PVI MAXIM Maintenance Manual

MAXIM Gas, Oil & Gas/Oil Water Heater

Installation, Operation & Maintenance Manual

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 important
information that will help you in maintaining and operating
this appliance.

PV500-17 • 12/2020

Important: This manual contains information required for
installation, operation and maintenance 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 unit.

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

Oil

Gas/Oil

Gas

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TABLE OF CONTENTS

1.

Safety Considerations

2.

Product Description

3.

Water Heater Installation

3.1 Checking Equipment Before You Install

3.2 Codes

3.3 Electrical Requirements

3.4 Handling and Location

3.5 Installation

3.6 Service Clearances

3.7 Clearances to Combustible Surfaces

3.8 Other Codes and Regulatory Clearances and Requirements

4.

General Piping Guidelines

4.1 Inlet and Outlet Connections

4.2 Typical Piping Diagrams

5.

Gas Supply and Piping

5.1 Gas Train and Controls Certification

5.2 Gas Control Train

5.3 Inlet Pressure

5.4 Manifold Pressure

5.5 Gas Piping Size

5.6 Appliance Isolation During Gas Supply Piping Pressure Test

5.7 Gas Connection

6.

Combustion and Ventilation Air

6.1 Equipment Located in Confined Spaces

7.

Venting

8.

Operating and Safety Controls

8.1 Temperature and Pressure Relief Valve(s)

8.2 Operating Temperature Control

8.3 High Water Temperature Limit Control

8.4 Cathodic Protection

8.5 Electronic Low Water Cut-off (Optional)

9.

TEMPTRAC Electronic Controller Panel

9.1 Principle of Operation

9.2 Upper LED Readout

9.3 Lower LED Readout

9.4 Control Buttons

9.5 Key Combinations

9.6 LED Icon Legend

9.7 To View the Setpoint

9.8 To Change the Setpoint

9.9 To Set the Current Time and Day (Military Time)

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9.10 To Set the Energy Saving Time (Nighttime Setback)

9.11 To Set Modulation Parameters

9.12 To Change Other Parameters

9.13 LED Display Alarm Messages

9.14 Audible Alarm

9.15 Alarm Recovery

10.

Initial Startup Requirements

10.1 Tools and Instrumentation Required

10.2 Resources

10.3 On Site Considerations

11.

Startup Procedures and Operation

12.

Initial Firing and Adjusting of Burner

12.1 Gas Burners

12.2 Oil Burners

13.

Periodic Maintenance

14.

Recommended Maintenance Schedule

15.

Requirements for the Commonwealth of Massachusetts

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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 death.

AVERTISSEMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au
minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matérial, toute blessure ou la mort

FOR YOUR SAFETY

• Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

• Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de

tout autre appareil.

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.

• Immediately call your gas supplier from a location away from your building and the smell of gas. Follow the gas

supplier's instructions.

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

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touches à aucun interrupteur; ne pas vous server des téléphones se trouvant dans le bâtiment.

• Appelez immediatement votre fournisseur de gaz depuis un voisin. Suivez les instructions de fournisseur.

• Si vous ne pouvez rejoinder le fournisseur, appelez le service de incendies.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.
L’installation et l’entretrien doivent être assurés ou un service d’entretien qualifié ou par le fournisseur de gaz.

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

Clearance in accordance with the local installation codes and the requirements of the gas supplier.
Dégagement conforme aux codes d’installation locaux et aux exigencies du foumisseunde gaz.
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.
En cas de surchauffe ou si l’alimentation en gas ne s’arrête pas, fermez manuellement le robinet d’arrêt de l’admission de gaz.

WARNING: Installation and service must be performed by a qualified installer, service agency or the gas supplier,
who must read and follow the supplied instructions before installing, servicing or removing this appliance. Refer to
the information contained in this manual. Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury, exposure to hazardous materials or death.

WARNING: Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the unit and to replace any part of the control system, all gas controls and all other items
affecting safe appliance operation and which has been under water.

AVERTISSEMENT: N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter
l’appareil par un technicien qualifé et remplacez toute partie du système de contrôle et toute commande qui ont été
plongés dans l’eau.

WARNING: In an emergency shut the main gas supply valve to the appliance from a location safely away from the
emergency. Failure to follow these instructions can cause property damage, personal injury, and exposure to
hazardous materials or death.

