PVI Industries PV500-45C manual

1 PV500-45C 06/12  INSTALLATION & MAINTENANCE MANUAL TRICON  WATER HEATER MODELS (40, 50, 75, 90, 100) (L, SS) 125 A-PVIF MODELS (50, 75, 90, 100) (L, SS) (250, 300) A-PVIF Installation and service must be perfor med by a qualified ser vice installer, service agency or the gas supplier. IMPORTANT: THIS MANUAL CONTAINS INFO RMATION RE QUIR[...]

2 PV500-45C 06/12  TABLE OF CONTENTS 1. Safety Considerations 2. Standard Features and Equipment 2.1 Performance 2.2 Pressure Vessel 2.3 Heat Exchanger 2.4 Code and Standards 2.5 Burner, Operating Controls & Safeties 2.6 Warranty and Service Policy (see wa rranty and service policy for d etails) 2.7 Miscellaneous 3. Product Descriptions 4. W[...]

3 PV500-45C 06/12   10. 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) 11. TEMPTRAC Electronic Controller Panel 11.1 Principal of Operation 11.2 Upper LED Readout 11.3 [...]

4 PV500-45C 06/12  1 SAFETY CONSIDERATIONS WARNING: If the information in the supplied manual(s) is no t 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 vicinit [...]

5 PV500-45C 06/12  IMPORTANT SAFETY NOTE It takes only 5 seconds of skin cont act with 140°F water to cause a second degree burn! You must protect aga inst high water temperatures at all lavatories, tubs, showers and othe r points of hot water contact. Accidental scalding from high w ater temperatures is a greater risk in some types of installa[...]

6 PV500-45C 06/12  2 STANDARD FEATURES AND EQUIPMENT 2.1 Performance  90% thermal efficiency at full fire from 40° to 140°F  Up to 96% thermal efficiency with modulation  < 20 ppm NOx (399 to 900 MBH)  Ducts direct combustion air up to 100 equivalent feet throu gh 6-inch diameter material (require s UL approved vent cap, see opt[...]

7 PV500-45C 06/12  3 PRODUCT DESCRIPTION Component, C ontrols and Connectio n Locatio ns (Locations May Vary) 125 SERIES[...]

8 PV500-45C 06/12  250 SERIES[...]

9 PV500-45C 06/12  300 SERIES[...]

10 PV500-45C 06/12  4 WATER HEATER INSTALLATION 4.1 Checking Equipment Before You Install Inspect the unit completely upon receipt from the frei ght carrier before signing the bill of la ding. Inspect the appli ance and all accompanying pa rts for signs of impact or mishandli ng. Verify the total numb er of pieces shown on packing slips with tho[...]

11 PV500-45C 06/12  8. Do not install on ca rpet or other co mbustible floor covering s. If installation over a combustible floor is required, follow these guidelines:  Use a ba se of hollow clay tile or concret e blocks from 8" to 12" thick and extending 24" beyond the sides.  Place the blo cks in line so that the holes lin[...]

12 PV500-45C 06/12  SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WI TH SUPP LEMENTAL STORAGE TANK[...]

13 PV500-45C 06/12  TWO WATER HEATERS WITH REVERSE RETURN PIPING 6 CONDENSATE DRAIN, T RAP & DISPOSAL The Tricon water heater is designed to produce significant amount s of condensate because of its high efficiency. Condensate occurs natura lly when water vapor in combustion ga ses is cooled below the dew point. A 3/4” NPT drain connection[...]

14 PV500-45C 06/12  Condensate Piping and Trap with Optional Condensate Neu trali zer 6.1 Condensate Neutraliza tio n System (optional) Although only slightly acidic (3-5 PH), conde nsate can be routed through an optional Condensate Ne utralization System (see image below) to becom e pH neutral allowing for disposal into any drain or se wer syst[...]

15 PV500-45C 06/12  7 GAS SUPPLY AND PIPING Verify that the type of gas spe cified on rating plate is supp lied 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. 7.1 Gas Train and Control[...]

