Installation and Operation Manual
Contents
1. Typical EZ Plate Storage Water Heater Construction 1 Heat Exchanger Heat Engine 9 Boiler Water Inlet 2 Control Enclosure 10 Boiler Water Outlet 3 Potable Water Inlet 11 Electronic Operating Control 4 Potable Water Outlet 12 Boiler Water Control Valve optional 5 Heat Exchanger Pressure Relief Valve 13 Integral Circulation Pump 6 Tank T amp P Relief Valve 14 Steam Y strainer 7 Isolation Shutoff Valves Customer obtained from PVI or others 8 Tank Drain Valve 15 Water Y strainer NOTE Components controls and connection locations may vary 4 PV500 64 10 15 3 1 3 2 3 3 3 4 EZ Plate Storage Water Heater WATER HEATER INSTALLATION Warranty Factory warranty does not cover improper installation or operation See warranty for complete details Warranty exclusions include but are not limited to failure or malfunctions resulting from 1 Failures to properly apply install operate or maintain the appliance in accordance with printed instructions 2 Abuse alteration accident fire flood and the like 3 Sediment or lime buildup freezing or any other conductions causing inadequate circulation 4 Corrosive or contaminated atmosphere Checking Equipment Before You Install Inspect the unit completely upon receipt from the freigh2. EZ Plate Storage Water Heater 4 6 Connecting Pump s and Valves if equipped WARNING Turn off all electrical service to the appliance before accessing electrical components or terminals located inside the control cabinet junction boxes or at other points of wiring access These terminals and components may be high voltage Close and fasten the control cabinet cover junction boxes and all other points of wiring access before restoring electrical service to the appliance If the electrical service is not turned off and these components or terminals are touched a dangerous shock can occur which can result in property damage personal injury or death Coupez l alimentation avant intervention sur l appareil After turning off all power to the water heater connect and tighten the supplied 1 2 flexible conduit and wires from the Heat Engine to the bottom fitting of the control panel attached to the storage tank Then remove the wire nuts from the wires grouped near the bottom inside the control panel and use those wire nuts to attach them to the same color wires coming from the Heat Engine conduit The following schematic is representative of how to make the matching color connections but the wire colors and number connections may vary YEL RED 2 3 YEL WHT R E GRN GRN i v o b BLU Le BLU 9 d 3 T n WHT WHT GRN GR 4 7 Filling the Unit 1 Fill the system with water To be sure that the unit is not
3. which it is connected To obtain the desired performance it must be installed to operate with the temperature and flow conditions specified when selecting the appliance The boiler water piping must be sized to deliver sufficient hot water to the heat exchanger without excessive pressure drop Always use a back up wrench on tank and heat engine piping when tightening unions valves flanges etc Damage caused by plumbing mistakes such as over tightening cross threading or other installation damage is not covered by warranty Install shut off valves and unions in the boiler water and potable water inlet and outlet piping to aid in servicing Use caution when threading pipe nipples into tank and heat engine connections to prevent cross threading or over tightening Obtain and install a Y strainer with a blow down valve piped to a suitable drain in the boiler supply piping near the heat exchanger inlet If the water heater is equipped with the optional factory installed 2 way on off control valve or 3 way diverting control valve a factory installed Y strainer and blow down valve is included and the blow down valve must be piped to a suitable drain Confirm an air separator in installed the boiler supply piping to the heat exchanger If a boiler water control valve is installed maintain standard design practice to avoid deadheading When two or more heaters are piped in parallel it is important that the piping systems are balanced to assu
4. Piping 4 5 Heat Exchanger Relief Valve Piping 4 6 Connecting Pump s and Valves if equipped 4 7 Filling the Unit Operating and Safety Controls 5 1 Thermostat Settings 5 2 High Water Temperature Limit Controls 5 3 Electronic Low Water Cut Off optional Description of Operation 6 1 Sequence of Operation Start Up and Shut Down Procedure Maintenance 8 1 Temperature and Pressure Relief Valve 8 2 Thermostats and Temperature Limiting Device 8 3 Control Valve Actuator if Supplied 8 4 Tank 8 5 Heat Exchanger 8 6 Checking and Adjusting 2 Way or 3 Way Valve Operation 8 7 Recommended Maintenance Schedule Troubleshooting Notes Warranty forms ship separately with each water heater PV500 64 10 15 EZ Plate Storage Water Heater 1 SAFETY CONSIDERATIONS 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 and any other items affecting safe appliance operation and which has been under water Failure to follow these instructions can cause property damage personal injury or exposure to hazardous materials or death IMPORTANT SAFETY NOTE It takes only 5 seconds of skin contact with 140 F 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 hig
