Lochinvar 100 Series Installation & Service Manual
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Lochinvar 100 Series Installation & Service Manual

Indirect plate water heater
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100271422_2000527669_Rev C
Indirect Plate Water Heater
Installation & Service Manual
Double-Wall Models:
IPW015DW - IPW120DW
Series 100
⚠WARNING
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions
before installing. Perform steps in
LOW LEAD CONTENT
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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Summary of Contents for Lochinvar 100 Series

  • Page 1 100271422_2000527669_Rev C Indirect Plate Water Heater Installation & Service Manual Double-Wall Models: IPW015DW - IPW120DW Series 100 ⚠WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions before installing. Perform steps in LOW LEAD CONTENT the order given.

  • Page 2: Table Of Contents

    Contents HAZARD DEFINITIONS ..........2 8. START-UP PLEASE READ BEFORE PROCEEDING ..... 3 Introduction ............... 25 THE IPW -- HOW IT WORKS .......... 4 Pre-operational checks and procedures ......25 1. DETERMINE IPW LOCATION Initial start-up ..............25 Before locating the appliance, check: ........ 5 Checking mixed inlet temperature ........

  • Page 3: Please Read Before Proceeding

    Indirect Plate Water Heater Installation & Service Manual Please read before proceeding General information – Installer – Read all instructions, including ⚠WARNING this manual before installing. Perform This instruction manual provides detailed coverage for the steps in the order given. Indirect Plate Water Heater (IPW).

  • Page 4: The Ipw - How It Works

    Indirect Plate Water Heater Installation & Service Manual The IPW - How it works... 1. Control valve 6. DHW inlet The 3-way electronic control valve is powered by 24 VAC ANSI flanged connections (2" or 3" depending on model size) with which is received from the electronic control system control stainless steel piping that receives cold water from the DHW box.

  • Page 5: Determine Ipw Location

    Indirect Plate Water Heater Installation & Service Manual Determine IPW location Before locating the appliance, check: This appliance is certified as an indoor ⚠WARNING appliance. Do not install the appliance Check for nearby connection to: outdoors or locate where the appliance will •...

  • Page 6: Ipw Water Heater Clearances

    Indirect Plate Water Heater Installation & Service Manual Determine water heater location Figure 1-1 IPW Water Heater Clearances and Dimensions 24.00 24.00 24.00 24.00 DIR #2000577419 MODEL IPW015DW 55" 44" 15" 35.5" 10.5" IPW030DW 55" 52" 15" 35.5" 10.5" IPW050DW 55"...

  • Page 7: Prepare Water Heater

    The shipping carton should be inspected for damage incurred during transit prior to signing the bill of lading. Lochinvar is not responsible for lost or NOTICE damaged freight. The freight carrier must be notified immediately of any damage detected.

  • Page 8: Hydronic Piping

    Indirect Plate Water Heater Installation & Service Manual Hydronic piping IPW piping assemblies Heating fluid and Domestic Hot Water (DHW) piping The diameter of the piping assemblies furnished with the water heater will depend on the size of the heat exchanger The diameter of the heating fluid (hot boiler water) and DHW installed in the model ordered.

