Vanguard POWERMAX PM200, POWERMAX PM400 Installation & Operation Manual
INSTALLATION & OPERATION MANUAL
DO NOT DISCARD THIS MANUAL!
POWERMAX
GAS INFRA-RED WATER BOOSTER HEATERS
Model PM200 and PM400
IMPORTANT FOR YOUR SAFETY
WARNING: IF THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, FIRE OR
EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH.
-Do not store or use gasoline or any other flammable liquids or vapors 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 electrical switch
• Do not use any phone in the area
• Immediately call your gas supplier from another location.
• Follow gas suppliers instructions
• If you cannot reach the gas supplier, call the local fire dept. or 911
-If overheating should occur or the automatic gas valve fails to operate properly, turn off
the manual gas valve on the gas supply piping to the appliance.
-Installation and service of this equipment must be performed by a qualified installer,
service agency or the gas supplier.
tm
NSF Std. 5, 1992
800-624-4809 CAN/CGA 1-4.3 M98
Tested to: ANSI Z21.10.3 1998
TABLE OF CONTENTS
Page
General Information 1
Installation Codes 2
Unpacking 2
Locating 2
Combustion Air/Ventilation 3
Exhaust Venting 3
Gas Piping 5
Water Requirements 6
Water Piping 7
Electrical 9
Wiring Diagrams 10
Operating Sequence 12
Start-up Procedure 13
Operating Instructions 14
To Turn Off Gas Appliance 15
Maintenance 16
Troubleshooting 17
Replacement Parts List 18
Limited Warranty 19
Appendix A 20
Sample Start Up Checklist 24
Interior View/Parts Breakdown 26
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GENERAL INFORMATION
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The POWERMAX
gas fired, infra-red water booster heater provides 180 degree
sanitizing rinse water for commercial dishwashing machines. Dishware and utensils used
in the preparation and serving of food are required by Health Codes and the National
Sanitation Foundation (NSF) to be sanitized by hot (min. 180 degrees Fahrenheit) water or
a chemical sanitizing solution to destroy bacteria and parasitical organisms. The
POWERMAXtm booster heater operates as a semi-instantaneous water heater. As 180
degree rinse water is drawn from the unit, incoming supply water flow activates the burner
and pump to circulate the water through a high efficiency finned copper coil heat
exchanger. Heat is provided by an advanced infra-red ceramic fabric power burner which
heats and maintains a constant supply of 180 degree rinse water. When the dishwasher is
not in use, the POWERMAXtm continues operating for a few minutes before going into a
stand-by mode, operating only as needed to maintain a small (approx. 4.5 gallon) reservoir
of 180 degree water for the next dishwashing rinse demand.
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INSTALLATION CODES
Installation must be performed in accordance with state and local codes, or, in the
absence of local codes, with the following: National Fuel Code, ANSI Z223.1 (latest
edition) the National Electric Code (NEC) ANSI/NFPA 70 (latest edition). Canada:
CAN/CGA B149.1, CAN/CGA B149.2 and CSA C22.2 No. 1 (latest edition).
UNPACKING
Immediately after unpacking, check thoroughly for any possible shipping damage. If the
POWERMAXtm is found to be damaged, contact the carrier immediately (15 days
maximum). Be sure to save all the packaging materials for shipper’s inspection.
LOCATING THE POWERMAXtm BOOSTER HEATER
Locate the POWERMAXtm so that all required clearances are maintained. The appliance
must be located in an area that is clear and free from combustible materials, including
gasoline and other flammable or corrosive liquids and vapors. The booster heater should
not be located in an area where water leakage could cause damage to adjacent areas or
areas below the unit. If this is not possible, the booster heater should be installed in an
adequate catch pan (preferably stainless steel) that is properly drained. If appliance is
installed on carpeting, it must be installed on a wood or metal panel extending beyond the
full width and depth of the appliance by at least 3 inches (76.2mm) in each direction. The
booster heater should be installed with no more than five feet of pipe between the 180degree outlet and the dishwasher rinse valve (as specified by NSF-5). If the piping
exceeds five feet, the optional circulation return kit must be installed to maintain proper
temperature at the dishwasher rinse valve. The POWERMAXtm may be installed up to 150
feet from the dishwasher when using the circulation kit. Call factory for details.
INSTALLATION CLEARANCES
Minimum clearances from combustible or non-combustible construction -
8” (fire 2”, service 8”) Left side, 2” Right side, 6” Back, 0” Top, 24” Front (minimum for
service). The four 6” adjustable legs allow the unit to be leveled on uneven floors by
screwing the feet up or down as needed.
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COMBUSTION AIR / VENTILATION
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The POWERMAX
must be provided with an adequate supply of air for proper
combustion and ventilation as required by the National Fuel Gas Code, ANSI Z 223.1 or
any local codes that supercede the National Code. Do not obstruct the combustion and/or
ventilation air supply openings.
