Lochinvar Shield SWR125 Installation & Service Manual
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Lochinvar Shield SWR125 Installation & Service Manual

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WARNING:
If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
-- Do not store or use gasoline or other flammable
vapors and 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 electrical switch; do not
use any phone in your building.
• Immediately
call
your
gas
a near by phone.
Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
fire department.
-- Installation and service must be performed
by a qualified installer, service agency, or the
gas supplier.
supplier
from
Installation & Service
Manual
Models: SWR125, SWR150, SWR200,
SWR285, SWR400, SWA150, SWA200,
SWA285, SWA400 and SWA500
⚠ WARNING
This manual must only be used by
a qualified heating installer / service
technician.
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.
100329111_2000585724 Rev A
Read all instructions in

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Summary of Contents for Lochinvar Shield SWR125

  • Page 1 100329111_2000585724 Rev A Installation & Service Manual Models: SWR125, SWR150, SWR200, SWR285, SWR400, SWA150, SWA200, SWA285, SWA400 and SWA500 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. -- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 2: Table Of Contents

    Contents PLEASE READ BEFORE PROCEEDING ....3 8. CONDENSATE DISPOSAL Condensate Drain ............49 Hazard Definitions ............3 9. START-UP THE SHIELD -- HOW IT WORKS ......4-6 RATINGS ................ 7 Check for Gas Leaks ............50 1. DETERMINE WATER HEATER LOCATION Inspect/fill Condensate System ........

  • Page 3: Please Read Before Proceeding

    Installation & Service Manual Please read before proceeding Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious ⚠...

  • Page 4: The Shield - How It Works

    Installation & Service Manual The Shield - How it works... Access cover - front 17. Heat exchanger access cover Provides access to the gas train, heat exchanger and controls. Allows access to the combustion side of the heat exchanger coils. Air intake adapter 18.
  • Page 5 Installation & Service Manual The Shield - How it works... (continued) Models SWR125 -- 200 DIR #2000586061 DIR #2000586061 Front View - Models SWR125 - 200 Rear View - Models SWR125 - 200 DIR #2000586061 DIR #2000586061 Right Side (inside unit) -- Models SWR125 - 200 Left Side (inside unit) -- Models SWR125 - 200...
  • Page 6 Installation & Service Manual The Shield - How it works... Models SWA285 DIR #2000586074 DIR #2000586074 Right Side (inside unit) - Models SWA285 Rear View - Models SWA285 Model SWA400 - 500 DIR #2000586092 DIR #2000586092 Right Side (inside unit) - Model SWA400 - 500 Rear View - Model SWA400 - 500...

  • Page 7: Ratings

    Installation & Service Manual Ratings LOW LEAD CONTENT Model Number Water Content Water Vent/Air Size Input Modulation Btu/hr Note: Change “N” Gallons Connections Connections to “L” for L.P. gas (Note 2) models. (Note 1) SWR125(N,L) 25,000 - 125,000 1-1/2" 1/2" 3"...

  • Page 8: Determine Water Heater Location

    Installation & Service Manual Determine water heater location Installation must comply with: This appliance requires a special venting ⚠ WARNING system. The vent connection to the • Local, state, provincial, and national codes, laws, appliance must be made with the CPVC regulations, and ordinances.
  • Page 9 Installation & Service Manual Determine water heater location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, ⚠ WARNING polypropylene or stainless steel 1/4" (6.35MM) MINIMUM CLEARANCE vent material MUST BE used in 1/4" (6.35MM) AROUND HOT WATER PIPES MINIMUM CLEARANCE a closet structure due to elevated AROUND HOT WATER PIPES...

  • Page 10: Flooring And Foundation

    Installation & Service Manual Determine water heater location Flooring and foundation Table 1A Corrosive Contaminants and Sources Products to avoid: Flooring Spray cans containing chloro/fluorocarbons The Shield water heater is approved for installation on combustible flooring, but must never be installed on carpeting. Permanent wave solutions Do not install the water heater on carpeting ⚠...