5. Strainers Cause Boiler water control valve is not fully opening Solution Check for proper operation of boiler water control valve and service if necessary Cause Heat exchanger is fouled Solution Inspect the heat exchanger for excessive scaling or fouling on the water side and clean if needed Cause Abnormal operating conditions Solution The water temperature has a significant effect on the efficiency of the heat exchanger Check if the setpoint is higher than specified Confirm the measured flow rate with meters or by volume and rate Check that there are no other loads on the heater Check if the boiler water to the heat exchanger is hot enough and that the required flow is maintained Problem 3 No hot water even at low flow a Cause Boiler water control valve not opening Solution Check that electrical coils are energized If not trace wiring problem If so the valve may be faulty or the linkage if applicable is out of adjustment Cause The domestic water circulator pump is not operating Solution Check that electrical power is being provided to the circulator pump during a call for heat If so replace the pump If not trace wiring problem Cause Malfunctioning or misadjusted thermostat s Solution Adjust thermostat to energize domestic circulator pump and boiler water control valve if supplied at the desired water temperature If the thermostat is properly adjusted and is not energizing the domestic
6. circulator pump verify wiring and replace the thermostatic control if necessary Cause The adjustable or fixed high temperature limit is open Solution Check the individual components of the system and repair or replace the failed component s as necessary 20 PV500 64 10 15 EZ Plate Storage Water Heater Problem 4 Outlet temperature is too high and above setpoint a Cause Malfunctioning or misadjusted thermostat s Solution Adjust thermostat to de energize domestic circulator pump and boiler water control valve if supplied at the desired water temperature If the thermostat is properly adjusted and is not de energizing the domestic circulator pump verify wiring and replace the thermostatic control if necessary Cause The pump is not deactivating Solution Relay in the system is malfunctioning Replace defective components as required Problem 5 Heat exchanger visibly leaking a Cause Plumbing connection loose Solution Check and tighten plumbing connection Cause Double wall heat exchanger leak Solution If one or more heat exchanger plate walls are breached a double wall heat exchanger will leak at the joint between the plates Isolate the heat exchanger and replace one more plates to resolve leak Cause Single wall heat exchanger leak Solution Once the leak is confirmed to be coming from the heat exchanger isolate the heat exchanger and replace 21 PV500 64 10 15 EZ Plate Storage Water
7. remains energized and allows the water heater to operate as long as the water level is above the electrode position in the storage tank When the water level falls below the electrode position for more than three seconds the low water cut off de energizes and turns off the pump which stops heat from being added to the storage tank DESCRIPTION OF OPERATION The EZ PLATE storage water heater can provide potable water up to 175 F using boiler water as the energy source The supplied boiler water temperature must be within the range of 125 F to a maximum of 180 F and must be at least 5 F above the potable water temperature desired from the water heater storage tank outlet The water heater storage tank and heat engine heat exchanger and associated components are assembled on separate skids then factory plumbed together in the typical side by side configuration If necessary the storage tank and heat engine can be relocated by the customer using field supplied piping A larger field supplied pump may be necessary when increasing the distance between the heat engine and the tank Sequence of Operation 1 When there is demand for hot water consumption hot water exits from the top of the storage tank and is replaced by cold water entering the bottom of the tank When enough cold water enters the storage tank to lower the stored hot water temperature below the set point entered into the programmable electronic operating control thermostat the co
8. sensor is not connected or is reading Check wiring and sensor incorrectly Terminals 15 amp 17 Temperature sensor is not connected or is reading Check wirina and sensor P3 TP3 probe failure incorrectly or flue gas temperature protection is g Terminals 16 amp 17 disabled HA High temperature limit setpoint Audible alarm sounds operation continues Press any button to reset exceeded while alarming LA Low temperature alarm Audible alarm sounds operation continues AL1 Digital input 1 is activated Unit de energized after timer delay Audible alarm Press any button to reset sounds while alarming Digital input 2 is activated Unit de energized after timer delay Audible alarm f Co sounds Alarm contacts close for remote indication AL2 This alarm indication is dedicated to of alarm Internal alarm register will communicate Press any Button toreset the Alarm On Any Failure feature of an alarm condition though the Modbus RTU while alarming this product communication link AL3 Digital input 3 is activated Unit de energized after timer delay Audible alarm Press any button to reset sounds while alarming Mn1 Maintenance alarm for output 1 Buzzer sounds operation continues Check wiring 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 rte a Ume COCK Rds lestts Energy sa
9. shutoff valves 3 Monthly Maintenance a Test low water cutoff device if equipped b Check gauges monitors and indicators c Check instrument and equipment settings 4 As Required a Tank flush and cleanout b Clean heat exchanger c Clean domestic water Y strainer near circulator pump d Blow down or clean boiler water Y strainer 19 PV500 64 10 15 EZ Plate Storage Water Heater 9 TROUBLESHOOTING NOTES Problem 1 Outlet water temperature not constant a Cause Insufficient recovery Solution Check and be sure heater design rating is not being exceeded Cause Malfunctioning or misadjusted thermostat s Solution If the thermostat or controller is always open then the outlet temperature will vary with load Measure the tank temperature near the thermostat and compare to setpoint The thermostat should turn on and off within approximately 5 F of setpoint unless user or service technician has adjusted to a larger or smaller differential Check wiring and replace if necessary Problem 2 Heater recovery is slow or outlet temperature is below setpoint a Cause The domestic water circulator pump is not operating properly Solution Check for proper operation of circulator pump Replace if necessary Cause Y Strainer in domestic water line near the recirculation pump or in the boiler water supply line to the heat exchanger is partially clogged Solution Blow down or clean boiler water and potable water Y
