PVI Industries Water Heater 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.  
CONTENTS  
TOPIC  
PAGE  
Typical Construction  
2
3
4
5
6
Important Safety Notice  
Location and Installation  
Clearances and Electrical Connections  
Start-up Procedures and Operation  
Maintenance  
7
Replacing Electric Elements  
Cleaning Electric Elements  
Element Continuity Checks  
Contactor to Element Wiring  
Typical Current Measurement  
Bolted Head Removal  
8
9
10  
11  
12  
13  
14  
Troubleshooting  
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.  
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  
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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.  
PV500-6 09/07  
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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 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.  
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.  
PV500-6 09/07  
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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.  
PV500-6 09/07  
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START-UP PROCEDURES AND OPERATION  
1. The tank must be full of water before turning on electricity. If elements are energized without water in the tank, they  
will burn out immediately. Warranty is void on dry starts. Use multimeter to check resistance to ground between all  
element terminals and the element mounting flange. (See table 1, page 10)  
Fill the heater with water. Open the relief valve to allow air in the tank to escape. Be sure all connections into the tank  
are tight as leaks at tank fittings or heating elements can cause damage.  
Check inside of electrical enclosure for leaks with tank full of water at water line pressure. Heating element gaskets  
are pressure tested at factory but may leak if unit has been in dry storage for a long period of time.  
If leaks are present, tighten all four nuts uniformly on the element mounting flange in a criss-cross pattern. Tighten  
one nut, then the nut on the diagonal from the first nut. Next, tighten the nut adjacent to the second nut, and then the  
nut diagonal from the third nut. Repeat this sequence until all nuts are tight. Each nut should be tightened to 15 foot  
pounds of torque. To avoid warping the flange, do not over tighten.  
IMPORTANT: All leaks must be corrected prior to turning on electricity to avoid damage to electrical components  
within the enclosure.  
Electric element (design may vary): 3 phase elements have 3 terminals; 1 phase elements have 6 terminals  
FIGURE 3  
2. Check all electrical connections for tightness before turning the unit on.  
3. Energize manual disconnect switch. Check for proper voltage (with voltmeter) on power circuit. Voltage should not  
vary more than 5% from voltage shown on data plate. If voltage exceeds these limits, immediately turn off main  
disconnect and contact utility company.  
4. Energize control circuit switch. Check for proper voltage.  
5. Check for proper amperage with ammeter on power circuit. Amperage should not vary more than 5%, when under full  
load, from amperage shown on data plate. (Element Continuity Checks, page 10). If amperage exceeds these limits,  
immediately turn off main manual disconnect and refer to Electric Water Heater Trouble Shooting Guide (page 14).  
6. Check magnetic contactors for noise. If noisy, i.e., buzzing or chattering, turn off main power disconnect, disassemble  
contactor and blow out foreign particles. Drill filings, dirt or other particles can cause pitting of points which will in turn  
burn out contactor and/or wire. Extra care has been taken during fabrication and inspection for cleanliness; however,  
field installation is often responsible for debris collecting on the contactor points.  
7. The top thermostat is a temperature limiting safety device set at 200°F. The upper operating thermostat is factory set  
at 130°F. The lower operating thermostat is set at 120°F Adjust stored water temperature by turning the Operating  
thermostat dial to the desired temperature. The Upper Operating and Operating thermostats should be set minimum  
10°F higher.  
PV500-6 09/07  
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8. If an optional proportional sequencer is furnished, adjust set point to desired water temperature. (All other temperature  
controls must be set above the sequencer’s set point.) Refer to manufacturer’s product literature for servicing,  
operation and maintenance of proportional sequencer.  
9. After startup and with the water heater operating, allow the water in the tank to reach the desired temperature and de-  
energize the heating elements. Draw hot water from a nearby faucet or outlet until the heating elements come back  
on. This will check for proper operation of the thermostats and other operating controls.  
