Tjernlund VP-2, VP-3 User Manual

TJERNLUND PRODUCTS, INC.

1601 Ninth Street • White Bear Lake, MN 55110-6794
PHONE [phone] • [phone] • FAX [phone]
Visit our web site • www.tjernlund.com

VP-2 For Millivolt Water Heaters up to
60,000 BTU/hr

Patented

MODELS

VP-3 For Millivolt Water Heaters from
60,000 to 120,000 BTU/hr

OWNERS INSTRUCTIONS

THESE INSTRUCTIONS MUST REMAIN

WITH EQUIPMENT

DO NOT DESTROY

ALWAYS FOLLOW WATER

HEATER MANUFACTURER’S
INSTRUCTIONS FOR PROPER
OPERATION OF HEATER AND

RE-LIGHTING OF PILOT

WATER HEATER VENT PACKAGE

For Natural Gas or LP

NOTE:

The VP-2 and VP-3 Water Heater Vent Packages use a solenoid valve as part
of the safety interlock circuit. The solenoid valve is installed in the gas supply piping
to the water heater’s thermostat/valve. To save installation time, do not pipe gas to
water heater before installing the gas solenoid valve.

OPTIONAL PILOT SAVER KIT AVAILABLE

The optional Pilot Saver Kit (P/N: 950-2061) allows for Solenoid Valve to be installed in
1/2” burner gas line from water heater gas valve to burner, eliminating pilot outages
caused by power interruptions.

Rev. A 01/00 Copyright © 2000, Tjernlund Products, Inc. All rights reserved. P/N 8504025

Tjernlund Products welcomes your comments and questions. Address all correspondence to: Customer Service,

Tjernlund Products Inc., 1601 Ninth Street, White Bear Lake, MN 55110-6794 or email us at [e-mail].

TABLE OF CONTENTS

In The Event of a Pilot Outage ........................................................................................................................................1

Typical Installation...........................................................................................................................................................2

Sequence of Operation ...................................................................................................................................................2

Installation Restrictions....................................................................................................................................................3

Actuation and Safety Controls Installation ......................................................................................................................3

Gas Solenoid Valve...........................................................................................................................................3

Gas Pressure Switch ........................................................................................................................................4

Linear Limit Spillage Sensing Switch ..........................................................................................................4 - 5

Vent Hood .......................................................................................................................................................................5

Code Restrictions & Termination Clearances...................................................................................................5

Vent Hood Installation .......................................................................................................................................6

Power Venter Installation.................................................................................................................................................6

Code Requirements and Installation Restrictions............................................................................................ 6

Power Venter Installation .............................................................................................................................6 - 7

Electrical Connections.....................................................................................................................................................7

Control Cord Routing.................................................................................................................................. 7 - 8

Actuation and Safety Control Circuit Connections ............................................................................................8

Operation Circuit Check ..................................................................................................................................................8

Safety Interlock Test ...................................................................................................................................................8 - 9

Ladder Wiring Diagram ...................................................................................................................................................9

Combustion Air Test .................................................................................................................................................9 - 10

Performance Curves......................................................................................................................................................10

Troubleshooting Guide...........................................................................................................................................11 - 12

Maintenance..................................................................................................................................................................13

How to Obtain Service Assistance & Warranty.............................................................................................................13

Replacement Parts List .................................................................................................................................................13

Vent Hood Mounting Template ......................................................................................................................................14

IN THE EVENT OF PILOT OUTAGE

1. Push the reset button in the center of the linear limit spillage sensing located on

the draft hood on the top of the water heater.

2. Turn the gas pilot knob at the top of water heater gas valve to “OFF” position.

WARNING: Gas pilot knob MUST REMAIN IN “OFF” POSITION FOR FIVE
MINUTES BEFORE PILOT IS RE-LIT. Perform steps 3 & 4 while waiting.

3. Visually verify that there is 115 volt power established to the Power Venter.

Check fuse or circuit breaker, wall plug and electrical connections.

4. Visually verify that all electrical connections of control cord circuit are intact.

5. Follow water heater manufacturer’s re-lighting instructions attached to water

heater or located in water heater owner’s manual.

USER NOTE:

Since the Power Venter cannot operate during a power outage, the safety interlock controls are designed to prohibit gas flow to the
water heater. Follow the above procedures and water heater manufacturer’s instructions for relighting the pilot when power has been
restored.

