Lochinvar Efficiency-Pac EW 150 -- 300 Installation & Service Manual Download

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Summary of Contents for Efficiency-Pac EW 150 -- 300

Page 1: ...ting installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage WARNING Save this manual for future reference EW I S Rev B_2000003735_100207764 LOW LEAD CONTENT ...

Page 2: ...ame Patterns 40 Combustion Air Adjustments 40 41 Burner Cleaning 41 42 Heat Exchanger Inspection 42 Gas Train 42 7 DIAGRAMS Ladder Diagram 43 Wiring Diagram 44 8 TROUBLESHOOTING Troubleshooting Charts 45 46 REVISION NOTES 48 DANGER WARNING CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potent...

Page 3: ...ipping damage Pay particular attention to parts accompanying the appliance which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing slip with those actually received In case there is damage or a shortage immediately notify carrier Experience has shown that improper installation or system design rather than faulty equipment is the cause of most ...

Page 4: ... Front View Cabinet Construction Figure 1 2 Typical Rear View Cabinet Construction Locating the water heater 1 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstan...

Page 5: ...servicing pipe connections pump and other auxiliary equipment as well as the appliance Figure 1 3 Installation Clearances Provisions for combustion and ventilation air must be in accordance with Section 5 3 Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances...

Page 6: ...nt applications Outside air openings shall directly communicate with the outdoors When combustion air is drawn from the outside through a duct the net free area of each opening must have twice 2 times the free area required for each Outside Air Openings The above requirements are for the appliance only additional gas fired appliances in the mechanical room will require an increase in the net free ...

Page 7: ...avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes tube headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure EXHAUS...

Page 8: ...tional venting systems use Type B double wall vent material Direct vent systems have specific vent kits and material requirements noted for each application Any vent materials not provided or specified must be listed by a nationally recognized test agency for use as vent material Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions Horizontal portions of the venting sy...

Page 9: ...gas meters regulators and relief equipment Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc Flue gases will form a white p...

Page 10: ...l Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes A bell increaser is installed directly on the appliance vent outlet The bell increases the vent size by 1 inch 25 4 mm in diameter The bell increaser MUST be installed on the appliance vent outlet for all conventional ne...

Page 11: ...stems before installation If there is any doubt about the sizing or condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system Masonry Chimney Installations Conventional venting only Inspection of a Masonry Chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products A clay tile lined chimney must...

Page 12: ...liance No additional draft diverter or barometric damper is required on single appliance installations with a dedicated stack and a negative draft maintained between 0 02 to 0 05 inches water The flue may be combined with the vent from any other negative draft Category I appliances Multiple appliance installations common vented with other negative draft appliancesrequirethateachappliancemusthaveab...

Page 13: ...of an L shaped structure The combustion air inlet cap must be installed at least one foot 30 cm above the roof top and above normal snow levels Incorrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the f...

Page 14: ... either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric 2 Do not install seams of vent pipe on the bottom of horizontal runs 3 Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installe...

Page 15: ...lled on the flue outlet MUST be used Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks The type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturers listing The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent conn...

Page 16: ... flow in the air inlet pipe connected to the unit Proper freeze protection must be provided see Freeze Protection Figure 2 10 E Sidewall Direct Vent System A Direct Vent System with Sidewall Terminations Follow all requirements in the General Venting section for venting flue products to the outdoors and general installation instructions All direct vent appliances must have combustion air supplied ...

Page 17: ...mmended caps may result in operational problems with the appliance or potentially hazardous spillage of flue products which can cause personal injury death or property damage Flue Pipe Materials Select venting material from the following specified vent materials Heat Fab Saf T CI Vent with AL29 4C stainless steel Call 800 772 0739 for nearest distributor Z Flex Z Vent with AL29 4C stainless steel ...

Page 18: ...and the air inlet cap connection Dryer vent should use a screw type clamp to seal the vent to the appliance and air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume Sealing of vent material for use with the Sidewall Direct Vent system The vent materials Heat Fab Saf T CI Vent Z Flex Z Vent Protech Systems Fas N Se...

Page 19: ...ilding The vent system shall terminate at least 1 foot 30 cm above grade and above normal snow levels The vent for a direct vent system shall NOT terminate above public walkways The vent shall not be installed closer than 10 feet 3 05 m from an inside corner of an L shaped structure Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent can not termin...

Page 20: ...air supplied directly to the appliance with a separate air pipe The bell increaser installed on the vent outlet must be removed The bell increaser is NOT USED with the direct vent system Vent connection is made directly to the top of the appliance No additional bell increaser draft diverter or barometric damper is required The direct vent system uses a two pipe system one pipe for the flue product...

Page 21: ...omplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury death or property damage A vertical vent cap as specified by the vent material manufacturer MUST be used to vent the flue products to the outdoors The vent cap for the flue products is...