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PRODUCT SAFETY INFORMATION

REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA

WARNING: This product contains or may come to contain 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.

RISKS:

• Air borne fibrous insulation is a possible cancer hazard by inhalation.

• Airborne crystalline silica may cause silicosis (lung disease) by inhalation.

• May cause temporary irritation to eyes, skin, and respiratory tract.

PRECAUTIONARY MEASURES:

• Minimize airborne fibers with engineering controls.

• Use NIOSH/MSHA approved respirators as required (see MSDS).

• Wear long sleeved, loose-fitting clothing, eye protection and gloves.

FIRST AID MEASURES: (If any of the irritations listed persists, seek medical attention)

• Eyes: Flush with water.

• Skin: Wash with soap and warm water.

• Ingestion: Do not induce vomiting. Get medical attention if gastrointestinal symptoms develop.

• Inhalation: Remove to fresh clean air.

WARNING: If you are unfamiliar with the safe handling of refractory ceramic fiber products, or if you wish additional
information prior to beginning any disassembly of the water heater or boiler that might expose refractory ceramic
fiber materials, contact: Unifrax Corporation, 2351 Whirlpool Street, Niagara Falls, NY 14305-2413, 1-800-322-2293.

IDENTIFICATION OF REFRACTORY CERAMIC FIBER MATERIALS (RCF):

The burner assembly utilizes RCF material. (The RFC materials are located within the product and not generally exposed
except during service, disassembly or assembly.)

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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. Some examples are:

HOMES FOR THE MENTALLY HANDICAPPED

HOMES FOR THE PHYSICALLY HANDICAPPED

HOSPITALS AND NURSING HOMES
ELDER CATE FACILITIES AND REST HOMES
ORPHANAGESAND CHILD CARE FACILITIES

OTHER INSTALLATIONS – WHERE RESPONSE TO CONTACT WITH HOT

WATER MAY BE SLOWER OR WHERE THE DANGER OF HOT WATER

CONTACT IS GREATER

Thermostatically controlled mixing valves must be used in the

design of the potable hot water system.

Potable hot water should be tempered to no more than

110°F when used for bathing or other personal use.

Good engineering practice mandates the use of thermostatically controlled

mixing valves set at 120°F to keep the delivered water temperature below

scalding temperatures.

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2 PRODUCT DESCRIPTION Component, Controls and Connection Locations

(Locations and Connections May Vary)

1.

Flue stack *

5.

Control switch(es) and fuse(s)

2.

Temperature limiting device

6.

Gas valve

(set at 200°F)

7.

Gas inlet

3.

Upper operating thermostat

8.

Gas line *

(set at 130°F)

9.

Drip leg *

4.

Operating thermostat

10.

Burner

(set at 120°F)

(* Not furnished by PVI)

For connection points on oil pumps, see Section 10 or specific burner manufacturer's installation and maintenance instructions.

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3 WATER HEATER INSTALLATION

3.1 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.

• Check the data decal on the appliance. Be sure the electrical, water and gas supply is adequate for the installation.

• Carefully remove all side and top shipping supports and bracing. If possible, do not remove the wooden base/skid

assembly until the product has been moved to its final location for installation and operation (see: Handling and
Locating the Water Heater).

WARNING: The fuel-fired burner supplied with this water heater may be removed, packaged and shipped
separately to avoid damage during transport and handling. Confirm the burner decal data matches with the
water heater’s rating decal data before mating in the field (i.e. Model, BTU/hr input, and Energy Source).

CAUTION: The hot and cold water distribution system piping connected to this product must be suitable for 150 psi at

210°F in the event the water heater controls malfunction.

3.2 Codes

The equipment must be installed in accordance with those installation regulations in force in the local area where the
installation is to be made. Authorities having jurisdiction must be consulted before installation is made. In the absence
of such requirements, the installation must be in accordance with the instructions in this manual, appliance markings
and supplemental instructions and in compliance with the latest edition of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. Where required by the Canadian authority having jurisdiction, the equipment must be installed in
accordance with the latest edition of the CAN/CSA B149.1-10 Natural Gas and Propane Installation Code and
applicable Provincial Regulations. All appliances conform to the current edition of the ASME Boiler and Pressure
Vessel Code, Section IV, Part HLW.

