Home

Installation & Operation Manual (399 to 800 MBtu)

1. Conventional Venting Through the Wall Venting Combining Vents with a Draft Inducer SOS L P 2 S L e x L AN HORIZONTAL MINIMUM N CLEARANCE i SEE SECTION 7 4 N i ae _ MIN 12 ui 4 ABOVE HIGHEST 1 SNOW LEVEL 55 55 5 Concentric Vent for Combustion Air and Exhausting Flue Products Concentric venting to enable a single side wall or roof penetration for both combustion air and flue exhaust terminations is available for the Conquest following the instructions located at www pvi com vent design html Before operating the Conquest confirm all of the associated installation operation and maintenance requirements provided for the concentric vent are followed Connecting to an Existing Vent System Do not connect the Conquest to an existing vent system until it has been confirmed the existing vent system complies with all requirements for a new vent system A venting system in full compliance with the instructions provided in this manual is required for safe and reliable operation of the Conquest Do not connect the Conquest to a masonry chimney WARNING Before operating the appliance conn
2. 9 9 Regulator Adjustment 2 Gas Train Illustration for Model 40 Optional components may not be shown Check Supply Fixed Gas Train Check Manifold Pressure Here Orifice in Union Valve Orifice Adjustment Safety Shutoff A a Regulator m dd One L Adjustment CTI Gas Train Illustration for Models 50 through 80 Optional components may not be shown 32 PV500 60 07 15 CONQUEST WATER HEATER Fixed Gas Train Check Manifold Dual Safety Orifice in Union Pressure Here Shutoff Valve and Regulator Valve Orifice Adjustment Check Supply Pressure Here F 1007 Regulator LEE Adjustment Alternate Gas Train Illustration for Models 50 through 80 Optional components may not be shown 33 PV500 60 07 15 14 CONQUEST WATER HEATER NSF FOOD SERVICE INSTALLATION GUIDELINES All Conquest water heater models that have the Intertek ETL Sanitation mark on the information decal affixed to the front of the appliance are listed to NSF 5 2009e This section
3. Jil LIST OF MATERIALS DESCRIPTION CONTROL PANEL COMPONENTS A TempTrac Control Templrac Kit for 399 MBtu H TempTrac Kit for 500 MBtu H Kit for 600 MBtu H Templrac Kit for 700 800 MBtu H 6 1 5613 JFuseHolder o 1 76267 8 1 121250 Metal Face Plate 91 1 121 75 BoardMount 6 122319 TermialBlock gt j 18 Blower VFD Modulating Heaters Only Blower VFD for 500 MBtu H Blower VFD for 600 MBtu H Blower VFD for 700 MBtu H Blower VFD for 800 MBtu H 39 PV500 60 07 15 CONQUEST WATER HEATER 16 3 Component Wiring and Conduit Routing Details INCLUDE 24 OF ADDITIONAL WIRE Q0 LENGTH FOR PUMP AIR SWITCH RED WIRE IS NOT USED FOR SINGLE SPEED BLOWER 1A G OPTION 1 M3 M2 M1 P33 IGNITOR CIRCULATOR P31 HIGH GAS PNK NC LWCO P22 LOW GAS PNK COM LWCO PROBE HIGH LIMIT RED COM BACK CNTL ENCL VIEW HIGH LIMIT SWTCHES CIRCULATOR TUBING amp SENSOR WRES USE HEYCO BUSHING CONDUIT OR TUBING LENGTH IN INCHES 40 PV500 60 07 15 17 CONQUEST WATER HEATER PERIODIC MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations Maintenance mus
4. MIXING N C Bypass VALVE HOT OUTLET 71 REFER TO VALVE anaa qu MANUFACTURER S ls PIPING INSTRUCTIONS BUILDING RETURN EC erm BUILDING CIRCULATOR 5 STORAGE 30 gpm TAP VALVE pump T amp P VALVE W Lf eX PIPE T amp P VALVE TO i DRAIN WITH NO SHUTOFF i Qi VALVES OR RESTRICTIONS IN I i THE LINE i 2 OR PER LOCAL CODE i T Tank REQUIREMENTS bu pac Thermostat WATER HEATER 90 DRAIN VALVE W n C DRAIN VALVE pipe to drain COLD MAKEUP CONDENSATE DRAIN LINE FLOOR DRAIN WITH NEUTRALIZER FLOOR DRAIN Notes 1 Do not exceed 160 F stored water temperature the storage tank 2 Circulating pumps require separate electrical circuit wired through the tank thermostat Tank mounted thermostat energizes pump on a call for heat Heater runs independently on its own set point Pump de energizes when tank temperature is restored Bypass piping allows heater to continue operation with the storage tank removed from the system 4 During initial startup of the heater and tank the heater may cycle occasionally SINGLE STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK TEMPERED TO BUILDING USE BALANCED OR REVERSE RETURN PIPING MIXING VALVE HOT OUTLET x REFER TO VALVE 1 MANUF
5. Maximum Length 30FT 50FT 75FT 100FT WARNING Turn off all electrical service to the appliance when accessing the remote connections These terminals can be High Voltage If the electrical service is not turned off and these terminals are touched a dangerous shock causing personal injury or death could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance Coupez l alimentation avant intervention sur l appareil Terminal Functions The following describes the functions of each of these terminals and the proper method for interfacing with an Energy Management System L1 L2 Used for incoming 120VAC power supply connection Terminal L1 is the hot terminal and L2 is neutral See the product catalog or specification document for circuit ampacity rating R1 R2 Used to activate de activate water heater from remote master control Terminals are wired to a relay in a remote Energy Management System When the relay closes the circuit from R1 to R2 is completed and appliance controls are enabled This appliance ships from factory with a jumper between terminals Remove jumper when connecting to a remote controller The indication of this function is described in section 10 8 LED Display Alarm Messages A1 A2 Used to activate a remote alarm signaling shutdown of combustion control Provides a maximum 3 amp relay contact closure when the flame safeguard terminates combust
6. Turn off main gas shutoff valve Disable or jumper out any BMS BAS control interface to allow independent setup and adjustment of each water heater Turn unit on using the rocker switch on the front of the control enclosure When the burner fails to light the flame control will lockout The burner combustion must be optimized during startup at both Low and High Fire Start the burner in Low Fire operation by setting the TempTrac Control for manual modulation output _ Push and hold the EXT key for more than 3 seconds The M ED switches ON and the PS4 parameter is displayed in the upper display while the PAS label is shown in the lower display _ Release the key and insert the password 3 2 1 The value of the modulation parameter PS4 will be displayed in the lower display nu stands for Not Used Return to this condition for automatic operation _ To adjust modulation manually push the SET key the value starts flashing Then use UP or DOWN keys to modify it 100 High Fire 0 Low Fire _ To exit press SET UP or wait 30s without pressing any key NOTE After a modification it will be possible to enter the Modulation output setting without entering the password for 10min After this time you will be asked for the password again 30 PV500 60 07 15 15 16 17 18 19 20 21 22 23 24 25 CONQUEST WATER HEATER Turn on main gas shutoff valve If the TempTrac operating control switch is cl
7. 11 2 Terminal Functions Sequence of Operation Initial Startup 13 1 Initial Startup Requirements 13 2 Tools and Instrumentation Required 13 3 Resources 13 4 On Site Considerations 13 5 Startup Procedure NSF Food Service Installation Guidelines Troubleshooting Guide Replacement Parts 16 1 Burner Assemblies 16 2 Control Panel Enclosure Component Layout and Replacement PN s 16 3 Component Wiring and Conduit Routing Details Periodic Maintenance Recommended Maintenance Schedule Warranty forms ship separately with each product PV500 60 07 15 CONQUEST WATER HEATER SAFETY CONSIDERATIONS WARNING If the information in the supplied manual s is not followed exactly a fire explosion or exposure to hazardous materials may result causing property damage personal injury or death FOR YOUR SAFETY e Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a location away from your building and the smell of gas Follow the gas supplier s instructions e f 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 This product contains or may come to contain mater
8. 2 13 3 13 4 13 5 CONQUEST WATER HEATER 9 Loss of Flame Signal a If the igniter fails to sense flame at any time the igniter and gas valve will be de energized and the flame control will reset and begin the call for heat sequence again This will occur 3 times one time if CSD 1 before the flame control will lockout If flame failure occurs following the third TFI period one time if CSD 1 post purge will continue until the alarm on any failure ends the call for heat This period of blower operation will exhaust any remaining combustion products from the system 10 Alarm on Any Failure a When any safety device or remote proving interlock prevents the burner from firing within the allotted time period once the call for heat is initiated the TempTrac will initiate an alarm notification This notification is indicated in the following ways i A flashing alarm message is displayed on the TempTrac screen ii A high pitch beeping audible alarm iii The dry contacts at terminals A1 amp A2 will close 3 amp max load iv The alarm register accessible through the Modbus RTU communication option b To reset the TempTrac once the alarm is activated attempt to determine the safety device which caused the condition and correct the condition Once the condition is corrected the TempTrac can be reset by pressing any button c Seethe troubleshooting guide for more details INITIAL STARTUP Initial Startup Requirements In
9. 2 2 2 2 M 31 4 37 PV500 60 07 15 CONQUEST WATER HEATER Burner Assembly Illustration for Models 50 through 80 Optional components may not be shown ATTACH TAG FOR 69 46 G9 OPTIONAL GAS PRESSURE SWITCHES REGULATOR THIS SIDE FACES UP Z 9 W 5 6 37 THIS SIDE FACES UP MIA LIST OF MATERIALS ITEM QTY PART NO DESCRIP TION BURNER ASSEMBLY COMPONENTS 1A 1 119467 BLOWER FIXED SPEED 1B 1 119466 BLOWER VARIABLE SPEED 2 4 3475 1 4 HEX NUT 3 4 3494 1 4 LOCK WASHER 4 4 15607 1 4 FLAT WASHER 5 1 5940 BLACK PLUG 1 4 6 1 101216 PRESSURE SWITCH HIGH GAS 7 1 122575 CAP ORIFICE 3 X 2 8 1 119469 FLEXIBLE ADAPTER 9 2 118016 1 8 NPT X 1 4 HOSE BARB 10 1 121704 4 PVC X 12 PIPE 11 1 116929 4 TO 6 PVC BUSHING 12 1 121853 AIR INLET SCREEN 6 63 OD TO 3 76797 3 4 SS TEK SCREW 14 1 115276 BURNER 15 2 120493 BLOWER FLANGE GASKET 16 4 79972 1 4 WING NUT 17 1 113960 IGNITER COVER 18 1 107775 HOT SURFACE IGNITER 19 1 111791 IGNITER GASKET 20 1 123822 BURNER BULKHEAD 21 1 6437 BRASS TEE 1 8 22 3 6157 BL
10. PVI INDUSTRIES LLC e 3209 Galvez Ave e Fort Worth Texas 76111 e Phone 1 800 433 5654 e www pvi com 44 PV500 60 07 15
11. at startup is air in the gas supply This can usually be corrected with multiple cycles or bleeding the line manually If the burner lights but blows out insure that the burner firing rate is locked in low fire and check for improper combustion or week flame signal as a possible cause Once the main burner flame is established the firing rate will be controlled by the TempTrac control Burner Combustion Adjustment Burner combustion must only be adjusted using a combustion analyzer Do not attempt to adjust burner by sound or sight With the burner firing insert the combustion analyzer probe in the flue vent approximately two feet from the appliance The water heater is equipped with one of two different gas trains requiring different adjustment instructions The Model 40 is adjusted as follows With the burner firing adjust the valve orifice screw counter clockwise to increase gas flow or clockwise to decrease flow The desired CO2 in the combustion products must be between 8 5 and 9 5 for natural gas 9 5 to 10 5 for LP gas Do not attempt to adjust combustion based on manifold pressure alone Manifold pressure should only be used as a reference point It should not be necessary to adjust the regulator for this model See Gas Train Illustrations for details The Model 50 60 70 amp 80 are adjusted as follows With the burner firing and adjusted to Low Fire adjust the regulator screw clockwise to increase gas flow or counter clockwise
