INSTALLATION & MAINTENANCE MANUAL
TURBOPOWER® 99 GAS WATER HEATER
MODELS: (742, 1485, 2228, 2971) N, P, L, SS (330, 425, 600, 950, 1200) A-TP
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. READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER
PROVIDED INSTRUCTIONS, LABELS AND MARKINGS BEFOR E INSTALLING, OPERATING OR SERVICING THIS
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.
UNIT.
PVI INDUSTRIES, LLC - Fort Worth, Texas 76111 - www.pvi.com - Phone 1-800-433-5654
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TABLE OF CONTENTS
1. Safety Considerations
2. Product Descriptions
3. Standard Features and Equipment
3.1 Warranty
4. Water Heater Installation
4.1 Checking Equipment Before You Install
4.2 Codes
4.3 Electrical Requirements
4.4 Location
4.5 Installation
4.6 Service Clearances
4.7 Clearances to Combustible Surfaces
5. Condensate Neutralization & Disposal
6. Combustion and Ventilation Air
7. Vertical and Horizontal Remote Air
7.1 Vertical or Horizontal Remote Air Option
7.2 Remote Air Piping Design
7.3 Maximum Allowed Combustion Air Vent Length (Equivalent Length)
7.4 Remote Air Piping of Multiple Units
8. Venting Products of Combustion
8.1 Vent System Design
8.2 Venting of Multiple Units
8.3 Maximum Allowed Vent Length (Equivalent Length)
8.4 Vent Construction and Assembly
8.5 Horizontal and Vertical Venting Through a Wall or Roof
9. Gas Supply and Piping
9.1 Inlet Pressure
9.2 Manifold Pressure
9.3 Gas Piping Size
9.4 Appliance Isolation during Gas Supply Piping Pressure Test
9.5 Gas Connection
9.6 Gas Train and Controls Certification
9.7 Gas Control Trains
10. General Information
10.1 Temperature and Pressure Relief Valve(s)
10.2 Upper LED Readout
10.3 High Water Temperature Limit Control
10.4 Cathodic Protection
10.5 Thermal Expansion
11. TempTrac Electronic Controller Panel
11.1 Principle of Operation
11.2 Lower LED Readout
11.3 Upper LED Readout
11.4 Control Buttons
11.5 To View the Setpoint
11.6 To Change the Setpoint
11.7 To Change Other Parameters
11.8 LED Display Alarm Messages
12. Remote Connections – Terminal Strip
13. Start-up Procedure
14. Periodic Maintenance
15. Diagrams
Warranty forms ship separately with each product.
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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 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.
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.
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
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 loss of life.
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 contro ls and all other items
affecting safe appliance operation and which has been under water.
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 loss of life.
PRODUCT SAFETY INFORMATION
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 th at 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, lower tank and upper and lower flue collector assemblies utilize RCF material. (The RFC materials are located
within the product and not generally exposed except during service, disassembly or assembly.)
REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA
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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 CARE FACILITIES AND REST HOMES
ORPHANAGES AND 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 uses.
Good engineering practice mandates the use of thermostatically
controlled mixing valves set at 120°F or less to keep the delivered water
temperature below scalding temperatures.
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2 PRODUCT DESCRIPTION
TURBOPOWER 99
WATER HEATER
1. Flue stack * 9. Burner
2. Fixed temperature high limit device 10. Upper flue collector
3. Adjustable temperature limit device 11. Lower flue collector
4. Digital operating temperature control 12. Rear module access (optional on some models)
5. Control switch(s) and fuse(s) 13. Condensate neutralization system
6. Gas valve 14. Condensate drain (must be plumbed to floor drain) *
7. Gas inlet
8. Drip leg (* Not furnished by PVI)
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3 STANDARD FEATURES AND EQUIPMENT
3.1 Warranty
Factory warranty does not cover improper installation or operation. (See warranty for complete details).
Warranty exclusions include but are not limited to failure or malfunctions resulting from:
1. Failures to properly apply, install, operate, or maintain the appliance in accordance to printed instructions.
2. Abuse, alteration, accident, fire, flood and the like.
3. Sediment or lime buildup, freezing or any other conditions causing inadequate circulation.
4. Corrosive or contaminated atmosphere.
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.
4.2 Codes
The equipment shall be installed in accordance with those installation regulations in force in the local area where
the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be
consulted before installation is made. In the absence of such requirements, the installation shall conform to the
latest edition of the National Fuel Gas Code, ANSI Z223.1. Where required by the authority having jurisdiction,
the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, No. (CSD-1). All appliances conform to the applicable sections of the
latest edition of ASME Boiler and Pressure Vessel Code, Section IV. Where required by the Canadian authority
having jurisdiction, the installation must comply with CAN/CSA B149 and/or B149.2 and/or provincial regulations.
