PVI Industries 180 manual

1 PV500-46U 06/12  INSTALLATION & MAINTENANCE MANUAL POWER VT  PLUS WATER HEATER MODELS (150, 180, 200) LX (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 REQUIRED FOR INSTALLATION, OPER ATION AND MAINTENANCE O[...]

2 PV500-46U 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 PV500-46U 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 PV500-46U 06/12  1 SAFETY CONSIDERATIONS WARNING: If the information in the supplied man ual(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 vicinit[...]

5 PV500-46U 06/12  IMPORTANT SAFETY NOTE It takes only 5 seconds of skin co ntact 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 PV500-46U 06/12  2 STANDARD FEATURES AND EQUIPMENT 2.1 Performance  95% thermal efficiency at full fire from 40° to 140°F  Up to 99% thermal efficiency with modulation  < 20 ppm NOx  Ducts direct comb ustion air up to 100 equivalent feet th rough 6 -inch diameter material (requires UL approved vent cap, see optional equipment [...]

7 PV500-46U 06/12  3 PRODUCT DESCRIPTION Component, Controls and Connectio n Locations (Locations May Vary) 250 SERIES[...]

8 PV500-46U 06/12  300 SERIES[...]

9 PV500-46U 06/12  4 WATER HEATER INSTALLATION 4.1 Checking Equipment Before You Install Inspect the unit completely upon receipt from th e freight carrier before signing the bill of lading. Inspect the appliance and all accompanying pa rts for signs of impact or mishandling. Verify the total number of pieces shown on packing slips with tho se a[...]

10 PV500-46U 06/12  8. Do not install on carpet or other co mbustible floor coverings. If installation over a combustible floor is required, follow these guidelines:  Use a base of hollow clay tile or co ncrete blocks from 8" to 12" thick and extending 24" beyond the sides.  Place the blocks in line so that the holes line up[...]

11 PV500-46U 06/12  SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WI TH SUPP LEMENTAL STORAGE TANK[...]

12 PV500-46U 06/12  TWO WATER HEATERS WITH REVERSE RETURN PIPING 6 CONDENSAT E DR AIN, T RAP & DISPOSAL The POWER VT PLUS water heater is designe d to produce significant amount s 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 [...]

13 PV500-46U 06/12  Condensate Piping and Trap w ith Optional Conden sate Neutralizer 6.1 Condensate Neutralization Sy stem (optional) Although only slightly acidic (3-5 PH), condensate can be routed through an optional Condensate Neutralization System (see image below) to becom e pH neutral allowing for disposal into any drain or sewer system w[...]

14 PV500-46U 06/12  7 GAS SUPPLY AND PIPING Verify that the type of gas specified on rating plate is supplie d to the unit. This unit is orificed for operation up to 2000 feet altitude. Appliance Btuh out put derates 4% per 1000 feet elevatio n above sea level. Consult Factory for installations above 2000 feet elevation. 7.1 Gas Train and Contro[...]

15 PV500-46U 06/12  7.6 Appliance Isolation during Gas Supply Pip ing Pressure Test 1. The appliance and its provided manual shutoff valv e must be disconnected from the gas supply piping system during any pressure testing of t hat system at test pressures in excess of ½ PSI (3.5 kPa). 2. The applianc e must be isolated from the gas supply pi p[...]

16 PV500-46U 06/12  8 COMBUSTIO N AND VENTILATION AIR Provisions for adequate combustion a nd ventilation air to the mechanical room must be in accordance with Section 5.3 “Air for Combustion and Ventilation” of the late st edi tion of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149, Installation Codes or applicable p rovisions o[...]

17 PV500-46U 06/12  Duct Fitting Equivalent Length Duct Pipe: 6” Duct 7” Duct 8” Duct 9” Duct 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 The following remote air duct informatio n is provided for use in design calculations, if needed. Remote Air Duct [...]

18 PV500-46U 06/12  9 VENTING 9.1 Venting the Power VT Plus “SANI” models: Power VT Plus model s with “SANI” in the model number are designed fo r operation only with stainless stee l venting listed by UL, ULC, ETL or CSA for Category IV, positive pres sure, gas appliance venting. Installation requires a field supplied stainless steel ad[...]

19 PV500-46U 06/12  The following vent information is provided for use in design calculat ions, if needed. Venting Specifications Input Mbtu Products of Combustion Volume (cfm) Max Vent Press. “W.C. 1500 350 1.7 1800 420 2.0 2000 467 2.0 9.4 CPVC Vent System Design, Cons truction and Assembly: The Power VT Plus water heater can be vented eithe[...]

20 PV500-46U 06/12  8. The solid CPVC vent pipe (Plastic venting is not allowed for mo dels with “SANI” in the model number) must be sealed to the wall or roof at the point where it passes th rough the wall or roof, to prevent rain, insect s or flue products from entering the l iving space. 9. For pro per vent operation and to protect the ga[...]

