INSTALLATION & SERVICE MANUAL
Contents
1. EGD 1 amp S 01 INSTALLATION amp SERVICE MANUAL DOUBLE WALL INDIRECT WATER HEATER To avoid damage or injury there must be no materials stored against the indirect water heater and proper care shall be taken to avoid unnecessary contact especially by children with the indirect water heater Do not store or use gasoline or other flammable liquids in the vicinity of this water heater or any other appliance For your family s comfort safety and convenience we recommend this water heater be installed and serviced by a plumbing professional TABLE OF CONTENTS Important Information scccssscsscsssssccsssssccssssseeseeeses 1 General Information scccssscccsssscsssssccessccessscessssscessese 3 Pre Installation ss0c000 Water Connections Electrical Connections scsssccssssscssssecscssscesssccesssccees 8 Operating Instructions ccscsscsssssssscsesssssesssseceeeees 10 Maintenance 5co5csaceansssceesecsveccousetssscepucesescssbecsesessesesescsons 13 Troubleshooting Guide scssssscsscssssscssseesesseesserseees 14 IMPORTANT INFORMATION The equipment must be installed in accordance with those installation regulations required in the area where the installation is to be made These regulations must be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made All wiring on water heaters installed in the2. Figure 2 Water Boiler Piping with Circulators VACUUM BREAKER COLD WATER SUPPLY HOT WATER OUTLET TEMPERATURE AIR VENT CIRCULATOR AND PRESSURE PRESSURE RELIEF VALVE REDUCING FROM BOILER SUPPLY VALVE ON eeN TO SPACE R HEATING ZONE S SPACE HEATING EXPANSION TANK CIRCULATOR AIR SEPARATOR EXPANSION TANK IF NEEDED SUPPLY SUPPLY Weegee Pilabund BOILER RETURN i TO BOILER RETURN MAN io y INDIRECT FIRED WATER HEATER FROM SPACE DRAIN VALVE HEATING ZONE S EGD 1 amp S 01 CONNECT STEAM BOILER SUPPLY PIPING Figure 3 represents a typical steam boiler connection diagram Refer to the boiler installation manual or contact the boiler manufacturer for an appropriate piping diagram The use of a union shut off valves and a drain valve is recommended for future service convenience The use of an in line Y style strainer is required to prevent accumulation of sludge in the water heater s coil Figure 3 Typical Steam Boiler Connections connections available below the water line VACUUM BREAKER MINIMUM LOW COLD WATER P WATER LINE HOT WATER OUTLET SUPPLY J 1 NPT MINIMUM PIPING TO CIRCULATOR TEMPERATURE AND PRESSURE RELIEF VALVE FROM BOILER SUPPLY EXPANSION WATER TANK TEMPERATURE IF NEEDED LIMIT Y STRAINER Reena 6 MAX SHU
3. Table 1 Water Heater Performance Pressure Drop at Rated Heat Source Flow Rate Feet of Head Hot Water Coil Heat Availability Transfer MODEL Minutes Area Sq Ft NOTICE If the boiler takes longer to heat up from a cold start than the water availability as noted above hot water shortage may occur Hot water availability is based off drawing 80 of the heated tank volume at 4 gallons per minute flow rate The maximum heat transfer through the coil heat input of the water heater at 240 F boiler water supply temperature and 210 F potable water temperature is 94 100 Btu hr for residential models and 180 300 Btu hr for commercial models Potable water temperature is limited to below 210 F and nominal water containing capacity is below 120 gallons for all single wall indirect models Accordingly per Part HLW 101 2 Section IV of the ASME Boiler and Pressure Vessel Code all Lochinvar Single wall Indirect products are exempted from compliance with the code GENERAL INFORMATION FEATURES This water heater contains the following features HEAT EXCHANGER The heat exchanger coil has 3 4 NPT female fittings Water heaters with a double wall heat exchanger meet the Uniform Plumbing Code for installation in all potable water systems The double wall construction provides protection in the event that either the potable or hydronic heat exchanger barrier is penetrated The fluid will move along in int
4. UNTIL THE LEAKAGE IS CORRECTED Liquefied petroleum gas propane gas is heavier than air and will remain at floor level if there is a leak Basements crawl spaces closets and areas below ground level will serve as pockets for accumulation of leaking gas This water heater is supplied with an adjustable thermostat to control water temperature Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and or death The temperature at which injury occurs varies with the person s age and the time of exposure The slower response time of disabled persons increases the hazards to them NEVER allow small children to use a hot water tap or to draw their own bath water NEVER leave a child or disabled person unattended in a bathtub or shower EGD 1 amp S 01 Installation is not complete unless a pressure and temperature relief valve is installed into the side of the water heater See the Water Connections section of this manual for details This water heater contains very hot water under high pressure Do not unscrew any pipe fittings or attempt to disconnect any components of this water heater without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this water heater to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the tempera
