PVI Industries 800-N-Z5DA-PV User manual

POST THESE INSTRUCTIONS WITH YOUR PVI WATER HEATER
Model No. Bco,p../-Z£OA-W-
Serial No.
---------
GENERAL INSTALLATION &MAINTENANCE MANUAL
(FOR ALL MODELS)
OTHER PVI WATER HEATER MANUALS:
SECTION 2 - ATMOSPHERIC GAS WATER HEATERS
SECTION 3-POWER GAS
,& OIL WATER HEATERS
SECTION 4 - TURBOPOWEn@ GAS, OIL, AND GAS/Oil WATER HEATERS
SECTION 6 -
DURAWAn® ELECTRIC WATER HEATERS
SECTION 8 - HIVET® &FLEXCOIL®
STEAM & HOT WATER WATER HEATERS
SECTION 9-GAS BURNEHS
SECTION 10- OIL BURNERS
SECTION 13- DOUBLE-WP,LL HOT WATER
SECTION
14- DOUBLE-WALL STEAM TO WATER
SECTION 17- VECTOR GJ1'3 BURNERS
• DO NOT try to light any ap-
Ipllance.
I
i. • DO NOT touch anyelectrical
switch; DO NOT use any
I phone In your bUilding.
.! •IMMEDIATELYcall your gas
supplier tram a phone out-
l
~ side the building. Follow the
gas supplier's Instructions.
•It you cannot reach your gas
I
supplier, CALL THE FIRE
DEPARTMENT.
FOR YOUR SAFETY
WARNING: Improper In-
stallation, adjustment, al-
teration, service or
maintenance can cause
injury or property
damage. Refer to this
manual for assistance or
additional information;
consult a qualified in-
staller, service agency, or
the gas supplier.
I
i
'.
l
FOR YOUR SAFETY
WHAT TO DO WHEN
YOU SMELL GAS: FOR YOUR SAFETY
DO NOT store or use
gasoline or other flam-
mable vapors and liquids
in the vicinity of this or
any other appliance.
PVIINOUSTRIES, INC.
P.O. Box 7124 •Fort Worth, Texas 76111
,1-800-433-5654
WH-\
(1 )SECTION 1

INSTALLA TION& MAINTENANCE MANUAL FOR
PQWERVr@
INTEGRATED WATER HEATING SYSTEM
IMPORTANT: READ AND FOLLOW THE INFORMATION IN THIS MANUAL, THE GENERAL
INSTALLATION &MAINTENANCE MANUAL, AND
ALL OTHER PROVIDED INSTRUCTIONS,
LABELS AND MARKINGS BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.
TABLE OF CONTENTS
Heater Illustration
Product Safety Information
Electrical
Venting Instructions
Condensate Neutralization
Start-up Procedures
Burner Illustration
Burner Start-up
Maintenance
Troubleshooting Guide
2
3-4
4
5-8
9
10
11
12-14
15-18
19-20
WARNING: If the information on th&appliance and 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 stofe Of use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your bUilding.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
•If
you cannot reach your gas suppHer, call the fire department.
Installation and service must be perfnrmed by a qualified installer, service agency, or the gas
supplier.
This product contains, or may come to contain, materials that have been identified as
carcinogenic, or possibly carcinogenic, to humans. Before installing, servicing, or removing this
product, read and foHow the supplied ,instructions.
PVIINDUSTRIES, LLC
P.O. Box 7124
F,qrt Worth, TX 76111
[phone]
www.pvi.com
PV500-19 04·2005
Section 19

POWERVT@WATER HEATER
Typical Construction
fII'L __ -t---'lZY
".-,.J;)!ltICitfioJl-----t--(
7
17
4
5
Figure 19-1
1. Cold water inlet
2. Hot water outlet
3. Drain
4. Condensate drain
5. I-beam skid
6. Flue outlet
7. Gas inlet
8. Induced draft blower motor
9. Circulating pump
10. Temperature &pressure relief valve
11. Electronic LWCO probe
12. Control enclosure with sWitch(es) &fuse(s)
13. Handhole access
14. Burner
15. Manual reset temperature limiting device
16. Operating control
17. Drip leg
18. Electronic LWCO control (optional)
19. Temperature &pressure gauges (optional)
20. Alarm bell
21. Differential air switch
22. Passive FGR duct (factory installed for Low NOx units)
23. Passive FGR duct (field installed for Low NOx units)
IMPORTANT: Clearance to unprotected combustible material must be 8" minimum at top, sides
and rear, and 24"minimum in front. Recommended access for service is 18" at sides and rear and
24" in front.
PV500-19 04-2005 2Section 19

