PVI Industries PV 500-6 User Manual

INSTALLATION & MAINTENANCE MANUAL

PVI DURAWATT® ELECTRIC WATER HEATERS

Installation and service must be performed by a qualified service installer, service agency or utility 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 BEFORE INSTALLING, OPERATING OR
SERVICING THIS UNIT.

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury, exposure to hazardous materials or loss of life. Refer to the information contained in this
manual. A qualified installer, service agency or the utility supplier, who must read and follow the supplied
instructions before installing, servicing or removing this appliance, must perform installation and service.

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, and any other items affecting safe
appliance operation. Failure to follow these instructions can cause property damage, personal injury, or loss of
life.

TOPIC PAGE
Typical Construction 2

Important Safety Notice 3
Location and Installation 4
Clearances and Electrical Connections 5
Start-up Procedures and Operation 6
Maintenance 7
Replacing Electric Elements 8
Cleaning Electric Elements 9
Element Continuity Checks 10
Contactor to Element Wiring 11
Typical Current Measurement 12
Bolted Head Removal 13
Troubleshooting 14

CONTENTS

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.

PV 500-6 09/07

TYPICAL CONSTRUCTION

DURAWATT® ELECTRIC WATER HEATER

FIGURE 1

Without 23” Diameter Tank Access

FIGURE 2

With 23” Diameter Tank Access

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DURAWATT® ELECTRIC WATER HEATER

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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DURAWATT® ELECTRIC WATER HEATER

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.

WARRANTY

Factory warranty does not cover improper installation or operation. (See warra nty 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.

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 Electrical Code.

LOCATION

1. Locate the unit in a clean and dry area as close as possible to the greatest hot water usage and as near to electrical
power as practical.

2. Install the unit on a firm, level foundation.

3. Locate the foundation on a pitched floor near a suitable drain, or make other provisions to prevent contact to areas
of the building subject to water damage should the boiler or a water connection leak. The drain must be sufficient to
contain water in excess of 210°F.

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 assembly.

1. Check the data decal on the heater. Be sure the electrical supply is adequate for the installation.

2. Carefully remove all shipping supports and bracing. (Float type devices have shipping plugs blocking the float).

3. 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.

4. 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.

5. The water heater is equipped with a temperature and pressure relief valve(s) rated for the input. 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.

6. Pipe the drain valve to a suitable open drain.

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DURAWATT® ELECTRIC WATER HEATER

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, electrical, pump and other
auxiliary equipment.

CLEARANCES TO COMBUSTIBLE SURFACES

The appliance must not be installed on a combustible floor, or on a non-combustible floor covering combustible material.
Clearance to unprotected combustible material must be 6” minimum at top, sides and rear, and 24” minimum in front.
Recommended access for service is 18” at sides and rear and 42” in front.

ELECTRICAL CONNECTIONS
Check rating plate on front for correct voltage, phase and amperage. Refer to wiring diagram for control components

mounted on heater.
Use proper wire size and branch circuit protection as required by National Electrical Code and state and local codes. The

PVI electric water heater specification sheets show number and size of power connectors furnished with the heater for
minimum 90°C copper connecting wire.

Use correct size ground wire, attach to pressure connector provided and marked with decal “GR.”
Connect supply feeders to distribution block (or circuit interrupter if furnished) inside electrical enclosure on the heater

IMPORTANT: Check all wiring connections in heater and element enclosure to assure tightness prior to energizing.
NOTE: Use only copper wire of proper sizing for incoming service. Damage resulting from use of aluminum

wiring is excluded from coverage under the warranty of this unit.

ELECTRONIC LOW WATER CUTOFF

The device consists of a probe in the tank that acts as a switch, closed when submerged in water and open when the
water level is below the probe, preventing heating elements from energizing. The probe should be kept free of scale
buildup to insure operation.

OPTIONAL EQUIPMENT
Shunt Trip Circuit Interrupter (optional on all models): The shunt trip, wired in the non-automatic circuit interrupter, is a

safety device designed to open the circuit interrupter and prevent the elements from energizing if the control panel door is
opened.

Time Sequencer (optional on all models):
Time sequencing is optional and used in lieu of the proportional sequencer. It is a series of time delay relays wired to the
contactors which allows approximately a 40 second delay in energizing each succeeding heating element when the
controls call for heat. This prevents all heating elements from energizing at the same time.

Proportional Sequencer (optional on all models): Progressive sequencing (orbital) equalizes the on time for each
contactor and heating element. The heating elements are staged-on based on the demand on the water heater. The
control gives visual, indication of stages that are on. In the event of power interruption, all contactors are turned off. When
power is resumed, the control will re-stage the elements beginning with number one.

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