Lochinvar EFB105 Installation, Commissioning, User And Maintenance Instructions
Wall hung gas fired condensing boilers
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- Page 1 WALL HUNG GAS FIRED CONDENSING BOILERS Installation, Commissioning, User and Maintenance instructions MODELS EFB85 EFB105 EFB125 EFB155 Installation manual_EFB_April 2019...
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Page 2: Table Of Contents
OCATION OF VERSION NUMBERS 3.2.1 Technical specifications datasheet ................... 11 ....................12 SPECIFICATIONS DATASHEET DIMENSIONS & CONNECTIONS ......................13 EFB85, EFB105 EFB125 ....................13 EFB155 ..........................14 4.3.1 Connection sizes all versions ................... 14 ACCESSORIES AND UNPACKING ....................15 .......................... 15 CCESSORIES .......................... - Page 3 9.8.1 Horizontal Concentric Flue Assemblies ............... 38 9.8.2 Horizontal Terminal Installation ..................38 9.8.3 Horizontal Concentric Flue Terminal ................38 EFB85-EFB105 ................. 39 LUME ANAGEMENT KITS FOR 9.9.1 Vertical Concentric Flue Assembly ................40 9.9.2 Vertical Terminal Installation .................... 40 9.9.3...
- Page 4 11.5.1 Pump start exercise every 24 hours ................. 69 11.5.2 Frost protection ........................ 69 11.5.3 Appliance selection ......................70 11.6 ........................70 GNITION CYCLE 11.6.1 Flame detection ....................... 71 11.6.2 Flame recovery ........................ 71 11.7 ........................ 72 ONTROL FUNCTIONS 11.7.1 Room thermostat only;...
- Page 5 17.4 ................. 111 ONVERSION FROM NATURAL GAS TO PROPANE PEFB 1 – Set for 85 and 105 ..................111 17.4.1 PEFB 2 – Set for 125 and 155 ..................111 17.4.2 17.4.3 Installing the orifice (see also picture below): ..............112 17.5 ......................
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Page 7: Introduction
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. EGULATIONS 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: Abbreviations
BBREVIATIONS EFB = Condensing Boiler DHW = For Direct Hot Water (drinking water) usage only. CH = Central Heating (for central heating purposes and/or indirect hot water). BCU = Burner control unit. PEFB = Printed circuit board (burner controller). PB = Pixel button = display board/ control panel. SAFETY GUIDELINES Keep these instructions near the boiler for quick reference. -
Page 9: What To D O I F 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 10: Technical Data Efb Boilers
TECHNICAL DATA EFB BOILERS UNCTIONAL INTRODUCTION EFB boilers are Gas Condensing central heating boilers with a very 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 11: Technical Specifications Datasheet
3.2.1 ECHNICAL SPECIFICATIONS DATASHEET Product I.D. Number 0063CT3633 Gas Appliance Type B23(P), C13, C33, C43, C63, C83, C93, C(10)3, C(11)3, C(12)3, C(13)3, C(14)3, C(15)3 Model Number EFB85 EFB105 EFB125 EFB155 Classification II2EL3P II2ELL3P GENERAL DATA Input (gross) G20 min-max 17.1 - 90.7 20.7 - 108.1... -
Page 12: Erp Specifications Datasheet
SPECIFICATIONS DATASHEET Type Boiler: EFB85 EFB105 EFB125 EFB155 Condensing boiler: low temperature boiler: B11 boiler: Cogeneration space heater: Combination heater: Unit: Value Value Value Value Rated heat output 78.9 94.3 115.6 140.9 P-rated (P4) at 58-77C 78.9 94.3 115.6 140.9 Heat output (p1) 30% at 30-37C 25.2... -
Page 13: Dimensions & Connections
DIMENSIONS & CONNECTIONS EFB85, EFB105 EFB125 EFB85 & EFB105 EFB125... -
Page 14: Efb155
EFB155 EFB155 Twin pipe Connections EFB85 EFB105 EFB125 EFB155 Flue gas 100-100 150-150 Air inlet flow Inch R1" R1¼" conden- flexible hose Ø25/21 mm sate return Inch R1" R1¼" Inch R¾" R1" Concentric Connections EFB85 EFB105 EFB125 EFB155 Flue gas... -
Page 15: Accessories And Unpacking
ACCESSORIES AND UNPACKING CCESSORIES Depending on the selected controlling behaviour for the central heating system and/or the optional use of a calorifier, the following items can be supplied with the boiler. Contact Lochinvar for prices and further information. Item Item Number... -
Page 16: Installation Of The Efb
A wall or stand to properly support the weight of the boiler. The wall used for mounting the boiler must be able to hold the weight of the boiler. If not, it is recommended to mount the boiler by means of a frame available from Lochinvar. -
Page 17: Boiler Installation Location Requirements
OILER NSTALLATION OCATION EQUIREMENTS Other considerations related to the boiler location. The ventilation of the boiler room must meet local and national standards and regulations, regardless of the selected supply of fresh air to the boiler. The flue gas pipes must be connected to the outside wall and/or the outside roof. ... -
Page 18: Mounting The Boiler
OUNTING THE BOILER Before mounting and installing the boiler the following connections must be considered: Flue gas system and the flue gas pipe connections Power supply (preferably the power connection posi- tioned above the boiler) Air supply system and connections ... -
Page 19: Connections
CONNECTIONS OILER CONNECTIONS 1 – Flow (Hot water out) 2 – Return (Cold water in) 3 – Gas 4 – Condensate trap cleaning point 5 – Condensate drain 6 – Automatic air vent. Strain on the gas valve and fittings may result in vibration, premature component failure and leakage and may result in a fire, explosion, property damage or serious injury. -
Page 20: Flow And Return Connections
A suitable kit of components is available from Lochinvar. EHS.T0501.100 RESSURE RELIEF VALVE The boiler has no internal pressure relief valve. This must be installed close to the boiler in the flow pipe of the heating system. When having cascaded boilers, each boiler must have its own pressure relief valve. -