12. components Check firing rate control Check piping and wiring of all interlocks and shutoff valves Inspect burner components Test high and low gas pressure interlocks If equipped check air filter and replace if required 3 Monthly Maintenance Test low water cutoff device alarm if equipped Check air filter if equipped every 3 6 months sooner in dirty environment Check flue vent stack or outlet dampers Check flame signal strength Check flame failure detection system Check firing rate control Listen to and visually check the pilot and main fuel valves 4 Daily Maintenance a Check gauges monitors and indicators b Check instrument and equipment settings 5 AsRequired a Check drip leg and gas strainers Test flame failure detection system Test temperature and pressure relief valves in accordance with ASME Boiler and Pressure Vessel Code Sections VI amp VII Tank flush and cleanout Chauffage d eau feront pr cipitants qui se d posent au fond de la cuve Enlever ces pr cipitants deux fois par an ou plus souvent dans certains endroits 43 PV500 60 07 15 CONQUEST WATER HEATER Since PVI cannot control the use of the appliance water conditions or maintenance the warranty on the heat exchanger does not cover poor performance structural failure or leaking due to an excessive accumulation of scale MODEL NUMBER SERIAL NUMBER INSTALLATION DATE
13. provides additional information for architects designers and contractors in food service installations requiring compliance with NSF codes NSF ANSI 5 2009e establishes health and sanitation requirements for the materials design and construction of commercial water heaters All Conquest water heaters are certified for compliance with NSF 5 and UL 795 by ETL Intertek and are therefore recognized as suitable for installation and use in commercial food service appllications when installed and used according to these instructions WARNING Do not use a pressurized water source to clean this water heater If the food service installation requires pressurized washing the water heater must be isolated from water spray Failure to isolate the heater from pressurized water may cause a hazardous condition resulting in property damage or high voltage electrical shock causing personal injury or death Conquest water heaters can be adjusted to operated at temperatures up to 190 F Refer to the Temperature Setting section of this manual for instructions to adjust the thermostat to the desired temperature NSF Installation The NSF 5 listed Conquest water heater requires no modification to become NSF 5 compliant is designed to supply potable hot water and is not intended or suitable for other purposes Where feasible the water heater should be located seperate from food and utensil handling areas When this is not possible in a food service installation the
14. release the Set 1 key on the face of the control When setpoint adjustment is enabled use the arrow keys to adjust the set point to the desired system temperature See TempTrac Electronic Controller Panel in this manual for more information Le thermostat est r gl environ 49 degr s Celsius Temp ratures de l eau sup rieures 52 degr s Celsius peut causer instantan ment de graves br lures ou la mort de br lures Suivez les instructions dans le manuel d installation et de maintenance pour modifier la temp rature de l eau High Water Temperature Limit Control The appliance is equipped with a manual reset high limit control to turn off the burner when the water temperature in the tank exceeds the set point of the control This control is located inside the burner vestibule accessed from the top of the Conquest The high limit control is reset by pressing the limit reset button accessible through a hole in the metal cover on top of the appliance Pressing the reset on the high limit control will not cause the control to reset until the water temperature has dropped below the set point of the manual reset high limit control WARNING Turn off all electrical service to the appliance when accessing the limit or high limit control located inside the control enclosure located inside the burner vestibule and close and fasten the control enclosure and burner vestibule cover before restoring electrical service to the appliance The the control encl
15. the exit and at least 2 feet 0 61 m above the highest point of the roof within a 10 foot 3 05 m radius of the termination 10 A vertical termination less than 10 feet 0 91 m from a parapet wall must be a minimum of 2 feet 0 61 m higher than the parapet wall Combining Category IV Vents Combined Conquest Category IV gas vent systems must incorporate an Exhausto Tjernlund or US Draft variable speed modulating mechanical draft inducer capable of maintaining the appropriate negative draft at the end of the common flue to assure that all water heaters in the combined vent system operate with a negative draft Do not exceed negative 0 25 W C See Combining Vents with a Draft Inducer illustration below Combining the exhaust vents of multiple Conquest condensing water heaters into a common unpowered or gravity vent is never recommended i e venting as Category Il Conquest water heaters are too efficient and their flue products are too cold to generate the natural buoyancy required for such combined vent systems to function reliably and safely WARNING Do not connect multiple water heaters vents into a single unpowered or fixed speed powered vent This could cause unsafe operation and the potential for poisonous carbon monoxide to enter occupied areas Such improper installation can cause property damage personal injury exposure to hazardous materials or death 21 PV500 60 07 15 8 5 8 6 CONQUEST WATER HEATER
16. to decrease flow The desired CO2 in the combustion products must be between 8 5 and 9 596 for natural gas 9 5 to 10 596 for LP gas Do not attempt to adjust combustion based on manifold pressure alone Manifold pressure should only be used as a reference point See Gas Train Illustrations for details a Once the desired combination is achieved at Low Fire raise the burner firing rate to High Fire Adjust the valve orifice clockwise to reduce the flow of gas and counter clockwise to increase the flow of gas in order to maintain the desired CO2 in the combustion products between 8 5 and 9 5 for natural gas 9 5 to 10 5 for LP gas b When High Fire combustion has been reached and combustion is within the proper range return to Low Fire to confirm settings again c CAUTION If at any point of the modulation range carbon monoxide is in excess of 300ppm contact PVI Industries Customer Service for assistance Return the PS4 modulation parameter value to nu for automatic operation Enable or reconnect any BMS BAS control interface removed prior to the setup and adjustment of each water heater 31 PV500 60 07 15 CONQUEST WATER HEATER Check Supply Dual Safety co Shutoff Valve _ Pressure and Regulator Q Valve Orifice Adjustment Check Manifold Pressure Here
17. water heater must be sealed to the floor to prevent water from accumulating underneath The floor must be clean smooth and level for adequate sealing Seal the water heater to the floor using an RTV sealant such as Red Devil 0826 Saf T Lok 732 or RTV 102 or an equivalent Follow the sealant manufacturers instructions to lay a bead of sealant between the edge of the heater base and the floor The supplied covers over the four floor bolting access openings must be installed NSF Service and Maintenance NSF 5 for food service installations require the appliance and its installation to prevent harborage of vermin Tight construction of the properly installed and assembled heater enclosure does not provide a haven for pests If the floor bolting access covers do not seal completely they must be replace with direct replacement covers available from PVI FLOOR BOLT ACCESS OPENING FOUR PLACES 34 PV500 60 07 15 CONQUEST WATER HEATER 15 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Starting or Pre purge Failure Power Supply Check fuse and or circuit breaker On Off Switch Check if On Off switch is illuminated when on If not check panel fuse or incoming power Temperature Control TempTrac Check that the operating temperature control is set higher than the temperature of the water heater See Table 10 8 for indications of control or sensor faults Remote ena
18. 3 6 Service Clearances Additional clearance beyond the minimum required to combustible material should be considered to facilitate easy access for inspection and service of items such as the burner gas controls and plumbing connections Also allow sufficient space for installing and servicing building water gas vent combustion air electrical pump and other auxiliary optional equipment and connections PV500 60 07 15 CONQUEST WATER HEATER GENERAL PIPING GUIDELINES 4 1 Inlet and Outlet Connections 1 Use only non ferrous water piping and fittings Do not use galvanized pipe or fittings Use of ferrous or galvanized pipe or fittings can cause rust to form 2 Install shut off valves and unions on the inlet and outlet water piping for servicing Use caution when threading pipe nipples into tank connections to prevent cross threading or over tightening Always use a back up wrench on tank nipples when tightening unions valves etc 3 Insulate hot water and return circulation lines Insulate cold water supply lines if subject to freezing during shutdown periods IMPORTANT Do not use the plumbing connected to the appliance as a ground for welding or any other purpose 4 Pipe the drain valve to a suitable open drain IMPORTANT Cold inlet water to the Conquest should not exceed 100 F Do not connect the building return or dishwasher recirculation piping to the cold inlet water supply The Conquest utilizes cold inlet water to help extra
19. ACK ELL 1 4 23 2 FT 101923 3 16 SILICONE TUBING 24 1 5995 3 4 X 6 NIPPLE 25 6 6011 1 X 2 NIPPLE 26 1 5929 1 UNION 27 3 6163 1 28 1 6018 1 X 7 NIPPLE 29 52823 1 SHUTOFF VALVE 30 1 6013 1X 3 1 2 NIPPLE 31 2 118269 SAFETY GAS VALVE 32 1 79524 REGULATOR 35 1 6012 1 X 3 NIPPLE NOTE 0184 tt A CONNECT TUBING TO HOSE BARB ON AIR INTAKE usd ADAPTER ELANGE B CONNECT TUBING TO GAS VALVE REGULATOR HOSE 36 1 115786 SHUTTER VALVE BARB ced 10100 GAS ATTACH SCREEN TO BUSHING WTH 3 SCREWS e D TIGHTEN ELBOW TO THE ANGLE INDICATED FOR los U PROPER POSITIONING OF THE GAS TRAIN E HIGH GAS PRESSURE SWITCH IS CONNECTED HERE TO 2 a add BRASS BUSHING 1 4 X 1 8 THE UPPER PORT ON THE REGULATOR m OK ERE a F LOW GAS PRESSURE SWITCH IS CONNECTED HERE TEST PORTS MUST BE ORIENTATED AS DEPICTED REMOVE HANDLE AND INSTALL 180 FROM ORIGINAL 45 4 38607 STAR WASHER 1 4 POSITION 46 1 122828 BRASS BARB HOSE BARB 47 7 FT 111248 INSULATION DURABLANKET 38 PV500 60 07 15 CONQUEST WATER HEATER 16 2 Control Panel Enclosure Component Layout and Replacement PN s O sa 999 QO of 92 7 5 8 fee pe SS 6 a 4 O O O Q N Bl O O lo lo ce
20. ACTURER S 2 4 PIPING INSTRUCTIONS BUILDING RETURN LA A PIPE VALVE E CT BUILDING 1 4 CIRCULATOR DRAIN WITH NO SHUTOFF VALVES OR RESTRICTIONS IN THE LINE 75 OR PER LOCAL CODE REQUIREMENTS gt T amp P VALVE eu gel n EO DUPLICATE PIPING FOR T amp P DRAIN AND CONDENSATE DRAIN FOR HEATER 2 ER HEATER 2 WATER HEATER 1 DRAIN VALVE p AI d ig COLD MAKEUP CONDENSATE DRAIN LINE FLOOR DRAIN WITH NEUTRALIZER TWO WATER HEATERS WITH REVERSE RETURN PIPING 10 PV500 60 07 15 CONQUEST WATER HEATER CONDENSATE DRAIN TRAP amp DISPOSAL The Conquest water heater produces a significant amount of condensate The condensate drain is under slightly positive flue pressure so the provided 3 4 PVC condensate trap must always be used This trap is sized and designed to fill with the proper amount of condensate to create a liquid barrier to prevent flue gases escaping through the condensate drain into the installed space WARNING The trap included with this unit must be installed as described in these instructions and must be included as part of the condensate pip
21. ALIZER ATTACH TO TOP OF NEUTRALIZER SUITABLE DRAIN SS FIELD INSTALLED ROTATE TO CONTACT FLOOR NEUTRALIZER OPTION Ec cma x F mu N MJ N Z 12 PV500 60 07 15 6 1 6 2 6 3 CONQUEST WATER HEATER Condensate Trap With Optional Condensate Neutralizer Located Below Conquest CONQUEST FLUE ALL 1 2 ID HEAVY WALL HOSE EXCEPT BYPASS LINE MUST STAY BELOW THIS BYPASS LINE FOR SUITABLE DRAIN CONDENSATE NEUTRALIZER ATTACH TO TOP OF NEUTRALIZER FIELD INSTALLED FLOOR CONDENSATE HOUSEKEEPING PAD NEUTRALIZER OPTION ES CONDENSATE TRAP ROTATE TOWARDS FLOOR r Ie pues w GAS SUPPLY AND PIPING Verify the type of gas specified on rating plate is supplied to the unit This unit is orificed for operation up to 2000 feet altitude Appliance Btu h input derates 4 per 1000 feet elevation above sea level Consult Factory for installations above 2000 feet elevation Gas Train and Controls Certification NOTE The gas train and controls assembly provided on this unit have been tested under the applicable Nationally Recognized Standard to comply with safety and performance criteria such as ignition combustion and safety shutdown operation Gas Control Trains All models include the following gas control train components manual shutoff valve two safety shutoff valves zero governor type regulator manual test valve and manifol
