Lochinvar EcoShield Series Installation, Commissioning And Maintenance Instructions Download

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The EcoShield™ range

High Efficiency Gas Fired Condensing Water Heaters

Installation, Commissioning and Maintenance
Instructions

INS0013 Issue No 5 | October 2013

SHW45-325CE

SHW60-325CE

SHW85-435CE

SHW115-435CE

SHW145-435CE

Models:

Summary of Contents for EcoShield Series

Page 1: ...d range High Efficiency Gas Fired Condensing Water Heaters Installation Commissioning and Maintenance Instructions INS0013 Issue No 5 October 2013 SHW45 325CE SHW60 325CE SHW85 435CE SHW115 435CE SHW145 435CE Models ...

Page 2: ... 2 COOLING VENTILATION 21 10 0 WATER CONNECTIONS 21 10 1 GENERAL 21 10 2 OPEN VENTED SYSTEM ARRANGEMENT 21 10 3 UNVENTED SYSTEM ARRANGEMENT 21 10 3 1 TEMPERATURE AND PRESSURE RELIEF VALVE 21 10 3 2 RELIEF VALVE DISCHARGE PIPEWORK 22 10 3 3 EXPANSION VESSEL SIZING 23 11 0 ELECTRICAL SUPPLY 23 11 1 EXTERNAL CONTROLS 23 11 1 1 REMOTE ENABLING 23 11 2 HIGH VOLTAGE CONNECTOR STRIP 24 11 3 LOW VOLTAGE C...

Page 3: ...E SYSTEM 39 15 10 3 CONDENSATE NEUTRALISATION KIT 40 16 0 USER CONTROL INTERFACE SETTINGS 40 16 1 ENTERING THE INSTALLER CODE 40 16 2 MENU SET D FUNCTIONS 40 16 2 1 RESET LAST 10 ERRORS 40 16 2 2 SERVICE MODE DELAY 40 16 3 MENU SET E WHR SETTINGS 41 16 3 1 TANK SETPOINT 41 16 4 MENU SET H CONTROL MODES 42 16 4 1 CONTROL SOURCE 42 16 4 2 CASCADE ADDRESS 42 16 4 3 MAX CASCADE SETPOINT 42 16 4 4 CASC...

Page 4: ...amily and LPG propane 3rd Family The information relating to propane firing is to be found in Section 14 LPG FUEL This equipment MUST NOT use gas other than that for which it has been designed and adjusted This equipment must be installed by a competent person registered with a H S E approved body All installations must conform to the relevant Gas Safety and Building Regulations Health Safety requ...

Page 5: ...r Allows access to the combustion side of the heat exchanger coils 16 Heat exchanger inlet temperature sensor This sensor monitors the inlet water temperature to the heat exchanger 17 Heat exchanger outlet temperature sensor This sensor monitors the heat exchanger outlet water temperature 18 High limit sensor Device that monitors the outlet water temperature If the temperature exceeds its setting ...

Page 6: ...6 FRONT VIEW MODELS SHW45 325CE SHW60 325CE LEFT SIDE INSIDE UNIT MODELS SHW45 325CE SHW60 325CE REAR VIEW MODELS SHW45 325CE SHW60 325CE RIGHT SIDE INSIDE UNIT MODELS SHW45 325CE SHW60 325CE ...

Page 7: ...7 REAR VIEW MODEL SHW85 435CE SHW115 435CE REAR VIEW MODEL SHW145 435CE RIGHT SIDE INSIDE UNIT MODEL SHW85 435CE SHW115 435CE RIGHT SIDE INSIDE UNIT MODEL SHW145 435CE ...

Page 8: ...lue gas mass rate g sec 10 5 CO2 16 7 23 2 31 6 44 2 55 4 Gas inlet connection size B S P 1 1 WATER DATA Water content litres 348 352 469 473 477 Water connections F R B S P 1 2 Max water pressure PMS bar 11 0 Maximum water temperature C 80 FLUE DATA TYPE B23 Nominal flue diameter mm 80 100 Maximum flue gas temp C 120 Maximum equivalent length m 60 Equivalent length 90 bend mm 1000 Equivalent leng...