  • Page 11: Using An Existing Vent System To Install A New Water Heater

    Installation & Service Manual Determine water heater location (continued) When removing a water heater from When using an existing vent system to existing common vent system: install a new water heater: Failure to follow all instructions can result ⚠ WARNING Do not install the Shield water heater ⚠...

  • Page 12: Removing Water Heater From Existing Common Vent . 11 Combustion & Ventilation Air Requirements

    Installation & Service Manual Determine water heater location Maintain minimum specified clearances for adequate If air is taken directly from outside the building operation. All installations must allow sufficient space for with no duct, provide two permanent openings to the equipment room (see FIG. 1-3): servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance.
  • Page 13 Installation & Service Manual Determine water heater location (continued) DIR# 2000586337 IF NECESSARY FOR DIR# 2000586336 TIGHT CONSTRUCTION Figure 1-6_Combustion Air from Outside - Single Opening Figure 1-5_Combustion Air from Interior Space If a single combustion air opening is provided to bring If air is taken from another interior space, each of the combustion air in directly from the outdoors, the opening two openings specified above should have a net free...
  • Page 14 Installation & Service Manual Determine water heater location The combustion air supply must be completely free of any Combustion air requirements are based on the latest edition flammable vapors that may ignite or chemical fumes which of the National Fuel Gas Code, ANSI Z223.1; in Canada refer may be corrosive to the appliance.

  • Page 15: General Venting

    Installation & Service Manual General venting Direct venting options - Sidewall Vent DIR #2000586391 DIR #2000586391 Figure 2-2 PVC/CPVC Concentric Sidewall Termination Figure 2-1 Two-Pipe Sidewall Termination Direct venting options - Vertical Vent DIR #2000586468 DIR #2000586468 DIR #2000586468 Figure 2-3 Two-Pipe Vertical Termination Figure 2-4 PVC/CPVC Concentric Figure 2-5 Vertical Vent, Sidewall Vertical Termination...

  • Page 16: Install Vent And Combustion Air Piping

    Installation & Service Manual General venting Install vent and combustion air piping The Shield water heater must be vented and The Shield water heater vent and air piping can be installed ⚠ DANGER supplied with combustion and ventilation through the roof or through a sidewall. Follow the procedures air as described in this section.

  • Page 17: Requirements For Installation In Canada

    EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) The 3" Concentric Vent Kit available from Lochinvar (see 45° elbows + (1) concentric vent kit (100140480) = 49 Section 3 – Sidewall Termination – Optional Concentric equivalent feet of piping.

  • Page 18: Materials

    Installation & Service Manual General venting Materials Air inlet pipe materials: The PVC, CPVC, or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable sealed with the pipe manufacturer’s recommended solvents combustion air inlet pipe materials from the following list: and standard commercial pipe cement for the material used.

  • Page 19: Optional Room Air

    Installation & Service Manual General venting (continued) Optional room air Air contamination Pool and laundry products and common household and hobby Optional room air is intended for NOTICE products often contain fluorine or chlorine compounds. When commercial applications. Combustion these chemicals pass through the water heater, they can form air piping to the outside is recommended strong acids.

  • Page 20: Pvc/Cpvc

    Installation & Service Manual General venting PVC/CPVC Work from the water heater to vent or air termination. Do not exceed the lengths given in this manual for the This product has been approved for use with the PVC/CPVC air or vent piping. vent materials listed in Table 2C.

  • Page 21: Polypropylene

    Installation & Service Manual The installer must use a specific vent starter General venting NOTICE adapter at the flue collar connection. The (continued) adapter is supplied by the vent manufacturer Polypropylene to adapt to its vent system. See Table 2E for This product has been approved for use with polypropylene approved vent adapters.

  • Page 22: Stainless Steel Vent

    Installation & Service Manual General venting Stainless steel vent Installation of a stainless steel vent system NOTICE should adhere to the stainless steel vent This product has been approved for use with stainless steel manufacturer’s installation instructions using the manufacturers listed in Table 2F. This unit requires supplied with the vent system.