5. USA must be in accordance with the National Electrical Code and or local regulations or in Canada installed in accordance with the Canadian Electrical Code and or local regulations The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage AN CAUTION Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards N DANGER DO NOT store or use gasoline or other flammable combustible or corrosive vapors and or liquids in the vicinity of this or any other appliance IF YOUSMELL GAS Q DO NOT try to light any appliance Q DO NOT touch any electric switch do not use any telephone in your building Q Immediately call your gas supplier from a telephone in another building Follow the gas supplier s instructions O Ifyou cannot reach your gas supplier call the fire department DO NOT OPERATE THEAPPLIANCE
6. installed to allow for complete drainage of both the temperature and pressure relief valve and the discharge line The discharge opening must not be subjected to blockage or freezing DO NOT thread plug or cap the discharge line It is recommended that a minimum clearance of four 4 inches be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve Do not place a valve between the combination temperature and pressure relief valve and the tank EGD 1 amp S 01 TEMPERATURE AND PRESSURE RELIEF VALVE 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 For protection against excessive temperatures and pressure install temperature and pressure protective equipment required by local codes but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 and the Standard CAN1 4 4 Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves The combination temperature and pressure relief valve must be marked with a maximum set pr
7. or alter the water heater and or controls DO NOT operate the water heater if any external part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system that was under water This water heater is suitable for installation on combustible flooring DO NOT install this water heater on carpeting DO NOT operate this water heater without first being certain it is filled with water Flammable items pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heater Containers of flammable gases should not be stored or used in the same room with this water heater Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend that the water faucet be opened for several minutes at the kitchen sink before you use any electrical appliance that is connected to the hot water system If hydrogen is present there will be unusual sounds such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open The maximum boiler water supply temperature to the indirect heat exchanger must not exceed 240 F 116 C EGD 1 amp S 01
8. supply piping Mount the circulator making sure the flow arrow points toward the water heater The use of shut off valves and unions are recommended for future service convenience The use of an air separator and vent is recommended to eliminate air in the system Pipe and fittings between the boiler and indirect fired water heater must be 3 4 diameter or larger Figure 1 Water Boiler Piping with Zone Valves VACUUM BREAKER COLD WATER HOT WATER OUTLET SUPPLY TEMPERATURE AIR VENT AND PRESSURE CIRCULATOR PRESSURE RELIEF VALVE REDUCING FROM BOILER SUPPLY VALVE AIR SEPARATOR EXPANSION TANK IF NEEDED TO SPACE HEATING ZONE S SUPPLY Fehon eee COLD WATER SUPPLY SPACE HEATING BOILER EXPANSION TANK ZONE VALVE TE RETURN FROM SPACE DRAIN VALVE HEATING ZONE S INDIRECT FIRED WATER HEATER 2 For a space heating system that utilizes CIRCULATORS refer to Figure 2 The indirect fired water heater connection labeled FROM BOILER SUPPLY should be piped to the boiler supply piping Mount the circulator making sure the flow arrow points toward the water heater The use of shut off valves and unions are recommended for future service convenience The use of an air separator and vent is recommended to eliminate air in the system Pipe and fittings between the boiler and indirect fired water heater must be 3 4 diameter or larger
9. Ueda CIRCULATOR MOUNTED BOILER RETURN CLOSE TO FLOOR INDIRECT FIRED WATER HEATER BOILER DRAIN VALVE NOTICE Typical steam boiler without connections available below the water line is not recommended due to insufficient water temperature especially during warmer months when the space heating system is not operational Boiler water temperature at the bottom of a steam boiler can be 50 F lower than the boiler s water temperature limit setting during such periods FILL BOILER SYSTEM 1 On new boiler installations do not purge the boiler or space heating system through the water heater During any boiler or space heating system flushing cleaning or purging the water heater should be isolated to avoid possible attack on the carbon steel coil by chemical additives 2 Purge air from boiler water heater piping 3 Check system for leaks Repair as necessary ELECTRICAL CONNECTIONS Install electric wiring in accordance with National Electric Code or the Canadian Electrical Code and local regulations See the boiler s installation manual for wiring diagrams Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the water heater or building Lock out all electrical boxes with padlock once power is turned off EGD 1 amp S 01 When installed the water heater must be electrically grounded in accordance with