22. EMENT PARTS 36 PV500 60 07 15 CONQUEST WATER HEATER 16 1 Burner Assemblies Burner Assembly Illustration for Model 40 Optional components may not be shown LIST OF MATERIALS QTY P N DESCRIPTION RNER ASSEMBLY COMPONENTS 119467 BLOWER FIXED SPEED 119466 BLOWER VARIABLE SPEED 3475 1 4 HEX NUT 3494 1 4 LOCK WASHER 15607 1 4 FLAT WASHER 110697 WRE HARNESS 114154 3 4 X 2 1 2 NIPPLE 122576 CAP ORIFICE 3 X 1 3 4 ID 119469 FLEXIBLE ADAPTER 118016 ELL BRASS HOSE CONNECTOR 121704 4 PVC X 12 PIPE 116929 4 TO 6 PVC BUSHING 121853 AIR INLET SCREEN 6 63 OD 76797 3 4 SS TEK SCREW 115276 BURNER 120493 BLOWER FLANGE GASKET 79972 1 4 WNG NUT 113960 IGNITER COVER 107775 HOT SURFACE IGNITER 111791 IGNITER GASKET 123822 BURNER BULKHEAD 122232 CONDUIT CONNECTOR GB NOTE CONNECT TUBING TO HOSE BARB ON AIR INTAKE ane AUI HEC CONNECT TUBING TO GAS VALVE REGULATOR AND 101923 3 16 ID SILICONE TUBING SECURE WITH CLAMP 5995 3 4 X 6 NIPPLE ATTACH SCREEN TO BUSHING WITH 3 TEK SCREWS Em 374 X 2 TIGHTEN ELBOW TO THE ANGLE INDICATED FOR 5928 3 4 UNION PROPER POSITIONING OF THE GAS TRAIN 6160 3 4 ELL 5993 3 4 X 4 NIPPLE 5336 3 4 SHUTOFF VALVE 114262 3 4 X 3 1 2 NIPPLE 109509 3 4 GAS VALVE 38607 STAR WASHER 1 4 111248 INSULATION DURABLANKET 2 2 2 2l2 2 s wl lel 2
23. Horizontal Vent Termination 1 The vent terminal must have a minimum clearance of 4 feet 1 22 m horizontally from and in no case be located above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment 2 The vent cap must terminate at least 3 feet 0 91 m above any forced air inlet within 10 feet 3 05 m 3 The vent shall terminate at least 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 0 3 m above any door window or building air inlet to the building 4 The vent system shall terminate at least 1 foot 0 3 m above grade and at least 1 foot 0 3m above possible snow accumulation levels and shall terminate at least 7 feet 2 13 m above grade when located adjacent to public walkways or gathering areas 5 To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc 6 The vent must not exit over a public walkway near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property or could be detrimental to the operation of regulators relief valves or other equipment 7 A horizontal vent must extend one foot beyond the wall 8 A horizontal vent terminal must not be installed closer than 3 feet 0 91m from an inside corner of an L shaped structure 9 A vertical vent must exhaust outside the building at least 3 feet 0 91m above the point of
24. INSTALLATION amp MAINTENANCE MANUAL CONQUEST WATER HEATER MODELS 50 60 70 80 L 130 A GCML a L x MODEL 40 L 130 A GCL p Installation and service must be performed by a qualified service installer service agency or the gas supplier IMPORTANT THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION OPERATION MAINTENANCE OF THIS EQUIPMENT READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER PROVIDED INSTRUCTIONS LABELS AND MARKINGS BEFORE INSTALLING OPERATING OR SERVICING THIS UNIT TO THE INSTALLER After installation these instructions must be given to the equipment user or left near the appliance SPECIAL INSTRUCTIONS TO THE OWNER Retain this manual for future reference These instructions contain important information that will help you in maintaining and operating this appliance E PVI INDUSTRIES LLC Fort Worth Texas 76111 Web www pvi com Phone 1 800 433 5654 PV500 60 07 15 CONQUEST WATER HEATER TABLE OF CONTENTS Safety Considerations Product Description Water Heater Installation 3 1 Checking Equipment Before You Install 3 2 Codes 3 3 Electrical Requirements 3 4 Handling and Locating the Water Heater 3 5 Clearances to Combustible Surfaces 3 6 Service Clearances General Piping Guidelines 4 1 Inlet and Outlet Connections 4 2 Building Return Piping Condensate Drain Trap amp Disposal 5 1 Condensate Neutralization System optional Gas Supp
25. MMENDED CAUSE RESULTS OF ALARM CONDITION MESSAGE ACTION Inlet temperature sensor is not connected or is Cheek winna and Sensor P1 TP1 probe failure reading incorrectly Call for heat and burner g 4 Terminals 14 amp 17 modulation output signal will revert to low fire po TP2 probe failure Temperature sensor is not connected or is Check wiring and sensor reading incorrectly Terminals 15 amp 17 Temperature sensor is not connected or is Check wirinq and safisar TP3 probe failure reading incorrectly or flue gas temperature 9 haqa tare Terminals 16 amp 17 protection is disabled HA High temperature limit setpoint Audible alarm sounds operation continues Manual reset required exceeded LA Low temperature alarm Audible alarm sounds operation continues AL1 Digital input 1 is activated Unit d e eriergized after timer delay Audible Manually reset required alarm sounds Digital input 2 is activated Unit de energized after timer delay Audible This al indication is dedi d alarm sounds Alarm contacts close for remote AL2 E Wn ON 1 i icate indication of alarm Internal alarm register will Manually reset required the Alarm On Any Failure feature o communicate an alarm condition though the this product Modbus RTU communication link AL3 Digital input 3 is activated Unit de energized after timer delay Audible alarm sounds Mn1 Maintenance alarm for output 1 Buzzer sounds operation continues Check wiri
26. PV500 60 07 15 CONQUEST WATER HEATER IMPORTANT SAFETY NOTE It takes only 5 seconds of skin contact with 140 water to cause a second degree burn You must protect against high water temperatures at all lavatories tubs showers and other points of hot water contact Accidental scalding from high water temperatures is a greater risk in some types of installations Some examples are HOMES FOR THE MENTALLY HANDICAPPED HOMES FOR THE PHYSICALLY HANDICAPPED HOSPITALS AND NURSING HOMES ELDER CARE FACILITIES AND REST HOMES ORPHANAGES AND CHILD CARE FACILITIES OTHER INSTALLATIONS WHERE RESPONSE TO CONTACT WITH HOT WATER MAY BE SLOWER OR WHERE THE DANGER OF HOT WATER CONTACT IS GREATER SS DANGER Water temperature over 125 F can cause 45 severe burns instantly death from scalds Children disabled and elderly are at highest risk of being scalded n s See instruction manual before setting temperature at water heater Feel water before bathing or showering If this appliance is used to produce water that could scald if too hot such as domestic hot water use adjust the outlet control limit or use temperature limiting valves to obtain a maximum water temperature of 120 F Thermostatically controlled mixing valves must be used in the design of the potable hot water system Potable hot water should be tempered to no more than 110 F when used for bathing or other personal uses Good engi
27. adout Probe 2 is the water temperature sensed near the middle of the water heater tank This is used to anticipate changes in the stored water temperature and ensure a consistent water supply temperature Control Buttons SET Displays and modifies the temperature set points In programming mode it selects a parameter or confirms an operation UP Displays and modifies the energy saving Night Time setback settings In programming mode it browses the parameter codes or increases a displayed value DOWN Displays the working hours of the load relays In programming mode it browses the parameter codes or decreases a displayed value CLOCK Changes lower display from the stored water temperature to current time and day EXT required Changes upper display from Probe 1 temperature to Probe 3 temperature displays the temperature difference of the stored water temperature minus Probe 2 temperature and firing rate of the burner from 0 to 10096 In programming mode it sets the 4 20mA output password is ON OFF Switches the control ON or OFF See TempTrac User Manual PV500 44 for full description 24 PV500 60 07 15 CONQUEST WATER HEATER 10 5 To View the Setpoint e Push and release the SET key to see the set point value e Toreturn to normal display press SET UP or wait 15 seconds without pressing any key 10 6 To Change The Setpoint e Push the SET key The upper display will show the St1
28. all stainless steel venting listed by ETL UL ULC or CSA for Category IV positive pressure gas appliance venting may be used instead of solid PVC or CPVC plastic pipe venting Utilisez une cat gorie IV PVC CPVC ou ETL UL ULC ou CSA acier inoxydable ou inscrits conduit d vacuation en polypropyl ne Ne s lectionnez pas la taille du tuyau de ventilation bas e uniquement sur le diam tre raccord de l appareil Follow the instructions below for installing solid PVC or CPVC pipe For other listed vent materials follow the vent manufacturer s instructions for installation sealing supporting and terminating their vent system Do not insulate plastic vent pipe The stainless steel vent connection located at the rear of the water heater is 6 5 8 O D to accept a 6 inch PVC or CPVC pipe coupling A reducer coupling may also be used to accommodate smaller or larger vent pipe See Maximum Vent Length tables Do not use a barometric damper with the Conquest positive pressure vent The Conquest water heater can be vented either vertically through a ceiling or roof or horizontally through a wall The Conquest is a Category IV positive pressure gas appliance venting and can be routed to the outdoors in any direction from the flue outlet of the water heater except down The vent must be installed and supported at least every four feet to slope downward toward the water heater vent connection with at least 74 inch drop per linear foot of horizontal ve
29. aucet opened in step b when water starts to flow o o o oo If venting through the safety valve when filling the appliance insure gags or fixtures are removed from the safety valve prior to start up Open the safety valve to allow air in the tank to escape Be sure all connections into the tank are tight as leaks at tank fittings will damage the insulation CAUTION Conduct the following gas train leakage test before start up at annual intervals and prior to investigating the cause of any reported occurrences of delayed ignition a Using an appropriate bubble detection solution thoroughly coat all gas train pipe connections If any bubbles are detected the leaking connection must be tightened recoated and rechecked to assure stoppage of the leak b Attach a manometer to measure the gas pressure at the manual gas shutoff valve located just upstream of the gas train Adjust gas train inlet pressure to the specified value e g 10 5 W C and tightly close the gas train manual shutoff valve closest to the burner c Reattach the manometer to the gas train manual shutoff valve at the burner and record the measured gas pressure in inches of water column W C Measure gas pressure again after 15 minutes If gas pressure has increased 0 5 W C or more the gas leak must be isolated to one or more of the operating gas valves For example a solenoid actuated gas shutoff valve After any leaking valve is replaced the reassembled gas train mus
30. ble disable open See Table 10 8 for indication of condition Enable water heater or place jumper between terminals R1 R2 Electronic Low Water Cut off when installed Check internal ELWCO board for indication of failure The red LED indicates a safe condition Manual reset is required Gas Pressure Switches when installed Gas pressure switches are attached to the gas train Check for a tripped condition indicated by the manual reset button on the switch Correct low gas pressure condition at the supply High Temperature Limiting Device The high limit device is set at 200 F This device is located at the control flange on the top head of the tank A high temperature condition may be caused by a failure of the TempTrac temperature sensors or the circulation pump This failure requires manual reset Combustion Air blower Check if fan control relay is closed Blower motor may have failed Fan VFD may be defective if equipped Verify proper voltage Air proving Switch if blower is functioning Check switch contacts are closed Check for 120V at the N O side of air switch Check for 120V at the common side of air switch Check if switch tubing is connected on both ends Flame Safeguard Control Check for bad ground or bad control Replace if necessary Remote Proving Interlock When terminal C1 and C2 are used a proving circuit for remote equipment failure to close th
