Lochinvar EFW 85 Installation, Commissioning, User And Maintenance Instructions
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Lochinvar EFW 85 Installation, Commissioning, User And Maintenance Instructions

Lochinvar EFW 85 Installation, Commissioning, User And Maintenance Instructions

Wall mounted gas fired condensing water heater
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EFW
Wall mounted gas fired condensing water
heater.
Installation, Commissioning, User and
Maintenance instructions
MODELS:
EFW 85
EFW 105
EFW 125
EFW 155

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Summary of Contents for Lochinvar EFW 85

  • Page 1 Wall mounted gas fired condensing water heater. Installation, Commissioning, User and Maintenance instructions MODELS: EFW 85 EFW 105 EFW 125 EFW 155...
  • Page 2 Document Control Article Language Version Date Modified by EcoForce Installation Instructions English 12-Oct-23 S Hunt...

  • Page 3: Table Of Contents

    OCATION OF VERSION NUMBERS ..................14 ECHNICAL SPECIFICATIONS DATASHEET ERP ..................15 ABLE TECHNICAL SPECIFICATIONS DIMENSIONS & CONNECTIONS ....................16 EFW 85 & EFW 105 ......................16 EFW 125 ........................17 EFW 155 ........................18 EFW 85 – 125 F ................19 PIGOT IMENSIONS 100 / 150 MM Coaxial flue spigot ..............
  • Page 4 ..................39 INIMUM REQUIRED PUMP HEAD ..................39 MAXIMUM ELECTRIC POWER 11 FLUE GAS AND AIR SUPPLY SYSTEM ..................40 ........................40 ENERAL ....................... 41 OLYPROPYLENE 11.2.1 Flexible polypropylene ..................41 ......................42 TAINLESS STEEL VENT ........................42 IR SUPPLY Combustion air quality ..................
  • Page 5 14.6.3 Menu’s and parameters ..................79 ........................80 ENERAL Pump start every 24 hours................80 14.7.1 14.7.2 Frost protection ....................80 ......................... 80 GNITION CYCLE Control functions ....................82 14.8.1 14.8.2 On board HMI and LED colors ................83 Flame detection ....................83 14.8.3 Flame recovery ....................
  • Page 6 21.2.2 Mounting the burner door................126 ....................3 NSTRUCTIONS FOR THE USER ........................3 ECYCLING 22 MAINTENANCE CHECKLIST ......................4 23 Spare parts ..........................5 24 USER’S PART ..........................6 ........................6 BBREVIATIONS ......................6 AFETY GUIDELINES ..................7 O TURN OFF GAS TO THE APPLIANCE ....................

  • Page 7: Introduction

    1 INTRODUCTION This manual has been written for: • The installer • System design engineers • Service engineers • End User READ AND UNDERSTAND THE INSTRUCTIONS Read and fully understand all instructions before attempting to operate maintain or install the unit. Regulations It is the law in the UK that a competent person registered with the HSE approved body and in accordance with the Gas Safety regulations installs all Gas appliances.

  • Page 8: Safety Guidelines

    The water heater should only be reset by a qualified service tech- nician after they have diagnosed and corrected the issue that caused the safety lockout of the water heater. Lochinvar Ltd recommends the installation of a carbon monoxide detector in the water heater room for all instal- lations.

  • Page 9: General Description Of Safety Symbols Used

    General Description Of Safety Symbols Used BANNED A black symbol inside a red circle with a red diagonal indicates an action that should not be performed WARNING A black symbol added to a yellow triangle with black edges indicates danger ACTION REQUIRED A white symbol inserted in a blue circle indicates an action that must be taken to avoid risk ELECTRICAL HAZARD...

  • Page 10: What To Do If You Smell Gas

    Do not re-enter the building until it is safe to do so Lochinvar Limited is not liable for any damage caused by inaccurately following these mounting instructions. Only original parts may be used when carrying out any repair or service work.

  • Page 11: Water Flow Velocity And Pump Selection

    Lochinvar Ltd is not liable for any damage caused by inaccurately following these instructions. Only Lochinvar Ltd parts may be used when carrying out any repair or service works.

  • Page 12: Safety Valve

    DO NOT apply a closing valve or any other form of narrowing between the water heater and the safety valve, be- cause this might disturb the correct functioning of the safety valve. Lochinvar will supply a correctly sized safety valve with the unvented kit for the complete system based on indi- vidual project requirements.

  • Page 13: Technical Data Efw Water Heaters

    4 TECHNICAL DATA EFW WATER HEATERS Functional introduction The EFW water heaters are water heaters with a maximum high efficiency. Such a performance can be reached by, amongst other things, using a special heat exchanger made of stainless steel. This allows the flue gases to cool down below the condensation point, and so release extra heat.

  • Page 14: Technical Specifications Datasheet

    Technical specifications datasheet GENERAL Product identification number: 0063CT3633 Gas Appliance Type B23(P), C13, C33, C43,C53, C63,C83, C93 C(10)3, C(11)3, C(12)3, C(13)3, C(14)3 ,C(15)3 Type boiler EFW 85 EFW 105 EFW 125 EFW 155 Classification UK II2H3P II2H3P II2H3P II2H3P Dimensions (h x w x d)

  • Page 15: Erp

    Type boiler EFW 85 EFW 105 EFW 125 EFW 155 ELECTRIC Maximum power consumption Power supply V/Hz 230 / 50 Protection class IPX4D NOTES Using propane, a restriction needs to be placed and the maximum fan speed needs to be reduced Min.