10. collecting water The drain pan can be purchased from your plumbing professional The drain pan must be piped to an adequate drain The piping must be at least 3 4 inch in diameter and pitched for proper drainage Table 2 Clearance from Combustible Materials Sides Rear Table 3 Recommended Service Clearances Non Piping Front T amp P Relief Rear Valve Side Side Thermostat i fo AN CAUTION MOVE THE WATER HEATER TO A PERMANENT POSITION BY SLIDING OR WALKING fiw CAUTION Do not drop water heater Do not bump water heater jacket against floor Appliance Location 1 Boiler Location Locate the indirect fired water heater as close to the boiler as practical 2 Fixture Locations For fastest delivery of hot water place the indirect fired water heater close to points of use Additional Recommended Components 1 Shut off Valves Allows isolation of water heater from domestic water system and or boiler system during service 2 Unions Allows water heater movement during service if adequate clearance cannot be provided 3 Thermal Expansion Tank If the water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water line provide thermal expansion control Contact the water supplier or local plumbing inspector for additional information EGD 1 amp S 01 NOTICE For California installation this water heater must be braced anchore
11. d or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California Office of the State Architect 400 P Street Sacramento CA 95814 WATER CONNECTIONS FAILURE TO INSTALLAND MAINTAIN A NEW LISTED TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROMANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time HYDROGEN GAS IS EXTREMELY FLAMMABLE To prevent the possibility of injury under these conditions we recommend the hot water faucet be opened for several minutes at the kitchen sink before you use any electrical appliance that is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is pen Keep clear of the 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 iy CAUTION If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections It is imperative that heat is not applied to the nipples co
12. direct fired heater zoned with a circulator DOMESTIC HOT WATER PRIORITY Two options are available Priority and Non Priority 1 Priority Demand for space heating is interrupted or postponed until the domestic hot water demand is satisfied This option provides maximum delivery of domestic hot water Priority is recommended when a Boiler net output is 100 000 Btu per hour or less or b When boiler output required to satisfy domestic hot water demand is at least 50 of the boiler output required to satisfy space heating demand or c When an interruption in space heating can be tolerated during a long domestic hot water draw 2 Non Priority Boiler output is divided between space heating and domestic hot water heating Delivery of domestic hot water can be reduced during simultaneous space and domestic hot water heating operations depending on such factors as boiler output boiler over sizing number of space heating zones calling for heat and the ratio of domestic hot water load to space heating load Component Location This water heater must be located in an area where leakage of the tank water line connections or the temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure When such locations cannot be avoided a suitable drain pan must be installed under the water heater The drain pan depth must be suitable for draining and
13. egrated leak path within the heat exchanger leaving the exchanger through a weep hole located in the fittings If a confirmed leak occurs contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for additional guidance This indirect fired water heater is appropriate for all potable heating systems even where a single wall exchanger is not approved by the authority having jurisdiction ADJUSTABLE THERMOSTAT The temperature may be adjusted from approximately 80 F to approximately 160 F The thermostat is factory set at 120 F It is recommended that lower temperatures be used to avoid the risk of scalding Refer to the Warnings and the section on SCALDING in Section VII Operating Instructions It is further recommended in all cases that the water temperature be set for the lowest temperature that satisfies our hot water needs This will also provide the most energy efficient operation of the water heater and minimizes scale formation Setting the water heater temperature at 120 F will reduce the risk of scalds Some states require settings to specific lower temperatures TEMPERATURE SETTING TO REDUCE SCALD Install a discharge line so that water discharged from the temperature and pressure relief valve will exit within six 6 inches above or any distance below the structural floor and cannot contact any live electrical part The discharge line is to be
