PVI Industries Water Heater PV500 26 User Manual

INSTALLATION & MAINTENANCE MANUAL  
QuickDraw® Storage and Semi-instantaneous  
Boiler Water Heaters  
Installation and service must be performed by a qualified service installer, service agency or the utility supplier.  
IMPORTANT: THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION, OPERATION AND  
MAINTENANCE OF THIS EQUIPMENT. READ AND FOLLOW ALL INSTRUCTIONS, LABELS AND MARKINGS  
BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.  
TABLE OF CONTENTS  
TOPIC  
PAGE  
Checking Equipment  
Location and Electrical  
Installation and Clearances  
Typical Construction  
Important Safety Notice  
Water Inlet/Outlet Connections  
Filling the Unit  
Relief Valve Piping  
Sequence of Operation  
Startup Procedure  
2
2
3
4
5
6
6
6
6
7
8
Maintenance  
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.  
PVI INDUSTRIES, LLC - P.O. Box 7124 - Fort Worth, Texas 76111 - 1-800-433-5654  
PV500-26 10/07  
 
QUICKDRAW® Boiler Water Heater  
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.  
3. Do not attempt to move or lift heater by the plumbing connections or heat exchanger. Lift only by the  
skid using industry standard safe rigging methods.  
4. Provide sufficient clearance in front of heat exchanger to facilitate maintenance and removal. See  
“Service Clearances” below.  
5. 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.  
6. 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.  
7. 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.  
8. Pipe the drain valve to a suitable open drain.  
WARNING: All system piping to the heat exchanger plumbing must be adequately  
supported. Failure to do so will result in excessive loads on the heat exchanger  
connections causing damage and/or leakage and potential injury to adjacent personnel.  
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.  
3
 
QUICKDRAW® Boiler Water Heater  
Typical QuickDraw® Storage Construction  
Typical QuickDraw® Instantaneous Construction  
1. U-tube Heat Exchanger  
2. Tank Drain  
5. Potable Water Inlet  
6. Steam Inlet  
3. Control Enclosure  
4. Relief Valve (AGA optional)  
7. Potable Water Outlet  
8. Condensate Outlet  
Note: Components, controls and connection locations may vary.  
4
 
QUICKDRAW® Boiler 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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QUICKDRAW® Boiler Water Heater  
WATER INLET / OUTLET CONNECTIONS  
Important: Do not use galvanized or steel pipe nipples when making waterside connections. Use  
non-ferrous nipples only.  
Make inlet and outlet water connections directly to the threaded bolt-on bronze tank flanges. Over tightening  
connections to the flanges may cause damage to the flange or tank and are not covered by warranty. For  
ease of service, install unions on inlet and outlet piping to the unit. Do not use galvanized nipples to make  
tank connections as these will cause corrosion and rust. Piping and components connected to the water  
heater must be suitable for potable water, for the water temperatures they will experience and for their  
application.  
CAUTION: Flush all water supply lines before connecting the unit.  
FILLING THE UNIT  
1. Fill the system with water. To be sure that the unit is not “air bound,” open the relief valve. Leave the  
valve open until a steady flow of water is observed. Close valve and complete filling the system.  
2. In hard water areas, potable water treatment should be used to reduce introduction of minerals into the  
system. Minerals in the water can collect on the tubes and heat-exchanger surfaces reducing the life of  
the product. Heat exchanger failure due to scale accumulation is not covered by the product warranty.  
3. Make sure there are no system leaks. DO NOT use petroleum based stop-leak products. All system  
leaks must be repaired.  
RELIEF VALVE PIPING  
The water heater is supplied with a pressure and temperature relief valve, sized in accordance with ASME  
requirements. Each relief valve should be piped to a suitable floor drain. No reducing coupling or other  
restriction can be installed in the discharge line. It is strongly recommended that this valve should be  
manually operating at least once a year.  
WARNING: Make sure the safety relief valve is piped to a proper drain per instructions.  
Scalding injury and/or water damage can occur from either the manual lifting of the lever or  
the normal operation of the valve if it is not piped to a proper drain. Insure that the safety  
relief valve piping is of the proper material and rating for the temperature and pressure of  
the system and that it is secured to prevent possible injury. If the valve fails to flow water or  
reseat, consult factory. The relief valve is a primary safety device.  
SEQUENCE OF OPERATION  
(Refer to figure on page 7)  
1. When power is supplied through the unit’s On-Off switch, if the stored water temperature is below the  
operating thermostat set point, the limit operating circuit closes creating a call-for-heat-demand, which  
energizes the actuator on the three-way mixing valve.  
2. The three-way mixing valve returns circulating boiler water to the boiler supply loop through its bypass  
ports. On a call-for heat, the actuator motor runs and the actuator shaft extends causing the valve to  
divert the boiler water through the heat exchanger before it is returned to the boiler supply loop.  
6
 
