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LOW LEAD CONTENT
LOW LEAD CONTENT
EW-I-S Rev B_2000003735_100207764
Installation & Service
Manual
Models: EW150 - 300
This manual must only be used by a
WARNING
qualified heating installer / service
technician. Read all instructions
in this manual before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Table of Contents
Related Manuals for Lochinvar EW150
Summary of Contents for Lochinvar EW150
- Page 1 EW-I-S Rev B_2000003735_100207764 Installation & Service Manual Models: EW150 - 300 This manual must only be used by a LOW LEAD CONTENT LOW LEAD CONTENT WARNING qualified heating installer / service technician. Read all instructions in this manual before installing.
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Page 2: Table Of Contents
Contents PLEASE READ BEFORE PROCEEDING ...... 3 5. ELECTRICAL CONNECTIONS Hazard Definitions ............3 Electrical Requirements ........... 35 Safety Warnings and Codes ........3 Temperature Adjustment ..........35 1. DETERMINE WATER HEATER LOCATION Temperature Sensors ............36 Location ................ 4-5 Room Thermostat Connections ........37 Clearances ............... -
Page 3: Please Read Before Proceeding
Installation & Service Manual Please read before proceeding Installer – Read all instructions, in this When servicing the water heater – WARNING manual before installing. Perform steps in • To avoid electric shock, disconnect electrical supply the order given. before performing maintenance. •... -
Page 4: Determine Water Heater Location
Installation & Service Manual Determine water heater location Installation Figure 1-1 Typical (Front View) Cabinet Construction 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 regulations shall be carefully followed in all cases. -
Page 5: Location
Installation & Service Manual Determine water heater location (continued) Combustion Ventilation Aire Locating the water heater (continued) Requirements Conventionally Vented Appliances The appliance must not be installed on carpet or other combustible material other than wood flooring. Provisions for combustion and ventilation air must be Outdoor models require the installation of an optional in accordance with Section 5.3, Air for Combustion and outdoor kit. - Page 6 Installation & Service Manual Determine water heater location Figure 1-5 Combustion Air through Ducts Figure 1-7 Air from Outside - Single Opening 2. If combustion and ventilation air is taken from the 4. If a single combustion air opening is provided to bring outdoors using a duct to deliver the air to the mechanical combustion air in directly from the outdoors, the room, each of the two openings should be sized based on...
- Page 7 Installation & Service Manual Determine water heater location (continued) All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12"(30 cm) of the ceiling and one must be within 12"...
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Page 8: General Venting
Installation & Service Manual General venting General The weight of the venting system must not rest on the appliance. Adequate support of the venting system must be Vent installations for connection to gas vents or chimneys provided in compliance with local codes and other applicable must be in accordance with Part 7, “Venting of Equipment,”... - Page 9 Installation & Service Manual General venting (continued) The vertical vent terminal should exhaust outside the unless a 4 foot (1.22 m) horizontal distance is maintained building at least 2 feet (61 cm) above the highest point of from electric meters, gas meters, regulators and relief the roof within a 10 foot (3.05 m) radius of the termination.
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Page 10: Conventional Venting
Installation & Service Manual General venting Vent system options Conventional Negative Draft Venting This appliance has five venting options. They are: System 1. Conventional Negative Draft Venting Follow all requirements in the General Venting section for Conventional negative draft venting with vertical venting flue products to the outdoors, obtaining adequate termination. -
Page 11: Inspection Of A Masonry Chimney
Installation & Service Manual General venting (continued) Inspection of a Masonry Chimney The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the A masonry chimney must be carefully inspected to upper and lower sides of each floor or ceiling through which determine its suitability for the venting of flue products. -
Page 12: Sidewall Air Inlet
Installation & Service Manual General venting 6. After it has been determined that each appliance The common vent and connectors from multiple appliances remaining connected to the common venting must be sized per the requirements of the venting tables system properly vents when tested as above, for type “B”... -
Page 13: Combined Air Inlet Points
Installation & Service Manual General venting (continued) The point of termination for the combustion air inlet cap Figure 2-7 E+ Vent with Roof Top Air MUST be at least 2 feet (61 cm) below the point of flue gas termination (vent cap) if it is located within 10’ (3.05 m) of the flue outlet. - Page 14 Installation & Service Manual General venting Air Inlet Pipe Materials 4. Ensure that the air inlet pipes are properly supported. The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from those specified in The PVC or CPVC air inlet pipe should be cleaned and this section.
- Page 15 Installation & Service Manual General venting (continued) Vent Kits Venting of Flue Products On a conventionally vented, negative draft appliance, the The sidewall E+Vent Kit must be ordered from the connection from the vent to the stack or vent termination manufacturer for single appliance installations with sidewall air inlet.
