PVI Industries PV500-44U manual

1 PV500-44U 06/12  INSTALLATION & MAINTENANCE MANUAL POWER VT  PLUS WATER HEATER MODELS (40, 50, 75, 90, 100) LX 125 A-PVIF MODELS (50, 75, 90, 100) 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 RE QUIRED [...]

2 PV500-44U 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 PV500-44U 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 PV500-44U 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 PV500-44U 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 PV500-44U 06/12  2 STANDARD FEATURES AND EQUIPMENT 2.1 Performance  98% thermal efficiency at full fire from 40° to 140°F  Up to 99% thermal efficiency with modulation  < 20 ppm NOx (399 to 900 MBH)  Ducts direct combustion air up to 100 eq uivalent feet through 6-inch diameter material (requires UL approved vent cap, see opti[...]

7 PV500-44U 06/12  3 PRODUCT DESCRIPTION Component, Controls and Connectio n Locatio ns (Locations May Vary) 125 SERIES[...]

8 PV500-44U 06/12  250 SERIES[...]

9 PV500-44U 06/12  300 SERIES[...]

10 PV500-44U 06/12  4 WATER HEATER INSTALLATION 4.1 Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight ca rrier before signing the bill of lading. Inspect the appliance and all accompanying pa rts for signs of impact or misha ndli ng. Verify the total number of pieces shown on packing slips with those[...]

11 PV500-44U 06/12  8. Do not install on ca rpet or other co mbustible floor coverings. If installation over a combu stible floor is required, follow these guidelines:  Use a ba se of hollow clay tile or concrete blocks from 8" to 12" thick and extending 24" beyond the side s.  Place the blo cks in line so that the holes lin[...]

12 PV500-44U 06/12  SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WI TH SUPP LEMENTAL STORAGE TANK[...]

13 PV500-44U 06/12  TWO WATER HEATERS WITH REVERSE RETURN PIPING 6 CONDENSATE DRAIN, T RAP & DISPOSAL The POWER VT PLUS water heater is designed to produce significant amount s of condensate be cause of its high efficiency. Condensate occurs naturally when water vapor in combustion gases is cooled b elow the dew point. Two 3/4” NPT drain c[...]

14 PV500-44U 06/12  Condensate Piping and Trap w ith Optional Conden sate Neutralizer 6.1 Condensate Neutraliza tio n System (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 [...]

15 PV500-44U 06/12  7 GAS SUPPLY AND PIPING Verify that the type of gas spe cified on rating plate is supp lied to th e 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 Contro[...]

16 PV500-44U 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 PV500-44U 06/12  7.7 Gas Connection 1. Safe operation of unit requires adequate gas supply with t he required static a nd dynamic (flow) pressures. Actual piping selection depends o n many variables that must be ca refully considered by the gas piping system de signer. Do not select gas pipe sizes ba sed only on the supplied tables. These tab[...]

18 PV500-44U 06/12  8.2 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 singl e wall pipe, such as galvanized ventilation pip e, is shown in the chart below titled Maximum Air Inlet[...]

19 PV500-44U 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 sizing. 9 VENTING 9.1 Venting the Power VT Plus “SANI” models: Power VT Plus models wit h “SANI” in the model number ar[...]

20 PV500-44U 06/12  WARNING: Do not v ent 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 sy stem and/or exposure to carbon monoxide which can result in property damage, perso nal injury or death. 9.3 Maximum Category IV Vent L[...]

21 PV500-44U 06/12  4. Dry-fit a solid 6” CPVC pipe into the female economizer flue outlet. Remove the pipe and ap ply a liberal coating of room temperature vulcanizing (RTV ) adhesive to the inside of the stainless st eel economizer flue outle t and to the outside of the plastic pi pe. Before the RTV sets , slide the plastic coupling or elbow[...]

22 PV500-44U 06/12  10. 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. 9.6 Combining Category IV Vents Combined Power VT Plus Category IV gas vent systems must incorpo rate an Exhausto or Tjernlund varia ble speed, modulating, mechanical draft indu cer capa[...]

23 PV500-44U 06/12  10.2 Operating Temperature Control An adjustable digital operating control is located in the front control panel. The control is factory pre-set at approximately 120 º F. To adjust the setpoint to deliver the desir ed water tempe rature, press and release the Set 1 key on the face of the control. When se tpoint adjust ment i[...]

24 PV500-44U 06/12  11 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 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 th[...]

25 PV500-44U 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, whi le the lower display will show its [...]

26 PV500-44U 06/12  11.8 LED Display Alarm Messages Alarm messages are displ ayed 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.) 12 REMOTE CONNECTIONS – TERMIN A L STRIP 12.1 Making BMS/BAS remote connections for analog and binary[...]

27 PV500-44U 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-T[...]

28 PV500-44U 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 the differential air switch to close, the 15 - second pr e-purge delay will sta rt. b. During this period any flue[...]

29 PV500-44U 06/12  14 INITIAL STARTUP 14.1 Initial Startup Requirements Installation should be complete prior to performing i nitial st artup; and the startup must be complete prior t o 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 PV500-44U 06/12  b. Attach a manometer to measure the gas pre ssure at the manual gas shutoff valve located just upst ream 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 trai n man[...]

31 PV500-44U 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 scre w counter-clockwise until the air proving light c[...]

32 PV500-44U 06/12  Gas Train Illustration for Models 40 through 50 (Optional compone nts may not be shown) Gas Train Illustration for Models 65 through 100 (Optional compone nts may not be shown)[...]

33 PV500-44U 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 PV500-44U 06/12  16 REPLACEMENT PARTS REPLACEMENT PARTS[...]

35 PV500-44U 06/12  16.1 Co ntrol Panel[...]

36 PV500-44U 06/12  16.2 Control Panel Components (Optional components may not be included) Key No. Part No. Description Qty. U/M 1 101947 CO NTROL, 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 N[...]

37 PV500-44U 06/12  16.3 Burner Assembly Optional components may or may not be shown[...]

38 PV500-44U 06/12  16.4 Burner Assembly Components (Optional compone nts 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 WA[...]

39 PV500-44U 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 [...]

40 PV500-44U 06/12  i. Cycle unit and test to verify all safety and operating controls are prop erly functioning and the burner top 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 avo[...]

41 PV500-44U 06/12  18 RECOMMENDED MAINTENANCE SCHEDULE 1. Annual Maintenance a. Check all joints and pipe connections fo r tightness, corrosion or deterioration. b. Check the electronic-ignition system for quick ignition and a proper flame sign al. c. Check all safety controls includ ing thermostat s for proper operation. d. Check safety shut-o[...]

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