CAUTION: Combustion air must not be contaminated by corrosive vapors or fumes, i.e.
salt, chlorine, refrigerant gases, detergents, paints, cleaners, etc.. Any damage caused by
insufficient or contaminated combustion air or improper venting will not be covered under
the warranty.
EXHAUST VENTING
The POWERMAX
tm
Booster Heater is classified as a category IV appliance (positive flue
pressure, flue gas temperature of approximately 190 degrees Fahrenheit, possible
condensate). Vent piping must be one of the types detailed in this manual or a factory
approved (in writing) alternate and must be installed according to the vent pipe
manufacturers instructions. All joints must be properly sealed and secured to maintain
joint integrity. All vent piping must slope toward the appliance a minimum of 1/4 inch per
foot of length. The National Fuel Gas Code, ANSI Z223.1 requires that the booster heater
be vented in one of the following three ways:
1. Into the dishwasher exhaust system. (See fig.1). The vent pipe must not penetrate
any grease filter, but should terminate within the hood “capture zone”. In cases of a
“pantleg” type of vent (see fig. 2), the vent pipe may terminate below an approved
‘eyebrow’ penetration of the duct. When vented into the dishwasher exhaust system,
an electrical interlock must be provided (by others) to prevent the appliance from
firing if the exhaust system is not providing sufficient draft for any reason.
3
2. Through the ceiling/roof (see fig.3) or through a sidewall (see fig. 4). Type B-1 vent
pipe (inch min. diameter) may be used when venting vertically through the roof,
provided a one inch minimum clearance to combustible material is maintained
throughout and the vent terminates into a listed wind cap above the roof.
3. Vented freely into the room or space where it is installed, provided that:
a) A Mechanical exhaust system is present in the space where the
booster heater is installed.
b) An electrical interlock is provided (by others) so that the booster will not fire if the
exhaust system is not providing adequate ventilation to the area.
c) The total BTU input rating of all the unvented gas appliances installed divided by
the total cubic foot volume of the room area (including any adjacent areas that
cannot be physically closed off from the installation area) does not exceed 20
BTU’s per hour per cubic foot of space.
For sidewall venting, the booster heater should be located as close as possible to the wall
being used. The minimum and maximum wall thickness is determined by the wall thimble
available from the vent manufacturer. Refer to the vent manufacturer’s installation
instructions.
All horizontal runs of vent pipe must have a minimum rise of 1/4 inch per foot of length and
must be supported every 5 feet or less (3 feet in Canada) and at every elbow.
For horizontal venting: The total length of approved 4 inch diameter vent pipe can be a
maximum of 40 feet, including two 90 degree elbows and one termination vent. For each
elbow above two, reduce the total allowable vent length by ten feet. Minimum horizontal
vent length is 2 feet.
For vertical venting: The maximum length of approved 4 inch diameter vent pipe is the
same as above; the same requirements for elbows and termination vent apply; the
minimum length for vertical venting is 5 feet. An auxiliary power vent kit is available for
installations where the vent length must exceed these lengths. Call the factory for
assistance. Additional requirements when venting through a sidewall:
-The vent terminal shall be located at least three feet above any forced air inlet located
within ten feet; at least four feet below and four feet horizontally from, or one foot above
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any door, opening window or gravity air inlet into any building. It shall also have a
minimum horizontal clearance of four feet from any electric meter, gas meter, regulator,
relief valve or other equipment.
-The vent terminal shall be located not less than seven feet above grade when it is
adjacent to public walkways.
-The bottom of the vent terminal shall be located at least twelve inches above grade or
ground or the normally expected snow accumulation level.
The snow level may be higher on walls exposed to prevailing winds.
-Avoid areas where local experience indicates that condensate drippage may cause
problems, such as above planters, patios, public walkways or areas where condensate or
vapor could cause a nuisance or hazard, or where its discharge could be detrimental to the
operation of regulators, relief valves or other equipment.
Examples of ACCEPTABLE VENT PIPING/ See Appendix A
MANUFACTURER MODEL MATERIAL
SPECIFICATION
Heat-Fab Inc.
38 Haywood St.
Greenfield, MA 01301
Z-Flex US, Inc.
20 Commerce Park North
Bedford, NH 03110
Flex-L International, Inc.
6385 Kennedy Rd
Mississauga, ON
L5T2W4
Saf-T-Vent AL 29-4C
Stainless Steel
Z-Vent AL 29-4C
Stainless Steel
StaR-34 AL 29-4C
Stainless Steel
Termination Box
Termination Tee
Part Name
Tee
Rain Cap
Mitre I Straight
Tee
Rain Cap
Wall Thimble
3”
Part Number
7390TEE
5300C1
7390GC
#02SVSTTX-3
#02VRSRCX03
#02SVSRTX-3
SRTT03
SRWT153
4”
Part Number
7490TEE
5400C1
-
#02SVSTTX-4
#02VRSRCX04
#02SVSRTX-4
SRTT04
SRWT154
GAS PIPING
The gas inlet pipe size is 3/4 inch NPT, male thread, located at the lower right front corner
of the appliance. The gas supply piping must be sized to adequately provide the input
BTU/hr rate for the appliance at the specified flowing pressure (see table 1). The
maximum inlet gas pressure must not exceed the maximum value shown in table 1. The
minimum gas pressure shown in Table 1 is for purposes of input adjustment.
