CONQUEST
®
WATER HEATER
58
PV500-71 02/16
20. PERIODIC
MAINTENANCE
Listed below are items that must be checked to ensure reliable operations. Maintenance must be performed by a
qualified service or maintenance provider. To ensure proper maintenance, the following instructions should be
posted near the appliance and maintained in legible condition. Verify proper operation after servicing.
WARNING: When servicing the controls, use exact, Factory authorized, replacement parts and label all
wires prior to disconnection. Verify proper operation after servicing. Incorrect parts substitution and wiring
errors can cause damage, improper operation, fire, carbon monoxide, exposure to toxic fumes or other
unexpected and unsafe conditions that can result in fire, personal injury or death.
1. Examine the appliance and venting system at least once a year. Check more often in first year to determine
inspection interval.
a. Check all joints and pipe connections for tightness, corrosion or deterioration.
b. Check the electronic-ignition system for quick ignition and a proper flame signal.
c. Check all safety controls including thermostats for proper operation.
d. Check safety shut-off valves for operation and tightness.
e. Have the entire system, including, but not limited to, the burner, heat exchanger and venting system,
periodically inspected by a qualified service agency.
2. Exposure to Dusty or Dirty Combustion Air: An appliance installed in a dust or dirt contaminated atmosphere will
require more frequent inspection and cleaning of the burner to prevent nuisance shutdowns or premature
burner failure.
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 will reduce efficiency. To inspect and clean the heat exchanger, a qualified service agent or installer should
use the procedures described in items 4, 5 & 6 below.
4. All gaskets on disassembled components must be replaced on reassembly with exact, Factory Authorized,
replacement parts only. Gasket kits are available from your PVI Industries
®
Representative or by contacting PVI
Industries
®
, LLC.
5. Burner and/or Heat Exchanger Inspection and Cleaning Procedure:
a. Turn off main power to unit.
b. Turn off gas supply.
c. Write notes and/or take pictures during this process to aid in correct reassembly.
d. Disconnect electrical the components by disconnecting the wires going to terminal strip in the top control
enclosure and the respective conduit connections on the back of the control enclosure. If a wiring diagram
is not attached to the back of the enclosure door or otherwise provided with the water heater, make careful
notes of the locations for all the wires.
e. Remove the metal cover on top of the appliance by disconnecting the fasteners holding it to the plastic
jacket.
f. Remove the hot surface igniter, (HSI) from the burner. Be very careful not to bump the igniter element due
to the fragility of the igniter.
g. Break the unions that connect the gas train to the blower and the gas supply pipe. Remove the gas train.
h. Remove the nuts that secure the burner top plate to the combustion chamber and lift the blower/burner
assembly up until it is completely extracted from water heater.
i. Inspect top plate refractory for damage. The refractory must provide a tight seal against the top edge of the
burner deck.
j. Inspect the burner surface for signs of cracking or thermal fatigue.
k. If internal inspection of the burner is desired or the burner or blower must be replaced, remove the nuts that
attach the blower to the burner top plate to remove the blower. The burner can now be extracted. Be careful
not to damage the refractory when removing the burner. With the burner removed, inspect the deck surface
of the burner for lent or other blockage carried in the fuel air stream. If blockage has accumulated, use
brush to loosen debris and use a vacuum or water to remove it from the burner cavities.
l. Replace any damaged components and reassemble in reverse order. (4-5 ft/lbs).
m. Cycle unit and test to verify all safety and operating controls are properly functioning and the burner top
plate flange is free of leaks.