  • Page 16: Dimensions & Connections

    5 DIMENSIONS & CONNECTIONS EFW 85 & EFW 105 Twin Pipe Concentric Connections Twin Pipe Concentric Hot water Outlet BSP 1” Cold water Inlet BSP 1” Condensate Flexible hose Ø 25 / 21 mm BSP ¾” E / F Flue gas / Air inlet...

  • Page 17: Efw 125

    EFW 125 Twin pipe Concentric Connections Twin Pipe Concentric Hot water Outlet BSP 1” Cold water Inlet BSP 1” Condensate Flexible hose Ø 25 / 21 mm BSP ¾” E / F Flue gas / Air inlet 100 / 100 mm 100 / 150 mm E93.1804.014...

  • Page 18: Efw 155

    EFW 155 Twin pipe Connections Twin Pipe Hot water Outlet BSP 1¼” Cold water Inlet BSP 1¼” Condensate Flexible hose Ø 25 / 21 mm BSP 1” E / F Flue gas / Air inlet 150 / 150 mm E93.1804.014...

  • Page 19: Efw 85 - 125 Flue Spigot Dimensions

    EFW 85 – 125 Flue Spigot Dimensions 5.4.1 100 / 150 MM C OAXIAL FLUE SPIGOT Unit outside inside insert [mm] [mm] [mm] [mm] EFW 85, 105, 125 100 + 0.3 / - 0.7 101 + 0.3 / - 0.3...

  • Page 20: Efw 155 Flue Spigot Dimensions

    EFW 155 Flue Spigot Dimensions 5.5.1 2 X 150 MM T WIN FLUE SPIGOTS Unit outside inside insert [mm] [mm] [mm] [mm] EFW 155 150 + 0.3 / - 0.7 151 + 0.5 / - 0.5 EFW 155 150 + 0.9 / - 0.9 E93.1804.014...

  • Page 21: Cascade Frames

    Cascade frames Frames for two, three and four water heaters. +50 / -5 Twin pipe EFW85 / EFW105 / EFW125: 1875 +50 / -5 Twin pipe EFW155: 1916 +50 / -5 Concentric EFW85 / EFW105 / EFW125: 1821 E93.1804.014...

  • Page 22: Cascade Frame Dimensions

    5.6.1 ASCADE FRAME DIMENSIONS E93.1804.014...

  • Page 23: Accessories And Unpacking

    (At the burner controller) Bottom part of the condensate drain assembly (packed into an additional box) A matched circulating pump is available and will be quoted by Lochinvar alongside the water heater, it is NOT included with the water heater.

  • Page 24: Installation Location Of The Efw

    If not, it is recommended to mount the water heater by means of a (cascade) stand available from Lochinvar. Locate the equipment so that if the appliance or any connecting pipework should leak, water damage will not occur.

  • Page 25: Water Heater Installation Location Requirements

    Water heater Installation Location Requirements: • The ventilation of the water heater room must meet local and national standards and regulations, re- gardless of the selected supply of fresh air to the water heater. • The flue gas pipes must be connected to the outside wall and/or the outside roof. •...
  • Page 26 Lock the suspension bracket with the security cover before making any other connections to the water heater. This secu- rity cover will prevent the wa- suspension ter heater from falling off the detail bracket. Do not use excessive force during the mounting of the water heater connections.

  • Page 27: Connections

    8 CONNECTIONS Tank positioning The tank must be placed on a stable floor, not too far from the water heater(s). The floor must be able to hold the weight of the storage vessel(s) filled with water. Water heater connections 1 – Hot Water / Supply 2 –...

  • Page 28: Non-Return Valve

    The condensate trap must al- ways be filled to the edge with water, before replacing to the unit. Non-Return valve All water heaters have a non-return valve installed in the gas-air mixing pipe just before the burner. Flue gas re- circulation is prevented by the non-return valve.

  • Page 29: Water Quality

    Water quality In direct water heating appliances, the water flows directly through the heat exchanger of the water heater. Because all the time fresh water, containing dissolved minerals, is heated, scaling may occur. To prevent this, water quality must meet a number of standards. The water must meet the specifications be- low: Water temperature max.

  • Page 30: Water Pressure

    16-17 of the control board. The Flowswitch must be commissioned correctly to ensure the water heater only fires when full flow at a ΔT of 16.5 has been achieved. Lochinvar will always quote a suitable Flowswitch item number LM900442P which is suitable for pipework sizes up to 6” diameter.

  • Page 31: The Efw Sanitairy System: Installation Instructions

    *(see table 3) NB! An X in the pump table does not necessarily mean that the corresponding installation cannot be built. If it can, it will need specific design effort and pump selection. Please consult Lochinvar technical support for advice.

  • Page 32: Stand-Alone Configuration

    Table 3: Pump types Stand-alone configuration EcoForce water heaters must always be installed with a suitable buffer vessel and bronze shunt pump; suitable bronze shunt pumps and buffer vessels will always be quoted alongside the EcoForce water heater. Failure to install a suitable bronze shunt pump, buffer vessel, and flow switch will render all warrantees on the EcoForce water heater null and void.

  • Page 33: Cascade Set-Up

    Cascade set-up EFW water heaters and tanks can be installed cascaded in a number of possible combinations according to the instructions below. For the installation of cascaded water heaters and tanks always consult your supplier. All requirements concerning pipe diameters and lengths and pump selection have to be calculated. By doing so you’ll improve the functioning and the life time of your HW installation.

