PVI Industries Water Heater PV500 2 User Manual

PVI ATMOSPHERIC GAS WATER HEATERS  
TYPICAL CONSTRUCTION  
MANUFACTURED AFTER JANUARY 1, 1994  
Figure 2-1  
1. Vent stack *  
7. Control switch(es) and fuse(s)  
8. Gas valve  
9. Pilot line  
10. Drip leg *  
11. Gas supply line *  
12. Handhole cleanout  
2. Draft diverter (hood)  
3. Flue damper (on some models)  
4. Temperature limiting device  
(set at 200°F)  
5. Upper operating thermostat  
(set at 130°F)  
6. Operating thermostat  
(set at 120°F)  
(* Not furnished by PVI)  
CAUTION: TEMPERATURES HIGHER THAN 125°F INCREASE THE RISK OF SCALD INJURY!  
IMPORTANT: Clearances to unprotected combustible material must be 8" minimum at top, sides and rear, and 24" in front.  
Clearances for servicing and inspection must be 18" minimum at sides and rear and 24" minimum in front.  
PV500-2 06/10  
1
Section 2  
 
START-UP PROCEDURES AND OPERATION  
1. Some PVI atmospheric gas-fired water heaters are  
3. Remove the control box cover to access the control  
thermostats and other electrical devices needed to  
operate the water heater. The thermostats are labeled  
as to their function. The temperature limiting device is  
set at 200°F. The thermostats are factory set at  
130°F. (the upper operating thermostat) and 120°F  
(the operating thermostat). Adjustment may be made  
by turning the thermostat dial to the desired  
temperature.  
designed to operate with a flue damper that is  
shipped with the water heater for installation in the  
field. If your water heater was shipped with a flue  
damper, it must be attached to the flue collector and  
interconnected to the ignition control module before  
proceeding with start-up.  
Flue Damper Installation  
CAUTION:  
BE SURE TO REATTACH THE  
a. Set the flue damper over the flue collector opening  
and align the damper drive housing to the front of  
the heater.  
CONTROL BOX COVER TO HELP PREVENT  
UNAUTHORIZED ACCESS TO CONTROLS.  
CAUTION:  
DO  
NOT  
OVERTIGHTEN  
b. Secure the flue damper to the flue collector at three  
locations using the fasteners provided.  
COMPRESSION FITTINGS ON THERMOSTAT  
BULBS AS CALIBRATION WILL BE CHANGED.  
c. Remove the damper drive housing cover, feed the  
damper interconnect cable through the access hole  
and attach the female connector to the four-pin  
receptacle. Secure the access hole cover, check to  
make sure the test switch is in the "NORMAL"  
position, and reattach the damper driver housing  
cover.  
CAUTION: TEMPERATURES HIGHER THAN 125°F  
INCREASE THE RISK OF SCALD INJURY!  
Gas Train Safety Inspection  
CAUTION: ALL VENTED GAS CONTROLS MUST  
BE VENTED TO THE OUTSIDE USING TUBING  
CAUTION: BE SURE THERE IS NO FOREIGN MATTER  
IN THE DAMPER HOUSING BEFORE ATTACHING  
THE DRAFT DIVERTER.  
SIZED  
FOLLOWING TABLE:  
IN  
ACCORDANCE  
WITH  
THE  
VENT LINE SIZING  
Fuel Line Size,  
Nominal Pipe Size,  
Inches  
Vent Line Size,  
Nominal Pipe Size,  
Draft Diverter Installation  
Inches  
Up to 1 1/2  
3/4  
The draft diverter (provided) is designed to mount on top  
of the flue damper. Set the draft diverter on top of the flue  
damper and secure in three locations using the fasteners  
provided.  
2
1
1 1/4  
1 1/4  
2
2 1/2  
3
4
5
6
8
Venting  
2
2 1/2  
3
Type B galvanized vent pipe, of the same diameter as the  
draft diverter outlet, must be installed to route combustion  
products either to existing overhead breeching or to an  
appropriate outside location.  
1. The control manufacturer's installation and service  
manual and start-up procedures for the control  
system on your water heater are shipped with the  
unit. Study the information carefully and follow the  
manufacturer's recommendations.  
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.  
PV500-2 06/10  
3
Section 2  
 