  • Page 9: Hydronic Piping Illustrations

    Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-2 Water to Water Heat Exchanger Single Unit BUILDING RETURN COLD WATER SUPPLY BOILER WATER OUT HOT WATER SUPPLY BOILER WATER IN DIR #2000577498 Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE...
  • Page 10 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-3 Water to Water Heat Exchanger Single Unit with Stratified Tank STRATIFIED HOT WATER STORAGE TANK RELIEF VALVE TANK HEIGHT TO DIAMETER RATIO 2:1 MIN., 3:1 PREFERRED TEMPERATURE GAUGE EXPANSION TANK HOT WATER SUPPLY PUMP...
  • Page 11 Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-4 Water to Water Heat Exchanger Multiple Units BOILER WATER HOT WATER SUPPLY TEMPERATURE GAUGE DIR #2000577546 BOILER WATER OUT COLD WATER SUPPLY 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 12 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-5 Water to Water Heat Exchanger Single Unit with Accumulator Tank RELIEF VALVE COLD WATER SUPPLY EXPANSION TANK ACCUMULATOR TANK BOILER WATER PUMP BOILER WATER BUILDING RETURN BALANCING VALVE FLOW INDICATOR TEMPERATURE GAUGE DIR #20005775360...
  • Page 13 Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-6 Multiple Units with Boiler Side Buffer Tank as a Zone AUTOMATIC AIR VENT ZONE SUPPLY BUFFER TANK ZONE RETURN IPW WATER HEATER ZONE PUMP DIR #2000577555 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 14 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-7 Multiple Units with Conventional Heating System as a Zone BOILER WATER IN HOT WATER SUPPLY BYPASS LINE BOILER WATER DIR #2000577549 COLD WATER SUPPLY 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 15: Adjustments

    (FIG. 4-1) and the IPW electronic control system. The control valve actuators are self-calibrating for all valve Prior to shipment from Lochinvar, control valve actuators are sizes; therefore, simply proceed as follows to automatically adjusted (auto-stroked) to ensure that they properly position...

  • Page 16: Manual Control Of 3-Way Valve

    Indirect Plate Water Heater Installation & Service Manual Adjustments Manual control of 3-way valve - removable handwheel 4. Set the control box POWER switch to the ON position to apply 24 VAC power to the control valve actuator (pins to hamper tampering 1 (G0) and 2 (G)).
  • Page 17 Indirect Plate Water Heater Installation & Service Manual Adjustments (continued) Ensure that the temperature controller is set to AUTO The control and the high limit are set at factory defaults. If (automatic) Mode and the AUTO indicator is lit. If the changes are required, the set point and high limit can be easily MAN indicator is lit, press the AUTO/MAN button to changed.

  • Page 18: Temperature Controller Operating Controls

    Indirect Plate Water Heater Installation & Service Manual Adjustments Table 4B Temperature Controller Operating Controls, Indicators and Displays CONTROL or INDICATOR MEANING FUNCTION Set Point SP for multiplier factory set at 0. Indicator Remote Set Illuminates when remote set point is active. Point Active Not used.

  • Page 19: Operating Information

    Indirect Plate Water Heater Installation & Service Manual Operating information Electronic control overview An electronic control system coupled with a control valve results in a highly responsive system which provides virtually The primary control mechanism for the electronic control constant hot water flow at the selected set point temperature. system is an electronic process controller which is installed in the control box.

  • Page 20: Wiring

    Energy Management System (EMS), Building Automation Section 11 of this manual. System (BAS), or computer. Proceed as follows: Lochinvar recommends that shielded, NOTICE Open the junction box on the side of the control box. twisted-pair...

  • Page 21: Modbus

    Indirect Plate Water Heater Installation & Service Manual ModBus Installation Procedure Turn OFF the main electrical power to the appliance. Open the control box door by loosening the screws clamping the door closed. Connect wires to the control following the diagram in Figure 7-1.

  • Page 22: Modbus Eexception Codes

    Indirect Plate Water Heater Installation & Service Manual ModBus ModBus Exception Codes MODBUS Exception Codes Code Name Meaning The function code received in the query is not an allowable action for the server (or slave). This may be because the function code is only applicable to newer ILLEGAL FUNCTION devices, and was not implemented in the unit selected.

  • Page 23: Primary Data Tables

    Indirect Plate Water Heater Installation & Service Manual ModBus (continued) Primary Data Tables Table Data Type Read / Write Input Registers 16-Bit Word Read Only Holding Registers 16 Bit Word Read / Write Memory Map Input Registers Address Description Default Unit Min.

  • Page 24: Procedure To Change Modbus Address

    Indirect Plate Water Heater Installation & Service Manual ModBus Procedure to change ModBus address Troubleshooting Press and hold Page ( ) until "Access Go To Should you encounter problems communicating over Level 1" appears. ModBus, the following items should be checked in this order: Press the button twice to get to Level 3.

