INSTALLATION & MAINTENANCE MANUAL
Contents
1. 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 Utiliser du fil de cuivre de la taille appropri e pour le service lectrique entrant Les dommages r sultant de l utilisation de fil d aluminium seront exclus du champ d application de la garantie de cet appareil 3 4 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 a boiler water or a water connection leak The drain must be sufficient to contain water in excess of 210 F 3 5 Installation 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 heater Be sure the electrical supply is adequate for the installation 2 Carefu2. Boiler Water Pressure Gauge 5 Intra tank Circulator 14 Tank Purge Valve 6 Relief Valve 7 Isolation Shutoff Valve Optional 8 Tank Drain Valve Supplied by Others 9 Boiler Water Inlet shown with dashed lines NOTE Components controls and connection locations may vary 4 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater ox 2 22 cee Typical QuickDraw Semi Instantaneous Construction U tube Heat Exchanger Control Enclosure Potable Water Inlet Potable Water Outlet Intra tank Circulator Relief Valve Isolation Shutoff Valve Tank Drain Valve Boiler Water Inlet Boiler Water Outlet Electronic Operating Control Boiler Water Temperature Gauge Boiler Water Pressure Gauge Tank Purge Valve Tank Pressure Gauge Optional Supplied by Others shown with dashed lines NOTE Components controls and connection locations may vary PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 3 WATER HEATER INSTALLATION 3 1 Checking Equipment Bef
3. Pipe the drain valve to a suitable open drain Thermal Expansion Tank If the water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water line provide thermal expansion control Contact the water supplier or local plumbing inspector for additional information 3 6 Service Clearances and Clearance to Combustibles 4 1 The appliance must not be installed on a combustible floor or on a non combustible floor covering combustible material A minimum clearance of 6 must be provided from any combustible material However the 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 Distance minimale aux mat riaux combustibles est de 15 cm sur le dessus et les c t s et ne doit pas tre install sur un plancher combustible GENERAL GUIDELINES Water Inlet Outlet Connections 1 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 the flange or tank and are not covered by warranty For ease of service install unions on inlet and outlet piping to the unit Piping and components connected to the water heater must be suitable for potable water f
4. 3 7 4 7 5 QuickDraw Storage and Semi instantaneous Boiler Water Heater MAINTENANCE WARNING Turn off all electrical 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 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 formati
5. 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 3 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 2 PRODUCT DESCRIPTIONS 16 3 or gE MU rS Ney Wrap oa Typical QuickDraw Storage Construction 1 U tube Heat Exchanger 10 Boiler Water Outlet 2 Control Enclosure 11 Tank Temperature and Pressure Gauges 3 Potable Water Inlet 12 Boiler Water Temperature Gauge 4 Potable Water Outlet 13
6. INSTALLATION amp MAINTENANCE MANUAL QuickDraw Storage and Semi instantaneous Boiler Water Heater p m I LEAD COMPLIANT Intertek Installation and service must be performed by a qualified service installer service agency or qualified plumbing contractor IMPORTANT THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION OPERATION AND MAINTENANCE OF THIS EQUIPMENT READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER PROVIDED INSTRUCTIONS LABELS AND MARKINGS BEFORE INSTALLING OPERATING OR SERVICING THIS UNIT TO THE INSTALLER After installation these instructions must be given to the equipment user or left near the appliance SPECIAL INSTRUCTIONS TO THE OWNER Retain this manual for future reference These instructions contain important information that will help you in maintaining and operating this appliance VE i PVI INDUSTRIES LLC 3209 Galvez Ave Fort Worth Texas 76111 1 800 433 5654 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater TABLE OF CONTENTS Safety Considerations Product Descriptions Water Heater Installation 3 4 Checking Equipment Before You Install 3 2 Codes 3 3 Electrical 3 4 Location 3 5 Installation 3 6 Service Clearances and Clearance to Combustibles General Guidelines 4 1 Water Inlet Outlet Connections 4 2 Boiler Water Piping 4 3 Relief Valve Piping 4 4 Filling the Unit Operating and Safety Controls 5 1 Oper
7. NG WELD GAUGE TEMPERATURE TEE BLACK WELD FLANGE RFWN o o o o G v o 9 SUPPLIED o 6 REF TT Eg REF ARTIS IN Du i NY VTL 9d EL 4 Same 4 l 59 MIN 3 x d HEAT TRAP ON FARSIDE NoTE 3 A NOTE 1 EE pes P E224 d 6 Qo w 7 td 6 a poy od I GEN x Ill Nel Se Fe Sf ALY ISS ams 9 8 Ne 9 9 G 9 9 A NOTES 1 CUSTOMER SUPPLIED FIELD PIPING DASHED LINES FRONT VIEW SIDE 2 ALL WELDS FREE OF SLAG INSIDE PIPE D 3 DRILL AND TAP HOLE OF APPROPRIATE SIZE INTO CENTER OF TEE FOR TYPICAL FLANGED BOILER WATER PIPING INSTALLATION INSTALLATION OF GAUGES A system bypass from supply to return is required when using two way valves to avoid deadhead operation of the boiler water loop Flow through the bypass must be adjusted to provide sufficient flow to enable the water heater to operate at maximum capacity When two or more heaters are piped in parallel it is important that the piping systems are balanced to assure the full combined capacity is realized Reverse return piping is recommended for multiple unit installations Relief Valve Piping The water heater is supplied with a pres