  • Page 34: Cascade Calculations

    Diameters D1 ( = Connections to water heater flow/return) (42 x 1.5 = Outside diameter mm x wall thickness mm e.g.) ΔT = 16.5°C ΔT = 12.5°C EFW 85 421.5 EFW 105 421.5 EFW 125 541.5 EFW 155 541.5...
  • Page 35 : single boiler and tank, see paragraph 8.1.1 for pipe lengths. - : A - in the table doesn’t necessarily mean that the corresponding installation cannot be built. If it can, it will need specific design effort and pump selection. Please consult Lochinvar technical support for advice. E93.1804.014...
  • Page 36 If your installation is outside the scope of this guidance, please contact Lochinvar Technical support before proceeding with the installation.

  • Page 37: Heat Exchanger Resistance Graphs

    10 HEAT EXCHANGER RESISTANCE GRAPHS Resistance graph EFW 85 Resistance graph EFW 85 ∆T=12.5 °C ∆T=16.5 °C Flowrate [ m Flowrate [m /h ] Resistance graph EFW 105 Resistance graph EFW 105 ∆T=12.5 °C ∆T=16.5 °C Flowrate [m Flowrate [ m /h ] E93.1804.014...

  • Page 38: Resistance Graph

    Resistance graph EFW 125 Resistance graph EFW 125 ∆T=12.5 °C ∆T=16.5 °C Flowrate [ m Flowrate [m /h ] Resistance graph EFW 155 Resistance graph EFW 155 ∆T=12.5 °C ∆T=16.5 °C Flowrate [ m Flowrate [m /h ] E93.1804.014...

  • Page 39: Minimum Required Pump Head

    Normally, an extra 2 m.WC of head is sufficient to overcome the resistance of the pipes and tank. Water heater at flow min. required head min. required head for ΔT = 16.5 °C rate for water heater installation: +2 m.WC [m.WC] [m.WC] EFW 85 4.26 5.45 7.45 EFW 105 5.08 5.65 7.65 EFW 125 6.23 5.54 7.54...

  • Page 40: Flue Gas And Air Supply System

    11 FLUE GAS AND AIR SUPPLY SYSTEM General The water heater has a positive pressure flue system. For a single water heater, the available combined pressure drop for the inlet and outlet system is 200 Pa for the complete water heater range. The EFW water heater is for either using outdoor combustion air or for installation using indoor combustion air.

  • Page 41: Polypropylene

    In general, water heaters are certified with their own flue gas material. The water heater must be provided with high efficiency stainless steel or PP flue gas components available at the Lochinvar Ltd. The parts have to be qual- ified for a overpressure class P1 or H1 and a temperature class of T120 minimum.

  • Page 42: Stainless Steel Vent

    Stainless steel vent. This product has been approved for use with stainless steel using the manufacturers listed. Use only the materials and vent systems listed. DO NOT mix vent systems of different types of manufacturers. Failure to comply could result in severe personal injury or substantial property damage. Installations must comply with all applicable laws and regulations Air supply When an air supply duct is connected from the outside of the building to the water heater, the water heater will...

  • Page 43: Air Contamination

    11.5.1 IR CONTAMINATION Pool and laundry products and common household and hobby products often contain fluorine or chlorine com- pounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the water heater wall, causing serious damage and presenting a possible threat of flue gas spillage or water leakage into the building.

  • Page 44: Flue Terminal Locations

    Flue terminal locations EFW85 EFW105 EFW125 EFW155 Location Description 2500 2500 2500 2500 Directly below an opening, air brick, opening windows etc. 1145 Above an opening, air brick, opening windows etc. 1145 Horizontally to an opening, air brick, opening windows etc. Below a gutter or sanitary pipework Below the eaves Below a balcony or car port roof...

  • Page 45: Water Heater Categories - Types Of Flue Gas Systems

    Water heater categories - types of flue gas systems. Type according EN 15502-2-1: 2012 Performance Description B23(P) * Roof terminal flue outlet Open * Without draught diverter Air supply from * Water heater room air supply. room * P = overpressure systems See: Typical examples - example C Notice: The installation room has to have special...
  • Page 46 Closed Type C43. A type C4 appliance incorporating a fan Air supply upstream of the combustion chamber/heat ex- from outside changer. EHS.D0500.5010.400 Closed * Separate air supply duct Air supply * Separate flue gas discharge duct. from outside * Air supply inlet and flue gas outlet at different Flue outlet air pressure zones.
  • Page 47 C63 - example Closed * Appliance sold without flue/air-inlet ducts Air supply * The flue gas parts are not part of the boiler. The from outside water heater is intended to be connected to a sep- Flue outlet arately approved and marketed system for the roof terminal supply of combustion air and discharge of combus- Air inlet...
  • Page 48 Type C93 . A type C9 appliance incorporating a Air supply fan upstream of the combustion chamber/heat- from outside exchanger. Minimum required diameter/ cross section area: boiler diameter area EFW 85, 105, 125 100 mm 7854 mm EFW 155 150 mm 17671 mm E93.1804.014...
  • Page 49 C10(3) Closed or open Over pressure common flue system: Air supply from * Flue gas discharge through individual or shared out-side or room flue ducting built into the building. * Air supply inlet and flue gas outlet * Condensate is not allowed to go to the boiler. * Technical data: nominal T 85 °C...
  • Page 50 C(12)3 Closed Air supply Over pressure common flue system: from outside * Flue gas discharge through individual or shared flue ducting built into the building. * Air supply inlet and flue gas outlet * Condensate is not allowed to go to the boiler. * Technical data: nominal T 85 °C...
  • Page 51 C(15)3 Closed Air Over pressure common flue system: supply from * Flue gas discharge through individual ducting outside built into the building. * Air supply inlet and flue gas outlet * Condensate is not allowed to go to the boiler. * Technical data: nominal T 85 °C...