Page 9: ...S TOP 450mm LEFT 600mm RIGHT 100mm FRONT 600mm REAR 600mm RESTRICTED HEIGHT SERVICE CLEARANCES TOP 100mm LEFT 600mm RIGHT 400mm FRONT 600mm REAR 600mm RECOMMENDED SERVICE CLEARANCES TOP 450mm LEFT 600mm RIGHT 100mm FRONT 600mm REAR 600mm RESTRICTED HEIGHT SERVICE CLEARANCES TOP 100mm LEFT 600mm RIGHT 400mm FRONT 600mm REAR 600mm ...

Page 10: ...omponents Concrete flue blocks BS 5440 1 2008 Flueing and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Specification for installation of gas appliances to chimneys and for maintenance of chimneys BS 5440 2 2009 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family ga...

Page 11: ...e refer to Section 9 AIR SUPPLY or to BS5440 2 or BS6644 as appropriate The Lochinvar EcoShield can also be used as a type B23 appliance If such a configuration is to be used then appropriate ventilation for cooling and combustion must be provided For further details please refer to Section 9 AIR SUPPLY or to BS5440 2 or BS6644 as appropriate 6 2 GENERAL REQUIREMENTS Corrosion of the heat exchange...

Page 12: ...l Gas 2H appear below for details relating to Propane 3P please refer to Section 14 LPG FUEL 7 1 SERVICE PIPES The local gas distributor must be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must not be used without prior consultation with the local gas distributor 7 2 METERS A new gas meter will be connect...

Page 13: ...ion Description SHW45 325CE SHW60 325CE SHW85 435CE SHW115 435CE SHW145 435CE A Directly below an opening air brick opening windows etc 300 2000 B Above an opening air brick opening windows etc 300 1000 C Horizontally to an opening air brick opening windows etc 300 1000 D Below a gutter or sanitary pipework 75 75 E Below the eaves 200 200 F Below a balcony or car port roof 200 200 G From a vertica...

Page 14: ...nnections concentric adaptor if required flue pipes air ducts if required and terminals If discharging at low level a suitable flue guard must be installed Due to the condensing nature of the water heater long external routes should be avoided to prevent the condensate freezing within the flue system unless necessary precautions are taken to insulate the flue During assembly precaution should be t...

Page 15: ... DETAILS SHW45 325CE SHW60 325CE ITEM DESCRIPTION 1 Flue Gas Test Point 2 Concentric Adaptor 3 80mm Dia x 500mm Length 4 90 Elbow 5 Air Intake Transition 6 Intake Connection Reducer 7 Exhaust Transition TABLE 8 2 FLUE CONNECTION DETAILS SHW45 325CE SHW60 325CE FIGURE 8 3 CUTTING ITEM 3 TO LENGTH X X ...

Page 16: ... Figure 8 2 fit the 80mm dia x 500mm length then fit one 90 elbow to the 500mm length 5 To the side intake connection of the concentric adaptor fit the remaining 90 elbows 6 Fit the exhaust section of the assembly to the heater ensuring the concentric adaptor is vertical and measure the distance between the centre of the air intake transition and the 90 elbow See Figure 8 3 7 Remove the 80mm dia x...

Page 17: ...between the centre of the air intake connection and the concentric adaptor See Figure 8 5 5 Remove the 100mm dia x 500mm length and cut the measured distance from the plain end See Figure 8 5 6 Insert the air intake transition Item 7 in Figure 8 4 into the intake connection Item 6 and tighten the worm drive clip 7 To the side intake connection of the concentric adaptor fit one of the 100mm dia x 5...

Page 18: ... with a fall to outside Max 10mm per metre to prevent the ingress of water NOTE When inserting the terminal ensure the air intake section is at the bottom 5 Fill the void between the terminal and wall with water resistant sealant 6 Fit the wall plates or rosette using appropriate fixings 7 Install the remainder of the flue system working progressively away from the water heater supporting the pipe...

Page 19: ...TIC FLAT AND TILED ROOFS FIGURE 8 8 INSTALLING TERMINAL THROUGH ROOF FLASHING 8 8 4 TYPE C43 This appliance can operate on a U Duct common flue system The maximum lengths for the interconnecting flue can be found in Table 3 1 Concrete components of the U Duct must meet the requirements of BS EN 1858 Model No Mass Rate 100 9 CO2 G20 Mass Rate 23 9 CO2 G20 Mass Rate 100 10 5 CO2 G31 Mass Rate 23 10 ...

