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INSTALLATION & MAINTENANCE MANUAL
Installation and service must be performed by a qualified service installer, service agency or the gas supplier.
THIS
MANUAL
IMPORTANT:
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.
POWER VT
PLUS WATER HEATER
MODELS (150, 180, 200) LX (250, 300) A-PVIF
CONTAINS
INFORMATION
PVI INDUSTRIES, LLC - Fort Worth, Texas 76111 - Web www.pvi.com - Phone 1-800-433-5654
REQUIRED
FOR
1
INSTALLATION,
OPERATION
PV500-46U 06/12
AND
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Table of Contents
Related Manuals for PVI Industries 150LX-250 A-PVIF
Summary of Contents for PVI Industries 150LX-250 A-PVIF
- Page 1 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. PVI INDUSTRIES, LLC - Fort Worth, Texas 76111 - Web www.pvi.com - Phone 1-800-433-5654 PV500-46U 06/12 ...
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Page 2: Table Of Contents
TABLE OF CONTENTS Safety Considerations Standard Features and Equipment Performance Pressure Vessel Heat Exchanger Code and Standards Burner, Operating Controls & Safeties Warranty and Service Policy (see warranty and service policy for details) Miscellaneous Product Descriptions Water Heater Installation Checking Equipment Before You Install Codes Electrical Requirements Handling and Location... - Page 3 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...
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Page 4: Safety Considerations
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 ... - Page 5 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.
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Page 6: Standard Features And Equipment
STANDARD FEATURES AND EQUIPMENT Performance 95% thermal efficiency at full fire from 40° to 140°F Up to 99% thermal efficiency with modulation < 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) ... -
Page 7: Product Descriptions
PRODUCT DESCRIPTION Component, Controls and Connection Locations (Locations May Vary) 250 SERIES PV500-46U 06/12 ... - Page 8 300 SERIES PV500-46U 06/12 ...
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Page 9: Water Heater Installation
WATER HEATER INSTALLATION Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading. Inspect the appliance and all accompanying parts for signs of impact or mishandling. Verify the total number of pieces shown on packing slips with those actually received. -
Page 10: Service Clearances
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. ... - Page 11 SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK PV500-46U 06/12 ...
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Page 12: Condensate Drain, Trap & Disposal
TWO WATER HEATERS WITH REVERSE RETURN PIPING CONDENSATE DRAIN, TRAP & 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”... -
Page 13: Condensate Neutralization System (Optional)
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. -
Page 14: Gas Supply And Piping
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. -
Page 15: Appliance Isolation During Gas Supply Piping Pressure Test
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). -
Page 16: Combustion And Ventilation Air
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. -
Page 17: Remote Combustion Air Cap
A UL Listed air intake termination cap is available from PVI Industries and may have shipped with the water heater as a purchased option. Vertical or Horizontal Remote Air Duct Termination ... -
Page 18: Venting
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. -
Page 19: Cpvc Vent System Design, Construction And Assembly
Vent Fitting Equivalent Length Vent Pipe: 6” Vent 7” Vent 8” Vent 9” Vent 90º Elbow 8 feet 9 feet 10 feet 11 feet 90º Long Radius Elbow 5 feet 5 feet 5 feet 6 feet 45º Elbow 5 feet 5 feet 5 feet 5 feet... -
Page 20: Vertical Or Horizontal Vent Termination
8. 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. -
Page 21: Operating And Safety Controls
Conventional Venting Through the Wall Venting Combining Vents with a Draft Inducer 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 turned off and these terminals are touched, a dangerous shock causing personal injury or loss of life could occur. -
Page 22: High Water Temperature Limit Control
10.3 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. -
Page 23: Temptrac Electronic Controller Panel
TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 11.1 Principle Of Operation The water heater operates to satisfy the setpoint of the TempTrac digital control whose sensor is located near the top of the water heater tank. Demand (flow) will typically create a drop in temperature, thus activating the water heater to add heat to the stored water. -
Page 24: To View The Setpoint
11.5 To View The Setpoint Push and release the SET key to see the set point value. To return to normal display, press SET + UP or wait 15 seconds without pressing any key. 11.6 To Change The Setpoint ... -
Page 25: Led Display Alarm Messages
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 CAUSE RESULTS OF ALARM CONDITION MESSAGE ACTION Inlet temperature sensor is not... -
Page 26: Remote Connections - Terminal Strip
REMOTE CONNECTIONS – TERMINAL STRIP 12.1 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. -
Page 27: Sequence Of Operation
SEQUENCE OF OPERATION 1. Incoming 120VAC a. Full time power to the Main Control Switch b. Full time power to the Variable Frequency Drive 2. Power On - When the main control switch is turned on: a. 120v is applied to the step-down transformer (24v) b. - Page 28 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.