14. essure not to exceed the maximum working pressure of the water heater The combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater The supplied combination temperature and pressure relief valve when properly installed and unrestricted will discharge the maximum input produced by a 240 F 116 C boiler supply temperature A lower boiler supply temperature will reduce the input required to be discharged in the event of excessive potable water temperatures Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater Some models may already be equipped or supplied with a temperature and pressure relief valve Verify that the combination temperature and pressure relief valve complies with local codes If the temperature and pressure relief valve does not comply with local codes replace it with one that does SACRIFICIAL ANODES Two sacrificial anode rods have been installed in the tank head to extend tank life The anode rods should be inspected annually to determine the amount of sacrificial decay and replaced when necessary to prolong tank life Water conditions in your area will influence the time interval for inspection and replacement of the anode rod The use of a water softener may increase the speed of anode consumption More frequent inspec
15. heat source having a DOE heating capacity of 55 000 BTU h Answer New Rating 98 gal hr x 55 000 BTU h 65 000 BTU h 98 gal hr x 0 846 83 gal hr NOTICE Increasing the boiler DOE heating capacity above the values listed in Table 3 will not increase the rating of the water heater EGD 1 amp S 01 2 Circulator Sizing Refer to Table 5 for the corresponding pressure drop through the coil for the given model Calculate the pressure drop of all straight pipe and fittings on the supply and return of the water heater at the selected flow rate Add the piping fitting pressure drop to the pressure drop through the water heater coil Select a circulator that will provide an appropriate flow rate at the combined pressure drop SYSTEM ZONE CONTROL The indirect fired water heater must be installed as a zone separate from the space heating system The domestic hot water zone s piping and circulator must be sized for a minimum flow rate with all zones in use and a maximum flow rate with only the water heater in use For this reason the preferred method of zone control is with circulators 1 Circulators With space heating zones using circulators the indirect fired heater should be added as an additional zone with a circulator 2 Zone Valves Select a valve with a low pressure drop to assure adequate flow through the water heater 3 Hybrid The space heating zone can be zoned using zone valves and the in
16. ing sure that the control is well covered and that the plastic terminal shield has not been displaced Replace the access panel The water heater is now ready for operation and the main switch can be closed After the indirect fired water heater completes a heat up cycle check the water temperature at a faucet Allow enough water to flow to ensure that the water temperature reflects the tank temperature Adjust the water heater s temperature setting as necessary Adjusting to a lower temperature setting will not immediately affect water temperature Draw sufficient water or allow the water heater to remain idle until a heat up cycle is initiated After the heater s heat up cycle is complete check the water temperature at a faucet to determine if further adjustment is necessary Adjusting to a higher temperature may not immediately affect water temperature If a heat up cycle begins allow the heat up cycle to complete before checking the water temperature If a heat up cycle does not begin draw sufficient water or allow the water heater to remain idle until a heat up cycle is initiated After the heater s heat up cycle is complete check the water temperature at a faucet to determine if further adjustment is necessary TEMPERATURE DIAL Figure 7 Thermostat 12 EGD 1 amp S 01 MAINTENANCE This indirect fired water heater is intended to provide a service life of many years Components that require service however
17. local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electric Code Failure to properly wire electrical connections to the water heater may result in serious physical harm Electrical power may be from more than one source Make sure all power is off before attempting any electrical work The thermostat incorporates a manual reset temperature limiting device Please refer to the TROUBLESHOOTING GUIDE section for manual reset operation The thermostat incorporates a manual adjustable temperature indicator to change the potable water temperature Please refer to WATER TEMPERATURE ADJUSTMENT in the OPERATING INSTRUCTIONS section for proper instruction in adjusting water temperature Turn off all power related to the boiler and heating system before proceeding with the electrical connections The thermostat switch is a single pole single throw device The field connections shall be used as a control for one leg of the electrical circuit The thermostat switch can be used in the range of 24 to 480 volts with a maximum current load of 15 amps Any and all wiring shall be sized and installed to satisfy the voltage and amperage used All wiring shall be done in accordance with all applicable local and state codes GENERAL INSTALLATIONS If a circulator is used to control the heating fluid flow from the water heater to the boiler a zone relay is required between the water hea