START-UP PROCEDURES AND OPERATION (con't)  
CAUTION: CONDUCT THE FOLLOWING GAS TRAIN  
LEAKAGE TESTS BEFORE START-UP, AT  
ANNUAL INTERVALS AND PRIOR TO  
6. The flue damper is closed.  
NOTE: The spark ignition system provides additional  
safety functions to close the pilot valve if the pilot  
flame is not established and to close the main burner  
valve if the pilot flame is extinguished while the  
burner is in operation.  
INVESTIGATING THE CAUSE OF ANY REPORTED  
OCCURENCES 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 and tested to assure stoppage of the leak.  
WATER HEATER START-UP  
NOTE: The following test equipment is required:  
a. Vent temperature gauge  
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  
specified value (e.g. 14"W.C.), and tightly close the  
gas train outlet manual shutoff valve.  
b. Manometer for checking gas pressure  
c. Draft gauge for checking draft in vent  
d. CO (carbon monoxide) tester  
e. CO2(carbon dioxide) or O2 (oxygen) tester  
f. Drill and ¼" drill bit for ¼" hole drilled in vent  
approximately 12" above draft hood outlet  
3. Reattach the manometer to the gas train outlet  
manual shutoff valve 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 00.5"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.)  
NOTE: Emergency shutoff can be made by turning off  
the fuel inlet shutoff valve.  
CAUTION:  
DO NOT START BURNER WITH  
COMBUSTION CHAMBER FULL OF GAS OR WITH  
VERY HOT COMBUSTION CHAMBER.  
The following steps must be performed to assure  
that the water heater is operating safely and  
efficiently.  
1. Read the enclosed control manufacturer's instruction  
sheet for start-up procedure. Allowing the pilot to  
ignite with the main burner gas valve turned to "off"  
position is required at initial start-up. The pilot flame  
can be visually checked for size and position. Check  
inlet gas pressure. It must not exceed 14"W.C. Press  
the control circuit switch on the front panel to "on"  
position. The control system will open the pilot valve  
allowing the pilot to ignite. Observe pilot flame. If  
satisfactory, open the main burner valve and main  
burner should ignite.  
Spark Ignition Systems  
These systems use 120 VAC power from an external  
source and are equipped with transformers to reduce the  
voltage to 24 volts to actuate the gas valve.  
At start-up or during operation when the thermostat calls  
for heat, the spark ignition system performs the following  
basic steps:  
1. Opens the flue damper.  
Pilot and main burner flames can be observed during  
adjustment and under operating conditions by using  
the stainless steel hand-held inspection mirror that is  
enclosed in the information packet that was shipped  
with this water heater.  
2. Activates a high voltage transformer to supply a  
sparking action to the pilot.  
3. Opens the pilot gas valve. The pilot gas ignites from  
the sparking.  
If the spark ignition fails to ignite the pilot flame, refer  
to the control manufacturer's manual supplied with  
the unit.  
4. A sensor located in the pilot flame signals the control  
module to open the main burner gas valve. The pilot  
flame ignites the main burner gas. An adequate pilot  
flame must be present before the main burner gas  
valve can open.  
2. Check gas pressure at the gas valve with a  
manometer. (See Figure 2-5.) Most gas valves have  
pressure taps for this purpose. Adjust gas pressure to  
the value shown on rating plate of the water heater.  
5. When the water temperature reaches the operating  
thermostat setting, the control circuit opens which  
closes both the pilot and main burner gas valves  
terminating burner operation.  
3. Drill ¼" diameter hole in vent about 12" above draft  
diverter. Insert draft gauge in drilled ¼" hole. Draft in  
vent should be -.02" -.06" W.C.  
PV500-2 06/10  
4
Section 2  
 
4. After 20 to 30 minutes of operation or when water in  
the tank is above 120°F, insert CO (carbon monoxide)  
tester in flue damper opening under the draft diverter  
(125 gallon models) or in the flue collector opening  
(250 gallon models). CO reading must be less than  
.02% (or 200 ppm).  
COMBINATION GAS VALVE  
5. Insert CO2 (carbon dioxide) tester in the flue damper  
opening under the draft diverter (125 gallon models)  
or in the flue collector opening (250 gallon models)  
and take reading. CO2 should be 6 to 8%.  
NOTE: Monitoring CO and CO2 readings in vent after the  
draft diverter will give erroneous readings. These  
measurements must be taken as flue gases exit the  
heater flue collector under the draft diverter as  
dilution with ambient air from the draft diverter occurs  
in the vent.  
6. Insert temperature gauge in ¼" hole and read vent  
temperature. Temperature should be at least 300°F  
but less than the room temperature plus 400°F when  
the water temperature is approximately 130°F.  
Figure 2-5  
7. Connect micro-amp meter as shown in Figure 2-6 and  
check micro-amps. A minimum of two micro-amps is  
required for proper operation.  
MICRO-AMP METER HOOK-UP  
8. Record the following information for future use:  
A. Inlet gas pressure ________________"W.C.  
B. Gas pressure, manifold (step 2) _____ "W.C.  
C. Vent draft (step 3) ________________"W.C.  
(should be minimum of 1 in. W.C.)  
D. CO reading (step 4) ______% (less than .02%)  
E. CO2 reading (step 5) __________% (6-8%)  
F. Vent gas temperature (step 6)  
Gross__________________F.  
Figure 2-6  
Less Ambient____________°F.  
Net____________________°F.  
G. Micro-amps reading (step 7)______________.  
PV500-2 06/10  
5
Section 2  
 