POWER VT® WATER HEATER
PRODUCT SAFETY INFORMATION
REFRACTORY CERAMIC FIBER PRODUCT
WITH CRYSTALLINE SILICA
WARNING: This product contains crystalline silica which has been identified by the International
Agency for Research on Cancer (IARC) as carcinogenic to humans. This product also contains
refractory ceramic fibers which have been identified by the (ARC as possibly carcinogenic to humans.
Avoid breathing fiber particulates and dust.
RISKS:
• Airborne fibrous insulation is a possible cancer hazard by inhalation.
• Airborne crystalline silica may cause silicosis (lung disease) by inhalation.
• May cause temporary irritation to eyes, skin, and respiratory tract.
PRECAUTIONARY MEASURES:
• Minimize airborne fibers with enginl~9ring controls.
• Use NIOSH/MSHA approved respirators as required (see MSDS).
• Wear long sleeved, loose-fitting clotning, eye protection, and gloves.
FIRST AID MEASURES:
Eyes: Flush with water.
Skin: Wash with soap and warm water.
Ingestion: Do not induce vomiting. Get medical attention if gastrointestinal symptoms develop.
Inhalation: Remove to fresh clean air.
If any of the above irritations persists, seek medical attention.
WARNINGI If you are unfamiliar with the safe handling of Refractory Ceramic Fiber
products, or if you wish additionai information prior to beginning any disassembly of
the water heater that might expose refractory ceramic fiber materials, contact: Unifrax
Corporation,2351
Whirlpool Street; Niagara Falls, NY 14305-2413, 1·800~322·2293.
PV500-19 04-2005 3 Section 19

POWER'VT®WATER HEATER
•Water temperature aver 12S"f
ccn couse severe burns Instantly
or death from scalds.
•Children. disabled and elderly are
at highest risk of being scolded.
•
See instruction manual before
setting temperature at water
heater.
•
Feel water before bathing
or showering.
•If
this appliance is used ta
produce water that could scald
if too hot, such as domestic hot
water use, adjust the outlet control
(limit) or use temperature limiting
valves to obtain a maximum water
temperature of 12S·F.
WARNING
This water heater is equipped with an
adjustable thermostat to control water
temperature.
Hot water temperatures
required for automatic dishwasher and
laundry use could cause scald iJums
resulting in serious personal injury
and/or death. The temperature at ,which
injury occurs varies with the person's
age and time of exposure. The slower
response time of disabled persons
increases the hazards to them. Never
allow small children to use a hot water
tap or to' draw their own bath water.
Never leave a child or disabled person
unattended in a
bathtub or shower.
Since the
thermostat temperature
setting could be set too high, adjust the
thermostat temperature setting to 125°F
or lower. Lower settings help reduce risk
of scald injury. Remember, no water
heater system will provide exact
temperature
at all tim.es. Allow afew
days
of operation at this setting to
determine the correct temperature
setting consistent with your needs and
remember, "Hotter water increases the
risk of scald injury." Also, the water
heater should be located in an area
where the general
public does not have
access to
set temperatures.
ELECTRICAL
1. Wiring to the unit should conform '0 the
National Electrical Code or the code legally
authorized
in your locality. Afused disconnect
switch should be used for the water heater.
When required, PVI' water heaters are
equipped with step-down transformers
10cated
within the NEMA enclosure. This allows for an
effective single point electrical connection to
the water heater.
2. Be certain that high and low Yoltages are
connected to the correct points.
3. When remote on/off, air praying interlock, or
lead-lag enable operation is used, remove
jumperfrom
R1 and R2 and wire in series.
4. Aproper earth ground for this unit must be
provided.
PVI recommends asingle conductor
ground wire be pulled from the' distribution
panel to the sub panel (or some similar type).
NOTE: Use only copper wiring of proper sizing for incoming service. Damage resulting from use
of aluminum wiring will be excluded from coverage under the warranty of this unit
PV500-19 04-2005 4Section19