Page 21: Bypass
YPASS The boiler has no internal bypass. When many thermostatic valves are being used, the system must have a bypass to allow an adequate flow when all thermostatic valves are closed. Instead of a bypass also a low-loss header can be used for this function. The boiler flow will also be influenced when a pipe of the heating system is frozen / blocked. -
Page 22: Water Quality
7.12 ATER QUALITY The pH value is reached with steady conditions. These Contaminant Maximum allowable level Units steady conditions will occur, when after filling the heating 7.5 to 9.5 system (pH around 7) with fresh water, the water will lose Total hardness 50 to 150 CaCO... -
Page 23: Chemical Water Treatment
7.13 HEMICAL WATER TREATMENT The chemical compatibility of several products for treatment of the central heating equipment has been tested on the heat exchangers and the boilers. See below for the list with the corrosion inhibitors in preventative and curative treatment for gas fired central heating boilers. If water treatment is required when filling the system or preforming maintenance an inhibitor must be used. -
Page 24: Plastic Piping In The Heating System
7.15 LASTIC PIPING IN THE HEATING SYSTEM When plastic pipes with no oxygen barrier are used in the central heating system, these must be separated from the boiler system by using a plate heat exchanger. Diffusion (through the plastic) can cause air to enter the heating system. This could damage the boiler, pumps and other components in the system. -
Page 25: Relevant Variables
7.16.1 R ELEVANT VARIABLES (Default) Specific Parameters Level Range Value De-Air Config 0: 24 hr pump 1: De-Air 2: Installer Configuration for the De-Air function 2: Disabled De-Air State 1: User Current state of the De-Air function. De-Air Repeation Cnt 2: Installer 0…255 On/Off repeation count for a De-Air cycle. -
Page 26: Installation Examples
7.19 NSTALLATION EXAMPLES 7.19.1 E XAMPLE OF A LOW RESISTANCE HEATING CIRCUIT valve BOILER air separator dirt separator strainer (water filter) HEATING ZONE pressure relief valve condensate trap pump automatic air vent expansion vessel 7.19.2 E XAMPLE OF A NORMAL SINGLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER PREFERABLE valve BOILER... -
Page 27: Example Of A Multiple Boiler Heating Circuit With Low Loss Header
7.19.3 E XAMPLE OF A MULTIPLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER NON RETURN VALVE BOILER BOILER (low resistance type) NOT SPRING LOADED HEATING ZONE... -
Page 28: Pump Characteristics
PUMP CHARACTERISTICS YDRAULIC GRAPHS EFB 85 HYDRAULIC GRAPH 10.0 FLOW [m ΔT=20K ΔT=25K BOILER PUMP INSTALLATION EFB 105 HYDRAULIC GRAPH 10.0 FLOW [m ΔT=20K ΔT=25K BOILER PUMP INSTALLATION... -
Page 29: Modulating Pump For Ch Demand
EFB 125 HYDRAULIC GRAPH 10.0 FLOW [m ΔT=20K ΔT=25K BOILER PUMP INSTALLATION EFB 155 HYDRAULIC GRAPH 10.0 FLOW [m ΔT=20K ΔT=25K BOILER PUMP INSTALLATION ODULATING PUMP FOR DEMAND The controller supports PWM modulation for the general pump. The boiler pump is modulated when there is a demand for CH. During any other demand, the PWM pump will run at a fixed speed set by the Default Duty cycle parameter. -
Page 30: Modulating Pump Modes
ODULATING PUMP MODES There are several modulating pump modes implemented in the software. By selecting a different modulating pump mode, the pump be- haviour can be changed. The following modulating pump modes are available. Modulating pump mode Details Disabled No pump modulation; the PWM duty cycle is always 0%. Delta temperature modulation Calculated duty cycle to create a delta temperature between the T_Supply and T_Return sensor. -
Page 31: Flue Gas And Air Supply System
Before installation of any flue system read the installation manual carefully for both the appliance and flue system to be used. Information on the flue system Supplied by Lochinvar can be found within this manual. -
Page 32: Flue System Technical Details
YSTEM ECHNICAL ETAILS Model Number EFB85 EFB105 EFB125 EFB155 FLUE DATA TYPE B Nominal flue diameter Maximum flue gas temp °C Flue gas temperature °C 60-90 Flue draught requirements mbar -0.03 to -0.1 Available pressure for the flue system Maximum flue gas volume 28.9... -
Page 33: Flue Terminal Minimum Distances
Location Description EFB85 EFB105 EFB125 EFB155 Directly below an opening, air brick, opening windows etc. 2500 2500 2500 2500 Above an opening, air brick, opening windows etc. 1145 Horizontally to an opening, air brick, opening windows etc. 1145 Below a gutter or sanitary pipework... -
Page 34: Installation Precautions
Summer Use Summer Use Summer Use High High High High High High Gross In- Model put Kw Net Input Kw EFB85 90.7 81.7 EFB105 108.1 97.3 1070 1168 EFB125 132.6 119.4 1194 1313 1433 EFB155 161.4 145.3 1453 1598 1017 1744 9.6.1... -
Page 35: Air Contamination
9.6.5 IR CONTAMINATION Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chem- icals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building. -
Page 36: Oiler Categories Types Of Flue Gas Systems
OILER CATEGORIES TYPES OF FLUE GAS SYSTEMS Type according EN 15502-2-1: 2012 Performance Description B23(P) flue outlet Open * Roof terminal Air supply from * Without draught diverter room * Boiler room air supply. * P = overpressure systems See: Typical examples - example C Be aware: The installation room has to have Special... - Page 37 C63 - example Closed * Appliance sold without flue/air-inlet ducts Flue outlet Air supply from * The flue gas parts are not part of the boiler. The boiler outside Roof terminal is intended to be connected to a separately approved and Air inlet marketed system for the supply of combustion air and discharge of combustion products.