MAINTENANCE AND SAFETY INSPECTIONS  
To Minimize Scale Accumulation in Tank  
Periodic Inspection of Operational Components  
1. A preventative maintenance program should be  
established to assure a long, trouble-free life of the  
water heater.  
Periodic inspections and check-out of the burner  
ignition system, control system and gas valve  
operation should be made and recorded for future  
reference.  
2. The tank should be flushed at two or three month  
intervals depending on water conditions in your  
location. To flush, turn off the 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. Draining two or three  
gallons from the bottom of the tank on a weekly basis  
will also help prevent an accumulation of sediment.  
Water impurities can consist of fine particles of soil or  
sand which will settle out and form a layer of  
sediment on the bottom of the tank.  
1. Pilot assemblies should be checked by a qualified  
serviceman using control manufacturer's instructions.  
Wiring connections on the ignition high voltage wire  
and flame sensor wire must be tight. Clearance  
between these wires and metal parts of the water  
heater or burner must be maintained to avoid possible  
shorting out. Positions of the electrode, flame sensor  
and pilot flames are very important and have been set  
by the manufacturer. If they are loose or if ceramic  
insulators are cracked or broken, replace the pilot  
assembly. To replace, remove pilot bracket from  
bottom of burner, disconnect the pilot gas line and  
replace pilot assembly on pilot bracket. Replace in  
reverse order. Do not bend or distort pilot bracket as  
this determines pilot flame position relative to burner  
orifices. (See Figure 2-7). Inspect individual burner  
jets for evidence of overheating. Replace burner jets  
as necessary.  
A scale of lime will normally form in the tank 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 the heating cycles.  
Some water supplies contain more of these elements  
than others, and the scale buildup will occur more  
rapidly. Other factors affecting the scale buildup are  
the amount of hot water used and the water  
temperature. As more hot water is used, the more  
fresh water containing the scale-forming elements is  
brought into the tank. As the temperature of the water  
increases, the rate of scale deposition will be  
increased.  
2. Examine the venting system at least quarterly for  
proper connections, alignment and the presence of  
corrosion. Any corroded vent section should be  
immediately replaced to prevent CO leakage. Re-  
check vent temperature (step 6, page 5) and correct if  
necessary.  
Sediment and scale accumulations in the tank will  
greatly reduce the water heating ability of the heater  
by reducing effectiveness of heat transfer surfaces.  
When heating energy from the burner cannot be  
effectively transferred to the water in the tank, the  
metal can overheat causing it to lose structural  
strength.  
CAUTION: THE RELIEF VALVE IS A PRIMARY  
SAFETY DEVICE.  
3. The temperature and pressure relief valve should be  
removed and inspected at regular intervals to  
determine its condition for safe operation. The  
openings inside the valve may become restricted by a  
buildup of scale and become inoperative. If the valve  
does not open and close properly when tested, it  
must be replaced with a like kind or one meeting the  
requirements stated on the rating tag located on the  
relief valve.  
3. Should a firetube leak for any reason, consult the  
factory for instructions. Inspect bottom tubesheet on a  
regular basis to determine if insulation may have  
pulled away from the tubesheet. Repair or replace as  
required.  
4. Spark ignition system operation should be checked as  
follows:  
NOTE: Condensate coming from the tubes on a cold start  
is normal and does not indicate a leaking tube.  
Flame failure – Close downstream gas train shutoff  
valve and determine safety shutdown timing.  
Flame signal – Determine flame signal strength in  
accordance with step 7 on page 5.  
4. The tank may have a handhole for inspection and  
cleaning use. The handhole cover should be  
periodically removed and the tank inspected for scale  
buildup. 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 should be determined by the  
rate of scale buildup. We recommend 30-60 day  
intervals.  
PV500-2 06/10  
6
Section 2  
 
MAINTENANCE AND SAFETY INSPECTIONS (con't)  
Taking the Water Heater Out of Service  
c. Tag power switch(es) indicating that fuel is off  
and tank is empty.  
Extended shutdown of the appliance and restarting  
instructions are as follows:  
d. To restart, refill tank with water and turn fuel  
and power switch(es) on. Reset all controls  
and conduct start-up of the appliance as  
discussed on preceding pages.  
a. Turn off all power and fuel supplies.  
b. Drain and flush tank as previously discussed.  
PILOT LOCATION & REMOVAL  
SPARK IGNITION SYSTEMS  
Figure 2-7  
PV500-2 06/10  
7
Section 2  
 

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