PVI Industries MAXIM INTEGRATED WATER HEATING SYSTEM User Manual
INSTALLATION & MAINTENANCE MANUAL FOR
DO NOT try to light
THE FIRE DEPARTMENT
DO NOT store or use gasoline or
other flammable vapors and
liquids in the vicinity of this or
maintenance can cause injury or
MAXIM
INTEGRATED WATER HEATING SYSTEM
TABLE OF CONTENTS
Start-up Procedures 2
Maintenance & Safety Inspections 3-5
Wiring Diagrams 6,7
Burner 8
Burner Start-up 9-12
Burner Troubleshooting 13.14
MXG Burner Manual Refer to PV500-21A
MXO Burner Manual Refer to PV500-22A
FOR YOUR SAFETY
WHAT TO DO WHEN YOU
SMELL GAS:
•
any appliance.
• DO NOT touch any
electrical switch; DO NOT
use any phone in your
building.
• IMMEDIATELY call
your gas supplier from a
phone outside the
building. Follow the gas
supplier’s instructions.
• If you cannot reach
your gas supplier, CALL
FOR YOUR SAFETY
.
any other appliance.
FOR YOUR SAFETY
WARNING: Improper
installation, adjustment,
alteration, service, or
property damage. Refer to this
manual for assistance, or
consult a qualified installer,
service agency, or the gas
supplier.
TYPICAL CONSTRUCTION
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 14. DIFFERENTIAL AIR PROVING SWITCH
CAUTION: Temperatures higher than 130°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.
(* NOT FURNISHED BY PVI)
PV500-17 05-2000 Section 17
MAXIM
1
START-UP PROCEDURES
CAUTION: 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. 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.
Adjustment may be made by turning the
thermostat dial to the desired temperature.
CAUTION: TEMPERATURES HIGHER THAN 130?F INCREASE THE RISK OF
SCALD INJURY.
CAUTION: CONDUCT THE FOLLOWING GAS TRAIN LEAKAGE TEST BEFORE
START-UP, 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.
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.)
PV500-17 05-2000 Section 17
2
MAXIM
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 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 the accumulation of
sediment. Water impurities consist of fine
particles of soil or sand which will settle out
and form a layer of sediment on the bottom of
the tank.
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 which 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
CARBON MONOXIDE WARNING:
CAUTION: IMPROPER COMBUSTION MAY CAUSE SERIOUS INJURY.
PVI recommends a seasonal or annual combustion check-out be performed by a
qualified service agency to ensure safe and efficient operation.
Periodic Inspection of Operational Components
Periodic inspection and check-out of the burner ignition, control system, and fuel valve operation
(for tight close-off) should be made. Refer to the burner installation instruction for
recommendations.
1. Examine the venting system at least once each
year for proper connections, alignment and
corrosion. The blower inlet will collect dust
from the air during operation. Disconnect the
power to the heater and clean the blower
wheel when necessary.
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.
4. The tank will have a handhole for inspection
and cleaning. (See Figure 17-1, page 1.) To
inspect tank for scale buildup, remove the
handhole cover. 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 will be determined
by the rate of scale buildup. Intervals of 3060 days is recommended.
5. If a firetube leaks for any reason, consult
factory for instructions.
NOTE: Condensate coming from the tubes on
a cold start is normal and does not
indicate a leaking tube.
6. Regularly inspect the bottom tubesheet.
Inspect the SCALEGUARD tubesheet
insulator for holes or areas that may have
pulled away from tubesheet. Repair or
replace as required.
Inspect all parts and make replacements when
necessary. Check wiring for loose connections
and burned wires.
PV500-17 05-2000 Section 17
3
MAXIM
MAINTENANCE AND SAFETY INSPECTIONS (continued)
Periodic Inspection of Operation Components (continued)
CAUTION: THE RELIEF VALVE IS A PRIMARY SAFETY DEVICE.
2. The temperature and pressure relief
valve may be checked by slowly lifting the
seat lever on top of the valve 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. Replace the relief valve
with like kind or one meeting the
requirements stated on the rating decal
located adjacent to the relief valve.
3. A table of periodic safety inspections
is an attachment of this manual for ease of
reference by the building service technician
or licensed equipment operator. Since
water
Instructions for Taking Water Heater Out of Service
Extended shutdown of the appliance and
restarting are as follows:
A. Turn off all power and fuel supplies.
B. Drain and flush tank as previously
discussed.
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.
heater designs vary, only some of these
listed inspections may be appropriate for
your particular model.
4. PVI strongly recommends the
recording of significant events, such as
maintenance or repair actions and safety
inspections, and encourage the
preparation of an event log for this
purpose. All recorded events should be
dated, fully described, and signed by the
individual performing the service, repair, or
inspection. (See Table 17-1, page 5 for
sample of Inspection Record.)
CALL YOUR PVI CUSTOMER SERVICE
REPRESENTATIVE IF YOU HAVE ANY
QUESTIONS. (1-800-433-5654)
C. Tag power switch(es) that fuel is off and
tank is empty.
D. Refill tank with water and turn fuel and
power switch(es) on to restart. Reset all
controls and conduct start-up of the
appliance as discussed in the previous
pages.
NOTE: 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.
PV500-17 05-2000 Section 17
4
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