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Page 16: Direct Vent Sidewall
Installation & Service Manual General venting Flue gas condensate can freeze on exterior walls or on Figure 2-10 E+ Sidewall Direct Vent System the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. - Page 17 Installation & Service Manual General venting (continued) The sidewall vent cap and sidewall air inlet cap supplied in Figure 2-11 Sidewall Direct Vent Caps the Sidewall Direct Vent Kit MUST be used to vent the flue products to the outdoors and supply combustion air. Use of a vent cap and/or air inlet cap other than the manufacturers recommended caps may result in operational problems with the appliance or potentially hazardous spillage of...
- Page 18 Installation & Service Manual General venting Sealing of vent material for use with the The use of double wall vent material NOTICE Sidewall Direct Vent system for the combustion air inlet pipe is recommended in cold climates to The vent materials, Heat-Fab Saf-T CI Vent, Z-Flex Z-Vent, prevent the condensation of airborne moisture in the incoming combustion Protech Systems Fas-N-Seal Vent, Flex-L Star-34 Vent, Metal-...
- Page 19 Installation & Service Manual General venting (continued) Failure to properly seal all vent joints The vent for a direct vent system shall NOT terminate DANGER and seams may result in flue gas spillage above public walkways. and carbon monoxide causing severe personal injury or death.
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Page 20: Direct Vent Vertical
Installation & Service Manual General venting Multiple Sidewall Direct Vent Installations Figure 2-15 Vertical Direct Vent Installation Figure 2-14 Installation of Multiple Direct Vent Caps 2’ 12’ 3’ MIN AIR INLETS FLUE OUTLET 3’ MIN AIR INLETS A Direct Vent System with Vertical Through the Roof Terminations The combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (91 cm) - Page 21 Installation & Service Manual General venting (continued) The direct vent vertical through-roof vent system DOES The termination ell on the air inlet must be located a NOT require the purchase of a special vent kit from the minimum of 12" (30 cm) above the roof or above normal manufacturer.
- Page 22 Installation & Service Manual General venting Air Inlet Pipe Materials The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and Select air inlet pipe material from the following specified standard commercial pipe cement for the material used. The materials: PVC, CPVC, or Dryer Vent air inlet pipe should use a silicone PVC or CPVC (4", 5"...
- Page 23 Installation & Service Manual General venting (continued) Combustion Air Inlet Appliances which are shut down or will CAUTION not operate may experience freezing Combustion air supply pipes can NOT be combined into a due to convective air flow in the air single pipe for multiple appliance installations.
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Page 24: Outdoor Installation
Installation & Service Manual General venting Do not install in locations where rain from building runoff Outdoor models MUST be installed WARNING drains will spill onto the appliance. outdoors and MUST use the vent cap supplied by the manufacturer. Personal Flue gas condensate can freeze on exterior walls or on the injury or product damage may result if vent cap. -
Page 25: Gas Connections
Installation & Service Manual Gas connections Gas supply Verify appliance is supplied with type gas specified on TABLE 3A rating plate. This appliance is orificed for operation up to INLET GAS PRESSURE 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. -
Page 26: Gas Connection
Installation & Service Manual Gas connections Gas connection Gas piping Safe operation of appliance requires properly sized gas Figure 3-1 Gas Piping to Heater supply piping. See data below. Gas pipe size may be larger than heater connection. Installation of a union is suggested for ease of service. Install a manual main gas shutoff valve, outside of the appliance gas connection and before the gas valve, when local codes require. -
Page 27: Manifold Pressure And Piping
Installation & Service Manual Gas connections (continued) Gas Manifold Pressure Adjustments Figure 3-2 Wrench to Support Gas Valve for Piping Connection The gas valve is referenced to the fan IMPORTANT pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the left side of the jacket. - Page 28 Installation & Service Manual Gas connections The gross manifold pressure will typically be within Figure 3-4 Gas Manifold Pressure Adjustment the range of 3.4" w.c. to 3.9" w.c. for Natural Gas and 6.1" w.c. to 6.7" w.c. for L.P. Gas at full fire. The difference in the gross manifold pressure and the front chamber pressure is the net manifold pressure setting of the gas valve’s regulator.