  • Page 25: Start-Up Introduction

    Initial start-up In order to prevent a possible over-temperature condition This section provides the pre-optional checks, initial start-up during initial start-up, Lochinvar recommends that the and operating procedures for the IPW water heater. following steps be performed in the order specified: 1.

  • Page 26: Checking Mixed Inlet Temperature

    Indirect Plate Water Heater Installation & Service Manual Start-up Checking mixed inlet temperature Shutting down the system To shut down the IPW for a short period of time, simply turn If desired, the water heater mixed inlet temperature can be OFF power and close the isolation valves as described in Steps monitored using the controls and displays on the temperature 1 and 2 below.

  • Page 27: Maintenance Maintenance And Annual Startup

    Maintenance and annual startup The IPW water heater requires regular routine maintenance to keep the unit operating at optimum efficiency. Lochinvar recommends that the tasks listed in Table 9A - Scheduled Maintenance Actions, be performed at the periodic intervals specified.

  • Page 28: Periodic Cleaning Of Heat Exchanger

    Indirect Plate Water Heater Installation & Service Manual Maintenance Periodic cleaning of heat exchanger Check water heater relief valve For a detailed description of the following 1. Inspect the relief valve and lift the lever to verify flow. maintenance tasks, reference the CD provided with Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald the unit:...

  • Page 29: Troubleshooting

    Indirect Plate Water Heater Installation & Service Manual Troubleshooting Table 10A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - Check external line switch, fuse, or breaker. - Ensure On/Off switch is in the ON position. No 120 VAC supplied to the unit - Check 120 VAC through the On/Off switch.

  • Page 30: Checking Temperature Sensors

    Indirect Plate Water Heater Installation & Service Manual Troubleshooting Checking temperature sensors The temperature sensors (inlet and outlet water) are 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. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.

  • Page 31: Sizing Data

    Indirect Plate Water Heater Installation & Service Manual Sizing data How to Properly Size Your Indirect Plate Water Heater Table 11A Sizing Chart _ 60 - 120 DOMESTIC WATER INLET- BOILER WATER INLET TEMP DOMESTIC BOILER IPW MODEL OUTLET (°F) (°F) FLOW (GPM) PRESSURE LOSS (PSI)
  • Page 32 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11B Sizing Chart _ 60 - 140 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 33 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11C Sizing Chart _ 60 - 160 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 34 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11D Sizing Chart _ 60 - 180 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 35 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11E Sizing Chart _ 40 - 120 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 36 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11F Sizing Chart _ 40 - 140 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 37 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11G Sizing Chart _ 40 - 160 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.
  • Page 38 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11H Sizing Chart _ 40 - 180 NOTE: Highlighted items are limited by the maximum fl ow velocity through the piping.

  • Page 39: Diagrams

    Indirect Plate Water Heater Installation & Service Manual Diagrams Figure 12-1 Wiring Diagram - Electrical Control System Control Box...

  • Page 40: Replacement Parts List

    Indirect Plate Water Heater Installation & Service Manual Replacement parts list When ordering replacement parts: When ordering replacement parts always give the following information: Model, serial, and part number Kit number Parts description Replacement Parts List Item Parts Description Kit # Model 100271293 IPW015DW-070DW...
  • Page 41 Indirect Plate Water Heater Installation & Service Manual Notes...
  • Page 42 Indirect Plate Water Heater Installation & Service Manual Notes...
  • Page 43 Indirect Plate Water Heater Installation & Service Manual Notes...

  • Page 44: Revision Notes

    Revision Notes: Revision A (Process #3000002314_Change #500002513) initial release. Revision B (PCP# 3000003781 / CN# 500004056) reflects the addition of the Modbus chapter on pages 21 through 24. Revision C (PCP #3000035575 / CN #500024078) reflects updates made to the manual and the addition of the Series break. MM #100271422_DIR #2000527669_Rev C 10/19...

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