18. may be subject to failure Failure to use the correct procedures or parts in these circumstances may make the water heater unsafe The owner should arrange to have the following inspections and simple maintenance procedure performed by qualified service personnel at the frequencies suggested 1 Boiler and Domestic Water Piping Annual Check all piping for signs of leakage at joints unions and shut off valves Repair as needed 2 Temperature Pressure Relief Valve Annual The temperature pressure relief valve should be checked to ensure that it is in operating condition To check the relief valve lift the lever at the end of the valve several times The valve should seat properly and operate freely If water does not flow remove and inspect for obstructions or corrosion Replace with a new valve of the recommended capacity as necessary Do not attempt to repair the valve as this could result in improper operation and a tank explosion In areas with poor water conditions it may be necessary to inspect the temperature pressure relief valve more often than once a year If the temperature pressure relief valve on the heater discharges periodically or continuously it may be due to thermal expansion of water in a closed water supply system or it may be due to a faulty relief valve iw CAUTION Before manually operating the valve make sure that a drain line has been attached to the valve to direct the discharge to an open d
19. mostat senses stored water temperature drops below desired setting a Domestic hot water priority only Normally closed contacts open to interrupt space heating 2 Thermostat satisfied a Thermostat contacts open turning off domestic hot water circulator and de energizing relay Water temperature over 125 F can Cause severe burns b Normally open contacts open stopping boiler instantly or death from scalds a Children disabled and elderly are at highest risk of bein c Domestic hot water priority only Normally closed ented Pa g contacts close returning boiler control to space i heating See instruction manual before setting temperature at water heater Feel water before bathing or showering WATER TEMPERATURE Temperature limiting valves are ADJ USTMENT available see manual Figure 6 Scald Warning SCALDING Table 4 details the approximate relationship of water This water heater can deliver scalding temperature temperature and time with regard to scald injury and may be water at any faucet in the system Be careful used as a guide in determining the safest water temperature whenever using hot water to avoid scalding injury for your applications By setting the thermostat on this water heater to obtain an increased water temperature you may create the potential for scald injury To protect against injury you should install an ASSE approved mixing valve a device to limit the temperature of water to protect agai
20. nst scald injury via mixing hot and cold water supply in the water system This valve will reduce point of discharge temperature in branch supply lines Such valves are available from the manufacturer of this water heater or a local plumbing supplier Please consult with a plumbing professional APPROXIMATE TIME TEMPERATURE RELATIONSHIPS IN SCALDS 125 F 1 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 Table 4 Scald Relationships 11 EGD 1 amp S 01 N CAUTION Before adjusting the thermostat turn off all power supplied to the indirect fired water heater The potable water temperature can be changed by adjusting the thermostat Before any work is done on the water heater disconnect all power to the water heater and heat source boiler by opening the switch s at the main electrical circuit breaker or fuse box Remove the access panel and fold the insulation outward away from the control Adjust the thermostat dial using a screwdriver until the minimum acceptable temperature is achieved The thermostat has been factory preset to 120 F 49 C Remember that lower temperature settings are more energy efficient Rotate the temperature dial clockwise to increase water temperature Rotate the thermostat dial counter clockwise to decrease the temperature setting Replace the insulation mak
21. ntaining a plastic liner INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE Cif not factory installed Temperature and pressure relief valve discharge piping must be piped near the floor to eliminate potential of severe burns Do not pipe in any area where freezing could occur Do not install any shut off valves plugs or caps to the temperature and pressure relief valve or piping INSTRUCTIONS FOR POTABLE CONNECTIONS 1 BEFORE PROCEEDING WITH THE INSTALLATION CLOSE THE MAIN WATER SUPPLY VALVE After shutting off the main water supply open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater After the pressure has been relieved close the faucet The COLD water inlet and HOT water outlet are identified on the top of the water heater Make the proper plumbing connections between the water heater and the plumbing system to the house Install a shut off valve in the cold water supply line 2 If this water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water supply provisions must be made to control thermal expansion DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion Warranties do not cover damages from thermal expansions such as pressure bulges and or deformities A properly sized expansion tank will alleviate most p
