Lochinvar EcoShield SHW60-325CE, EcoShield, EcoShield SHW45-325CE, EcoShield SHW85-435CE, EcoShield SHW145-435CE Installation, Commissioning And Maintenance Instructions

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Page 1

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:

Page 2

Table of Contents

1.0 INTRODUCTION ................................................................................................................................................................................................... 4

2.0 PRINCIPLE PARTS ............................................................................................................................................................................................... 5

3.0 TECHNICAL DATA ................................................................................................................................................................................................ 8

4.0 GENERAL REQUIREMENTS ............................................................................................................................................................................. 10

4.1 RELATED DOCUMENTS ............................................................................................................................................................................. 10

5.0 WATER QUALITY ............................................................................................................................................................................................... 11

6.0 LOCATION ........................................................................................................................................................................................................... 11

6.1 PLANT ROOM REQUIREMENTS ................................................................................................................................................................ 11

6.2 GENERAL REQUIREMENTS ....................................................................................................................................................................... 11

6.3 CLEARANCES .............................................................................................................................................................................................. 12

6.4 CONDENSATE DRAIN ................................................................................................................................................................................. 12

7.0 GAS SUPPLY ...................................................................................................................................................................................................... 12

7.1 SERVICE PIPES ........................................................................................................................................................................................... 12

7.2 METERS ....................................................................................................................................................................................................... 12

7.3 GAS SUPPLY PIPES .................................................................................................................................................................................... 12

7.4 BOOSTED SUPPLIES .................................................................................................................................................................................. 12

7.5 PLANT-ROOM CONTROL VALVE ............................................................................................................................................................... 12

7.6 EQUIPMENT GAS SYSTEM LEAK CHECK ................................................................................................................................................ 13

8.0 FLUE SYSTEM .................................................................................................................................................................................................... 13

8.1 FLUE SYSTEM GENERAL REQUIREMENTS............................................................................................................................................. 14

8.2 APPROVED FLUE SYSTEM ........................................................................................................................................................................ 14

8.3 INSTALLATION PRECAUTIONS ................................................................................................................................................................. 14

8.4 MAXIMUM LENGTH ..................................................................................................................................................................................... 14

8.5 FLUE DISCHARGE ....................................................................................................................................................................................... 14

8.6 CONDENSATE DRAIN ................................................................................................................................................................................. 14

8.7 CONCENTRIC FLUE CONNECTION ASSEMBLY ...................................................................................................................................... 15

8.7.1 SHW45-325CE & SHW60-325CE .......................................................................................................................................................... 15

8.7.2 SHW85-435CE, SHW115-435CE & SHW145-435CE ........................................................................................................................... 16

8.8 FLUE TERMINAL INSTALLATION ............................................................................................................................................................... 17

8.8.1 TYPE B23 ................................................................................................................................................................................................ 17

8.8.2 TYPE C13 ................................................................................................................................................................................................ 18

8.8.3 TYPE C33 ................................................................................................................................................................................................ 18

8.8.4 TYPE C43 ................................................................................................................................................................................................ 19

8.8.5 TYPE C53 ................................................................................................................................................................................................ 20

8.9 FLUE TERMINAL GUARDING ..................................................................................................................................................................... 20

9.0 AIR SUPPLY ........................................................................................................................................................................................................ 20

9.1 COMBUSTION VENTILATION ..................................................................................................................................................................... 20

9.2 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 CONNECTOR STRIP ........................................................................................................................................................ 25

11.4 ELECTRICAL CONNECTIONS .................................................................................................................................................................... 25

11.5 FUSES .......................................................................................................................................................................................................... 25

11.6 ARC WELDING PRECAUTIONS.................................................................................................................................................................. 26

11.7 WIRING DIAGRAM ....................................................................................................................................................................................... 27

11.8 LADDER DIAGRAM ...................................................................................................................................................................................... 28

12.0 USER CONTROL INTERFACE ........................................................................................................................................................................... 29

12.1 GENERAL ..................................................................................................................................................................................................... 29

12.2 USER CONTROL INTERFACE PANEL ....................................................................................................................................................... 29

12.3 SEQUENCE OF OPERATION ...................................................................................................................................................................... 30

12.4 STATUS DISPLAY SCREENS ..................................................................................................................................................................... 31

13.0 COMMISSIONING AND TESTING ..................................................................................................................................................................... 32

13.1 ELECTRICAL INSTALLATION ..................................................................................................................................................................... 32

13.2 GAS INSTALLATION .................................................................................................................................................................................... 32

13.3 WATER CONNECTIONS.............................................................................................................................................................................. 32

13.4 COMMISSIONING THE EQUIPMENT ......................................................................................................................................................... 32

13.4.1 GENERAL CHECKS PRIOR TO LIGHTING ................................................................................................................................... 32

13.4.2 EQUIPMENT CHECKS PRIOR TO LIGHTING............................................................................................................................... 32

13.4.3 PROCEDURE FOR INITIAL LIGHTING .......................................................................................................................................... 33