4.3 Electrical Requirements
WARNING: Turn off all electrical service to the appliance when accessing the controls located inside the
control cabinet. The cabinet contains high voltage wiring and terminals. If the electrical service is not
turned off and these wires or terminals are touched, a dangerous shock causing personal injury or loss of
life could occur. Close the control cabinet before restoring electrical service to the appliance.
See product specification sheets and/or appliance labeling for branch service requirements. The appliance, when
installed, must be electrically 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.
When the unit is installed in Canada, it must conform to the CSA C22.1, Canadian Electrical Code, Part 1 and/or
Local Electrical Codes.
1. All wiring between the unit and field installed devices must be made with type T wire.
2. Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad
cable.
3. To avoid serious damage, DO NOT energize the unit until the system and appliance is full of water.
4.4 Location
These units are suitable for indoor installation only.
1. 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.
2. Protect associated electrical components and electrical connections from water (dripping, spraying, rain, etc.)
during appliance operation and service.
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3. Place the appliance on a level, non-combustible floor. Concrete over wood is not considered non-
combustible.
4. Do not install on carpet or other combustible floor coverings.
5. Installation over a combustible floor: Units installed over a combustible floor MUST be provided with 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.
4.5 Installation
WARNING: Use industry standard safe rigging methods when attempting to lift or move this product.
Failure to follow these instructions could result in property damage, serious injury or death. One common
method includes the use of straps and spreader bars, lifting from the water heater base skid asse mbly.
1. Check the data decal on the appliance. Be sure the electrical, water, oil, or gas supply is adequate for the
installation.
2. Carefully remove all shipping supports and bracing.
3. Use only non-ferrous water piping and fittings. Do not use galvanized pipe or fittings. Use of ferrous or
galvanized pipe or fittings can cause rust to form.
4. Install shut-off valves and unions on the inlet and outlet water piping 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.
5. Insulate hot water and return circulation lines. Insulate cold water supply lines if subject to freezing during
shutdown periods. IMPORTANT: Do not use the plumbing connected to the appliance as a ground for
welding or any other purpose.
6. Pipe the drain valve to a suitable open drain.
4.6 Service Clearances
Allow sufficient space to provide adequate clearances on all sides for service and inspection. Recommended
clearance is 24” at the top and front, 18” at left and right sides of the appliance. 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.
4.7 Clearances to Combustible Surface s
The appliance must not be installed on a combustible floor, on carpet, on other combustible floor coverings or on
a non-combustible floor covering combustible material. The minimum clearance to unprotected combustible
material is 6” from the front, top, left and right sides of the burner and flue collector. Combustible materials are
allowed to contact the tank sides and top, however service clearances are recommended.
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5 CONDENSATION NEUTRALIZATION AND DISPOSAL
The TURBOPOWER
®
99 condensing water heater will 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. Although only slightly acidic, the condensate is routed through a condensate neutralization system to
become lower the pH, allowing for disposal into a drain or sewer system.
The supplied condensate neutralization system contains a crushed limestone neutralization bath. Condensate
slowly flows through a crushed limestone bed and is neutralized, thus avoiding chemical treatment or dilution
using substantial quantities of tap water. Over time the limestone is consumed by this process and must be
replaced. Periodically test the condensate with a pH meter or pH paper and if lower than 5, the crushed limestone
must be replaced. If no condensate is observed, the main pipe containing the crushed limestone should be
inspected for blockage.
If the heater is not installed on a housekeeping pad to ensure gravity drainage, a means of removing condensate,
such as a pump, will be required. The neutralization bath and condensate trap are filled with condensate (water),
even when the heater is not running. Therefore, protection must be provided to the neutralization bath, the
condensate trap and to the condensate drain path, so that condensate does not freeze and damage parts or
block condensate flow.
6 COMBUSTION AND VENTILATION AIR
Provisions for adequate combustion and ventilation air to the mechanical room must be in accordance with the
“Air for Combustion and Ventilation” section in the latest edition of the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CSA B149, Installation Codes or applicable provisions of the local building codes.
Equipment located in confined spaces requires two openings installed within 12” (300 m) from the top and bottom
of the room to assure adequate combustion air and proper ventilation. The total input of all gas utilization
equipment installed in the room must be used to determine the required minimum air volume needed for
combustion, ventilation and dilution of flue gasses.
1. All Air From Outdoors:
a. Each opening requires a minimum free area of 1 square inch
per 4000 Btu/hr input if directly
communicating with the outdoors or communicating to the outdoors through vertical ducts.
b. Each opening requires a minimum free area of 1 square inch
per 2000 Btu/hr input if communicating
with the outdoors through horizontal ducts.
2. All Air From Inside The Building:
Each opening requires a minimum free area of 1 square inch
square inches (0.06 m
2)
.
per 1000 Btu/hr input, but not less than 100
3. Combination Of Air From The Indoors And From The Outdoors:
Refer to National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149, Installation Codes or applicable
provisions of the local building codes.
