Lochinvar Shield SWA150 Installation & Service Manual Download Page 6

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The Shield - How it works...

DIR #2000586074

Rear View - Models SWA285

DIR #2000586092

Rear View - Model SWA400 - 500

Right Side (inside unit) - Model SWA400 - 500

Right Side (inside unit) - Models SWA285

Models SWA285

Model SWA400 - 500

DIR #2000586074

DIR #2000586092

Installation & Service Manual

Summary of Contents for Shield SWA150

Page 1: ...er flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service mus...

Page 2: ... Power Cord Connection 46 Runtime Contacts 46 Alarm Contacts 46 8 CONDENSATE DISPOSAL Condensate Drain 49 9 START UP Check for Gas Leaks 50 Inspect fill Condensate System 50 Final Checks Before Starting the Water Heater 51 54 Shield Control Module 55 Setup Wizard 56 10 OPERATING INFORMATION How the Water Heater Operates 57 Temperature Control 57 Protection Features 57 Water Heater Temperature Regu...

Page 3: ...d liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qu...

Page 4: ...upply 16 Gas valve The gas valve senses the negative pressure created by the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing 17 Heat exchanger access cover Allows access to the combustion side of the heat exchanger coils 18 Heat exchanger inlet temperature sensor This sensor monitors the inlet water temperature to the heat exchanger 19 Heat exchanger outl...

Page 5: ...2 DIR 2000586061 Left Side inside unit Models SWR125 200 25 3 17 26 9 33 21 7 18 19 DIR 2000586061 Right Side inside unit Models SWR125 200 The Shield How it works continued DIR 2000586061 23 27 35 34 2 31 13 7 30 Rear View Models SWR125 200 5 Models SWR125 200 Installation Service Manual ...

Page 6: ...34 13 31 36 7 25 18 19 5 15 Rear View Model SWA400 500 Right Side inside unit Model SWA400 500 Right Side inside unit Models SWA285 Models SWA285 Model SWA400 500 DIR 2000586074 23 26 8 21 11 17 29 33 3 16 32 14 35 34 13 20 DIR 2000586092 23 1 22 26 8 21 20 17 11 16 32 14 5 3 35 33 29 4 Installation Service Manual ...

Page 7: ...ote Change N to L for L P gas models CSA Input Modulation Btu hr Note 2 Water Content Gallons Water Connections Gas Connections Vent Air Size Min Max Note 1 SWR125 N L 25 000 125 000 65 1 1 2 1 2 3 SWR150 N L 30 000 150 000 90 1 1 2 1 2 3 SWA150 N L 30 000 150 000 91 1 1 2 1 2 3 SWR200 N L 39 800 199 000 91 1 1 2 1 2 3 SWA200 N L 39 800 199 000 91 1 1 2 1 2 3 SWR285 N L 57 000 285 000 91 1 1 2 3 4...

Page 8: ... If you do not provide the minimum clearances shown it may not be possible to service the water heater without removing it from the space Closet and alcove installations This appliance requires a special venting system The vent connection to the appliance must be made with the CPVC pipe section provided with the appliance The field provided vent fittings must be cemented to the CPVC pipe section U...

Page 9: ...on Minimum Required Clearances WARNING 9 1 Determine water heater location continued RECOMMENDED SERVICE CLEARANCES Top 18 457 mm Left Right Side 24 610 mm Front 24 610 mm RECOMMENDED SERVICE CLEARANCES Top 18 457 mm Left Right Side 24 610 mm Front 24 610 mm Installation Service Manual WARNING For closet installations CPVC polypropylene or stainless steel vent material MUST BE used in a closet str...

Page 10: ...om laundry facilities These areas will always contain contaminants WARNING WARNING 1 Determine water heater location Remove water heater from wood pallet 1 Remove the sides and the top of the crate 2 Remove the blocks on the base of the crate to allow for easier removal 3 The water heater can then be slid off the base of the crate for installation Do not drop the water heater or bump the jacket on...