  • Page 23: Sidewall Direct Venting

    Installation & Service Manual Sidewall direct venting Figure 3-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent Vent/air termination – sidewall TO BOILER INTAKE AIR CONNECTION Follow instructions below when ⚠ WARNING FROM BOILER determining vent location to avoid VENT PIPE CONNECTION possibility of severe personal injury, 12"...
  • Page 24 Installation & Service Manual Sidewall direct venting Vent/air termination – sidewall 6. Locate terminations so they are not likely to be damaged Figure 3-1C Alternate PVC/CPVC/SS/ Polypropylene Venting by foreign objects, such as stones or balls, or subject to Arrangement (if Space Allows) w/Field Supplied Fittings buildup of leaves or sediment.
  • Page 25 Installation & Service Manual Sidewall direct venting (continued) Figure 3-3A Direct Vent Terminal Clearances Table 3B Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
  • Page 26 Installation & Service Manual Sidewall direct venting Table 3B Direct Vent Terminal Clearances (continued) 6 in (15 cm) for appliances < 10,000 Btuh 6 in (15 cm) for appliances < 10,000 Btuh Clearance to nonmechanical air supply (3kW), 12 in (30 cm) for appliances > (3kW), 9 in (23 cm) for appliances >...
  • Page 27 Installation & Service Manual Sidewall direct venting (continued) Table 3C Other than Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances < 10,000 Btuh (3 kW), 12 in (30 cm) for appliances >...
  • Page 28 Installation & Service Manual Sidewall direct venting Prepare wall penetrations Figure 3-4A PVC/CPVC Sidewall Termination Assembly Reference Table 3D when locating the vent and air intake holes and mounting holes. Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as VENT close as desired to the air pipe outside diameter.
  • Page 29 Installation & Service Manual Sidewall direct venting (continued) Prepare wall penetrations (Alternate - Figure 3-5A Multiple Vent Terminations (must also Field Supplied Option) comply with Figure 3-1A) Air pipe penetration: 12" MIN. BETWEEN EDGE OF AIR Cut a hole for the air pipe. Size the air pipe hole as INLET AND ADJACENT VENT OUTLET close as desired to the air pipe outside diameter.
  • Page 30 Sidewall direct venting Sidewall termination – optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent 3. Cut one (1) hole (5 inch diameter for #100140480 pipe termination kits (Factory Kit #100140480 for 3" diameter - installations or 7 inch diameter for #100140484 Models 125 - 200 and #100140484 for 4"...
  • Page 31 Installation & Service Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 3-9 Concentric Vent Dimensional Drawing - Figure 3-10 Concentric Vent Dimensional Drawing - Models 125 -- 200 / 100140480 Models 285 -- 500 / 100140484 "A"...
  • Page 32 Installation & Service Manual Sidewall direct venting Sidewall termination – optional concentric vent Figure 3-12 Concentric Vent Sidewall Attachment Note: 100140480 shown for illustration purposes. Multiventing sidewall terminations DO NOT use field-supplied couplings CAUTION to extend pipes. Airflow restriction When two (2) or more direct vent appliances are vented near will occur and may cause intermittent each other, each appliance must be individually vented (see FIG.

  • Page 33: Vertical Direct Venting

    Installation & Service Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining ⚠ WARNING Rooftop vent and air inlet terminations ⚠ WARNING vent location to avoid possibility of severe must terminate in the same pressure zone, personal injury, death or substantial unless vertical vent sidewall air is set up as property damage.
  • Page 34 Installation & Service Manual Vertical direct venting Vent/air termination – vertical Prepare roof penetrations Figure 4-2 Vertical Terminations with Multiple Water Air pipe penetration: Heaters Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: Cut a hole for the vent pipe.
  • Page 35 Vertical termination – optional concentric vent Description and usage 2. Cut one (1) hole (5 inch diameter for #100140480 Lochinvar offers an optional concentric combustion air and installations or 7 inch diameter for #100140484 installations) vent pipe termination kit. Both combustion air and vent into the structure to install the termination kit.
  • Page 36 Installation & Service Manual Vertical direct venting Vertical termination – optional concentric vent Do not operate the appliance with DO NOT use field-supplied couplings ⚠ WARNING CAUTION the rain cap removed or recirculation to extend pipes. Airflow restriction will of combustion products may occur. occur.