Page 20: ...ater heater installations only If more than one water heater is being used BS6644 should be consulted to calculate the necessary requirements 9 1 COMBUSTION VENTILATION When used as a Type C appliance provided sufficient clearance is provided ventilation for combustion is not necessary as the combustion air is ducted directly from outside When used as a Type B appliance the combustion air requirem...

Page 21: ... connection to the water system are detailed in Table 3 1 Technical Data 4 Ideally individual valves should be fitted to each unit to enable isolation from the system The arrangement must comply with the requirements of BS6644 5 Typical pipework schematics are available from Lochinvar Limited upon request 10 2 OPEN VENTED SYSTEM ARRANGEMENT The Lochinvar EcoShield can be used in an open vented arr...

Page 22: ...ility at one or other of these locations Examples of acceptable discharge arrangements are I Ideally below the fixed grating and above the water seal in a trapped gulley II Downward discharges at a low level i e up to 100mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that where children play or otherwise come into contact with discharges a wi...

Page 23: ...NTS WARNING THIS APPLIANCE MUST BE EARTHED A suitably competent person MUST check wiring Normal supply required is 230 volts AC single phase 50 Hz An isolator with a contact separation of at least 3mm in all poles should be sited close to the equipment and must only serve that equipment The double pole switch must be readily accessible under all conditions 11 1 EXTERNAL CONTROLS The Lochinvar EcoS...

Page 24: ...STRAT RETURN FIGURE 11 2 HIGH VOLTAGE CONNECTION STRIP CONNECTION NOTES RETURN 230 VAC Live Neutral and Earth connections for a system return pump If the pump rating exceeds 190 watts the Live and Neutral connections should be used to energise a suitable contactor DE STRAT 230 VAC Live Neutral and Earth connections for a system de stratification pump If the pump rating exceeds 190 watts the Live a...

Page 25: ...s to be used to ensure the incoming gas pressure is correct the link should be taken out of pins 17 18 and the gas pressure switch wiring installed If there is no continuity across the terminals the heater will not fire 19 20 AUX PROVING DEVICE If an auxiliary device such as a fan dilution system or mechanical ventilation system is to be used the link should be taken out of pins 19 20 and the auxi...

Page 26: ...he control module cover Only replace with an equivalent rated fuse Use of non equivalent fuses or link wires will invalidate the warranty 11 6 ARC WELDING PRECAUTIONS The appliance must be isolated from the mains electricity supply in the event of electric arc welding being carried out on any connecting pipework ...

Page 27: ...bles can lead to operational problems which could result in non repairable damage to the integrated controller or other components minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having s...

Page 28: ...wn on diagrams depending upon whether utilities electricity connected to the unit As such actual switch states may 1 Where possible switches are shown without utilities gas water or NOTES CN4 14 X6 2 X2 2 19 20 21 22 17 10 18 16 15 HIGH VOLTAGE SPARK LEAD CAUTION HIGH VOLTAGE LOW VOLTAGE 230 VAC CONTROL INTEGRATED INTEGRATED CONTROL ROD SPARK FLAME ROD X1 7 TR1 1 25A F3 3 5A F2 3 5A F4 5A 5 4 2 1 ...

Page 29: ...FACE 12 1 GENERAL The Lochinvar EcoShield user control interface gives information on set up system status and diagnostic data in words rather than codes 12 2 USER CONTROL INTERFACE PANEL FIGURE 12 1 USER CONTROL INTERFACE PANEL ...

Page 30: ...igh limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve WHR IGNITION OUT 61 5C 65 5 If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge On the SHW45 325CE to SHW115 435CE models the control will perform another prepurge and will try to light the...

Page 31: ...trol does not detect the flue sensor SHORTED The flue sensor wires or the sensor itself has become grounded TANK C The control will display the stored water temperature the set point appears in brackets OPEN The control does not detect the tank sensor SHORTED The tank sensor wires or the sensor itself has become shorted Press the Next arrow key on the user control interface panel to access Screen ...

Page 32: ...at personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages are clear 2 Adequate ventilation exists in the plant room if necessary 3 The system is fully charged with water ready to receive heat All necessary valves are open and the building return pump if fitted is circulating water 4 The gas supply pipework is clear of any loose ...