Page 11: ...tion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA and or CAN CSA B149 1 Natural Gas and Propane Installation Code DANGER WARNING 1 Determine water heater location continued 11 Installation Service Manual Failure to follow all instructions can...

Page 12: ...ance is approved for zero clearance from combustible surfaces however service access will be limited from the sides Do not block the pump access cover see FIG s 1 1 and 1 2 Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using DIR 2000586334 Figure 1 3_Combustion Air Direct from Outside 1 If air is taken ...

Page 13: ... cm2 125 807 cm2 42 271 cm2 150 38 246 cm2 38 246 cm2 75 484 cm2 75 484 cm2 150 968 cm2 150 968 cm2 50 323 cm2 200 50 323 cm2 50 323 cm2 100 646 cm2 100 646 cm2 200 1 291 cm2 200 1 291 cm2 67 433 cm2 285 72 465 cm2 72 465 cm2 143 923 cm2 143 923 cm2 285 1 839 cm2 285 1 839 cm2 95 613 cm2 400 100 646 cm2 100 646 cm2 200 1 291 cm2 200 1 291 cm2 400 2 581 cm2 400 2 581 cm2 134 865 cm2 500 125 807 cm2...

Page 14: ...a of a combustion air opening a minimum of approximately 25 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30cm of the ceiling and one must be within 12 30cm of the floor of the equipment room Each opening must have net free area as specified in Table 1B Single openings shall commence within 12 30cm of the ceiling CAUTION Un...

Page 15: ...ing Installation Service Manual DIR 2000586391 Figure 2 2 PVC CPVC Concentric Sidewall Termination DIR 2000586468 Figure 2 3 Two Pipe Vertical Termination DIR 2000586468 Figure 2 4 PVC CPVC Concentric Vertical Termination DIR 2000586468 Figure 2 5 Vertical Vent Sidewall Air Direct venting options Vertical Vent ...

Page 16: ...e National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 2 7 thru 2 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate The Shield water heater vent and a...

Page 17: ...nada Minimum Maximum allowable combustion air and vent piping lengths are as follows Combustion Air 12 equivalent feet minimum 150 equivalent feet maximum Vent 12 equivalent feet minimum 150 equivalent feet maximum The appliance output rating will reduce by up to 1 0 for each 25 feet of vent length NOTICE Table 2B Concentric Vent Kit Equivalent Vent Lengths Sizing The Shield water heater uses mode...

Page 18: ...th a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer s recommended solvents and standard commercial pipe cement for the material used The PVC CPVC ...

Page 19: ...ethod provisions for combustion and ventilation air must be in accordance with 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 and Equipment or applicable provisions of the local building codes Commercial applications utilizing the Shield water heater ma...

Page 20: ...pported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the water heater to allow drainage of condensate Horizontal runs shall have supports suitable for non metallic vent piping that do not clamp tightly onto vent allowing for vent expansion or contraction Supports shall be as close to joints and fittings as practical and no more than 5 feet apart NOTICE WARNING The vent ...

Page 21: ...n Tables 2D and 2E DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage WARNING Installations must comply with applicable national state and local codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system NOTICE Installation of a polypropylene vent system shoul...

Page 22: ...using the manufacturers listed in Table 2F This unit requires Category IV venting Use only the materials vent systems and terminations listed in Tables 2F and 2G DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage WARNING Installations must comply with applicable national state and local codes Sta...

Page 23: ...m the air inlet as shown in FIG 3 1B Installation Service Manual TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION VENT AIR TERMINATION GRADE OR SNOW LINE 12 MIN 12 MIN TO OVER HANG POSSIBLE ORIENTATIONS Figure 3 1A PVC CPVC Polypropylene Sidewall Termination of Air and Vent Follow instructions below when determining vent location to avoid possibility of severe personal injury death...

Page 24: ...12 inches below roof overhang b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG 3 1B Condensate could freeze and block vent pipe c Do not terminate closer than 4 feet horizontally from any electric meter gas meter regulator relief ...

