PVI Industries 100 LX 125 A-PVIF Installation & Maintenance Manual Download Page 32 | Manualshive

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PV500-46U 06/12

Gas Train Illustration

(Optional components may not be shown)

Alternate Gas Train Illustration

(Optional components may not be shown)

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Summary of Contents for 100 LX 125 A-PVIF

Page 1: ...T 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 tha...

Page 2: ...ate Drain Trap Disposal 6 1 Condensate Neutralization System optional 7 Gas Supply and Piping 7 1 Gas Train and Controls Certification 7 2 Gas Control Trains 7 3 Inlet Pressure 7 4 Manifold Pressure 7 5 Gas Piping Size 7 6 Appliance Isolation during Gas Supply Piping Pressure Test 7 7 Gas Connection 8 Combustion and Ventilation Air 8 1 Equipment Located in Confined Spaces 8 2 Maximum Allowed Remot...

Page 3: ...1 7 To Change Other Parameters 11 8 LED Display Alarm Messages 12 Remote Connections Terminal Strip 12 1 Making BMS BAS Remote Connection for Analog and Binary Signals 12 3 Terminal Functions 13 Sequence of Operation 14 Initial Startup 14 1 Initial Startup Requirements 14 2 Tools and Instrumentation Required 14 3 Resources 14 4 On Site Considerations 14 5 Startup Procedure 15 Troubleshooting Guide...

Page 4: ...ncy shut the main gas supply valve 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 PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA WARNING This product contains or may come to contain crystalline silica which has been...

Page 5: ...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...

Page 6: ...mpliant FM compliant ASHRAE 90 1 compliant 2 5 Burner Operating Controls Safeties Pre mix surface burner with self adjusting proportionate gas air ratio UL 795 compliant gas train Electronic flame safeguard with pre and post purge Combustion sequence panel lights including lockout Programmable electronic operating control with digital temperature readouts adjustable from 70 F to 180 F Immersion te...

Page 7: ...7 PV500 46U 06 12 3 PRODUCT DESCRIPTION Component Controls and Connection Locations Locations May Vary 250 SERIES ...

Page 8: ...8 PV500 46U 06 12 300 SERIES ...

Page 9: ...l Electrical Code ANSI NFPA No 70 In Canada the electrical service must conform to local electrical codes and or CSA C22 1 Canadian Electrical Code Part 1 All wiring between the unit and field installed devices must be made with type T copper wire Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable To avoid serious damage DO NOT energize th...

Page 10: ...ir electrical pump and other auxiliary equipment 4 6 Clearances To Combustible Surfaces Minimum 1 clearance must be provided from any vent surface to adjacent combustible material The minimum clearances to unprotected combustible material are 24 be provided at the front 8 be provided at the rear and 8 at top left and right sides of the appliance 5 GENERAL PIPING GUIDELINES 5 1 Inlet and Outlet Con...

Page 11: ...11 PV500 46U 06 12 SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK ...

Page 12: ...posure to hazardous materials or loss of life 1 Installing the water heater on a 4 inch to 6 inch housekeeping pad is recommended to ensure proper condensate drainage 2 Attach a 3 4 CPVC Coupling and Tee to the economizer condensate drain then use 3 4 CPVC pipe to plumb from the heater condensate outlet to economizer Tee to a 3 CPVC trap and on to a suitable floor drain or collection system Each c...

Page 13: ... System in the condensate piping as shown in the FIELD INSTALLED CONDENSATE DIAGRAM above 3 Position with removable crushed limestone fill cap in vertical position only The bottom of the condensate neutralization system outlet pipe must not be higher than the bottom of the water heater 4 For proper operation the water heater condensate outlet must be plumbed with CPVC plastic pipe to the lowest fi...

Page 14: ...e minimum and maximum values while the unit is at rest and while the unit is operating at maximum firing rate 7 4 Manifold Pressure Measure at the pressure tap located downstream side of the manual valve closest to the burner The rated manifold pressure appears on the product data label located near the front of the appliance 7 5 Gas Piping Size Use the values in Convert Fittings To Equivalent Str...

Page 15: ... and before the appliance provided appliance manual shutoff gas valve when Codes require 5 The gas system installer should clearly identify the emergency shut off device 6 A sediment trap drip leg MUST be provided in the inlet of the gas connection to the unit 7 The code compliant vent limiters are designed and must respond to pressure changes in the installation environment as opposed to outdoor ...

Page 16: ...ssure Particular care should be taken when exhaust fans compressors air handling units etc may rob air from the appliance The combustion air supply must be completely free of any chemical or fumes which may be corrosive to the appliance Some common chemical fumes to avoid are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichloroethy...