10. the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code and or Local Electrical Codes e Supply the electrical service specified on the water heater data decal to each water heater Separate electrical circuits are recommended for multiple appliance installations e Branch circuit protection and a disconnecting means must be furnished by the installer Refer to the provided wiring diagram when installing or troubleshooting electrical components of this appliance e All wiring between the water heater and field installed devices must be made with type T copper wire of proper size for the appliance load Damage resulting from use of aluminum wiring is not covered by the product warranty e Line voltage wire exterior to the water heater must be enclosed in approved conduit or approved metal clad cable e Protect all water heater internal and external electrical components wiring and electrical service connections from water dripping spraying rain etc at all times 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 including the use straps and spreader bars and lifting from the water heater bas
11. Heater Since PVI cannot control the use of the appliance water conditions or maintenance the warranty on the EZ Plate Water Heater does not cover poor performance structural failure or leaking due to an excessive accumulation of scale MODEL NUMBER SERIAL NUMBER INSTALLATION DATE PVI Industries LLC e 3209 Galvez Ave e Fort Worth TX 76111 e 1 800 433 5654 e www pvi com 22 PV500 64 10 15
12. INSTALLATION amp MAINTENANCE MANUAL EZ PLATE STORAGE WATER HEATER Boiler Water Energy Source a Models 600 7200 L 150 4500 A TRPF TRBP Installation and service must be performed by a qualified service installer service agency or qualified plumbing contractor IMPORTANT THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION OPERATION AND 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 EQUIPMENT 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 i Vi i PVI INDUSTRIES LLC 3209 Galvez Ave Fort Worth Texas 76111 1 800 433 5654 PV500 64 10 15 EZ Plate Storage Water Heater TABLE OF CONTENTS Safety Considerations Product Descriptions Water Heater Installation 3 1 Warranty 3 2 Checking Equipment Before You Install 3 3 Codes 3 4 Electrical Requirements 3 5 Handling and Locating the Water Heater 3 6 Service Clearances and Clearance to Combustibles General Piping Guidelines 4 1 Potable Water Inlet and Outlet Connections 4 2 Storage Tank Relief Valve Piping 4 3 Cathodic Protection 4 4 Boiler Water
13. air bound open the relief valve Leave the valve open until a steady flow of water is observed Close valve and complete filling the system 2 Make sure there are no system leaks DO NOT use petroleum based stop leak products All system leaks must be repaired 10 PV500 64 10 15 5 1 EZ Plate Storage Water Heater OPERATING AND SAFETY CONTROLS WARNING Turn off all electrical service to the appliance before accessing electrical components or terminals located inside the control cabinet junction boxes or at other points of wiring access These terminals and components may be high voltage Close and fasten the control cabinet cover junction boxes and all other points of wiring access before restoring electrical service to the appliance If the electrical service is not turned off and these components or terminals are touched a dangerous shock can occur which can result in property damage personal injury or death Coupez l alimentation avant intervention sur l appareil Thermostat Settings The TempTrac electronic controller is a digital operating thermostat located in the front control panel The thermostat is factory adjusted to a set point of 120 F and must be adjusted to serve the system design requirements Follow the safety instructions and warnings included in Section 1 Safety Considerations and elsewhere in this manual and with the product when adjusting the set point of the operating temperature control to deliver t
14. 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 Changes upper display from Probe 1 temperature to Probe 3 temperature displays the EXT temperature difference of the stored water temperature minus Probe 2 temperature and firing rate of the burner from 0 to 100 In programming mode it sets the 4 20mA output password is required ON OFF Switches the control ON or OFF See TempTrac User Manual PV500 40 TempTrac Service and Setup Manual PV500 41 and TempTrac BAS Connection and Protocol Information Manual PV 500 42 for additional TempTrac information To View the Setpoint e Push and release the SET key to see the set point value e To return to normal display press SET UP or wait 15 seconds without pressing any key To Change the Setpoint e Push the SET key The upper display will show the St1 parameter name while the lower display will show its value Use the UP or DOWN key to cycle through the parameter names Push the SET key to modify a parameter value The value starts flashing in the lower display To change it push the UP or DOWN keys Push the SET key again to confirm the value and pass to the s
