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PVI Industries 180 User's Manual

1. INDICATING LIGHTS ALARM SILENCING SWITCH WHEN USED Ss QQQ Q Q PV500 46U 06 12 16 2 Control Panel Components Optional components may not be included Pa jemmememmweweme 0 Ls o ense memes eurem s rome owners ees Contact factory for more information 36 PV500 46U 06 12 16 3 Burner Assembly ADJUST SETPOINT 7 TURNS FROM TOP OJO OG APPLY INSULATION DISC 1600 X 110 TO BURNER FACE 5 SHOWN USING WATER GLASS GLUE 09 QQ GC 64 s s 6969 9 B SET DISTANCE io INSTALL O RING BETWEEN FLANGE AND VALVE BODY Optional components may or may not be shown 37 PV500 46U 06 12 16 4 Burner Assembly Components Optional components may not be included Item No Qty PVI Part No Description BURNER ASSEMBLY COMPONENTS 1 117188 B amp C 2000 MBTU MXIF PVIF 2 1 117189 ASSY BURNER PVIF 2000M 3 1 113752 ASSY BURNER TOP PLATE RETURN TUBE 17 4 1 117190 ASSY FILTER BOX 12 x 24 PVIF 5 1 117191 GAS AIR FILTER TUBE 6 1 117192 ASSY BLOWER HOUSING 14 2000M PVIF 7 1 117193 HOUSING BLOWER FB14 PVIF 8 1 1171
2. 8 5 Remote Air Consideration for Combined Remote Air Ducting Each water heater MUST have separate intake piping Consult factory for common air intake pipe sizing PV500 46U 06 12 9 1 9 2 9 3 VENTING Venting the Power VT Plus SANI models Power VT Plus models with SANI in the model number are designed for operation only with stainless steel venting listed by UL ULC ETL or CSA for Category IV positive pressure gas appliance venting Installation requires a field supplied stainless steel adapter from the 6 5 8 female economizer outlet to the specific size six inch minimum and model vent used Follow the vent manufacturer s instructions for installation sealing supporting and terminating their vent system Do not use plastic venting of any type on models with SANI in the model number Do not use a barometric damper with the Power VT Plus positive pressure vent WARNING On Power VT Plus models with SANI in the model number use only stainless steel venting listed by a nationally recognized testing laboratory for Category IV positive pressure gas appliance venting Use of plastic pipe of any type or use of venting materials other than specified in these instructions can result in failure of the venting system and or exposure to carbon monoxide which can result in property damage personal injury or death Venting the Power VT Plus The Power VT Plus except models with SANI in the model number see
3. L l BOTTOM OF ECONOMIZER 3 SUITABLE HEATER CONDENSATE DRAIN ROTATE FITTINGS AS PIPING MAY BE LOWER FROM THIS POINT REQUIRED TO REST ON FLOOR IF HEATER S ON HOUSEKEEPING PAD Condensate Piping and Trap with Optional Condensate Neutralizer 6 1 Condensate Neutralization System optional Although only slightly acidic 3 5 PH condensate can be routed through an optional Condensate Neutralization System see image below to become pH neutral allowing for disposal into any drain or sewer system without concern for corrosion Condensate slowly flows through a neutralization bath filled with renewable crushed limestone becoming neutralized thus avoiding chemical treatment or dilution using substantial quantities of tap water To obtain a Condensate Neutralization System please contact your local PVI representative 1 Follow the steps 1 through 4 in the Condensate Drain Trap amp Disposal section above 2 Locate the Condensate Neutralization System in the condensate piping as shown in the FIELD INSTALLED CONDENSATE DIAGRAM above 3 Position with removable crushed limestone fill cap in vertical position only The bottom of the condensate neutralization system outlet pipe must not be higher than the bottom of the water heater 4 For proper operation the water heater condensate o
4. Combining Category IV Vents Combined Power VT Plus Category IV gas vent systems must incorporate an Exhausto or Tjernlund 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 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 loss of life 20 PV500 46U 06 12 10 10 1 10 2 Conventional Venting Through the Wall Venting Combining Vents with a Draft Inducer HORIZONTAL SON 5 F COMMON FLUE REMOTE AIR SN 12 FROM HIGHEST OW LEVEL OPERATING AND SAFETY CONTROLS WARNING Turn off all electrical service to the appliance when accessing the limit or other controls located inside the control cabinet This cabinet contains High Voltage wiring and terminals If the electrical service is not
5. 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 PV500 46U 06 12 2 2 2 3 2 4 2 5 2 6 2 7 STANDARD FEATURES AND EQUIPMENT Performance 95 thermal efficiency at full fire from 40 to 140 F Up to 99 thermal efficiency with modulation lt 20 ppm NOx Ducts direct combustion air up to 100 equivalent feet through 6 inch diameter material requires UL approved vent cap see optional equipment list Vents up to 100 equivalent feet through 6 inch diameter material Pressure Vessel AquaPLEX tank unlined duplex alloy Storage tank ASME stamped and National Board registered for 150 psi MAWP Nonferrous removable fittings at all tank connections Hand hole cleanout Fiberglass insulation Steel jacket panels with industrial grade finish Drain valve Heat Exchanger Three pass fire tube design AquaPLEX fire tubes Secondary economizer for low temperature flue gas Codes And Standards Intertek ETL listed to US and Canadian safety standards Intertek ETL listed for use with CPVC vent material SANI models require listed Cat IV SS vent ntertek ETL certified as low lead compliant FM compliant ASHRAE 9
6. 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 open flames or turn electrical switches on or off near the faucet at the time it is open Electronic Low Water Cut Off Optional 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 recedes 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 22 PV500 46U 06 12 11 11 1 11 2 11 3 11 4 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 wil
7. provided appliance manual shutoff gas valve when Codes require The gas system installer should 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 The code compliant vent limiters are designed and must respond to pressure changes in the installation environment as opposed to outdoor pressure For proper operation do not connect to outdoor atmosphere PV500 46U 06 12 8 1 8 2 COMBUSTION AND VENTILATION AIR Provisions for adequate combustion and ventilation air to the mechanical room must be in accordance with Section 5 3 Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes or applicable provisions of the local building codes Equipment Located In Confined Spaces Equipment located in confined spaces requires two openings installed within 12 30 5 cm from the top and bottom of the 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 e All Air From Outdoors Each opening requires a minimum free area of 1 square inch per 4000 Btu hr input if directly communicating with the outdoors or communicating to the outdoors through vertical ducts Each opening requ