Page 17: ...p is available from PVI Industries and may have shipped with the water heater as a purchased option 8 4 Vertical or Horizontal Remote Air Duct Termination Air inlet and exhaust vents should terminate in the same wind pressure area whenever possible Air inlet must be located no less than 3 feet 0 91m below the exhaust terminal if they are within 10 feet 3 05 m of each other If terminating through t...

Page 18: ... s instructions for installation sealing supporting and terminating their vent system Do not use a barometric damper with the Power VT Plus positive pressure vent WARNING On Power VT Plus except models with SANI in the model number see above use only solid CPVC pipe or stainless steel venting listed by a nationally recognized testing laboratory for Category IV positive pressure gas appliance venti...

Page 19: ...he inside of the stainless steel economizer flue outlet and to the outside of the plastic pipe Before the RTV sets slide the plastic coupling or elbow back into the RTV coated economizer flue outlet while rotating the pipe approximately 1 8 of a turn Inspect and apply RTV to the inside and outside of the plastic to stainless steel joints to provide a continuous water and gas tight assembly 5 Drill...

Page 20: ...d a blocked flue condition keep the vent cap clear of snow ice leaves debris etc 6 The vent must not exit over a public walkway near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property or could be detrimental to the operation of regulators relief valves or other equipment 7 A horizontal vent must extend one foot beyond the ...

Page 21: ...lve opening and must be secured to prevent it from lifting out of the drain under discharge pressure Caution Do not install a reducing coupling valve or other restriction in the T P relief valve s discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year Thermal Expansion A relief valve that periodically dis...

Page 22: ...tilizing cathodic protection hydrogen gas can be produced when the hot water system has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions one of the hot water system faucets should be opened for several minutes before using any electrical device connected to the hot water system If hyd...

Page 23: ...ive or directly from PVI to remotely monitor water temperatures such as blended water temperature downstream of a thermal mixing valve or a remote storage tank Both Probe 1 and Probe 2 temperatures are available for monitoring through the optional MODBUS RTU interface 11 4 Control Buttons SET Displays and modifies the temperature set points In programming mode it selects a parameter or confirms an...

Page 24: ...t set point Repeat the operations described at points 3 4 5 To Exit press SET UP or wait 15 seconds without pressing any key NOTE Each point has a time out of 15 seconds If any key is pushed within 15 seconds the controller exits the set points programming procedure NOTE The set value is stored even when the procedure is exited by waiting the time out to expire 11 7 To Change Other Parameters Push...

Page 25: ...ctly or flue gas temperature protection is disabled if used Check wiring and sensor Terminals 16 17 HA High temperature limit setpoint exceeded Buzzer sounds operation continues Manual reset required LA Low temperature alarm Buzzer sounds operation continues HP Digital input 3 is activated for one or more of the following Flame failure or any control component failure if equipped with alarm on any...

Page 26: ...control Terminals are wired to a relay in a remote Energy Management System When relay closes circuit from R1 to R2 is completed and appliance controls are enabled Appliance ships from factory with jumper between terminals Remove jumper when connecting to a remote controller A1 A2 Used to activate a remote alarm signaling shutdown of combustion control Provides a maximum 10 amp relay contact closu...

Page 27: ...use the differential air switch to close the 15 second pre purge delay will start b During this period any flue products or combustible gases which may have settled in the water heater are evacuated 5 Heat Up Following the pre purge delay the hot surface igniter will be energized a The flame control will monitor the current applied to the hot surface igniter b If the flame control determines the p...

Page 28: ...ion d As heat is transferred to the building the water heater loop temperature will fall below the set point The TempTrac will sense this condition and begin the call for heat sequence again 9 Flame Safeguard LED Diagnostic Indicator If the Fenwal Flame Safeguard Control at any time during the operating sequence senses an improper operating state and locks out the diagnostic red LED located on the...

Page 29: ... can cause personal injury property damage or loss of life 14 2 Tools and Instrumentation Required Stack Temperature Gauge Stack Draft Gauge Electronic Combustion Analyzer Manometer for checking gas pressure 2 minimum AC DC Multi meter with 20 000 OHM Volt rating Amp Meter Normal Hand Tools 14 3 Resources Product Installation Maintenance Manuals Start up Report with instructions Local State Federa...

Page 30: ...esting 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 pressure regulator 12 Connect a second manometer to the manifold test port at the shutoff valve closest to the burner 13 Turn off main gas shutoff valve 14 Disable or jumper out any BMS BAS contr...