31. c fibers which have been identified by the IARC as possibly carcinogenic to humans Avoid breathing fiber particulates and dust RISKS Air borne fibrous insulation is a possible cancer hazard by inhalation Airborne crystalline silica may cause silicosis lung disease by inhalation May cause temporary irritation to eyes skin and respiratory tract PRECAUTIONARY MEASURES Minimize airborne fibers with engineering controls Use NIOSH MSHA approved respirators as required see MSDS Wear long sleeved loose fitting clothing eye protection and gloves FIRST AID MEASURES If any of the irritations listed persists seek medical attention Eyes Flush with water Skin Wash with soap and warm water Ingestion Do not induce vomiting Get medical attention if gastrointestinal symptoms develop Inhalation Remove to fresh clean air WARNING If you are unfamiliar with the safe handling of refractory ceramic fiber products or if you wish additional information prior to beginning any disassembly of the water heater or boiler that might expose refractory ceramic fiber materials contact Unifrax Corporation 2351 Whirlpool Street Niagara Falls NY 14305 2413 1 800 322 2293 IDENTIFICATION OF REFRACTORY CERAMIC FIBER MATERIALS RCF The burner assembly utilizes RCF material The RFC materials are located within the product and not generally exposed except during service disassembly or assembly
32. cating with the outdoors or communicating to the outdoors through vertical ducts Each opening requires a minimum free area of 1 square inch per 2000 Btu hr of the total input rating of all appliances in the enclosure if communicating with the outdoors through horizontal ducts PV500 60 07 15 7 2 CONQUEST WATER HEATER e All Air From Inside The Building Follow the requirements of NFPA 54 National Fuel Gas Code ANSI Z223 1 section Indoor Combustion Air Combination Of Air From The Indoors And From The Outdoors Follow the requirements of NFPA National Fuel Gas Code ANSI Z223 1 section Combination Indoor and Outdoor Combustion Air e From Outdoors Through One Opening Follow the requirements of NFPA National Fuel Gas Code ANSI Z223 1 section One Permanent Opening Method NOTE This unit may be installed with a remote air intake system which uses a make up air duct to draw combustion air directly from outdoors WARNING Adequate clean combustion air must be provided to the appliance The appliance must never operate under a negative pressure Particular care must be taken when exhaust fans compressors air handling units etc may rob air from the appliance The combustion air supply must be completely free of any chemical or fumes which may be corrosive to the appliance Some common chemical fumes to avoid are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents su
33. ch as Freon trichloroethylene perchlorethylene chlorine etc These chemicals when in contact with the equipment or when burned form acids which quickly attack the tubes flue collector stack and other appliance and auxiliary equipment Failure to provide adequate clean combustion air or operating under negative pressure can cause premature unwarranted product failure or unsafe operation producing carbon monoxide that could escape into the building Exposure to carbon monoxide can lead to personal injury or death Maximum Allowed Remote Combustion Air Inlet Length Equivalent Length A vertical or horizontal remote air inlet system can be connected to this appliance without modification The maximum length of field supplied single wall pipe such as galvanized ventilation pipe is shown in the chart below titled Maximum Air Inlet Duct Equivalent Length Use metal tape or RTV sealant to seal each pipe joint Maximum Air Inlet Duct Equivalent Length Max Elbows Duct Size 4 Duct 6 Duct 8 Duct Max Equivalent Length Model 40 125 feet 4 200 feet 10 300 feet 10 Max Equivalent Length Model 50 80feet 3 200 feet 10 300 feet 10 Max Equivalent Length Model 60 80 N A 250 feet 10 300 feet 10 To determine the maximum straight length of duct allowed use the Duct Fitting Equivalent Length chart below to find the total equivalent length for all duct fittings in your combustion air system Then subtract thi
34. controls are serviced or replaced label all connections as they are removed to know the proper placement on the replacement part All replacement parts are available through your PVI Industries Dealer If you need assistance identifying or contacting your local dealer you may contact PVI Industries LLC directly at the address and telephone number located on the first and last page of this manual If the appliance is to be shut down for an extended period of time the primary gas valve and the water supply should be shut off When the appliance is returned to service any standing water in the tank must be flushed and a thorough inspection of all utilities and general appliance condition should be conducted 42 PV500 60 07 15 CONQUEST WATER HEATER 18 RECOMMENDED MAINTENANCE SCHEDULE 1 Annual Maintenance m 72070200970 Check all joints and pipe connections for tightness corrosion or deterioration Check the electronic ignition system for quick ignition and a proper flame signal Check all safety controls including thermostats for proper operation Check safety shut off valves for operation and tightness Test flame failure detection system Test high limit and operating temperature controls Conduct a combustion test Perform leakage test on pilot and main gas valves Test air switch in functionality 2 Semi Annually Recalibrate all indicating and recording gauges Check flame failure detection system
35. ct almost all of the heat energy from the products of combustion which lowers the vent temperature to allow the use of PVC vent pipe Higher cold inlet water temperatures will reduce heater efficiency and increase the vent temperature If the vent temperature approaches the maximum allowed a vent temperature limit switch will cycle the heater off to protect the PVC vent 4 2 Building Return Piping To maximize water heater efficiency do not connect the building return or dishwasher recirculation piping 5 gpm directly to the cold inlet Connect directly to the dedicated building return fitting located at the rear of the tank at mid tank level TEMPERED TO BUILDING A MIXING VALVE HOT OUTLET REFERTO VALVE MANUFACTURER S L 5 1 PIPING INSTRUCTIONS BUILDING PIPE T amp P VALVE TO RETURN DRAIN WITH NO SHUTOFF LA A VALVES OR RESTRICTIONS j VW V IN THE LINE OR PER LOCAL CODE REQUIREMENTS 5 gpm VALVE F o lt WATER HEATER DRAIN COLD MAKEUP VALVE 2 im O nA raei C E CONDENSATE DRAIN LINE FLOOR DRAIN WITH NEUTRALIZER SINGLE WATER PIPING PV500 60 07 15 CONQUEST WATER HEATER TEMPERED TO BUILDING
36. d pressure taps These components may be separate or combined in a common housing WARNING Do not adjust or remove any screws or bolts on gas train control components which are secured with a red or blue sealing compound In addition to voiding warranties and certification listings such adjustment or disassembly can cause improper operation which could result in property damage personal injury or death Inlet Pressure Measure at the inlet pressure tap located at the main gas cock The inlet pressure must remain within the minimum and maximum values while the unit is at rest and while the unit is operating at maximum firing rate INLET PRESSURE NAT GAS Propane Maximum Static Pressure Inches Water Column 14 0 13 0 Minimum Flow Pressure Inches Water Column 3 5 8 0 13 PV500 60 07 15 6 4 6 5 Nominal Iron CONQUEST WATER HEATER Manifold Pressure Measure at the pressure tap located downstream side of the manual valve closest to the burner The rated manifold pressure appears on the product data label located near the front of the appliance Gas Piping Size Do not use the gas pipe connection size to determine the gas supply piping Designing and sizing a gas supply piping system requires consideration of many factors and must be done by a gas supply piping expert Always follow NFPA 54 National Fuel Gas Code for gas pipe sizing and gas pipe system design The following charts provide examples of so
37. d to confirm all joints in the vent system are air and water tight After the vent is assembled close the end of the vent with a taped plastic bag or some other temporary closure With the gas supply turned off energize the Conquest combustion blower to apply air pressure to the vent system Spray each joint and vent connection with commercially available leak detection liquid to confirm no air is escaping from any point Repair any leaks and retest After testing is complete de energize the combustion blower wipe clean the leak detection liquid and REMOVE the temporary vent closure 10 The vent pipe must be sealed at the point where it passes through a wall or roof to prevent rain insects or flue products from entering the living space or interior of the building 11 For proper vent operation and to protect the gas vent from wind and weather attach a UL listed vent termination to the outdoor end of the vent or otherwise provide suitable termination to prevent wind water debris or animals from obstructing or entering the vent 12 Do not use a barometric damper with the Conquest venting system Barometric dampers are designed for use with certain Category negative pressure vent systems The Conquest uses certain Category IV positive pressure vent systems and will not operate safely with a barometric damper WARNING Use only solid PVC or CPVC pipe or use Polypropylene or stainless steel venting single or double wall listed by a nationally r
38. e outlet terminates with a straight discharge the air inlet can be located no less than 18 inches 0 46m below the exhaust terminal e f terminating through the roof the air inlet must terminate at least 12 inches 0 3 m above roof level and at least 12 inches 0 3 m above snow levels e f terminating through a sidewall the air inlet must terminate at least 12 inches 0 3 m above grade and or at least 12 inches 0 3 m above possible snow levels Vertical Remote Air Horizontal Remote Air gt MIN 12 r ABOVE HIGHEST LC SNOW LEVEL ceu HORIZONTAL REMOTE AIR REMBTE AIS 1 PROTECTIVE DEBRIS SCREEN WITH A MINIMUM MINIMUM CLEARANCE MINIMUM 1 4 TO A CLEARANCE MAXIMUM 3 4 MESH TEE 36 RECOMMENDED FOR AIR INLET AND FLUE 2 A OUTLET 2 AIR INLET TERMINATION SHOULD BE DIRECTED DOWNWARD A j DRIER VENT TYPE AIR e ABOVE HIGHEST REGISTER WITH SNOW LEVEL ADEQUATE INLET AREA OR ELBOW WITH SCREEN AS DESCRIBED IN NOTE 1 CAN USED When flue outlet is terminated with a straight discharge separation of terminations must be a minimum of 18 Combining Remote Air Ducting Each water heater MUST have separate intake piping unless the air inlet piping ex
39. ecognized testing laboratory for Category IV positive pressure gas appliance venting Use of ABS pipe or use of PVC or CPVC pipe with cell foam type construction or use of use of venting materials other than specified in these instructions can result in failure of the venting system and or exposure to carbon monoxide or other toxic fumes which can result in property damage personal injury or death WARNING Do not vent this water heater into an existing or traditional gas vent or chimney or combine the vent with any other appliance Such venting could result in failure of the venting system and or exposure to carbon monoxide which can result in property damage personal injury or death Maximum Vent Length Equivalent Length The maximum length of field supplied Category IV vent is shown in the chart below Maximum Allowable Equivalent Vent Length Max Elbows Duct Size 4 Duct 6 Duct 8 Duct Max Equivalent Length Model 40 125 feet 4 200 feet 10 300 feet 10 Max Equivalent Length Model 50 80 feet 3 200 feet 10 300 feet 10 Max Equivalent Length Model 60 80 N A 250 feet 10 300 feet 10 Pipe fittings reduce the maximum allowable vent length Use the Category IV vent manufacturer s equivalent length deduction for all elbows terminations etc If the information is not readily available from the vent manufacturer use the Vent Fitting Equivalent Length chart below to find the total equivalent length for all ve