QUICKDRAW® Boiler Water Heater  
3. When the demand is satisfied, the limit operating circuit opens and the valve actuator is de-energized.  
The actuator motor stops running and the actuator shaft spring returns to the retracted position causing  
the boiler water to divert through the bypass ports and return to the boiler water supply loop.  
START-UP PROCEDURE  
1. When placing the unit into operation, open relief valve to purge air from top of tank and begin to fill  
the tank with cold water. Check for plumbing leaks. Be sure the tank is completely filled before  
closing the relief valve.  
CAUTION: Do not energize the heater until the tank is full of water. Serious damage may result.  
2. Push control switch, located on the control box, to “ON” to activate the three-way valve and  
thermostats. Check the valve for operation; the valve actuator motor should “run” to open the valve  
when operating switch is pushed “on”. Check operating thermostat settings.  
Temperature Setting: The operating thermostat is set at the factory at approximately 120°F and  
the upper operating thermostat (if supplied) is set at approximately 125°F. Adjustment may be  
made by turning the thermostat’s dial to the desired temperature. The temperature limiting device is  
factory set at 200°F.  
CAUTION: Gradually introduce fluids to the unit. Failure to do so can cause damage to the heat  
exchanger.  
3. Push the operating switch to “OFF” before opening manual main boiler water supply valve. Do not  
admit boiler water to the unit suddenly when empty or cold to prevent thermal shock. Gradually  
open boiler water supply valve until all passages of the heat exchanger are filled. Slowly bring the  
unit up to temperature.  
4. Do not operate unit under conditions in excess of those specified on nameplate.  
WARNING: Failure to operate the heat exchanger within the design pressure and  
temperature on the nameplate may result in damage to the heat exchanger and potential  
injury to adjacent personnel.  
5. Open nearby hot water tap to maintain a flow of water through the tank when starting up units.  
Regulate flow of water through the tank to allow the control valve to cycle off and on, and check  
operation of all safety and operating controls.  
7
 