  • Page 37: System Piping

    Installation & Service Manual System piping System water piping methods 2. If this water heater is installed in a closed water supply system, such as the one having a backflow preventer in Observe a minimum of one inch clearance around all the cold water supply, provisions must be made to control un-insulated hot water pipes when openings around the pipes thermal expansion.

  • Page 38: Water Chemistry

    Installation & Service Manual System piping Piping components The following chart (Table 5A) details the relationship of water temperature and time with regard to scald injury Check valves: and may be used as a guide in determining the safest water temperature for your applications.

  • Page 39: Piping Diagrams

    Installation & Service Manual System piping (continued) Figure 5-2 Single Unit EXPANSION MIXING VALVE TANK BUILDING RECIRCULATION PUMP Y-STRAINER UNION FLOW-CHECK VALVE BALL VALVE DIR # 2000587161 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 40 Installation & Service Manual System piping Figure 5-3 Multiple Units EXPANSION MIXING VALVE TANK BUILDING RECIRCULATION PUMP Y-STRAINER UNION FLOW-CHECK VALVE BALL VALVE DIR # 2000587161 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 41 Installation & Service Manual System piping (continued) Figure 5-4 Two Temperature - Single Unit HIGH TEMPERATURE ZONE TEMPERATURE SENSOR MIXING VALVE LOW TEMPERATURE ZONE EXPANSION TANK BUILDING RECIRCULATION PUMP UNION Y-STRAINER FLOW-CHECK VALVE BALL VALVE DIR # 2000587161 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 42: Gas Connections Connecting Gas Supply Piping

    Installation & Service Manual Gas connections Connecting gas supply piping 1. Install ground joint union for servicing, when 4. Support piping with hangers, not by the water heater or its required. accessories. The gas valve and blower will not support 2.

  • Page 43: Natural Gas

    Installation & Service Manual Gas connections (continued) Natural gas: ⚠ WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe Pipe sizing for natural gas personal injury, death, or substantial property damage. 1. Refer to Table 6A for pipe length and diameter. Based on Shield water heaters are typically shipped ⚠...

  • Page 44: Check Inlet Gas Supply

    Installation & Service Manual Gas connections Table 6A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4...

  • Page 45: Gas Pressure

    Installation & Service Manual Gas connections (continued) Gas pressure 17. Check burner performance by cycling the system while you observe burner response. The burner should ignite The gas pressure must remain between 4 inches w.c. (natural), promptly. Flame pattern should be stable. Turn system 8 inches w.c.

  • Page 46: Field Wiring

    Installation & Service Manual Field wiring Installation must comply with: ⚠ WARNING ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply 1. National Electrical Code and any other national, state, before making any electrical connections provincial, or local codes, or regulations. to avoid possible electric shock hazard.
  • Page 47 Installation & Service Manual Field wiring (continued) Figure 7-3 Low Voltage Field Wiring Connections DIR #2000587038...
  • Page 48 Installation & Service Manual Field wiring Figure 7-4 Control Inputs/Outputs LOUVER PROVING INPUTS SWITCH LOW VOLTAGE CONNECTION BOARD LOW WATER CUTOFF ENABLE SWITCH TANK SENSOR INLET TEMPERATURE SENSOR OUTLET TEMPERATURE/ HIGH LIMIT SENSOR FLUE GAS SENSOR BLOCKED AIR PRESSURE SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH CONTROL BOARD...

  • Page 49: Condensate Disposal Condensate Drain

    Installation & Service Manual Condensate disposal Condensate drain To allow for proper drainage on large NOTICE horizontal runs, a second line vent may 1. This water heater is a high efficiency appliance that be required and tubing size may need to produces condensate.

  • Page 50: Start-Up

    Installation & Service Manual Check for gas leaks Start-up Before starting the water heater, and ⚠ WARNING during initial operation, smell near the Check/control water chemistry floor and around the water heater for gas odorant or any Conduct water quality testing prior unusual odor.