40. ected to an existing vent system confirm it complies with all guidance and requirements for a new vent system provided in this manual Failure to confirm the existing vent system complies can result in unsafe operation and the potential for poisonous carbon monoxide to enter occupied areas and can cause property damage personal injury exposure to hazardous materials or death OPERATING AND SAFETY CONTROLS Temperature and Pressure Relief Valve s A Temperature and Pressure Relief Valve s sized in accordance with the ASME Boiler and Pressure Vessel Code Section IV HLW is installed in the tank WARNING Secure the relief valve pipe to a suitable floor drain such that very hot water does not openly splash during a significant relief valve discharge If the relief valve pipe is not routed and secured to a suitable drain hot water discharge can result in property damage scalding and personal injury or death e The drain pipe may not be smaller than the relief valve opening and must be secured to prevent it from lifting out of the drain under discharge pressure e CAUTION Do not install a reducing coupling valve or other restriction in the relief valve s discharge line discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year e Thermal Expansion A relief valve that periodically discharges may result from thermal expansion if the water heater is installed in a
41. es 4 Locate on a level surface Installation on a 4 inch to 6 inch housekeeping pad is recommended 5 Locate the water heater near a floor drain Locate the unit so if the tank or water connections should leak water damage will not occur to the adjacent area or to lower floors of the building When such locations are unavoidable install an adequately drained metal drain pan underneath the water heater The manufacturer s warranty does not cover water damage 6 Protect associated electrical components and electrical connections from water dripping spraying rain etc during appliance operation and service 7 Locate the water heater where the vent and air intake piping when installed will remain within the maximum equivalent lengths allowed See Venting PV500 60 07 15 CONQUEST WATER HEATER 8 Use the following diagram to locate anchors or attachment points when connecting the heater to the floor Typical concrete anchors 5 16 x 1 3 4 double expansion shield 3 5 Clearances To Combustible Surfaces The minimum clearance to combustible material is 15 from the top 24 from the front and zero clearance 0 from the sides and back of the water heater The Conquest can be installed directly on a combustible floor Distance minimale aux mat riaux combustibles est gale z ro 0 cm sur les c t s et l arri re avant les 61 cm 38 cm de haut et peut tre install directily sur un plancher combustible
42. g decal for electrical service requirements The appliance must be electrically supplied and grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 In Canada the electrical service must conform to local electrical codes and or CSA C22 1 Canadian Electrical Code Part 1 All wiring between the unit and field installed devices must be made with type T copper wire e Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable e To avoid serious damage DO NOT energize the unit until the system and appliance is full of water Utiliser du fil de cuivre de la taille appropri e pour le service lectrique entrant Les dommages r sultant de l utilisation de fil d aluminium seront exclus du champ d application de la garantie de cet appareil Handling and Locating the Water Heater WARNING Use industry standard safe rigging methods such as strapping around the water heater base skid assembly and using spreader bars when attempting to lift or move this product Failure to follow industry standard safe rigging methods can result in property damage serious injury or death 1 The water heater must be located indoors 2 This water heater can be installed directly on a combustible floor 3 Locate the water heater in an area that is not exposed to freezing temperatur
43. gniter until the operating thermostat ends the call for heat condition Modulation Release Once the Delay On Low Fire Hold relay has timed out the TempTrac will regulate the speed of the blower through the VFD a The TempTrac will continue to monitor the stored water temperature in the tank b When the setpoint temperature is reached the call for heat signal to the flame safeguard control is discontinued When the call for heat condition ends the gas valve will close and the burner will end operation c The VFD will ramp the blower speed down and stop after 10 seconds for modulating burners or the blower will stop for the fixed input burners d As the heated water in the tank is used the water temperature in the tank will fall below the set point The TemprTrac will sense this condition and begin the call for heat sequence again Integral Circulating Pump The circulating pump is controlled independently of the call for heat a When the main control switch is turned on and the TempTrac is energized The TempTrac will continuously monitor the water temperature in the tank and attempt to maintain a uniform water temperature within the tank by using the provided circulating pump located on the top of the tank The pump operation is indicated at the TempTrac by illumination of the M Icon The operation of the integral circulating pump may occur before during or after the call for heat period 28 PV500 60 07 15 13 13 1 13
44. h call for heat control a The Electronic Low Water Cut Off control when installed is the first devise in the safety circuit The following devices are listed in circuit order b The High Gas Pressure and Low Gas Pressure Switch both optional are energized and their safe condition is proved c High Temperature Limit is energized Call For Heat If the TempTrac operating control senses a call for heat condition and the previous safety devices are energized the following sequence will begin a The enable contacts for the VFD are energized for the modulating burner models or the blower contacts close for the fixed input burner models b The Airflow Proving Switch then proves the operation of the burner blower c The thermostat contact on the Fenwal Flame Ignition Control is energized Heat Up Following the pre purge delay the hot surface igniter will be energized a The flame control will send 120V to the hot surface igniter for 20 seconds Ignition When dwell time is completed a 4 second Trial for Ignition TFI period is initiated a The Delay On Low Fire Hold Relay and the Gas Safety Valves are energized b During TFI the flame safeguard control will monitor the flame using flame rectification through the hot surface igniter c If the flame control senses the presence of flame before the end of the TFI period the igniter will be de energized and the flame control will continue to monitor the flame through the i
45. handling Verify the total number of pieces shown on packing slips with those actually received Contact the freight carrier immediately if any damage or shortage is detected Check the data decal on the appliance Be sure the electrical water and gas supply is adequate for the installation Carefully remove all side and top shipping supports and bracing If possible do not remove the wooden base skid assembly until the product has been moved to its final location for installation and operation see Handling and Locating the Water Heater 3 2 Codes 3 3 3 4 The equipment must be installed in accordance with those installation regulations in force in the local area where the installation is to be made Authorities having jurisdiction must be consulted before installation is made In the absence of such requirements the installation shall be in accordance with the instructions in this manual appliance markings and supplemental instructions and in compliance with the latest edition of the National Fuel Gas Code ANSI Z223 1 Where required by the Canadian authority having jurisdiction the equipment must be installed in accordance with the latest edition of the Installation Code for Gas Burner Appliances and Equipment CAN CSA B149 1 and or B149 2 and applicable Provincial Regulations All appliances conform to the current edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW Electrical Requirements See appliance ratin
46. haust duct and other system considerations have been fully evaluated and a combined duct system designed by one of the duct design firms identified at www pvi com vent design html Before operation of a combined remote air ducting system all of the duct design firm s system installation and operation requirements must be in place their instructions followed and the system must be properly maintained WARNING Do not combine remote air ducting of multiple appliances into a single remote air duct unless the combined remote air ducting system has been evaluated and designed by a specified duct design firm and the combined remote air duct system is installed operated and maintained following instructions from that firm Combining remote air ducting without following these requirements can result in failure of the water heater and venting system and or exposure to carbon monoxide and can result in property damage personal injury or death 17 PV500 60 07 15 CONQUEST WATER HEATER 7 6 Optional Filter Box for Dusty or Dirty Combustion Air The field installed optional air inlet filter box must be attached to the combustion air inlet on any appliance located where it is exposed to dusty dirty or lint filled combustion air Replace the filter on a 3 to 6 month schedule or more often based on severity of contamination Inadequate combustion air or non combustible particulate matter such as dust dirt dryer lint concrete dust dry wall dust or the like ca
47. her located at the end of the condensate trap All piping from the condensate trap to the suitable drain must remain below the highest point top of the condensate outlet pipe on the properly attached condensate trap Condensate Trap Without Optional Condensate Neutralizer CONQUEST FLUE 1 2 ID HEAVY WALL HOSE OR 3 4 PVC PIPE MUST STAY BELOW THIS LINE SUITABLE DRAIN DOWNHILL TO DRAIN FIELD SUPPLIED FLOOR AND INSTALLED N CONDENSATE TRAP ROTATE TO CONTACT FLOOR 77 N V PV500 60 07 15 CONQUEST WATER HEATER 5 1 Condensate Neutralization System optional Condensate is only slightly acidic 3 5 PH however this slight acidity can be neutralized by routing it through an optional PVI Condensate Neutralization System Some authorities having jurisdiction require such neutralization before condensate disposal through a suitable drain Condensate is neutralized while slowly flowing through a container filled with renewable crushed limestone The condensate neutralizer reduces or avoids the need for separate chemical treatment or dilution using substantial quantities of tap water Contact your local PVI representative to obtain Condensate Neutralization System and follow the instructions included for assembly and connection Condensate Neutralization Systems CNS Installation Requirements 1 Follow the steps 1 through 6 in the Condensate Drain Trap amp Disposal section above 2 The Conde
48. ials that have been identified as carcinogenic or possibly carcinogenic to humans Before installing servicing or removing this product read and follow the supplied instructions WARNING Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this appliance Refer to the information contained in this manual Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or death WARNING Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the unit and to replace any part of the control system all gas controls and all other items affecting safe appliance operation and which has been under water WARNING In an emergency shut the main gas supply valve to the appliance from a location safely away from the emergency Failure to follow these instructions can cause property damage personal injury and exposure to hazardous materials or death PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA WARNING This product contains or may come to contain crystalline silica which has been identified by the International Agency for Research on Cancer IARC as carcinogenic to humans This product also contains refractory cerami