8. 6 Clearances to Combustible Surfaces General Piping Guidelines 5 1 Inlet and Outlet Connections 52 Building Return Piping Condensate Drain Trap amp Disposal 6 1 Condensate Neutralization System optional Gas Supply and Piping 7 1 Gas Train and Controls Certification 7 2 Gas Control Trains 7 3 Inlet Pressure 7 44 Manifold Pressure 7 5 Gas Piping Size 7 6 X Appliance Isolation during Gas Supply Piping Pressure Test 7 7 Gas Connection Combustion and Ventilation Air 81 Equipment Located in Confined Spaces 8 2 Maximum Allowed Remote Combustion Air Inlet Length 8 3 Remote Combustion Air Cap 8 4 Vertical or Horizontal Remote Air Duct Termination 8 5 Remote Air Consideration for Combined Remote Air Ducting Venting 9 1 Venting the Power VT Plus SANI Model 9 2 Venting the Power VT Plus 9 3 Maximum Category IV Vent Length 94 CPVC Vent System Design Construction and Assembly 9 5 Vertical or Horizontal Vent Termination 9 6 Combining Category IV Vents PV500 46U 06 12 10 11 12 13 14 15 16 17 18 Operating and Safety Controls 10 1 Temperature and Pressure Relief Valve s 10 2 Operating Temperature Control 10 3 High Water Temperature Limit Control 10 4 Cathodic Protection 10 5 Electronic Low Water Cut off optional TEMPTRAC Electronic Controller Panel 11 1 Principal of Operation 11 2 Upper LED Readout 11 3 Lower LED Readout 11 4 Control Buttons 11 5 To View the Setpoint 11 6 To Chan
9. OUTLET 68 INLET CONNECTION 1 22 NPT BUILDING RETURN CONNECTION 2 NPT 40 ABOVE FLOOR DRAIN VALVE 1 NPT RELIEF VALVE SUPPLY OUTLET CONNECTION 92 74 CONTROL BOX ELECTRICAL CONNECTION COMBUSTION AIR BAS CONNECTION INLET sb 0 LI 1 6 Z SUPPLY OUTLET CONNECTION 2 NPT COMBUSTION AIR INLET AIR FILTER ACCESS DOOR BOTTOM GAS CONNECTION td NPT 59 HANDHOLE CLEANOUT FLUE OUTLET INLET Es CONNECTION CONNECTION BACK OF HEATER 4 3 X 64 SKIDS a PV500 46U 06 12 300 SERIES FLUE OUTLET CONNECTION CONDENSATE OUTLET OUTLET e O D 3 FEMALE CPVC INLET CONNECTION BUILDING RETURN CONNECTION 2 NPT 940 ABOVE FLOOR DRAIN VALVE 1 NPT RELIEF VALVE SUPPLY OUTLET CONNECTION 92 74 CONTROL BOX ELECTRICAL CONNECTION COMBUSTION AIR BAS CONNECTION INLET L J oH 6 SUPPLY OUTLET CONNECTION 2 NPT COMBUSTIONAIR INLET AIR FILTER ACCESS DOOR BOTTOM GAS CONNECTION 1 15 NPT HANDHOLE 50 CLEANOUT INLET CONNECTION FLUE OUTLET CONNECTION BACK OF HEATER 3 X 64 SKIDS PV500 46U 06 12 4 1 4 2 4 3 4 4 WATER HEATER INSTALLATION Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the
10. a thorough inspection of all utilities and general appliance condition should be conducted FILTER REPLACEMENT ILLUSTRATION REMOVE FILTER BOX ACCESS COVER TO REPLACE FILTER NOMINAL FILTER SIZE 12 X 24 PLEATED 41 PV500 46U 06 12 18 RECOMMENDED MAINTENANCE SCHEDULE 1 Annual Maintenance o eo o 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 Semi Annually oo gt o 296 Recalibrate all indicating and recording gauges Check flame failure detection system components Check firing rate control Check piping and wiring of all interlocks and shutoff valves Inspect burner components Check igniter Test high and low gas pressure interlocks Check air filter and replace if required Monthly Maintenance 0 Test low water cutoff device and alarm if equipped 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
11. above is designed for operation with a positive pressure vent system constructed of locally obtained 6 or larger schedule 40 or 80 solid CPVC pipe Do not use CPVC pipe with cell foam type construction such as CellCore or other non solid CPVC plastic pipe Larger solid CPVC pipe may be substituted however a solid CPVC increaser from 6 to the larger size must be used for connection to the stainless steel 6 5 8 female flue outlet from the water heater economizer Do not insulate the plastic vent pipe Stainless steel venting listed by UL ULC ETL or CSA for Category IV positive pressure gas appliance venting may be used instead of CPVC plastic pipe venting If such stainless steel venting is used follow the vent manufacturer s instructions for installation sealing supporting and terminating their vent system Do not use a barometric damper with the Power VT Plus positive pressure vent WARNING On Power VT Plus except models with SANI in the model number see above use only solid CPVC pipe or stainless steel venting listed by a nationally recognized testing laboratory for Category IV positive pressure gas appliance venting Use of ABS pipe CPVC pipe pipe with cell foam type construction plastic vent pipe other than solid CPVC or use of venting materials other than specified in these instructions can result in failure of the venting system and or exposure to carbon monoxide which can result in property damage personal injury
12. 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 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 latest edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW Electrical Requirements See appliance rating 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 el
13. feet 11 feet 90 Long Radius Elbow 5 feet 5 feet 5 feet 6 feet 45 Elbow 5 feet 5 feet 5 feet 5 feet The following remote air duct information is provided for use in design calculations if needed Remote Air Duct Specifications Required Max Duct Loss Air SCFM inches Water 1500 325 0 784 1800 390 1 11 2000 433 1 356 8 3 Remote Combustion Air Cap A UL Listed air intake vent termination cap MUST be attached to the remote combustion air vent termination to adequately protect the combustion air inlet from wind and weather A UL Listed air intake termination cap is available from PVI Industries and may have shipped with the water heater as a purchased option 8 44 Vertical or Horizontal Remote Air Duct Termination Air inlet and exhaust vents should terminate in the same wind pressure area whenever possible 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 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 fterminating 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 normal snow levels Horizontal Remote Air Vertical Remote Air HORIZONTAL EMOTE Al ms
14. is set higher than the temperature of the water heater Flame Safeguard Control Check for bad ground or bad control Replace if necessary Remote enable disable open Enable water heater or place jumper between terminals R1 R2 Combustion Air blower Air proving Switch Check if fan connection terminals on flame control is closed Check for 24V at field access terminal C2 Remote interlock may be open Fan VFD may be defective Verify proper voltage Check switch contacts are closed Check for 24V at the N O side of air switch Check for 24V at the common side of air switch Check for proper blower pressure setting adjust if required Air switch may be defective Blocked Filter Switch Flame Control Pressure Switch Check for 24V at the N C side of the blocked filter switch Replace filter or switch as required Check for 24V at the pressure switch terminal Loose Wire Connections Check connections to all components Flame Failure Power Supply Check fuse and or circuit breaker Check voltage at 120 24V step down transformer Flame Safeguard Control Check for bad ground or bad control Replace if necessary Hot Surface Igniter Check amp draw during heat up Replace if amps greater than 3 1A Check for overheating condition due to damaged refractory around igniter Air proving Switch Check if switch is bouncing Adjust or replace Gas Pres
15. 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 Category IV Vent Length Equivalent Length A vertical or horizontal remote Category IV vent system must be used with this appliance The maximum length of field supplied Category IV vent is shown in the chart below titled Category IV Vent Equivalent Length Maximum Category IV Vent Equivalent Length Vent Size 6 Vent 7 Vent 8 Vent 9 Vent Max Equivalent Length 100 feet 130 feet 250 feet 450 feet 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 vent 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 require