NOTE: This unit may be installed with an optional remote air intake system which uses a make-up air duct to
draw combustion air directly from outdoors. (See Vertical and Horizontal Remote Air Section.)
WARNING: Adequate clean combustion air must be provided to the appliance. Under no circumstances
should the appliance ever be under a negative pressure. Particular care should be taken when exhaust
fans, compressors, air handling units, etc. may rob air from the appliance. The combustion air supply
must be completely free of any chemical or fumes, which may be corrosive to the appliance. Some
common chemical fumes to avoid are fluorocarbons and other halogenated compounds, most commonly
present as refrigerants or solvents, such as Freon, trichloroethylene, perchlorethylene, chlorine, etc.
These chemicals, when in contact with the equipment or w hen burned, form acids which quickly attack
the tubes, flue collector, stack and other appliance and auxiliary equipment. The result of inadequate
clean combustion air or negative pressure can be premature unwarranted product failure or unsafe
operation producing carbon monoxide that could escape into the building. Exposure to carbon monoxide
can lead to injury or death.
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7 VERTICAL AND HORIZONTAL REMOTE AIR
7.1 Vertical or Horizontal Remote Air Option
The vertical or horizontal remote air system requires a factory or site installed remote combustion air inlet option
package. If your water heater does not include this optional equipment, contact your PVI sales representative to
purchase the Remote Air Kit. The air inlet termination cap supplied with combustion air inlet option must be
installed. Do not fabricate this from locally available parts as it may cause unsafe operation. Combustion air
supplied from outdoors must be free of contaminants.
7.2 Remote Air Piping Design
The water heater can obtain remote air either vertically, through a ceiling or roof, or horizontally through a wall.
Locally obtained solid PVC pipe must be attached to the remote air inlet. Larger solid PVC pipe may be
substituted; however a PVC increaser must be used.
When the remote combustion air inlet and flue gas outlet are located on the same roof top surface, the cap must
terminate at least 3 feet lower than the flue gas outlet, if located within a 10 foot radius.
Locate the remote combustion air inlet and the flue gas vent outlet in a wall or roof with similar wind pressure.
Install the inlet cap at least one foot above the rooftop or at least 18" above grade and at least one foot above
normal snow levels.
WARNING: Locate the termination of the combustion air inlet outdoors to minimize flue gas recirculation
and to minimize the opportunity for products of combustion to enter the building. Recirculation of flue
gas (products of combustion drawn from the flue gas outlet into the combustion air inlet) can cause
operational problems, premature unwarranted product failure or unsafe operation producing carbon
monoxide. Exposure to carbon monoxide can result in property damage, personal injury or death.
7.3 Maximum Allowed Combustion Air Vent Length (Equivalent Length)
Water
Heater
Prefix
Input, Btu/h
W/Remote
Air
Input, Btu/h
100 equivalent
feet, vent
diameter:
225 equivalent
feet, vent
diameter:
742 500,000 500,000 6” 10”
1485 999,000 950,000 6” 10”
2228 1,500,000 1,500,000 8” 12”
2971 1,950,000 1,850,000 8” 12”
VENT PIPE FITTINGS EQUIVALENT (in feet)
90º Elbow 14 feet
90º Long Radius Elbow 12 feet
45º Elbow 6 feet
For maxim allowed remote air lengths (equivalent length) longer than those shown above, contact the factory.
7.4 Remote Air Piping of Multiple Units
Each unit must have a dedicated remote combustion air duct. Combining multiple-unit combustion air ducts into a
common duct or breeching is not allowed.
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8 VENTING PRODUCTS OF COMBUSTION
The TURBOPOWER
®
99 is designed for operation with a "positive pressure vent system" constructed of locally
obtained 4” or 5" (or larger) schedule 40 or 80 solid PVC or CPVC pipe. Do not use PVC or CPVC pipe with
cell/foam type construction (such as “CellCore”) or other non-solid PVC plastic pipe. Larger solid PVC pipe may
be substituted; however, a PVC increaser to the larger size must be used. Do not insulate the plastic vent pipe.
Stainless steel venting listed by a nationally recognized testing laboratory for category IV positive pressure gas
appliance venting may be used instead of plastic pipe 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.
CAUTION: DO NOT use ABS pipe in the venting system. ABS can emit toxic fumes in the event of a building fire.
8.1 Vent System Design
These water heater can be vented either vertically, through a ceiling or roof, or horizontally through a wall in any
direction except down. The vent must be installed and supported to slope downward toward the water heater vent
connection with at least ¼ inch drop per linear foot of horizontal vent run, to allow proper drainage of
condensation.
8.2 Venting of Multiple Units
Multiple heaters must not be vented into a common duct or breeching. Each unit must be independently vented
in accordance with the instructions for either horizontal or vertical venting included above.
