Lochinvar 50-Gal., 40-Gal, 65-Gal., 80-Gal Service Manual
INSTALLATION & SERVICE MANUAL
DOUBLE-WALL INDIRECT
WATER HEATER
WARNING
T o 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.
EGD-I&S-01
WARNING
Indicates a potentially hazardous situation, which, if
not avoided, may result in moderate, or minor injury
or property damage.
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.
TABLE OF CONTENTS
Important Information .......................................................1
General Information .........................................................3
Pre-Installation .................................................................4
Water Connections ...........................................................6
Electrical Connections......................................................8
Operating Instructions ...................................................10
Maintenance.................................................................... 13
T roubleshooting Guide....................................................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 the 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.
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 YOU SMELL GAS:
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not
use any telephone in your building.
Immediately call your gas supplier from a
telephone in another building. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier, call
the fire department.
DO NOT OPERA TE THE APPLIANCE 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 .
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WARNING
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 temperature 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.
WARNING
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 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.
CAUTION
The maximum boiler water supply temperature to the
indirect heat exchanger must not exceed 240°F
(116°C).
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T able 1 W ater Heater Performance
Pressure Drop at
Hot W ater Coil Heat Rated Heat
Availability Transfer Source Flow Rate
MODEL (Minutes) Area (Sq Ft) (Feet of Head)
40-Gal. 6.8 14.2 2.4
50-Gal. 8.6 14.2 2.4
65-Gal. 10.8 14.2 2.4
80-Gal. 13.5 14.2 2.4
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 HL W-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 INFORMA TION
FEATURES
This water heater contains the following features:
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.
ADJUST ABLE THERMOST AT – The temperature may be
adjusted from approximately 80°F to approximately160°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
WARNING
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 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.
HEA T 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 integrated
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.
Do not place a valve between the combination
temperature and pressure relief valve and the tank!
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TEMPERATURE AND PRESSURE
RELIEF VALVE
WARNING
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
T emperature, Pr essure, Temperature and Pr essure Relief
Valves and Vacuum Relief Valves. The combination
temperature and pressure relief valve must be marked
with a maximum set pressure 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.
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.
IMPORT ANT DECISIONS
REQUIRED
BEFORE INST ALLATION
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
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 inspection of the anode is needed when using
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 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 T able 3 will not increase the rating
of the water heater .
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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 CONTR OL
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 V alves – 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 indirect-fired heater zoned with a
circulator.
Component Location
CAUTION
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 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
¾ inch in diameter and pitched for proper drainage.
Table 2 - Clearance from Combustible Materials
Top Sides Front Rear
0" 0" 0" 0"
Table 3 – Recommended Service Clearances
Non-Piping Front T & P Relief
Side (Thermostat) Rear Valve Side
4" 16" 0" 4"
CAUTION
DOMESTIC HOT WA TER PRIORITY
T wo 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 oversizing, number of space heating zones calling for heat,
and the ratio of domestic hot water load to space
heating load.
MOVE THE W A TER HEA TER TO A PERMANENT
POSITION BY SLIDING OR W ALKING.
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.
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