PVI PVI DURAWATT Instruction Manual

PV500-6 05/13
INSTALLATION & MAINTENANCE MANUAL
PVI DURAWATT®ELECTRIC WATER HEATERS
Installation and service must be performed by a qualified service installer, service agency or qualified electrical
contractor.
IMPORTANT: THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION, OPERATION AND
MAINTENANCE OF THIS EQUIPMENT. READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER
PROVIDED INSTRUCTIONS, LABELS AND MARKINGS BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.
TO THE INSTALLER: After installation, these instructions must be given to the equipment user or left near the appliance.
SPECIAL INSTRUCTIONS TO THE OWNER: Retain this manual for future reference. These instructions contain important
information that will help you in maintaining and operating this appliance.
PVI INDUSTRIES, LLC - Fort Worth, Texas 76111 - www.pvi.com - 1-800-433-5654

DURAWATT®ELECTRIC WATER HEATERS
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TABLE OF CONTENTS
1. Safety Considerations
2. Product Descriptions
3. Water Heater Installation
3.1 Checking Equipment Before You Install
3.2 Codes
3.3 Electrical Requirements
3.4 Location
3.5 Installation
3.6 Service Clearances
3.7 Clearances to Combustible Surfaces
3.8 Electronic Low Water Cutoff
4. Optional Equipment
4.1 Shunt Trip Circuit Interrupter
4.2 Time Sequencer
4.3 Proportional Sequencer
5. Start-up Procedures and Operation
6. Element Continuity Checks
7. Maintenance
7.1 Flushing
7.2 Draining the Tank
7.3 Sediment / Lime Scale Removal
7.4 T&P Relief Valve
7.5 Low Water Cutoff
7.6 Electrical Connections
7.7 Replacing Electric Elements
7.8 Cleaning Electric Elements
8. Troubleshooting Guide
Warranty forms ship separately with each product.

DURAWATT®ELECTRIC WATER HEATERS
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1 SAFETY CONSIDERATIONS
WARNING: If the information in the supplied manual(s) is not followed exactly, a fire, electrical short 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 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 electric switch; do not use any phone in your building.
Immediately call your gas supplier from a location away from your building and the smell of gas. Follow the gas
supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or qualified electrical contractor.
WARNING: Installation and service must be performed by a qualified installer, service agency or qualified electrical
contractor, who must read and follow the supplied instructions before installing, servicing or removing this
appliance. Refer to the information contained in this manual. Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury, exposure to hazardous materials or loss of life.
WARNING: Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the unit and to replace any part of the control system, all controls and all other items affecting
safe appliance operation and which has been under water.
WARNING: In an emergency disconnect all electrical power to the appliance from a location safely away from the
emergency. Failure to follow these instructions can cause property damage, personal injury, and exposure to
hazardous materials or loss of life.

DURAWATT®ELECTRIC WATER HEATERS
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IMPORTANT SAFETY NOTE
It takes only 5 seconds of skin contact with 140°F water to cause a
second degree burn! You must protect against high water temperatures at all
lavatories, tubs, showers and other points of hot water contact.
Accidental scalding from high water temperatures is a greater
risk in some types of installations. Some examples are:
HOMES FOR THE MENTALLY HANDICAPPED
HOMES FOR THE PHYSICALLY HANDICAPPED
HOSPITALS AND NURSING HOMES
ELDER CARE FACILITIES AND REST HOMES
ORPHANAGES AND CHILD CARE FACILITIES
OTHER INSTALLATIONS - WHERE RESPONSE TO CONTACT WITH HOT
WATER MAY BE SLOWER OR WHERE THE DANGER OF HOT WATER
CONTACT IS GREATER
Thermostatically controlled mixing valves must be used in the
design of the potable hot water system.
Potable hot water should be tempered to no more than
110°F when used for bathing or other personal uses.
Good engineering practice mandates the use of thermostatically controlled
mixing valves set at 120°F or less to keep the delivered water temperature
below scalding temperatures.