16. temperature is reached the call for heat signal to the flame safeguard control is discontinued c The flame safeguard control deenergizes the VFD blower system and the gas valve thereby suspending burner operation d As heat is transferred to the building the water heater loop temperature will fall below the set point The TemprTrac will sense this condition and begin the call for heat sequence again 9 Flame Safeguard LED Diagnostic Indicator If the Fenwal Flame Safeguard Control at any time during the operating sequence senses an improper operating state and locks out the diagnostic red LED located on the control board will flash to indicate one of the following conditions exist LED INDICATION FAULT MODE On Normal Operation OFF Internal Control Failure check power 1 Flash Airflow Fault 2 Flashes Erroneous Flame Signal 3 Flashes Ignition Lockout 4 Flashes Hot Surface Igniter Fault 5 Flashes Low Voltage 24 VAC 6 Flashes Valve Relay Problem 28 PV500 46U 06 12 14 14 1 14 2 14 3 14 4 14 5 INITIAL STARTUP Initial Startup Requirements Installation should 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 instructio
17. 0 1 compliant Burner Operating Controls amp Safeties Pre mix surface burner with self adjusting proportionate gas air ratio UL 795 compliant gas train Electronic flame safeguard with pre and post purge Combustion sequence panel lights including lockout Programmable electronic operating control with digital temperature readouts adjustable from 70 F to 180 F Immersion temperature limiting device high limit control ASME rated temperature and pressure relief valve 1 control enclosure Terminals for remote on off Flame failure audible alarm and indicating light with remote contacts Seamless VFD modulation with 10 to 1 turndown Warranty and Service Policy see warranty or service policy for details 10 tank warranty PV 627 9 Year scale failure warranty PV 563 First year cost free service policy PV 551 10 chloride induced stress corrosion cracking warranty PV 8083 Miscellaneous Factory authorized startup Vent termination cap 6 inch diameter larger cap optional Factory equipped for connection to direct inlet air requires UL listed vent termination cap see options list Condensate P trap provided for field installation Direct inlet air filter PV500 46U 06 12 3 PRODUCT DESCRIPTION Component Controls and Connection Locations Locations May Vary 250 SERIES CONDENSATE OUTLET FLUE OUTLET CONNECTION 3 FEMALE CPVC
18. 94 PLATE MTG BLOWER MOTOR 14 PVIF 9 1 110467 WHEEL FAN PUNKER HL45 PLATED 10 1 y MOTOR 1 1 2 HP BLDR 11 4 30 110483 STRIP ADHESIVE 1 8 x 3 4 SILICONE FOAM 12 3 111037 GASKET BLOWER INLET 8 ROUND 13 1 111038 GASKET BLOWER OUTLET 6 1 2 SQUARE 14 4 00 104911 STRIP ADHESIVE 3 4 x 3 16 VINYL FOAM 15 1 117195 SUPPORT GAS TRAIN FB14 PVIF 16 35 3475 NUT HEX 1 4 x 20NC ZINC PLT 17 1 110265 FILTER AIR 12 x 24 18 1 8 3604 PYROBOARD 1 4 x 23 x 16 RR 937 PYROLITE 19 33 15607 WASHER FLAT 1 4 PLT 20 3 6480 CONNECTOR 1 8 MPT x 1 4 COMP 21 2 6493 ELL 1 8 MPT x 1 4 COMP 22 2 79972 NUT WING 1 4 x 20 NC STEEL 23 107775 IGNITER HOT SURFACE 271Y 1 INSERTION 24 1 111791 GASKET IGNITER 232 CRANEGLAS Y271 25 1 111810 INSULATION COMPOSITE 12 625 OD W HIS 26 1 5616 BOX HANDY 2 x 2 x 4 27 1 5617 COVER HANDY BOX 2 2 4 8 1 100476 U BOLT 1 4 x 2 x 3 1 4 WIPLATE 29 4 3476 NUT FLANGE LOCK 5 16 x 18 NC 30 4 3506 WASHER FLAT 5 16 31 59189 SWITCH AIR PROVING ANTUNES SMD 32 35 3494 WASHER LOCK 1 4 PLT 33 1 6437 TEE BRASS 1 8 34 1 6550 BUSHING BRASS 1 2 X 1 4 35 1 6508 NIPPLE BRASS 1 8 X CL 36 1 6496 ELL 1 4 MPT X 1 4 COMPRESSION 37 1 119375 TUBING CUT ALUMINUM 1 4 IN X 6 FT 38 1 t ORIFICE AIR INTAKE continued on next page 38 PV500 46U 06 12 BURNER GAS TRAIN COMPONENTS 50 1 114530 PKG GAS TRAIN 1 1 2 M x 3 8 P x 1 2 C 51 1 116921 REGULATOR 1 1 2 M
19. AXITROL 210EZ ZERO GOVERNOR 52 1 102836 VALVE GAS DUNGS DMV D 703 6 24VAC 53 1 5972 NIPPLE BLACK 1 4 x 1 54 2 102838 FLANGE BLACK 1 1 2 DUNGS 55 2 45327 VALVE SHUTOFF 1 1 2 GAS COMBU 56 5 5973 BLACK 1 4 x 2 57 2 6168 ELL BLACK 89DEG 1 1 2 58 101216 SWITCH PRESSURE HKGP G ANTUNES MANUAL 59 101201 SWITCH PRESSURE RLGP G ANTUNES MANUAL 60 2 6055 NIPPLE BLACK 1 1 2 x 3 61 1 69559 NIPPLE BLACK 1 1 2 x 4 1 2 62 1 57612 NIPPLE BLACK 1 1 2 x 7 63 1 6059 NIPPLE BLACK 1 1 2 x 6 64 1 6053 NIPPLE BLACK 1 1 2 x 2 Contact factory for more information 39 PV500 46U 06 12 17 PERIODIC MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations Maintenance must 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 and other unexpected and unsafe conditions that could result in fire injury or death 1 Examine the appliance and venting system at least once a year Check more often in first year to determine inspection interva
20. INSTALLATION amp MAINTENANCE MANUAL Jj Lis reo POWER VT PLUS WATER HEATER Intertek MODELS 150 180 200 LX 250 300 A PVIF 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 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 UNIT POWER VT PLUS 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 Vm B V B PVI INDUSTRIES LLC Fort Worth Texas 76111 Web www pvi com Phone 1 800 433 5654 PV500 46U 06 12 TABLE OF CONTENTS Safety Considerations Standard Features and Equipment 2 1 Performance 2 2 Pressure Vessel 2 3 Heat Exchanger 24 Code and Standards 25 Burner Operating Controls amp Safeties 2 6 Warranty and Service Policy see warranty and service policy for details 2 7 Miscellaneous Product Descriptions Water Heater Installation 41 Checking Equipment Before You Install 4 2 Codes 4 3 Electrical Requirements 4 4 Handling and Location 4 5 Service Clearances 4
21. STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK 11 PV500 46U 06 12 Union Isolation Ball Valves T Building Return 5 to 10 gpm Expansion Check Valve Check Valve Building Return should be piped to the dedicated Tank building return fittings at the mid level of the tanks gt and not into the cold makeup piping Zl OI T amp P Relief Valve pipe in accordance with local codes or direct to drain with no valves or restrictions a Cold Makeup 52 Cold Makeup Tempered Water to Building consult codes for required temperatures Mixing Valve refer to valve manufacturer for piping instructions Water Heater TWO WATER HEATERS WITH REVERSE RETURN PIPING CONDENSATE DRAIN TRAP amp DISPOSAL The POWER VT PLUS water heater is designed to produce significant amounts of condensate because of its high efficiency Condensate occurs naturally when water vapor in combustion gases is cooled below the dew point Two 3 4 NPT drain connections are provided A trap with three inches of standing water below the bottom of the heater 3 above the base of the skids and no higher than the bottom of the heater must be field installed as part of the condensate piping WARNING A trap with three inches of standing water as described in these instructions must be included as part of the condensate piping system This trap is required to keep hazardous products o