POWERVT@WATER HEATER
VEN"nNG INSTRUCTIONS
VENT SIZING ,
The POWER
~ is designed for operation with a
"positive pressure vent system" constructed of 4"
schedule 40 CPVC pipe. If 4" pipe is difficult to
obtain locally, alarger diameter
tidY be
substituted.
CAUTION: DO NOT use ABS or PVC pipe
in the venting system. A8S can emit
,toxic fumes in the event
of abliilding
fire, and PVC is not temperature rated
for this appliance. "
VENT SYSTEM DESIGN
The POWER Wcan be vented either verticallyI
through aceiling or roof, or horizontally through a
wall. From the vent pipe at the blower outlet, the
vent can be routed in any direction except down.
Like any closed piping system, the vent'should
maintain adownward slope toward the heater of
at least Xinch per lirieal foot of horizontal vent
run to allow proper drainage
of any accumulated
moisture. Despite this flexibility, the following
limitations and precautions must be observed.
Determination of Equivalent Length
Maximum equivalent length of vent must not
exceed the length identified in Table 19-1:
Vent Equivalent length Maximum Vent
Pipe Length
90° 45° 1000 All
elbow
elbow MBtu others
414 550 ·100
515 6150
300
617 7
390
,:'500
Table 19-1
A. Add the total length of straight pipe (in fciet).
B. Multiply the number of 90° elbows used in
vent system \by the equivalent length of
straight pipe specified in Table 19-1.
C. MUltiply the number of 45° elbows used in
vent system by the equivalent length of
straight pipe specified in Table 19-1.
D. Add (A), (B) and (C) together to obtain the
total feet of venting. This length must not
exceed the maximum vent length identified
in
Table 19-1.
Example: A 4" venting system of 25 ft. of straight
pipe and two 90° elbows.
•Total straight pipe =20 feet.
•Number
of elbows (2) x14 =28 equivalent feet
of straight pipe. .
•20 feet plus 28 feet =48 equivalent feet of
venting.
This
is an acceptable vent system.
Horizontal Venting Through aWall
The vent must extend one foot beyond the wall.
The vent must
be terminated with the UL listed
vent termination provided
by PVI.
The vent must not exit over apUblic walkway or
over any other area where condensate
or vapor
could be hazardous.
The vent must discharge at least three feet above
grade
of the level of normal snow accumulation.
The vent must terminate at least four feet below,
four feet horizontally from, or one foot above any,
building air inlet including doors and windows.
Vertical Venting Through a Roof
•The vent must extend upwards beyond nearby
obstructions in accordance with Figures 19-2
and 19-3 (see page 7).
•The vent must be terminated with the UL listed
venttermination provided by PVI.
Venting of Multiple Units
•MUltiple POWER ~ models must not be
vented into acommon duct or breeching. Each .
unit must be independently vented in
accordance with the instructions for either
horizontal or vertical venting included above.
PV500-19 04-2005 5Section 19

Vent Construction
POWER YT@WATER HEATER
VENTING INSTRUCTIONS (can't)
Direct Venting Duct System Design
•Joining vent components -All joints in the vent
system must be air tight. Use an all purpose
CPVC cement for 4" diameter pipe and rated for
180°F when joining adjacent components (e.g.
astraight length of pipe and an elbow).
•Vent support -The vent system shq,uld be
supported at six-foot horizontal intervals to
prevent sagging and distortion.
DIRECT VENTING OPTION
Direct venting is defined as ameans ofducting
the outside combustion air to the burner ·or the
purpose of avoiding corrosion that can be caused
by contaminants which may be contained in
indoor air. If your POWER ~ water ,heater
requires direct venting,it can be connected
directly to the burner inlet cap with self-tapping
screws. No additional parts are necessary.
Constructing the Direct Venting Duct
•Use 6 inch, PVC sewer and drain pipe when
constructing the combustion air duct for all
POWER ~ models.
CAUTION: DO NOT use ASS pipe in the
venting system. ASS can emit toxic
fumes in
the event of a building fire:
•The combustion air duct should be constructed
and routed in amanner similar to the vent
system.
When ducting horizontally through awall:
(Figure 19-5, page 8)
• The duct must extend one foot beyond the wall.
•The duct must be terminated with the UL listed
venttermination provided by PVI.
•The duct must terminate at least three-foot
above grade or the level of normal snow
accumulation.
When dueting vertically through aroof:
(Figure 19-4, page 8)
•The duct must be terminated with the UL listed
vent termination provided by PVI.
Maximum Equivalent Length of Duet
• The combustion air duct should be no more
than 100 equivalent feet in length but it may be
of different configuration. See section on vent
construction and joining for details concerning
combustion air duct construction.
PV500·19 04-2005 6Section
19

Typical Termination Locations for Vertical Vent Pipes
to' tlR, LESS -..:..
I J' f.lIN.
!~J
1t::0
Termin,atlon of less then 10 feet
Figure 19-2
r-
MORE ll<AN '0'
r---
MD MINIMUM l
.
.+
W"lL OR
PARAPET
VENT
HElGHT AllOY!: ANY
ROOf" SURfACE MTHI~
10' HQRIZOtHAllY
VENT
Termination of morethan 10 feet
Figure 19-3
Vertical vent pipe must be terminated with the UL listed vent termination supplied by PVI.
PV500·19 04~2005
7
Section 19

Typical Locations for Vertical and Horizontal Vent Pipes
APPROVED FOR:'-~ DO NOT TERMINATE
USE \\llH AIR \iN CONTAMINATED
INTAKE CAP , ATMOSPHERE d FLUE OUTLET
W/LiSTED CAP
'~Q
~.~
t=~ .. ~ __ ~
l.~ I I
FY) I I
J : I :
I I 'I
.. ~ ,
e" RElAOTE AIR INTAKE PIPE Y: : :
STANDARD SINGlE-WAll I I :
METAL PIPE OR PVC I ~, I
SEWER & DRAIN l-.-, I
I
I
I
I
,
I
I
I
I I
I-i
Y""""""'==!~'ii?:_ -C ~ :
J-
-(~I CONDENSATE
DRAIN
CPVC FLUE VEKTING
Vertical Venting
Figure 19-4
,--------_. '------------------,
.- AGI0TE AlR lNTN<E P1P£
STANDARD SING\.[ WAlL
"'ETAl PIPE OR PVC SEWER II; VRAIN
"Horizontal Venting
,Figure 19-5
•Install flue outlet and fresh air inlet with adequate separation to prevent recirculation of combustion products.
Although the National Fuel Gas Code provides minimum clearances, sound engineering judgement should be
used, considering prevailing winds, obstructions and the type vent termination used, etc.
•Eitherflue or remote air intake can be
rootor side wall vented.
•Maximum length
of remote intake ducting is 100 equivalent feet.
•See Table 19-1 for maximum length of combustion venting.
PV500·19 04·2005 8
Section 19