21 PV500-46U 06/12  Conventional Venting Through the Wall Venting Combining Vents with a Draft Inducer 10 OPERATING AND SAFETY CONTROLS WARNING: Turn off all electrical serv ice to the appliance when accessing the limit or other controls located inside the control cabinet. This cabinet con tains High Voltage w i ring and terminals. If the electr[...]

22 PV500-46U 06/12  10.3 High Water Temperature Limit Control Appliances are equipped with adjustable limit and high lim it controls to control the maximum di scharge 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 manu[...]

23 PV500-46U 06/12  11 TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 11.1 Principle Of Operation The water heater operates to satisfy the setpoint of the Te mpTrac digital control whose sensor is l ocated 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 t[...]

24 PV500-46U 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 show the “St1” parameter name, while the lower d isplay will show its [...]

25 PV500-46U 06/12  11.8 LED Display Alarm Messages Alarm messages are displayed in the upper LED readout an d alternate with the default di splay. An alarm LED ICON is also illuminated. (See TempTrac User Manual PV500-40 for full description.) ALARM MESSAGE CAUSE RESULTS OF ALARM CONDITION RECOMMENDED ACTION “P1” TP1 probe failure Inlet tem[...]

26 PV500-46U 06/12  12 REMOTE CONNECTIONS – TERMINAL STRIP 12.1 Making BMS/BAS remote connections for analog and binary ( on/off) signals A terminal strip for the remote connectio n is located behind the hinged control panel at the to p of the cabinet and is accessed by removing the bottom cover and then removi ng the screws at the top of the [...]

27 PV500-46U 06/12  13 SEQUENCE OF OPERATION 1. Incoming 12 0VAC 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 o n: a. 120v is applied to the step-down transformer (24v) b. 120v is applied to the L.W.C.O. terminal L1 (if used) c. 120v is appli[...]

28 PV500-46U 06/12  8. Delay-On Rela y - Once the Delay-O n (Low Fire Hold) Relay has timed out, it energizes the Modulation Relea se Relay (SPDT) to enable the analog signal from the T empTrac 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 t[...]

29 PV500-46U 06/12  14 INITIAL STARTUP 14.1 Initial Startup Requirements Installation should b e complete prior to performing initial st artup; a nd the startup must be complete prior to placing the water heater into serv ice. Starting the water heater wit hout proper piping, comb ustion air, venting or electrical systems can be da ngerous and m[...]

30 PV500-46U 06/12  b. Attach a manometer to measu re the gas pressure at the manual gas shutoff valve located just upstream of the gas train. Adjust gas train inlet pre ssure to the specified value (e.g. 14" W.C. ), and tightly close the g as train manual shutoff valve closest to the burner. c. Reattach the manometer to the gas train manua[...]

31 PV500-46U 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 is not made the blower will stay on for a pe riod of time then lockout. To adjust the air-proving switch, turn the adjustment screw counter-cloc kwise until the air pr oving light comes on, then[...]

32 PV500-46U 06/12  Gas Train Illustration (Optional compone nts may not be shown) Alternate Gas Train Illustration (Optional compone nts may not be shown)[...]

33 PV500-46U 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 [...]

34 PV500-46U 06/12  16 REPLACEMENT PARTS REPLACEMENT PARTS[...]

35 PV500-46U 06/12  16.1 Cont rol Pane l[...]

36 PV500-46U 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[...]

37 PV500-46U 06/12  16.3 Burner Assembly Optional components may or may not be shown[...]

38 PV500-46U 06/12  16.4 Burner Assembly Components (Optional components may not be included) Item No. Qt y. PVI Part No. Description BURNER ASSEMBLY COMPONENTS 1 117188 B&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 [...]

39 PV500-46U 06/12  BURNER GAS TRAIN CO MPONENTS 50 1 114530 PKG, GAS TRAIN 1 1/2 M x 3/8 P x 1 1/2 C 51 1 116921 REGULATOR, 1 1/2 MAXITROL #210E Z ZERO GOVERNOR 52 1 102836 VALVE, GAS DUNGS DMV-D 70 3/6 24VAC 53 * 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 * 5973 NIPPLE, BLACK 1[...]

40 PV500-46U 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 ng instruction s should be posted near the appliance and maintai ned in legible c ondition. Verify [...]

41 PV500-46U 06/12  6. The combustion air filter should b e replaced every six months. If filter blockage becomes exce ssive the filter safety switch will not allow the burn er to fire. To avoid nuisance shutdo wn in dirty environments, check and replace filter more frequently. 7. Inspect low water cutoffs and reli ef valves for proper oper atio[...]

42 PV500-46U 06/12  18 RECOMMENDED MAINTENANCE SCHEDULE 1. Annual Maintenance a. Check all joints and pipe connection s fo r tightness, corrosion or deterioration. b. Check the electronic-ignition system for quick ignition and a proper flame signal. c. Check all safety controls includ ing thermostats for proper o peration. d. Check safety shut-o[...]

43 PV500-46U 06/12 [...]

44 PV500-46U 06/12  PVI INDUSTRIES ® , LLC  3209 Galvez Av e.  Fort Worth, Texas 76111  Phone 1-800-433-5 654  www.pvi.com[...]