed of according to local regulations NOTE Z FLEX recommends using a neutralizer kit when using a condensate trap A condensate pump may be required t a 1 i _ 4 f 1 4 y S 3 a n VERTICAL VENTING NOTE The vent termination must be at least 3 ft 1 m above the roof line and 2 ft 61 higher than any part of a structure within 10 ft 3 1 The to
35. water Fig ELECTRICAL The electrical power supply requirement for the booster heater is 120 volts AC 60Hz 6 0 amps or less Field wiring connections and electrical grounding must comply with local codes or in the absence of local codes with the latest edition of the National Electric Code NEC ANSI NFPA 70 NOTE Polarity must be observed for the booster heater to operate properly Consult wiring diagram Provide a separate fused circuit from the main electrical panel to the booster heater and a means of disconnecting within sight of the heater Electrical connection is made from the bottom left front of the unit and into the 2 4 field wiring connection box All internal electrical components are factory wired and operate with the heater control system NOTE If it is necessary to replace any of the original wiring it must be replaced with 105 degree centigrade rated wire or its equivalent CAUTION DO NOT TURN THE POWER SWITCH ON UNTIL THE BOOSTER HEATER HAS BEEN FILLED WITH WATER AND ALL AIR HAS BEEN PURGED FROM HEAT EXCHANGER AND THE ACCUMULATOR TANK If an auxiliary power vent is installed or in certain cases if the booster heater is vented through the dishwasher exhaust system an airflow proving switch must be installed in the duct system to interrupt power to the booster heater and prevent its operation without sufficient draft The airflow proving switch is provided by others If the optional circulation kit for rem
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