Page 25: ...ppliances 10 000 Btuh 3 kW and 50 000 Btuh 15 kW 12 in 30 cm for appliances 50 000 Btuh 15 kW C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each si...

Page 26: ... veranda porch deck or balcony is fully open on a minimum of two sides beneath he floor NOTES 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code Table 3B Direct Vent Terminal Clearances continued Figure 3 3B Other than Direct Vent Terminal Clearances J Clearance to nonmechanical air suppl...

Page 27: ...l distance of 15 ft 4 5 m J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a mechanical air supply inlet ...

Page 28: ...wn the sidewall adapters flush to the vent plate FIG 3 4B 3 For PVC CPVC Only Install the vent and air intake piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 2C on page 20 to seal the vent pipe 4 Mount and secure the vent plate to the wall using stainless steel screws 5 Seal all gaps between the pipes and wall...

Page 29: ... 4 inch hole for 3 inch vent pipe 5 inch hole for 4 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole as shown in FIG 3 4C 3 Reference Table 3D for the correct location of hole centers 4 Follow all local codes for isolation of vent pipe when passing through floors or walls 5 Seal exterior openings thoroughly with exterior caulk All vent pipes and air inlets must terminate at...

Page 30: ...ER Figure 3 8 Kit Contents_100140484 285 500 Sidewall termination optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits Factory Kit 100140480 for 3 diameter Models 125 200 and 100140484 for 4 diameter Models 285 500 Both combustion air and vent pipes must attach to the termination kit The termination kits must terminate ou...

Page 31: ...ion or other materials to accumulate inside the pipe assembly when installing through the hole 7 Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for 100140480 installations and fastened tightly into the rubber adapter for 100140484 installations 8 Secure the a...

Page 32: ... to avoid recirculation of flue gases Figure 3 13 Concentric Vent and Combustion Air Termination Figure 3 12 Concentric Vent Sidewall Attachment DO NOT use field supplied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 9 Cement appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 3 12 for proper pipe attachment 10...

Page 33: ...enting Section on page 17 of this manual 2 Prepare the vent termination and the air termination elbow FIG 4 1A by inserting bird screens Bird screens should be obtained locally 3 The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 4 The air piping must terminate in a down tu...

Page 34: ...e flashing and sealing boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple Shield water heaters terminate each vent air connection as described in this manual FIG 4 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury death or substantial property damage WARNING 2 Place ro...

Page 35: ... Cement the Y concentric fitting to the larger diameter kit pipe see FIG s 3 7 and 3 8 page 30 b Cement rain cap to the smaller diameter kit pipe see FIG s 3 7 and 3 8 page 30 c Do not attach a U Bent to the rain cap Doing so could cause recirculation see FIG 4 5 NOTICE WARNING 4 Vertical direct venting continued Installation Service Manual Vertical termination optional concentric vent Description...

Page 36: ...nnections Multiventing vertical terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 4 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 4 7 It is important that vent terminations be made as sho...

Page 37: ...listed temperature and pressure relief valve will release the manufacturer from any claim which might result from excessive temperature and pressures Keep clear of the combination temperature and pressure relief valve discharge line outlet The discharge may be hot enough to cause scald injury The water is under pressure and may splash Hydrogen gas can be produced in an operating water heater that ...

Page 38: ...ris from causing damage to the heat exchanger Water chemistry Water with a hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing non warrantable damage to the pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions The...

Page 39: ... EXPANSION TANK Y STRAINER MIXING VALVE UNION DIR 2000587161 Figure 5 2 Single Unit Installation Service Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE ...

Page 40: ...SION TANK Y STRAINER MIXING VALVE UNION DIR 2000587161 Figure 5 3 Multiple Units Installation Service Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE ...

Page 41: ... UNION TEMPERATURE SENSOR LOW TEMPERATURE ZONE HIGH TEMPERATURE ZONE DIR 2000587161 Figure 5 4 Two Temperature Single Unit Installation Service Manual Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE ...

