INSTALLATION & MAINTENANCE MANUAL POWER VT PLUS WATER HEATER MODELS (40, 50, 75, 90, 100) LX 125 A-PVIF MODELS (50, 75, 90, 100) LX (250, 300) A-PVIF Installation and service must be performed by a qualified service installer, service agency or the gas supplier. IMPORTANT: THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION, OPERATION AND MAINTENANCE OF THIS EQUIPMENT.
TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. Safety Considerations Standard Features and Equipment 2.1 Performance 2.2 Pressure Vessel 2.3 Heat Exchanger 2.4 Code and Standards 2.5 Burner, Operating Controls & Safeties 2.6 Warranty and Service Policy (see warranty and service policy for details) 2.7 Miscellaneous Product Descriptions Water Heater Installation 4.1 Checking Equipment Before You Install 4.2 Codes 4.3 Electrical Requirements 4.4 Handling and Location 4.5 Service Clearances 4.
10. 11. 12. 13. 14. 15. 16. 17. 18. Operating and Safety Controls 10.1 Temperature and Pressure Relief Valve(s) 10.2 Operating Temperature Control 10.3 High Water Temperature Limit Control 10.4 Cathodic Protection 10.5 Electronic Low Water Cut-off (optional) TEMPTRAC Electronic Controller Panel 11.1 Principal of Operation 11.2 Upper LED Readout 11.3 Lower LED Readout 11.4 Control Buttons 11.5 To View the Setpoint 11.6 To Change the Setpoint 11.7 To Change Other Parameters 11.
1 SAFETY CONSIDERATIONS WARNING: If the information in the supplied manual(s) is not followed exactly, a fire, explosion or exposure to hazardous materials may result, causing property damage, personal injury or loss of life. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building.
IMPORTANT SAFETY NOTE It takes only 5 seconds of skin contact with 140°F water to cause a second degree burn! You must protect against high water temperatures at all lavatories, tubs, showers and other points of hot water contact. Accidental scalding from high water temperatures is a greater risk in some types of installations.
2 STANDARD FEATURES AND EQUIPMENT 2.1 Performance 98% thermal efficiency at full fire from 40° to 140°F Up to 99% thermal efficiency with modulation < 20 ppm NOx (399 to 900 MBH) Ducts direct combustion air up to 100 equivalent feet through 6-inch diameter material (requires UL approved vent cap, see optional equipment list) Vents up to 100 equivalent feet through 6-inch diameter material 2.
3 PRODUCT DESCRIPTION Component, Controls and Connection Locations (Locations May Vary) 125 SERIES 7 PV500-44U 06/12
250 SERIES 8 PV500-44U 06/12
300 SERIES 9 PV500-44U 06/12
4 WATER HEATER INSTALLATION 4.1 Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading. Inspect the appliance and all accompanying parts for signs of impact or mishandling. Verify the total number of pieces shown on packing slips with those actually received. Contact the freight carrier immediately if any damage or shortage is detected. 4.
8. Do not install on carpet or other combustible floor coverings. If installation over a combustible floor is required, follow these guidelines: Use a base of hollow clay tile or concrete blocks from 8" to 12" thick and extending 24" beyond the sides. Place the blocks in line so that the holes line up horizontally to provide a clear passage through the blocks. Install 1/2” fireproof millboard with a 20-gage sheet metal cover over the block base. Center the unit on the base.
SINGLE WATER PIPING SINGLE STORAGE WATER HEATER WITH SUPPLEMENTAL STORAGE TANK 12 PV500-44U 06/12
TWO WATER HEATERS WITH REVERSE RETURN PIPING 6 CONDENSATE DRAIN, TRAP & DISPOSAL The POWER VT PLUS water heater is designed to produce significant amounts of condensate because of its high efficiency. Condensate occurs naturally when water vapor in combustion gases is cooled below the dew point. Two 3/4” NPT drain connections are provided.