22. ormer primary side The second leg of the primary side is to be connected to L2 120V neutral The secondary side of the transformer is to be connected to the zone valve coil The contact side of the zone valve is to be connected to the boiler operating control Connect the black wire on the water heater to L1 120V hot see figure5 These connections enable the water heater thermostat to control the zone valve and the boiler operating control Other installations may require slightly different wiring arrangements In all cases it is important to remember that the thermostat on the water heater only controls one leg of the system OPERATING INSTRUCTIONS Water heaters are heat producing appliances To avoid damage or injury there must be no materials stored against the water heater and proper care must be taken to avoid unnecessary contact especially by children with the water heater UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THE WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved Plumbing and electrical work are required 10 EGD 1 amp S 01 SYSTEM START UP Follow boiler installation instructions to place boiler in A D A N Gi E R operation SEQUENCE OF OPERATIONS 1 Ther
23. rain Failure to take this precaution could mean contact with extremely hot water discharging from the valve during this checking operation Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled Then the relief valve will open allowing some water to escape slightly lowering the pressure Contact your water supplier or local plumbing inspector on how to control this situation ABOVEALL DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE THIS IS NOTA SOLUTION AND CAN CREATE A HAZARDOUS SITUATION 13 3 Anode Inspection and Replacement This water heater is equipped with multiple sacrificial anodes Anodes protect the glass lined tank from corrosion by sacrificing themselves through electrolysis When the anode material is consumed there is no more protection and corrosion of the tank accelerates Inspection of the anode every year allows you to identify a spent anode and replace Replace the anode when its diameter is 3 8 of an inch or every other year which ever is first Aggressive very hot and softened water causes rapid consumption of the anode requiring frequent inspections Anodes are available from your distributor or from the manufacturer To inspect or replace an anode The anodes on this water heater are easily accessible from the top of the heater making replacement
24. roblems Your water supplier or local plumbing inspector should be contacted on how to control this situation 3 After installation of the water lines open the main water supply valve and fill the water heater While the water heater is filling open several hot water faucets to allow air to escape from the water system When steady streams of water flow through the faucets close them and check all water connections for possible leaks 4 NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN THAT IT IS FILLED WITH WATER INSTRUCTIONS FOR BOILER CONNECTIONS The indirect fired heater connection labeled To Boiler Return should be piped to the boiler return piping as close to the boiler as possible and especially after any flow control or check valves in the space heating return piping The use of a union and a shut off valve is recommended The use of a flow control or check valve is required to prevent back flow through the water heater during operation of the space heating system Pipe and fittings between the boiler and indirect fired water heater should be 3 4 diameter or larger EGD 1 amp S 01 CONNECT WATER BOILER SUPPLY PIPING Maximum boiler water supply temperature to the indirect heat exchanger MUST NOT exceed 240 F 116 C 1 Fora space heating system that utilizes ZONE VALVES refer to Figure 1 The indirect fired water heater connection labeled FROM BOILER SUPPLY should be piped to the boiler
25. simple and quick a Turn the water heater electricity off for the zone containing the indirect fired water heater Flow water until the discharge is cool or allow enough time for the potable water to cool naturally Connect a hose to the drain valve Locate the hose s discharge in an area where any remaining hot water will not cause any damage or injury b Open the drain valve to flush any sediment out of the bottom to the heater c Shut off the cold water supply Make sure all hot water fixtures and circulating pumps are turned off d Wait for water flow from the hose to stop Remove the anode using a socket of the appropriate size Do not use an impact wrench e Inspect and replace the anode as required Use pipe tape or sealant when reinstalling the anode f Close the drain valve Open a hot water fixture to allow air to escape Open the cold water supply to the heater and allow the tank to fill g Check your anode and drain valve for leaks h Turn the water heater electricity on for the zone containing the indirect fired water heater Sediment Annual but harsh water quality may dictate more frequent service Depending on water conditions a varying amount of sediment may collect in the tank Levels requiring service are indicated by a small temperature difference in the supply and return lines See also Scale below Repeated flushing usually clears such material As a preventive measure water should be dra
26. t too high Adjust thermostat setting See Section VII too hot Improper system plumbing Compare plumbing to Section V Improper system wiring Compare wiring to Section VI Insufficient hot Thermostat setting Adjust thermostat to higher setting water too low See Section VII Undersized boiler with Rewire for priority no priority to domestic hot water Peak use of hot water Determine peak usage and compare to is greater than tank storage tank capacity capacity Faulty tank thermostat Replace thermostat Boiler cycles Excessive demand Reduce demand or consider larger tank more than 5 Faulty thermostat Replace thermostat times per day Boiler high limit set too low Increase boiler high limit setting in summer 14