POWER 'VT®WATER HEATER
CONDENSATE NEUTRALIZATION &DISPOSAL
The POWER ~ water heaters produce
significant amounts
of condensate because of
their high efficiency. Condensate occurs naturally
when water vapor in combustion gases is cooled
below the dew point. Although only slightly acidic,
POWER
~ condensate can be routed through
an optional neutralization system to become pH
neutral allowing for disposal into any drain or
sewer system without concern for corrosion. A
fitting should be provided in the venting to route
any vent condensate away from the corr,bustion
blower. This can be accomplished
by ins~alling a
tee
in the vent not more than 18" from the
combustion blower outlet.
Crushed limestone fills the condensate
neutralization bath, Condensate slowly flows
through the limestone bed and
is neutralized thus
avoiding chemical treatment or dilution using
substantial quantities
of tap water. If the
condensate pH is lower than 4when checked with
a
pH meter or pH paper, consult the factory for
replacement treatment system. Condensate
drainage from the POWER
~ will only occur
after arecovery run cycle. If
no condensate is
drained during this time, the drainpipe should be
inspected for blockage. Should the heater not be
installed
on ahousekeeping pad to ensure gravity
drainage, ameans
of removing condensate, such
as apump, should be supplied
in the system.
PV500·19 04-2005 9Section
19

POWER VT®WATER HEATER
START-UP PROCEDURES
.CAUTION: DO NOT RELIGHT PILOT OR START BURNER WITH COMBUSTION
CHAMBER FULL OF GAS OR WITH VERT HOT COMBUSTION CHAMBER.
WARNINGI
YOU MUST CONNECT THE SUPPLIED GAS TRAIN TO THE BURNER UNION.
THE GAS SUPPLY MUST THEN BE CONNECTED TO THE GAS TRAIN.
DO
NOT CONNECT THE GAS SUPPLY DIRECTLY TO THIS UNION.
FAILURE TO INSTALL THE SUPPLIED GAS TRAIN TO THE BURNER UNION
BEFORE CONNECTING THE GAS SUPPLY MAY RESULT
IN
UNCONTROLLED GAS FLOW INTO THE APPLIANCE AND/OR THE
APPLIANCE AREA.
FAILURE TO FOLLOW THIS WARNING COULD RESULT IN FIRE OR
EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
1. The Power VT gas valve and control train (gas
train) provided with the appliance must be directly
connected to the union piped out of the )urner.
After the gas train is attached to the burner, the
gas supply can
be connected to the gas !,hut-off
valve (gas cock) at the gas train inlet. After gas
plumbing is complete, verify the gas train is
adequately supported
and connect the conduit
and multipin plug into the multipin receptacle in
the gas train conduit box.
2. Carefully study the burner start-up information
included in this manual. .
3. Fill the water heater tank with water. Open the
relief valve or a nearby hot water faucet to allow
air in the tank
to escape. Be sure all connections
into the tank are tight,
as leaks at tank fittings will
damage the insulation.
4. The temperature limiting safety device is fixed at
200°F. The operating thermostat is set at the
factory
to 120°F. Adjustment may be made by
turning the thermostat dial to the desired
temperature.
CAUTION: CONDUCT THE FOLLOWING GAS TRAIN LEAKAGE TEST BEFORE START-
UP, AT ANNUAL INTERVALS AND PRIOR TO INVESTIGATING THE CAUSE OF ANY
REPORTED OCCIJRENCES OF DELAYED IGNITION.
1. Using an appropriate bubble detection solution,
thoroughly coat all gas train pipe connections. If
any bubbles are detected, the leaking connection
must be tightened, recoated, and rechecked
to
assure stoppage ofthe leak. ,
2. Attach amanometer to the measure 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 in.
WC.), and tightly close the gas train manual
shutoff valve closest to the burner.
3. Reattach the manometer to the gas train manual
shutoff valve at the burner
and· record the
measured gas pressure
in inches of water
column (W.C.). Measure gas pressure again after
15 minutes. If gas pressure has increased 0.5"
W.C. or more, the gas leak must be isolated to
one or more of the operating gas valves. (For
example, asolenoid actuated gas shutoff valve.)
After any leaking valve
is replaced, the
reassembled gas train must
be leak tested again
before start-up is attempted.
PV500·19 04·2005 10 Section 19