8.3 Maximum Allowed Vent Length (Equivalent Length)
Maximum equivalent length of vent must not exceed the length identified in the table below (consult factory for
longer equivalent lengths):
Water Heater
Prefix
Input, Btu/h
W/Remote Air
Input, Btu/h
100 equivalent feet,
vent diameter:
225 equivalent feet,
vent diameter:
742 500,000 500,000 4” 6”
1485 999,000 950,000 4” 6”
2228 1,500,000 1,500,000 5” 8”
2971 1,950,000 1,850,000 5” 8”
VENT PIPE FITTINGS EQUIVALENT (in feet)
90º Elbow 14 feet
90º Long Radius Elbow 12 feet
45º Elbow 6 feet
8.4 Vent Construction and Assembly
1. Clean and deburr all solid PVC, or solid CPVC pipe ends and the joint area and trial assemble (dry-fit) the
vent before joining with PVC cement following the cement manufacturer’s instructions for making sound air
and water tight joints.
2. If category IV stainless steel venting listed by a nationally recognized testing laboratory is used, follow the
manufacturer’s instructions and assure all joints provide a water and gas tight assembly.
3. Vent support – The vent system should be supported at intervals no greater than four feet, to prevent sagging
and distortion.
4. Testing for leaks. After the vent is assembled, close the end of the vent. With the gas supply turned off,
energize the combustion blower to apply air pressure to the vent system. Spray each joint and vent
connection with commercially available leak detection liquid to confirm no air is escaping from any point.
Repair any leaks and retest. After testing is complete, REMOVE the temporary vent closure.
5. Attach the PVI vent termination cap supplied with the appliance. This termination is required for proper
operation and no substitution is allowed.
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8.5 Horizontal and Vertical Venting Through a Wall or Roof
Vent terminal locations, clearances, warnings and requirements stated in this manual apply, whether combustion
air comes from the room or is ducted from outdoors.
1. The solid PVC or CPVC vent pipe must be sealed to the wall or roof at the point where it passes through the
wall or roof.
2. The vent must be terminated with the vent termination cap provided by PVI.
3. The vent terminal must have a minimum clearance of 4 feet (1.22 m) horizontally from, and in no case be
located above or below, electric meters, gas meters, regulators and relief equipment.
4. The vent cap shall terminate at least 3 feet (0.91 m) above any forced air inlet within 10 feet (3.05 m).
5. The vent shall terminate at least 4 feet (1.22 m) below, 4 feet (1.22 m) horizontally from or 1 foot (0.3 m)
above any door, window or building air inlet to the building.
6. The vent system shall terminate at least 1 foot (0.3 m) above grade and at least 1 foot (0.3m) above possible
snow accumulation levels and shall terminate at least 7 feet (2.13 m) above grade when located adjacent to
public walkways or gathering areas.
7. To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.
8. The vent must not exit over a public walkway, near soffit vents or crawl space vents or other areas where
condensate or vapor could create a nuisance or hazard or cause property or could be detrimental to the
operation of regulators, relief valves or other equipment.
9. A horizontal vent must extend at least one foot beyond the wall.
10. A horizontal vent terminal must not be installed closer than 3 feet (0.91m) from an inside corner of an Lshaped structure.
11. A vertical vent should exhaust outside the building at least 2 feet (0.61 m) above the highest point of the roof
within a 10-foot (3.05 m) radius of the termination.
12. The vertical termination must be a minimum of 3 feet (0.91 m) above the point of exit. 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.
13. Follow all requirements in the “Venting” sections of this manual and other instructions and markings for
venting flue products to the outdoors, obtaining adequate combustion and ventilation air and general
installation instructions.
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Horizontal Venting and Outside Combustion Air
WATER HEATER
Follow all requirements in this manual and other instructions and markings for venting flue products to the outdoors,
obtaining adequate combustion and ventilation air and general installation instructions.
Vertical Venting and Outside Combustion Air
Follow all requirements in this manual and other instructions and markings for venting flue products to the outdoors,
obtaining adequate combustion and ventilation air and general installation instructions.
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9 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. The appliance Btu/h output, like other similar equipment, derates approximately 4% per 1000
feet above sea level. Consult Factory for installations above 2000 feet elevation.
9.1 Inlet Pressure: Measured at the inlet pressure tap located at the main gas cock. The inlet pressure must remain
within the minimum flow pressure and maximum static pressure charted below while the unit is at rest and while
the unit is operating at maximum firing rate.
Water Heater
Prefix
Min Inlet Flow Pressure
(in. W.C.)
Max Static Pressure
(in. W.C.)