Page 42: ...ly Piping Models 400 500 5 Purge all air from the gas supply piping 6 Before placing the water heater in operation check the water heater and its gas connection for leaks a The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa b The appliance must be isolated from the gas supply piping system...

Page 43: ...sure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with water heater on Minimum 4 inches w c with gas flowing verify during water heater startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane gas Pipe sizin...

Page 44: ...ap on top of the gas valve Re tighten the set screw inside the pressure tap Check inlet gas supply NOTICE CSA or UL listed flexible gas connections are acceptable but you must exercise caution to ensure that the line has adequate capacity to allow your water heater to fire at full rate Consult with local codes for proper installation or service procedures DO NOT attempt to measure gas valve outlet...

Page 45: ... 2000586431 Figure 6 5 Inlet Gas Supply Check Model 400 A LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP DETAIL A DIR 2000586420 Figure 6 6 Inlet Gas Supply Check Model 500 DO NOT attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane when configured fo...

Page 46: ...the correct terminals Reference Fig 7 3 on page 47 of this manual for appropriate wiring of the switch If the incorrect tab is removed a jumper wire may be added across the terminals to take the place of the tab Louver relay output louver proving switch input When installed using the optional room air configuration the heater is able to control powered louvers to allow outside air into the room Co...

Page 47: ...7 1 2 3 4 5 6 8 9 10 11 12 13 B BIAS A SHIELD ALARM CONTACTS RUN TIME 24V RELAY COM LOUVER SWITCH ENABLE LOUVER PROVING SW CONTACTS SHIELD CN1 CN4 CN2 CN3 A B C C B A LOW WATER CUTOFF LOW WATER CUTOFF DIR 2000587038 ALARM BELL BUILDING MANAGEMENT SYSTEM Installation Service Manual ...

Page 48: ...NITOR BLOWER GAS VALVE DISPLAY PANEL DIR 2000586867 LOUVER PROVING SWITCH LOW WATER CUTOFF ENABLE SWITCH TANK SENSOR INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HIGH LIMIT SENSOR FLUE GAS SENSOR BLOCKED AIR PRESSURE SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH DOOR TEMPERATURE SWITCH DISPLAY PANEL LOW VOLTAGE CONNECTION BOARD CONTROL BOARD Installation Service Manual ...

Page 49: ...CPVC pipe fittings and cement 4 A condensate removal pump is required if the water heater is below the drain When installing a condensate pump select one approved for use with condensing water heaters and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired to the auxiliary device proving switch terminals on the low voltage...

Page 50: ...eptable range Chloride 150 ppm Acceptable range Table 9A Water Chemistry NOTICE 1 Do not use the water heater to directly heat swimming pool or spa water 2 At initial fill and during water heater start up and testing check system thoroughly for any leaks Repair all leaks before proceeding further 3 When water hardness levels are less than 5 gpg or 85 5 mg l the following is recommended a Flush and...

Page 51: ...of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the water heater 1 Read and follow the Operating instructions in FIG s 9 2 and 9 3 pages 53 and 54 If water heater does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is wat...

Page 52: ...n 150 ppm for a properly installed unit If the combustion is not within the specified range reference the Troubleshooting section of this manual for possible causes and corrective actions 7 Once the combustion analysis is complete exit Service Mode Changethetargetfanspeedinincrementsof100rpm Toggle between operating at high fire and low fire Exit Service Mode and return to the Home Screen 8 Replac...

Page 53: ...53 Figure 9 2 Operating Instructions Models 125 285 9 Start up continued Installation Service Manual ...

Page 54: ...54 Figure 9 3 Operating Instructions Models 400 500 9 Start up Installation Service Manual ...

Page 55: ...lame signal is detected Indicates that the unit is running in Service Mode Indicates that Freeze Protection is active Home screen The Home Screen can be used to view the current operating information of the Shield water heater The and buttons can be used to page through the screen sequence displaying various operating statistics Figure 9 5 Screen Sequence Press to select various operating data Pre...