22. 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 Place the appliance on a level non combustible floor Concrete over wood is not considered non combustible PV500 46U 06 12 8 Do not install on carpet or other combustible floor coverings If installation over a combustible floor is required follow these guidelines Use a base of hollow clay tile or concrete blocks from 8 to 12 thick and extending 24 beyond the sides Place the blocks in line so that the holes line up horizontally to provide a clear passage through the blocks nstall 1 2 fireproof millboard with a 20 gage sheet metal cover over the block base Center the unit on the base Also follow this procedure if electrical conduit runs through the floor and beneath the appliance A field installed base must meet all local fire and safety code requirements Service Clearances Allow sufficient space to provide adequate clearances on all sides for service and inspection At least 24 above the water heater is required for filter replacement and burner gas control service 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 gas vent combustion air electrical pump and other
23. anual 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 must be leak tested again before start up is attempted Remove enclosure panel cover on the appliance to expose control circuit A wiring diagram included in this packet will show the controls used in our circuitry 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 control for reading the flame response signal 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 destroy 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
24. auxiliary equipment Clearances To Combustible Surfaces Minimum 1 clearance must be provided from any vent surface to adjacent combustible material The minimum clearances to unprotected combustible material are 24 be provided at the front 8 be provided at the rear and 8 at top left and right sides of the appliance GENERAL PIPING GUIDELINES 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 Building Return Piping To maximize water heater efficiency connect the building return 5 gpm directly to the return fitting located at the rear of the tank PV500 46U 06 12 Union Expansion Tank Isolation Ball Valves Building Return 5 gpm Check Valve Building Return should be piped to the dedicated b
25. be 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 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 PV500 46U 06 12 8 10 The solid CPVC vent pipe Plastic venting is not allowed for models with SANI in the model number must be sealed to the wall or roof at the point where it passes through the wall or roof to prevent rain insects or flue products from entering the living space For proper vent operation and to protect the gas vent from wind and weather attach to the outdoor end of the vent the UL listed vent termination supplied with the Power VT Plus water heater This termination is required for proper operation and no substitution is allowed Do not use a barometric damper with the Power VT Plus positive pressure vent 95 Vertical or Horizontal Vent Termination 9 6 1 10 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 me
26. d for the addition of the vent system terminal PV500 46U 06 12 9 4 Vent Fitting Equivalent Length Vent Pipe 6 Vent 7 Vent 8 Vent 9 Vent 90 Elbow 8 feet 9 feet 10 feet 11 feet 90 Long Radius Elbow 5 feet 5 feet 5 feet 6 feet 45 Elbow 5 feet 5 feet 5 feet 5 feet The following vent information is provided for use in design calculations if needed Venting Specifications Products of Combustion Max Vent Input Mbtu Volume cfm Press W C 1500 350 1 7 1800 420 2 0 2000 467 2 0 CPVC Vent System Design Construction and Assembly The Power VT Plus water heater can be vented either vertically through a ceiling or roof or horizontally through a wall The solid CPVC CPVC not allowed on models with SANI in the model number or stainless steel venting listed by a nationally recognized testing laboratory for Category IV positive pressure gas appliance venting can be routed to the outdoors in any direction from the flue outlet of the water heater economizer except down The vent must be installed and supported every four feet to slope downward toward the water heater vent connection with at least 1 4 inch drop per linear foot of horizontal vent run to allow proper drainage of accumulated condensation 1 2 Read and follow the information instructions and warnings in VENTING section Do not insulate the plastic vent pipe Clean and d
27. e can be premature unwarranted product failure or unsafe operation producing carbon monoxide that could escape into the building Exposure to carbon monoxide can lead to 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 Duct Size 6 Duct 7 Duct 8 Duct 9 Duct Max Equivalent Length 100 feet 130 feet 250 feet 450 feet 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 this 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 PV500 46U 06 12 Duct Fitting Equivalent Length Duct Pipe 6 Duct 7 Duct 8 Duct 9 Duct 90 Elbow 8 feet 9 feet 10
28. e efficiency To inspect and clean the heat exchanger a qualified service agent or installer should use the procedures described in item 5 amp 6 below 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 c Write notes and or take pictures during this process to aid in correct reassembly d 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 e Remove the nuts that secure the burner top plate to the burner flange and lift the burner top plate up until it is completely extracted from the burner f Inspect top plate refractory for damage The refractory should provide a tight seal against the top edge of the burner deck The silicone foam gasket located on the top plate flange should also be checked for damage or excessive compression set g With the burner top plate 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 to loosen debris and use a vacuum to remove from the burner cavities Do not brush or scrub the metal fiber burner surface as this can cause permane
29. e end of that period the gas valve is opened for approximately 4 seconds After the burner has lit 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 lockout When this happens press the reset button on the front of the control to recycle burner 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 Refer to TempTrac manual PV500 41 Burner Combustion Adjustment Burner combustion should 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 See Gas Train Illustration below for details With the burner firing and adjusted to low fire adjust the regulator screw clockwise to increase gas flow or counter clockwise to decrease flow The desired in the combustion products should be between 8 0 and 9 0 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 a Once the desired combustion is achieved at low fire raise the burner firing rate to high fire Adjust the valve orifice clockwise to red
30. eburr all solid CPVC plastic pipe not allowed for venting models with SANI in the model number pipe ends and the joint area and trial assemble the vent before joining with CPVC cement following the CPVC cement manufacturer s instructions for making sound air and water tight joints Dry fit a solid 6 CPVC pipe into the female economizer flue outlet Remove the pipe and apply a liberal coating of room temperature vulcanizing RTV adhesive to the inside of the stainless steel economizer flue outlet and to the outside of the plastic pipe Before the RTV sets slide the plastic coupling or elbow back into the RTV coated economizer flue outlet while rotating the pipe approximately 1 8 of a turn Inspect and apply RTV to the inside and outside of the plastic to stainless steel joints to provide a continuous water and gas tight assembly Drill a pilot hole through the top of the stainless steel economizer flue outlet and into the 6 CPVC pipe and attach with a sheet metal screw stainless steel screws are recommended Repeat this step adding a sheet metal screw to each side of this economizer flue outlet to positively attach the pipe to the flue outlet Do not drill or use a screw in the bottom of the flue connector or pipe as condensate might drip from this point Vent support The vent system must be supported at intervals no greater than four feet to prevent sagging and distortion Testing for leaks All joints in the vent system must