IMPORTANT: After approximately 30 minutes of operation, turn off all power to the unit. With main disconnect  
off, check each wire connection and fuse clip for elevated temperature. If an elevated temperature is noted, there  
is a loose connection at the point of greatest heat. All connections must be tight for proper performance.  
MAINTENANCE  
A preventative maintenance program is required to ensure a long trouble-free life of the water heater.  
Maintenance Schedule  
COMPONENT  
Tank  
OPERATION  
Sediment Removal  
Inspect  
INTERVAL  
Every 3 Months  
Every 6 Months  
Monthly  
REQUIRED  
Flushing  
Relief Valve  
Test  
Electrical Connections  
Electric Elements  
Electric Elements  
Inspect  
Inspect for wire discoloration  
Amp Draw  
Check  
Every 6 Months  
See Page 9  
Remove & Clean  
Flushing  
1. Turn off the heater electrical disconnect switch.  
2. Open the drain valve and allow water to flow until it runs clean.  
3. Close the drain valve when finished flushing.  
4. Turn on the heater electrical disconnect switch.  
Draining the Tank  
The heater must be drained if it is to be shut down and exposed to freezing temperature. Maintenance and service  
procedures may also require draining the heater.  
1. Turn off the heater electrical disconnect switch.  
2. Close the cold water inlet and hot water outlet valve to heater.  
3. Open a relief valve to vent the tank pressure.  
4. Open the heater drain valve.  
5. If the heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this period.  
PV500-6 09/07  
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Sediment / Lime Scale Removal  
Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom  
of the tank and adheres to heat exchange surfaces. The amount of calcium carbonate (lime) released from water is in  
direct proportion to water temperature and usage. The higher the water temperature or water usage, the more lime  
deposits are dropped out of the water. Lime accumulation not only reduces the life of the equipment but also reduces  
efficiency of the heater.  
T & P Relief Valve  
The pressure relief valve should be checked at regular intervals by manually opening the valve. The openings inside the  
valve may become restricted by a buildup of scale and become inoperative. If the valve does not open and close properly  
and does not blow off internal pressure when tested, it must be replaced. Shut down heater, relieve internal pressure and  
replace relief valve with a like kind or one meeting the requirements stated on the rating decal located adjacent to the  
relief valve mounting location.  
Low Water Cut-Off  
The standard low water control is electronic. Inspection should be made of the electrode on water heaters equipped with  
electronic low water devices.  
Electrical Connections  
Check all electrical connections approximately one to two weeks after initial start-up to assure tightness. Heating and  
cooling from operation can loosen connections. Visually inspect wire terminal points for any discoloration on a monthly  
basis. Discoloration is likely due to a loose connection at the point nearest discoloration. Check Contactors periodically  
and clean if necessary and repair or replace pitted points caused by foreign particles. Check Fuses periodically for  
continuity and replace if necessary with the same dual-element type.  
REPLACING ELECTRIC ELEMENTS  
Some electric heating elements installed in dished heads may be factory bent to allow clearance from adjacent elements.  
Replacement elements must be identical to the original equipment installed. The Bend Angle Stamp # is required for all  
replacement electric element requests. Important: Install the element facing away from the center of the head.  
Typical Electric Element  
FIGURE 4  
BEND ANGLE  
STAMP  
#1  
25°  
18°  
#2  
FIGURE 4  
Note: No stamp on element flange means that element is not bent.  
PV500-6 09/07  
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CLEANING ELECTRIC ELEMENTS  
Electric immersion INCOLOY® sheath elements are wound at high wattage ratings and must be completely covered by  
water while in operation. Otherwise, they overheat and burn out. Scale from the water will collect on the sheathing of the  
element over a period of time and must be removed periodically to extend the life of the element. Water in some areas will  
produce the scale buildup more rapidly than other areas. The rapidity of the scale buildup is also determined by the watt  
density of the element.  