Page 22: ...commercial pipe cement for the material used The PVC CPVC or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection Dryer vent should use a screw type clamp to seal the vent to the appliance and the assembly of 90 ells which make up the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants an...

Page 23: ...eneral venting section must be maintained on multiple appliance installations CAUTION Appliances which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit Proper freeze protection must be provided see Freeze Protection The Outdoor Vent System Figure 2 18 Outdoor Installation Appliances can be installed outdoors when equip...

Page 24: ... 4 feet 1 22m below and 4 feet 1 22m horizontally from any window door walkway or gravity air intake The combustion air inlet of the outdoor cap must be located at least 1 foot 0 30m above grade and above normal snow levels Locate appliance at least 10 feet 3 05m away from any forced air inlet Locate appliance at least 3 feet 0 91m outside any overhang Clearances around outdoor installations can c...

Page 25: ...RT Nominal Iron Pipe Size IN Length of Pipe in Straight Feet 10 20 30 40 50 60 70 80 90 100 125 150 175 200 3 4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 267 246 256 210 200 179 164 149 138 1 1 4 1 400 974 789 677 595 543 502 472 441 410 369 308 308 287 1 1 2 2 150 1 500 1 210 1 020 923 830 769 707 666 636 564 472 472 441 2 4 100 2 820 2 260 1 950 1 720 1 560 1 440 ...

Page 26: ...2 2 3 4 5 Equivalent Length of Straight Pipe Feet 2 2 1 2 3 1 2 4 5 10 14 20 Gas piping Figure 3 1 Gas Piping to Heater All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gases All piping must comply with local codes and ordinances Tubing installations must comply with approved standards and practices Install Piping to Control 1 The...

Page 27: ...nifold pressure to obtain actual net manifold pressure for normal operation A manometer or magnahelic gauge legible in 0 1 increments up to 10 water column is required to check and adjust the manifold pressure The regulator cover screw on the gas valve must be in place and tight for the appliance to operate properly 1 Turn the power switch to the OFF position 2 Remove the top front jacket panel 3 ...

Page 28: ...Natural Gas and 6 1 w c to 6 7 w c for L P Gas at full fire The difference in the gross manifold pressure and the front chamber pressure is the net manifold pressure setting of the gas valve s regulator Compare the net setting to the setting specified for the type of gas used Adjust regulator as required Set the thermostat to a setting lower than the appliance s water temperature to turn the burne...

Page 29: ...ter column 10 5 w c 13 w c Minimum Inches water column 4 0 w c 8 w c 6 Turn the power switch to ON position 7 Turn the gas valve knob to ON position 8 Set the thermostat to call for heat 9 Observe the gas supply pressure as the burners are firing Ensure inlet pressure is within specified range 10 If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency...

Page 30: ...witch is available as a factory supplied option on 150 000 through 300 000 Btu hr water heaters The flow switch should be wired across the X and B terminals on the appliance s internal terminal strip Remove the jumper between the terminals before connecting flow switch wires to the terminals This wiring connection installs the flow switch in the 24 VAC safety circuit for the ignition control A flo...

Page 31: ...ese units equipped with the Pump Delay Systems are all bronze pumps to ensure that no water discoloration can occur in an extended off cycle of the pump Water velocity control IMPORTANT To ensure proper velocity through the heat exchanger it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet This must be done on initial installation and periodically rechec...

Page 32: ... exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated ...

Page 33: ...s of those shown above DEDUCT 5 FEET from maximum allowable straight pipe in heater to tank circulating loop TABLE 4C MINIMUM PUMP PERFORMANCE Based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 PPM See Water Chemistry Btu hr Input GPM Ft Hd 150 000 300 000 55 10 Heat exchanger On all models header inspection plugs can be removed...

Page 34: ...F 1 1 2 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1 2 seconds 155 F About 1 second WARNING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Optional relief valve The wate...

Page 35: ...ll wall thermostat on inside wall DO NOT install thermostat in an area affected by drafts sunlight light fixtures hot or cold water pipes or near a fireplace TABLE 5A AMP DRAW DATA 150 000 300 000 Btu hr Models Firing Control Fan Valve Controls Max Total Amps at 120 VAC F 9 Single Stage 1 15 3 97 5 12 M 9 Two Stage 1 15 4 15 5 30 Pump Wiring The circulating pump must be purchased locally The maxim...

Page 36: ...t Water Temperature Sensor This sensor measures the inlet water temperature coming into the appliance Multi Purpose Temperature Sensor Depending upon how your appliance is set up this sensor can be used as a system sensor or a tank sensor for water heater applications Connect this sensor to the two blue wires in the upper left hand corner of the control panel Placement of Sensors Tank Sensor The t...

Page 37: ...etting manual reset high water temperature limit control This manual reset temperature limit control has a fixed limit setting of 230 F 110 C If water temperature exceeds this set point the limit will break the control circuit and shut down the appliance The limit control can only be reset after the water temperature has cooled below the set point of the limit Reset of the limit control is accompl...