27. ter thermostat and the boiler Connect the white wire on the water heater to one leg of the circulator The second leg of the circulator is to be connected to L2 120V neutral Connect the white wire on the water heater to one leg of the zone relay The second leg of the zone relay is to be connected to L2 120V neutral The contact side of the zone relay is to be connected to the boiler operating control see figure 4 Connect the black wire on the water heater to L1 120V hot These connections enable water heater thermostat to control the circulator the zone relay and the boiler operating control Figure 4 Electrical Connection with Circulator WIRE NUT OR EQUIVALENT 120V HOT JUNCTION BOX I Me ee WHITE THERMOSTAT L2 120V NEUTRAL CIRCULATOR ZONE RELAY HONEYWELL R4222 OR EQUIVALENT m Aq L2 120V NEUTRAL TO BOILER OPERATING CONTROL EGD 1 amp S 01 Figure 5 Electrical Connection with Zone Valve JUNCTION BOX L1 120V 120VAC 24VAC HOT REUTRAL ZONE STEP DOWN TRANSFORMER WIRE NUT OR EQUIVALENT END SWITCH ZONE VALVE TO BOILER CONTROL CIRCUIT If a zone valve to used to control the heating fluid flow from the boiler to the water heater a zone step down transformer is required between the water heater thermostat and the zone valve Connect the white wire on the water heater to one leg of the transf
28. tion of the anode is needed when using softened or phosphate treated water Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information PRE INSTALLATION UNPACKING INSPECT SHIPMENT carefully for any signs of damage If damage is noted do not install the product Contact the shipper or manufacturer All equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of the packaged water heater to the carrier in good condition NOTE Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee This water heater MUST be installed indoors out of the wind and weather IMPORTANT DECISIONS REQUIRED BEFORE INSTALLATION SIZING 1 Boiler DOE Heating Capacity The indirect fired water heater will provide the rated performance only if used in conjunction with a heat source with a DOE heating capacity Heat Output at least as much as the minimum noted in Table 3 If the heat source has less capacity the output of the tank will be reduced To determine the approximate reduction in output from the tank use the following formula New Rating maximum continuous draw rating x Actual Output of Heat Source Minimum Output of Heat Source For example what would the continuous draw rating be if a 50 gallon indirect fired water heater were installed with a
29. ture and pressure of the water heater This water heater contains components that become very hot Do not touch any components unless they are cool Improper installation adjustments alteration service or maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read and understand all instructions including all those contained in component manufacturer s manuals which are provided with the appliance before installing starting up operating maintaining or servicing this appliance Keep this manual and literature in legible condition and posted near the appliance for reference by owner and service technician This water heater requires regular maintenance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by an experienced skilled and knowledgeable installer or service agency NOTICE Insulation blankets are not required for this water heater This water heater meets or exceeds the ASHRAE IES 90 1b standards with respect to insulation and standby loss requirements It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete DO NOT operate the water heater with jumpered or absent controls or safety devices DO NOT tamper with
30. wn from the tank at the drain valve until it runs clear Scale Annual Hard water may cause scale to build up on the outside of the heat exchanger coil A water softener will prevent this problem See also Sediment above Symptoms would be reduced recovery capacity or reduced temperature differential between boiler supply and return lines Repeated flushing should resolve the problem EGD 1 amp S 01 TROUBLESHOOTING GUIDE PROBLEM CAUSE SOLUTION No hot water Boiler does not Refer to boiler installation instructions at faucet operate Check main service switch Check fused disconnect Circulator does not Check power supply operate Replace as necessary Temperature high Determine reason for trip limit on thermostat Depress red RESET tripped button on thermostat Improper Adjust tank thermostat to thermostat setting appropriate setting or calibration See Section VII Zone valve does Check power supply not open if used Replace as necessary Electrical problem Check fuse and replace relay wiring etc Check circuit breaker and reset if applicable Check power supply Scale build up If boiler circulator and tank are operating satisfactorily coil may have scale coating See Section VIII Maintenance Clogged cold water Clean or replace filter or strainer filter or boiler supply strainer if used Water at faucet Thermostat se
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