  • Page 51: Final Checks Before Starting The Water Heater

    Installation & Service Manual Start-up (continued) Final checks before starting the water Start the water heater heater 1. Read and follow the Operating instructions in FIG.’s 9-2 and 9-3, pages 53 and 54. q Read this manual to familiarize yourself with electronic control module operation.
  • Page 52 Installation & Service Manual Start-up Check flame and combustion Replace the flue sensor and grommet into the vent 1. Shut the water heater down by pressing the UP button for connection. five (5) seconds. Place the Shield water heater back into normal operation. 2.
  • Page 53 Installation & Service Manual Start-up (continued) Figure 9-2 Operating Instructions - Models 125 -- 285...
  • Page 54 Installation & Service Manual Start-up Figure 9-3 Operating Instructions - Models 400 -- 500...

  • Page 55: Shield Control Module

    Installation & Service Manual Start-up (continued) Shield control module Use the control panel (FIG. 9-4) to set temperatures, operating conditions, and monitor water heater operation. Figure 9-4 Control Panel • Press to select various operating data • Press to adjust parameters in •...

  • Page 56: Setup Wizard

    Installation & Service Manual Start-up Setup wizard TANK SETPOINT DIFFERENTIAL • Number of degrees below which the tank thermostat must fall for the electronic control to begin The Shield water heater control has a Setup Wizard feature firing the heater to achieve the target temperature. that can be used to help with the initial start-up of the unit.

  • Page 57: Operating Information

    Installation & Service Manual Operating information General The control monitors the temperature difference between the heat exchanger inlet and the heat exchanger outlet sensors. How the water heater operates If this difference exceeds 80°F the control will reduce the fan speed.

  • Page 58: Water Heater Temperature Regulation

    Installation & Service Manual Operating information Water heater temperature regulation Adjustable control parameters User adjustable parameters Operating temperature (target) The User Adjustable Parameters Menu can be accessed by The electronic control module senses water temperature in pressing the ◄ button from the Main Home Screen. Once the tank and regulates water heater ignition and firing rate to pressed, the tank temperature setpoint will be shown.

  • Page 59: Installer Adjustable Parameters

    Installation & Service Manual Operating information (continued) Installer adjustable parameters Parameters in the installer menu: The Installer Menu can be accessed by pressing the ► - GENERAL Submenu button from the Main Screen and then entering the installer • TIME / DATE password.
  • Page 60 Installation & Service Manual Operating information GENERAL submenu parameters Night setback TIME / DATE The Night Setback submenu is located within the Installer Submenu. Access the Night Setback submenu by using the The water heater control uses an internal clock for the night arrow keys to select NIGHT SETBACK from the submenu setback feature and for logging events.

  • Page 61: Service Mode

    Installation & Service Manual Operating information (continued) Building Management System (BMS) Low water cutoff protection The electronic control module uses sensing of both heat exchanger supply and return temperatures. If the flow rate is too low or either temperature too high, the control module The Shield Water Heater can be controlled by a Building modulates and shuts the burner down.
  • Page 62 Installation & Service Manual Operating information Set Point at Maximum Volts When programmed for BMS control through ModBus/ BACnet and the BMS type is programmed as SETPOINT, the setpoint represented by the Volts at Maximum parameter is set by the Setpoint at Maximum Volts parameter. The minimum value is the Setpoint at Minimum Volts setting and the maximum is 180°F (88°C).

  • Page 63: Maintenance Maintenance And Annual Startup

    Installation & Service Manual Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water Daily •...

  • Page 64: Address Reported Problems

    Installation & Service Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature ⚠ WARNING shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

  • Page 65: Check Expansion Tank

    Installation & Service Manual Maintenance (continued) Check expansion tank 2. After following the warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. 1. Expansion tanks provide space for water to move in and Ensure that the reason for relief valve weeping is the valve out as the water expands due to temperature increase or and not over-pressurization of the system due to expansion...

  • Page 66: Check Burner Flames

    Installation & Service Manual Maintenance Check burner flame Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER 1. Inspect flame through observation window. LINING 2. If the flame is unsatisfactory at either high fire or low The combustion chamber insulation in ⚠...

  • Page 67: Oiled Bearing Circulators

    Installation & Service Manual Maintenance (continued) * Do NOT use a metal brush. Only use ⚠ CAUTION 3. Remove the nuts securing the heat exchanger access the kit provided brush or an equivalent cover to the heat exchanger and set aside. replacement nylon brush.