Page 56: ...n which all temperature will be displayed Range F C Default F TANK SETPOINT Target water temperature for the tank thermostat Theelectroniccontrolsensesthetanktemperature and regulates water heater ignition and firing rate to achieve the target temperature Range 60 F 180 F Default 140 F TANK SETPOINT DIFFERENTIAL Numberofdegreesbelowwhichthetankthermostat must fall for the electronic control to beg...

Page 57: ...the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 225 F 107 C the control will shut the unit down The unit will restart automatically once the flue temperature drops 10 F 6 C and the minimum off time has expired The control monitors the temperature difference between the h...

Page 58: ...3 Navigate to the GENERAL submenu and select MRHL SETPOINT from the menu options 4 Adjust the MRHL SETPOINT value to a temperature below the noted HEX OUTLET temperature from Step 1 5 Press the button to save changes and return to the Installer Menu 6 Press the button to return to the Main Screen 7 The water heater will lock out and display OUTLET MRHL 8 Enter the Installer Menu by pressing the bu...

Page 59: ...9 Once the final digit has been entered press the button to access the Installer Menu Entering the installer password will allow future access to the Installer Menu without requiring the password for up to an hour after the last button is pressed Installer main menu The Installer Menu is arranged in a menu submenu structure to help with navigation to the desired settings The Installer Main Menu gi...

Page 60: ...button 5 The minutes digits will then start flashing Use the and buttons to adjust the minutes for the current trigger then press the button 6 The AM PM selection will then start flashing Use the and buttons to select the appropriate AM PM setting for the current trigger 7 Repeat steps 2 through 6 to set day and time for all necessary start and stop triggers Once all necessary triggers have been s...

Page 61: ...s or BACnet control The water heater control can be configured by the installer to use a 0 10 VDC signal to control either tank setpoint or firing rate When the BMS parameter is set to INACTIVE the 0 10 VDC input will be ignored When set to ACTIVE the set point or modulation will be controlled by the voltage on the 0 10 VDC input in the case of 0 10 VDC BMS control or the 0 10 VDC input value rece...

Page 62: ...Bus BACnet the Volts at Maximum parameter should be set to the maximum voltage signal sent to the water heater control The range of this parameter is the Volts at Minimum value to 10 0V The default value is 10 0V Off Differential Volts When programmed for BMS control through ModBus BACnetandtheBMSThermostatInputissettoINACTIVE the Off Differential Volts parameter determines how far below the On Vo...

Page 63: ... inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Check anode rods Check Delta T Temperature Rise If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ANNUAL START UP Owner maintenance Daily Check ...

Page 64: ...ook for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 6 Gas Connections Check all piping for leaks The condensate trap must be filled with water during all times of water heater operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death WARNING WARNING WAR...

Page 65: ...r and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the water heater until a new relief valve has been installed 2 After following the warning directions if the relief v...

Page 66: ... in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite 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 guidelines Avoid breathing dust...

Page 67: ...y solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat ex...

Page 68: ...rify during water heater startup Check control module fuses ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF power to the water heater at the external disconnect switch 2 Remove front access cover 3 Remove the control module cover 4 Insp...

Page 69: ...board Blown fuse Replace fuse F3 on the main control board see page 68 of this manual No Burner Operation Tank temperature set point satisfied Review temperature setting Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 72 of this manual for corrective actions Unit Does Not Modulate Above 50 Flue sensor open Verify that the flue sensor is located in th...

Page 70: ...r tank water and flue are all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its corresponding table replace the sensor Installation Service Manual Table 12C Outlet Water Sensor Resistance vs Temperature S1a...

Page 71: ...ths do not exceed the maximum listed in the General Venting section Dirty damaged burner Refer to page 66 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Very pump operation Air in the piping system Properly purge all air from the piping system No Pump Operation Blown fuse Replace fuse F5 on the contr...