Condensate Piping and Trap with Optional Condensate Neutralizer 6.1 Condensate Neutralization System (optional) Although only slightly acidic (3-5 PH), condensate can be routed through an optional Condensate Neutralization System (see image below) to become pH neutral allowing for disposal into any drain or sewer system without concern for corrosion.
7 GAS SUPPLY AND PIPING Verify that the type of gas specified on rating plate is supplied to the unit. This unit is orificed for operation up to 2000 feet altitude. Appliance Btuh output derates 4% per 1000 feet elevation above sea level. Consult Factory for installations above 2000 feet elevation. 7.
Use this corrected total distance from the meter for determining the suggested pipe size in the “Single Unit Installation Suggested Gas Pipe Size” table. SINGLE UNIT INSTALLATION SUGGESTED PIPE SIZE Maximum Capacity for Natural Gas* MBTU/HR Based on 0.5" W.C.
7.7 Gas Connection 1. Safe operation of unit requires adequate gas supply with the required static and dynamic (flow) pressures. Actual piping selection depends on many variables that must be carefully considered by the gas piping system designer. Do not select gas pipe sizes based only on the supplied tables. These tables are for use by the gas piping system designer as a reference in checking pipe size selections. 8 2. Gas pipe size may be larger than heater connection. 3.
8.2 Maximum Allowed Remote Combustion Air Inlet Length (Equivalent Length) A vertical or horizontal remote air inlet system can be connected to this appliance without modification. The maximum length of field supplied single wall pipe, such as galvanized ventilation pipe, is shown in the chart below titled Maximum Air Inlet Duct Equivalent Length. Use metal tape or RTV sealant to seal each pipe joint.
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.
WARNING: Do not vent this water heater into an existing or traditional gas vent or chimney or combine the vent with any other appliance. Such venting could result in failure of the venting system and/or exposure to carbon monoxide which can result in property damage, personal injury or death. 9.3 Maximum Category IV Vent Length (Equivalent Length) A vertical or horizontal remote Category IV vent system must be used with this appliance.
4. Dry-fit a solid 6” CPVC pipe into the female economizer flue outlet. Remove the pipe and apply a liberal coating of room temperature vulcanizing (RTV) adhesive to the 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.
10. A vertical termination less than 10 feet (0.91 m) from a parapet wall must be a minimum of 2 feet (0.61 m) higher than the parapet wall. 9.6 Combining Category IV Vents Combined Power VT Plus Category IV gas vent systems must incorporate an Exhausto or Tjernlund variable speed, modulating, mechanical draft inducer capable of maintaining the appropriate negative draft at the end of the common flue, to assure that all water heaters in the combined vent system operate with a negative draft.
10.2 Operating Temperature Control An adjustable digital operating control is located in the front control panel. The control is factory pre-set at approximately 120ºF. To adjust the setpoint to deliver the desired water temperature, press and release the Set 1 key on the face of the control. When setpoint adjustment is enabled, use the arrow keys to adjust the set point to the desired system temperature. See TempTrac Electronic Controller Panel in this manual for more information. 10.
11 TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 11.1 Principle Of Operation The water heater operates to satisfy the setpoint of the TempTrac digital control whose sensor is located near the top of the water heater tank. Demand (flow) will typically create a drop in temperature, thus activating the water heater to add heat to the stored water. This setpoint is the desired water temperature to maintain. 11.
11.5 To View The Setpoint Push and release the SET key to see the set point value. To return to normal display, press SET + UP or wait 15 seconds without pressing any key. 11.6 To Change The Setpoint Push the SET key. The upper display will show the “St1” parameter name, while the lower display will show its value. Use the UP or DOWN key to cycle through the parameter names. Push the SET key to modify a parameter value. The value starts flashing in the lower display.
11.8 LED Display Alarm Messages Alarm messages are displayed in the upper LED readout and alternate with the default display. An alarm LED ICON is also illuminated. (See TempTrac User Manual PV500-40 for full description.) ALARM MESSAGE 12 CAUSE RESULTS OF ALARM CONDITION RECOMMENDED ACTION Check wiring and sensor Terminals 14 & 17 “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.