8. ater temperatures and flows to which it is connected To obtain the desired performance it must be installed to operate with the temperature and flow conditions specified when selecting the appliance The boiler water piping must be appropriately sized and include a strainer isolation valves pressure gauges drain valve and over pressure protection where required The domestic water piping must also be appropriately sized and include isolation valves drain valve temperature and pressure relief valve and expansion tank or other means of expansion control Boiler water supply piping should be sized to deliver sufficient hot water to the appliance without excessive pressure drop A heat trap of at least 3x pipe diameters must be used for the boiler water supply piping as depicted in the above typical piping arrangement When larger sized boiler water supply and return piping is not furnished by PVI the installation must comply with the typical piping installation diagram shown below It is important that a minimum of 3x pipe diameters heat trap be installed on the boiler water supply line to achieve proper performance of the heat exchanger 8 PV500 26 05 13 4 3 QuickDraw Storage and Semi instantaneous Boiler Water Heater LIST OF MATERIALS DESCRIP TION B amp G HEAT EXCHANGER 3 WAY MIXING VALVE FLANGED FLANGE REDUCING SLIP ON BLACK ELL BLACK WELD 90DEG PIPE BLACK FLANGE COMPANION BLACK RING BACKI
9. ating Temperature Control 5 2 Thermostat Settings for QuickDraw Semi Instantaneous Heaters only 5 3 High Water Temperature Limit Control 5 4 Electronic Low Water Cut Off optional 5 5 Sequence of Operation Start up Procedure Maintenance 7 1 Temperature and Pressure Relief Valve 7 2 Thermostats and Temperature Limiting Device 7 3 Control Valve Actuator 7 4 Tank 7 5 Cleaning the Heat Exchanger 7 6 Checking and Adjusting 3 way Valve Operation 7 7 Recommended Maintenance Schedule Troubleshooting Notes Warranty forms ship separately with each product 2 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 1 SAFETY CONSIDERATIONS 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 Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and
10. e 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 Sequence of Operation Refer to figure below 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 VALVE COIL a B 5 SE I I Gia RETURN BYPASS STEM DOWN FLOW THROUGH STEM UP FLOW THROUGH COIL BYPASS SUPPLY 3 When the demand is satisfied the limit operating 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 11 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater START UP PROCEDURE 1 When placing the unit into operation open relief valve to pu
11. e 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 OPERATING AND SAFETY CONTROLS WARNING Turn off all electrical service to the appliance when accessing the remote connections located inside the control cabinet and close and fasten the control cabinet cover before restoring electrical service to the appliance Terminals and components in the control cabinet are high voltage If the electrical service is not turned off and these terminals or components are touched a dangerous shock can result in property damage personal injury or loss of life Coupez l alimentation avant intervention sur l appareil Operating Temperature Control The adjustable Operating Thermostat is located in the front control panel The thermostat is factory pre set at approximately 120 F Adjust the operating thermostat to the desired water temperature Thermostat Settings For QuickDraw Semi Instantaneous Heaters The adjustable operating temperature control is located just above the fro
12. ey Combinations 1 TO UNLOCK THE KEYBOARD Press and hold the UP DOWN keys for 3 seconds When the PON flashing message is displayed the keys are unlocked 2 TO LOCK THE KEYBOARD Press and hold the UP DOWN keys for seconds When the POF flashing message is displayed the keys are locked 3 TO RETURN TO TEMPERATURE DISPLAY Press the SET UP keys 10 PV500 26 05 13 5 3 5 4 5 5 QuickDraw Storage and Semi instantaneous Boiler Water Heater High Water Temperature Limit Control The appliance is equipped with an adjustable temperature limit control and a non adjustable high temperature limit control These controls are located inside the control cabinet and are accessed by removing the bottom cover The adjustable limit control is an auto reset type and should be adjusted at least 10 degrees above the set point of the Operating Thermostat The high limit is an auto reset type with a fixed set point but is optionally available as a manual reset type If the high limit is a manual reset type it cannot be reset until the water temperature has dropped below its reset point Electronic Low Water Cut Off Optional 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 ther
