PVI Industries QUICKDRAW PV500-26 User's Manual
Contents
1. 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 Scale will normally form in the tank during operation and will accumulate on the bottom of the tank The natural chemicals in the water forms scale which precipitate out during the heating cycles Some water supplies contain more of these chemicals than others do and the scale buildup will occur more rapidly Other factors affecting the 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 the scale forming chemicals enter into the tank As the temperature of the water increases the rate of scale deposited also increases The frequency of inspections will be determined by the rate of scale buildup Until the appropriate inspection 8 QUICKDRAW Boiler Water Heater and cleaning frequency is established initially inspect the tank every six months or more frequently if higher scaling conditions are present Flush the tank at two or three month intervals depending on water conditions in your location to help prevent the accumulation of scale To flush turn off electrical disconnect switch 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 valve2. or cold to prevent thermal shock Gradually open boiler water supply valve until all passages of the heat exchanger are filled Slowly bring the unit up to temperature 4 Do not operate unit under conditions in excess of those specified on nameplate WARNING Failure to operate the heat exchanger within the design pressure and temperature on the nameplate may result in damage to the heat exchanger and potential injury to adjacent personnel 5 Open nearby hot water tap to maintain a flow of water through the tank when starting up units Regulate flow of water through the tank to allow the control valve to cycle off and on and check operation of all safety and operating controls QUICKDRAW Boiler Water Heater 6 In all installations there should be no pulsation or water hammer since this causes vibration and strain with resulting leaks 7 Retighten bolting on all gasketed joints after the heat exchanger has reached temperature to prevent leaks and gasket failures Retightening should be done uniformly and in a diametrically staggered pattern see Maintenance a On high pressure and high temperature applications or any application where spiral wound gaskets are required it is recommended that the gasketed joints of the heat exchanger be retightened to the required torque see Maintenance after 24 hours at operating pressures and temperatures to compensate for any relaxation or creep that may have occurred b In shutt
3. Authorities having jurisdiction shall be consulted before installation is made All appliances conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW ELECTRICAL The heater is wired for 120VAC 1ph 60Hz volts and must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA When unit is installed in Canada it must conform to the CSA C22 1 Canadian Electrical Code CEC Part 1 and or local electrical codes 1 Branch circuit protection and disconnecting means must be furnished by the installer Refer to the wiring diagram provided with this unit when installing or troubleshooting the electrical components of this heater 2 All wiring must be in accordance with all local state or federal codes 3 Provide proper overload protection for the system s circulating pump Note Use only copper wire of proper sizing for incoming service The warranty on this unit does not cover damage resulting from the use of aluminum wiring QUICKDRAW Boiler Water Heater INSTALLATION WARNING Use industry standard safe rigging methods when attempting to lift or move this product Failure to follow these instructions could result in property damage serious injury or death One common method includes the use of straps and spreader bars lifting from the water heater base skid assembly 1 Check the data decal on t
4. ES 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 severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded 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 125 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 QUICKDRAW Boiler Water Heater WATER INLET OUTLET CONNECTIONS Important Do not use galvanized or steel pipe nipples when making waterside connections Use non ferrous nipples only Make inlet and outlet water connections directly to the threaded bolt on bronze tank flanges Over tightening connections to the flanges may cause damage to th
5. INSTALLATION amp MAINTENANCE MANUAL QuickDraw Storage and Semi instantaneous Boiler Water Heaters Installation and service must be performed by a qualified service installer service agency or the utility supplier IMPORTANT THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION OPERATION AND MAINTENANCE OF THIS EQUIPMENT READ AND FOLLOW ALL INSTRUCTIONS LABELS AND MARKINGS BEFORE INSTALLING OPERATING OR SERVICING THIS UNIT TABLE OF CONTENTS TOPIC PAGE a Checking Equipment Location and Electrical Installation and Clearances Typical Construction Important Safety Notice Water Inlet Outlet Connections Filling the Unit Relief Valve Piping Sequence of Operation Startup Procedure Maintenance 2 2 3 4 5 6 6 6 6 7 8 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 O VI i PVI INDUSTRIES LLC P O Box 7124 Fort Worth Texas 76111 1 800 433 5654 PV500 26 10 07 QUICKDRAW Boiler Water Heater 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 mishandling Verify the total numbe