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2 PRODUCT DESCRIPTIONS
Without 23” Diameter Tank Access
FIGURE 1
With 23” Diameter Tank Access
FIGURE 2

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3 WATER HEATER INSTALLATION
3.1 Checking Equipment Before You Install
Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading. Inspect the
appliance and all accompanying parts for signs of impact or mishandling. Verify the total number of pieces shown
on packing slips with those actually received. Contact the freight carrier immediately if any damage or shortage is
detected.
3.2 Codes
The equipment must be installed in accordance with those installation regulations in force in the local area where
the installation is to be made. Authorities having jurisdiction must be consulted before installation is made. In the
absence of such requirements, the installation shall be in accordance with the instructions in this manual, appliance
markings and supplemental instructions and in compliance with the latest edition of the National Electrical Code,
NFPA-70. Where required by the Canadian authority having jurisdiction, the equipment must be installed in
accordance with the latest edition of the Canadian Electrical Code, C22.1 and applicable provincial regulations. All
appliances conform to the current edition of the ASME Boiler and Pressure Vessel Code, Section IV, Part HLW or
Section VIII.
3.3 Electrical Requirements
1. Check rating plate on front for correct voltage, phase and amperage. Refer to the wiring diagram for control
components mounted on the heater.
2. Use proper wire size and branch circuit protection as required by the latest edition of the National Electrical
Code, NFPA-70 and state and local codes or in Canada, as required by the latest edition of the Canadian
Electrical Code, C22.1 and provincial and local codes. The PVI electric water heater specification sheets show
the number and size of power connectors furnished with the heater for minimum 90°C copper connecting wire.
3. Use proper wire size for the ground connection. Attach to the bottom ground terminal connection on the terminal
block assembly marked with decal "GR".
4. Connect supply feeders to the distribution block (or circuit interrupter if furnished) inside the electrical enclosure
on the heater.
IMPORTANT: Check all wiring connections in heater and element enclosure to assure tightness prior to energizing.
NOTE: Use only copper wire of proper sizing for incoming service. Damage resulting from use of aluminum wiring is
excluded from coverage under the warranty of this unit.
Utiliser du fil de cuivre de la taille appropriée pour le service électrique entrant. Les dommages résultant de
l'utilisation de fil d'aluminium seront exclus du champ d'application de la garantie de cet appareil.
3.4 Location
1. Locate the unit in a clean and dry area as close as possible to the greatest hot water usage and as near to
electrical power as practical.
2. Install the unit on a firm, level foundation.
3. Locate the foundation on a pitched floor near a suitable drain, or make other provisions to prevent contact to
areas of the building subject to water damage should the water heater or a water connection leak. The drain
must be sufficient to contain water in excess of 210°F.
3.5 Installation
WARNING: Use industry standard safe rigging methods when attempting to lift or move this product.
Failure to follow these instructions could result in property damage, serious injury or death. One common
method includes the use of straps and spreader bars, lifting from the water heater base skid assembly.
1. Check the data decal on the heater. Be sure the electrical supply is adequate for the installation.
2. Carefully remove all shipping supports and bracing. (Float type devices have shipping plugs blocking the float).
3. Install shut-off valves and unions on the inlet and outlet water piping for servicing. Use caution when threading
pipe nipples into tank connections to prevent cross threading, or over-tightening. Always use a back-up wrench
on tank nipples when tightening unions, valves, etc.