  • Page 52: C63 Certified

    C63 certified. The heater is C63 certified. This means that flue gas and air supply parts can be selected which have a separate CE marking according the building products regulations. These parts must be able to handle condensate forming (W) and transport, overpressure (P1) and must have a minimum temperature class of T120.

  • Page 53: Flue Gas And Air Supply Resistance Table

    In the next section, for six typical flue gas outlet & air inlet configurations the maximum lengths of the straight pipes will be calculated. First all component resistance values are given in the next table: PARALLEL EFW 85 EFW 105 EFW 125...

  • Page 54: Typical Examples

    NOTE: specific resistance values are used in this example. Flue and air pipes of other suppliers can have other values Note: The resistance values used are for Lochinvar supplied M&G flue pipe only, flue supplied via third parties will have different resistance values. E93.1804.014...

  • Page 55: Example B: Twin Pipe System With Concentric Roof Terminal

    The total resistance is more than 200 Pa. This flue gas / air supply system is NOT functional. Note: The resistance values used are for Lochinvar supplied M&G flue pipe only, flue supplied via third parties will have different resistance values. E93.1804.014...
  • Page 56 Concentric roof terminal Flue outlet Air inlet concentric/ parallel adaptor Example B Example A Example A (C63) water heater type → EFW 85 EFW 105 EFW 125 EFW 155 Diameter air pipe [mm] Diameter flue pipe [mm] Diam. roof terminals...

  • Page 57: Example C: Single Flue Gas Outlet. Air Supply From Water Heater Room

    Flue and air pipes of other suppliers can have other values FLUE OUTLET VENTED AREA AIR INLET AIR INLET EXAMPLE: C Example C (B23, B23P) water heater type → EFW 85 EFW 105 EFW 125 EFW 155 Diameter air pipe [mm] Diameter flue pipe [mm] Diam.

  • Page 58: Example D: Concentric Flue Gas/Air Supply Pipe (Roof-Mounted)

    11.12.4 E D: C XAMPLE ONCENTRIC FLUE GAS AIR SUPPLY PIPE ROOF MOUNTED Calculation example with given lengths: checking resistance. Water heater type: EFW 85 Diameter: 100/150 mm. Number Pa total Straight tube m total 31.9 Bend 45° 12.8 Bend 90°...
  • Page 59 Examples D and E maximum pipe lengths CONCENTRIC ROOF TERMINAL CONCENTRIC WALL TERMINAL EXAMPLE: D EXAMPLE: E Example D (C33) water heater type → EFW 85 EFW 105 EFW 125 EFW 155 Diameter concentric pipe [mm] 100/150 Concentric roof terminal [mm] 100/150 POSSIBLE...

  • Page 60: Example F: Separate Air Supply Duct & Flue Duct In Different Pressure Zone (C53)

    Flue and air pipes of other suppliers can have other values. FLUE OUTLET Example F maximum pipe lengths AIR INLET EXAMPLE: F Example F (C53) boiler type → EFW 85 EFW 105 EFW 125 EFW 155 Diameter wall terminal [mm] Diameter air pipe...

  • Page 61: Common Flue Cascading

    12 COMMON FLUE CASCADING C10 Common flue gas systems. WARNING: If other than M&G flue gas materials are used, please contact your boiler supplier. If using C10 flue gas system for a so called “CLV” system the following must be applied: A data plate shall be present on the connection interface to the common flue duct.
  • Page 62 Ad 2. CO detection and switch off module: Use a CO detection system which has an alarming and switching module. Use a switching module that has an Normally Closed (N.C.) contact. The water heater safety loop will be extended with the CO detectors by connect- ing the N.C.

  • Page 63: Existing Common Venting Guidelines

    • Power mode 1: Power control algorithm to have a minimum number of heaters/heaters active. • Power mode 2: Power control algorithm to have a maximum number of heaters/heaters active. • Power mode 3: Power control algorithm to have a balanced number of heaters/heaters active. Ad 4.

  • Page 64: Electrical Installation

    13 ELECTRICAL INSTALLATION General • For operation, the water heater needs a power supply of 230 VAC/ 50Hz. • The wiring for the connections can be entered at the bottom of the water heater through the cable glands. • NOTICE: Before starting to work on the water heater, it must be switched off and the power supply to the water heater must be disconnected.
  • Page 65 High power ignitor A separate connector for an external igniter is located on the cable tree, near the water heater controller and labelled "High power ignitor". The "external ignition transformer" can be ordered, see § 5.1 "Accessories". This accessory is provided with detailed mounting instructions. E93.1804.014...

  • Page 66: Explanation Of The Low Voltage Connections

    Explanation of the low voltage connections. DO NOT USE Do not connect wires to these terminals SYSTEM SENSOR It is mandatory for single and cascaded heaters to use also a pipe strap-on system sensor besides the tank sensor. This system sensor has to be connected to connections 3-4 “System Sensor” (Cascaded heaters need one system sensor connected to the managing boiler only.) DHW SENSOR The tank sensor can be mounted in a bulb in the tank or glued to the tank dependent on the used type of sensor.

  • Page 67: Explanation Of The Mains Voltage Connections

    Explanation of the mains voltage connections. 1-2-3-PE DO NOT USE Do not connect wires to these terminals 4-5-PE DO NOT USE Do not connect wires to these terminals 6-7-PE GENERAL or WATER HEATER PUMP Connections for the power supply of a water heater pump. (P1, see chapter 9.6 for detailed electrical specifications). 8-9-PE-PE MAINS SUPPLY The power supply connection of the unit.

  • Page 68: Electrical Schematics

    Electrical schematics E93.1804.014...
  • Page 69 E93.1804.014...

