PVI Industries PV500-12 User Manual
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
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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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