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4. Insulate hot water and return circulation lines. Also, if subject to freezing during shutdown or during operation,
insulate all water piping and take whatever steps are necessary to keep the appliance and all water containing
pipes and components from freezing. IMPORTANT: Do not use the plumbing connected to the appliance as a
ground for welding or any other purpose.
5. The water heater is equipped with a temperature and pressure relief valve(s) rated for the input. Pipe the relief
valve discharge to a suitable open drain. The drain pipe may not be smaller than the relief valve opening and
must be secured to prevent it from lifting out of the drain under discharge pressure. Do not install valves or
restrictions in the discharge line.
6. Pipe the drain valve to a suitable open drain.
3.6 Service Clearances
Allow sufficient space to provide adequate clearances on all sides for service and inspection. Recommended
clearance is 24” at the top and front, 18” at left and right sides of the appliance. Optional equipment may increase
the clearance requirements. Allow sufficient space for installing and servicing connections such as water, electrical,
pump and other auxiliary equipment.
3.7 Clearances to Combustible Surfaces
The appliance must not be installed on a combustible floor, or on a non-combustible floor covering combustible
material. The minimum clearance to combustible material is 6” from the top, sides and rear, and 24” from the front.
Distance minimale aux matériaux combustibles est de 15 cm sur le dessus, les côtés et à l'arrière et 61 cm à l’avant
et ne doit pas être installé sur un plancher combustible.
3.8 Electronic Low Water Cutoff
The device consists of a probe in the tank that acts as a switch, open when submerged in water and closed when
the water level is below the probe, preventing heating elements from energizing. The probe should be kept free of
scale buildup to insure operation.
4 OPTIONAL EQUIPMENT
4.1 Shunt Trip Circuit Interrupter (optional on all models): The shunt trip, wired in the non-automatic circuit
interrupter, is a safety device designed to open the circuit interrupter and prevent the elements from energizing if
the control panel door is opened.
4.2 Time Sequencer (optional on all models): Time sequencing is optional and used in lieu of the proportional
sequencer. It is a series of time delay relays wired to the contactors which allows approximately a 40 second delay
in energizing each succeeding heating element when the controls call for heat. This prevents all heating elements
from energizing at the same time.
4.3 Proportional Sequencer (optional on all models): Progressive sequencing (orbital) equalizes the on time for each
contactor and heating element. The heating elements are staged-on based on the demand on the water heater. The
control gives visual, indication of stages that are on. In the event of power interruption, all contactors are turned off.
When power is resumed, the control will re-stage the elements beginning with number one.

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5 START-UP PROCEDURES AND OPERATION
WARNING: Turn off all electrical service to the appliance when accessing the controls located inside the
control cabinet. The cabinet contains high voltage wiring and terminals. If the electrical service is not
turned off and these wires or terminals are touched, a dangerous shock causing personal injury or loss of
life could occur. Close the control cabinet before restoring electrical service to the appliance.
Coupez l'alimentation avant intervention sur l'appareil.
1. Use multimeter to check resistance to ground between all element terminals and the element mounting flange.
(See table 1)
Fill the heater with water. Open the relief valve to allow air in the tank to escape. Be sure all connections into
the tank are tight as leaks at tank fittings or heating elements can cause damage.
Check inside of electrical enclosure for leaks with tank full of water at water line pressure. Heating element
gaskets are pressure tested at factory but may leak if unit has been in dry storage for a long period of time.
If leaks are present, tighten all four nuts uniformly on the element mounting flange in a criss-cross pattern.
Tighten one nut, then the nut on the diagonal from the first nut. Next, tighten the nut adjacent to the second nut,
and then the nut diagonal from the third nut. Repeat this sequence until all nuts are tight. Each nut should be
tightened to 15 foot pounds of torque. To avoid warping the flange, do not over tighten.
IMPORTANT: All leaks must be corrected prior to turning on electricity to avoid damage to electrical
components within the enclosure.
Electric element (design may vary): 3 phase elements have 3 terminals; 1 phase elements have 6 terminals.
FIGURE 3
2. The tank must be full of water before turning on electricity. If elements are energized without water in the tank,
they will burn out immediately. Warranty is void on dry starts.
3. Check all electrical connections for tightness before turning the unit on.
4. Energize manual disconnect switch. Check for proper voltage (with voltmeter) on power circuit. Voltage should
not vary more than 5% from voltage shown on data plate. If voltage exceeds these limits, immediately turn off
main disconnect and contact utility company.
5. Energize control circuit switch. Check for proper voltage.