13. fied design pressure and temperature may result in damage to the heat exchanger property damage personal injury or loss of life 4 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 5 In all installations there should be no pulsation or water hammer since this causes vibration and strain with resulting leaks 6 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 for proper torque specs 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 relaxation or creep that may have occurred b In shutting 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 12 PV500 26 05 13 7 1 7 2 7
14. lly 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 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater Use only non ferrous water piping and fittings for potable water plumbing and connections Do not use galvanized pipe or fittings Use of ferrous or galvanized pipe or fittings can cause rust to form Insulate hot water and return circulation lines Also if subject to freezing during shutdown or during operation insulate all water piping and take whatever steps are necessary to keep the appliance and all water containing pipes and components from freezing IMPORTANT Do not use the plumbing connected to the appliance as a ground for welding or any other purpose This appliance is equipped with a temperature and pressure relief valve s rated for the input The relief valve must be pipe to and attached to a suitable open drain Relief Valve Piping 9
15. move actuator mounting screws 3 Slide actuator back on mounting bracket and remove cam from actuator shaft Lift valve stem and plunger assembly to full upward position Install the cam onto the actuator shaft with the cam lobe facing up gt o a 0 Reposition actuator and install the mounting screws g Apply power to actuator Should drive CW rotation and stem down h Install cover and screws i Install indicator with screw pointing toward open 3 Adjust Valve Stem a Loosen stem locknut b Screw valve stem into stem extension until valve has contacted at top of valve stroke c Screw valve stem into extension and additional 11 2 turns d Cycle heater with thermostats to confirm proper operation Actuator Nylon Bushing A Plunger Assembly Ring Front Cover Plunger Cam Mounting Screws 3 By e Mounting Bracket N 29 z N Indicator Screw Tm Aen V C amp E Stem ESSI a Cover Screws 2 r Stem Locknut Packing Nut A Mounting ez AX Not included in AV Kits Valve Body AA Used with 1 2 through 2 valve bodies VB 7XXX Shown Typical Components for Valve Installation of Standard Actuator 16 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 7 7 Recommended Maintenance Schedule 1 Annual Maintenance a Check all joints and pipe connections for tightness corrosion or deterioration b Check all safety controls and de
16. nt control panel cover This control utilizes a temperature sensing thermistor located in the control flange on top of the tank Follow the safety instructions and warnings included in this manual and with the product when adjusting the set point of the operating temperature control to deliver the desired water temperature The setpoint SET determines the desired stored water temperature in the tank and is factory set at approximately 120 F If the tank temperature decreases below the set point a call for heat sequence is activated The heating sequence is turned off when the tank temperature again reaches the set point value Le thermostat est r gl environ 49 degr s Celsius Temp ratures de l eau sup rieures 52 degr s Celsius peut causer instantan ment de graves br lures ou la mort de br lures Suivez les instructions dans le manuel d installation et de maintenance pour modifier la temp rature de l eau To View the Setpoint 1 Press and quickly release the SET key This will display the setpoint for 5 seconds To Change the Set Point 1 Press and hold the SET key for at least 2 seconds to enter the setpoint change mode 2 The setpoint is displayed and the LEDs of the first and third digits blink 3 To change the value use the UP and DOWN keys 4 The new value can be stored either by pressing the SET key the control restores temperature display or by waiting the exit time out to expire 15 seconds K
17. on NOTICE Since PVI cannot control the use of the appliance water conditions or maintenance the warranty on the appliance does not cover poor performance structural failure or leaking due to an excessive accumulation of scale a If the unit requires shut down remove all power from the system Close all boiler water and cold water supply valves to the unit b If the unit is removed from service for an extended period of time it must be drained completely to reduce the risk of freezing biologic growth and corrosion from stagnant water conditions When the appliance is returned to service conduct a thorough inspection of all utilities and general appliance condition Cleaning the Heat Exchanger 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 13 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 3 Tube bundle removal a When practical and if the heat exchanger is connected to a collar assembly leave tube bundle attached to collar assembly and remove by unbolting collar assembly from tank b During bundle removal the dead weight of the bundle should never be