POWER "T@WATER HEATER
GAS BURNER
CARBON MONOXIDE WARNING: An annual or seasonal combustion checkout must be
performed by aqualified service agency to ensure
safe operation. Failure to maintain
proper combustion can result in injury or death.
Typical Construction
Figure 19-6
1.
Static farl 11. Manual shutoff valves
2. End cap
12.
Main gas pressure regulator
3.
Gas nozzle assembly 13. Main gas valve
4. Pressure plate 14. Pilot gas valve
5. Blast tube &burner housing junctiop 15. Auxiliary gas valve
6.
Ignition transformer 16. Electrode clamp
7. Ignition electrode 17. Fresh air vent damper
8. Flame sensing electrode 18. FGR union with orifice
9. Ignition electrode boot (red) 19. Flame electrode boot (black)
10. Electrode clamp 20. Pilot gas pressure regUlator
PV500-19 04-2005
11
Section 19

POWER VT®WATER HEATER
GAS BURNER START -UP
(Refer to Figure 19-6, page 11 to identify burner parts)
WARNING: START~UP SHOULD ONLY BE PERFORMED BY AQUALIFIED TECHNICIAN.
1. Remove enclosure panel cover on . thE; water
heater to expose control circuit. Awiring dLsgram,
included in this packet, will show the :.ontrols
used in our circuitry.
2. Visually check that all components are int~"\ct and
no damage has occurred during transit
3. Check all connections within the control cabinet.
Aloose connection could cause intermittent
shutdowns.
4. Some burners will use direct spark ignition They
may use asingle gas pressure regulator and gas
valve or multiple valves and regulators. 01' a call
for heat, the motor starts, gas primary. control is
energized, the air vent damper opens and after a
short delay (pre-purge), the gas valve(s) opens
and ignition should occur.
NOTE: Do not tamper with or readjust program
dipswitch settings. This will cause the control to
become inoperable. Damage resulting from
tampering will be excluded from coverag( under
the warranty of this unit.
5. Connect atest meter to the control for p~ading
the flame response signal.
NOTE: Some controls read the flame si~lflal in
micro amps and some in volts DC. The Mseries
control has two terminals marked for reading
volts in DC.
CAUTION: Be sure the tank is filled with
water. Dry
firing can destroy the water
heater.
6. Check the gas pressure before start-up, u$ing a
U-tube manometer or a 0 to 28" W.C. pre.ssure
gauge for inlet gas pressure. (This is the
pressure measured before all components in the
gas train.) The manometer must stay connected
throughout the testing, as the inlet pressure must
be monitored. during the firing of the burner.
Record static pressure; it must not exceed 14"
W.C. Pressures above this could cause damage
to the diaphragm in the gas valve or pr€:ssure
regUlator.
7. Connect amanometer to the manifold test port at
the shutoff valve closest to the burner. Tl.lrn off
main gas shutoff valve. Turn unit on using the
rocker switch on the side of the control enclosure
assembly. If the operating control switches are
closed, the burner blower should come on and
pre-purge begins.
8. If nothing happens, check the control; if it is not in
the tripped position, reset it by pushing the flame
safeguard reset button. The burner should pre-
purge at least thirty seconds.
9. When the blower motor starts, the air damper will
open and the airflow prOVing light or; the
MEC120 should be on. This indicates apositive
airflow condition. If the air proving light is not on,
check the air-proving switch for operation. To
adjust the air-proving switch, turn the adjustment
screw counter-clockwise until the air proving light
comes on, then turn the screw one turn counter-
clockwise. If the gas valves open and close
intermittently during normal operation, turn screw
one half turn counter-clockwise until this
condition ceases. This procedure should be
followed with every burner.
This section is for single-stage and two-stage
firing: After purging is complete, terminal 3on
the flame control energizes the pilot valve and
terminal 4energizes the ignition transformer. The
pilot is then established. The VDC reading on the
meter should read asteady 6-10 VDC; 6VDC is
{he minimum flame signal for it to operate
reliably. If the pilot fails to light during the initial
period, it is probably due to air in the line. The
control will lockout and require reset.
Once the flame is established, the ignition
transformer will de-energize and terminal 5will
energize the main valve. At this point the water
heater is operating at maximum firing rate (high
fire). In order to insure the water heater is
operating at the rated input, it is necessary to
check the manifold gas pressure (measured at
the pressure tap on the gas valve closest to
burner). The manifold gas pressure should be
adjusted at main gas regulator to the factory
recommended pressure shown on tag
attached to gas train. Do not screw the
adjusting nut of the regUlator in beyond point
where no further Increase in manifold pressure
is noted.
PV500-19 04-2005 12 Section 19