15. e skid assembly when attempting to lift or move this product Failure to follow industry standard safe rigging methods can cause uncontrolled tipping or dropping the water heater resulting in property damage personal injury or death 1 Do not attempt to move or lift the water heater by the plumbing connections or heat exchanger Lift only by the skid using industry standard safe rigging methods 2 Locate the water heater in a clean and dry area as close as possible to the greatest hot water usage and as near to boiler water and or electrical power as practical 3 Confirm that the system utilities are adequate to meet the water heater requirements on the information decal 5 PV500 64 10 15 3 5 EZ Plate Storage Water Heater 4 These water heaters are suitable for indoor installation only and must not be subject to freezing 5 The water heater must be placed on a level surface Installation on a 4 inch to 6 inch housekeeping pad is recommended 6 Locate the water heater so that if water connections should leak water damage will not occur Water damage is not covered by the manufacturer s warranty 7 Locate the water heater near a suitable drain capable of accepting hot water discharge potentially in excess of 210 F from the water heater temperature and pressure relief valve 8 Floor mounting provisions and tie down anchor points are provided Pilot holes are indicated on the jacket for securing the equipment Code requirem
16. e upper cleaning port to the descaler solution e Circulate through the heat exchanger and check the effectiveness of the solution visually and pH test e Flush system after cleaning e Remove all hoses from the CIP fittings close the valves and replace the plugs e Open the tank water isolation valves located near the heat exchanger domestic water inlet and outlet Follow the section titled Start Up and Shut Down Procedure to properly bring the water heater back online If needed the double wall exchanger can be mechanically cleaned See the supplemental instructions provided by the heat exchanger manufacturer After cleaning the heat exchanger clean the Y strainer in the domestic water pipe near the circulator pump CLEAN IN PLACE CONNECTIONS Heat Exchanger Clean In Place Fittings 17 PV500 64 10 15 EZ Plate Storage Water Heater 8 6 Checking and Adjusting 2 Way or 3 Way Valve Operation if equipped 1 Check Operation a Remove indicator screw and indicator b Remove cover screws 2 Remove cover c Apply power to actuator drive motor d Notice actuator rotation valve stem direction and linkage cam direction Should drive CW and valve stem down 2 To Reverse Operation Turn off power supply Actuator should drive CCW Remove actuator mounting screws 3 Slide actuator back on mounting bracket and remove cam from actuator shaft Lift valve stem and plunger assembly to full upward positi
17. ed every six months or more frequently if higher scaling conditions become apparent Factors that may affect the rate of scale buildup are the amount of hot water used and the temperature of the water The more hot water used the more fresh water containing scale forming compounds is brought into the heat exchanger As the temperature of water increases the rate of scale deposition will increase The heat exchanger is provided with isolation shutoff valves to allow for quick isolation of the heat exchanger from the system and clean in place CIP fittings for chemical descaling without removing the heat exchanger from the plumbing system Close the isolation valves to the tank and cold water recirculation inlet With the heat exchanger properly cooled and depressurized remove the plugs from the CIP fittings The heat exchanger is cleaned by flushing with a suitable food grade acid detergent or biodegradable descaler available at most plumbing supply outlets e Isolate the heat exchanger from the hot boiler water and close the tank water isolation valves located near the heat exchanger domestic water inlet and outlet Allow the heat exchanger to cool before cleaning e Install a hose connection to the threaded cleaning ports e Prepare a 50 dilution of a commercial descaler in open container e Place a submersible utility pump into the descaler solution e Connect a hose from the pump to the lower cleaning port e Connect a second hose from th
18. ents vary by geographical location additional strapping or braces may be required Please refer to your local codes for specific requirements 9 Once the water heater storage tank and heat engine are placed in their final location carefully remove all shipping supports and bracing Service Clearances and Clearance to Combustibles Service Clearance A minimum service clearance of 18 is recommended on all sides and above the appliance to facilitate easy access for inspection and service of installed components Optional equipment may increase the clearance requirements Also allow sufficient space for installing and servicing connections such as building water electrical pump boiler water and other auxiliary optional equipment Clearance to combustibles A minimum clearance to combustible materials of 6 is required Un d gagement minimal aux mat riaux combustibles est de seize cm 16 cm est n cessaire GENERAL PIPING GUIDELINES Potable Water Inlet and Outlet Connections CAUTION To maintain tank corrosion resistance and warranty do not contact inside water side of tank nozzles or stainless steel fittings with ferrous i e iron or steel metal tools brushes etc IMPORTANT Do not use di electric nipples galvanized pipe or fittings or steel pipe or fittings when making waterside connections Use only non ferrous waterside materials 1 All domestic and boiler water pipes should be flushed before assembly and installatio
19. etting of next set point NOTE Each point has a time out of 15 seconds If any key is pushed within 15 seconds the controller exits the set Repeat the operations described at points 3 4 5 To Exit press SET UP or wait 15 seconds without pressing any key points programming procedure NOTE The set value is stored even when the procedure is exited by waiting the time out to expire 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 12 PV500 64 10 15 EZ Plate Storage Water Heater 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 RECOMMENDED CAUSE RESULTS OF ALARM CONDITION MESSAGE ACTION Inlet temperature sensor is not connected or is Gheak wing andeensar P1 TP1 probe failure reading incorrectly Call for heat and burner i 9 Terminals 14 amp 17 modulation output signal will revert to low fire po TP2 probe failure Temperature