13.4.4 GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS ................................................................................................ 33

13.5 TEMPERATURE ADJUSTMENT PROCEDURE ......................................................................................................................................... 33

13.6 INSTALLATION NOISE ................................................................................................................................................................................ 33

14.0 LPG FUEL ............................................................................................................................................................................................................ 34

14.1 RELATED DOCUMENTS ............................................................................................................................................................................. 34

14.2 CONVERSION TO LPG ................................................................................................................................................................................ 34

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14.2.1 SHW45-325CE – SHW85-435CE ................................................................................................................................................... 34

14.2.2 SHW115-435CE .............................................................................................................................................................................. 35

14.2.3 SHW145-435CE .............................................................................................................................................................................. 36

14.3 LPG COMMISSIONING AND TESTING ...................................................................................................................................................... 37

14.3.1 LPG PRESSURE ADJUSTMENT AND COMBUSTION CHECKS ................................................................................................. 37

15.0 MAINTENANCE ................................................................................................................................................................................................... 37

15.1 GENERAL ..................................................................................................................................................................................................... 37

15.2 MAINTENANCE SCHEDULE ....................................................................................................................................................................... 37

15.3 BURNER INSPECTION ................................................................................................................................................................................ 37

15.4 BURNER REMOVAL .................................................................................................................................................................................... 38

15.5 CLEANING THE HEAT EXCHANGER ......................................................................................................................................................... 38

15.6 DRAINING THE WATER HEATER SYSTEM............................................................................................................................................... 38

15.7 STORAGE VESSEL: INSPECTION AND CLEANING ................................................................................................................................. 39

15.8 SACRIFICIAL ANODES: INSPECTION AND REPLACEMENT .................................................................................................................. 39

15.9 REFILLING THE SYSTEM ........................................................................................................................................................................... 39

15.10 OTHER CHECKS ................................................................................................................................................................................... 39

15.10.1 RELIEF VALVE ................................................................................................................................................................................ 39

15.10.2 FLUE 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 CASCADE OFFSET ........................................................................................................................................................................ 42

16.4.5 CASCADE OFF-ON DIFFERENTIAL .............................................................................................................................................. 42

16.5 MENU SET I CIRCULATION PUMPS .......................................................................................................................................................... 42

16.5.1 DHW PUMP DELAY ........................................................................................................................................................................ 42

16.6 MENU SET J SERVICE NOTIFICATION ..................................................................................................................................................... 42

16.6.1 SERVICE NOTIFICATION IN MONTHS ......................................................................................................................................... 42

16.6.2 SERVICE NOTIFICATION RUNNING HOURS .............................................................................................................................. 42

16.6.3 SERVICE NOTIFICATION BOILER CYCLES................................................................................................................................. 42

16.6.4 RESET SERVICE NOTIFICATION COUNTER .............................................................................................................................. 43

17.0 USER INSTRUCTIONS ....................................................................................................................................................................................... 43

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1.0 INTRODUCTION

 The Lochinvar EcoShield™ range is a floor standing direct gas-fired condensing storage water heater. The

equipment comprises a stainless steel mesh radial burner assembly, a heat exchanger that permits fully condensing operation, a vitreous enamel lined steel storage vessel, a bronze glanded-construction circulating pump and interconnecting pipework between the storage vessel and heat exchanger.

 The burner is initiated by a full electronic ignition sequence control that incorporates a spark ignition and a

flame rectification device for supervision of the flame.

 The output from the water heater is regulated by a variable speed combustion fan and gas/air ratio controls

to maintain the correct combustion at all levels of modulation. This configuration allows modulation down to 20% of the rated output.

 This equipment is intended for use on Group H Natural Gas (2

Family) 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 requirements must also be taken into account when installing any equipment. Failure to comply with the above may lead to prosecution.

 If the equipment is to be connected to an unvented (pressurised) system, care must be taken to ensure all

extra safety requirements are satisfied should a high or low-pressure condition occur in the system.

 The equipment is designed for direct connection to a flue system.  Ancillary Options:  Unvented/Boosted Water System Kits WH17

 Expansion Vessel for Larger System Volumes V25  De-stratification Pump Kit WH9  Condensate Neutralisation Kit KIT2000  Pre-Fabricated Interconnecting Pipework Contact Lochinvar Limited  Flue System Components Contact Lochinvar Limited

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2.0 PRINCIPLE PARTS

ITEM

DESCRIPTION

FUNCTION

Access cover - front

Provides access to the gas train and the heat exchanger.

Air intake adapter

Allows for the connection of the air intake pipe to the water heater.

Air pressure switch

The air pressure switch detects blocked inlet conditions.

Air shroud

The air shroud controls air and gas flow into the burner.

Fan

The fan pulls in air and gas through the venturi. Air and gas mix inside the fan and are pushed into the burner, where they burn inside the combustion chamber.