16 PV500-45C 06/12  Use this corrected total distance from the meter for determining the suggested pipe size in the “Single Unit Installation Suggested Ga s Pipe Size” table. *Multiplier for Propane: 1.57 **Multiplier for alternate pressure drop s: 0.3" W.C. 0.77; 1.0" W.C. 1.41; 2.0" W.C. 2.00; and 4.0" W.C. 2.8 2. 7.6 A[...]

17 PV500-45C 06/12  7.7 Gas Connection 1. Safe operation of unit requires adequate gas supply with t he required static and dynamic (flow) pressures. Actual piping selection depends o n many variables that must be ca refully considered by the gas pipi ng system designer. Do not select gas pipe sizes ba sed only on the supplied tables. These tabl[...]

18 PV500-45C 06/12  8.2 Maximum Allowed Remote Combustion Air Inlet Length (Equivalent Length) A vertical or horizontal remote air inl et system can be connected to this appliance without modification. The maximum length of field supplied singl e wall pipe, such as galvanize d ventilation pipe, is shown in the cha rt below titled Maximum Air Inl[...]

19 PV500-45C 06/12  Vertical Remote Air Horizontal Remote Air 8.5 Remote Air Consideration for Combi ned Remote Air Ducting Each water heater MUST have separate intake pipin g. Consult factory for common air intake pipe sizin g. 9 VENTING 9.1 Venting the TRICON: TRICON models are designed for op eration only with stainl ess steel venting listed [...]

20 PV500-45C 06/12  The following vent information is provided for use in design calculat ions, if needed. Venting Specifications Input MBtu Combus tion Air Volume (cfm) Max Vent Press. ”W.C. 399 136 0.5 500 170 0.6 750 255 1.0 900 306 1.2 1000 340 1.3 9.3 Vertical or Horizontal Vent Termination: 1. The vent terminal must have a minimum cleara[...]

21 PV500-45C 06/12  WARNING: Do not connect multiple water heaters vents into a single un powered or fixed speed powered vent. This could cause unsafe operation and th e potential for poisonous carbon monoxide to en ter occupied areas. Such improper installation c an cause property damage, personal injury, exposure to h azardous materials or los[...]

22 PV500-45C 06/12  10.3 High Water Temperature Limit Control Appliances are equipped with adjustable limit and high lim it controls to con trol the maximum discharge water temperature. These controls are loca ted inside the control cabinet and are accessed by removing the bottom cover. The high limit control i s optionally available as the m an[...]

23 PV500-45C 06/12  11 TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 11.1 Principle Of Opera tion The water heater operates to satisfy the setpoint of the Te mpTrac digital control wh ose sensor is located near the top of the water heater tank. Demand (flow) will typically create a dr op in temperature, thus activating the water heater to add heat to [...]

24 PV500-45C 06/12  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  Push the SET key. The upper display will sho w the “St1” parameter name, whi le the lower display will show its[...]

25 PV500-45C 06/12  11.8 LED Display Alarm Messages Alarm messages are displ ayed in the upper LED rea dout and alternate with the default display. An alarm LED ICON is also illuminated. (See TempTrac User Manual PV500-40 for full description.) 12 REMOTE CONNECTIO NS – TERMINAL STRIP 12.1 Making BMS/BAS remote connections for analog and binary[...]

26 PV500-45C 06/12  12.2 The Following Describes The Functions Of Each Of The se Terminals And The Factory-Installed Options Required To Activate The Terminals: Note : Terminal P1-P2 are functional only when the water heate r is equipped with the factory installed options required to activate the terminals. Terminals R1-R2 , A1-A2, C1-C2 and T1-[...]

27 PV500-45C 06/12  4. Proof of Air Pressure Switch - The control will look for a signal from t he airflow-proving swi tch, indicating that the blower is operating: a. When the airflow generated by the blo wer is sufficient to cause th e differential air switch to close, the 15 - second pr e-purge delay will sta rt. b. During this period any flu[...]