It is good maintenance practice to remove and clean 80 W/in² (18kW) density elements on a monthly basis. The interval  
between removal and cleaning can usually be extended to six months when 40 W/in² (9kW) density elements are  
installed. Most installations where 20 W/in² (4 1/2kW) density elements are used, require only annual cleaning. Elements  
are cleaned by soaking in a scale dissolving solution. A 30” piece of four or six inch PVC pipe with a cap on one end  
makes an ideal container for element cleaning. (See figure 5.) Contact a chemical supply house for advice on the proper  
cleaning solution for your area.  
Element Cleaner  
FIGURE 5  
PV500-6 09/07  
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ELEMENT CONTINUITY CHECKS  
I.  
II  
III.  
IV.  
V.  
V.  
I.  
II.  
III.  
IV.  
ELEMENT RATING  
OHM  
READING  
NORMAL  
OHM READING  
TERMINAL TO  
FLANGE  
CHECK OPEN  
OHM READING 1 OHM READING OHM READING 3  
COILS  
LEG OPEN  
2 LEGS OPEN  
LEGS OPEN  
kW  
18  
VOLT  
480  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
A-B  
B-C  
26  
26  
26  
7
78  
39  
39  
20  
10  
10  
15  
7.5  
39  
10  
7.5  
DEPENDING ON  
THE SEVERITY  
OF THE SHORT,  
THE OHM  
READING MAY  
VARY FROM  
18  
18  
240  
208  
7
ZERO, (DIRECT  
SHORT) TO  
SEVERAL  
7
5
HUNDRED  
5
OHMS (PARTIAL  
SHORT). IN  
C-A  
5
7.5  
ANY CASE  
WHERE THE  
OHM READING  
9
9
480  
240  
208  
480  
240  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
A-B  
B-C  
C-A  
51  
51  
153  
76.5  
76.5  
39  
76.5  
51  
IS NOT INFINITY,  
THE ELEMENT  
SHOULD BE  
13  
REPLACED  
13  
19.5  
19.5  
30  
19.5  
13  
9
10  
10  
15  
15  
10  
15  
4.5  
4.5  
102  
102  
102  
26  
306  
153  
153  
78  
153  
26  
39  
39  
26  
39  
29  
4.5  
208  
19  
58  
19  
19  
29  
29  
TABLE 1  
PV500-6 09/07  
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TYPICAL SINGLE PHASE WIRING  
TYPICAL THREE PHASE WIRING  
FIGURE 8  
FIGURE 6  
TYPICAL WIRE TERMINATIONS  
FIGURE 9  
FIGURE 7  
FIGURE 10  
PV500-6 09/07  
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TYPICAL CURRENT MEASUREMENT  
FIGURE 11  
FIGURE 12  
3 Ø AMPS PER ELEMENT  
AMPS PER LEG AMPS TOTAL  
13 1/2 13 1/2  
1 Ø AMPS PER ELEMENT  
AMPS PER LEG AMPS TOTAL  
KW-VOLTAGE  
*14 kW-600V  
*7 kW-600V  
18 kW-480V  
9 kW-480V  
7
22  
7
22  
25  
13  
6
75  
38  
18  
87  
44  
22  
11  
11  
4.5 kW-480V  
18 kW-240V  
9 kW-240V  
5 1/2  
44  
5 1/2  
44  
22  
22  
4.5 kW-240V  
18 kW-208V  
9 kW-208V  
11  
11  
50  
50  
29  
15  
7
25  
25  
4.5 kW-208V  
12 1/2  
12 1/2  
TABLE 2  
NOTE: Elements are usually wired to contactors in groups, in order to maintain an amperage draw of close to, but not more  
than, 50 amps per contactor.  
*Applications for 600V use a re-rated 480V element. Therefore, the 40W/in.2 is rated for 14 kW instead of 9 kW.  