31. ectrical 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 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable To avoid serious damage DO NOT energize the unit until the system and appliance is full of water Handling and Location WARNING Use industry standard safe rigging methods such as including the use straps and spreader bars and lifting from the water heater base skid assembly when attempting to lift or move this product Failure to follow industry safe rigging methods could result in property damage serious injury or death 1 Check the data decal on the appliance Be sure the electrical water oil or gas supply is adequate for the installation 2 Carefully remove all shipping supports and bracing 3 These units are suitable for indoor installation only 4 Installing the water heater on a 4 inch to 6 inch housekeeping pad is recommended to ensure proper condensate drainage 5 Locate the unit so that if water connections should leak water damage will not occur When such locations are unavoidable install a suitable drain pan and plumb pan to ensure adequate drainage in the event of a leak Under no circumstances is the manufacturer responsible for water damage in connection with this unit or any of its components
32. ectrical service to the appliance when accessing the remote connections located inside the control cabinet These terminals are High Voltage If the electrical service is not turned off and these terminals are touched a dangerous shock causing personal injury or loss of life could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance The Following Describes The Functions Of Each Of These Terminals And The Factory Installed Options Required To Activate The Terminals Note Terminal P1 P2 are functional only when the water heater is equipped with the factory installed options required to activate the terminals Terminals R1 R2 A1 A2 C1 C2 and T1 T2 are standard pre wired functions on all models 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 relay closes circuit from R1 to R2 is completed and appliance controls are enabled Appliance ships from factory with jumper between terminals Remove jumper when connecting to a remote controller A1 A2 Used to activate a remote alarm signaling shutdown of combustion control Provides a maximum 10 amp relay contact closure when the flame safeguard terminates combustion due to a tripped safety interlock i e air proving switch high limit switch low water flow switch or flame sensor etc P1 P2 Activates remote equipment and requires confirmation
33. ency for Research on Cancer IARC as carcinogenic to humans This product also contains refractory ceramic 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 lf 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 lower tank and upper and lower flue collector assemblies ut
34. essional to resolve this situation e Caution Do not plug the relief valve as this will eliminate the critical water temperature and pressure protection it provides Operating Temperature Control An adjustable digital operating control is located in the front control panel The control is factory pre set at approximately 120F To adjust the setpoint to deliver the desired water temperature press and 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 21 PV500 46U 06 12 10 3 10 4 10 5 High Water Temperature Limit Control Appliances are equipped with adjustable limit and high limit controls to control the maximum discharge water temperature These controls are located inside the control cabinet and are accessed by removing the bottom cover The high limit control is optionally available as the manual reset type and may be reset by pressing the limit reset button accessible through the control panel cover 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 The Lower Limit is of the auto reset type and can be dial adjusted to operate just above the set point of the main Operating Temperature Control Cathodic Protection
35. f combustion from continually entering the room through the condensate piping Failure to provide this trap can cause personal injury exposure to hazardous materials or loss of life 1 Installing the water heater on a 4 inch to 6 inch housekeeping pad is recommended to ensure proper condensate drainage Attach a 3 4 CPVC Coupling and Tee to the economizer condensate drain then use 3 4 CPVC pipe to plumb from the heater condensate outlet to economizer Tee to a 3 CPVC trap and on to a suitable floor drain or collection system Each condensing appliance must drain separately Do not combine condensate drains from multiple condensing appliances into a single drain pipe Each condensate drain must contain a trap or siphon pigtail to provide at least 3 inches of standing water to prevent flue gas flow through the condensate piping To construct the trap connect to the 3 4 condensate drain route the piping downward until the standing water in the trap is not higher than the bottom of the water heater Install the condensate plumbing as shown in the following diagram All condensate plumbing must be protected from freezing Do not locate the condensate piping such that an ice dam of frozen condensate can block the outlet 12 PV500 46U 06 12 FLUE OUTLET CONNECTION e 3 TRAP 9 ol ECONOMIZER UNIT CONDENSATE CONDENSATE DRAIN DRAIN ye
36. for determining the suggested pipe size in the Single Unit Installation Suggested Gas Pipe Size table SINGLE UNIT INSTALLATION SUGGESTED PIPE SIZE Equivalent Feet Maximum Capacity for Natural Gas From Meter MBTU HR Based on 0 5 W C Pressure Drop 1 1 4 1 1 2 2 2 3 4 25 860 1320 2475 3900 7000 40 660 990 1900 3000 5300 60 810 1520 2400 4300 80 690 1300 2050 3700 100 620 1150 1850 3250 6700 125 1020 1650 2950 6000 150 950 1500 2650 5500 175 850 1370 2450 5000 200 800 1280 2280 4600 Multiplier for Propane 1 57 Multiplier for alternate pressure drops 0 3 W C 0 77 1 0 W C 1 41 2 0 W C 2 00 and 4 0 W C 2 82 14 PV500 46U 06 12 MULTIPLE UNIT INSTALLATIONS GAS PIPING 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 Foot of Gas and 0 60 Specific Gravity Nominal Iron Length of Pipe in Straight Feet conan 727712 OOO s ae ER CREE 6 95 106 113 121 128 141 155 174 205 256 369 697 477 384 328 292 267 246 256 210 200 179 164 138 1400 974 789 677 595 543 502 472 441 410 369 333 308 287 923 830 769 707 636 564 513 472 441 E me