  • Page 70: Ladder / Logic Diagram

    Ladder / Logic diagram MAINS VOLTAGE VOLTAGE AL-bus power E93.1804.014...

  • Page 71: Sensor Availability

    Sensor availability The following table shows the sensor availability for all DHW control modes. Sensors not mentioned in the table are optionally available for other functions DHW Mode 0 N.A. 2 N.A. 3 N.A. 4 N.A. 5 N.A. 6 N.A. 7 N.A.
  • Page 72 para- Display: INPUTS: para- Display: OUTPUTS: re-mark meter mark meter (117) Prog. Input 2. 0 Disabled (127) Prog. Output 3. 0 Disabled 1 DHW flow sensor N.A. 1 Module pump N.A. 2 DHW flow switch 2 CH pump N.A. 3 CH flow sensor N.A.

  • Page 73: Display And Buttons

    14 DISPLAY AND BUTTONS. 13:56 Standby T3:40 °C 3.7 bar 50 °C DHW Store Setpoint Display and buttons ON/OFF. On/off switch. Switches electrical power to the boiler. COMPUTER. Connector for computer cable RESET. Reset lockout error MENU. Enter the main menu ESCAPE.

  • Page 74: Display Configuration

    Display configuration. The Status overview has the three different sections that show specific information: Header Middle section Footer DHW Control Enabled An example of the Status overview and the different sections Header Left: For cascade systems the cascade icon is shown, with the cascade manager indication (M) or the de- pendent number.

  • Page 75: Starting The Water Heater

    Starting the water heater If the water heater is not on make sure the gas switch beneath the water heater is open and the power cord is connected to the mains, use the on/off button to switch the water heater on. The following screen will occur: This screen is active during power up until communication with the main Control has been established.

  • Page 76: Protected Menu Items

    14.3.3 ROTECTED MENU ITEMS The display supports 3 different access levels; each with its own set of available menu items/parameters: Level Description 0: User Basic info and settings only that are accessible for everyone. 1: Installer Advanced information and settings; only to be accessed by an experienced installer/person. 2: Factory Highest level information and settings, only available/relevant for factory Engineers.

  • Page 77: Change Language Via The Menu

    The following paragraph describes how to change the display language. No matter which language you have set, the menu icons will always remain universal. 14.3.6 HANGE LANGUAGE VIA THE MENU 1. From the Status Overview, press the MENU button once 2.

  • Page 78: Error Logging

    Error logging. Error logging is available. This functionality is linked to the Real-Time Clock functionality. Errors will be logged for a stand-alone system or for a complete cascade system (based on the cascade settings). The PB display will monitor the error codes it receives from the water heater(s) and if an error code is a new error code the error will be stored in the error log.

  • Page 79: Service Reminder

    Service reminder The Service reminder will remind the owner/user of the appliance to service the appliance at a specified "Service Interval", factory set on 2000 burn hours. When service is not done within this time, a service reminder will be shown on the screen: "Service is required!", alternating with the normal status display.

  • Page 80: General

    General The water heater controller is designed to function as a standalone control unit for intermittent operation on heat- ing appliances with a premix (modulating) burner and a pneumatic air-gas system. Mains input 1 x 5AT, 230V Fuses Flame establishing period 2 seconds 5 seconds Safety time...
  • Page 81 Burner state Actions ▪ INIT Controller initialization ▪ RESET Software reset (and initialization) ▪ STANDBY Standby (waiting for demand) ▪ Fan is not running PRE_PURGE_0 ▪ When an APS is enabled the APS position is checked ▪ Fan starts at ignition speed PRE_PURGE_1 ▪...

  • Page 82: Control Functions

    14.8.1 ONTROL FUNCTIONS Dependent on the required functions of the appliance and connected sensors and com- ponents, several operation modes for Cen- tral Heating (CH) and Domestic Hot Water (DHW) can be selected, which are de- scribed hereafter. The demand controls all work according to a defined state machine.

  • Page 83: On Board Hmi And Led Colors

    14.8.2 N BOARD COLORS On the burner controller a basic on-board Human Interface (HMI) is available which consists of a push button and a 2 color (red/green) LED. These are used to indicate basic status information about the control. Status LED Reset button 900MN Control operational...

  • Page 84: Demand For Domestic Hot Water

    Demand for Domestic Hot water 14.9.1 DHW S ; DHW TORAGE WITH BULB AND STRAP ON SENSOR MODE Only use DHW mode 1 for a standalone water heater and for a Cascade water heater. Do not use another DHW mode because the water heater will not work properly. Also, the heater must be programmed as managing heater and a system sensor is needed next to a DHW sensor.

  • Page 85: Anti-Legionella Protection

    If the supply temperature T_Supply is below DHW_Store_Setpoint plus DHW_Tank_Supply_Extra minus DHW_Tank_Supp_Hyst_Dn the heater is started as well. The power is PID-modulated so T_Supply is regulated towards the DHW_Store_Setpoint plus DHW_Tank_Supply_Extra. DHW_Tank_Supply_Extra is default set to 0⁰C because the supply temperature of the water is almost the same as the tank temperature.
  • Page 86 Every time an Anti-Legionella demand has ended the Anti_Legionella_Active_Counter is incremented to indicate how many Anti-Legionella actions have been performed. Also the Anti_Legionella_Wait_Time is started to delay the next Anti-Legionella cycle. The anti-legionella demand has priority over any DHW demand. However, when the anti-legionella protection is active and there is no heat or burn demand because the Anti_Legionella_Sensor is already at a high enough tem- perature DHW demand will be accepted as normal.