PV500-6 09/07  
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SUPERTANKBOLTED HEAD REMOVAL  
SUPERTANKwater heaters and storage tanks will have one or more removable heads or bolted tank sections. The  
heads are used to mount an energy module (i.e. TURBOPOWER® module, electric elements, QUICKDRAW® or steam or  
water heat exchanger heating elements) or bolted head for access to the tank. If a head or module is removed during the  
course of maintenance, replace the O-ring and all special high quality 9/16”-12 NC, grade 8 bolts, washers and nuts with  
identical parts available from your PVI representative or directly from PVI. Do not reuse or substitute these special  
fasteners with similar grade 8 bolts, washers and nuts. Install the flange bolts and nuts with a flat washer under each bolt  
head and nut. First, snug them in an alternating star pattern. Then, using a calibrated torque wrench, and in an alternating  
star pattern, tighten the bolts in 2 increments: 95 ft lbs and 145 ft lbs. Use a small amount of silicone RTV to hold the o-  
ring in place while positioning the flanged head or heat exchanger. Apply adhesive sparingly!  
Contact PVI at 1-800-433-5654 for replacement Fastener Kits and O-Ring Replacement Instructions.  
IMPORTANT: Mark one hole on head and on tank flange for reference when removing head. Be certain to align these  
holes during reassembly to insure the original gasket or O-ring mating surfaces will be correctly positioned.  
Typical Vertical SUPERTANKBolted Head Attachment  
FIGURE 13  
PV500-6 09/07  
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ELECTRIC WATER HEATER TROUBLESHOOTING GUIDE  
TROUBLE  
PROBABLE CAUSE  
REMEDY  
Thermostat(s)  
Check to assure proper thermostat setting.  
Check continuity between all three thermostats or pressure  
controls. Complete circuit. If one is open, it must be replaced.  
Contractors will not pull in  
Control circuit switch is in OFF position  
Control circuit fuse blown  
Close switch. (Turn to ON position)  
Isolate cause for failure and replace fuse.  
Check continuity. Replace coil if not a complete circuit.  
Contractor(s) coil open  
Check for 120 volts to coil on first sequencer step. Allow ample  
time for additional steps to energize. If steps do not energize in  
reasonable time, replace only the defective relay step. See  
wiring diagram.  
No hot water  
Time delay sequencer not operating  
Proportional sequencer not operating  
Check for 120 volts to line connection (L) on sequencer. Check  
fuse for continuity. See wiring diagram. Consult factory.  
Check for open circuit. Check water level in tank. Replace low  
water cutoff if defective.  
Low water cutoff open  
Heating elements  
Check for open legs. (See table 2).  
Heater not large enough to satisfy peak  
demands  
Add booster or additional kw input. Consult local PVI  
representative.  
Add insulation; it will protect against heat loss and save on cost  
of operation.  
Hot water lines not insulated  
Power fuse(s) blown  
Check fuses for continuity. Replace if blown. If blown, determine  
cause of break before replacing with same type fuse.  
Insufficient hot  
water  
Contractor(s) not closing  
Check coil for continuity. If defective, replace.  
Thermostat(s) not correctly set  
Check to assure proper thermostat control setting.  
Check for proper amperage draw. Check for proper ohm  
resistance. Replace if defective. Consult factory.  
(See table 1)  
Element(s) not heating  
Loose connections  
Tighten all connections. If charred, replace wire with wire of  
same type and size.  
Burned or  
discolored wires  
Remove contactor points and inspect. If dirty, clean with emery  
paper. CAUTION: Point must remain flat. If pitted or burned,  
contractor points must be replaced.  
Dirty or pitted contactor points  
Check all connections for tightness. Check ohm resistance in  
electric elements. Replace.  
Blown fuses  
Loose connection. Defective element  
Local utility  
High or low  
voltage  
Check with local utility.  
High or low  
amperage  
Check with local utility. Low amperage, check fuses, tighten  
connections. Check ohm resistance on elements.  
High or low voltage. Defective element  
Wire burned  
or melted at  
element  
Tighten connection and replace wire. Isolate leaking water and  
repair. Replace wire with same type and size.  
Loose connections. Water leaking on elements  
PV500-6 09/07  
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