20. f valve CAUTION To avoid pump damage do not energize the heater or circulating pump until the tank is full of water 2 Push control switch located on the control box to ON to activate the pump and thermostats Check the pump for operation the pump motor should run when operating switch is pushed ON Check operating thermostat settings The operating thermostat is set at the factory at approximately 120 F The temperature limiting device is factory set at approximately 200 F CAUTION To avoid damage to the heat exchanger gradually introduce boiler water to the heat exchanger 3 Push the operating switch to OFF before opening manual main boiler water supply valve To prevent thermal shock do not admit boiler water to the heat exchanger suddenly when it is empty or cold Gradually open boiler water supply valve until all passages of the heat exchanger are filled and slowly bring the heat exchanger up to temperature WARNING Do not operate heat exchanger under conditions in excess of those specified on nameplate and ASME data plate Failure to operate the heat exchanger within the specified design pressure and temperature can cause damage to the heat exchanger resulting in property damage personal injury or death 4 Push the operating switch to ON to energize the pump and boiler water control valve if supplied and to begin heating the water in the storage tank Allow the water temperature in the st
21. h water temperatures is a greater risk in some types of installations Some examples are HOMES FOR THE MENTALLY OR 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 Water temperature over 125 F can cause cng severe burns instantly or death from scalds CM Children disabled and elderly are at highest risk of being scalded we Ji See instruction manual before setting aa temperature at water heater s Feel water before bathing or showering qd If this appliance is used to produce water ZX bX that could scald if too hot such as domestic Sv 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 engineering practice mandates the use of thermostatically controlled mixing valves set at 120 F or less to keep the delivered water temperature below scalding temperatures 3 PV500 64 10 15 EZ Plate Storage Water Heater 2 PRODUCT DESCRIPTION
22. he desired water temperature Bon g nie impose l utilisation d une vanne de m lange thermique fix a 43 degr s Celsius ou moins pour garder l eau en dessous de la temp rature d chaudage The water heater operates to satisfy the set point of the TempTrac digital control whose sensor is located in a storage tank fitting Demand flow will typically create a drop in temperature thus activating the water heater to add heat to the stored water This set point is the desired water temperature to maintain Upper LED readout gt Lower LED readout gt Upper LED Readout The default display of the upper readout Probe 1 is the water temperature near the hot water outlet This readout can display additional information by pushing the EXT button to cycle through the following items 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 readout 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 11 PV500 64 10 15 EZ Plate Storage Water Heater SET Displays and modifies the temperature set points In programming mode it selects a parameter or confirms an operation UP Displays
23. ical disconnect switch to restore power NOTICE Since PVI cannot control the use of the appliance water conditions or maintenance the warranty on the appliance does not cover poor performance structural failure or leaking due to an excessive accumulation of scale a Ifthe unit requires shut down remove all power from the system and close all boiler water and cold water supply valves to the unit If the water heater is removed from service for an extended period of time the storage tank heat exchanger and piping must also be drained completely to reduce the risk of damage by freezing biologic growth or by corrosion from stagnant water conditions b When the appliance is returned to service conduct a thorough inspection of all utilities and general appliance condition 16 PV500 64 10 15 EZ Plate Storage Water Heater 8 5 Heat Exchanger Lime and scale deposited in the heat exchanger will result in an increase in pressure drop lower temperature difference on the domestic water side or a high exit temperature on the boiler water side Cleaning and flushing can be done without removing the heat exchanger from the system There are threaded cleaning ports near the hot water outlet and cold water inlet of the heat exchanger The frequency of cleaning descaling deliming will be determined by the rate of scale buildup Until the appropriate cleaning interval is established it is recommended that the heat exchanger be internally clean
24. ke have open flames or turn electrical switches on or off near the faucet at the time it is open 7 PV500 64 10 15 4 4 EZ Plate Storage Water Heater soca FIELD INSTALLED UNLESS SPECIFIC OPTIONS ORDERED FROM FACTORY FACTORY INSTALLED Ui ee mae HOT WATER Ri ni pg faa 1 ces ete ere tes d ao Led amp R BUILDING CIRCULATION gari 1 i ra HF L i Bene Daas cea i Wein ne E S EEE E Hi Mo me aaa H CBO gt Re ji i l 1 1 BOILER WATER IN i 7 tt HE acer ty i BOILER WATER OUT Ted rare oo trea i 44 Lo i 1 tury aae mt i a nt Ti ga ftr H il TEREC IEA HIHN i rh COLD WATER i ie i tot 1 I ou EXPANSION os V7TTT TANK FLOOR FLOOR Mest j DRAIN DRAIN Typical EZ Plate Storage Piping Arrangement Boiler Water Piping WARNING All system piping to the heat exchanger plumbing must be adequately supported Failure to provide adequate support will result in excessive loads on the heat exchanger connections that can cause hot water discharge resulting in property damage scalding and personal injury or death 1 All boiler and domestic water pipes should be flushed before assembly and installation Failure to flush lines could cause components to clog or malfunction This water heater will perform in accordance with the boiler water and domestic water temperatures and flows to