POWER VT®WATER HEATER
GAS BURNER START-UP (con't)
While firing, check the gas pressure at the inlet of
the gas train. The minimum supply pressure
requirement on the Power VT water heatet is 4.5"
W. C. supply flow pressure unless otherwise
specified
on the data plate. It shou/o be a
minimum of that shown above with the water
heater running
at high fire. This is recoi'ded as
inlet flow pressure. It is important ihcoming
pressure does not fall below this minimum or
nuisance control lockouts could occur.
This section is for two-stage firing only: After
adjusting
the high fire manifold gas pressL:re, it is
now important to check the operation of t~e first
stage (low fire). There is atoggle switch
on the
control cabinet labeled "Auto/Low Fire",Switch
from the auto position to low fire and the main
valve will de-energize shutting offthe high fire gas
supply and the air damper will close reducing the
airflow to aminimum. Once the water
heat~r is at
low fire the manifold gas pressure can be adjusted
as described in the previous paragraph but using
the pilot gas regulator instead of the main gas
regulator. Proceed to paragraph 10
to tAst and
document combustion results for low fire and high
fire,
10. Check flue gases with an electronic flue a;,alyzer
to make final settings of gas pressure regulator.
a) The readings need to be taken from a :101e in
the vent several inches downstream of the fan
outlet connection.
b) Insert 0-6" W.C. manometer into ttl:! test
opening
in the vent. Pressure in stack should
not exceed 2" W.C.
c) When water in tank is above 120°F, insert
analyzer or O2testing
in test opening; take O2
reading in percentage.
d) Increase manifold gas pressure at the main
gas pressure regulator taking O2
rearJ!:lg at
each adjustment of gas regulator until
optimum O2%(5-7%) is reached. If, O2%
decreases, reduce the gas pressure i'::> last
reading where the greatest reading
is
achieved.
e) CO should not exceed 200 ppm. Areading
greater than 200
ppm indicates lack of air.
Reduce manifold gas pressure slightly and
take readings until
CO is within proper range.
Optimum reading
is no CO.
f) If manifold pressure was changed during
startup, take afinal CO and O2reading.
g) Record
CO
2and
NO
x
if applicable. See
paragraph 11 if NO
xmeasurement
is required,
h) Insert vent temperature gauge in test opening
and read gross vent temperature; maximum
gross stack
is to be 250°F. If an excessively
high gross vent temperature is recorded;
consult the factory.
11. When the Power VT water heater is equipped
for Low NOxoperation, it may be necessary
to
measure the NO
xlevels
in the flue prodUcts for
compliance verification. The
NO
xconcentrations
are measured
in ppm (parts per million). When
documenting the measurements
on the startup
report, be sure to note whether or not the
readings are corrected to abaseline O2level. If
during the course of startup the
NO
xlevels do
not meet your locally mandated requirements, it
may
be necessary to change the FGR (flue gas
re-circulation) orifice, This orifice is contained
in
the FGR union shown on page 11, Figure 19-6.
This union may contain two or more orifices.
This allows the removal
of one or more of the
orifices in order to increase the flow of FGR and
thereby reduce
NO
x
in the flue products. If the
FGR orifice is changed for any reason, the
startup procedure
in paragraph 10 should be
repeated.
12. Check each operating and limit control to be
sure they function properly by lowering and
raising the temperature setting
on each of the
controls, causing burner to cycle on
and off.
NOTE: During the initial firing of the burner,
smoke that
is not related to the burner will be
emitted from the heater. This
is normal during
"burn in" and could possibly continue for
several hours.
PV500·19 04-2005 13 Section 19

POWER Vr@WATER HEATER
GAS BURNER START-UP (con't)
13. Record the following information for future use:
a)
Manifold gas pressure 'w.e. t) NOxreading
ppm
b)
Vent pressure "w.e. g) Vent temperature
c) O2reading %(5-7%) Gross of.
d) CO2reading %(3-9%) Less ambient
of.
e)
CO reading __ ppm (less than 300 ppm) Net of.
PV500-19 04-2005 14
Section 19