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6. Check for proper amperage with ammeter on power circuit. Amperage should not vary more than 5%, when
under full load, from amperage shown on data plate. (Table 2). If amperage exceeds these limits, immediately
turn off main manual disconnect and refer to Electric Water Heater Trouble Shooting Guide.
7. Check magnetic contactors for noise. If noisy, i.e., buzzing or chattering, turn off main power disconnect,
disassemble contactor and blow out foreign particles. Drill filings, dirt or other particles can cause pitting of
points which will in turn burn out contactor and/or wire. Extra care has been taken during fabrication and
inspection for cleanliness; however, field installation is often responsible for debris collecting on the contactor
points.
8. The top thermostat is a temperature limiting safety device set at 200°F. The upper operating thermostat is
factory set at 130°F. The lower operating thermostat is set at 120°F Adjust stored water temperature by turning
the Operating thermostat dial to the desired temperature. The Upper Operating and Operating thermostats
should be set minimum 10°F higher.
Le thermostat est réglé à environ 49 degrés Celsius. Températures de l'eau supérieures à 52 degrés Celsius
peut causer instantanément de graves brûlures ou la mort de brûlures. Suivez les instructions dans le manuel
d'installation et de maintenance pour modifier la température de l'eau.
9. If an optional proportional sequencer is furnished, adjust set point to desired water temperature. (All other
temperature controls must be set above the sequencer’s set point.) Refer to manufacturer’s product literature
for servicing, operation and maintenance of proportional sequencer.
10. After startup and with the water heater operating, allow the water in the tank to reach the desired temperature
and de-energize the heating elements. Draw hot water from a nearby faucet or outlet until the heating elements
come back on. This will check for proper operation of the thermostats and other operating controls.
IMPORTANT: After approximately 30 minutes of operation, turn off all power to the unit. With main disconnect
off, check each wire connection and fuse clip for elevated temperature. If an elevated temperature is noted,
there is a loose connection at the point of greatest heat. All connections must be tight for proper performance.

DURAWATT®ELECTRIC WATER HEATERS
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6 ELEMENT CONTINUITY CHECKS
I. II III. IV. V.
I. II. III. IV. V.
ELEMENT RATING CHECK
OPEN
OHM
READING
NORMAL
OHM
READING
1 LEG
OPEN
OHM
READING
2 LEGS
OPEN
OHM
READING
3 LEGS
OPEN
OHM READING
TERMINAL TO
FLANGE
kW VOLT COILS
18 600 A-B 40 120 ∞∞Depending on the
severity of the
short, the OHM
reading may vary
from zero, (direct
short) to several
hundred ohms
(partial short). In
any case where
the OHM reading
is not infinity, the
element should
be replaced.
B-C 40 60 60 ∞
C-A 40 60 ∞∞
18 480 A-B 26 78 ∞∞
B-C 26 39 39 ∞
C-A 26 39 ∞∞
18 380 A-B 17 50 ∞∞
B-C 17 25 25 ∞
C-A 17 25 ∞∞
18 240 A-B 7 20 ∞∞
B-C 7 10 10 ∞
C-A 7 10 ∞∞
18 208 A-B 6 16 ∞∞
B-C 6 8 8 ∞
C-A 6 8 ∞∞
9 600 A-B 80 240 ∞∞
B-C 80 120 120 ∞
C-A 80 120 ∞∞
9 480 A-B 52 154 ∞∞
B-C 52 77 77 ∞
C-A 52 77 ∞∞
9 380 A-B 33 98 ∞∞
B-C 33 49 49 ∞
C-A 33 49 ∞∞
9 240 A-B 14 40 ∞∞
B-C 14 20 20 ∞
C-A 14 20 ∞∞
9 208 A-B 10 30 ∞∞
B-C 10 15 15 ∞
C-A 10 15 ∞∞
4.5 600 A-B 160 480 ∞∞
B-C 160 240 240 ∞
C-A 160 240 ∞∞
4.5 480 A-B 103 308 ∞∞
B-C 103 154 154 ∞
C-A 103 154 ∞∞
4.5 380 A-B 65 194 ∞∞
B-C 65 97 97 ∞
C-A 65 97 ∞∞
4.5 240 A-B 26 78 ∞∞
B-C 26 39 39 ∞
C-A 26 39 ∞∞
4.5 208 A-B 20 58 ∞∞
B-C 20 29 29 ∞
C-A 20 29 ∞∞
TABLE 1
TYPICAL CURRENT MEASUREMENTS