Page 31: ...ce the main burner flame is established the firing rate will be controlled by the TempTrac control Refer to TempTrac manual PV500 41 Burner Combustion Adjustment Burner combustion should only be adjusted using a combustion analyzer Do not attempt to adjust burner by sound or sight With the burner firing insert the combustion analyzer probe in the flue vent approximately two feet from the appliance...

Page 32: ...32 PV500 46U 06 12 Gas Train Illustration Optional components may not be shown Alternate Gas Train Illustration Optional components may not be shown ...

Page 33: ...tch Check for proper blower pressure setting adjust if required Air switch may be defective Blocked Filter Switch Check for 24V at the N C side of the blocked filter switch Replace filter or switch as required Flame Control Pressure Switch Check for 24V at the pressure switch terminal Loose Wire Connections Check connections to all components Flame Failure Power Supply Check fuse and or circuit br...

Page 34: ...34 PV500 46U 06 12 16 REPLACEMENT PARTS REPLACEMENT PARTS ...

Page 35: ...35 PV500 46U 06 12 16 1 Control Panel ...

Page 36: ...TC 25FT NICKEL BRASS 1 EA 9 105266 PROBE THERMOSTAT DIXELL 50DSS NTC 1 5M SST 1 EA 10 116458 RELAY SPST 30A 24V OMRON G7L 1A TUB J CB AC24 N O EA 11 102835 RELAY TIME DELAY ON SSAC TDU3000A 24 120 VAC DC 1 TO 102 EA 12 70565 SWITCH CARLING LTILA51 6SBLAM NBL 125N INDP BLACK W AMBER 1 EA 13 70573 SWITCH SPST N C MOMENTARY CONTACT SELECTA SS229 EA 14 75908 SWITCH SPST N O MOMENTARY CONTACT SELECTA S...

Page 37: ...37 PV500 46U 06 12 16 3 Burner Assembly Optional components may or may not be shown ...

Page 38: ...FOAM 15 1 117195 SUPPORT GAS TRAIN FB14 PVIF 16 35 3475 NUT HEX 1 4 x 20NC ZINC PLT 17 1 110265 FILTER AIR 12 x 24 18 1 8 3604 PYROBOARD 1 4 x 23 x 16 RR 937 PYROLITE 19 33 15607 WASHER FLAT 1 4 PLT 20 3 6480 CONNECTOR 1 8 MPT x 1 4 COMP 21 2 6493 ELL 1 8 MPT x 1 4 COMP 22 2 79972 NUT WING 1 4 x 20 NC STEEL 23 107775 IGNITER HOT SURFACE 271Y 1 INSERTION 24 1 111791 GASKET IGNITER 232 CRANEGLAS Y27...

Page 39: ...102838 FLANGE BLACK 1 1 2 DUNGS 55 2 45327 VALVE SHUTOFF 1 1 2 GAS COMBU 56 5973 NIPPLE BLACK 1 4 x 2 57 2 6168 ELL BLACK 89DEG 1 1 2 58 101216 SWITCH PRESSURE HKGP G ANTUNES MANUAL 59 101201 SWITCH PRESSURE RLGP G ANTUNES MANUAL 60 2 6055 NIPPLE BLACK 1 1 2 x 3 61 1 69559 NIPPLE BLACK 1 1 2 x 4 1 2 62 1 57612 NIPPLE BLACK 1 1 2 x 7 63 1 6059 NIPPLE BLACK 1 1 2 x 6 64 1 6053 NIPPLE BLACK 1 1 2 x 2...

Page 40: ...erviceman or installer should use the procedures described in item 5 6 below 3 Any sign of soot on the heat exchanger or in the flue indicates the need for a combustion inspection Properly installed and adjusted units seldom need heat exchanger cleaning If soot has formed the most common causes are restricted combustion air or excessive gas A blocked heat exchanger can cause unsafe operation and w...

Page 41: ...low of combustion and ventilation air is unobstructed to the appliance 10 When electrical controls are serviced or replaced refer to ELECTRICAL COMPONENT LOCATIONS for identification and location of components 11 All replacement parts are available through your PVI Industries Dealer If you need assistance identifying or contacting your local dealer you may contact PVI Industries LLC directly at th...

Page 42: ...lure detection system components c Check firing rate control d Check piping and wiring of all interlocks and shutoff valves e Inspect burner components f Check igniter g Test high and low gas pressure interlocks h Check air filter and replace if required 3 Monthly Maintenance a Test low water cutoff device and alarm if equipped b Check flue vent stack or outlet dampers c Check flame signal strengt...

Page 43: ...43 PV500 46U 06 12 ...

Page 44: ...44 PV500 46U 06 12 PVI INDUSTRIES LLC 3209 Galvez Ave Fort Worth Texas 76111 Phone 1 800 433 5654 www pvi com ...

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