Troubleshooting guide

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PV500-23 04-2005 Section 23

INSTALLATION & MAINTENANCE MANUAL FOR

POWER VT

BOILER

IMPORTANT: READ AND FOLLOW THE INFORMATION IN THIS MANUAL, THE GENERAL

INSTALLATION & MAINTENANCE MANUAL, AND ALL OTHER PROVIDED INSTRUCTIONS,

LABELS AND MARKINGS BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.

TABLE OF CONTENTS

Heater Illustration 2

Product Safety Information 3 – 4

Electrical 4

Venting Instructions 5 – 8

Condensate Neutralization 9

Start-up Procedures 10

Burner Illustration 11

Burner Start-up 12 – 14

Maintenance 15 – 18

Troubleshooting Guide 19 – 20

WARNING: If the information on the appliance and 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 and 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 electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's

instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or the gas

supplier.

This product contains, or may come to contain, materials that have been identified as

carcinogenic, or possibly carcinogenic, to humans. Before installing, servicing, or removing this

product, read and follow the supplied instructions.

PVI INDUSTRIES, LLC

P.O. Box 7124

Fort Worth, TX 76111

(800) 433-5654

www.pvi.com

Summary of content (20 pages)

PAGE 1
INSTALLATION & MAINTENANCE MANUAL FOR POWER VT® BOILER IMPORTANT: READ AND FOLLOW THE INFORMATION IN THIS MANUAL, THE GENERAL INSTALLATION & MAINTENANCE MANUAL, AND ALL OTHER PROVIDED INSTRUCTIONS, LABELS AND MARKINGS BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.
PAGE 2
POWER VT® BOILER Typical Construction Figure 23-1 1. Boiler water return 13. Handhole access 2. Boiler water supply 14. Float LWCO (optional) 3. Blowdown 15. Manual reset temperature limiting device 4. Condensate drain 16. Operating control 5. I-beam skid 17. Drip leg 6. Flue outlet 18. Electronic LWCO control 7. Gas inlet 19. Temperature &pressure gauges 8. Induced draft blower motor 20. Alarm bell 21. Differential air switch 22.
PAGE 3
POWER VT® BOILER PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA WARNING: This product contains crystalline silica which has been identified by the International Agency for Research on Cancer (IARC) as carcinogenic to humans. This product also contains refractory ceramic fibers which have been identified by the IARC as possibly carcinogenic to humans. Avoid breathing fiber particulates and dust.
PAGE 4
POWER VT® BOILER WARNING This boiler is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for automatic dishwasher and laundry use could cause scald burns resulting in serious personal injury and/or death. The temperature at which injury occurs varies with the person's age and time of exposure. The slower response time of disabled persons increases the hazards to them. Never allow small children to use a hot water tap or to draw their own bath water.
PAGE 5
POWER VT® BOILER VENTING INSTRUCTIONS VENT SIZING C. Multiply the number of 45° elbows used in vent system by the equivalent length of straight pipe specified in Table 23-1. Venting to and from this unit should conform to the National Fuel Gas Code, Latest Edition. The POWER VT® boiler is designed for operation with the 4", 5” or 6” positive pressure vent systems constructed of AL29-4C stainless steel. D. Add (A), (B) and (C) together to obtain the total feet of venting.
PAGE 6
POWER VT® BOILER VENTING INSTRUCTIONS (con't) AIR INLET DUCT OPTION When ducting horizontally through a wall: (Figure 23-5, page 8) Air inlet duct is defined as a means of ducting the outside combustion air to the burner for the purpose of avoiding corrosion that can be caused by contaminants which may be contained in indoor air and/or providing sufficient fresh air for proper combustion.
PAGE 7
Typical Termination Locations for Vertical Vent Pipes Termination of less than 10 feet Figure 23-2 Termination of more than 10 feet Figure 23-3 Vertical vent pipe must be terminated with the UL listed vent termination supplied by PVI.
PAGE 8
Typical Locations for Vertical and Horizontal Vent Pipes Vertical Venting Figure 23-4 Horizontal Venting Figure 23-5 • • • • Install flue outlet and fresh air inlet with adequate separation to prevent recirculation of combustion products. Although the National Fuel Gas Code provides minimum clearances, sound engineering judgement should be used, considering prevailing winds, obstructions and the type vent termination used, etc. Either flue or remote air intake can be roof or side wall vented.
PAGE 9
POWER VT® BOILER CONDENSATE NEUTRALIZATION & DISPOSAL The POWER VT® boiler can produce significant amounts of condensate because of their high efficiency. Condensate occurs naturally when water vapor in combustion gases is cooled below the dew point. Although only slightly acidic, POWER VT® boiler condensate can be routed through an optional neutralization system to become pH neutral allowing for disposal into any drain or sewer system without concern for corrosion.