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Page 29: Initial Startup
INITIAL STARTUP 14.1 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. - Page 30 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.
- Page 31 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.
- Page 32 Gas Train Illustration (Optional components may not be shown) Alternate Gas Train Illustration (Optional components may not be shown) PV500-46U 06/12 ...
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Page 33: Troubleshooting Guide
TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Check fuse and/or circuit breaker. Check voltage at Power Supply 120/24V step-down transformer. On-Off Switch Check if On-Off switch is lighted Check that the operating temperature control is set Temperature Control higher than the temperature of the water heater. Check for bad ground or bad control. -
Page 34: Replacement Parts
REPLACEMENT PARTS REPLACEMENT PARTS PV500-46U 06/12 ... -
Page 35: Control Panel
16.1 Control Panel PV500-46U 06/12 ... -
Page 36: Control Panel Components
16.2 Control Panel Components (Optional components may not be included) Part No. Description Qty. 101947 CONTROL, HOT SURFACE IGNITION FENWAL CONTROL, TEMPERATURE TEMPTRAC DRIVE, VARIABLE FREQUENCY AC EMERSON 5613 FUSEHOLDER, PANEL TYPE #HTB-28I 5742 FUSE, MDA 15 AMP BUSS 250V NO SUBSTITUTE 113915 LWCO, PROTODESIGN #LW-3-C-1-A-03 58154... -
Page 37: Burner Assembly
16.3 Burner Assembly Optional components may or may not be shown PV500-46U 06/12 ... -
Page 38: Burner Assembly Components
16.4 Burner Assembly Components (Optional components may not be included) Item No. Qty. PVI Part No. Description BURNER ASSEMBLY COMPONENTS 117188 B&C, 2000 MBTU MXIF/PVIF 117189 ASSY, BURNER PVIF 2000M 113752 ASSY, BURNER TOP PLATE / RETURN TUBE 17 117190 ASSY, FILTER BOX 12 x 24 PVIF 117191 GAS / AIR FILTER TUBE... - Page 39 BURNER GAS TRAIN COMPONENTS 114530 PKG, GAS TRAIN 1 1/2 M x 3/8 P x 1 1/2 C 116921 REGULATOR, 1 1/2 MAXITROL #210EZ ZERO GOVERNOR 102836 VALVE, GAS DUNGS DMV-D 703/6 24VAC 5972 NIPPLE, BLACK 1/4 x 1 102838 FLANGE, BLACK 1 1/2 DUNGS 45327 VALVE, SHUTOFF 1 1/2 GAS COMBU...
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Page 40: Periodic Maintenance
5 & 6 below. 4. 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 ®... - Page 41 11. All replacement parts are available through your PVI Industries Dealer. If you need assistance identifying or contacting your local dealer, you may contact PVI Industries, LLC directly at the address and telephone number located on the first and last page of this manual.
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Page 42: Recommended Maintenance Schedule
RECOMMENDED MAINTENANCE SCHEDULE 1. Annual Maintenance 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. c. Check all safety controls including thermostats for proper operation. d. - Page 43 PV500-46U 06/12 ...
- Page 44 ® , LLC 3209 Galvez Ave. Fort Worth, Texas 76111 Phone 1-800-433-5654 www.pvi.com PVI INDUSTRIES PV500-46U 06/12 ...