37. ge the Setpoint 11 7 To Change Other Parameters 11 8 LED Display Alarm Messages Remote Connections Terminal Strip 12 1 Making BMS BAS Remote Connection for Analog and Binary Signals 12 3 Terminal Functions Sequence of Operation Initial Startup 14 1 Initial Startup Requirements 14 2 Tools and Instrumentation Required 14 3 Resources 14 4 On Site Considerations 14 5 Startup Procedure Troubleshooting Guide Replacement Parts 16 1 Control Panel 16 2 Control Panel Components 16 3 Burner Assembly 16 4 Burner Assembly Components Periodic Maintenance Recommended Maintenance Schedule Warranty forms ship separately with each product PV500 46U 06 12 1 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 loss of life FOR YOUR SAFETY 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 Do nottry 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 instal
38. hutoff valve two safety shutoff valves proportionator regulator and a final manual valve with the manifold pressure tap on the side of the valve These components may be separate or two or more may be combined in a common housing Caution Do not adjust or remove any screws or bolts on gas train control components which are sealed with a red or blue colored compound Doing so will void all approvals and warranties 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 LP Maximum Static Pressure Inches Water Column 14 14 Minimum Flow Pressure Inches Water Column 4 5 11 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 Use the values in Convert Fittings To Equivalent Straight Pipe 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 1 11 2 3 4 5 Equivalent Length of Straight Pipe feet 2 2 3 4 5 40 14 20 Use this corrected total distance from the meter
39. ilize RCF material The RFC materials are located within the product and not generally exposed except during service disassembly or assembly PV500 46U 06 12 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 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 4 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 120 F Thermostatically controlled mixing valves must be used in the design of the potable hot water system
40. ires a minimum free area of 1 square inch per 2000 Btu hr input if communicating with the outdoors through horizontal ducts e All Air From Inside The Building Each opening requires a minimum free area of 1 square inch per 1000 Btu hr input but not less than 100 square inches 0 06 m e Combination Of Air From The Indoors And From The Outdoors Refer to National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes or applicable provisions of the local building codes 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 Under no circumstances should the appliance ever be under a negative pressure Particular care should 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 such 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 The result of inadequate clean combustion air or negative pressur
41. l a Check all joints and pipe connections for tightness corrosion or deterioration b 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 e 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 replacement of the filter on a 3 to 6 month schedule or more often based on severity of contamination Contaminants can be drawn in with the combustion air Inadequate combustion air 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 without a suitable replacement To inspect and clean the burner a qualified serviceman or installer should use the procedures described in item 5 amp 6 below 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 reduc
42. l 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 CALL FOR HEAT LOW WATER TEST m AIR PROVING BURNER ON Lower LED Readout The default display of the lower readout Probe 1 is the stored water temperature sensed near the top of the water heater tank This is used to regulate the temperature of the water heater Upper LED Readout The default display of this readout will display nu This readout can display a temperature reading from a 2 probe The pm probe can be installed in a thermal well this optional probe and thermal well with heat conductive paste is custom and must be ordered from your PVI representative or directly from PVI to remotely monitor water temperatures such as blended water temperature downstream of a thermal mixing valve or a remote storage tank Both Probe 1 and Probe 2 temperatures are available for monitoring through the optional MODBUS RTU interface Control Buttons Displays and modifies the temperature set points SET In programming mode it selects a parameter confirms 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 decrea
43. ler service agency or the gas supplier This product contains or may come to contain materials 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 loss of life 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 loss of life 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 Ag
44. main fuel valves Daily Maintenance a Check gauges monitors and indicators b Check instrument and equipment settings As Required a Check drip leg and gas strainers b Testflame failure detection system c Test temperature and pressure relief valves in accordance with ASME Boiler and Pressure Vessel Code Sections VI amp VII d Tank flush and cleanout 42 PV500 46U 06 12 43 PV500 46U 06 12 PVI INDUSTRIES LLC e 3209 Galvez Ave gt Fort Worth Texas 76111 gt Phone 1 800 433 5654 e www pvi com 44 PV500 46U 06 12
45. mperature Ignition When dwell time is completed 4 second Trial for Ignition period is initiated a b The Delay On Low Fire Hold Relay and the Gas Safety Valves are energized During TFI the flame safeguard control will monitor the flame using flame rectification through the hot surface igniter If the flame control senses the presence of flame before the end of the period the igniter will be de energized and the flame control will continue to monitor the flame through the igniter until the operating thermostat ends the call for heat condition 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 When the call for heat condition ends or flame failure occurs following the third TFI period one time if CSD 1 a 30 second post purge period will begin This period of blower operation will exhaust any remaining combustion products from the system 27 PV500 46U 06 12 8 Delay On Relay Once the Delay On Low Fire Hold Relay has timed out it energizes the Modulation Release Relay SPDT to enable the analog signal from the TempTrac to the VFD to regulate the speed of the blower a The TempTrac will continue to monitor the stored water temperature in the tank b When the setpoint
46. ns should be followed precisely in order to achieve safe and efficient operation to assure trouble free service life WARNING Proper startup must be made by a qualified installer or service agency who must read and follow the supplied instructions and appliance markings Failure to complete proper startup before use tampering with controls or not following all instructions and markings may damage this equipment void the warranty and may result in property damage personal injury or death A Start up Form is included with each product and must be completed by the qualified installer or service agency conducting the startup and must be returned to the manufacture to register the warranty Copies are available at www pvi com WARNING Turn off all power to the water heater when servicing or accessing the blower drive The blower drive still has power when appliance switch is off Failure to turn off all power to the water heater can cause personal injury property damage or loss of life Tools and Instrumentation Required e Stack Temperature Gauge e Stack Draft Gauge e Electronic Combustion Analyzer e Manometer for checking gas pressure 2 minimum 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 Considera