742 5.0" Nat. Gas 14" Nat. Gas
1485 5.5" Nat. Gas 14" Nat. Gas
2228 6.0" Nat. Gas 14" Nat. Gas
2971 11.0" Nat. Gas 14" Nat. Gas
9.2 Manifold Pressure: Measure at the pressure tap on the downstream side of the final manual shutoff valve for
each stage of operation. The rated manifold pressure appears on the data label. The manifold pressure is preset
at the factory and adjustment is not usually required. If adjustment is required, the burner must be firing at the
minimum and/or full rate while the manifold pressure is adjusted.
9.3 Gas Piping Size:
for each elbow or tee to obtain the total distance from the meter. Use this corrected total distance from the meter for
determining the suggested pipe size in the “Single Unit Installation Suggested Gas Pipe Size” table.
Use the values in “Convert Fittings To Equivalent Straight Pipe” to add the equivalent straight pipe
CONVERT FITTINGS TO EQUIVALENT STRAIGHT PIPE
Fitting Size (inches) ¾" 1" 1¼" 1½" 2" 3" 4" 5"
Equivalent Length of
Straight Pipe (feet)
2' 2' 3' 4' 5' 10' 14' 20'
Equivalent Feet
From Meter
25 860 1320 2475 3900 7000 40 660 990 1900 3000 5300 60 - 810 1520 2400 4300 -
80 - 690 1300 2050 3700 100 - 620 1150 1850 3250 6700
125 - - 1020 1650 2950 6000
150 - - 950 1500 2650 5500
175 - - 850 1370 2450 5000
200 - - 800 1280 2280 4600
SINGLE UNIT INSTALLATION SUGGESTED PIPE SIZE
Maximum Capacity for Natural Gas*
MBTU/HR Based on 0.5" W.C. Pressure Drop*
1-1/4" 1-1/2" 2" 2½" 3" 4"
**Multiplier for alternate pressure drops: 0.3" W.C. 0.77; 1.0" W.C. 1.41; 2.0" W.C. 2.00; and 4.0" W.C. 2.82.
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WATER HEATER
MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART
Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a
pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity).
Nominal Iron
Pipe Size,
Inches
3/4
1
1 1/4
1 1/2
2
2 1/2
3
4
10 20 30 40 50 60 70 80 90 100 125 150 175 200
369 256 205 174 155 141 128 121 113 106 95 86 79 74
697 477 384 328 292 267 246 256 210 200 179 164 49 138
1400 974 789 677 595 543 502 472 441 410 369 333 308 287
2150 1500 1210 1020 923 830 769 707 666 636 564 513 472 441
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820
6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
11200 7900 6400 5400 4870 4410 4000 3800 3540 3300 3000 2720 2500 2340
23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720
Length of Pipe in Straight Feet
9.4 Appliance Isolation during Gas Supply Piping Pressure Test
1. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in excess of ½ PSI (3.5 kPa).
2. The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½
PSI (3.5 kPa).
3. The appliance and its gas connection must be leak-tested before placing it in operation.
9.5 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 sele ctions.
2. Gas pipe size may be larger than heater connection.
3. Installation of a union is suggested for ease of service.
4. Install a manual main gas shutoff valve, outside of the appliance gas connection and before the appliance
gas valve, when Local Codes require.
5. The gas system installer should clearly identify the emergency shut-off device.
6. A sediment trap (drip leg) MUST be provided in the inlet of the gas connection to the unit.
7. Vent limiters/are designed and must respond to pressure changes in the installation environment, as opposed
to outdoor ventilation. For proper operation, do not connect the vent to outdoor atmosphere.
9.6 Gas Train and Controls Certification
NOTE: The gas train and controls assembly provided on this unit have been tested under the applicable
American National Standard to meet minimum safety and performance criteria such as safe lighting, combustion
and safety shutdown operation.
9.7 Gas Control Trains
All models include gas control trains with the following at least the following components (may be separate or
combined in common housing): manual gas shutoff valve, two safety shutoff valves, regulator or proportionator,
manifold pressure tap.
CAUTION: Do not adjust or remove any screws or bolts on gas train control components which are sealed with a
red or blue colored compound. Doing so will void all approvals and warranties.
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10 GENERAL INFORMATION
10.1 Temperature and Pressure Relief Valve(s)
Pipe the relief valve discharge to a suitable open drain. The drain pipe 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.
10.2 Lower LED Readout
An adjustable digital operating control is located in the front control panel. The control is factory pre-set at
approximately 120
º
F.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 info rmation.
10.3 High Water Temperature Limit Control
Appliances are equipped with adjustable limit and fixed high limit controls to control the maximum discharge
water temperature. These controls are located inside the control cabinet. The high limit control is optionally
available as the manual reset type and may be reset by pressing the limit reset button accessible through the
control panel cover. The adjustable limit is of the auto reset type and can be dial adjusted to operate just above
the set point of the main operating temperature control. Pressing the reset on the high limit control will not cause
the control to reset until the water temperature has dropped below the set point of the manual reset high limit
control.