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Page 38: C 13 Horizontal Concentric Flue Assemblies
ONCENTRIC YSTEMS Model Description Flue Assembly Item number EFB85 Horizontal Concentric flue kit 100/150mm CPMH003 EFB105 Horizontal Concentric flue kit 100/150mm CPMH003 EFB125 Horizontal Concentric flue kit 100/150mm CPMH004 EFB155 Not available 9.8.1 ORIZONTAL ONCENTRIC SSEMBLIES 9.8.2 ORIZONTAL ERMINAL NSTALLATION... -
Page 39: Plume Management Kits For Efb85-Efb105
EFB85-EFB105 LUME ANAGEMENT KITS FOR For installations where the flue exhaust may present a nuisance pluming problem but is installed as per IGEM/UP/10 then Lochinvar can offer a plume management kit as below. Item No Description Elbow 100/150 High level flue terminal... -
Page 40: C Vertical Concentric Flue Assembly
9.9.1 ERTICAL ONCENTRIC SSEMBLY Model Description Flue Assembly Item number EFB85 Vertical Concentric flue kit 100/150mm CPMV003 EFB105 Vertical Concentric flue kit 100/150mm CPMV003 EFB125 Vertical Concentric flue kit 100/150mm CPMV004 EFB155 Not available 9.9.2 ERTICAL ERMINAL NSTALLATION When the heater is installed as a Type C appliance, the flue system should be installed as follows: Confirm that the roof flashing is correct for the type of roof through which the terminal is to be installed. -
Page 41: General Concentric Flue System Installation Guidelines
9.9.5 ENERAL ONCENTRIC YSTEM NSTALLATION UIDELINES DO NOT DRILL OR SCREW INTO THE FLUE SYSTEM... - Page 42 Max distance between brackets...
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Page 45: C 53 Twin Pipe Flue Systems
Due to the large Flue pipe size required Lochinvar does not supply Twin-Pipe flue components for models EFB155. For this installation type a flue system designer/installer should be consulted. -
Page 46: General Twin-Pipe Installation Guidelines
9.10.1 ENERAL NSTALLATION UIDELINES... -
Page 49: C63 Certified
9.11 CERTIFIED If a heater is C63 certified, the flue gas and air supply parts must have a separate CE marking according to the building products regulations. The parts must be able to handle the condensate forming (W) and transport, overpressure (P1) and must have a minimum temperature class of T120. -
Page 50: Pipe Heights And Mutual Distances On A Flat Roof
9.12 IPE HEIGHTS AND MUTUAL DISTANCES ON A FLAT ROOF Height A This is the height of the air inlet. A rain hood must prevent rainwater en- tering the air supply system. When the inlet and outlet are mounted on a flat roof, the inlet must be at least 152.4 cm (60 inch) above the roof surface and at least 76.2 cm (30 inch) above the maximum snow level. -
Page 51: Flue Gas And Air Supply Resistance Table
9.13 LUE GAS AND AIR SUPPLY RESISTANCE TABLE In the next section, for five 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: BOILER EFB 85 EFB 105... -
Page 52: Typical Examples
Concentric pipe for flue gas/air supply (roof-mounted) Concentric pipe for flue gas/air supply (wall-mounted) Specific resistance values of Lochinvar supplied flue gas and air intake parts are used for these examples. Do not use for other flue systems 9.14.1 E... -
Page 53: Example B: Twin Pipe System With Concentric Roof Terminal
9.14.2 E B: T XAMPLE WIN PIPE SYSTEM WITH CONCENTRIC ROOF TERMINAL Calculation example with given lengths: checking resistance Boiler type: EFB 125 Diameter: 100 mm Number Pa total Straight tube /m total 30.0 Bend 90° 18.3 36.6 concentric Roof terminal 55.7 55.7 100/150... -
Page 54: Example C: Single Flue Gas Outlet. Air Supply From Boiler Room
9.14.3 E C: S XAMPLE INGLE FLUE GAS OUTLET IR SUPPLY FROM BOILER ROOM Calculation example with given lengths: checking resistance Boiler type: EFB 105 Diameter: 100 mm Number Pa total Straight tube m¹ total 42.9 Bend 90° 12.1 24.2 Bend 45°... -
Page 55: Example D: Concentric Flue Gas/Air Supply Pipe (Roof-Mounted)
9.14.4 E D: C XAMPLE ONCENTRIC FLUE GAS AIR SUPPLY PIPE ROOF MOUNTED Calculation example with given lengths: checking resistance Boiler type: EFB 85 Diameter: 100/150 mm. Pa total quantity Straight tube m total 26.4 Bend 90° 25.5 Bend 45° 10.6 Concentric terminal roof... -
Page 56: 10 Electrical Installation
10 ELECTRICAL INSTALLATION 10.1 ENERAL For operation, the boiler needs a power supply of 230 VAC 50Hz. The boiler main supply connection is phase/neutral sensitive. The wiring for the connections can be entered at the bottom of the boiler through the cable glands. ... -
Page 57: Low Voltage Connections
X1-X2-X3 HIGH POWER IGNITER (external igniter) A separate connector for an external igniter is located on the cable tree, near the boiler controller and labelled "High power ignitor". This is a connection for an external ignition transformer. Instead of the internal igniter, an external igniter can be connected. Available as an accessory, see §... - Page 58 12-13 ON/OFF STAT OR OPENTHERM HEATING CIRCUIT OPTION 1: An ON/OFF thermostat can be connected. If these terminals are bridged, the set/ programmed flow temperature of the boiler will be used. OPTION 2: An OpenTherm (OT) controller can be connected to these terminals. The boiler software will detect and use this OpenTherm signal automatically.