25. n Failure to flush lines could cause components to clog or malfunction 2 To avoid shipping damage some piping assemblies may be disconnected and separately secured to the shipping container Such assemblies must be reconnected Align and re connect the heat engine potable water lines to the storage tank as shown in the product description If necessary the storage tank and heat engine can be relocated by the customer using field supplied piping A larger field supplied pump may be necessary when increasing the distance between the heat engine and the tank 3 Always use a back up wrench on tank and heat engine piping when tightening unions valves flanges etc Damage caused by plumbing mistakes such as over tightening or not using a backup wrench is not covered by warranty 4 Piping and components connected to the water heater must be suitable for potable water for the water temperatures they will experience and for their application 5 Install shut off valves and unions in the potable water and boiler water inlet and outlet piping to aid in servicing Use caution when threading pipe nipples into tank and heat engine connections to prevent cross threading or over tightening 6 Thermal Expansion Tank If the water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water line provide thermal expansion control 7 Pipe the Y strainer blow down valve and the storage tank drain val
26. ntrol circuit closes creating a call for heat which energizes the circulating pump and boiler water control valve if supplied 2 When the circulating pump is energized and boiler water control valve if supplied the pump circulates domestic water from the storage tank through one side of the heat exchanger plates Boiler water flowing on the other side of the heat exchanger plate heats the domestic water before it returns to the storage tank 3 When the stored water temperature increases above the set point entered into the programmable electronic operating control thermostat the control circuit opens and the circulating pump and boiler water control valve if supplied is de energized 4 When the circulating pump is de energized the pump stops running and no more heated water flows from the heat exchanger to the storage tank 5 If for any reason the water temperature in the storage tank raises above the set point entered into the programmable electronic operating control thermostat the circulating pump and boiler water control valve if supplied will be de energized by the adjustable limit control or the fixed high limit 14 PV500 64 10 15 EZ Plate Storage Water Heater START UP AND SHUTDOWN PROCEDURE 1 When placing the unit into operation open relief valve to purge air from top of tank and begin to fill the tank with cold water Check for plumbing leaks Be sure the tank is completely filled before closing the relie
27. om stagnant water conditions 15 PV500 64 10 15 8 1 8 2 8 3 8 4 EZ Plate Storage Water Heater MAINTENANCE WARNING Turn off all electrical service to the appliance before accessing electrical components or terminals located inside the control cabinet junction boxes or at other points of wiring access These terminals and components may be high voltage Close and fasten the control cabinet cover junction boxes and all other points of wiring access before restoring electrical service to the appliance If the electrical service is not turned off and these components or terminals are touched a dangerous shock can occur which can result in property damage personal injury or death Coupez l alimentation avant intervention sur l appareil Temperature and Pressure Relief Valve Manually test operate the temperature and pressure relief valve s T amp P on the storage tank and the pressure relief valve PRV on the heat exchanger at least once a year by briefly lifting the relief valve lever If a relief valve does not open and close properly when test operated it must be replaced with a new relief valve of the same type rating and relieving capacity as the original equipment relief valve it is replacing See the sections titled Storage Tank Relief Valve Piping and Heat Exchanger Relief Valve Piping for important instructions and warnings Thermostats and Temperature Limiting Device The temperature limiting device and
28. omplete drainage of the valve and line and it must be positioned in the floor drain such that water or steam forcefully exiting the drain line does not openly splash The water heater must not be operated without a correctly installed properly sized and properly operating relief valve If a replacement relief valve is required it must be of the same type pressure rating and relieving capacity as the original relief valve supplied with the water heater Do not plug or restrict the relief valve or the relief valve drain line It is strongly recommended that the relief valve s should be manually operated at least once a year If water does not freely flow from the manually operated relief valve or if it does no fully reseat when released the relief valve must be replaced with a new relief valve with the same ratings WARNING Do not install a reducing coupling valve or other restriction between the relief valve discharge and a suitable floor drain Such restriction could prevent the valve from fully relieving if the pressure settings are exceeded which could result in property damage personal injury or death WARNING Secure the relief valve piping 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 9 PV500 64 10 15