49. ing system This trap is required to keep hazardous products of combustion from continually entering the installed space where the condensate piping terminates Failure to properly install this trap can cause personal injury exposure to hazardous materials or death 1 Attach the supplied 3 4 PVC condensate trap to the mating PVC union connection on the water heater condensate drain pipe located near the flue outlet The trap must be rotated so the offset in the pipe aims down toward the floor Do not rotate the offset toward the ceiling Do not use tools to tighten the PVC union Hand tighten the PVC union to seat the internal gasket Do not combine condensate drains from multiple condensing appliances into a single drain line Route each drain line into a drain suitable for condensate and make certain the end of the drain lines are not submerged or otherwise blocked All condensate plumbing must be protected from freezing Do not locate the condensate piping such that an ice dam of frozen condensate can block condensate from leaving the outlet The condensate is only slightly acidic 3 5 PH however local codes may require it to be neutralized prior to entering the drainage system An optional field installed Condensate Neutralization System is available from the factory Connect a condensate drain line or the PVI Condensate Neutralization System to the barbed hose connection sized for 1 2 ID heavy wall Vinyl tubing rated for 170 F or hig
50. ion due to a tripped safety interlock i e air proving switch high limit switch or flame sensor etc P1 P2 Activates remote equipment and requires confirmation signal back to the appliance Provides a maximum 10 amp relay contact closure to activate a remote device i e mechanical room air louvers draft inducer or power vent etc The remote device must send return signal via proving switch to confirming proper operation to terminals 1 2 prior to the appliance being able to energize C1 C2 Used for proving operation of remote device Terminals are wired to a proving switch on a remote device such as a power venter When relay closes circuit from C1 to C2 is completed and appliance controls are enabled This appliance ships form the factory with jumper between terminals e wc 0O00 00 0Q00 VUXSRERSOBLS 27 PV500 60 07 15 12 CONQUEST WATER HEATER SEQUENCE OF OPERATION 1 Incoming 120VAC a Full time power to the Fuse b Full time power to the Main Control Switch Power On When the main control switch is turned on a 120V is applied to the step down transformer 24V b 120V is applied to the L W C O terminal L1 if used c 120V is applied to the Fenwal Flame Ignition Control d 24V is applied to the TempTrac operating temperature control terminal L1 e Full time power to the Variable Frequency Drive Safety Device Pre check Power flows through the following safety devises before reac
51. is circuit within the allotted time for Call for Heat will prevent operation and cause an alarm indication Check for proper operation and proving of remote equipment Loose Wire Connections Check connections to all components Flame Failure Power Supply Flame Safeguard Control 120 VAC is required for operation Low voltage can cause failure Voltage below 110 VAC must be investigated Check for bad ground or bad control Replace if necessary Hot Surface Igniter Check resistance at room temperature and then the amperage draw during heat up Replace if the measured amperage is not within 3 5 to 5 0 Amps or if measured resistance is not within 40 100 ohms at room temperature Also check for overheating condition due to damaged refractory around igniter Air proving Switch Check if switch is bouncing Adjust or replace Check VFD for proper speed settings Gas Pressure Check for proper inlet static and dynamic gas pressure 3 5 WC minimum Inadequate flame signal may result from improper combustion Adjust to proper CO2 levels at low fire Inability Combustion to achieve proper combustion throughout the modulation range may be caused by a defective gas valve regulator or blockage in the in the burner or combustion air supply Grounding Check for proper ground from flame control to burner housing 35 PV500 60 07 15 CONQUEST WATER HEATER 16 REPLACEMENT PARTS REPLAC
52. ly and Piping 6 1 Train and Controls Certification 6 2 Gas Control Trains 6 3 Inlet Pressure 6 4 Manifold Pressure 6 5 GasPiping Size 6 6 Appliance Isolation During Gas Supply Piping Pressure Test 6 7 Gas Connection Combustion and Ventilation Air 7 1 Equipment Located in Confined Spaces 7 2 Maximum Allowed Remote Combustion Air Inlet Length 7 3 Remote Combustion Air Cap 7 4 Vertical or Horizontal Remote Air Duct Termination 7 5 Combining Remote Air Ducting 7 6 Optional Filter Box for Dusty or Dirty Combustion Air Venting 8 1 Venting the CONQUEST 8 2 Maximum Vent Length 8 3 Vertical or Horizontal Vent Termination 8 4 Combining Category IV Vent 8 5 Concentric Vent for Combustion Air and Exhausting Flue Products 8 6 Connecting to an Existing Vent System PV500 60 07 15 10 11 12 13 14 15 16 17 18 CONQUEST WATER HEATER Operating and Safety Controls 9 1 Temperature and Pressure Relief Valve s 9 2 Cathodic Protection 93 Electronic Low Water Cut off 9 4 Operating Temperature Control 9 5 High Water Temperature Limit Control TEMPTRAC Electronic Controller Panel 10 1 Principal of Operation 10 2 Upper LED Readout 10 3 Lower LED Readout 10 4 Control Buttons 10 5 To View the Setpoint 10 6 To Change the Setpoint 10 7 To Change Other Parameters 10 8 LED Display Alarm Messages Remote Connections Terminal Strip 11 1 Making BMS BAS Remote Connection for Analog and Binary Signals
53. me of the information used by the gas supply piping expert to determine proper pipe sizes Use the values in the following table to add the equivalent straight pipe for each elbow or tee to obtain the total distance from the meter CONVERT FITTINGS TO EQUIVALENT STRAIGHT PIPE Diameter Fitting inches Equivalent Length of Straight Pipe feet Use the following table to determine the possible pipe size based on distance from gas meter for a Single Unit Installation using Schedule 40 Metallic Gas Pipe SINGLE UNIT INSTALLATION POSSIBLE SCHEDULE 40 METALLIC GAS PIPE SIZE Distance from meter in equivalent feet of schedule 40 metallic gas pipe Based on inlet pressure less than 2 psi specific gravity of 0 60 and a pressure drop of 0 5 in w c MODEL 0 10 11 25 26 50 51 100 101 200 201 300 301 500 40 1 1 1 1 4 1 1 4 1 1 2 2 2 50 1 1 1 4 1 1 4 1 1 2 2 2 2 1 2 60 1 1 1 4 1 1 2 1 1 2 2 2 2 1 2 70 1 1 4 1 1 4 1 1 2 2 2 2 1 2 2 1 2 80 1 1 4 1 1 4 1 1 2 2 2 1 2 2 1 2 3 See 54 National Fuel Gas Code for actual pipe size selection and for sizing Propane gas piping MULTIPLE UNIT INSTALLATIONS SCHEDULE 40 METALLIC GAS PIPE SIZE CHART Maximum Capacity of Pipe in Thousands of BTU s per hour for gas pressures of 14 Inches Water Column 0 5 PSIG or less and a pressure drop of 0 05 Inch Water Column Based on NAT GAS 1025BTU s per Cubic F
54. n be drawn in with combustion air and block burner ports This can cause unreliable operation and non warrantable failures When the optional field installed filter box is required do not operate the appliance without a suitable filter See the following illustration for filter and filter box kit part numbers and installation instructions FILTER BOX INSTALLATION KIT PART NUMBER 121850 Slide filter box over the air intake connector and secure the metal collar to the PVC connector with the three self drilling screws provided Remove screen from air inlet connector before installing air filter option Attach the anchor foot to the plastic jacket by drilling a 1 4 hole through the jacket behind the mounting hole in the foot Secure the foot to the jacket using the plastic push rivet provided REPLACEMENT FILTER PART NUMBER 110265 NOTE Can Use Any Standard Capacity MERV 7 Pleated Air Filter 12 X 24 X 1 PV500 60 07 15 CONQUEST WATER HEATER VENTING Venting the CONQUEST All Conquest models use the positive pressure generated by the burner system blower to push combustion products out of the vent Since the vent system is under positive pressure and must be capable of containing condensate it must be constructed of schedule 40 or 80 solid PVC or CPVC pipe Do not use PVC or CPVC pipe with cell foam type construction such as CellCore or other non solid PVC or CPVC plastic pipe Polypropylene or single or double w
55. nclosure and the respective conduit connections on the back of the control enclosure If a wiring diagram is not attached to the back of the enclosure door or otherwise provided with the water heater make careful notes of the locations for all the wires e Remove the metal cover on top of the appliance by disconnecting the fasteners holding it to the plastic jacket f Remove the hot surface igniter HSI from the burner Be very careful not to bump the igniter element due to the fragility of the igniter Break the unions that connect the gas train to the blower and the gas supply pipe Remove the gas train Remove the nuts that secure the burner top plate to the combustion chamber and lift the blower burner assembly up until it is completely extracted from water heater i Inspect top plate refractory for damage The refractory must provide a tight seal against the top edge of the burner deck j Inspect the burner surface for signs of cracking or thermal fatigue 41 PV500 60 07 15 CONQUEST WATER HEATER k If internal inspection of the burner is desired or the burner or blower must be replaced remove the nuts that attach the blower to the burner top plate to remove the blower The burner can now be extracted Be careful not to damage the refractory when removing the burner With the burner removed inspect the deck surface of the burner for lent or other blockage carried in the fuel air stream If blockage has accumulated use brush
56. neering practice mandates the use of thermostatically controlled mixing valves set at 120 F or less to keep the delivered water temperature below scalding temperatures PV500 60 07 15 2 CONQUEST WATER HEATER PRODUCT DESCRIPTION Component Controls and Connection Locations Locations May Vary CONDENSATE DRAIN BARB FITTING HOT OUTLET CONNECT FROM TOP T amp P VALVE 2 NPT ELECTRICAL ENCLOSURE VENT CONNECTION 6 O D REFER TO MANUAL FOR VENT SIZING COLD INLET BUILDING RETURN GAS CONNECTION CONNECT FROM TOP TOP ACCESS OPENING COMBUSTION AIR CONNECTION eg O D REMOVABLE FOR DOORWAY CLEARANCE 52 3 41 REMOVABLE 4 SECTION FOR 4 DOORWAY CLEARANCE T amp P VALVE OPTIONAL TIE DOWN POINTS KIT ATTACHMENT POINTS INSIDE JACKET FIELD INSTALLED EACH SIDE ELECTRICAL SERVICE CONNECTION BUILDING RETURN 1 NPT ON BACK COLD INLET DRAIN VALVE 2 NPT 1 NPT ON BACK VENT CONNECTION 10 TI 7 Ea FRONT VIEW SIDE VIEW PV500 60 07 15 3 CONQUEST WATER HEATER WATER HEATER INSTALLATION 3 4 Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading Inspect the appliance and all accompanying parts for signs of impact or mis
57. ng and sensor Mn2 Maintenance alarm for output 2 Buzzer sounds operation continues Check wiring and sensor Mn3 Maintenance alarm for output 3 Buzzer sounds operation continues Check wiring and sensor rtc 2 Energy saving function disabled Reprogram clock CONTROL MESSAGE CAUSE RESULTS OF CONTROL CONDITION NOTES If the burner does not operate KS A call for heat condition The burner operating sequence should begin check safety devices or Remote Proving Interlock On The R1 R2 terminals have been The remote enable disable has The small flame icon will flash indicating the opened by the remote master 3 been triggered standby state control The heater will remain Flashing in standby 4 Intearal circulation The integral circulation pump will operate until the Pump may operate before AW 9 pump water temperature has equalized during or after the call for heat 26 PV500 60 07 15 11 11 1 11 2 CONQUEST WATER HEATER REMOTE CONNECTIONS TERMINAL STRIP Making BMS BAS remote connections for analog and binary on off signals A terminal strip for the remote connection is located behind the bottom control panel door and is accessed removing the four thumb screws a lifting the hinged door IMPORTANT Do not use single strand bell wire for remote field connections to terminals R1 R2 and C1 C2 Use only multi strand copper wire See table below for wire length and gauge Wire Gauge 18GA 16GA 14GA 12GA