POWER VT®WATER HEATER
MAINTENANCE AND SAFETY INSPECTIONS
1. Establish apreventive maintenance program to
assure alonger water heater life.
2. The tank should be flushed at two- or three-
month intervals depending
on water cond!~ions in
your location. To flush, turn off E!lectrical
disconnect switch to prevent the burner from
operating. Open the drain valve and allow water
to flow through
the tank until it runs clear. Close
the drain valve and turn the electrical switch back
on. Draining two or three gallons from the. bottom
of the tank
on aweekly basis will also help
prevent the accumulation
of sediment Water
impurities consist of fine particles
of s?iI and
sand, which will settle out and form alayer of
sediment
on the bottom ofthe tank. .
3. Ascale of lime will normally form during
operation
and will accumulate on the bottom of
the tank. Lime is formed from the natural
chemicals
in the water, which precipit;,;Je out
during heating cycles. Some water sJpplies
contain more of these chemicals than others
do
and scale buildUp will occur more rapidly.
Other factors affecting scale buildup
are the
amount of hot water used and the temperature of
the water. The more hot water used, the more
fresh water containing scale-forming chemicals is
brought into the tank. As the temperature of
water increases, the
rate of scale deposition will
increase.
4. The tank may have ahandhole for inspection and
cleaning. (See Figure 19-1, page 2). To inspect
tank for scale buildup, remove the
hand hole
cover. Ifscale is present, it can be loosened with
ahigh-pressure stream of water. The smaller
pieces can be flushed through the drain and the
larger pieces removed by hand through the
handhole. The frequency of inspections will
be
determined by the rate of scale bUildup. Intervals
of
30--60 days are recommended.
5. If afiretube leaks for any reason, consult the
factory for instructions.
NOTE: Condensate coming from the tubes on
acold start is normal and does not indicate a
leaking tube.
CARBON MONOXIDE WARNING:
CAUTION: IMPROPER COMBUSTION
MAY CAUSE SERIOUS INJURY OR DEATH.
PVI
recommends a seasonal or annual combustion checkout be performed by a
qualified service agency to ensure safe and efficient operation.
Periodic Inspection of Operational Components
Periodic inspection and checkout of the burner ignition, control system, and fuel valve operation (for
tight close off) should
be made. Refer to he burner installation instructions for recommended.
NOTE: Always secure gas lines and tag "Out
of Service" before servicing burner nozzle or
electrodes.
3. Remove the flame safeguard control from its
base. Check the connections in control mounting
base; loose connections can cause nuisance
shutdowns.
4. Pull the nozzle assembly to check the flame
and ignition electrodes. This is done by first
disconnecting the gas train
by breaking at the
unions. Then remove the nozzle assembly with
the electrodes and pressure plate attached.
Disconnect the electrode wires. Take care not
to damage the insulation on the electrodes.
POWER VT®WATER HEATER
1. Examine the venting system at least once each
year for proper connections, alignment and
corrosion. The static fan inlet will collect dust
from the air during operation. DisconnEct the
power to the heater and clean the fan: guard
when necessary. .
2. The burner should be cleaned each year
according
to the burner manufacturer's
recommended procedures. Inspect
all parts and
make replacements when necessary.· Check
wiring for loose connections
and burned wires.
PV500-19 04-2005 15 Section 19

MAINTENANCE (con't)
,
5. With electrodes exposed, check for the proper
settings as
in Figure 19-7, page 17. Check for
any hairline cracks in the insulators. Should
replacement of burner electrodes
be required,
certain procedures must
be followed In all
cases, removal of electrodes is accomplished
by loosening the electrode mounting (:iamps.
Draw electrodes out of the nozzle assembly
through the holes
in the pressure plate.
6. Inspect electrodes for cracked cercHllic or
loose retaining studs that hold
the wire: within
the ceramic. Select the proper pressuri:! plate
hole to place each electrode and insert
electrode through hole, retaining stud end
first.
7. Tighten electrode-mounting clamp slightly until
electrode ceramics are seated
firm!.!' and
completely in the mounting bracket without
gaps between ceramics
and mounting hracket
at the bearing faces.
8. Measure and set electrodes according to
Figure 19-7, page 17. After gaps and setting
are complete, fully tighten the electrode-
mounting
clamp. Do not overtighten or ce:ramic
insulation may crack.
9. Replace nozzle assembly; be sure to connect
the flame
and spark rod wires before irr,·.talling
nozzle assembly fUlly into blast tube. Check
connections
on the ends of the flame and
spark rod wires for good contact. lO'Jk for
properly stripped wire ends.
Be sure
connections are firmly attached
to the· flame
and ignition rod ends. Insulating boots can give
afalse feeling of proper seating. DO' NOT
MOVE ELECTRODES. Be careful not to bump
electrodes. Check fan wheel for free rotai1on .
. '.
' ...
10. Reinstall gas nozzle assembly.
CAUTION: THE RELIEF VALVE IS A
PRIMARY SAFETY DEVICE.
11. The temperature and pressure relief valve
may
be checked by slowly lifting the seat lever
on top of the valve to determine
its condition
for safe operation. Openings inside the valve
may become restricted
by a bUildUp of scale
and become inoperative. If the valve does not
open
and close properly when tested, it must
be replaced. Replace the relief valve with like
kind or one meeting the requirements stated
on the rating decal located adjacent.
to the
relief valve.
12. Atable of periodic safety inspections is
attached to this manual for ease of reference
by the building service technician or licensed
equipment operator. Since water heater
designs
vary, only some of these listed
inspections may
be appropriate for your
particular
model.
13. PVI strongly recommends the recording of
significant events,
such as maintenance or
repair actions
and safety inspections, and
encourages
the preparation of an event log for
this purpose. All recorded events should be
dated, fully described,
and signed by the
individual performing the service, repair, or
inspection. (See Table 19-2,
page 18 for
sample
at Inspection Record.)
CALL YOU PVI CUSTOMER SERVICE
REPRESENTATIVE
IF YOU HAVE ANY. QUESTIONS (1-800-784-8326)
PV500-19 04-2005 16 Section 19