29. on Install the cam onto the actuator shaft with the cam lobe facing up Reposition actuator and install the mounting screws Apply power to actuator Should drive CW rotation and stem down 53 Qo gt ODO A290 70 Install cover and screws Install indicator with screw pointing toward open 3 Adjust Valve Stem a Loosen stem locknut b Screw valve stem into stem extension until valve has contacted at top of valve stroke c Screw valve stem into extension and additional 1 turns d Cycle heater with thermostats to confirm proper operation Actuator Nylon Bushing A Plunger Assembly Front Cover Plunger Cam Indicator k Sy Indicator Screw oO a Cover Screws 2 ae Stem Locknut Packing AN Mounting Nut AX Not included in AV Kits A Valve Body Used with 1 2 through 2 valve bodies VB 730CX Shown Typical Components for Valve Installation of Optional Actuator 18 PV500 64 10 15 EZ Plate Storage Water Heater 8 7 Recommended Maintenance Schedule 1 Annual Maintenance a Check all joints pipe connections and the heat exchanger for tightness corrosion or deterioration b Check all pumps valves controls and devices including thermostats for proper operation c Check relief valves for proper operation d Test high limit and operating temperature controls 2 Semi Annually a Recalibrate all indicating and recording gauges b Check piping and wiring of all interlocks and
30. orage tank to rise above the set point entered into the programmable electronic operating control thermostat and to de energize the circulating pump and boiler water control valve if supplied Then open a nearby hot water tap s to consume hot water from the tank with is replaced with cold makeup water lowering the stored water temperature Confirm the pump cycles on when the stored water temperature drops enough to cause the programmable electronic operating thermostat to re energize the circulating pump Close the hot water tap s and again allow the stored water temperature to rise and the pump turn off Repeat as necessary and check operation of all safety and operating controls Confirm there is no pulsation or water hammer since this can cause vibration and strain which can result in damage or leaks Contact a water heater or plumbing professional to resolve this situation Follow the supplemental instructions provided by the heat exchanger manufacturer to retighten the gasket joints after the heat exchanger has reached temperature to prevent leaks and gasket failures To shut the water heater down remove all power from the system and close all boiler water and cold water supply valves to the unit If the water heater is removed from service for an extended period of time the storage tank heat exchanger and piping must also be drained completely to reduce the risk of damage by freezing biologic growth or by corrosion fr
31. pressure relief valve s sized in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section IV The relief valve s must be threaded directly into the dedicated relief valve fitting s located near the top of the storage tank and each relief valve discharge must be separately plumbed to an appropriate floor drain The discharge line must not be smaller than the relief valve opening must allow complete drainage of the valve and line and it must be positioned in the floor drain such that water or steam forcefully exiting the drain line does not openly splash The water heater must not be operated without a correctly installed properly sized and properly operating relief valve If a replacement relief valve is required it must be of the same type temperature and pressure rating and relieving capacity as the original relief valve supplied with the water heater Do not plug or restrict the relief valve or the relief valve drain line It is strongly recommended that the relief valve s should be manually operated at least once a year If water does not freely flow from the manually operated relief valve or if it does not fully reseat when released the relief valve must be replaced with a new relief valve meeting the same ratings WARNING Do not install a reducing coupling valve or other restriction between the relief valve discharge and a suitable floor drain Such restriction could prevent the valve from fully relieving if the pressure
32. re the full combined capacity is realized Reverse return piping is recommended for multiple unit installations 8 PV500 64 10 15 4 5 EZ Plate Storage Water Heater 9 Do not use the water heater or attached piping as an electrical ground of any kind 10 After plumbing confirm all connections components and fittings are leak free 11 After checking for leaks the heat exchanger and all boiler water and hot potable water piping must be insulated to the minimum pipe insulation thickness specified in ASHRAE 90 1 Energy Standard for Buildings Except Low Rise Residential buildings WARNING Insulate or guard all surfaces containing hot water Uninsulated or unguarded surfaces containing hot water can be hot enough to cause severe burns instantly if contacted Failure to insulate or guard all surfaces containing hot water can result in property damage personal injury or death Isoler ou prot ger toutes les surfaces contenant de l eau chaude Heat Exchanger Pressure Relief Valve Piping The EZ Plate heat exchanger is supplied with a pressure relief valve sized in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section VIII The relief valve must be threaded directly into the dedicated relief valve fitting located near the top of the heat exchanger and each relief valve discharge must be separately plumbed to an appropriate floor drain The discharge line must not be smaller than the relief valve opening must allow c
33. settings are exceeded which could result in property damage personal injury or death WARNING Secure the relief valve piping 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 IMPORTANT Thermal Expansion A relief valve that periodically discharges may result from thermal expansion If the water heater is installed in a system closed by components such as a backflow preventer or check valve in the cold water supply the system must be provided with means to control expansion Contact a water heater or plumbing professional to resolve this situation 4 3 Cathodic Protection PVI water heaters do not utilize cathodic protection However in hot water systems containing other water heaters that utilize 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 is frequently an unusual sound such as air escaping through the pipe as the hot water begins to flow Do not smo