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Page 59: Ladder /Logic Diagram
10.5 ADDER OGIC IAGRAM... -
Page 60: Electrical Schematics
10.6 LECTRICAL SCHEMATICS... -
Page 62: Sensor Availability
10.7 ENSOR AVAILABILITY The following table shows the sensor availability for all CH and DHW control modes. Sensors not mentioned in the table are optionally available for other functions CH Mode T_Supply T_Return T_DHW T_Outdoor 0-10 Volt Water Flow DHW RT Switch M = Mandatory, O = Optional, --- = Disabled. -
Page 63: Rogrammable In And Outputs
10.9 ROGRAMMABLE IN AND OUTPUTS It is possible to re-program some in- and outputs to other functions. To do this use list below and go to: Menu\settings\boiler settings\"1122" (installer password)\boiler parameters boiler parameter name default description terminal (117) Prog. Input 2. DHW flow switch LV 16-17 (118) -
Page 64: 11 Burner Controller And Display
11 BURNER CONTROLLER AND DISPLAY. 11.1 ISPLAY AND BUTTONS On / off switch. Switches electrical power to the boiler 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) Left Return to previous menu item or Status overview... -
Page 65: Display Icons
11.1.1 D ISPLAY ICONS The following table gives a short description of the icons that can be visible on the main screen during operating: Icon Description Boiler Status CH control state RT_Input Central Heating demand (Central Heating controller state) (Room thermostat open of closed) 0 = Idle 0=Open 1 = Request... -
Page 66: Entering The Menu
11.2.2 E NTERING THE MENU Enter the menu by pressing the MENU button once. The header in the display shows you are inside the main menu. While scrolling through the menu you will see that the selected menu item is shown in a white rectangle. Central Heating (CH) Domestic Hot Water (DHW) Information... -
Page 67: Protected Menu Items
The display has a number of different language options, such as English, French, Chinese and Italian. BE AWARE: DO NOT set the language to the Chinese Language if you are not familiar with this language. Contact Lochinvar for instruc- tions if the display is set to Chinese and needs to be reset to another language. -
Page 68: Boiler History
11.3 OILER HISTORY The boiler history found in the information menu displays several history counters that keep track of the boiler usage. The history cannot be erased and will continue for the burner controller life cycle. The following boiler history data is available: (Sub) Menu item Description Successful Ignitions... -
Page 69: General
The error log screen will show on the first line: Boiler ID for which boiler the error was detected (cascade system only), Error Code, (internal) Error Number, Error Type (Lockout/Blocking). The second line will show the Error Description. The bottom line will show the Time Stamp (date and time) when the error was detected (in the format as configured in the Date Time Settings menu), and also the selected error index from the total number of errors in the (filtered) error log. -
Page 70: Appliance Selection
11.5.3 A PPLIANCE SELECTION The controller is designed to store specific parameter sets of different boiler models. By defining specific setting for different appliance models the same controller can be used for a complete product range. Depending on which model boiler the controller is applied to, it only will be necessary to change just one single parameter. See 17.4 "Conversion from natural gas to propane", part: "Change the appliance type"... -
Page 71: Flame Detection
11.6.1 F LAME DETECTION When the boiler is firing, and the flame is not detected anymore, the gas valve will be closed, and the controller will perform a post-purge, after which a restart will take place. When the flame disappears three times within one heat demand, the controller will lockout. The presence of a flame is measured through the flame rod that points into the flame. -
Page 72: Control Functions
11.7 ONTROL FUNCTIONS Dependent on the required functions of the appliance and connected sensors and components, several operation modes for Central Heating (CH) and Domestic Hot Water (DHW) can be selected. 11.7.1 R ; CH 0 (D OOM THERMOSTAT ONLY MODE EFAULT SETTING For this mode the CH mode must be set to 0 and no outdoor sensor is needed. -
Page 73: With An Outdoor Temperature Reset And Thermostat; Ch Mode 1
11.7.2 CH ; CH WITH AN OUTDOOR TEMPERATURE RESET AND THERMOSTAT MODE If the parameter CH_Mode is set to 1, the “Outdoor temperature reset with room thermostat” mode is selected. This mode will only function when an outdoor temperature sensor is connected. If the outdoor sensor is connected, the boiler automatically uses Reset_Curve_Boiler_Maximum. - Page 74 Setpoint adjustment It is possible to adjust the calculated setpoint with parameter CH_Setpoint_Diff. The calculated setpoint can be increased or decreased with a maximum of 10 ºC (18 °F). The CH setpoint limits (Reset_Curve_Boiler_Minimum and Reset_Curve_Boiler_Maximum) are respected while adjusting the setpoint. Apart from the calculated setpoint the functionality is the same as described in 11.7.1 "Room thermostat only...”...