  • Page 87: Display Menu Structure Summary

    Display menu structure summary. Menu structure Display: Access Description: level 1. Central Heating (CH) User Enter the Central Heating (CH) menu 2. Domestic Hot Water (DHW) User Enter the Domestic Hot Water (DHW) menu 3. Information User Enter the Information menu 4.
  • Page 88 3.2 Boiler status min. max. Default unit Access Description: level Flow Temperature °C User Actual supply flow temperature Flow 2 Temperature °C User Actual supply 2 flow temperature Return Temperature °C User Actual return temperature DHW Temperature °C User Actual DHW temperature DCW Temperature °C User...
  • Page 89 4.1.1 Language min. max. Default unit Access Description: level English User Select the English language Italiano User Select the Italian language Pусский User Select the Russian language Hrvatski User Select the Croatian language 中文 User Select the Chinese language Français User Select the French language Español...
  • Page 90 4.1.5 Other settings min. max. unit Access Description: fault level Status Overview Settings User Configure which information is shown on the Status overview Modbus Address 0…255 User Select the Modbus communication ad- dress Modbus Stop bits 1 – 2 User Select the number of Modbus communi- cation stop bits 4.1.5.1 Status Overview...
  • Page 91 Design Supply ⁰C Installer Set the outdoor reset curve minimum set- Min. Limit point Design Supply ⁰C Installer Set the outdoor reset curve maximum set- Max. Limit point Warm Weather ⁰C Installer Set outdoor temp. above CH demand is Shutdn blocked Boost Temp Incre- ⁰C...
  • Page 92 cont.: 4.2.1 Boiler min. max. Default unit Access Description: Display parameters level DHW Instant PID P 1275 Installer Set the DHW instantaneous PID P factor DHW Instant PID I 1275 Installer Set the DHW Instantaneous PID I factor DHW On Off Period Installer Set the on/off modulation period PreHeat mode...
  • Page 93 4.2.2 Module Cas- min. max. Default unit Access Description: Display cade Settings level Burner Address Manag- Installer Set the cascade burner address Permit Emergency Installer Enable/disable the cascade Mode emergency mode Emergency Setpoint °C Installer Set the emergency mode setpoint Delay Per Start Next 1275 sec.
  • Page 94 4.2.3 Boiler Cascade min. max. Default unit Access Description: Display Settings level Boiler Address stand- Set the cascade boiler address alone staller Permit Emergency Enable/disable the cascade Mode staller emergency mode Emergency Setpoint °C Set the emergency mode setpoint staller Delay Per Start Next 1275 1275...

  • Page 95: Temperature Protection

    15 TEMPERATURE PROTECTION The difference between Supply temperature and Inlet Temperature is continuously monitored. A too big difference can indicate a defective pump or a clogged heat exchanger. To protect the water heater, the burner controller re- duces the input when the temperature difference ΔT becomes too high: At maximum water heater input ΔT is limited to 18 °C In between 18 °C and 26 °C water heater input modulates between minimum and maximum.

  • Page 96: Lockout Codes

    Lockout codes Lock- Error Description Cause Solving code EEPROM Internal software error wrongly programmed BCU reset BCU or replace BCU and / or Read Er- or PB display unit Ignition Five unsuccessful ignition at- no gas, wrongly adjusted check gas supply and adjust gas Error tempts in a row gas valve...
  • Page 97 Lock- Error Description Cause Solving code Stack Error Internal software error wrongly programmed reset BCU or replace BCU and / BCU or PB or display unit Instruction Error Internal software error wrongly programmed reset BCU or replace BCU and / BCU or PB or display unit Ion Check Failed...

  • Page 98: Blocking Codes

    Blocking codes Blocking Error Description Cause Solving code WD Error Internal software error wrongly pro- reset BCU or replace BCU and grammed BCU or PB / or display unit WD Error Internal software error wrongly pro- reset BCU or replace BCU and grammed BCU or PB / or display unit WD Error...
  • Page 99 Blocking Error Description Cause Solving code T DHW Open DHW sensor open malfunctioning DHW check connection to BCU or sensor or not con- check resistance NTC sensor Cascade System: Depending nected boilers parameter 35 “DHW Modify parameter 35 (DHW Mode” not changed to 0 Mode) to 0 of depending boil- ers only T Flue Open...

  • Page 100: Warnings

    Warnings Warning Error Description Cause Solving Comm. Lost with Cascade System: Managing cas- connection between Check wiring between boiler or module cade control lost communication cascaded boilers is distance between boilers is to with one of the depending. interrupted or wiring is broken or parame- or set parameter 147.

  • Page 101: Cascading

    Lockshield Valve Cascade control can han- Expansion Vessel dle up to 16 water heaters. Tundish For further advice contact Lochinvar technical sup- Expansion Valve port Temperature & Pressure Relief Valve Pump Tank Temperature Sensor Strap on Temperature Sensor...

  • Page 102: Quick-Guide Cascade Set-Up

    Quick-guide cascade set-up Below a quick set-up, all settings are described in detail in the successive chapters Link the boilers with a 2-wire cable in parallel. Connect 20 on the managing boiler to 10 on the dependent boilers and connect 21 on the managing boiler to 11 on the dependent boilers.

  • Page 103: Water Heater Cascade Communication Setup

    Water heater cascade communication setup. In order for the system to work for cascade the communication busses must be parallel linked together. The man- aging water heater uses the AL-bus connection 20-21 for the cascade. The depending water heaters must be con- nected to the managing water heater on the 10-11 connection terminals.

  • Page 104: Setting Of The Cascade Parameters

    The bus power is provided by the managing water heater on terminals 20-21, switch S1 must be set in the OFF position (all controls). 17.3.2 ETTING OF THE CASCADE PARAMETERS 1.Enter the main menu by pushing the menu button 2. Now select Boiler Settings and enter the right now select settings by toggling the up and down password to continue.

