PVI Industries PV500-47C manual

1 PV500-47C 06/12  INSTALLATION & MAINTENANCE MANUAL TRICON  WATER HEATER MODELS (150, 180, 200) (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 REQUIRED FOR INSTALLATION, OPER ATION AND MAINTENANCE OF [...]

2 PV500-47C 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 PV500-47C 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 PV500-47C 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 PV500-47C 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 PV500-47C 06/12  2 STANDARD FEATURES AND EQUIPMENT 2.1 Performance  87% thermal efficiency at full fire from 40° to 140°F  Up to 92% thermal efficiency with modulation  < 20 ppm NOx  Ducts direct comb ustion air up to 100 equivalent feet th rough 6-inch diam eter material (requires UL a pproved vent cap, see optional equipment[...]

7 PV500-47C 06/12  3 PRODUCT DESCRIPTION Component, C ontrols and Connectio n Locatio ns (Locations May Vary) 250 SERIES[...]

8 PV500-47C 06/12  300 SERIES[...]

9 PV500-47C 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 si gning 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 [...]

10 PV500-47C 06/12  8. Do not install on carpet or other co mbustible floor coverings. If installation over a combustibl e 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 u[...]

11 PV500-47C 06/12  SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WI TH SUPP LEMENTAL STORAGE TANK[...]

12 PV500-47C 06/12  TWO WATER HEATERS WITH REVERSE RETURN PIPING 6 CONDENSAT E DR AIN, T RAP & DISPOSAL The TRICON water heate r is designed to pro duce significant amounts of condensate because of its high eff iciency. Condensate occurs naturally when water vapor in combustion g ases is cooled below the dew point. A 3/4” NPT drain connect[...]

13 PV500-47C 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), condensate can be routed through an optional Condensate Ne utralization System (see image below) to be come pH neutral allowing for disp osal into any drain or se wer syst[...]

14 PV500-47C 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 PV500-47C 06/12  7.6 Appliance Isolation during Gas Supply Piping 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 sup ply pi p[...]

16 PV500-47C 06/12  8 COMBUSTIO N AND VENTILATION AIR Provisions for adequate co mbustion and ventilation air to the mech anical room must be in a ccordance with Section 5.3 “Air for Combustion and Ventilation” of the late st edi tion of the National F uel Gas Code, ANSI Z223.1 and/o r CAN/CSA B149, Installation Codes or applicable p rovisio[...]

17 PV500-47C 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 neede d. Remote Air Duct[...]

18 PV500-47C 06/12  9 VENTING 9.1 Venting the TRICON: TRICON models are designed for o peration only with stainl ess steel venting listed by UL, ULC, ETL or CSA for Category IV, positive pressure, gas appliance venting. Follo w the vent manuf acturer’s instructions for installation, sealing, supporting and t erminating their vent system. Do no[...]

19 PV500-47C 06/12  9.3 Vertical or Horizontal Vent Termination: 1. The vent terminal must have a minim um clearance of 4 feet (1.22 m) hori zontally from, and in no case be located above or below, unless a 4 foo t (1.22 m) horizont al distance is maint ained from electric meters, gas meters, regulators and relief equipment. 2. The vent cap must[...]

20 PV500-47C 06/12  10 OPERATING AND SAFETY CONTROLS WARNING: Turn off all electrical serv ice to the appliance w hen accessing the limit or other controls located inside the control cabinet. This cabinet con tains High Voltage wiring and terminals. If the electrical service is not turned off and these terminals are to uched, a dangerous shock c[...]

21 PV500-47C 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 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 t[...]

22 PV500-47C 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 lo wer display will show its [...]

23 PV500-47C 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 CONNECTIONS – TERMINAL STRIP 12.1 Making BMS/BAS remote connections for analog and binary [...]

24 PV500-47C 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-[...]

25 PV500-47C 06/12  4. Proof of Air Pressure Switch - The control will look for a signal from t he airflow-proving switch, 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 flue[...]

26 PV500-47C 06/12  14 INITIAL STARTUP 14.1 Initial Startup Requirements Installation should be complete prior to perfo rming initial st artup; and the startup must b e complete 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 m[...]

27 PV500-47C 06/12  b. Attach a manometer to measu re the gas pressure at the ma nual 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 gas train manual shutoff valve closest to the burner. c. Reattach the manometer to the gas train man u[...]

28 PV500-47C 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[...]

29 PV500-47C 06/12  Gas Train Illustration (Optional compone nts may not be sho wn) Alternate Gas Tr ain Illustration (Optional compone nts may not be sho wn)[...]

30 PV500-47C 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 [...]

31 PV500-47C 06/12  16 REPLACEMENT PARTS REPLACEMENT PARTS[...]

32 PV500-47C 06/12  16.1 C ontrol Pane l[...]

33 PV500-47C 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[...]

34 PV500-47C 06/12  16.3 Burner Assembly Optional components may or may not be shown[...]

35 PV500-47C 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 [...]

36 PV500-47C 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[...]

37 PV500-47C 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 [...]

38 PV500-47C 06/12  i. Cycle unit and test to verify all safety and operating controls are properly functioning and the burner to p plate flange is free of leaks. 6. The combustion air filter should b e replaced every six months. If filter blockage becom es excessive the filter safety switch will not allow the burn er to fire. To avoid nuisance [...]

39 PV500-47C 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 ope ration. d. Check safety shut-o[...]

40 PV500-47C 06/12  PVI INDUSTRIES ® , LLC  3209 Galvez Av e.  Fort Worth, Texas 76111  Phone 1-800-433-5654  www.pvi.com[...]