6. al injury to adjacent personnel 10
7. and turn the electrical switch back on WARNING Since PVI cannot control the use of the water heater water conditions or maintenance the warranty on the water heater does not cover poor performance structural failure or leaking due to an excessive accumulation of scale Cleaning the Heat Exchanger refer to figure below 1 Do not open until all pressure is removed the unit is drained and the equipment surfaces cooled to ambient temperature 2 Heat exchangers subject to fouling or scaling should be cleaned periodically A light sludge or scale coating on the tube greatly reduces its effectiveness A marked increase in pressure drop and or reduction in performance usually indicate cleaning is necessary 3 Tube bundle removal a When practical leave tube bundle attached to collar assembly and remove by unbolting collar assembly from tank b During bundle removal the dead weight of bundle should never be supported on individual tubes or contact any lined interior tank surface Following removal rest the bundle on the tube sheet support plates or wood blocks cut to fit periphery of the bundle c Tube bundles may be raised using slings formed by bending light sheet metal into a U form and attaching lifting lugs to the ends of the sheets Baffles can be easily bent and damaged if dragged over rough surfaces d Before reinserting the tube bundle into the unit place the ring tank gasket over the end of the tube bundle and brin
8. e flange or tank and are not covered by warranty For ease of service install unions on inlet and outlet piping to the unit Do not use galvanized nipples to make tank connections as these will cause corrosion and rust 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 CAUTION Flush all water supply lines before connecting the unit FILLING THE UNIT 1 Fill the system with water To be sure that the unit is not 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 In hard water areas potable water treatment should be used to reduce introduction of minerals into the system Minerals in the water can collect on the tubes and heat exchanger surfaces reducing the life of the product Heat exchanger failure due to scale accumulation is not covered by the product warranty 3 Make sure there are no system leaks DO NOT use petroleum based stop leak products All system leaks must be repaired RELIEF VALVE PIPING The water heater is supplied with a pressure and temperature relief valve sized in accordance with ASME requirements Each relief valve should be piped to a suitable floor drain No reducing coupling or other restriction can be installed in the discharge line It is strongly recommended that this valve should be manually operating a
9. erating circuit opens and the valve actuator is de energized The actuator motor stops running and the actuator shaft spring returns to the retracted position causing the boiler water to divert through the bypass ports and return to the boiler water supply loop START UP 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 relief valve CAUTION Do not energize the heater until the tank is full of water Serious damage may result 2 Push control switch located on the control box to ON to activate the three way valve and thermostats Check the valve for operation the valve actuator motor should run to open the valve when operating switch is pushed on Check operating thermostat settings Temperature Setting The operating thermostat is set at the factory at approximately 120 F and the upper operating thermostat if supplied is set at approximately 125 F Adjustment may be made by turning the thermostat s dial to the desired temperature The temperature limiting device is factory set at 200 F CAUTION Gradually introduce fluids to the unit Failure to do so can cause damage to the heat exchanger 3 Push the operating switch to OFF before opening manual main boiler water supply valve Do not admit boiler water to the unit suddenly when empty
10. g forward to the backside of the tube sheet CAUTION When cleaning a tube bundle tubes should not be hammered on with any metallic tool and in case it is necessary to use scrapers care should be exercised that the scraper is not sharp enough to cut the metal of the tubes TUBE BUNDLE PARTIALLY REMOVED HEAD GASKET TANK GASKET HEAD QUICKDRAW Boiler Water Heater 4 When replacing the heat exchanger head use a torque wrench to tighten the bolts studs and nuts Use the following chart as a guide All torque values apply to well lubricated nut bearing surfaces TIGHTENING TORQUES COMPRESSED FIBER GASKETS Recommended Bolt Torque Torque Max Dia ft lbs Increment Torque 1 2 40 5 60 5 8 80 5 120 SPIRAL WOUND GASKETS Recommended Bolt Stud Torque Torque Max Dia ft lbs Increment Torque 1 2 40 5 60 5 8 80 5 120 3 4 120 5 200 7 8 200 10 320 1 300 10 490 1 1 8 450 10 710 11 4 600 10 1000 5 Tighten uniformly and in a diametrically staggered pattern as illustrated below START WARNING It is extremely important to follow a proper tightening sequence If not followed the flanges can become cocked and a leak will result When tightening flanges with spiral wound gaskets if cocking occurs the result can be deformation and non repairable damage to the gaskets in addition to a resultant leak Any gasket leak can result in potenti