WARNING: Turn off all electrical service to the appliance when accessing the limit or high limit controls
located inside the control cabinet. This cabinet contains High Voltage wiring and terminals. If the
electrical service is not turned off and these terminals are touched, a dangerous shock causing personal
injury or loss of life could occur. Close and fasten the control cabinet cover before restoring electrical
service to the appliance.
10.4 Cathodic Protection
PVI water heaters do not utilize cathodic protection. However, in hot water systems utilizing cathodic protection,
hydrogen gas can be produced when the hot water system has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these
conditions, one of the hot water system faucets should be opened for several minutes before using any electrical
device connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air
escaping through the pipe as the hot water begins to flow. Do not smoke, have open flames or turn electrical
switches on or off near the faucet at the time it is open.
10.5 Thermal Expansion
A relief valve that discharges periodically may be due to thermal expansion in a closed system, such as water
heaters or hot water supply boilers installed in a system closed by components, such as a backflow preventer or
check valve in the cold water supply or a closed boiler heating loop. These systems must be provided with
means to control expansion. Contact a water heater or plumbing professional to resolve this situation. Do not
plug the relief valve.
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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.
11.2 Lower LED Readout
The default display of the lower readout (Probe 1) is the stored water temperature sensed near the top of the
water heater tank. This is used to regulate the temperature of the water heater.
11.3 Upper LED Readout
The default display of the upper readout (Probe 3) is the flue gas temperature exiting the heater. This readout
may also display a temperature reading from Probe 2. Probe 2 can be installed in a thermal well (this optional
probe and thermal well, with heat conductive paste, is custom and must be ordered from your PVI representative
or directly from PVI) to remotely monitor water temperatures, such as blended water temperature, downstream
of a thermal mixing valve or a remote storage tank. All the probes temperatures are available for monitoring
through the optional MODBUS RTU interface.
11.4 Control Buttons
SET
Displays and modifies the temperature set points.
In programming mode, it selects a parameter or confirms an operation.
When held for 3 seconds, displays and modifies the energy saving (Night Time setback)
UP
settings.
In programming mode, it browses the parameter codes or increases a displayed value.
DOWN
When held for 3 seconds, displays the working hours of the load relays.
In programming mode, it browses the parameter codes or decreases a displayed value.
CLOCK
EXT
ON/OFF
Changes lower display from the stored water temperature to current time and day.
Changes upper display from Probe 2 temperature to Probe 3 temperature (when installed).
Also displays the temperature difference of the stored water temperature minus Probe 2
temperature. When held for 3 seconds, will put you in manual mode for setting 4-20mA
output used in startup (password is required).
Switches the control ON or OFF. The BAS can still monitor the probe temperatures.
Appliance will not heat when in the off-state.
(See TempTrac User Manual PV500-40 for full description)
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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.
To change it push the UP or DOWN keys. Push the SET key again to confirm the value and pass to the
setting of next set point.
Repeat the operations described at points 3, 4, 5.
To Exit: press SET + UP or wait 15 seconds without pressing any key.
NOTE: Each point has a time out of 15 seconds. If any key is pushed within 15 seconds the controller exits the
set points programming procedure.
NOTE: The set value is stored even when the procedure is exited by waiting the time-out to expire.
11.7 To Change Other Parameters
Push the SET and DOWN arrow simultaneously for 3 seconds.
Select the required parameter. The name of the parameter is on the upper display; its value is on the lower
display.
Press the SET key: the value of the parameter will start blinking.
Use UP or DOWN to change the value.
Press SET to store the new value and move to the following parameter.
To Exit: Press SET + UP or wait 15s without pressing a key.
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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
CAUSE RESULTS OF ALARM CONDITION
Inlet temperature sensor is not
“P1” TP1 probe failure
connected or is reading incorrectly. Call
for heat and burner modulation output
signal will revert to low fire.
“P2” TP2 probe failure
Temperature sensor is not connected
or is reading incorrectly.
Temperature sensor is not connected
“P3” TP3 probe failure
or is reading incorrectly or flue gas
temperature protection is disabled (if
used).
