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INSTALLATION & MAINTENANCE MANUAL
®
TURBOPOWER 99 GAS WATER HEATER
MODELS: (742, 1485, 2228, 2971) N, P, L, SS (330, 425, 600, 950, 1200) A-TP
Installation and service must be performed by a qualified service installer, service agency or the gas 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 INSTAL
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TURBOPOWER 99 WATER HEATER TABLE OF CONTENTS 1. Safety Considerations 2. Product Descriptions 3. Standard Features and Equipment 3.1 Warranty 4. Water Heater Installation 4.1 Checking Equipment Before You Install 4.2 Codes 4.3 Electrical Requirements 4.4 Location 4.5 Installation 4.6 Service Clearances 4.7 Clearances to Combustible Surfaces 5. Condensate Neutralization & Disposal 6. Combustion and Ventilation Air 7. Vertical and Horizontal Remote Air 7.1 Vertica
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TURBOPOWER 99 WATER HEATER 1 SAFETY CONSIDERATIONS WARNING: If the information in the supplied manual(s) is not followed exactly, a fire, explosion or exposure to hazardous materials may result, causing property damage, personal injury or loss of life. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids 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 electri
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TURBOPOWER 99 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
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TURBOPOWER 99 WATER HEATER 2 PRODUCT DESCRIPTION 1. Flue stack * 9. Burner 2. Fixed temperature high limit device 10. Upper flue collector 3. Adjustable temperature limit device 11. Lower flue collector 4. Digital operating temperature control 12. Rear module access (optional on some models) 5. Control switch(s) and fuse(s) 13. Condensate neutralization system 6. Gas valve 14. Condensate drain (must be plumbed to floor drain) * 7. Gas inlet 8. Drip leg (* Not fur
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TURBOPOWER 99 WATER HEATER 3 STANDARD FEATURES AND EQUIPMENT 3.1 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
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TURBOPOWER 99 WATER HEATER 3. Place the appliance on a level, non-combustible floor. Concrete over wood is not considered non- combustible. 4. Do not install on carpet or other combustible floor coverings. 5. Installation over a combustible floor: Units installed over a combustible floor MUST be provided with a base of hollow clay tile or concrete blocks from 8" to 12" thick and extending 24" beyond the sides. Place the blocks in line so that the holes line up horizontally to provide
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TURBOPOWER 99 WATER HEATER 5 CONDENSATION NEUTRALIZATION AND DISPOSAL ® The TURBOPOWER 99 condensing water heater will produce significant amounts of condensate because of its high efficiency. Condensate occurs naturally when water vapor in combustion gases is cooled below the dew point. Although only slightly acidic, the condensate is routed through a condensate neutralization system to become lower the pH, allowing for disposal into a drain or sewer system. The supplied condens
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TURBOPOWER 99 WATER HEATER 7 VERTICAL AND HORIZONTAL REMOTE AIR 7.1 Vertical or Horizontal Remote Air Option The vertical or horizontal remote air system requires a factory or site installed remote combustion air inlet option package. If your water heater does not include this optional equipment, contact your PVI sales representative to purchase the Remote Air Kit. The air inlet termination cap supplied with combustion air inlet option must be installed. Do not fabricate this from lo
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TURBOPOWER 99 WATER HEATER 8 VENTING PRODUCTS OF COMBUSTION ® The TURBOPOWER 99 is designed for operation with a "positive pressure vent system" constructed of locally obtained 4” or 5" (or larger) schedule 40 or 80 solid PVC or CPVC pipe. Do not use PVC or CPVC pipe with cell/foam type construction (such as “CellCore”) or other non-solid PVC plastic pipe. Larger solid PVC pipe may be substituted; however, a PVC increaser to the larger size must be used. Do not insulate the plastic v
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TURBOPOWER 99 WATER HEATER 8.5 Horizontal and Vertical Venting Through a Wall or Roof Vent terminal locations, clearances, warnings and requirements stated in this manual apply, whether combustion air comes from the room or is ducted from outdoors. 1. The solid PVC or CPVC vent pipe must be sealed to the wall or roof at the point where it passes through the wall or roof. 2. The vent must be terminated with the vent termination cap provided by PVI. 3. The vent terminal must have a mi
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TURBOPOWER 99 WATER HEATER Horizontal Venting and Outside Combustion Air Follow all requirements in this manual and other instructions and markings for venting flue products to the outdoors, obtaining adequate combustion and ventilation air and general installation instructions. Vertical Venting and Outside Combustion Air Follow all requirements in this manual and other instructions and markings for venting flue products to the outdoors, obtaining adequate combustion and vent
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TURBOPOWER 99 WATER HEATER 9 GAS SUPPLY AND PIPING Verify that the type of gas specified on rating plate is supplied to the unit. This unit is orificed for operation up to 2000 feet altitude. The appliance Btu/h output, like other similar equipment, derates approximately 4% per 1000 feet above sea level. Consult Factory for installations above 2000 feet elevation. 9.1 Inlet Pressure: Measured at the inlet pressure tap located at the main gas cock. The inlet pressure must remain wit
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TURBOPOWER 99 WATER HEATER MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity). Nominal Iron Length of Pipe in Straight Feet Pipe Size, 10 20 30 40 50 60 70 80 90 100 125 150 175 200 Inches 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74
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TURBOPOWER 99 WATER HEATER 10 GENERAL INFORMATION 10.1 Temperature and Pressure Relief Valve(s) 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. 10.2 Lower LED Readout An adjustable digital operating control is located in the front control panel. The control is
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TURBOPOWER 99 WATER HEATER 11 TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 11.1 Principle Of Operation The water heater operates to satisfy the setpoint of the TempTrac digital control whose sensor is located near the top of the water heater tank. Demand (flow) will typically create a drop in temperature, thus activating the water heater to add heat to the stored water. This setpoint is the desired water temperature to maintain. 11.2 Lower LED Readout The default display of the low
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TURBOPOWER 99 WATER HEATER 11.5 To View the Setpoint Push and release the SET key to see the set point value. To return to normal display, press SET + UP or wait 15 seconds without pressing any key. 11.6 To Change the Setpoint Push the SET key. The upper display will show the “St1” parameter name, while the lower display will show its value. Use the UP or DOWN key to cycle through the parameter names. Push the SET key to modify a parameter value. The value starts flas
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TURBOPOWER 99 WATER HEATER 11.8 LED Display Alarm Messages Alarm messages are displayed in the upper LED readout and alternate with the default display. An alarm LED ICON is also illuminated. (See TempTrac User Manual PV500-40 for full description.) ALARM RECOMMENDED CAUSE RESULTS OF ALARM CONDITION MESSAGE ACTION Inlet temperature sensor is not connected or is reading incorrectly. Call Check wiring and sensor “P1” TP1 probe failure for heat and burner modulation output Terminals
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TURBOPOWER 99 WATER HEATER 12 REMOTE CONNECTIONS – TERMINAL STRIP A terminal strip for the remote connection is located behind the hinged control panel at the top of the cabinet and is accessed by removing the bottom cover and then removing the screws at the top of the hinged cover. The following describes the functions of each of these terminals and the factory-installed options required to activate the terminals: WARNING: Turn off all electrical service to the appliance when acce
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TURBOPOWER 99 WATER HEATER 13 START-UP PROCEDURE WARNING: You must connect the supplied gas train assembly to the burner union. Then connect the gas supply to the gas train. Do not connect the gas supply directly to this union. Failure to install the supplied gas train to the burner union before connecting the gas supply may result in uncontrolled gas flow into the appliance and/or the appliance area. Failure to follow this warning could result in fire or explosion causing property d