18. on Scale and particulates can result in stem and packing scratches and can adversely affect packing life and other parts of the hydronic system Contact the manufacturer for replacement packing and stem amp plug assembly Tank Depending on water quality and operating temperature scale can form during operation and will accumulate on the bottom of the tank Natural minerals in water forms scale which precipitates out during the heating cycles Some water supplies contain more of these minerals than others so 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 minerals come 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 and cleaning frequency is established inspect the tank every six months or more frequently if higher scaling conditions are present Flush the tank at the appropriate interval based on water conditions in your location to help prevent the accumulation of scale To flush turn off the electrical disconnect switch to remove power and prevent the unit from operating Open the drain valve and allow water to flow through the tank until it runs clear Close the drain valve and turn the electrical switch back
19. or the water temperatures they will experience and for their application After plumbing the unit and checking for leaks the heat exchanger and boiler water and hot water piping should be insulated Insulation will reduce wasteful heat loss and will help protect operators from contacting hot surfaces WARNING Insulate or guard and hot water surfaces Uninsulated or unguarded steam and hot water surfaces can cause burns instantly 7 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater GERENS ee Po Cass Crs HOT WATER L f HOUSE CIRCULATION BS eS E ee Bi RELIEF VALVE Ty tb HI UMIT TO DRAI 45 S e ro TO DRAIN iri wit i OPTIONAL BOILER WATER OUT i MN HW BOILER WATER IN SEI Il RB 3xdMN deg es HEAT TRAP 3 COLD WATER P E EXPANSION TANK i TI TI XX FLOOR DRAIN TYPICAL PIPING ARRANGEMENT 4 2 Boiler Water Piping WARNING All system piping to the heat exchanger plumbing must be adequately supported Failure to provide adequate support will result in excessive loads on the heat exchanger connections that can cause hot water or steam discharge resulting in property damage scalding and personal injury or loss of life This appliance will perform in accordance with the boiler water and domestic w
20. ore 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 number of pieces shown on packing slips with those actually received Contact the freight carrier immediately if any damage or shortage is detected 3 2 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 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 or Section VIII 3 3 Electrical Requirements 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 NFPA 70 When unit is installed in Canada it must conform to the Canadian Electrical Code CEC CSA C22 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
21. rge 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 or circulating pump 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 130 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 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 WARNING Do not operate unit under conditions in excess of those specified on nameplate and ASME data plate Failure to operate the heat exchanger within the speci
22. 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 bring 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 COLLAR TUBE BUNDLE PARTIALLY REMOVED HEAD GASKET TANK GASKET HEAD 4 The COLLAR assembly if equipped is connected to the tank nozzle flange using 9 16 grade 8 bolts To reinstall the collar assembly use a calibrated torque wrench and in an alternating star pattern tighten the bolts in two increments 95 ft lbs and 145 ft lbs collar assembly threads and nut bearing surfaces must be clean rust free and NOT lubricated 5 When replacing the heat exchanger HEAD use a calibrated torque wrench to tighten the bolts studs and nuts in an alternating star pattern Use the following chart as a guide All heat exchanger head torque val
23. sure and temperature relief valve sized in accordance with ASME requirements Each relief valve must be piped and secured 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 operated at least once a year See Maintenance WARNING Do not install a reducing coupling valve or other restriction between the relief valve discharge and a suitable floor drain Such restriction could prevent the valve from fully relieving if the pressure settings are exceeded which could result in property damage personal injury or death WARNING The relief valve discharge must be piped to a suitable floor drain to avoid exposure to hot discharge water during relief valve operation Exposure to hot discharge water can cause water damage and or burns resulting in property damage personal injury or death 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 9 PV500 26 05 13 4 4 5 1 5 2 QuickDraw Storage and Semi instantaneous Boiler Water Heater Filling the Unit 1 Fill the system with water To be sure that the unit is not air bound open the relief valve Leav