Page 72: ...e 68 of this manual Flow Switch LWCO will require a manual reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The low water cutoff LWCO is not making Check water heater pump operation on a call for heat Check for closed valves or obstructions in the water heater piping Verify system is full of water and all air has been purged from the system Check ...

Page 73: ...l manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 12C on page 70 of this manual Replace sensor if necessary Check operation of diverter valve motor Replace if necessary AIR PRESSURE SWITCH will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Air pressure switch contact...

Page 74: ...e is present replace the main control board If 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail f...

Page 75: ...120 vac to water heater pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the water heater pump is not operating replace the pump If operating on something other than an outlet sensor check temperature setting of the main control board Check resistance of water...

Page 76: ... call for heat too quickly after the previous call for heat has ended Thecontrolboardwillreleasethecallforheatafter60 seconds The control board will release the call for heat if the outlet temperature drops 10 F DELTA T HIGH The temperature rise across the heat exchanger has exceeded the set parameters for the water heater Verify that the system is full of water and that all air has been properly ...

Page 77: ...e DHW sensor and its associated wiring Repair or replace as needed LOCKOUT INLET SENSOR FAULT The inlet sensor has been disconnected Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 70 of this manual Replace the sensor if necessary The inlet sensor has been shorted ...

Page 78: ...SIBLE CAUSE CORRECTIVE ACTION Vent Air Intake Length or Obstruction Refer to Section 2 General Venting for the proper venting and air intake methods for the Shield water heater Check for obstructions at the vent air intake terminals Gas Supply Pressure Refer to Section 6 Gas Connections for the proper gas supply for the Shield water heater Dirty Damaged Burner Refer to page 66 of this manual for b...

Page 79: ...n the specified range revisit the possible causes in Table 12H on page 78 or replace the gas valve THROTTLE ADJUSTMENT SCREW DIR 2000586627 Figure 12 2 Gas Valve Adjustment Models 125 285 THROTTLE ADJUSTMENT SCREW DIR 2000586627 Figure 12 3 Gas Valve Adjustment Models 400 500 Models 400 500 Locate the throttle adjustment screw on the front of the gas valve see FIG 12 3 Using a screwdriver turn the...

Page 80: ...lt condition is present 2 See wiring diagram for additional notes HIGH VOLTAGE SPARK LEAD CAUTION X5 2 X5 11 X5 10 AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH CN2 7 X4 10 LOUVER RELAY COIL 24VAC LOUVER PROVING SWITCH CN2 8 X4 4 CN2 1 X4 5 LWCO ENABLE SWITCH CN2 10 X4 12 CN2 6 X4 8 CN3 4 CN3 2 CN3 3 CN3 1 24 VAC CONNECTION BOARD 120 VAC 24 VAC X1 6 F2 3 15A F1 5A INTEGRATED CONTROL X1 1 DHW PUMP RELAY...

Page 81: ...12 3 X5 15 X5 8 X5 7 X5 16 X5 9 X5 1 INTEGRATED CONTROL X7 TANK SENSOR S4 SPARK ROD TR2 BL FLAME SENSOR GY X1 1 X1 5 X1 6 X1 8 X1 2 X6 10 X6 14 X1 7 12 3 45 X4 8 X4 5 X4 4 X5 2 X5 10 X5 11 X4 10 X4 12 X4 10 X4 3 CN2 9 CN2 1 CN2 10 CN2 8 CN2 7 CN2 5 CN2 4 CN2 3 CN2 2 CN2 6 ALARM CONTACTS RUN TIME CONTACTS CN3 1 CN3 2 CN3 3 24V LOUVER COM RELAY LOUVER PROVING SWITCH SHEILD SWITCH CN1 BL R X5 4 X5 12...

Page 82: ...82 Notes ...

Page 83: ...83 Notes ...

Page 84: ...Revision Notes Revision A PCP 3000038210 CN 500026403 initial release MM 100329111_DIR 2000585724 Rev A 04 20 ...

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