“HA”
High temperature limit
setpoint exceeded
Buzzer sounds, operation continues Manual reset required
“LA” Low temperature alarm Buzzer sounds, operation continues
Digital input 3 is activated
for one or more of the
following:
HP
Flame failure or any control
Unit de-energized after timer delay Manually reset required
component failure, if
equipped with alarm on any
failure option
RECOMMENDED
ACTION
Check wiring and sensor
Terminals 14 & 17
Check wiring and sensor
Terminals 15 & 17
If no probe, change
TempTrac setting of P2P
Check wiring and sensor
Terminals 16 & 17
LP Digital input 2 is activated Unit de-energized after timer delay Manually reset required
Mn1
Mn2
Mn3
“rtc”
Maintenance alarm for
output 1
Maintenance alarm for
output 2
Maintenance alarm for
output 3
The real time clock has lost
its setting
Buzzer sounds, operation continues Check wiring and sensor
Buzzer sounds, operation continues Check wiring and sensor
Buzzer sounds, operation continues Check wiring and sensor
Energy saving function disabled Reprogram clock
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12 REMOTE CONNECTIONS – TERMINAL STRIP
A terminal strip for the remote connection is located behind the hinged control panel at the top of the cabinet and
is accessed by removing the bottom cover and then removing the screws at the top of the hinged cover. The
following describes the functions of each of these terminals and the factory-installed options required to activate
the terminals:
WARNING: Turn off all electrical service to the appliance when accessing the remote connections
located inside the control cabinet. These terminals are High Voltage. If the electrical service is not turned
off and these terminals are touched, a dangerous shock causing personal injury or loss of life could
occur. Close and fasten the control cabinet cover before restoring electrical service to the appliance
Terminals A1-A2 and P1-P2 are functional only when equipped with the factory installed option required to
activate the terminals.
Terminals R1-R2 and C1-C2 are standard pre-wired functions on all models.
R1
R2
A1
A2
P1
P2
C1
C2
T1
T2
CAUTION: Do not use single strand bell wire for remote field connections to terminals R1-R2 and C1-C2. Use
only multi-strand copper wire. See table below for wire length and gauge:
R1-R2: Used to activate /de-activate appliance from remote master control.
Terminals are provided for wiring to a relay in a remote controller or Energy
Management System. When the remote relay closes, the circuit from R1 to R2 is completed
and appliance controls are enabled. Remove the supplied jumper between terminals, if
remote activation/de-activation is used.
Option Code Required: NONE (provided as standard on this appliance)
A1-A2: Used to activate a remote alarm signaling shutdown of combustion control
Provides a maximum 10 amp relay contact closure when flame safeguard terminates
combustion due to any fault tripping, such as: air proving switch, high limit switch, flame
sensor, etc. that are normally proved after a call for heat.
Option Code Required: NONE (provided as standard on this appliance)
P1-P2: Activates remote equipment and requires confirmation signal back to the appliance.
Provides a maximum 10 amp relay contact closure to activate a remote device, such as
mechanical room air louvers, draft inducer or power venter. The remote device must
complete the circuit between terminals C1-C2 with a proving switch or relay, prior to the
appliance being able to energize.
Option Code Required: LOUVR (Relay With Contacts To Operate Air Damper Or
Mechanical Draft)
C1-C2: Used for proving operation of remote device.
Terminals are provided for wiring to a remote proving switch or relay on devices such as a
power venter and/or exhaust fan. When the proving switch or relay closes, the circuit from C1
to C2 is completed and appliance controls are enabled. Remove jumper between terminals, if
remote proving is used.
Option Code Required: NONE (provided as standard on this appliance)
T1-T2: Not Used
Wire Gauge 18 GA 16GA 14 GA 12 GA
Maximum Length 30 FT 50 FT 75 FT 100 FT
WATER HEATER
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13 START-UP PROCEDURE
WARNING: You must connect the supplied gas train assembly to the burner union. Then connect the gas
supply to the gas train. Do not connect the gas supply directly to this union. Failure to install the
supplied gas train to the burner union before connecting the gas supply may result in uncontrolled gas
flow into the appliance and/or the appliance area. Failure to follow this warning could result in fire or
explosion causing property damage, personal injury or death.
1. Turn off all electrical power to the appliance.
2. Check all electrical connections for tightness, proper voltage and proper grounding.
3. Fill the unit with water. Open the relief valve and vents until a steady water flow is observed flowing from the
highest point in the tank or system. Close the relief valve and continue filling the system at a rate that
permits air to vent out of the piping.
4. Be sure all connections into the tank are tight, as leaks at tank fittings will damage the insulation.
5. 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.
a. 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.
b. Attach a manometer to measure the gas pressure at the manual gas shutoff valve located just upstream
of the gas train. Assure the gas train inlet pressure is within the maximum static pressure specified (e.g.
14" W.C.), and tightly close the gas train manual shutoff valve closest to the burner. Disconnect the
manometer.
c. Attach the manometer to the gas train manual shutoff valve closest to the burner and record the
measured gas pressure in inches of water column (W.C.). Measure and record the gas pressure again
after 15 minutes. If gas pressure has increased from the starting gas pressure, there is a gas leak
through all gas valve seats. The gas leak must be further isolated to one or more of the operating gas
valves. (For example, a solenoid actuated gas shutoff valve.)
d. Turn off the main manual gas shutoff valve. Replace any leaking valve, then reassemble and leak test
the gas train again before start-up is attempted.
6. Verify that the unit is supplied with the type of gas specified on the rating plate.
7. Before beginning test, make sure the main manual gas valve is in the “OFF “position.
8. Check the inlet gas pressure before start-up, using a manometer or a 0 to 28" W.C. pressure gauge (This is
the pressure measured before all components in the gas train). The manometer must stay connected
throughout the testing, as the inlet pressure must be monitored during the firing of the burner. Record static
pressure. The maximum inlet gas pressure must not exceed the value specified on the information label.