47. nt damage to the burner material h Replace any damaged components and reassemble in reverse order 4 5 ft Ibs i Cycle unit and test to verify all safety and operating controls are properly functioning and the burner top plate flange is free of leaks 40 PV500 46U 06 12 The combustion air filter should be replaced every six months If filter blockage becomes excessive the filter safety switch will not allow the burner to fire To avoid nuisance shutdown in dirty environments check and replace filter more frequently 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 controls are serviced or replaced refer to ELECTRICAL COMPONENT LOCATIONS for identification and location of components All replacement parts are available through your 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
48. re is exited by waiting the time out to expire 11 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 24 PV500 46U 06 12 11 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 See TempTrac User Manual PV500 40 for full description ALARM RECOMMENDED MESSAGE CAUSE RESULTS OF ALARM CONDITION ACTION Inlet temperature sensor is not upa connected or is reading incorrectly Call Check wiring and sensor 2 TET propetallure for heat and burner modulation output Terminals 14 amp 17 signal will revert to low fire Temperature sensor is not connected m P2 TP2 probe failure or is reading incorrectly Freeze Sneck wiring and sensor DPA Terminals 15 amp 17 protection is disabled Temperature sensor is not connected pan or is reading incorrectly or flue gas Check wiring and sensor pa temperature protection is disabled if Terminals 16 amp 17 used HA High temperature Buz
49. ses a displayed value CLOCK Changes lower display from the stored water temperature to current time and day Changes upper display from Probe 2 temperature to Probe 3 temperature when installed EXT Also displays the temperature difference of the stored water temperature minus Probe 2 temperature 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 for full description 23 PV500 46U 06 12 11 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 11 6 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 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 change 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 procedu
50. 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 C1 C2 prior to the appliance being able to energize Options Required Consult Factory 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 T1 T2 Used for external modulation control To connect external modulation control disconnect and cap the blue wire connected to terminal T2 and connect the external modulating signal to terminals T1 positive and T2 negative 26 PV500 46U 06 12 13 SEQUENCE OF OPERATION Incoming 120VAC 1 a b Full time power to the Main Control Switch Full time power to the Variable Frequency Drive Power On When the main control switch is turned on a b d 120v is applied to the step down transformer 24v 120v is applied to the L W C O terminal L1 if used 120v is applied to the Fenwal Flame Safeguard Control 24v is applied to the TempTrac operating temperature control terminal L1 Call For Heat If the TempTrac operating control senses a call for heat condi
51. sure Check for proper inlet static and dynamic gas pressure Combustion Inadequate flame signal may result from improper combustion Adjust to proper CO2 levels at low fire Grounding Check for proper ground from flame control to burner housing Safety Limits 33 Check all safety limits for fault condition and correct as required PV500 46U 06 12 16 REPLACEMENT PARTS REPLACEMENT PARTS 16 1 Control Panel ALARM E ENUNCIATOR WHEN USED 2 OW TERMINAL STRIP L1 120VAC L2 NEUT 120VAC L2 NEUT 120VAC L1 FUSED L3 24VAC L3 24VAC L4 NEU GROUND GO ELECTRICAL Po NF L4 NEUT GROUND GROUND LUG FOR FIELD CONNECTION 0 0 0 0 t SER 8193 5 mE na Vl 2e LWCO 1 0 LAT LAT Hl TD lo eT D VFD 5 d 1 9 IGNITION ojo CONTROL fo 35 TERMINAL STRIP INSIDE TOP COVER 2 EXTERNAL CONTROL 1 02 REMOTE PROVING INTERLOCK 1 2 REMOTE EQUIPMENT 1 2 REMOTE ALARM 1 82 REMOTE ON OFF KNOCKOUTS
52. ters regulators and relief equipment The vent cap must terminate at least 3 feet 0 91 m above any forced air inlet within 10 feet 3 05 m 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 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 To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc 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 A horizontal vent must extend one foot beyond the wall A horizontal vent terminal must not be installed closer than 3 feet 0 91m from an inside corner of an L shaped structure A vertical vent must exhaust outside the building at least 3 feet 0 91m above the point of 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 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
53. testing as the inlet pressure must be monitored during the firing of the burner Record static pressure it must not exceed 14 W C Pressures above this could cause damage to the diaphragm in the gas valve or pressure regulator Connect a second manometer to the manifold test port at the shutoff valve closest to the burner 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 assembly When the burner fails to light the flame control will lockout Start the burner in Low Fire Burner combustion must be optimized at both Low and High Fire To set the TempTrac control for manual modulation output Push and hold the EXT key for more than 3 seconds The LED 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 ou
54. tion a The High Gas Pressure and Low Gas Pressure Switch both optional are energized and their safe condition is proved The thermostat contact on the Fenwal Flame Safeguard Control is energized The flame control will then verify the Airflow Proving Switch is in the open position which must exist before the blower is powered Energizing the blower should close the airflow proving switch If the airflow proving switch is not in the closed position the flame control s fan terminals F1 F2 will power the Variable Frequency Drive VFD blower system at low speed for pre purge If the airflow proving switch does not close following the blower being energized the flame control will lockout Proof of Air Pressure Switch The control will look for a signal from the airflow proving switch indicating that the blower is operating a When the airflow generated by the blower is sufficient to cause the differential air switch to close the 15 second pre purge delay will start During this period any flue products or combustible gases which may have settled in the water heater are evacuated Heat Up Following the pre purge delay the hot surface igniter will be energized a b The flame control will monitor the current applied to the hot surface igniter If the flame control determines the proving current meets the threshold a dwell time delay starts to assure the hot surface igniter has sufficient time to reach ignition te