DURAWATT®ELECTRIC WATER HEATERS
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TYPICAL SINGLE PHASE WIRING TYPICAL THREE PHASE WIRING
FIGURE 4 FIGURE 6
TYPICAL WIRE TERMINATIONS
FIGURE 5 FIGURE 7
FIGURE 8
REQUIRED WIRE SIZE
Contactor Fuseholder Wire Size
600V – 30A 10 AWG
300V – 60A 6 AWG
600V – 60A 6 AWG
TORQUEING REQUIREMENTS
Wire Size Terminal Type In-lbs
10 AWG RING 25
10 AWG BOX 35
6 AWG BOX 45

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FIGURE 9 FIGURE 10
3 Ø AMPS PER ELEMENT 1 ØAMPS PER ELEMENT
KW-
VOLTAGE
AMPS PER
LEG
AMPS
TOTAL
AMPS PER
LEG
AMPS
TOTAL
*14 kW-600V 13 1/2 13 1/2 — —
*7 kW-600V 7 7 — —
18 kW-600V 18 18 — —
9 kW-600V 9 9 — —
4.5 kW-600V 4 1/2 4 1/2 — —
18 kW-480V 22 22 — —
9 kW-480V 11 11 — —
4.5 kW-480V 5 1/2 5 1/2 — —
18 kW-380V 28 28 — —
9 kW-380V 14 14 — —
4.5 kW-380V 7 7 — —
18 kW-240V 44 44 25 75
9 kW-240V 22 22 13 38
4.5 kW-240V 11 11 6 18
18 kW-208V 50 50 29 87
9 kW-208V 25 25 15 44
4.5 kW-208V 12 1/2 12 1/2 7 22
TABLE 2
NOTE: Elements are usually wired to contactors in groups, in order to maintain an amperage draw of close to, but
not more than, 50 amps per contactor.
*Applications for 600V may be a re-rated 480V element. Therefore, the 40W/in.2 may be rated for 14 kW instead of
9 kW.

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7 MAINTENANCE
A preventative maintenance program is required to ensure a long trouble-free life of the water heater.
Maintenance Schedule
COMPONENT OPERATION INTERVAL REQUIRED
Tank Sediment Removal Every 3 Months Flushing
Relief Valve Inspect Every 6 Months Test
Electrical Connections Inspect Monthly Inspect for wire discoloration
Electric Elements Check Every 6 Months Amp Draw
Electric Elements Remove & Clean See Page 9
7.1 Flushing
1. Turn off the heater electrical disconnect switch.
2. Open the drain valve and allow water to flow until it runs clean.
3. Close the drain valve when finished flushing.
4. Turn on the heater electrical disconnect switch.
7.2 Draining the Tank
The heater must be drained if it is to be shut down and exposed to freezing temperature. Maintenance and service
procedures may also require draining the heater.
1. Turn off the heater electrical disconnect switch.
2. Close the cold water inlet and hot water outlet valve to heater.
3. Open a relief valve to vent the tank pressure.
4. Open the heater drain valve.
5. If the heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this
period.
7.3 Sediment / Lime Scale Removal
Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the
bottom of the tank and adhere to heat exchange surfaces. The amount of calcium carbonate (lime) released from
water is in direct proportion to water temperature and usage. The higher the water temperature or water usage, the
more lime deposits are dropped out of the water. Lime accumulation not only reduces the life of the equipment but
also reduces efficiency of the heater.
7.4 Temperature and Pressure Relief Valve
The relief valve should be checked at regular intervals by manually opening the valve. The openings inside the
valve may become restricted by a buildup of scale and become inoperative. If the valve does not open and close
properly and does not blow off internal pressure when tested, it must be replaced. Shut down heater, relieve internal
pressure and replace relief valve with a like kind or one meeting the requirements stated on the rating decal located
adjacent to the relief valve mounting location.
7.5 Low Water Cutoff
The standard low water control is electronic. Inspection should be made of the electrode on water heaters equipped
with electronic low water devices.