OPTIONAL PILOT SAVER KIT AVAILABLE

The optional Pilot Saver Kit (P/N: 950-2061) allows for Solenoid Valve to be installed in 1/2” burner gas line from water heater gas
valve to burner, eliminating pilot outages caused by power interruptions.

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INSTALLER NOTES

1. The installer must read and follow these instructions carefully to assure proper installation and operation of the water
heater vent package.

2. The installer must fill in the required information on the nameplate located on the Power Venter electrical box.

3. The installer must affix the wiring diagram label included with these instructions to the water heater casing adjacent to
its rating plate.

4. The water heater may only be installed on the suction side of Power Venter.

5. The installer must notify the homeowner of the maintenance (Page 13) required with the use of this product.

6. The installer must verify that the pilot safety controls on water heater are in good operating condition before
installation of the water heater vent package.

7. No more than 2 water heaters may be vented by either the VP-2 or VP-3.

8. The Power Venter must not be installed into any portion of a vent system which serves appliances other than the
one(s) vented by the VP-2 or VP-3.

SEQUENCE OF OPERATION

1. Water heater thermostat calls for heat.

2. Simultaneously, the Power Venter is actuated by the gas pressure switch and the burner fires.

3. When the thermostat is satisfied the burner shuts down.

4. The Power Venter continues to operate for a non-adjustable time period of approximately 45 seconds to purge the
vent system of residual flue gases.

5. If, at any time, sustained flue gas spillage is detected by the linear limit spillage sensing switch the solenoid valve is
de-energized, disrupting the flow of gas to the burner and pilot. The reset button on the linear limit will need to be
pushed in and the pilot will need to be relit to establish water heater operation. NOTE: If optional Pilot Saver kit
(P/N: 950-2061) is installed pilot light should not have to be relit.

TYPICAL INSTALLATION

NOTE: The installer must install the Power

Venter downstream of the draft hood.

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INSTALLATION RESTRICTIONS

The Power Venter shall not be installed on incinerators, condensing type appliances or solid-fuel burning appliances.
The Power Venter may only be installed on appliances equipped with a draft hood, draft diverter or barometric draft control.

The Power Venter shall not be installed on an appliance with an automatic valve having a manual opener unless the manual opener
has been rendered inoperative or the automatic valve has been replaced with a valve not equipped with a manual opener.

CAUTION:

1. Failure to install, maintain and/or operate the Power Venter in accordance with manufacturer’s instructions
may result in conditions which can produce bodily injury and property damage.

2. The Power Venter must be installed by a qualified installer in accordance with these instructions and all local
codes or in their absence in accordance with the 1988 (or latest) Edition of the National Fuel Gas Code (NFPA #54), The
1987 (or latest) Edition of the National Electric Code (NFPA #70) and The Occupational Safety and Health Act (OSHA)
when applicable. If improperly installed a hazardous condition such as an explosion or carbon monoxide poison
accumulation could result.

3. “Qualified Installer” shall mean an individual properly trained and licensed.

4. The installer must write or imprint name, phone number, date of installation and sign in the appropriate space on the Power Venter
nameplate.

5. Plan the vent system so that Code required distances are maintained from plumbing and wiring.

6. The Power Venter motor shaft must be mounted horizontally to prevent motor bearing wear.

7. Flue gas temperature must not be exceed 5750F at Power Venter inlet. Ambient temperature must not exceed 1040F.

8. Disconnect power supply when making wiring connections or when working around the fan blade and motor. Failure
to do so may result in severe personal injury and equipment damage.

9. Make certain the power source is adequate for the fan motor requirements. Do not add the Power Venter to a circuit
where the total load is unknown.

10. The installer must verify that the BTU/hr input of the water heater does not exceed the recommended input of the

VP-2 (60,000) or VP-3 (120,000).

11. A safety inspection of the water heater must be performed before installation of the VP-2 or VP-3 as outlined in

ANSI Z223.1/NFPA #54, Appendix H.

ACTUATION AND SAFETY CONTROLS INSTALLATION

GAS SOLENOID VALVE INSTALLATION

After opening carton, inspect thoroughly for hidden damage. Fan blade should rotate freely. If any damage is found notify freight
carrier and your distributor immediately and file a concealed damage claim.