58. not select gas pipe sizes based only on the supplied tables These tables are for use by the gas piping System designer as a reference in checking pipe size selections 3 Gas pipe size may be larger than heater connection 4 Installation of a union is suggested for ease of service 5 Install a manual main gas shutoff valve on the gas supply piping connected to the appliance to isolate the burner and gas train from the main supply gas in compliance with NFPA 54 National Fuel Gas Code and most local Codes 6 The gas system installer must clearly identify the emergency shut off device A sediment trap drip leg MUST be provided in the inlet of the gas connection to the unit 8 The combination gas valves and or gas regulators incorporate either an internal vent limiter or an externally mounted vent limiting orifice and 1 4 aluminum tube located in a T attached to the regulator vent port Venting to outdoors is not required Never remove cut splice or alter the flexible tubing attached directly to the regulator vent port or to a vent limiting fitting attached externally to the regulator as this will cause unreliable ignition and can cause improper operation Although not required a connection to the open end of 1 4 aluminum tube be made and routed to the outdoors No other connection point is allowed Do not remove the aluminum tubing and connect directly to the T as damage to the required vent limiter and impro
59. nsate Neutralization System CNS must be mounted horizontally and level with the mounting strap legs on the floor 3 Locate the CNS in a convenient place between the condensate outlet and a suitable drain and where the 3 threaded end cap can be removed to recharge the Neutralizer with crushed limestone a The CNS must be located such that condensate will flow downhill from the condensate trap outlet to the inlet on one end of the CNS and downhill from the other end of the CHS to the drain If this continuous downhill flow is not maintained the trap will not properly operate and condensate could back up into the heater b Follow the instructions included in the Condensate Neutralization System for connecting the supplied 1 2 Vinyl tubing 4 Keep the Condensate Neutralization System closed at all times except for maintenance when the appliance is turned off WARNING Keep the Condensate Neutralization System closed at all times the appliance is operating The system must remain closed to prevent hazardous products combustion from continually enter the room Failure to keep the Condensate Neutralization System closed during appliance operation can cause property damage personal injury exposure to hazardous materials or death Condensate Trap With Optional Condensate Neutralizer Located On Same Level As Conquest CONQUEST ALL 1 2 ID HEAVY WALL HOSE FLUE EXCEPT BYPASS LINE MUST STAY BELOW THIS BYPASS LINE FOR CONDENSATE NEUTR
60. nt fittings in your combustion air system Then subtract this number of feet from the total equivalent length allowed in Maximum Category IV Vent Equivalent Length chart above The sum of this calculation is the maximum length of straight vent allowed If a longer length is required repeat the calculation using a larger vent size When using this chart no additional deduction is required for the addition of the vent system terminal Vent Pipe Fitting Equivalent Length for Model 40 50 xti Other PP Other Vent Pipe 4 Vent 4 Vent 6 Vent 6 Vent 90 Elbow 20 feet 18 feet 12 feet 10 feet 5 feet 90 Long Radius Elbow 12 feet 10 feet 7 feet 6 feet 3 feet 45 Elbow 12 feet 10 feet 7 feet 6 feet 3 feet PP polypropylene Other PVC CPVC or Stainless Steel Vent Pipe Fitting Equivalent Length for Model 60 80 An PP Other Vent Pipe 6 Vent 6 Vent 8 Vent 90 Elbow 22 feet 20 feet 10 feet 90 Long Radius Elbow 14 feet 12 feet 6 feet 45 Elbow 14 feet 12 feet 6 feet PP polypropylene Other PVC CPVC or Stainless Steel 20 PV500 60 07 15 8 3 8 4 CONQUEST WATER HEATER The following vent information is provided for use in design calculations if needed Venting Specifications een 399 136 0 5 500 170 0 5 600 205 0 5 700 239 0 5 800 273 0 5 Vertical or
61. nt run to allow proper drainage of accumulated condensation All penetrations through walls and roofs must be weather and gas tight such that rain and products of combustion cannot pass from outdoors back indoors Additional steps required when venting with solid PVC or CPVC pipe 1 Read and follow the information instructions and warnings in VENTING section 2 Do not insulate the plastic vent pipe 3 Design the vent pipe route so that normal expansion pipe getting longer and contraction pipe getting shorter due to on and off temperatures does not bind or put stress on cemented pipe fittings 4 A 6 inch pipe coupling must always be the first fitting attached to the Conquest vent connection when using PVC or CPVC vent system If a listed stainless steel or polypropylene Category IV vent system is used the correct adapter for attaching and sealing to the Conquest 6 5 8 inch O D vent connection must be obtained from the manufacturer of the vent system to be installed 5 For PVC or CPVC dry fit the 6 pipe coupling onto the Conquest vent connector Then remove the coupling and apply a liberal coating of room temperature vulcanizing RTV adhesive to the outside of the vent connector and to the inside of the plastic pipe coupling Before the RTV sets slide the coupling over the vent connector while rotating approximately 1 8 of a turn Inspect and apply additional RTV to the joints if needed to provide a sound air and water tight
62. oot of Gas and 0 60 Specific Gravity Length of Pipe in Straight Feet Size Inches r pee pe mm ow m om n n 1 1 2 Lm pepe pm pm m m po m m n enm pm pm vm m m m m m e n Ls epe m m n n m e e nm n 774 ee e e e n em s gt v e s s See 54 National Fuel Gas Code for actual pipe size selection and for sizing Propane gas piping PV500 60 07 15 CONQUEST WATER HEATER 6 6 Appliance Isolation During Gas Supply Piping Pressure Test 1 The appliance and its provided manual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of gt PSI 3 5 kPa 2 The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than PSI 3 5 kPa 3 The appliance and its gas connection must be leak tested before placing it in operation 6 7 Gas Connection 7 1 1 Safe operation of unit requires adequate gas supply with the required static and dynamic flow pressures Actual piping selection depends on many variables that must be carefully considered by the gas piping system designer 2 Do
63. open flames or turn electrical Switches on or off near the faucet at the time it is open Electronic Low Water Cut Off When the water level is above the electrode position in the tank the reset pushbutton will energize the control LED will be lit The control remains energized until the water level drops below the electrode position LED will not be lit Unless otherwise specified there is a three second time delay on decreasing level Water level must be below tank probe location for full three seconds before control de energizes The Electronic Low Water Cut Off is located in the top head of the water heater WARNING Turn off all electrical service to the appliance when accessing the limit or other controls located inside the control cabinet or inside the burner vestibule inside the top of the appliance Close and fasten the control cabinet and burner vestibule cover before restoring electrical service to the appliance The cabinet and burner vestibule contain High Voltage wiring and terminals If the electrical service is not turned off and these terminals are touched a dangerous shock causing property damage personal injury or death could occur Coupez l alimentation avant intervention sur l appareil Operating Temperature Control An adjustable digital operating control is located in the front control panel The control is factory pre set at approximately 120 F To adjust the setpoint to deliver the desired water temperature press and
64. osed indicated by the e icon the burner blower should come on and pre purge begins If nothing happens check for a safety device lockout Some safety devices such as the Low Water Cut off Gas Pressure Switches and the High Temperature limit will require manual reset after lockout and therefore can be easily identified When the blower motor starts the Flame Ignition Control will not be energized until positive air flow is established and the Remote Proving Interlock when used has closed If the Flame Ignition Control does not energize see the troubleshooting guide for help The Air Proving Switch can be easily identified by checking for 120V on both sides of the switch If the amber colored call for heat indicating light is not illuminated it is likely that the Remote proving interlock is open Check remote device After the pre purge the flame control energizes the HSI for the heat up period approximately 20 seconds At the end of that period the gas valve is opened for approximately 4 seconds After the burner lights and the primary safety control senses a flame the burner will remain on until the call for heat is satisfied or operation is interrupted by a safety device If the burner fails to light the flame control will recycle two more times before lockout When lockout occurs cycle the main power switch to reset the flame ignition control before the alarm on any failure occurs When the burner fails to ignite the most common cause
65. osure and buner vestibule contain High Voltage wiring and terminals If the electrical service is not turned off and these terminals are touched a dangerous shock could occur causing personal injury or death 23 PV500 60 07 15 10 10 1 10 2 10 3 10 4 CONQUEST WATER HEATER TEMPTRAC ELECTRONIC CONTROLLER PANEL Principle Of Operation The water heater operates to satisfy the setpoint of the TempTrac digital control whose sensor is located near the top of the water heater tank Demand flow will typically create a drop in temperature thus activating the water heater to add heat to the stored water This setpoint is the desired water temperature to maintain UPPER LED READOUT LOWER LED READOUT Upper LED Readout The default display of the upper readout Probe 1 is the water temperature near the hot water outlet This sensing location serves as the primary control temperature for the TempTrac This readout can display additional information by pushing the EXT button to cycle through the following items e The temperature reading from Probe 3 which is located in the flue connection and monitors the flue gas temperature e firing rate of the burner indicated by O to 100 e The temperature difference between Probe 1 and Probe 2 e All of the display information described above is available for monitoring through the optional MODBUS RTU interface Lower LED Readout The default display of the lower re
66. parameter name while the lower display will show its value e Use the UP or DOWN key to cycle through the parameter names e Push the SET key to modify a parameter value The value starts flashing in the lower display e Tochange it push the UP or DOWN keys Push the SET key again to confirm the value and pass to the setting of next set point e Repeat the operations described at points 3 4 5 e To Exit press SET UP or wait 15 seconds without pressing any key NOTE Each point has a time out of 15 seconds If any key is pushed within 15 seconds the controller exits the set points programming procedure NOTE The set value is stored even when the procedure is exited by waiting the time out to expire 10 7 To Change Other Parameters e Push the SET and DOWN arrow simultaneously for 3 seconds e Select the required parameter The name of the parameter is on the upper display its value is on the lower display e Press the SET key the value of the parameter will start blinking e Use UP or DOWN to change the value e Press SET to store the new value and move to the following parameter e To Exit Press SET UP or wait 15s without pressing a key 25 PV500 60 07 15 CONQUEST WATER HEATER 10 8 LED Display Alarm Messages Alarm messages are displayed in the upper LED readout and alternate with the default display An alarm LED ICON is also illuminated ALARM RECO