55. tions 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 in this manual 2 Fill system tank with water Some water appliances may be equipped with an optional air vent 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 4 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 29 PV500 46U 06 12 10 11 12 13 14 15 16 17 18 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 14 W C and tightly close the gas train manual shutoff valve closest to the burner c Reattach the manometer to the gas train m
56. tput setting without entering the password for 10min After this time you will be asked for the password again Turn on main gas shutoff valve If the operating control switches are closed the burner blower should come on and pre purge begins If nothing happens check for a lockout condition and reset it by pushing the flame safeguard reset button Some safety devices are wired in the operating circuit and may not indicate alarm If no indication of alarm exists check gas pressure switches electronic low water cutoffs if equipped and temperature limits 30 PV500 46U 06 12 19 20 21 22 23 When the blower motor starts the flame control will check for a positive air flow If the air switch or blocked filter switch is not made the blower will stay on for a period of time then lockout To adjust the air proving switch turn the adjustment screw counter clockwise until the air proving light comes on then turn the screw one turn counter clockwise The blocked filter switch should only be adjusted when the filter is new This switch should be turned clockwise until switch makes and then two additional turns If the gas valves open and close intermittently during normal operation adjust pressure switches to increase the operational threshold until this condition ceases This procedure should be followed with every burner After the pre purge the flame control energizes the HSI for the heat up period approximately 30 seconds At th
57. turned off and these terminals are touched a dangerous shock causing personal injury or loss of life could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance Temperature and Pressure Relief Valve s A Temperature and Pressure Relief Valve s sized in accordance with the ASME Boiler and Pressure Vessel Code 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 loss of life e 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 T amp P relief valve s discharge line The 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 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 prof
58. uce the flow of gas and counter clockwise to increase the flow of gas in order to maintain the desired in the combustion products between 8 0 and 9 0 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 Enable or reconnect any BMS BAS control interface removed prior to the setup and adjustment of each water heater 31 PV500 46U 06 12 MANIFOLD PRESSURE VALVE ORIFICE ADJUSTMENT REGULATOR ADJUSTMENT DUAL SAFETY SHUTOFF VALVE INLET PRESSURE Gas Train Illustration Optional components may not be shown REGULATOR ADJUSTMENT VALVE ORIFICE ADJUSTMENT INLET PRESSURE it LOW PRESSURE GAS SWITCH OPTIONAL DUAL SAFETY SHUTOFF VALVE MANIFOLD PRESSURE HIGH GAS PRESSURE SWITCH OPTIONAL Alternate Gas Train Illustration Optional components may not be shown 32 PV500 46U 06 12 15 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Starting or Pre purge Failure Power Supply Check fuse and or circuit breaker Check voltage at 120 24V step down transformer On Off Switch Check if On Off switch is lighted Temperature Control Check that the operating temperature control
59. uilding return fitting at the mid level of the tank and not into the cold makeup piping T amp P Relief Valve pipe in accordance with local codes or direct to drain with no valves or restrictions ZO Cold Makeup Cold Makeup Hot Outlet Tempered Water A to Building Cold Inlet consult codes for required temperature Mixing Valve referto valve manufacturer for piping instructions SINGLE WATER PIPING Union Building Return 5 to 10 gpm Isolation Ball Valves Building Return should be piped to the dedicated building return fitting at the mid level of the tank and not into the cold makeup piping Check Valve Expansion T amp P Relief Valve pipe in accordance Tank with local codes or direct to drain with no valves or restrictions Cold Makeup Cold Makeup Hot Outlet Hot Outlet Tempered Water to Building consult codes for required Cold Inlet temperature Mode of Operation Mixing Valve refer to valve manufacturer for piping instructions storage tank are available at temperature to satisfy the building dump load Storage from both the water heater and the Fitting locatons may differ from illustration Heater input is sized to recover temperature of both tanks in time for the next dump load Pump operates continuously and is sized to circulate the entire contents of the storage tank in time for the next dump load SINGLE
60. utlet must be plumbed with CPVC plastic pipe to the lowest fitting of the Condensate Neutralization System connecting to the INLET as shown in the graphic below 5 Keep the Condensate Neutralization System closed at all times except for maintenance 4 SCH40 PVC NPT PLUG CRUSHED LIMESTONE Optional Condensate Neutralization System 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 can cause property damage personal injury exposure to hazardous materials or loss of life PV500 46U 06 12 7 1 7 2 7 3 7 4 7 5 GAS SUPPLY AND PIPING Verify that 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 Btuh output 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 American National Standard to comply with safety and performance criteria such as proper ignition combustion and safety shutdown operation Gas Control Trains All models include gas control trains with the following components main manual s
61. we m m n e n ne e ae ae n om en ae e n Es we rr rm oe om se se 7 6 Appliance Isolation during Gas Supply Piping Pressure Test 1 3 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 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 The appliance and its gas connection must be leak tested before placing it in operation 7 7 Gas Connection 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 Do 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 Gas pipe size may be larger than heater connection Installation of a union is suggested for ease of service Install a manual main gas shutoff valve outside of the appliance gas connection and before the appliance
62. zer sounds operation continues Manual reset required setpoint exceeded LA Low temperature alarm Buzzer sounds operation continues Digital input 3 is activated for one or more of the following HP Flame failure or any control Unit de energized after timer delay Manually reset required component failure if equipped with alarm on any failure option LP Digital input 2 is activated Unit de energized after timer delay Manually reset required Mn1 alarm for Buzzer sounds operation continues Check wiring and sensor Mn2 227 alarm for Buzzer sounds operation continues Check wiring and sensor Mn3 mns aao Buzzer sounds operation continues Check wiring and sensor rtc he real Energy saving function disabled Reprogram clock its setting 25 PV500 46U 06 12 12 12 1 12 2 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 hinged control panel at the top of the cabinet and is accessed by removing the bottom cover and then removing the screws at the top of the hinged cover 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 Maximum Length SOFT 75 100 FT WARNING Turn off all el

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