POWER VT®WATER HEATER
MAINTENANCE (con't)
'PRESSURE PLATE
5/16±1/16
FLAME ROD
PRESSURE PLATE
ELECTRODE
PRESSURE PLATE
Set up and Tolerances
Figure 19-7
Instructions for Taking Water Heater Out of Service
Extended shutdown of the unit and restarting are as
follows: '
a) Turn off all power and fuel supplies.
b) Drain and flush tank as previously discussed on
page 15. ;
c) Tag power switch(es) that fuel is off and tank is
empty.
d) Refill tank with water and turn fuel and power
sWitch(es) on to restart. Reset all controls and
conduct start-up of the appliance as discussed
on page 10.
PV500-19 04-2005 17 Section 19

MAINTENANCE &SAFETY INSPECTION REPORT
DATE BURNER COMBUSTIO TANK TANK FLUSH TANK FITTING VENT THERMOSTAT GAS TRAIN
INSPECTION NINSPECTION &CLEANOUT INSPECTION INSPECTION INPSECTlON LEAK TEST
'UAI v.""
.'
,
\
-
'"'
-'
Recommended
YEARLY
6
'6
36 YEARLY YEARLY YEARLY
Inspection MONTHS MQNTHS MONTHS MONTHS
Intervals Table 19-2
'."
,
PV500·19 04-2005
18
Section 19

POWER VT@WATER HEATER
TROUBLESHOOTING SUGGESTIONS
GAS BURNER
1. BURNER FAILS TO START:
a) Defective on/off switch. Replace switch.
b) Control circuit has open control c:lntact.
Check limits, low water cutoff, and 01l.ers as
applicable.
c) Bad fuse or switch opens on incoming' power
source. Correct as required.
d) Flame safeguard
control safety switch tripped
out. Reset and determine cause of apparent
flame failure.
e) Loose connections or faulty wiring. Tighten all
terminal screws and consult wiring diagram
furnished with the heater.
f) Flame safeguard control starting .-circuit
blocked due to flame relay being enwglzed.
Possible defective scanner or flame rod - t-aplace.
Possible defective amplifier -replace. ~';~nner
actually sighting flame due to leaking fuel valve -
correct unwanted flame cause. Defective flame
safeguard control -replace.
g) Defective blower motor. Check for free Iatation
of fan wheel. Repair or replace.
h)
Air proving switch is not properly adjusted.
Adjust per instructions; page
12, paragraph 9.
i) Defective circulation pump. Repair or replace.
j) Circulation flow switch not properly adllJsted.
Adjust flow switch counter-clockwise until airflow
light comes on.
2. OCCASIONAL LOCKOUTS FOR NO APPARENT
REASON:
a) Gas pilot ignition failure. Check to see that
ignition is instant and flame signal readings are
stable and above minimum values. Use
an incline
manometer to make certain pressure
is as
recommended.
b) Loose or broken wires. Check all wi,.e nut
connections and tighten all terminal screw
connections in panel and elsewher-3 as
appropriate.
c) With flame safeguard controls that incorporate
the air flow switch in the non-recycling circuit,
ensure that when main flame lights, the air flow
switch is not so critically set as to allow occasional
momentary opening of the air switch contacts.
d) Occasional low supply voltage. Contact local
utility
to correct. Make certain the burner control
circuit transformer (if supplied) is of the correct
voltage and power (AC) being supplied.
e) Occasional low gas supply pressure. Contact
local utility to correct.
f) Excessive flue gas recirculation, causing
unreliable or unstable operation. Reduce the
orifice size in the FGR union and readjust the gas
regulators to achieve proper excess air
in
combustion.
3. BURNER MOTOR RUNS, BUT PILOT DOES NOT
LIGHT:
a) Gas supply to burner shut off. Make sure all
manual gas supply valves are open. Automatic
high-pressure valve
at meter such as "Sentry"
type tripped shut due to high gas pressure. Reset
valve and correct cause for trip out.
b) Pilot solenoid valve not opening. Listen and
feel for valve actuation. Solenoid valve not
being powered. ChecK electrical circuitry.
Replace coil
of entire valve ifcoil is burned out.
c) Defective gas pilot regulator. Replace.
d) Gas
pressure too high or too low at pilot
orifice (if supplied). Check orifice size in gas pilot
assembly. Replace if incorrect. Readjust pressure
as required.
e) Defective ignition transformer. Replace.
Incorrect ignition electrode settings. Readjust
as required.
f) Defective flame safeguard control or plug in
purge
timing card. Replace as required.
g)
Airflow switch not making circuit. Check out
electrically. Defective air flow switch. Replace.
Air switch negative pressure sensing tube out
of position. Reposition as necessary.
PV500-19 04·2005
19
Section 19