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7.6 Electrical Connections
Check all electrical connections approximately one to two weeks after initial start-up to assure tightness. Heating
and cooling from operation can loosen connections. Visually inspect wire terminal points for any discoloration on a
monthly basis. Discoloration is likely due to a loose connection at the point nearest discoloration. Check contactors
periodically and clean if necessary and repair or replace pitted points caused by foreign particles. Check fuses
periodically for continuity and replace if necessary with the same type and rating.
7.7 Replacing Electric Elements
Some electric heating elements installed in dished heads may be factory bent to allow clearance from adjacent
elements. Replacement elements must be identical to the original equipment installed. The Bend Angle Stamp # is
required for all replacement electric element requests.
IMPORTANT: Install the element facing away from the center of the head.
Typical Electric Element
BEND ANGLE STAMP
25° #1
18° #2
FIGURE 11
NOTE: No stamp on the element flange means that the element is not bent.

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7.8 Cleaning Electric Elements
Electric immersion INCOLOY®sheath elements are wound at high wattage ratings and must be completely covered
by water while in operation. Otherwise, they overheat and burn out. Scale from the water will collect on the
sheathing of the element over a period of time and must be removed periodically to extend the life of the element.
Water in some areas will produce the scale buildup more rapidly than other areas. The rapidity of the scale buildup
is also determined by the watt density of the element.
It is good maintenance practice to remove and clean 80 W/in² (18kW) density elements on a monthly basis. The
interval between removal and cleaning can usually be extended to six months when 40 W/in² (9kW) density
elements are installed. Most installations where 20 W/in² (4 1/2kW) density elements are used, require only annual
cleaning. Elements are cleaned by soaking in a scale dissolving solution. A 30” piece of four or six inch PVC pipe
with a cap on one end makes an ideal container for element cleaning. (See figure 12.) Contact a chemical supply
house for advice on the proper cleaning solution for your area.
Element Cleaner
FIGURE 12

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8 TROUBLESHOOTING GUIDE
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
No hot water
Thermostat(s) Check to assure proper thermostat setting.
Contactors will not pull in Check continuity between all three thermostats or pressure
controls. Complete circuit. If one is open, it must be replaced.
Control circuit switch is in OFF position Close switch. (Turn to ON position)
Control circuit fuse blown Isolate cause for failure and replace fuse.
Contactor(s) coil open Check continuity. Replace coil if not a complete circuit.
Time delay sequencer not operating
Check for 120 volts to coil on first sequencer step. Allow ample
time for additional steps to energize. If steps do not energize in
reasonable time, replace only the defective relay step. See
wiring diagram.
Proportional sequencer not operating Check for 120 volts to line connection (L) on sequencer. Check
fuse for continuity. See wiring diagram. Consult factory.
Low water cutoff closed Check for open circuit. Check water level in tank. Replace low
water cutoff if defective.
Heating elements Check for open legs. (See table 2).
Insufficient hot
water
Heater not large enough to satisfy peak
demands Add booster or additional kw input. Consult local PVI representative.
Hot water lines not insulated Add insulation; it will protect against heat loss and save on cost
of operation.
Power fuse(s) blown Check fuses for continuity. Replace if blown. If blown, determine
cause of break before replacing with same type fuse.
Contactor(s) not closing Check coil for continuity. If defective, replace.
Thermostat(s) not correctly set Check to assure proper thermostat control setting.
Element(s) not heating Check for proper amperage draw. Check for proper ohm resistance. Replace if defective. Consult factory.
(See table 1)
Burned or
discolored wires
Loose connections Tighten all connections. If charred, replace wire with wire of
same type and size.
Dirty or pitted contactor points Remove contactor points and inspect. If dirty, clean with emery
paper. CAUTION: Point must remain flat. If pitted or burned,
contactor points must be replaced.
Blown fuses Loose connection. Defective element Check all connections for tightness. Check ohm resistance in
electric elements. Replace.
High or low
voltage Local utility Check with local utility.
High or low
amperage High or low voltage. Defective element Check with local utility. Low amperage, check fuses, tighten
connections. Check ohm resistance on elements.
Wire burned or
melted at
element Loose connections. Water leaking on elements Tighten connection and replace wire. Isolate leaking water and
repair. Replace wire with same type and size.

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PVI INDUSTRIES®, LLC 3209 Galvez Ave. Fort Worth, Texas 76111 1-800-433-5654 www.pvi.com