34. t carrier before signing the bill of lading Inspect the appliance and all accompanying parts for signs of impact or mishandling 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 Codes The equipment must be installed in accordance with the instructions in this manual appliance markings and supplemental instructions and in compliance with those installation regulations in force in the local area where the installation is to be made These must be carefully followed in all cases Authorities having jurisdiction must be consulted before installation is made In the absence of such regulations the installation must be in accordance with the instructions in this manual appliance markings supplemental instructions and in compliance with the latest edition of the applicable state and local mechanical and plumbing codes The storage tank conforms to the current edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW and the plate heat exchanger conforms to the current edition of the ASME Boiler and Pressure Vessel Code Section VIII Electrical Requirements This appliance is wired for 120VAC 1ph 60Hz service as standard check decal on product The appliance must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of
35. thermostat temperature sensors extend into the water in the tank Depending on the water conditions in your area scale may coat the sensors This coating will affect accuracy of sensors and can allow water temperature to exceed the desired limits Remove and inspect these controls at necessary intervals and remove scale if present Control Valve Actuator if supplied The boiler water control valve actuator is sealed and requires no maintenance Durability of valve stems and packing is dependent upon maintaining non damaging water conditions Inadequate water treatment or filtration can result in corrosion scale and abrasive particle formation Scale and particulates can result in stem and packing scratches and can adversely affect packing life and other parts of the hydronic system Contact the manufacturer for replacement packing and stem amp plug assembly Tank Depending on water quality and operating temperature scale can form during operation and will accumulate on the bottom of the tank Inspect the tank every six months or more frequently if higher scaling conditions are present To help prevent the accumulation of scale flush the tank at the appropriate interval based on water conditions in your location To flush turn off the electrical disconnect switch to remove power and to prevent the unit from operating Open the drain valve and allow water to flow through the tank until it runs clear Close the drain valve and turn on the electr
36. ve to a suitable open drain capable of accepting hot water at the temperature discharged when opening the water heater drain valves 6 PV500 64 10 15 4 2 EZ Plate Storage Water Heater 8 When two or more water heaters are piped in parallel it is important that the piping systems are balanced to assure the full combined capacity is realized Reverse return piping is recommended for multiple unit installations 9 Do not use the water heater or attached piping as an electrical ground of any kind 10 After plumbing confirm all connections components and fittings are leak free 11 After checking for leaks the heat exchanger and all boiler water and hot potable water piping must be insulated to the minimum pipe insulation thickness specified in ASHRAE 90 1 Energy Standard for Buildings Except Low Rise Residential buildings Insulate or otherwise protect cold water supply lines if subject to freezing during operation or shutdown periods WARNING Insulate or guard all surfaces containing hot water Uninsulated or unguarded surfaces containing hot water can be hot enough to cause severe burns instantly if contacted Failure to insulate or guard all surfaces containing hot water can result in property damage personal injury or death Isoler ou prot ger toutes les surfaces contenant de l eau chaude Storage Tank Temperature and Pressure Relief Valve Piping The EZ Plate water heater storage tank is supplied with temperature and
37. ving function disabled Reprogram clock CONTROL CAUSE RESULTS OF CONTROL CONDITION NOTES MESSAGE If the burner does not operate eS A call for heat condition The burner operating sequence should begin check safety devices or Remote Proving Interlock On The R1 R2 terminals have q 5 The remote enable disable has The small flame icon will flash indicating the been opened by the remote been triggered standby state master control The heater will Flashing remain in standby 1237 intedraliciretlation pum 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 13 PV500 64 10 15 5 2 5 3 6 1 EZ Plate Storage Water Heater High Water Temperature Limit Control The appliance is equipped with an adjustable temperature limit control and a non adjustable high temperature limit control These controls are located inside the control cabinet and are accessed by removing the bottom cover The adjustable limit control is an auto reset type and should be adjusted at least 10 degrees above the set point of the Operating Thermostat The high limit is an auto reset type with a fixed set point but is optionally available as a manual reset type If the high limit is a manual reset type it cannot be reset until the water temperature has dropped below its reset point Electronic Low Water Cut Off Optional The optional low water cut off
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