11. he heater Be sure the electrical supply is adequate for the installation 2 Carefully remove all shipping supports and bracing 3 Do not attempt to move or lift heater by the plumbing connections or heat exchanger Lift only by the skid using industry standard safe rigging methods 4 Provide sufficient clearance in front of heat exchanger to facilitate maintenance and removal See Service Clearances below 5 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 6 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 7 The water heater is equipped with a temperature and pressure relief valve s rated for the input Pipe the relief valve discharge to a suitable open drain 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 Do not install valves or restrictions in the discharge line 8 Pipe the drain valve to a suitable open drain WARNING All system piping to the heat exchanger plumbing must be adequately supported Failure to do
12. ing down remove all power from the system Close all boiler water and cold water supply valves to the unit c If the unit is removed from service for an extended period of time it must be drain completely to eliminate the possibility of freezing and corrosion from stagnant water conditions MAINTENANCE WARNING To reduce the risk of electrical shock injury or death on control systems using 120 volt external power be certain switch is off and power disconnected before work is performed on this heater Temperature and Pressure Relief Valve Operate the temperature and pressure relief valve at least once a year by lifting the lever briefly If the valve does not open and close properly when testing it must be replaced with a like relief valve Thermostats and Temperature Limiting Device The temperature limiting device and 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 Remove scale if present Control Valve Actuator 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
13. r of pieces shown on packing slips with those actually received Contact the freight carrier immediately if any damage or shortage is detected 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 to printed instructions 2 Abuse alteration accident fire flood and the like 3 Sediment or lime buildup freezing or any other conditions causing inadequate circulation 4 Corrosive or contaminated atmosphere LOCATION 1 Locate the unit 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 2 Install the unit on a firm level foundation 3 Locate the foundation on a pitched floor near a suitable drain or make other provisions to prevent contact to areas of the building subject to water damage should the boiler or a water connection leak 4 The drain must be sufficient to contain water in excess of 210 F CODES The equipment shall 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 shall be carefully followed in all cases
14. so will result in excessive loads on the heat exchanger connections causing damage and or leakage and potential injury to adjacent personnel SERVICE CLEARANCES Allow sufficient space to provide adequate clearances on all sides for service and inspection Recommended clearance is 24 at the top and front 18 at left and right sides of the appliance Optional equipment may increase the clearance requirements Allow sufficient space for installing and servicing connections such as water electrical pump and other auxiliary equipment QUICKDRAW Boiler Water Heater Typical QuickDraw Instantaneous Construction 1 U tube Heat Exchanger 5 Potable Water Inlet 2 Tank Drain 6 Steam Inlet 3 Control Enclosure 7 Potable Water Outlet 4 Relief Valve AGA optional 8 Condensate Outlet Note Components controls and connection locations may vary QUICKDRAW Boiler Water Heater 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 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 HOM
15. t least once a year WARNING Make sure the safety relief valve is piped to a proper drain per instructions Scalding injury and or water damage can occur from either the manual lifting of the lever or the normal operation of the valve if it is not piped to a proper drain Insure that the safety relief valve piping is of the proper material and rating for the temperature and pressure of the system and that it is secured to prevent possible injury If the valve fails to flow water or reseat consult factory The relief valve is a primary safety device SEQUENCE OF OPERATION Refer to figure on page 7 1 When power is supplied through the unit s On Off switch if the stored water temperature is below the operating thermostat set point the limit operating circuit closes creating a call for heat demand which energizes the actuator on the three way mixing valve 2 The three way mixing valve returns circulating boiler water to the boiler supply loop through its bypass ports On a call for heat the actuator motor runs and the actuator shaft extends causing the valve to divert the boiler water through the heat exchanger before it is returned to the boiler supply loop QUICKDRAW Boiler Water Heater VALVE c COIL 4 A A BEN RETURN BYPASS STEM DOWN FLOW THROUGH COIL STEM UP FLOW THROUGH COIL BYPASS aL SUPPLY 3 When the demand is satisfied the limit op
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