  • Page 105: Cascade - Depending Water Heater

    Cascade_Setpoint temperature. Water heater input Rates A cascade system operates most effective and efficiently when all of the water heaters in the system are the same type. (so all EFW 85 e.g.) 17.3.4 – D...

  • Page 106: Next Module To Start Selection

    17.4.1 EXT MODULE TO START SELECTION When the cascade Module_Rotation_Interval has passed the control will perform the cascade rotation. At this moment the next available control based on the current First_Module_To_Start is selected. A depending control is available when the control is present on the communication bus and the control is not blocked by an error.

  • Page 107: Loss Of Cascade Communication

    For proper functioning of this emergency mode, the following settings are necessary in the managing water heater (installer password required): - Module Cascade parameter no. 72: "Permit_Emergency_Mode" has to be set on "yes". - Module Cascade parameter no. 74: "Emergency_Setpoint" has to be set on the right temperature. - Water heater parameter no.

  • Page 108: Commissioning The Water Heater

    19 COMMISSIONING THE WATER HEATER First: flushing the water heater with water After installation of the water heater the first step, before commissioning, is to flush the water heater and the whole installation with fresh water to remove pollution, debris and other materials that might cause a blocking. This must also be done with installations, where only the water heater is replaced.

  • Page 109: Checking Gas Pressure

    When the water heater receives a heat demand the burner controller will start the operation of the water heater. Before the water heater is used, the water heater must be adjusted and set at the minimum and maximum load. Checking gas pressure Check the gas pressure available at the gas connection of the water heater.

  • Page 110: Adjusting And Setting The Water Heater

    Gas type: natural gas G20 propane G31 Heater type max load min load max load min load EFW 85 6.0 / 8.4 6.9 / 7.9 4.9 / 10.5 6.7 / 9.3 EFW 105 6.0 / 8.4 6.9 / 7.9 5.2 / 10.3 6.7 / 9.3...

  • Page 111: Setting Screws Venturi- And Gas Valves: Drawings

    20.1.2 ETTING SCREWS VENTURI AND GAS VALVES DRAWINGS Location of the setting screws: Gas pressure High Fire: nipple [3] screw [2] Low Fire: screw [1] High Fire: venturi adjustment screw: use hex key 4 mm (Allen key 5/32) High Fire: screw [2] Low Fire: gas valve adjustment screw: Torx T40.

  • Page 112: Adjustment Procedures

    Adjustment procedures Procedure 1: adjust at High Fire Carry out the next steps: 1. From status screen, press MENU . → "Central Heating/ Information/ Settings/ System Test" 2. Press UP/DOWN ↑↓ to select "System Test" Press CONFIRM 3. Password needed to continue 4.

  • Page 113: Venturi Replacement Adjustment

    6. Confirmation: apply the propane sticker and mark the boxes. 1. Check the heater model. Check if you have a EFW 85, 105, 125 or 155 water heater. The model number is on the data plate, on the inside of the boiler casing, top side.
  • Page 114 Installing the orifice (see also picture): Required tools: wrench 55, hex key 5 mm and hex key 4 mm. 1. Close the external gas shutoff valve and disconnect the electrical power before opening the heater. 2. Use a wrench to open the coupling in the gas line in the heater. The three screws, with which the venturi is mounted onto the fan, can now be removed.
  • Page 115 The fan speed has to be changed in the software of the water heater according to the tables below: Water heater Fan speed high fire Fan speed low fire type parameter 92 parameter 93 Propane G31 Nat. gas Propane G31 Nat. gas EFW 85 6500 7400 1850 1800 Internal EFW 105 7300 7900 2000 1900...

  • Page 116: Start Up Checklist

    Start Up Checklist Installer information Company Engineer name Address Postal code City State/province Telephone number Site information Site name Site contact (owner/end user) Address Postal code City State/province Telephone number Water heater information Model Serial number Installation date Cascade installation (Y/N) (YES / NO) Number of heaters Type of heaters in cascade...
  • Page 117 Condensate Drain Check the level of the heat exchanger; It must have a slight angle from the rear to ensure that the condensate drains from the heat exchanger. Condensate trap (from package) installed according installation manual? Inside diameter of drain piping Is there a definite air gap between the condensate trap and the connection to drain pipe? Total drop in height from water heater to drain piping exit point Any additional trap points?
  • Page 118 Voltage incoming (Hot to Ground) Voltage measured between Ground and Neutral Total of amperage switched by the Water heater Controller is below 3.5 A or 800 W Additives Used chemical additions Mixing Ratio When complete send a copy of this form to info@lochinvar.ltd.uk E93.1804.014...

  • Page 119: Inspection, Maintenance And Service

    21 INSPECTION, MAINTENANCE AND SERVICE. General For a good, safe and long-time operation of the water heater and to maintain warranty it is mandatory to carry out inspection, maintenance and service on the water heater at least once a year. Inspection, maintenance and service of the water heater should also be carried out on the next occasion •...
  • Page 120 The non-return valve is placed directly after the fan and has to be replaced once every five years during mainte- nance. For EFW 85, 105 and 125: Replace the non-return valve by removing the 4 nuts that are holding the fan.
  • Page 121 Burner Check the burner surface to see if it has damages, signs of rust and/or cracks. When the burner surface is damaged the burner must be replaced. The burner can be cleaned by using a soft (non-metallic) brush. The dust can be removed with a vacuum cleaner or pressurized air.
  • Page 122 Fiber braid replacement If the high temp braided rope has discolored or is damaged, it has to be replaced by new braids using the method described below. The high temp braided rope is attached to the burner door by silicone glue. - Remove the braids by sliding under the periphery a thin tool to loosen the braids and remove it.
  • Page 123 Insulation The insulation of the heat exchanger (located on the rear wall inside the heat exchanger and burner door) must be inspected. If this insulation disc shows any signs of (water) damage or degradation it must be exchanged. Also check if there are any indications in the burner room of a high condensate level (caused by a blocked condensate trap) that might have wetted the rear wall insulation.
  • Page 124 Install the new insulation: 1. put two dots of temperature-resistant silicone glue, (Loctite 5366 or Otto 2. seal S17), according to the location indicated. 3. make sure that the burner is in proper condition, remove any possible 4. insulation residues on the burner 5.