28 PV500-45C 06/12  14 INITIAL STARTUP 14.1 Initial Startup Requirements Installation should b e complete prior to performing i nitial st artup; and the startup must be co mplete prior to placing the water heater into serv ice. Starting the water heater wit hout proper pi ping, combustion air, venting or electrical systems can be da ngerous and [...]

29 PV500-45C 06/12  b. Attach a manometer to measure the gas pre ssure at the manual gas shutoff valve located ju st upstream of the gas train. Adjust gas train inlet pre ssure to the specified value (e.g. 14" W.C. ), and tightly close the gas train manual shutoff valve closest to the burner. c. Reattach th e manometer to the gas trai n man[...]

30 PV500-45C 06/12  19. When the blower motor starts, the flam e control will check for a positive air flow . If the air switch or blocked filter switch (if equipped) 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 co[...]

31 PV500-45C 06/12  Gas Train Illustration for Models 40 through 50 (Optional compone nts may not be sho wn) Gas Train Illustration for Models 65 through 100 (Optional compone nts may not be sho wn)[...]

32 PV500-45C 06/12  15 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Starting or Pre-purge Failure Power Supply Check fuse and/or circuit b reaker. Check voltage at 120/24V step-down transfo rmer. On-Off Switch Check if On-Off switch is lighted Temperature Control Check that the operating te mperature control is set higher than [...]

33 PV500-45C 06/12  16 REPLACEMENT PARTS REPLACEMENT PARTS[...]

34 PV500-45C 06/12  16.1 Co ntrol Panel[...]

35 PV500-45C 06/12  16.2 Control Panel Components (Optional components may not be included) Key No. Part No. Description Qty. U/M 1 101947 CONTROL, HOT SURFACE IGNITION FENWAL 1 EA 2 - CONTROL, TEMPERATURE TEMPTRAC 1 EA 3 - DRIVE, VARIABLE FREQ UENCY AC EMERSON 1 EA 4 5613 FUSEHOLDER, PANEL TYPE #HTB-28I 1 EA 5 5742 FUSE, MDA 15 AMP BUSS 250V NO[...]

36 PV500-45C 06/12  16.3 Burner Assembly Optional components may or may not be shown[...]

37 PV500-45C 06/12  16.4 Burner Assembly Components (Optional components may not be included) Item No. Qty. PVI Part No. Description 1 1 111876 BLOWER, FASCO #70430 069 2 1 * ASSY, BULKHEAD REFRACTORY 3 1 * BURNER, METAL PUNCHED 4 6 114513 SPACER, NYLON 1/4 ID X 1/2 OD X 11/16 MCMASTER C 5 1 115248 ASSY, INTAKE GAS AIR 7 OD X 1 NPT 6 14 3494 WAS[...]

38 PV500-45C 06/12  17 PERIODIC MAIN TENANCE Listed below are items that must be ch ecked to ensure safe reliable operations . Maintenance must be performed by a qualified service or maintenance prov ider. To ensure proper maintenance, the followi n g instructions should be posted near the appliance and maintai ned in legible c ondition. Verify [...]

39 PV500-45C 06/12  i. Cycle unit and test to verify all safety and operating controls are prop erly functioning and the burner to p plate flange is free of leaks. 6. If equipped, the combustion air filter should be replaced every six months. If filter blockage becom es excessive the filter safety switch will not allow the burner to fi re. To av[...]

40 PV500-45C 06/12  18 RECOMMENDED MAINTENA NCE SCHEDULE 1. Annual Maintenance a. Check all joints and pipe conne ctions fo r tightness, corrosion or deterioration. b. Check the electronic-ignitio n system for quick ignition and a proper flame signal. c. Check all safety controls includ ing thermostat s for proper operation. d. Check safety shut[...]

41 PV500-45C 06/12 [...]

42 PV500-45C 06/12  PVI INDUSTRIES ® , LLC  3209 Galvez Av e.  Fort Worth, Texas 76111  Phone 1-800-433-5654  www.pvi.com[...]