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Page 75: With Constant Circulation System Outdoor Reset; Ch Mode 2
11.7.3 CH ; CH WITH CONSTANT CIRCULATION SYSTEM OUTDOOR RESET MODE When CH_Mode is set to 2, full weather compensator is chosen. For this mode an outdoor sensor has to be connected. The CH_Setpoint is calculated on the same way as described in 11.7.2 "CH with an outdoor temperature reset and thermostat; CH mode 1" However, the demand does not depend on the Room Thermostat input but on the outdoor temperature and the outdoor reset setpoint. -
Page 76: Central Heating With Analogue Input Control Of Setpoint; Ch Mode 4
11.7.5 C ; CH ENTRAL EATING WITH ANALOGUE INPUT CONTROL OF SETPOINT MODE CH mode is set to 4. In this mode of operation, the boiler CH setpoint is controlled by an analogue input signal provided by a remote means such as a Building Management System or a system controller. -
Page 77: With Analogue Input Control Of Power Output; Ch Mode 5
11.7.6 CH ; CH WITH ANALOGUE INPUT CONTROL OF POWER OUTPUT MODE In this mode of operation, the boiler power (boiler input) is controlled by an analogue input signal provided by a remote means such as a Building Management System or a system controller. The analogue input 0-10 VDC is used to adjust the boiler power output between the minimum boiler input and the maximum boiler input settings. -
Page 78: Demand For Domestic Hot Water
11.8 EMAND FOR OMESTIC ATER 11.8.1 N ; DHW OMESTIC ATER MODE No domestic hot water is available. The T_DHW_Out sensor does not need to be connected. 11.8.2 DHW S ; DHW TORAGE WITH SENSOR MODE Mode 1: DHW is prepared by warming up a store. Either a DHW pump or 3-way valve can be used to switch to DHW mode. The DHW temperature in the tank is measured with sensor T_Store and set with parameter DHW_Store_Setpoint. -
Page 79: Dhw Storage With Thermostat; Dhw Mode 2
11.8.3 DHW S ; DHW TORAGE WITH THERMOSTAT MODE In this mode DHW is prepared by warming up an indirect tank. Either a DHW pump or 3-way valve can be used to switch to DHW mode. The temperature of the DHW in the indirect tank is regulated by a thermostat/aquastat (instead of a sensor), which should provide only an open/closed signal to the controller. -
Page 80: Anti-Legionella Protection
11.8.5 A LEGIONELLA PROTECTION Anti-Legionella protection is enabled for DHW modes with an external tank with a sensor (DHW Mode 1) or for the direct fired water heater (DHW Mode 6 & 7) and when DHW is not switched OFF. To prevent legionella a special function is implemented in the software. -
Page 81: Display Menu Structure Summary
11.8.6 D ISPLAY MENU STRUCTURE SUMMARY Access Description: Menu structure Display: 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 82 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 DHW Temperature °C User Actual DHW temperature DCW Temperature °C User Actual DCW temperature Outside Temperature...
- Page 83 4 Settings min. max. Default unit Access Description: level 4.1 General Settings User Enter the General Settings menu 4.2 Boiler Settings User Enter the Boiler Settings menu 4.1 General settings min. max. Default unit Access Description: level 4.1.1 Language User Enter the Language menu 4.1.2 Unit Type User...
- Page 84 4.2 Boiler settings min. max. Default unit Access Description: level 4.2.1 Boiler Parameters installer Enter the Boiler Parameters menu 4.2.2 Module Cascade Set- installer Enter the Module Cascade Settings tings menu 4.2.3 Boiler Cascade Set- installer Enter the Boiler Cascade Settings menu tings Dis- 4.2.1 Boiler parameters...
- Page 85 cont.: min. max. Default unit Access Description: Dis- 4.2.1 Boiler parameters level play DHW Tank Supply Extra Installer Set the DHW tank supply setpoint ⁰C offset DHW Priority Installer Set the DHW priority mode DHW Max. Priority Time min. Installer Set the maximum DHW priority time DHW Pump Overrun...
- Page 86 4.2.2 Module Cascade Set- min. max. Default unit Access Description: Dis- tings level play Burner Address Stand Installer Set the cascade burner address alone Permit Emergency Mode Yes/N Installer Enable/disable the cascade emergency mode Emergency Setpoint °C Installer Set the emergency mode setpoint Delay Per Start Next Mod.
- Page 87 4.2.3 Boiler Cascade Settings min. max. Default unit Access Description: Dis- level play Boiler Address stand Installer Set the cascade boiler address alone Permit Emergency Mode Yes/N Installer Enable/disable the cascade emergency mode Emergency Setpoint °C Installer Set the emergency mode setpoint Delay Per Start Next Blr 1275 1275...