  • Page 125: Decalcifying Of The Heat Exchanger

    When faults and abnormalities are found by the service technician during service and maintenance and these are not repairable, this information should be reported to the owner/end-user of the installation. Also the owner/end-user should be advised how to fix these faults and these faults should be reported in the service report / log file of the water heater.

  • Page 126: Mounting The Burner Door

    Tighten in given order. 21.2.2 OUNTING THE BURNER DOOR torque value = 8 Nm IMPORTANT: Before mounting the burner door, make sure that its gaskets and insulation are in excellent shape. If any signs of damage or ageing are present, these parts must be replaced.

  • Page 127: Instructions For The User

    When done servicing the service reminder can be reset, see § 13.6 on pages 81/82. Instructions for the user. After installing and commissioning of the water heater, demonstrate the operation of the entire water heating system to the end-user. The user should be made familiar with all safety precautions of the water heater and the installation.

  • Page 128: Maintenance Checklist

    22 MAINTENANCE CHECKLIST Allowing the water heater to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as required by the manual and dictated by the operating location could result in water heater failure, property damage or personal injury. Such product failures ARE NOT covered under warranty Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently.

  • Page 129: Spare Parts

    23 Spare parts A full spare parts list is available at www.lochinvar.ltd.uk...

  • Page 130: User's Part

    The water heater should only be reset by a qualified service technician after he has diagnosed and corrected the issue that caused the safety lockout of the water heater. Lochinvar Ltd recommends the installation of a carbon monoxide detector in the water heater room for all instal- lations.

  • Page 131: To Turn Off Gas To The Appliance

    Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury (exposure to hazardous materials)* or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler.

  • Page 132: Display And Buttons

    Display and buttons 13:56 Standby T3:40 °C 3.7 bar DHW Store Setpoint 50 °C 24.5.1 XPLANATION OF THE BUTTONS On/off switch. Switches electrical power to the water heater Connector for computer cable Reset lockout error Main Menu Escape / Return to the status overview Right Enter a menu item or confirm selection in Status overview (when directly setting Actual setpoint or DHW setpoint)

  • Page 133: Display Configuration

    24.5.2 ISPLAY CONFIGURATION The Status overview has the three different sections that show specific information: Header Middle section Footer Header Left: For cascade systems the cascade icon is shown, with the cascade manager indication (M) or the de- pendent number. Center: Shows the CH and/or DHW disabled icons when CH and/or DHW is disabled Right: Shows the time (only if the real-time clock is available).

  • Page 134: Entering The Menu

    Starting the water heater. If the water heater is not on make sure the gas switch beneath the water heater is open and the power cord is connected to the mains, use the on/off button to switch the water heater on. The following screen will occur: This screen is active during power up until communication with the main Control has been established.

  • Page 135: Changing The Setpoint Dhw

    Changing the Setpoint DHW. This can be done directly via the Status overview (as shown below) or via the MENU. You can adjust the DHW setpoint directly on the bottom of the Status overview. 24.7.1 /DHW CTUAL SETPOINT SETPOINT DIRECTLY VIA THE TATUS OVERVIEW You can adjust the DHW setpoint directly on the bottom of the Status overview.

  • Page 136: Available Menu Items

    Available Menu items Depending on the installed/programmed options by the installer following menu items could be visible. Menu / Parameter Description Value / Unit Central Heating (CH) Enter the Central Heating (CH) menu Domestic Hot Water Enter the Domestic Hot Water (DHW) menu (DHW) Information Enter the Information menu...

  • Page 137: Service

    24.9.6 ATER HEATER ISTORY Menu / Parameter Description Value / Unit Successful Ignitions Display the number of successful ignitions Failed Ignitions Display the number of failed ignitions Flame Failures Display the number of flame losses Operation Days Display the total time in operation days CH Burner Hours Display the amount of burn hours for CH...
  • Page 138 24.9.14 T IME ZONE SETTINGS Menu / Parameter Description Value / Unit Time Zone Correction Set the time zone correction Daylight Savings Time Select the daylight savings time mode 24.9.15 D ISPLAY SETTINGS Menu / Parameter Description Value / Unit Time Notation Select 24h or 12h time notation 24h/12h...

  • Page 139: Error Logging

    Error logging Errors will be logged for a stand-alone system or for a complete cascade system (based on the cascade settings). The display will monitor the error number(s) it receives from the water heater(s): new errors will be stored in the error log.

  • Page 140: Appendix

    (1) General Warranty If within 2(Two) years of the invoice date or commissioning date of a water heater supplied by Lochinvar Ltd., following verification, and at the sole discretion of Lochinvar Ltd., an assembly or part (with exclusion of the heat exchanger) proves to be defective or fails to function correctly due to manufacturing and/or material defects, then Lochinvar Ltd.
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This manual is also suitable for:

Efw 105Efw 125Efw 155

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