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PVI Industries EZ Plate, Installation & Maintenance Manual

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EZ Plate™ Storage Water Heater 

 

 2 

PV500-64 12/14

 

TABLE OF CONTENTS 

 

1 Safety 

Considerations 

2 Product 

Descriptions 

3 

Water Heater Installation

 

3.1 Warranty 

3.2  Checking Equipment Before You Install 

3.3 Codes 

3.4 Electrical 

Requirements 

3.5  Handling and Locating the Water Heater 

3.6  Service Clearances and Clearance to Combustibles 

4 

General Piping Guidelines

 

4.1  Potable Water Inlet and Outlet Connections 

4.2  Storage Tank Relief Valve Piping 

4.3 Cathodic 

Protection 

4.4  Boiler Water Piping 

4.5  Heat Exchanger Relief Valve Piping 

4.6  Connecting Pump(s) and Valves (if equipped) 

4.7  Filling the Unit 

5 

Operating and Safety Controls

 

5.1  Thermostat Settings  

5.2  High Water Temperature Limit Controls 

5.3  Electronic Low Water Cut-Off (optional) 

6 

Description of Operation 

6.1  Sequence of Operation

 

7 

Start-Up and Shut-Down Procedure 

8 Maintenance 

8.1  Temperature and Pressure Relief Valve 

8.2  Thermostats and Temperature Limiting Device 

8.3  Control Valve Actuator (if Supplied) 

8.4 Tank 

8.5 Heat 

Exchanger 

8.6  Checking and Adjusting 2-Way or 3-Way Valve Operation 

8.7  Recommended Maintenance Schedule 

9 Troubleshooting 

Notes 

10  Standard EZ Plate Storage Water Heater Wiring Diagrams 

10.1  Point to Point Wiring Diagram

 

10.2 Ladder 

Diagram

 

 

Warranty forms ship separately with each water heater.

 

Summary of Contents for EZ Plate

Page 1: ...ANCE 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 EQUIPMENT 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...

Page 2: ...ting Pump s and Valves if equipped 4 7 Filling the Unit 5 Operating and Safety Controls 5 1 Thermostat Settings 5 2 High Water Temperature Limit Controls 5 3 Electronic Low Water Cut Off optional 6 Description of Operation 6 1 Sequence of Operation 7 Start Up and Shut Down Procedure 8 Maintenance 8 1 Temperature and Pressure Relief Valve 8 2 Thermostats and Temperature Limiting Device 8 3 Control ...

Page 3: ...ories 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 OR 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 O...

Page 4: ...e 7 Isolation Shutoff Valves 2 Control Enclosure 8 Tank Drain Valve 3 Potable Water Inlet 9 Boiler Water Inlet 4 Potable Water Outlet 10 Boiler Water Outlet 5 Heat Exchanger Pressure Relief Valve 11 Electronic Operating Control 6 Tank T P Relief Valve 12 Boiler Water Control Valve optional NOTE Components controls and connection locations may vary ...

Page 5: ...equirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code and or Local Electrical Codes Supply the electrical service specified on the water heater data decal to each water heater Separate electrical cir...

Page 6: ...iler water pipes should be flushed before assembly and installation Failure to flush lines could cause components to clog or malfunction 2 To avoid shipping damage some piping assemblies may be disconnected and separately secured to the shipping container Such assemblies must be reconnected Align and re connect the heat engine potable water lines to the storage tank as shown in the product descrip...

Page 7: ...t is strongly recommended that the relief valve s should be manually operated at least once a year If water does not freely flow from the manually operated relief valve or if it does not fully reseat when released the relief valve must be replaced with a new relief valve meeting the same ratings WARNING Do not install a reducing coupling valve or other restriction between the relief valve discharg...

Page 8: ... piping when tightening unions valves flanges etc Damage caused by plumbing mistakes such as over tightening cross threading or other installation damage is not covered by warranty 4 Install shut off valves and unions in the boiler water and potable water inlet and outlet piping to aid in servicing Use caution when threading pipe nipples into tank and heat engine connections to prevent cross threa...

Page 9: ...er than the relief valve opening must allow complete drainage of the valve and line and it must be positioned in the floor drain such that water or steam forcefully exiting the drain line does not openly splash The water heater must not be operated without a correctly installed properly sized and properly operating relief valve If a replacement relief valve is required it must be of the same type ...