  • Page 68: Troubleshooting

    Installation & Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection ⚠ WARNING when servicing controls. Wiring errors ALWAYS check control module fuses can cause improper and dangerous NOTICE before replacing control module or any operation. Always disconnect power major components (blower, etc.).

  • Page 69: Troubleshooting Chart - No Display

    Installation & Service Manual Troubleshooting (continued) Table 12A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker. • Check wiring harness connection between display board and main control board. Connect harness at both points.

  • Page 70: Checking Temperature Sensors

    Installation & Service Manual Troubleshooting Checking temperature sensors The water heater temperature sensors (inlet water, outlet water, tank water, and flue) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature.

  • Page 71: Troubleshooting Chart - Noisy System

    Installation & Service Manual Troubleshooting (continued) Table 12E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures should be between 4 inches w.c. and • Refer to Section 6 - Gas Connections for detailed 14 inches w.c.

  • Page 72: Troubleshooting Chart - Fault Messages Displayed

    Installation & Service Manual Troubleshooting Table 12F Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION MEMORY The control module has detected parameter • Replace control module. ERROR settings that are corrupted. • Vent/air intake lengths exceed the maximum allowed lengths.
  • Page 73 Installation & Service Manual Troubleshooting (continued) Table 12F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference Section 10 - Operating Information for adjusting procedures.
  • Page 74 Installation & Service Manual Troubleshooting Table 12F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect spark electrode and associated wiring for damage and connection. Reference page 65 of this manual for removal and cleaning procedures.
  • Page 75 Installation & Service Manual Troubleshooting (continued) Table 12F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect the heat exchanger. Reference page 66 of FLUE TEMP The stack temperature has exceeded the this manual for the procedure on how to clean the flue LIMIT Flue Temp Limit set parameters.
  • Page 76 Installation & Service Manual Troubleshooting Table 12F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION OUTLET SENSOR FAULT • Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged. (will require a manual One or both of the outlet sensors has reset once the condition...
  • Page 77 Installation & Service Manual Troubleshooting (continued) Table 12F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check 120 vac supply to the transformer. • Check wiring connections at the low voltage terminal strip.

  • Page 78: Combustion Analysis Procedure

    Installation & Service Manual Troubleshooting Combustion Analysis Procedure 7. Once the combustion analysis is complete, exit Service 1. Shut the water heater down by pressing the UP button for Mode. five (5) seconds. Replace the flue sensor and grommet into the vent 2.

  • Page 79: Gas Valve Adjustment Procedure

    Installation & Service Manual Troubleshooting (continued) Gas valve adjustment procedure Models 400 -- 500 If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are Locate the throttle adjustment screw on the front of the gas model specific.) valve, see FIG.

  • Page 80: Diagrams

    Installation & Service Manual Diagrams Figure 13-1 Ladder Diagram 120 VAC SUPPLY INTEGRATED CONTROL X1-1 X1-6 BLOWER 3.15A JUNCTION BOX DHW PUMP PUMP CONTACTS X1-2 Lorem ipsum DHW PUMP DHW PUMP RELAY RELAY X4-3 24V DC SUPPLY X5-9 X5-1 120 VAC 24 VAC CONNECTION BOARD INTEGRATED...

  • Page 81: Wiring Diagram

    Installation & Service Manual Diagrams (continued) Figure 13-2 Wiring Diagram X2-1 VALVE X2-2 R/BK X5-4 OUTLET SENSOR X5-12 OUTLET SENSOR X5-6 PK/BK INLET SENSOR LWCO W/BK X5-5 FLUE SENSOR X5-13 FLUE SENSOR CONNECTION X5-14 X5-14 BOARD CN3-1 X5-2 CN3-2 CN3-3 X5-10 CN3-4 X5-11...
  • Page 82 Notes...
  • Page 83 Notes...
  • Page 84 Revision Notes: Revision A (PCP #3000038210 / CN #500026403) initial release. MM #100329111_DIR #2000585724 Rev A 04/20...

This manual is also suitable for:

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