3.3 Electrical Requirements

See appliance rating decal for electrical service requirements. The appliance must be electrically supplied and
grounded in accordance with the requirements 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. In Canada, the electrical
service must conform to local electrical codes and/or CSA C22.1, Canadian Electrical Code, Part 1.

• All wiring between the unit and field installed devices must be made with properly rated stranded copper wire.

• Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable.

• To avoid serious damage, DO NOT energize the unit until the system and appliance is full of water.

Utiliser du fil de cuivre de la taille appropriée pour le service électrique entrant. Les dommages résultant de l'utilisation
de fil d'aluminium seront exclus du champ d'application de la garantie de cet appareil.

120V 1 phase, 60 Hz service wiring connections are located in the enclosure on the water heater. Some models may
additionally have high voltage connections located on the burner.

Be certain that high and low voltages are connected to the correct points; also, check rotation of motors on three phase
models. The burners are shipped separately from the heaters and are provided with connecting wires in conduit to be
connected after the burner is in place in the combustion chamber. Wires and terminal block connections are marked
for simplified hookup.

3.4 Handling and Locating the Water Heater
WARNING: Use industry standard safe rigging methods, such as including the use straps and spreader bars

and lifting from the water heater base skid assembly, when attempting to lift or move this product. Failure to
follow industry safe rigging methods could result in property damage, serious injury or death.

WARNING: This product should NOT be oriented in any directions other than vertical. Failure to comply may
result in equipment damage not covered by the warranty.

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1. These units are suitable for indoor installation only (unless specified).

2. Locate the unit so that if water connections should leak, water damage will not occur. When such locations are

unavoidable, install a suitable drain pan, and plumb pan to ensure adequate drainage in the event of a leak. Under
no circumstances is the manufacturer responsible for water damage in connection with this unit, or any of its
components. The manufacturer’s warranty does not cover water damage.

3. Protect associated electrical components and electrical connections from water (dripping, spraying, rain, etc.)

during appliance operation and service.

4. Place the appliance on a level, non-combustible floor. Concrete over wood is not considered non-combustible.

5. 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. Also follow this procedure if electrical conduit runs through the floor, and beneath

the appliance. A field-installed base must meet all local fire and safety code requirements.

3.5 Installation
WARNING: Some units are top heavy. Use caution when moving and rigging these products.

1. Connections to the cold water inlet and hot water outlet should be installed with shut-off valves and unions so that

the unit may be disconnected for servicing. Use caution when threading pipe nipples into tank connections to
prevent cross threading, or over-tightening. Always use a back-up wrench on tank nipples when tightening unions,
valves, etc.

IMPORTANT: Do not use galvanized or steel pipe nipples when making connections to the tank. Use non­ferrous nipples only.

2. Some tank fittings will be attached to the tank wall with studs. Check these type fittings for leaks after filling tank.

Do not over-tighten the studded connections as damage to the O-ring under the fittings may occur. A maximum
torque of (15) ft. lbs. (unlubricated) should be used on studded connections - tighten only in alternating pattern.

3. Hot water and return circulation lines should be insulated. Cold water supply lines should be insulated if subject to

freezing during shutdown periods.

4. A thermal expansion valve (or diaphragm-type expansion tank) should be installed in the cold water line between

the water heater and any check valve.
IMPORTANT: Do not use the plumbing connected to the appliance as a ground for welding or any other purpose.

5. The water heater is equipped with a temperature and pressure relief valve rated for the input of the energy source

and the working pressure of the tank. The relief valve discharge should be piped to a suitable open drain. The
drainpipe may not be smaller than the relief valve opening and must be secured to prevent it from lifting out of the
drain under discharge pressure. Do not install valves or restrictions in the discharge line. Storage tanks must have
over pressure protection. If not factory installed, a properly rated temperature and/or pressure relief valve must be
installed in the fitting furnished for that purpose.

6. The drain valve should be piped to a suitable open drain.

3.6 Service Clearances

Clearances for servicing and inspection must be 18" minimum at sides and rear and 24" minimum in front. Optional
equipment may increase the clearance requirements. Allow sufficient space for installing and servicing connections
such as water, gas, vent, combustion air, electrical, pump and other auxiliary equipment.

3.7 Clearances To Combustible Surfaces

The minimum clearance to unprotected combustible material must be 8"min. at top, sides and rear, and 24" min. in
front. Minimum 1” clearance must be provided from any vent surface to adjacent combustible material.