67. per gas control could result COMBUSTION AND VENTILATION AIR Provisions for adequate combustion and ventilation air to the mechanical room must be in accordance with Section Air for Combustion and Ventilation in the latest edition of the NFPA 54 National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes or applicable provisions of the local building codes Any method addressed in NFPA 54 National Fuel Gas Code section Air for Combustion and Ventilation is acceptable and several are outlined below Equipment Located In Confined Spaces Equipment located in confined spaces requires two openings one commencing within 12 30 5 cm from the top of the enclosure room and one commencing within 12 from bottom of the enclosure room to assure adequate combustion air and proper ventilation The total input of all gas utilization equipment installed in the room must be used to determine the required minimum air volume needed for combustion ventilation and dilution of flue gasses Also consider makeup air requirements from other equipment within the mechanical room or other rooms that are pressure connected with the mechanical room Some examples of other makeup air requirements are from kitchen exhaust hoods clothes dryers powered exhaust fans etc All Air From Outdoors Each opening requires a minimum free area of 1 square inch per 4000 Btu hr of the total input rating of all appliances in the enclosure if directly communi
68. s number of feet from the total equivalent length allowed in Maximum Air Inlet Duct Equivalent Length chart above The sum of this calculation is the maximum length of straight duct allowed If a longer length is required repeat the calculation using a larger duct size No additional deduction is required for the addition of the duct system terminal Duct Fitting Equivalent Length for Model 40 50 Duct Pipe 4 Duct 6 Duct 90 Elbow 18 feet 10 feet 90 Long Radius Elbow 10 feet 6 feet 45 Elbow 10 feet 6 feet Duct Fitting Equivalent Length for Model 60 80 Duct Pipe 6 Duct 8 Duct 90 Elbow 20 feet 10 feet 90 Long Radius Elbow 12 feet 6 feet 45 Elbow 12 feet 6 feet 16 PV500 60 07 15 7 3 7 4 7 5 CONQUEST WATER HEATER The following remote air duct information is provided for use in design calculations if needed Remote Air Duct Specifications Input MBtu h Required Air SCFM 399 87 500 108 600 130 700 152 800 173 Remote Combustion Air Cap A suitable remote air termination must be used to prevent water debris animals or obstructing material from entering the remote air supply Vertical or Horizontal Remote Air Duct Termination e Air inlet must be located no less than feet 0 91m below the exhaust terminal if they are within 10 feet 3 05 m of each other unless the flue outlet terminates with a straight discharge If the flu
69. seal 6 Drill a pilot hole through the PVC or CPVC coupling flange and into the center of the stainless steel vent connector flange in three equally spaced locations around the pipe Drive stainless steel sheet metal screws through the pilot holes to attach and firmly hold the plastic coupling onto the vent connector flange 7 Clean and deburr all solid PVC or CPVC pipe ends then trial assemble the entire vent system vent before joining with cement Mark the pipe and fittings to identify their locations then disassemble Reassemble the vent system using fresh PVC cement to connect PVC pipe and fresh CPVC cement to connect CPVC pipe If both solid PVC and solid CPVC pipe are used in the same vent system all joints between the two types of pipe must be made with fresh cement suitable for both materials Follow the cement manufacturer s instructions for making sound air and water tight joints 8 Vent support For PVC or CPVC the vent system must be supported at intervals no greater than four feet to prevent sagging distortion and stress on pipe fittings Vertical pipe must also be supported to avoid stress on all cemented pipe fittings and to prevent putting excessive weight on the appliance vent connection For listed stainless steel or polypropylene vent system follow the vent system manufacturer s instructions 19 PV500 60 07 15 8 2 CONQUEST WATER HEATER 9 Testing for leaks Once the vent system is installed it must be checke
70. stallation must be complete prior to performing initial startup and the startup must be complete prior to placing the water heater into service Starting the water heater without proper piping combustion air venting or electrical systems can be dangerous and may void the product warranty The following startup instructions must be followed precisely in order to achieve safe and efficient operation to assure trouble free service life Tools and Instrumentation Required e Stack Temperature Gauge e Stack Draft Gauge e Electronic Combustion Analyzer Two U tube Manometers or pressure gauges e AC DC Multi meter with 20 000 OHM Volt rating e Amp Meter e Normal Hand Tools Resources e Product Installation amp Maintenance Manuals e Start up Report with instructions e Local State amp Federal Codes e Toll Free 24 Hour Technical Support 1 800 433 5654 On Site Considerations e Electrical Supply in accordance with Nameplate Rating e Uncontaminated Combustion Air e Adequate Fuel Supply e Treated Water Supply Water heaters e Consistent Draft Startup Procedure 1 Carefully study the burner start up information included this manual 29 PV500 60 07 15 10 11 12 13 14 CONQUEST WATER HEATER Fill system tank with water a Close the drain valve Open a nearby hot water faucet to permit the air in the system to escape Fully open the cold water inlet valve to fill the tank Close the hot water f
71. system closed by components such as a backflow preventer or check valve in the cold water supply These systems must be provided with means to control expansion Contact a water heater or plumbing professional to resolve this situation WARNING Do not plug the relief valve s use discharge piping smaller than the relief valve opening or install a reducing coupling valve or other restriction in the relief valve discharge line Failure to comply with these relief valve and discharge piping requirements can prevent the relief valve from providing its intended temperature and pressure protection which can result in a sudden loss of pressure containment that can cause property damage exposure to hazardous materials personal injury or death 22 PV500 60 07 15 9 2 9 3 9 4 9 5 CONQUEST WATER HEATER Cathodic Protection PVI water heaters do not utilize cathodic protection However in hot water systems utilizing cathodic protection hydrogen gas can be produced when the hot water system has not been used 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 one of the hot water system faucets should be opened for several minutes before using any electrical device connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow Do not smoke have
72. t an inlet air filter contaminants or non combustible particulate matter such as dust dirt dryer lint concrete dust dry wall dust or the like can block burner ports and cause unsafe operation and a non warrantable failure Do not remove filter until a suitable replacement is available The air filter is available through your PVI Industries Dealer or use any standard capacity MERV 7 pleated air filter 12 x24 x1 Any sign of soot on the heat exchanger or in the flue indicates the need for a combustion inspection Properly installed and adjusted units seldom need heat exchanger cleaning If soot has formed the most common causes are restricted combustion air or excessive gas A blocked heat exchanger can cause unsafe operation and will reduce efficiency To inspect and clean the heat exchanger a qualified service agent or installer should use the procedures described in items 4 5 amp 6 below o o All gaskets on disassembled components must be replaced on reassembly with exact Factory Authorized replacement parts only Gasket kits are available from your PVI Industries Representative or by contacting PVI Industries LLC Burner and or Heat Exchanger Inspection and Cleaning Procedure a Turn off main power to unit b Turn off gas supply Write notes and or take pictures during this process to aid in correct reassembly d Disconnect electrical the components by disconnecting the wires going to terminal strip in the top control e
73. t be leak tested again before start up is attempted Open the hinged top enclosure panel cover on the appliance to expose control circuit A wiring diagram is attached to the back of this panel Visually check that all components are intact and no damage has occurred during transit Check all connections within the control cabinet A loose connection could cause intermittent shutdowns All burners will use a hot surface igniter HSI as the ignition source They may use a single gas pressure regulator and valves valve regulator combinations or multiple gas trains Connect a test meter to the ignition control to read the flame current in microamps NOTE Some flame controls read the flame signal in micro amps and some in volts DC CAUTION Be sure the tank is filled with water Dry firing can cause unwarranted damage to the appliance Check the inlet gas pressure before start up using a manometer or a 0 to 28 W C pressure gauge for inlet gas pressure This is the pressure measured before all components in the gas train This manometer must stay connected throughout the testing as the inlet pressure must be monitored during the firing of the burner Record static pressure it must not exceed 10 5 W C Pressures above this could cause damage to the diaphragm in the gas valve or pressure regulator The inlet gas pressure must not fall below 3 5 W C Connect a second manometer to the manifold test port at the shutoff valve closest to the burner
74. t be performed by a qualified service or maintenance provider To ensure proper maintenance the following instructions should be posted near the appliance and maintained in legible condition Verify proper operation after servicing WARNING When servicing the controls use exact Factory authorized replacement parts and label all wires prior to disconnection Verify proper operation after servicing Incorrect parts substitution and wiring errors can cause damage improper operation fire carbon monoxide exposure to toxic fumes or other unexpected and unsafe conditions that can result in fire personal injury or death 1 Examine the appliance and venting system at least once a year Check more often in first year to determine inspection interval a Check all joints and pipe connections for tightness corrosion or deterioration Check the electronic ignition system for quick ignition and a proper flame signal Check all safety controls including thermostats for proper operation Check safety shut off valves for operation and tightness Have the entire system including but not limited to the burner heat exchanger and venting system periodically inspected by a qualified service agency Exposure to Dusty or Dirty Combustion Air An appliance installed in a dust or dirt contaminated atmosphere will require an option air inlet filter box Replace the filter on a 3 to 6 month schedule or more often based on severity of contamination Withou
75. to loosen debris and use a vacuum or water to remove it from the burner cavities Replace any damaged components and reassemble in reverse order 4 5 ft Ibs m Cycle unit and test to verify all safety and operating controls are properly functioning and the burner top plate flange is free of leaks If equipped the combustion air filter should be replaced every six months To avoid nuisance shutdown in dirty environments check and replace filter more frequently The flue connector is connected to the flue collector shell by 8 studs and the seal between them is maintained by die cut elastomeric gasket A leak at this joint may be evidenced by condensate forming on the surrounding surfaces or pooling below the connection Any leak must be addressed immediately by replacing the gasket with the factory authorized replacement part only Inspect the integral circulation pump for gasket leaks or failure or the pump motor Rotation of the pump is indicated by the cooling fan on the back of the motor See the Troubleshooting Guide or Table 10 8 for information about operation of the pump Inspect low water cutoffs and relief valves for proper operation at every six months or more often if indicated by inspection Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Check frequently to be sure the flow of combustion and ventilation air is unobstructed to the appliance When electrical

Installation & Operation Manual (399 to 800 MBtu)

Contents

Download Pdf Manuals

Related Search

Related Contents

Installation &amp; Operation Manual (399 to 800 MBtu)

Contents

Download Pdf Manuals

Related Search

Related Contents

Installation & Operation Manual (399 to 800 MBtu)