PVI Industries 100LX 125 A-PVIF Installation & Maintenance Manual Download Page 19

19 

PV500-44U  06/12

 

 

Vertical Remote Air 

Horizontal Remote Air 

 

 
8.5  Remote Air Consideration for Combined Remote Air Ducting 

Each water heater MUST have separate intake piping. Consult factory for common air intake pipe sizing. 

 
 

9 VENTING 

 

9.1  Venting the Power VT Plus “SANI” models:

 

Power VT Plus models with “SANI” in the model number are designed for operation only with stainless steel venting 
listed by UL, ULC, ETL or CSA for Category IV, positive pressure, gas appliance venting. Installation requires a field 
supplied stainless steel adapter from the 6-5/8 female economizer outlet to the specific size (six inch minimum) and 
model vent used. Follow the vent manufacturer’s instructions for installation, sealing, supporting and terminating their 
vent system. Do not use plastic venting of any type on models with SANI in the model number. Do not use a 
barometric damper with the Power VT Plus positive pressure vent. 
 

WARNING: On Power VT Plus models with “SANI” in the model number, use only stainless steel venting 
listed by a nationally recognized testing laboratory for Category IV, positive pressure, gas appliance venting. 
Use of plastic pipe of any type or use of venting materials other than specified in these instructions can 
result in failure of the venting system and/or exposure to carbon monoxide which can result in property 
damage, personal injury or death. 

 

9.2  Venting the Power VT Plus:

 

The Power VT Plus (except models with “SANI” in the model number, see above) is designed for operation with a 
"positive pressure vent system" constructed of locally obtained 6" or larger schedule 40 or 80 solid CPVC pipe. Do 
not use CPVC pipe with cell/foam type construction (such as “CellCore”) or other non-solid CPVC plastic pipe. Larger 
solid CPVC pipe may be substituted, however a solid CPVC increaser from 6” to the larger size must be used for 
connection to the stainless steel 6-5/8” female flue outlet from the water heater economizer. Do not insulate the 
plastic vent pipe. Stainless steel venting listed by UL, ULC, ETL or CSA for Category IV positive pressure gas 
appliance venting may be used instead of CPVC plastic pipe venting. If such stainless steel venting is used, follow 
the vent manufacturer’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 venting. Use of ABS pipe, CPVC pipe, pipe with cell/foam type construction, 
plastic vent pipe other than solid CPVC or use of venting materials other than specified in these instructions 
can result in failure of the venting system and/or exposure to carbon monoxide which can result in property 
damage, personal injury or death. 

Summary of Contents for 100LX 125 A-PVIF

Page 1: ...CE 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 import...

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: ...ified as low lead compliant 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 t...

Page 7: ...7 PV500 44U 06 12 3 PRODUCT DESCRIPTION Component Controls and Connection Locations Locations May Vary 125 SERIES ...

Page 8: ...8 PV500 44U 06 12 250 SERIES ...

Page 9: ...9 PV500 44U 06 12 300 SERIES ...

Page 10: ...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 11: ...tion air 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 Outl...

Page 12: ...12 PV500 44U 06 12 SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK ...

Page 13: ...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 14: ... 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 15: ...d in a common housing CAUTION Do not adjust or remove any screws or bolts on gas train control components which are sealed with a red or blue colored compound Doing so will void all approvals and warranties 7 3 Inlet Pressure Measure at the inlet pressure tap located at the main gas cock The inlet pressure must remain within the minimum and maximum values while the unit is at rest and while the un...

Page 16: ... 5 W C Pressure Drop 1 1 4 1 1 2 2 2 3 4 25 860 1320 2475 3900 7000 40 660 990 1900 3000 5300 60 810 1520 2400 4300 80 690 1300 2050 3700 100 620 1150 1850 3250 6700 125 1020 1650 2950 6000 150 950 1500 2650 5500 175 850 1370 2450 5000 200 800 1280 2280 4600 MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART Maximum Capacity of Pipe in Thousands of BTU s per hour for gas pressures of 14 Inches Wate...

Page 17: ... determine the required minimum air volume needed for combustion ventilation and dilution of flue gasses All Air From Outdoors Each opening requires a minimum free area of 1 square inch per 4000 Btu hr input if directly communicating with the outdoors or communicating to the outdoors through vertical ducts Each opening requires a minimum free area of 1 square inch per 2000 Btu hr input if communic...

Page 18: ...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 information is provided for use in design calculations if needed Remote Air Duct Specifications Input MBtu Required Air SCFM 399 87 500 108 750 163 900 195 1000 217 8 3 Remo...

