PVI Industries MAXIM Installation & Maintenance Manual
INSTALLATION & MAINTENANCE MANUAL FOR
MAXIM
INTEGRATED WATER HEATING SYSTEM
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
Typical Construction 2
Introduction 3
Start-up Procedures & Warnings 4 – 5
Electrical 5
Maintenance & Safety Inspections 5 – 7
MX Burner Manual, Start-up & Troubleshooting Guide 8 – 14
MXG Burner Manual Refer to PV500-21A
MXO Burner Manual Refer to PV500-22A
MXL Burner Manual Refer to Heat Wise SU-3
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.
PV500-17 07/13 Section 17
PVI INDUSTRIES, LLC
3209 Galvez Ave.
Fort Worth, TX 76111
(800) 433-5654
www.pvi.com
1
MAXIM
INTEGRATED WATER HEATING SYSTEM
TYPICAL CONSTRUCTION - MX MODEL
FIGURE 17-1
1. VENT STACK * 8. HANDHOLE CLEANOUT
2. TEMPERATURE LIMITING DEVICE (set at 200°F) 9. UPPER OPERATING THERMOSTAT (set at 130°F)
3. OPERATING THERMOSTAT (set at 120°F) 10. COLD WATER INLET & RETURN CONNECTION
4. CONTROL SWITCH(es) AND FUSE(s) 11. DRAIN
5. GAS VALVE 12. RELIEF VALVE
6. GAS INLET 13. PRIMARY SAFETY CONTROL
7. BURNER (MX model shown) 14. DIFFERENTIAL AIR PROVING SWITCH
(* NOT FURNISHED BY PVI)
WARNING! Temperatures higher than 125°F increase the risk of scald injury!
IMPORTANT! Clearance to unprotected combustible material must be 8"min. at top, sides and rear, and
24" min. in front.
PV500-17 07/13 Section 17
2
MAXIM
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.
RISKS:
Airborne 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:
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.
If any of the above irritations persists, seek medical attention.
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 that might expose refractory ceramic fiber materials, contact: Unifrax
Corporation, 2351 Whirlpool Street, Niagara Falls, NY 14305-2413, 1-800-322-2293.
This manual covers installation, operation and maintenance on all PVI commercial water heaters and storage tanks. Read all
instructions thoroughly before attempting to start any unit.
CAUTION: Factory authorized start-up may be required on this equipment. Labeling on
the unit will indicate this requirement.
City, state and national codes governing installation of commercial water heaters and storage tanks must
be followed and take precedence over recommendations in this manual.
CODES FOR WATER HEATERS & BOILERS INSTALLATIONS
ANSI Z223.1 National Fuel Gas Code
ANSI Z83.1 Installation of Gas Piping & Gas Equipment
on Industrial & Certain other premises
American Gas Association
NFPA No.31 Installation of Oil Burning Equipment
ANSI Z95.1 National Fire Protection Association
NFPA No.54 Installation of Gas Appliances & Gas
Piping
Avoid breathing fiber particulates and dust.
INTRODUCTION
CSA B149 Natural Gas & Propane Installation Code
CSA B139 Installation Code for Oil Burning Equipment
National Electrical Code National Fire Protection
Association
Canadian Electrical Code Part 1
All Provincial Ordinances
All State & Local Codes
PV500-17 07/13 Section 17
3
MAXIM
START-UP PROCEDURES
WARNING!
This water heater 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. Never leave a child
or disabled person unattended in a
WARNING!
Failure to follow these instructions can
result in serious person injury or death.
Do not relight pilot or start burner with
combustion chamber full of gas or oil
vapor, or with very hot combustion
chamber.
1. Study the burner start-up information included
in this manual carefully.
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.
PV500-17 12-2004 Section 17
bathtub or shower. Since the thermostat
temperature setting could be set too high,
adjust the thermostat temperature setting
to 125°F or lower. Lower settings help
reduce risk of scald injury. Remember, no
water heater system will provide exact
temperature at all times. Allow a few days
of operation at this setting to determine
the correct temperature setting consistent
with your needs and remember, “Hotter
water increases the risk of scald injury.”
Also, the water heater should be located
in an area where the general public does
not have access to set temperatures.
Be sure all connections into the tank are tight
as leaks at tank fittings will damage the
insulation.
3. The top thermostat is a temperature limiting
safety device set at 200°F. The thermostats
are set at the factory at 130°F on the upper
operating thermostat and 120°F on the lower
operating thermostat. The lower operating
thermostat should be set 10° lower than the
upper operating thermostat setting. Adjustment
may be made by turning the thermostat dial to
the desired temperature.
4
MAXIM
START-UP PROCEDURES (con't)
CAUTION!
Conduct the following gas train leakage test before start-up, at annual intervals and
prior to investigating the cause of any reported occurrences 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,
recoated and rechecked to assure stoppage
of the leak.
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 in. W.C.), and tightly close the gas
train manual shutoff valve closest to burner.
ELECTRICAL
1. Wiring to the unit should conform to the
National Electrical Code or the code legally
authorized in your locality. A fused disconnect
switch should be used for water heater
control. Service wiring connections of 120V, 1
phase, 60 Hz. are located in the enclosure on
the water heater.
MAINTENANCE AND SAFETY INSPECTIONS
1. Establish a preventive maintenance program
to assure a longer water heater life.
2. The tank should be flushed at two- or threemonth intervals depending on water conditions
in your location. To flush, turn off electrical
disconnect switch to prevent the burner from
operating. Open 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 the accumulation of sediment.
Water impurities consist of fine particles of soil
or sand that will settle out and form a layer of
sediment on the bottom of the tank.
3. Reattach the manometer to the gas train
manual shutoff valve at the burner 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 0.5" 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.)
IMPORTANT
Use only copper wire of proper sizing for
incoming service. Damage resulting from
use of aluminum wiring will be excluded
from coverage under the warranty of this
unit.
3. A scale of lime will normally form during
operation and will accumulate on the bottom of
the tank. Lime is formed from the natural
chemicals in the water that precipitate out
during heating cycles. Some water supplies
contain more of these chemicals than others
and scale buildup will occur more rapidly.
Other factors affecting scale buildup are the
amount of hot water used and temperature of
the water. The more hot water used, the more
fresh water containing scale-forming chemicals
is brought into the tank. As the temperature of
water increases, the rate of scale deposition
will be increased.
PV500-17 07/13 Section 17
5
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