Pressures above this value could cause damage to the diaphragm in the gas valve or pressure regulator.
9. Drill hole in vent pipe 12” to 24” from appliance flue outlet, but below draft regulator (for combustion analysis
equipment).
10. Turn on all electrical power to the appliance. Reset all safety devices (high limit, pressure switch, Low-water
Cutoff, etc.).
11. Set the digital Temperature Control on the front control panel to the desired inlet water temperature.
12. Set the adjustable limit just above the setpoint of the digital control.
13. Turn the manual gas valve to the “ON” position.
14. The Ignition Control should go through its “Call For Heat” process and ignite the burner (see “Sequence of
Operation”).
15. If the operating control switches are closed, the burner blower should come on and pre-purge begins.
16. If nothing happens, check for a lockout condition and reset it by pushing the flame safeguard reset button.
Some safety devices are wired in the operating circuit and may not indicate alarm. If no indication of alarm
exists, check gas pressure switches, electronic and float low water cutoffs and temperature limits.
17. After the pre-purge, the flame control energizes spark ignition and opens the gas valve for approximately 4
seconds. After the burner has lit and the primary safety control senses a flame, the burner will remain on
until the call for heat is satisfied or operation is interrupted by a safety devise.
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18. If the burner fails to light, the flame control will lockout. When this happens press the reset button on the
front of the control to recycle burner.
19. Once the main burner flame is established the firing rate will be controlled by the TempTrac control.
20. While the unit is running, verify the inlet gas pressure is within the range shown in the “GAS SUPPLY AND
PIPING” section of this manual.
21. Burner Combustion Adjustment. Burner combustion should only be adjusted using a combustion analyzer.
Do not attempt to adjust burner by sound or sight. With the burner firing, insert the combustion analyzer
probe in the flue vent approximately two feet from the appliance. Adjust to obtain the desired O
and CO2 in
2
the combustion products.
22. Perform flue gas analysis while the stored water is near the desired temperature and unit is in stable
operation (after running about 2 to 5 minutes):
Net stack temperature should be 10ºF to 40ºF (Maximum 160ºF)
2 should be from 3% to 5%. (target 4%)
O
CO
2 should be from 9% to 10% (target 9½%)
CO should not exceed 200 PPM
IMPORTANT: If the appliance is to be shut down for an extended period of time, the primary gas valve and the
water supply should be shut off. When the appliance is returned to service, a thorough inspection of all utilities
and general appliance condition should be conducted.
14 PERIODIC MAINTENANCE
Listed below are items that must be checked to insure safe reliable operations. Maintenance must be performed
by a qualified service or maintenance provider. Verify proper operation after servicing.
WARNING: When servicing the controls, use exact, factory authorized, replacement parts and label all
wires prior to disconnection. Verify proper operation after servicing. Incorrect parts substitution and
wiring errors can cause damage, improper operation, fire, carbon monoxide and other unexpected and
unsafe conditions that could result in fire, injury or death.
1. Examine the appliance and venting system at least once a year. Check more often in first year to determine
inspection interval:
a. Check all joints and pipe connections for tightness, corrosion or deterioration.
b. Check the electronic-ignition system for quick ignition and a proper flame signal.
c. Check all safety controls including thermostats for proper operation.
d. Check safety shut-off valves for operation and tightness.
e. Have the entire system, including, but not limited to, the burner, heat exchanger and venting system,
periodically inspected by a qualified service agency.
2. Any sign of soot in the burner or in the flue indicates the need for a combustion inspection. If soot has
formed, the most common causes are restricted combustion air or excessive gas. A blocked heat exchanger
can cause unsafe operation and will reduce efficiency. Contact a qualified serviceman or installer to inspect
and clean the heat exchanger or vent.
3. Inspect low water cutoffs and relief valves for proper operation at every six months, or more often if indicated
by inspection.
4. Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and
liquids.
5. Check frequently to be sure the flow of combustion and ventilation air is unobstructed to the appliance.
6. If the appliance is to be shut down for an extended period of time, the primary gas valve and the water
supply should be shut off. When the appliance is returned to service, a thorough inspection of all utilities and
general appliance condition should be conducted.
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15 DIAGRAMS
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WATER HEATER
PV500-12 08/12 22
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Wiring Diagram
PV500-12 08/12 23
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Burner Diagram
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WATER HEATER
MODEL NUMBER:
SERIAL NUMBER:
INSTALLATION DATE:
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PVI INDUSTRIES
®
, LLC 3209 Galvez Ave. Fort Worth, Texas 76111 Phone 1-800-433-5654 www.pvi.com
PV500-12 08/12 26
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