Page 19: ...death 9 2 Venting the Power VT Plus The Power VT Plus except models with SANI in the model number see above is designed for operation with a positive pressure vent system constructed of locally obtained 6 or larger schedule 40 or 80 solid CPVC pipe Do not use CPVC pipe with cell foam type construction such as CellCore or other non solid CPVC plastic pipe Larger solid CPVC pipe may be substituted h...

Page 20: ...is required for the addition of the vent system terminal The following vent information is provided for use in design calculations if needed Venting Specifications Input MBtu Combustion Air Volume cfm Max Vent Press W C 399 136 0 5 500 170 0 6 750 255 1 0 900 306 1 2 1000 340 1 3 9 4 CPVC Vent System Design Construction and Assembly The Power VT Plus water heater can be vented either vertically th...

Page 21: ...or roof at the point where it passes through the wall or roof to prevent rain insects or flue products from entering the living space 9 For proper vent operation and to protect the gas vent from wind and weather attach to the outdoor end of the vent the UL listed vent termination supplied with the Power VT Plus water heater This termination is required for proper operation and no substitution is a...

Page 22: ...g personal injury or loss of life could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance 10 1 Temperature and Pressure Relief Valve s A Temperature and Pressure Relief Valve s sized in accordance with the ASME Boiler and Pressure Vessel Code is installed in the tank WARNING Secure the relief valve pipe to a suitable floor drain such that very ho...

Page 23: ...mit is of the auto reset type and can be dial adjusted to operate just above the set point of the main Operating Temperature Control 10 4 Cathodic Protection PVI water heaters do not utilize cathodic protection However in hot water systems utilizing 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 Hyd...

Page 24: ...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 25: ...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 26: ... P1 TP1 probe failure Inlet temperature sensor is not connected or is reading incorrectly Call for heat and burner modulation output signal will revert to low fire Check wiring and sensor Terminals 14 17 P2 TP2 probe failure Temperature sensor is not connected or is reading incorrectly Check wiring and sensor Terminals 15 17 P3 TP3 probe failure Temperature sensor is not connected or is reading in...

Page 27: ...f remote device Terminals are wired to a proving switch on a remote device such as a power venter When relay closes circuit from C1 to C2 is completed and appliance controls are enabled This appliance ships form the factory with jumper between terminals T1 T2 Used for external modulation control To connect external modulation control disconnect and cap the blue wire connected to terminal T2 and co...

Page 28: ...control will reset and begin the call for heat sequence again This will occur 3 times one time if CSD 1 before the flame control will lockout b When the call for heat condition ends or flame failure occurs following the third TFI period one time if CSD 1 a 30 second post purge period will begin This period of blower operation will exhaust any remaining combustion products from the system 8 Delay O...

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: ... cause 22 Once 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 t...

Page 32: ...32 PV500 44U 06 12 Gas Train Illustration for Models 40 through 50 Optional components may not be shown Gas Train Illustration for Models 65 through 100 Optional components may not be shown ...

Page 33: ...eck for proper blower pressure setting adjust if required Air switch may be defective Blocked Filter Switch if equipped 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 circ...

Page 34: ...34 PV500 44U 06 12 16 REPLACEMENT PARTS REPLACEMENT PARTS ...

Page 35: ...35 PV500 44U 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 44U 06 12 16 3 Burner Assembly Optional components may or may not be shown ...

Page 38: ...W 18 101201 SWITCH PRESSURE LGP G ANTUNES 8103116202 1 20 W 19 1 NIPPLE BLACK 1 20 1 5929 UNION BLACK 1 21 1 115255 ASSY BURNER EXTENSION 2 X 5 FASCO MOD 43 22 1 113571 GASKET BLOWER OUTLET 4 665 ROUND AMORIM CR 55R 1 23 14 3475 NUT HEX 1 4 X 20 NC STEEL ZINC PLT 24 2 107449 GASKET FLANGE BLOWER 1 8 23 CRANGLAS 25 6 115745 STUD THREADED 1 4 X 20 NC X 2 CRS GRAINGER 4REW2 26 6 55854 BOLT 1 4 X 20 N...

Page 39: ... filter is installed it is recommended that the filter not be removed until a suitable replacement is available To inspect and clean the burner a qualified serviceman 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 exchange...

Page 40: ...e and other flammable vapors and liquids 9 Check frequently to be sure the flow 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 co...

Page 41: ...etection 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 If equipped 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 s...

Page 42: ...42 PV500 44U 06 12 PVI INDUSTRIES LLC 3209 Galvez Ave Fort Worth Texas 76111 Phone 1 800 433 5654 www pvi com ...

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