12.2 The Following Describes The Functions Of Each Of These Terminals And The Factory-Installed Options Required To Activate The Terminals: Note: Terminal P1-P2 are functional only when the water heater is equipped with the factory installed options required to activate the terminals. Terminals R1-R2, A1-A2, C1-C2 and T1-T2 are standard pre-wired functions on all models. R1-R2: Used to activate / de-activate water heater from remote master control.
4. Proof of Air Pressure Switch - The control will look for a signal from the airflow-proving switch, indicating that the blower is operating: a. When the airflow generated by the blower is sufficient to cause 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.
14 INITIAL STARTUP 14.1 Initial Startup Requirements Installation should be complete prior to performing initial startup; and the startup must be complete prior to placing the water heater into service. Starting the water heater without proper piping, combustion air, venting or electrical systems can be dangerous and may void the product warranty. The following startup instructions should be followed precisely in order to achieve safe and efficient operation to assure trouble-free service life.
b. Attach a manometer to measure the 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 manual shutoff valve closest to the burner. c. Reattach the manometer to the gas train manual shutoff valve at the burner and record the measured gas pressure in inches of water column (W.C.). Measure gas pressure again after 15 minutes. If gas pressure has increased 0.5" W.C.
19. When the blower motor starts, the flame control will check for a positive air flow. If the air switch or blocked filter switch (if equipped) is not made the blower will stay on for a period of time then lockout. To adjust the airproving switch, turn the adjustment screw counter-clockwise until the air proving light comes on, then turn the screw one turn counter-clockwise. The blocked filter switch (if equipped) should only be adjusted when the filter is new.
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) 32 PV500-44U 06/12
15 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Power Supply Check fuse and/or circuit breaker. Check voltage at 120/24V step-down transformer. On-Off Switch Check if On-Off switch is lighted. Check that the operating temperature control is set higher than the temperature of the water heater. Temperature Control Check for bad ground or bad control. Replace if necessary.
16 REPLACEMENT PARTS REPLACEMENT PARTS 34 PV500-44U 06/12
16.
16.2 Control Panel Components (Optional components may not be included) Key No. Part No. Description Qty. U/M CONTROL, HOT SURFACE IGNITION FENWAL 1 EA 1 101947 2 - CONTROL, TEMPERATURE TEMPTRAC 1 EA 3 - DRIVE, VARIABLE FREQUENCY AC EMERSON 1 EA 4 5613 FUSEHOLDER, PANEL TYPE #HTB-28I 1 EA 5 5742 FUSE, MDA 15 AMP BUSS 250V NO SUBSTITUTE 1 EA 6 113915 LWCO, PROTODESIGN #LW-3-C-1-A-03 1 EA 7 58154 PROBE, LWCO WARRICK #3L1D002.
16.
16.4 Burner Assembly Components (Optional components may not be included) Item No. Qty. PVI Part No.
17 PERIODIC MAINTENANCE Listed below are items that must be checked to ensure safe 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.
i. Cycle unit and test to verify all safety and operating controls are properly functioning and the burner top plate flange is free of leaks. 6. If equipped, the combustion air filter should be replaced every six months. If filter blockage becomes excessive the filter safety switch will not allow the burner to fire. To avoid nuisance shutdown in dirty environments, check and replace filter more frequently. 7.
18 RECOMMENDED MAINTENANCE SCHEDULE 1. Annual Maintenance a. b. c. d. e. f. g. h. i. 2. Semi-Annually a. b. c. d. e. f. g. h. 3. Test low-water cutoff device and alarm (if equipped). Check flue, vent, stack, or outlet dampers. Check flame signal strength. Check flame failure detection system. Check firing rate control. Listen to and visually check the pilot and main fuel valves. Daily Maintenance a. b. 5. Recalibrate all indicating and recording gauges.
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