Ventura PV500-27A Manual

PV500-27A 07/04 1
INSTALLATION & MAINTENANCE MANUAL FOR
VENTURA®
LOW NOx WATER HEATER
TYPICAL CONSTRUCTION
FIGURE 27A-1
1. VENT STACK * 6. DRAIN
2. BURNER 7. CONTROL SWITCH(es) and FUSE(s)
3. TEMPERATURE LIMITING DEVICE (set at 200°F) 8. HANDHOLE CLEANOUT
4. OPERATING THERMOSTAT (set at 120°F) 9. COLD WATER INLET and RETURN CONNECTION
5. RELIEF VALVE 10. HOT WATER OUTLET
(* NOT FURNISHED BY PVI)
WARNING: WATER TEMPERATURES OVER 125°F CAN CAUSE SEVERE BURNS INSTANTLY OR DEATH
FROM SCALD!
Important! Clearance to unprotected combustible material must be 8” min. at top, sides and rear, and 24” min. in front.
TABLE OF CONTENTS
Start-up Procedures 2
Maintenance & Safety Inspections 3-5
FOR YOUR SAFETY
WHAT TO DO WHEN 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 phone
outside the building.
Follow the gas supplier’s
instructions.
•If you cannot reach your
gas supplier, CALL THE
FIRE DEPARTMENT.
FOR YOUR SAFETY
DO NOT store or use gasoline or
other flammable vapors and
liquids in the vicinity of this or
any other appliance.
FOR YOUR SAFETY
WARNING: Improper installation,
adjustment,alteration,service,or
maintenance can cause injuryor
property damage. Refer to this
manual for assistance,or consult
a qualified installer, service
agency, or the gas supplier.

PV500-27A 07/04 2
VENTURA®
LOW NOx WATER HEATER
START-UP PROCEDURES
CAUTION: DO NOT RELIGHT PILOT OR START BURNER WITH COMBUSTION
CHAMBER FULL OF GAS VAPOR, OR WITH VERY HOT COMBUSTION CHAMBER.
1. Study the Installation & Maintenance
manual for the burner carefully.
2. 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.
3. Follow the enclosed warnings on the
water temperature control when setting
the operating thermostats. The water
heater has three temperature controls.
The top control is the temperature limiting
device and should be set at 200°F. The
lowest control is the operating thermostat
and must be adjusted 10 degrees (10°)
lower then the upper operating control. A
common setting is 130°F for the upper
operating control and 120°F for the
operating thermostat. Your thermostat
settings must take into account your
application. To avoid scalds, follow the
enclosed warnings on water temperature
control when setting the thermostats.
CAUTION: ON MODELS WITH FLUE GAS RECIRCULATION (FGR), THE FGR DUCT
AND PLUMBING WILL BE HOT DURING AND AFTER OPERATION. USE CARE TO
AVOID CONTACT WITH SKIN WHILE MAKING ADJUSTMENTS.
CAUTION: CONDUCT THE FOLLOWING GAS TRAIN LEAKAGE TEST BEFORE
START-UP, ANNUAL INTERVALS AND PRIOR TO INVESTIGATING THE
CAUSE OF ANY REPORTED OCCURRENCES 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 of the leak.
2. Attach a manometer, to measure gas
pressure, at the manual gas shutoff valve
located just upstream of the gas train.
Adjust gas train inlet pressure to the
specifiedvalue on heater decalandtightly
close the gas train manual shutoff valve
closest to 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 (in 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, a solenoid
actuated gas shutoff valve. After any
leaking valve is replaced, the
reassembled gas train must be leak
tested again before start-up is attempted.
(NOTE: All gas valves removed
because of suspected leakage must be
returned to PVI Customer Service for
disposition.)