1. Remove the carton labeled “Actuation and Safety Controls.”

2. Open this carton and remove the gas solenoid valve. Make sure that the black coil guard
is covering the coil of the solenoid valve as shown, (See Diagram A).

3. Remove the 3/8” to 1/2” adapters and install as shown. Use thread sealant to ensure a
gas-tight seal. NOTE: 3/8” to 1/2” adapters are not used if using Pilot Saver kit
(P/N: 950-2061).

4. Turn off the gas supply line to the water heater using the shutoff valve in the supply line
to the water heater.

5. Install the solenoid valve between the manual shut off valve and the water heater
thermostat/valve. NOTE: If using Pilot Saver kit (P/N: 950-2061), Solenoid Valve is
installed in 1/2” burner gas line from water heater gas valve to burner.

6. Verify that the arrow on the solenoid valve points in the direction of gas flow to the water
heater. The solenoid valve should be positioned so the top of the coil cover is on top of
or horizontal to the solenoid valve. The top of the solenoid cover must not be pointing
downward.

7. After installation of the solenoid valve conduct a gas leakage test of the appliance piping
and control system down stream of the shutoff valve in the supply line to the appliance
as outlined in the 1988 (or latest) Edition of NFPA 54, ANSI Z223.1, part 4. Any leaks
detected must be repaired and retested.

DIAGRAM A

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GAS

PRESSURE

SWITCH

INSTALLATION

Remove the gas pressure switch from the carton also remove the 1/8” compression fitting, the four 1/2” x #10 self tapping screws and
the 2 sections of 1/4” diameter aluminum tubing from the master carton liner.

The gas pressure switch is mounted on the casing of the water heater adjacent to the heater’s thermostat/valve. It should be mounted
close enough so that the supplied 1/4” tubing will reach from the gas pressure switch fittings to the burner. The four provided screws
are self tapping and drilling. They do not require the use of a drill. Their 1/2” length assures that the inner tank will not be penetrated.

1. Mount the gas pressure switch by securing it to the heater casing with a screw in each of the four mounting holes.

2. Using a tube cutter, cut the appropriate length of 1/4” tubing to reach from the fitting marked “connect to gas valve” to the pressure
tap port of the thermostat/valve, (See Diagram B). NOTE: DO NOT alter the heater’s PILOT GAS LINE, (See Diagram B, Gas

Control Valve).

3. Remove the pressure tap plug from the underside of the thermostat/valve and install the supplied compression fitting. Use thread
sealant, do not over tighten.

4. Use 1/4” tubing to connect the fitting installed in step #3 to the fitting marked “connect to gas valve” on the gas pressure switch.
Make sure each end of the tubing is not pinched closed.

5. Measure and cut an appropriate length of tubing to reach from the fitting marked “warning” to the burner of the water
heater. Connect tubing to gas pressure switch and route to pilot/burner area. NOTE: DO NOT locate the tubing in the

pilot/burner flame.

6. Conduct a gas leakage test of the aluminum tubing as outlined in the 1988 (or latest) edition of NFPA 54, ANSI Z223.1, part 4.
NOTE: The gas pressure switch has a built in pressure tap marked “gauge port”.

DIAGRAM B

LINEAR LIMIT SPILLAGE SENSING SWITCH INSTALLATION

PURPOSE:

To provide a means for appliance shut-down in the event of flue blockage
or Power Venter failure.

OPERATION:

When concentrated spillage of the products of combustion occurs from the
draft hood, the linear limit sensing switch circuit will open preventing burner
operation.

NOTE: Do not alter pilot gas line

DIAGRAM C

1. Attach the linear limit sensing switch mounting bracket to the top of the

water heater using the sheet metal screws provided. The linear limit
bracket should be approximately 1/2” from the draft hood.

2. Attach the three linear limit capillary mounting brackets around the draft

hood, equally spaced.

3. Insert the linear limit spillage sensing switch capillary into the “U” of the

linear limit brackets outlining the perimeter of the draft hood. The linear limit capillary may be overlapped if necessary,
(See Diagram C). IMPORTANT: DO NOT CUT THE CAPILLARY, it will be destroyed and water heater will be disabled.

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