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Page 88: 12 Temperature Protection
12 TEMPERATURE PROTECTION The difference between supply temperature and return temperature is continuously monitored (ΔT). If this becomes too high it can indicate a defective pump or a clogged heat exchanger. To protect the boiler, the burner controller reduces the input when the temperature difference ΔT becomes too high: At maximum boiler input ΔT is limited to 35°C (63 °F) - (Hx_Diff_DeltaT_Min ) In between 35°C (63 °F) and 43 °C (77 °F) boiler input modulates between minimum and maximum. -
Page 89: 13 Error Information
13 ERROR INFORMATION. Errors can be divided in three groups: •Manual reset locking errors (can only be reset by the reset button). •Blocking errors (will disappear when error is gone) •Warnings (will disappear when the warning is gone, not stored in the controls e2prom) The boiler pump will continue to run during most locking and blocking error codes. -
Page 90: Lockout Codes
13.3 OCKOUT CODES Lockout Error Description Cause Solving code wrongly programmed BCU reset BCU or replace BCU E2PROM_READ_ERROR Internal software error or PB and or display unit check gas supply and Five unsuccessful ignition no gas, wrongly adjusted IGNIT_ERROR adjust gas valve, reset attempts in a row gas valve short circuit in coil of the... - Page 91 Lockout Error Description Cause Solving code wrongly programmed BCU reset BCU or replace BCU STACK_ERROR Internal software error or PB and or display unit wrongly programmed BCU reset BCU or replace BCU INSTRUCTION_ ERROR Internal software error or PB and or display unit wrongly programmed BCU reset BCU or replace BCU ION_CHECK_ FAILED...
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Page 92: Blocking Codes
13.4 LOCKING CODES Lockout Error Description Cause Solving code wrongly programmed BCU reset BCU or replace WD_ERROR_RAM Internal software error or PB BCU and or display unit wrongly programmed BCU reset BCU or replace WD_ERROR_ROM Internal software error or PB BCU and or display unit wrongly programmed BCU reset BCU or replace... - Page 93 Lock- Error Description Cause Solving code Low water pressure, gen- erated when the pressure Fill up the system and LOW_WATER_PRES- drops below Not enough water pressure check if there are any SURE_SENSOR Minmal_Pressure, or water leakages when the pressure drops below 0.3 bar (4.5 PSI) Watchdog communication wrong program-med BCU or...
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Page 94: Warnings
Lockout Error Description Cause Solving code WD_CONFIG_ER- Watchdog fan configuration set- wrongly program-med reset BCU or replace BCU ting error BCU or PB and or display unit Error is generated immediately when the pressure drops below The water pressure is refill the system until the pres- FILL_WARNING Minimal_Pressure. -
Page 95: 14 Cascading
14 CASCADING 14.1 YSTEM SETUP The boiler controller can control multiple boilers in a cascade setup. A system sensor is necessary to measure the cascade system supply temperature. The sensor is connected to the boiler controller. A pump output is also available to run the system pump, as well as an output for the DHW pump. When the CH supply temperature is calculated based on an outdoor sensor, only one outdoor sensor is needed. -
Page 96: Setting Up The Cascade Parameters
14.2.1 S ETTING UP THE CASCADE PARAMETERS Enter the main menu by pushing the menu button, now select settings by toggling the up and down arrow and enter settings by pushing the enter button. Now select Boiler Settings Select the Module Cascade Settings Change burner address into Managing or Dependent. -
Page 97: Location Of Switch S1: Red Rectangle
Setting the boiler address: Address rules The cascade managing address (parameter 184) must be set to ‘Managing’ on the managing boiler. The cascade depending addresses (parameter 184) must be set in a logical numbered order from 1: Dep. 1, Dep. 2 etc. -
Page 98: Cascade - Domestic Hot Water Settings
– D 14.2.4 ASCADE OMESTIC ATER ETTINGS In the installer DHW menu of the managing boiler controller the DHW_Mode must be set. Available DHW modes in cascade are mode 1 = sensor or 2 = aquastat (see 11.8 "Demand for Domestic Hot Water"). Dependent Boiler In case a boiler is set as dependent (parameter 184: "Burner address") the DHW setpoint is always provided by the managing boiler, the internal control of the setpoint functions are disabled. - Page 99 Starting and Stopping Burners With a small difference between T_System and the Cascade_Setpoint the call for a start or stop of respectively the next or last depending burner is executed. • Starting Burners: If T_System is Hyst_Down_Start_Burner degrees below the Cascade_Setpoint the burners are started at intervals of Start_Next_Depending_Delay, for example 200 seconds.