PV500-27A 07/04 3
VENTURA®
LOW NOx WATER HEATER
MAINTENANCE AND SAFETY INSPECTIONS
1. Establish a preventive maintenance program
to assure a longer water heater life.
2. The tank should be flushed at two- or three-
month intervals depending on water
conditions in your location. To flush, turn off
electrical 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. Drainingtwo or
three gallons from the bottom of the tank on
a weekly basis will also help prevent the
accumulation of sediment. Water impurities
consist of fine particles of soil or sand, which
will settle out and form a layer of sediment
on the bottom of the tank.
3. A scale 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 precipitate out
during heating cycles. Some water supplies
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 that is used, the more fresh water
containing scale-forming chemicals is
brought into the tank. As the temperature of
water increases, the rate of scaledeposition
will be increased.
4. The tank will have ahandhole for inspection
and cleaning. (See Figure 27A-1, page 1.)
To inspect tank for scale buildup, remove
the handhole cover. If scale is present, it
can be loosened with a high 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 a firetube leaks for any reason, consult
factory for instructions.
NOTE: Condensate coming from the tubes
on a cold start is normal and does not
indicate a leaking tube.
6. Regularly inspect the bottom tubesheet.
Inspect the SCALEGUARD®tubesheet
insulator for holes or areas that may have
pulled away from tubesheet. Repair or
replace as required.
CARBON MONOXIDE WARNING:
CAUTION: IMPROPER COMBUSTION MAY CAUSE SERIOUS INJURY.
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 the burner installation instruction for recommendations.
1. Examine the venting system at leastonce
each year for proper connections,
alignment and corrosion. The blower inlet
will collect dust from the air during
operation. Disconnect the power to the
heater and clean the blower wheel when
necessary.
Inspect all parts and make replacements
when necessary. Check wiring for loose
connections and burned wires.

PV500-27A 07/04 4
VENTURA®
LOW NOx WATER HEATER
MAINTENANCE AND SAFETY INSPECTIONS (cont'd)
Periodic Inspection of Operation Components (cont'd)
CAUTION: THE RELIEF VALVE IS A PRIMARY SAFETY DEVICE.
2. The temperature and pressurerelief valve
may be checked by slowly lifting the seat
lever on top of the valve to determine its
conditionfor safe operation. The openings
insidethe valve may becomerestrictedby
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.
3. A table of periodic safety inspections is an
attachment of 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.
4. PVI strongly recommendsthe recording of
significant events, such as maintenance
or repair actions and safety inspections,
and encourage 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 27A-1, page 5 for sample of
Inspection Record.)
CALL YOUR PVI CUSTOMER SERVICE
REPRESENTATIVE IF YOU HAVE ANY
QUESTIONS. (1-800-784-8326)
Instructions for Taking Water Heater Out of Service
Extended shutdown of the appliance and
restarting are as follows:
A. Turn off all power and fuel supplies.
B. Drain and flush tank as previously
discussed.
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 in the previous
pages.
ELECTRICAL
1. Wiring to the unit should conform to the
National Electrical Code or the code
legally authorized in your locality. A fused
disconnect switch should be used for
water heater control. Service wiring
connections of 120V, 1 phase, 60 Hz. are
located in the enclosure on the water
heater.
NOTE: Use only copper wire of proper
sizing for incoming service. Damage
resulting from use of aluminum wiring will
be excluded from coverage under the
warranty of this unit.

PV500-27A 07/04 5
MAINTENANCE & SAFETY INSPECTION REPORT
DATE BURNER
INSPECTION COMBUSTION ANALYSIS TANK INSPECTION TANK FLUSH & CLEANOUT TANK FITTING INSPECTION VENT INSPECTION THERMOSTAT INSPECTION GAS TRAIN LEAK TEST
Recommended
Inspection
Intervals YEARLY 6 MONTHS 6 MONTHS 3 MONTHS 6 MONTHS YEARLY YEARLY YEARLY
TABLE 27A-1
NOTE: Burner Inspection and Combustion Analysis should be done by a factory authorized service person.