QUICKDRAW® Boiler Water Heater  
6. In all installations, there should be no pulsation or water hammer since this causes vibration and  
strain with resulting leaks.  
7. Retighten bolting on all gasketed joints after the heat exchanger has reached temperature to  
prevent leaks and gasket failures. Retightening should be done uniformly and in a diametrically  
staggered pattern (see “Maintenance”).  
a. On high pressure and high temperature applications or any application where spiral wound  
gaskets are required, it is recommended that the gasketed joints of the heat exchanger be  
retightened to the required torque (see “Maintenance”) after 24 hours at operating pressures  
and temperatures to compensate for any relaxation or creep that may have occurred.  
b. In shutting down, remove all power from the system. Close all boiler water and cold water supply  
valves to the unit.  
c. If the unit is removed from service for an extended period of time, it must be drain completely to  
eliminate the possibility of freezing and corrosion from stagnant water conditions.  
MAINTENANCE  
WARNING: To reduce the risk of electrical shock injury or death, on control systems  
using 120 volt external power, be certain switch is off and power disconnected before  
work is performed on this heater.  
Temperature and Pressure Relief Valve  
Operate the temperature and pressure relief valve at least once a year by lifting the lever briefly. If the  
valve does not open and close properly when testing, it must be replaced with a like relief valve.  
Thermostats and Temperature Limiting Device  
The temperature limiting device and thermostat temperature sensors extend into the water in the tank.  
Depending on the water conditions in your area, scale may coat the sensors. This coating will affect  
accuracy of sensors and can allow water temperature to exceed the desired limits. Remove and inspect  
these controls at necessary intervals. Remove scale if present.  
Control Valve Actuator  
The boiler water control valve actuator is sealed and requires no maintenance. Durability of valve stems  
and packing is dependent upon maintaining non-damaging water conditions. Inadequate water  
treatment or filtration can result in corrosion, scale, and abrasive particle formation. Scale and  
particulates can result in stem and packing scratches and can adversely affect packing life and other  
parts of the Hydronic system. Contact the manufacturer for replacement packing and stem & plug  
assembly.  
Tank  
Scale will normally form in the tank during operation and will accumulate on the bottom of the tank. The  
natural chemicals in the water forms scale which precipitate out during the heating cycles. Some water  
supplies contain more of these chemicals than others do, and the scale buildup will occur more rapidly.  
Other factors affecting the scale buildup are the amount of hot water used and the temperature of the  
water. The more hot water used the more fresh water containing the scale-forming chemicals enter into  
the tank. As the temperature of the water increases, the rate of scale deposited also increases. The  
frequency of inspections will be determined by the rate of scale buildup. Until the appropriate inspection  
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QUICKDRAW® Boiler Water Heater  
and cleaning frequency is established, initially inspect the tank every six months or more frequently if  
higher scaling conditions are present.  
Flush the tank at two or three-month intervals depending on water conditions in your location to help  
prevent the accumulation of scale. To flush: turn off electrical disconnect switch to prevent the unit  
from operating. Open the drain valve and allow water to flow through the tank until it runs clear. Close  
the drain valve and turn the electrical switch back on.  
WARNING: Since PVI cannot control the use of the water heater, water conditions, or  
maintenance, the warranty on the water heater does not cover poor performance,  
structural failure, or leaking due to an excessive accumulation of scale.  
Cleaning the Heat Exchanger (refer to figure below)  
1. Do not open until all pressure is removed, the unit is drained and the equipment surfaces cooled to  
ambient temperature.  
2. Heat exchangers subject to fouling or scaling should be cleaned periodically. A light sludge or scale  
coating on the tube greatly reduces its effectiveness. A marked increase in pressure drop and/or  
reduction in performance usually indicate cleaning is necessary.  
3. Tube bundle removal:  
a. When practical, leave tube bundle attached to collar assembly and remove by unbolting collar  
assembly from tank.  
b. During bundle removal, the dead weight of bundle should never be supported on individual  
tubes or contact any lined interior tank surface. Following removal, rest the bundle on the tube  
sheet, support plates, or wood blocks cut to fit periphery of the bundle.  
c. Tube bundles may be raised using slings formed by bending light sheet metal into a “U” form  
and attaching lifting lugs to the ends of the sheets. Baffles can be easily bent and damaged if  
dragged over rough surfaces.  
d. Before reinserting the tube bundle into the unit place the ring/tank gasket over the end of the  
tube bundle and bring forward to the backside of the tube sheet.  
CAUTION: When cleaning a tube bundle, tubes should not be hammered on with any metallic  
tool and, in case it is necessary to use scrapers, care should be exercised that the scraper is  
not sharp enough to cut the metal of the tubes.  
9
 
QUICKDRAW® Boiler Water Heater  
4. When replacing the heat exchanger head, use a torque wrench to tighten the bolts/studs and nuts.  
Use the following chart as a guide. All torque values apply to well-lubricated nut bearing surfaces.  
TIGHTENING TORQUES  
COMPRESSED FIBER GASKETS  
Recommended  
Bolt  
Dia.  
1/2"  
5/8"  
Torque  
ft-lbs  
40  
Torque  
Increment  
Max.  
Torque  
60  
5
5
80  
120  
SPIRAL WOUND GASKETS  
Recommended  
Bolt/Stud  
Dia.  
Torque  
ft-lbs  
40  
Torque  
Increment  
Max.  
Torque  
60  
1/2"  
5/8"  
5
5
80  
120  
3/4"  
7/8"  
1"  
1 1/8"  
1 1/4"  
120  
200  
300  
450  
600  
5
200  
320  
490  
710  
10  
10  
10  
10  
1000  
5. Tighten uniformly and in a diametrically staggered pattern as illustrated below:  
WARNING: It is extremely important to follow  
a proper tightening sequence. If not followed,  
the flanges can become cocked and a leak  
will result. When tightening flanges with  
spiral wound gaskets, if cocking occurs, the  
result can be deformation and non-repairable  
damage to the gaskets in addition to a  
resultant leak. Any gasket leak can result in  
potential injury to adjacent personnel.  
10  
 

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