Page 10: ...n the relief valve Leave the valve open until a steady flow of water is observed Close valve and complete filling the system 2 Make sure there are no system leaks DO NOT use petroleum based stop leak products All system leaks must be repaired 5 OPERATING AND SAFETY CONTROLS WARNING Turn off all electrical service to the appliance before accessing electrical components or terminals located inside t...

Page 11: ...iddle of the water heater tank This is used to anticipate changes in the stored water temperature and ensure a consistent water supply temperature Control Buttons SET Displays and modifies the temperature set points In programming mode it selects a parameter or confirms an operation UP Displays and modifies the energy saving Night Time setback settings In programming mode it browses the parameter ...

Page 12: ...tting of next 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 To Change Other Paramete...

Page 13: ... Failure feature of this product Unit de energized after timer delay Audible alarm sounds Alarm contacts close for remote indication of alarm Internal alarm register will communicate an alarm condition though the Modbus RTU communication link Press any button to reset while alarming AL3 Digital input 3 is activated Unit de energized after timer delay Audible alarm sounds Press any button to reset ...

Page 14: ...ed together in the typical side by side configuration If necessary the storage tank and heat engine can be relocated by the customer using field supplied piping A larger field supplied pump may be necessary when increasing the distance between the heat engine and the tank 6 1 Sequence of Operation 1 When there is demand for hot water consumption hot water exits from the top of the storage tank and...

Page 15: ...age personal injury or death 4 Push the operating switch to ON to energize the pump and boiler water control valve if supplied and to begin heating the water in the storage tank Allow the water temperature in the storage tank to rise above the set point entered into the programmable electronic operating control thermostat and to de energize the circulating pump and boiler water control valve if su...

Page 16: ...esent 8 3 Control Valve Actuator if supplied The boiler water control valve actuator is sealed and requires no maintenance Durability of valve stems and packing is dependent upon maintaining non damaging water conditions Inadequate water treatment or filtration can result in corrosion scale and abrasive particle formation Scale and particulates can result in stem and packing scratches and can adve...

Page 17: ...alves to the tank and cold water recirculation inlet With the heat exchanger properly cooled and depressurized remove the plugs from the CIP fittings The heat exchanger is cleaned by flushing with a suitable food grade acid detergent or biodegradable descaler available at most plumbing supply outlets Isolate the heat exchanger from the hot boiler water and close the tank water isolation valves loc...

Page 18: ...n mounting bracket and remove cam from actuator shaft d Lift valve stem and plunger assembly to full upward position e Install the cam onto the actuator shaft with the cam lobe facing up f Reposition actuator and install the mounting screws g Apply power to actuator Should drive CW rotation and stem down h Install cover and screws i Install indicator with screw pointing toward open 3 Adjust Valve ...

Page 19: ...ves for proper operation d Test high limit and operating temperature controls 2 Semi Annually a Recalibrate all indicating and recording gauges b Check piping and wiring of all interlocks and shutoff valves 3 Monthly Maintenance a Test low water cutoff device if equipped b Check gauges monitors and indicators c Check instrument and equipment settings 4 As Required a Tank flush and cleanout b Clean...

Page 20: ...nspect the heat exchanger for excessive scaling or fouling on the water side and clean if needed e Cause Abnormal operating conditions Solution The water temperature has a significant effect on the efficiency of the heat exchanger Check if the setpoint is higher than specified Confirm the measured flow rate with meters or by volume and rate Check that there are no other loads on the heater Check i...

Page 21: ...cessary b Cause The pump is not deactivating Solution Relay in the system is malfunctioning Replace defective components as required Problem 5 Heat exchanger visibly leaking a Cause Plumbing connection loose Solution Check and tighten plumbing connection b Cause Double wall heat exchanger leak Solution If one or more heat exchanger plate walls are breached a double wall heat exchanger will leak at...

Page 22: ...EZ Plate Storage Water Heater 22 PV500 64 12 14 10 STANDARD EZ PLATE STORAGE WATER HEATER WIRING DIAGRAMS 10 1 EZ Plate Storage Water Heater Point to Point Wiring Diagram ...

Page 23: ...EZ Plate Storage Water Heater 23 PV500 64 12 14 10 2 EZ Plate Storage Water Heater Ladder Diagram ...

Page 24: ...ter conditions or maintenance the warranty on the EZ Plate Water Heater does not cover poor performance structural failure or leaking due to an excessive accumulation of scale MODEL NUMBER SERIAL NUMBER INSTALLATION DATE PVI Industries LLC 3209 Galvez Ave Fort Worth TX 76111 1 800 433 5654 www pvi com ...

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