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Page 100: Cascade - Power Balance Mode
Relevant variables Specific Parameters Level (Default) Value Range Start_Next_Depending_Delay 2: Installer 200 (sec) 0…1275 Start Delay Time Stop_Next_Depending_Delay 2: Installer 180 (sec) 0…1275 Stop Delay Time Quick_Start_Next_Depending_Delay 2: Installer 50 (sec) 0…1275 Quick Start Interval Quick_Stop_Next_Depending_Delay 2: Installer 30 (sec) 0…1275 Quick Stop Interval Hyst_Down_Start_Burner... -
Page 101: Power Mode = 1 (Minimum Boilers On)
14.2.8 P = 1 (M OWER MODE INIMUM BOILERS ON Power Mode 1 guarantees to have as minimum as possible dependent ON in order to reach the T_System. The modulation of most boilers/burners is forced to 100%, and the last 2 boilers/burners are PID controlled by the setpoint (Cascade_Set- point) from the managing burner in relation to the system temperature (T_System). -
Page 102: Power Mode 2 - Maximum Burners On
2 – M 14.2.9 P OWER MODE AXIMUM BURNERS ON Power mode 2 is designed to have as many depending burners on as possible. When the average burner power of the active depending burners is above a set minimum power, another burner is started Burner start-up The next burner is started under the following conditions: •... -
Page 103: Boiler Rotation
14.3 OILER ROTATION The boiler rotation function can change the start/stop sequence for the cascade boilers. The parameter Boiler_Rotation_Interval sets the number of days after which the sequence is updated. When Boiler_Rotation_Interval is set to 0 boiler rotation is disabled. When the parameter Burner_Rotation_Interval is updated the boiler rotation days left will be initialized to the new Burner_Rotation_Interval setting. -
Page 104: Emergency Mode
14.4.1 E MERGENCY MODE Open / Shorted boiler or system sensor When the setting Emergency_Mode is enabled, the controller can go into emergency mode when the system sensor status is open or shorted. The managing boiler display may show that the system is in emergency mode. In emergency mode the system setpoint is set to the Emergency_Setpoint (settable via installer menu) and all cascaded boilers are allowed to start burning on this setpoint. -
Page 105: 15 System Test
15 SYSTEM TEST. For testing the system at fixed power rates, a system test can be activated via the Installer menu. Via the system test the boiler can be started without CH or DHW being present. The system test has priority. The following modes are available: System test mode Description... -
Page 106: 16 Commissioning The Boiler
16 COMMISSIONING THE BOILER 16.1 IRST FLUSHING THE BOILER WITH WATER After installation of the boiler the first step, before commissioning, is to flush the boiler and the whole heating installation with fresh water to remove pollution, debris and other materials that might cause a blocking. This must also be done with heating installations, where only the boiler is replaced. -
Page 107: Mounting Condensate Trap
16.4 OUNTING ONDENSATE When mounting the bottom part of the condensate trap, before commissioning the boiler and/or after maintenance, it must ALWAYS be completely filled with water. This is a safety measure: the water in the condensate trap keeps the flue gases from leaking out of the heat exchanger via the condensate drain. -
Page 108: 17 Adjusting And Setting The Boiler
17 ADJUSTING AND SETTING THE BOILER Before carrying out any adjustment of the burner, carefully read this complete chapter. The initial lighting of the appliance must be performed by a fully trained competent Engineer. Failure to follow these instructions may result in property damage, serious injury or death. As soon as the appliance has been fully installed (with regard to hydraulics, filling and de-aeration of installation, gas, flue gas, air intake, wiring etc.) according to the preliminary installation instructions, the boiler may then be wired to an electrically grounded power supply source. -
Page 109: Setting Screws Venturi And Gas Valves Drawings
17.1.2 S 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 (5/32 Allen wrench) High Fire: screw [2] Low Fire: gas valve adjustment screw: Torx T40. -
Page 110: Adjustment Procedures
17.2 DJUSTMENT 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" 3. Press CONFIRM to activate the system test. →... -
Page 111: Conversion From Natural Gas To Propane
Adjustment of the boiler to a different gas type must be performed by a fully trained competent Engineer Use only parts/conversion kits obtained from Lochinvar and intended to be used with this particular boiler. Every conversion kit is provided with instructions how to assemble the kit to the boiler. -
Page 112: Installing The Orifice (See Also Picture Below)
17.4.3 I NSTALLING THE ORIFICE SEE ALSO PICTURE BELOW Needed tools: wrench 55 or pipe wrench, Hex key 5 mm and Hex key 4 mm 1. Close the external gas shutoff valve and disconnect the electrical power before opening the boiler. 2. - Page 113 Also mark the box, indicating that the correct value has been set for the appliance type. It is possible to improve the ignition spark by using an external ignition transformer. Available on request, contact Lochinvar for further details...
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Page 114: Start U P Checklist
County Telephone Telephone number number Boiler information After filling in form please send a copy Model by e-mail to: info@lochinvar.ltd.uk or Serial number send a copy to address: Installation date Cascade installation (Y/N) (YES/NO) Number of boilers Lochinvar Limited. Type of boilers in cascade... - Page 115 Water circulation & temperature regulation (for DHW) Piping diameter Total length of straight pipe between boiler & tank Number of elbows Number of tees Temperature rise between inlet and outlet after 5 min. cold-start operating max. power °C / °F Water temperature setpoint Test of Water Flow Switch (DHW)? (Yes/NO)
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Page 116: Inspection, Maintenance And Service
18 INSPECTION, MAINTENANCE AND SERVICE. 18.1 ENERAL For a good, safe and long-time operation of the boiler and to maintain warranty it is mandatory to carry out inspection, maintenance and service on the boiler at least once a year. Inspection, maintenance and service of the boiler must also be carried out on the following occasions: •... - Page 117 Water leakage The water pressure of the heating installation must be more than 1.0 bar (21 psi) and at a maximum of 4.0 bar (87 psi) in normal operation. When the water pressure drops below the minimum occasionally, there might be a water leak. Check the boiler and the complete heating installation for any water leakages and have these repaired.
- Page 118 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 119 Fibre braid replacement If the high temp braided rope is damaged and needs to be changed, it has to be replaced by new braids using the method described below. The high temp braided rope is maintained by silicone glue. - Remove electrodes. - Remove the braids by sliding under the periphery a thin tool to loosen the braids and remove it.
- Page 120 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 121 Install the new insulation: Put two dots of glue silicone, temperature-resistant (Loctite 5366 or Ottoseal S17), according to the location indicated. Make sure that the burner is in proper condition, remove any possible insulation residues on the burner Put a plastic protection skirt around the burner to protect the insulation from the burner. Engage the insulation carefully and place it in contact with the two dots of silicone glue Remove the plastic protection skirt Check the condition of the electrode, if necessary replace it...