Page 38: ...ing 3 Turn electric power on 4 The ignition module will lock out and the LED will blink 5 Readjust thermostat to normal setting 6 Turn on gas supply 7 Turn power off then on again to reset ignition module 8 If ignition system fails to operate properly repair work must be performed by a qualified serviceman or installer Hot surface ignition system The hot surface ignition module is not repairable A...

Page 39: ...low 40 F the pump relay will turn ON When the temperature rises above 50 F the pump relay will turn OFF 2 Location appliances must be located in a room having a temperature safely above freezing 32 F 0 C 3 Caution A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing The cold outside air pulled dow...

Page 40: ...aused by blockage of primary air flow to the burner s or excessive gas input This condition MUST be corrected immediately D Lifting Flames Lifting flames can be caused by over firing the burner s or excessive primary air If improper flame is observed examine the venting system ensure proper gas supply and adjust the combustion air 3 Combustion Air Shutter Adjustment This appliance uses a fan assis...

Page 41: ...in this application do not reach 2192 F 1200 C NOTICE The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guides F If adjustment is necessary follow these steps If no adjustment is necessary go to step I 1 Loosen two combustion air blower mounting nuts and slide the air shutter to t...

Page 42: ...ust be cleaned and problem corrected Proceed as follows a Removemanifold orificeassemblyasdescribedin steps a through e in Burner Removal b Disconnect wiring from hot surface igniter and hose from burner tap c Remove inner combustion chamber door mounting screws tilt slightly and slide door assembly out toward front of appliance Use caution to prevent damage to refractory hot surface igniter hose ...

Page 43: ... LWCO LWCO 6 2 LBL20019 REV A IF EQUIPPED PUMP DELAY 24VDC PUMP DELAY MRHL R2 W2 HFGV X B GAS VALVE C NO NC C NO NC TDR ALARM CONTACTS LOUVER CONTACTS RELAY ALARM LIMIT SWITCH FLOW SWITCH LOW AIR IGNITION MODULE ALARM BELL PUMP IGN MOD P6 CN 7 CN 8 CN 2 2 CN 1 3 CN 2 1 CN 1 4 P 3 1 P 3 7 P 3 8 P 3 2 P 3 3 P 3 6 P 3 5 OPTIONAL EQUIPMENT WIRING WATER HEATER Figure 7 1 Ladder Diagram ...

Page 44: ...ERIES TO SCREW TERMINALS NOTE REMOVE JUMPER BETWEEN X B OPTIONAL AMRHL REQUIRES MAX STOP SET 240 F INLET SENSOR BK BK TANK SENSOR 8 7 C 6 NO 5 NC 1 2 C 3 NO 4 NC 1 4 3 6 2 5 IF NOT EQUIPPED WITH LWCO CONNECT TO R1 ELSE CONNECT TO LWCO COM BL BL OR Y Y BL BL BL BR BR ALARM BELL ALARM 24V RELAY TIME DELAY RELAY BL BL BL BL SPLICE 5 Y Y T Y IF NOT EQUIPPED WITH LWCO WIRES TIED OFF CAPPED IF NO HIGH F...

Page 45: ...WIRING CONNECTIONS YES REPLACE CAB YES STEP 6 NO AIR SHUTTER ADJUSTMENT CORRECT SEE INSTRUCTIONS AIR PROVING SWITCH CLOSES NO ADJUST AIR SHUTTER TO PROPER SET POINTS CHECK FOR AIR LEAKS FROM BURNER COMPARTMENT PRESSURE HOSE YES IGNITION MODULE PURGE LED LIGHTS UP NO LED BURNED OUT BUT CONTROL FUNCTIONS REPLACE AT A CONVENIENT TIME YES REPLACE SWITCH YES STEP 7 IGNITION MODULE IGNITER LED LIGHTS UP...

Page 46: ...ALVE LED TURNS OFF YES MANIFOLD PRESSURE CORRECT NO SET MANIFOLD PRESSURE SEE INSTRUCTIONS YES REPLACE IGNITER CONTINUITY OF CHASSIS GROUND CONNECTIONS NO TIGHTEN OR REPLACE GROUND YES IGNITER SENSOR MOUNTED PROPERLY NO CORRECT MOUNTING YES REPLACE IGNITER CHASSIS GROUND WIRING CONNECTIONS TO IGNITER IGNITER SENSOR MOUNT PROPERLY GAS SUPPLY PRESSURE TO GAS VALVE CORRECT SET THERMOSTAT ABOVE WATER ...

Page 47: ...47 Notes ...

Page 48: ...Revision A ECO C15343 initial release Revision B Change 500000694 reflects the addition of non metallic venting information to page 14 EW I S Rev B_DIR 2000003735_MM 100207764 06 15 ...

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