PAGE 10
POWER VT® BOILER START-UP PROCEDURES WARNING: START-UP SHOULD ONLY BE PERFORMED BY A QUALIFIED TECHNICIAN. CAUTION: DO NOT RELIGHT PILOT OR START BURNER WITH COMBUSTION CHAMBER FULL OF GAS OR OIL VAPOR, OR WITH VERY HOT COMBUSTION CHAMBER. WARNING! YOU MUST CONNECT THE SUPPLIED GAS TRAIN TO THE BURNER UNION. THE GAS SUPPLY MUST THEN BE CONNECTED TO THE GAS TRAIN. DO NOT CONNECT THE GAS SUPPLY DIRECTLY TO THIS UNION.
PAGE 11
POWER VT® BOILER GAS BURNER CARBON MONOXIDE WARNING: An annual or seasonal combustion checkout must be performed by a qualified service agency to ensure safe operation. Failure to maintain proper combustion can result in injury or death. Typical Construction Figure 23-6 1. Static fan 11. Manual shutoff valves 2. End cap 12. Main gas pressure regulator 3. Gas nozzle assembly 13. Main gas valve 4. Pressure plate 14. Pilot gas valve 5. Blast tube & burner housing junction 15.
PAGE 12
POWER VT® BOILER GAS BURNER START-UP (Refer to Figure 23-6, page 11 to identify burner parts) WARNING: START-UP SHOULD ONLY BE PERFORMED BY A QUALIFIED TECHNICIAN. 1. Remove enclosure panel cover on the boiler to expose control circuit. A wiring diagram, included in this packet, will show the controls used in our circuitry. 2. Visually check that all components are intact and no damage has occurred during transit. 3. Check all connections within the control cabinet.
PAGE 13
POWER VT® BOILER GAS BURNER START-UP (con't) While firing, check the gas pressure at the inlet of the gas train. The minimum supply pressure requirement on the Power VT boiler is 4.5" W.C. supply unless otherwise specified on the data plate. It should be a minimum of that shown above with the boiler running at high fire. This is recorded as inlet flow pressure. It is important incoming pressure does not fall below this minimum or nuisance control lockouts could occur.
PAGE 14
POWER VT® BOILER GAS BURNER START-UP (con't) 13. Record the following information for future use: NOx reading a) Manifold gas pressure " W.C. f) b) Vent pressure " W.C. g) Vent temperature ppm c) O2 reading % (5-7%) Gross °F. d) CO2 reading % (8-9%) Less ambient °F. Net °F.
PAGE 15
POWER VT® BOILER MAINTENANCE CARBON MONOXIDE WARNING: An annual or seasonal combustion checkout must be performed by a qualified service agency to ensure safe operation. Failure to maintain proper combustion can result in injury or death. CAUTION: Be sure manual valves and burner electrical switch are turned off before removing any part for service or cleaning. Do not push relay contacts in manually; accidental opening of main automatic valve can result.
PAGE 16
POWER VT® BOILER MAINTENANCE (con't) 8. 9. The need to periodically check water level controls and waterside of the pressure vessel cannot be over emphasized. Most instances of major boiler damage are the result of operating with low water or the use of untreated (or incorrectly treated) water. Determine piping is vertically aligned after shipment and installation and throughout the life of the equipment.
PAGE 17
POWER VT® BOILER MAINTENANCE (con't) Burner and Control Maintenance to place each electrode and insert electrode through hole, retaining stud end first. 13. Remove the flame safeguard control from its base. Check the connections in control mounting base; loose connections can cause nuisance shutdowns. 17. Tighten electrode-mounting clamp slightly until electrode ceramics are seated firmly and completely in the mounting bracket without gaps between ceramics and mounting bracket at the bearing faces.
PAGE 18
MAINTENANCE & SAFETY INSPECTION REPORT DATE BURNER INSPECTION COMBUSTION ANALYSIS TANK INSPECTION TANK FLUSH & CLEANOUT TANK FITTING INSPECTION VENT INSPECTION THERMOST AT INPSECTION GAS TRAIN LEAK TEST Recommended Inspection Intervals YEARLY 6 MONTHS 6 MONTHS 3 MONTHS 6 MONTHS YEARLY YEARLY YEARLY TABLE 23-2 PV500-23 04-2005 18 Section 23
PAGE 19
POWER VT® BOILER TROUBLESHOOTING SUGGESTIONS GAS BURNER 1. BURNER FAILS TO START: c) With flame safeguard controls that incorporate the air flow switch in the nonrecycling circuit, ensure that when main flame lights, the air flow switch is not so critically set as to allow occasional momentary opening of the air switch contacts. a) Defective on/off switch. Replace switch. b) Control circuit has open control contact. Check limits, low water cutoff, and others as applicable.
PAGE 20
POWER VT® BOILER TROUBLESHOOTING SUGGESTIONS GAS BURNER (con't) c) Excessive flue gas recirculation, causing insufficient excess air for complete combustion. Reduce the FGR orifice size and readjust the gas regulators to achieve proper excess air in combustion. g) Airflow switch not making circuit. Check out electrically. Defective airflow switch. Replace. Air switch negative pressure sensing tube out of position. Reposition as necessary. h) Regulator vent line(s) plugged. Remove blockage. 6.