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Page 122: Mounting The Burner Door
Gas/air ratio With every service check and/or maintenance of the boiler always check the gas/air ratio by measuring the CO percentage (flue gas) at the maximum and minimum load of the boiler. If necessary, adjust these values. See for information chapter “Adjusting and setting the boiler”... -
Page 123: Maintenance Checklist
18.3 AINTENANCE HECKLIST Allowing the boiler to operate with a dirty combustion chamber will damage operation. Failure to clean the heat exchanger as required by the manual and dictated by the operating location could result in boiler failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty Periodic maintenance must be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. -
Page 124: 19 User Instructions
19 USER INSTRUCTIONS After installing and commissioning of the boiler, demonstrate the operation of the entire central heating system to the end-user. The user must be made familiar with all safety precautions of the boiler and the installation. The user must be instructed that service and maintenance of the boiler is required every twelve months. -
Page 125: 20 Installation Examples
20 INSTALLATION EXAMPLES The following schematics present several examples of heating installations: All schematics are purely functional. Safety components, bypass, control devices and so on must be added to conform to all applicable standards and regulations. YSTEM XAMPLE 20.1 Low Voltage Connections BOILER Wire termi- Name... -
Page 126: Ystem Xample 3
20.3 YSTEM XAMPLE Low Voltage Connections BOILER Name Wire terminal Room thermostat 12-13 HEATING ZONE Outdoor temperature sensor Flow temperature sensor Low loss header High Voltage Connections Boiler pump 4-PE-5 System heating pump 6-PE-7 20.4 YSTEM XAMPLE Low Voltage Connections Name Wire terminal BOILER... -
Page 127: Ystem Xample 5
20.5 YSTEM XAMPLE Low Voltage Connections BOILER Name Wire terminal HEATING Room thermostat 12-13 ZONE Flow temperature sensor Outdoor temperature sensor Tank thermostat or sensor Low loss header DHW indirect Tank (low resistance type) High Voltage Connections Boiler pump 4-PE-5 HWS primary pump 2-3-PE System heating pump... -
Page 128: Ystem Xample 7
20.7 YSTEM XAMPLE BOILER 1 BOILER 2 BOILER 3 BOILER 4 Managing Depending 1 Depending 2 Depending 3 HEATING ZONE Low Voltage Connections Name Wire terminal Room thermostat 12-13 Outdoor temperature sensor Flow temperature sensor Tank thermostat or sensor DHW indirect Tank NRV (low resistance type) Low loss header High Voltage Connections... -
Page 129: 21 User Instructions
21 USER INSTRUCTIONS This section is written for the user Lochinvar is not accountable for any damage caused by incorrectly following these instructions. For service and repair purposes use only original Lochinvar spare parts. All documentation produced by the manufacturer is subject to copyright law. -
Page 130: T O Turn Off Gas To The Appliance
21.3 O TURN OFF GAS TO THE APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. The main gas switch is situated underneath the boiler in the gas supply line. clockwise to OFF.”... -
Page 131: Display And Buttons
21.5 ISPLAY AND BUTTONS On / off switch. Switches electrical power to the boiler 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) Left Return to previous menu item or Status overview... -
Page 132: Display Icons
21.6 ISPLAY CONS Icon Description Central Heating demand Domestic Hot Water demand Indicates that the appliance burner is ON Cascade Emergency Mode active Error notification 21.7 TARTING THE BOILER If the boiler is not on make sure the gas switch beneath the boiler is open and the power cord is connected to the mains, use the on/off button to switch the boiler on. -
Page 133: Changing The Setpoint And / Or Enabling Ch/Dhw
21.8 CH/DHW. HANGING THE ETPOINT AND NABLING This can be done directly via the Status overview (as shown above) or via the MENU. When CH is active, you can adjust the Actual setpoint directly on the bottom of the Status overview. When DHW is active, you can adjust the DHW setpoint directly on the bottom of the Status overview. -
Page 134: The Menu (Button )
21.9 HE MENU UTTON Enter the menu by pressing the MENU button once. The header in the screen shows you are inside the main menu. Whilst scrolling through the menu you will see that the selected menu item is shown in a white rectangle. At the right, there will be an icon shown, depending on the selected item. -
Page 135: Central Heating (Ch)
21.12.1 C (CH) ENTRAL EATING Menu / Parameter Description Value / Unit CH Setpoint Set the CH setpoint °C/°F Outdoor reset Enter the Outdoor Reset menu 21.12.2 D (DHW) OMESTIC ATER Menu / Parameter Description Value / Unit DHW Setpoint Set the DHW setpoint °C/°F DHW Store Setpoint... -
Page 136: Service
21.12.8 S ERVICE Menu / Parameter Description Value / Unit Service history Display the service history Burn hours since last service Display the burn hours since last service hrs. Burn hours till service Display the hours remaining until next service hrs. -
Page 137: Boiler Settings
21.12.18 B OILER SETTINGS Menu / Parameter Description Value / Unit Boiler Parameters Enter the Boiler Parameters menu Module Cascade Settings Enter the Module Cascade Settings menu Boiler Cascade Settings Enter the Boiler Cascade Settings menu Service Enter the Service menu 21.13 OILER ISTORY... -
Page 138: Service Reminder
21.15 ERVICE REMINDER If set, the Service reminder will remind the owner/user of the appliance to service the appliance at a specified Service Interval (Factory setting). When service is not done within the specified time, a Service reminder will be shown on the screen, alternating with the normal status display. -
Page 139: System Test
21.16 YSTEM TEST For testing the system at fixed power rates a system test can be activated via the menu. Via the system test the boiler can be started without CH or DHW being present. The system test has priority. The following modes are available: System test mode Description...
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