24. sure the tank temperature near the thermostat and compare to setpoint The thermostat should turn on and off within 5 F of setpoint Replace if necessary Cause The control valve is not closing properly Solution See the adjustment instructions in this manual or for the specific temperature control valve assembly installed Replace worn components as required Problem 5 Heat exchanger visibly leaking Cause Plumbing connection loose Solution Check and tighten plumbing connection Cause Double wall heat exchanger tube leak Solution If one of the tube walls is breached a double wall heat exchanger will leak at the joint between the tubesheets Isolate the heater and replace the heat exchanger 18 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater Since PVI cannot control the use of the appliance water conditions or maintenance the warranty on the heat exchanger does not cover poor performance structural failure or leaking due to an excessive accumulation of scale MODEL NUMBER SERIAL NUMBER INSTALLATION DATE 19 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater PVI Industries LLC 3209 Galvez Ave e Fort Worth TX 76111 e 1 800 433 5654 e www pvi com 20 PV500 26 05 13
25. ues apply to well lubricated nut bearing surfaces 14 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater HEAT EXCHANGER HEAD LUBRICATED 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 6 Tighten uniformly and in a diametrically staggered pattern alternating star pattern as illustrated below WARNING Follow the proper tightening sequence torque increments and maximum torque values Failure to follow these requirements can cause non repairable damage to gaskets or heat exchangers and can result in leaking property damage personal injury or loss of life 15 PV500 26 05 13 QuickDraw Storage and Semi instantaneous Boiler Water Heater 7 6 Checking and Adjusting 3 Way Valve Operation 1 Check Operation a Remove indicator screw and indicator b Remove cover screws 2 Remove cover c Apply power to actuator drive motor d Notice actuator rotation valve stem direction and linkage cam direction Should drive CW and valve stem down 2 To Reverse Operation Turn off power supply Actuator should drive CCW Re
26. ution Reconfigure water return piping and check valve to allow for proper drainage Check for restriction in the water drain line Cause Heat exchanger is breached Solution Shut off the boiler water supply Residual flow should stop after a short period of time If the flow continues water is leaking from the tank into the coil Disassemble inspect repair or replace as required following the instructions in this manual Cause Heat exchanger is fouled Solution Inspect the heat exchanger for excessive scaling or fouling on the water side Cause Abnormal operating conditions Solution The water temperature has a significant effect on the efficiency of the heat exchanger Check if the setpoint is higher than specified Confirm the measured flow rate with meters or by volume and rate Check that there are no other loads on the heater Problem 3 No hot water even at low flow h Cause Control valve not opening Solution Check that electrical coils are energized If not trace wiring problem If so the valve may be faulty the boiler water flow and temperature is inadequate or the linkage if applicable is out of adjustment Cause The high temperature limit is open Solution Check the individual components of the system and repair or replace the failed component s as necessary Problem 4 Outlet temperature is too high j Cause Malfunctioning or misadjusted thermostat s Solution Check thermostat setting Mea
27. vices including thermostats for proper operation c Check safety shut off valves for operation and tightness d Test high limit and operating temperature controls Semi Annually a Recalibrate all indicating and recording gauges b Check piping and wiring of all interlocks and shutoff valves Monthly Maintenance a Test low water cutoff device and alarm if equipped b Check gauges monitors and indicators c Check instrument and equipment settings As Required a Tank flush and cleanout 17 PV500 26 05 13 8 QuickDraw Storage and Semi instantaneous Boiler Water Heater TROUBLESHOOTING NOTES Problem 1 Outlet water temperature not constant a Cause Insufficient recovery Solution Check and be sure heater design rating is not being exceeded Cause Malfunctioning or misadjusted thermostat s Solution If the thermostat or controller is always open then the outlet temperature will vary with load Measure the tank temperature near the thermostat and compare to setpoint The thermostat should turn on and off within 5 F of setpoint Replace if necessary Problem 2 Heater recovery is slow or outlet temperature is below setpoint C Cause The temperature control valve is not opening properly Solution Check for proper operation of valve actuator and linkage Replace if necessary Cause Return water not draining water drain line is restricted water check valve is leaking or have failed Sol
Download Pdf Manuals
Related Search