Page 33: ... valve or venturi will invalidate the warranty Combustion figures should be as follows Model No CO2 CO SHW45 325CE 9 0 0 5 100 ppm SHW60 325CE 9 0 0 5 100 ppm SHW85 435CE 8 8 0 5 100 ppm SHW115 435CE 8 8 0 5 100 ppm SHW145 435CE 8 8 0 5 100 ppm TABLE 13 1 NATURAL GAS COMBUSTION FIGURES If the combustion figures are not within the range specified contact Lochinvar Limited for further guidance Combu...

Page 34: ...a competent person certified for work on LPG fuel In the event of any seal or gasket being broken it is essential that the seal or gasket be replaced Contact Lochinvar Limited for replacement seals and gaskets Due to the gas air ratio design of the water heater the conversion to LPG involves inserting An orifice plate into the gas valve to reduce the gas flow Model Part No Stamp Size SHW45 325CE O...

Page 35: ...conversion kit bag Verify that the stamping on the orifice disk is correct for the water heater see Table 14 1 LPG ORIFICE MARKING 6 Remove the existing orifice from the O ring in the side of the gas valve and replace it with the orifice from the kit Position and secure the orifice in the valve as shown in Figure 14 2 7 Reposition the gas valve against the venturi and replace the star drive screws...

Page 36: ...6 Remove the existing orifice from the O ring in the side of the injector plate and replace it with the orifice from the kit Position and secure the orifice in the injector plate as shown in Figure 14 3 7 Reposition the manifold adapter to the injector plate and replace the four manifold adapter mounting screws Handle the O ring with care do not damage 8 Reposition the injector plate to the air sh...

Page 37: ...4 GENERAL REQUIERMENTS Servicing is recommended at intervals no greater than 12 months to ensure trouble free operation Even if the maintenance schedule for the storage vessel is determined to be less than annually it is important that all controls and safety features are checked for correct operation on an annual basis Measuring flue gas CO2 and flue gas temperatures will give an indication of th...

Page 38: ...good condition or are replaced as necessary NOTE PARTICULAR ATTENTION SHOULD BE PAID TO THE COMBUSTION CHAMBER REAR WALL INSULATION IF ANY DETERIORATION IN THE INSULATING MATERIAL IS NOTED THE INSULATION PANEL MUST BE REPLACED 15 5 CLEANING THE HEAT EXCHANGER To clean the heat exchanger the following procedure should be carried out 1 Remove the burners as above 2 Use a vacuum cleaner to remove any...

Page 39: ...of the water therefore it is essential that the anodes are inspected at least once a year 1 Drain the water heater Refer to Section 15 6 DRAINING THE WATER HEATER SYSTEM 2 Remove the outer caps covering the anodes 3 Remove each anode and inspect its condition If the anode has reduced in size by more than 40 or if the surface is severely pitted the anode should be replaced Particular attention shou...

Page 40: ...play should now show Enter Menu Code 0309 7 Press the Up button 5 times The display should now show Enter Menu Code 5309 8 Press the Enter Reset button The display should now show Enter Menu Code INSTALLER CODE In addition to menu sets A and C as detailed in the User Guide the installer has access to various other menus By pressing the Up and Down buttons the various menu sets can be selected and ...

Page 41: ... setpoint to determine the firing rate of the water heater based on the actual water temperature The desired temperature can be adjusted in increments using the Up or Down buttons and the desired value stored by pressing the Enter Reset button The temperature range of this parameter is 0 C to 80 C The default value is 65 C ...

Page 42: ...ays of installation the water heater display will alternate the standard water heater display text with the message SERVICE DUE every 5 seconds This parameter is adjustable in 1 month intervals using the Up or Down buttons and then stored by pressing the Enter Reset button The time range for this parameter is 0 months to 36 months The default service interval is 12 months 16 6 2 SERVICE NOTIFICATI...

Page 43: ...ssioning is complete the equipment owner or their representative should be made aware of the lighting and operating instructions A practical demonstration should be given describing each functional step Incorrect use may result in injury and will also invalidate the warranty The Installation Commissioning and Maintenance Instructions should be handed over and kept in a safe place for easy referenc...

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