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Page 29: Checking Gas Supply Pressure
Installation & Service Manual Gas connections (continued) Turn the power switch to “ON” position If the regulator cover screw it not in NOTE place and tight, the appliance will not Turn the gas valve knob to “ON” position function properly. Set the thermostat to call for heat. -
Page 30: System Piping
Installation & Service Manual System piping Water connections Water Flow Switch (if equipped) Figure 4-1 Connection to the Appliance A water flow switch is available as a factory supplied option on 150,000 through 300,000 Btu/hr water heaters. The flow switch should be wired across the X and B terminals on the appliance’s internal terminal strip. -
Page 31: Heating Domestic Water
Installation & Service Manual System piping (continued) Combination gas valve Water velocity control Each appliance has a combination gas valve to cycle the gas To ensure proper velocity through IMPORTANT supply on and off to the burners. The combination valve the heat exchanger, it is necessary to consists of a gas regulator and two valve seats to meet the regulate the temperature rise across... -
Page 32: Typical Piping
Installation & Service Manual System piping 2. Sustained high water velocity and low temperature TABLE 4B rise may result in pitting or erosion of the copper COMMON WATER MANIFOLD SIZE tubes in the heat exchanger. This is a non-warrantable FOR MULTIPLE WATER HEATER failure. -
Page 33: Scald
Installation & Service Manual System piping (continued) Pump operation Thermostat Settings The thermostat is adjusted to a low test setting when The water heater must be connected to a properly sized shipped from the factory. pump that circulates water between the heater and storage tank. -
Page 34: Optional Relief Valve
Installation & Service Manual System piping Optional relief valve Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the heat exchanger and operational The water heater is normally supplied with a temperature problems. -
Page 35: Electrical Connections
Installation & Service Manual Electrical connections This appliance is wired for 120 VAC service. The appliance, Figure 5-1 Control Panel when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the National Electrical Code ANSI/NFPA No. -
Page 36: Maximum Set Point Determination
Installation & Service Manual Electrical connections Maximum Set Point Determination The High-Fire offset knob has settings between 0°F and 20°F. If set at 0°F, the High-Fire offset is disabled and The maximum set point for the control is factory set. the appliance will operate at the High-Fire stage until the Water heaters are set to 190°F max., and specialty state and set point is reached and the temperature control shuts the... -
Page 37: Room Thermostat Connections
Installation & Service Manual Electrical connections (continued) 3. Do not locate temperature sensor wiring near electric Figure 5-3 Terminal Strip motors. 4. Do not locate temperature sensor wiring near welding equipment. 5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller. -
Page 38: Operation And Startup
Installation & Service Manual Operation and startup Lighting instructions: Please read This appliance is equipped with an ignition device which before operating automatically lights the burners. DO NOT try to light the burners by hand. If you do not follow the instructions Turn the gas control knob on the gas valve clockwise to WARNING exactly, a fire or explosion may result... -
Page 39: Operation And Diagnostic Lights
Installation & Service Manual Operation and startup (continued) Freeze protection Figure 6-2 Operation and Diagnostic Lights 1. For water heaters with the pump delay option, if either the inlet sensor or the optional multi-purpose temperature sensor reads below 40°F, the pump relay will turn ON. When the temperature rises above 50°F the pump relay will turn OFF. -
Page 40: Maintenance
Installation & Service Manual Operation and startup Maintenance Listed below are items that must be checked to ensure safe If improper flame is observed, examine the venting system, reliable operations. Verify proper operation after servicing. ensure proper gas supply and adjust the combustion air. Label all wires prior to disconnection 3. -
Page 41: Burner Cleaning
Installation & Service Manual Operation and startup (continued) If the differential pressure cannot be obtained, If adjustment is necessary, follow these steps. If no shut the appliance down and inspect the vent adjustment is necessary, go to step “I”. system (both air and flue gas passageways) for Loosen two combustion air blower mounting obstructions or leaks. -
Page 42: Heat Exchanger Inspection
Installation & Service Manual Operation and startup REMOVAL OF COMBUSTION CHAMBER Remove inner combustion chamber door LINING OR BASE PANELS: mounting screws, tilt slightly and slide door • Avoid breathing dust and contact with skin and eyes. assembly out toward front of appliance. Use •... -
Page 43: Diagrams
Installation & Service Manual Diagrams Figure 7-1 Ladder Diagram TO 120 VAC POWER SUPPLY (HOT) POWER SWITCH PUMP PUMP DELAY COMBUSTION AIR BLOWER IGN MOD P5 IGNITER IGN MOD P6 120 VAC TRANSFORMER 24 VAC LWCO 24VDC PUMP THERMOSTAT DELAY CN 7 CN 8 LIMIT... -
Page 44: Wiring Diagram
Installation & Service Manual Diagrams Figure 7-2 Wiring Diagram PROBE... -
Page 45: Troubleshooting
Installation & Service Manual Troubleshooting TROUBLESHOOTING CHART WITH 120 VAC POWER TO STEP APPLIANCE, TURN ON POWER CHECK 120 VAC POWER SUPPLY. 120 VAC POWER TO UNIT? SWITCH, SWITCH LIGHTS UP? CHECK WIRING TO SWITCH? CHECK WIRING CONNECTIONS. CHECK 120 VAC THRU SWITCH? REPLACE SWITCH. - Page 46 Installation & Service Manual Troubleshooting TROUBLESHOOTING CHART STEP IGNITER / SENSOR WARMS UP 120 VAC AT IGNITER/SENSOR? CHECK WIRING CONNECTIONS. AND GLOWS RED. REPLACE IGNITER/SENSOR. REPLACE MODULE. STEP "LED" BURNED OUT BUT CONTROL IGNITION MODULE VALVE FUNCTIONS. REPLACE AT A "LED"...
- Page 47 Notes...
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Page 48: Revision Notes
Revision A (ECO C15343) initial release. Revision B (Change #500000694) reflects the addition of non-metallic venting information to page 14. EW-I-S Rev B_DIR #2000003735_MM #100207764 06/15...