FLOWING Gas Pressure Requirement (not static)
Inches W.C. (Water Column)
Incoming Line Pressure Natural Gas/LP
Minimum Maximum
Manifold
Pressure
PM200 4.5”NG/10”LP 10.5”NG/14”LP 3.5”NG/7.5”LP
PM400 4.5”NG/10”LP 10.5”NG/14”LP 3.5”NG/7.5”LP
TABLE 1
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The gas valve is provided with a pressure tap to measure gas pressure downstream, which is also
the manifold pressure (fig. 5.). The gas piping must have a sediment trap ahead of the heater gas
controls and an approved manual shut-off valve (provided by others) located outside the jacket and
easily accessible. The heater and its gas connections must be leak tested before placing the
appliance in operation. DO NOT use an open flame for leak testing. The heater must be isolated
from the gas supply piping by closing its individual manual shut-off valve during any pressure
testing of the gas supply piping at test pressures equal to or less than 1/2 p.s.i.g. (3.5 kPa). The
heater and its individual shut-off valve must be disconnected from the gas supply during any
pressure testing of that system at test pressures in excess of 1/2 p.s.i.g. (3.5 kPa). Dissipate test
pressure from the gas supply line before re-connecting the heater and its manual shut-off valve to
the gas supply line.
CAUTION: Failure to follow this procedure may damage the gas valve and cause a
dangerous condition. Over pressured gas valve damage is not covered under
warranty.
NOTE: Do not use Teflontm tape on gas line threads. Use only a flexible thread sealant
approved for use with fuel gases.
Local water conditions vary greatly between even near-by locations and can greatly affect
the performance and maintenance requirements of warewashing equipment, including
your booster heater. Proper water conditions will provide lower chemical costs, improved
cleaning performance, reduced spotting and longer equipment life as well as more efficient
labor use and reduced damage to dishware and utensils. Proper water treatment for
effective and efficient performance of this equipment will vary depending upon the makeup of the local water supply.
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WATER REQUIREMENTS
Recommended water hardness is 4-6 grains of hardness per gallon. Chlorides must NOT
exceed 50 parts per million. Water hardness above 6 grains per gallon should be treated
with a proper water conditioner (water softener or in-line treatment). Water hardness
below 4 grains per gallon also requires water treatment to reduce its corrosive effects.
Sediment, silica, chlorides or other dissolved solids may require particulate filtration or
reverse osmosis treatment. Proper water treatment has been shown to reduce machine
cleaning, mineral build-up, detergent usage and corrosion of metal surfaces in booster
heaters and dishwashers.
Damage caused by water conditions is not covered under warranty.
WATER PIPING
WARNING: All piping and plumbing connections must comply with applicable
sanitary, safety and plumbing codes.
CAUTION: All piping and any components connected to this appliance for the
purpose of space heating shall be suitable for use with potable water. Toxic
chemicals, such as used for boiler treatment, shall not be introduced into the
potable water used for space heating. This appliance, when used to supply
potable water, shall not be connected to any heating system or component(s)
previously used with a non-potable water heating appliance or system.
The inlet and outlet water connections are 1 inch NPT (inlet is 1” female pipe, outlet is 1”
male pipe). An inlet and outlet union adaptor is provided with your POWERMAXtm Booster
Heater.
The inlet water supplied to the booster heater should be a minimum of 110-degrees
Fahrenheit, except in the case of single rack, door type dishwashers and some “watersaver” conveyor machines, in which case incoming water can be as low as 45 degrees
tm
Fahrenheit. DO NOT connect the POWERMAX
Booster Heater to a cold water supply
pipe if it is to be used with a full flow conveyor dishwasher.
Recommended flowing water pressure to the booster heater is 45 p.s.i. Flowing water
pressure at the dishwasher rinse valve should be 20 p.s.i. An optional pressure regulating
valve and pressure gauge for the booster heater outlet is available from Vanguard
Technology if the dishwasher is not equipped with these items. The supply water inlet to
the booster heater does not require a pressure-regulating valve unless the supply water
pressure exceeds 50 p.s.i. A full-flow shut off valve must be provided in the water supply
piping to the booster heater. Installation of a suitable water hammer arrester is
recommended between the booster heater and the dishwasher rinse valve.
A drain valve assembly is provided for installation on the lower outlet at the back of the
booster heater.
The Temperature and Pressure Relief valve is installed at the left side of the booster
heater. Install a suitable 3/4” i.d. drainpipe from the discharge of the Temperature and
Pressure Relief valve to a suitable drain or catch pan with drain. The Temperature and
Pressure Relief valve should be manually test-operated at least once annually to ensure
that it is functioning properly. Be careful when operating the relief valve.
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