Burner (not shown)

Made with metal fibre and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

Condensate drain connection

Connects the condensate drain line to a ½” PVC union.

Control module

The control responds to internal and external signals and controls the fan, gas valve, and pumps to meet the demand.

Electronic display

The electronic display consists of 7 buttons and a dual line 32-character liquid crystal display.

Flame inspection window

The quartz glass window provides a view of the burner surface and flame.

Flame sense electrode

Used by the control module to detect the presence of burner flame.

Flue gas sensor

This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the water heater if the flue gas temperature gets too hot. This protects the flue pipe from overheating.

Gas connection pipe

Threaded pipe connection, ½”, ¾”, or 1", depending on the model. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the water heater.

Gas valve

The gas valve senses the negative pressure created by the fan, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

Heat exchanger access cover

Allows access to the combustion side of the heat exchanger coils.

Heat exchanger inlet temperature sensor

This sensor monitors the inlet water temperature to the heat exchanger.

Heat exchanger outlet temperature sensor

This sensor monitors the heat exchanger outlet water temperature.

High limit sensor

Device that monitors the outlet water temperature. If the temperature exceeds its setting, it will break the control circuit, shutting the water heater down.

Ignition electrode

Provides direct spark for igniting the burner.

Mains voltage junction box

The junction box contains the connection points for the mains voltage power and all pumps.

Low voltage connection board

The connection board is used to connect external low voltage devices.

Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

Mains voltage wiring connections (knockouts)

Conduit connection points for the mains voltage junction box.

Pump

Circulates water between the storage vessel and heat exchanger.

Pump relay

Switches power to the pump.

Stainless steel heat exchanger

Allows water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

Tank sensor

Used by the control to monitor the temperature of the storage vessel.

Top panel

Removable panel to gain access to the internal components.

Flue pipe adapter

Allows for the connection of the flue system to the water heater.

Venturi

The venturi controls air and gas flow into the burner.

Water heater drain valve

Location from which the water heater can be drained.

Water inlet

BSP water connection that returns water from the system to the heat exchanger, either 1 ½” or 2", depending on the model.

Water outlet

BSP water connection that supplies hot water to the system, either 1 ½” or 2", depending on the model.

TABLE 2.1 THE ECOSHIELD WATER HEATER - HOW IT WORKS...

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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

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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

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3.0 TECHNICAL DATA

Model Number

SHW45-325CE

SHW60-325CE

SHW85-435CE

SHW115-435CE

SHW145-435CE

GENERAL DATA

Input (gross) – kW

44.0

61.5

83.5

116.9

146.5

Input (net) – kW

39.6

55.4

75.2

105.3

132.0

Recovery Rate (44°) – l/hr

806

1153

1567

2164

2768

Recovery Rate (50°) – l/hr

709

1014

1379

1904

2436

Shipping Weight – kg

281

290

379

388

406

Full Weight – kg

614

625

825

838

860

NOX Class

Appliance Category

2H3P

Countries of Destination

GB/IE

GAS DATA – G20

Nominal gas inlet pressure – mbar

Maximum gas inlet pressure – mbar

Minimum gas inlet pressure – mbar

17.5

Gas flow rate – m3/hr

4.2

5.7

8.0

11.1

14.0

Flue gas mass rate – g/sec (@ 9.0% CO2)

16.0

22.3

30.4

42.5

53.2

Gas inlet connection size – “ B.S.P

¾ 1 1

GAS DATA – G31

Nominal gas inlet pressure – mbar

Maximum gas inlet pressure – mbar

Minimum gas inlet pressure – mbar

Gas flow rate – m3/hr

1.7

2.3

3.1

4.4

5.5

Flue 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

¾ 1 1

WATER DATA

Water content – litres

348

352

469

473

477

Water connections (F & R) – “ B.S.P

1 ½

Max. water pressure (PMS) – bar

11.0

Maximum water temperature – C

FLUE DATA TYPE B23

Nominal flue diameter – mm

100

Maximum flue gas temp. – C

120

Maximum equivalent length – m

Equivalent length 90 bend – mm

1000

Equivalent length 45 bend – mm

500

Flue gas temperature – C

Flue draught requirements – mbar

-0.03 to -0.1

FLUE DATA TYPE C13 & C33

Nominal flue diameter – mm

80/125

100/150

Maximum flue gas temp. – C

120

Maximum equivalent length – m

Equivalent length 90 bend – mm

1000

Equivalent length 45 bend – mm

500

FLUE DATA TYPE C43 & C53

Nominal flue diameter – mm

100

Average flue gas temp. – C (80/60 Flow/Return)

Maximum flue gas temp. – C

120

Maximum equivalent length – m

60*

Equivalent length 90 bend – mm

1000

Equivalent length 45 bend – mm

500

* On twin pipe systems, the maximum equivalent length is the sum the air inlet components and the exhaust

components.

TABLE 3.1 TECHNICAL DATA

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FIGURE 3.1 ENCLOSURE INSTALLATION CLEARANCES (mm)

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

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

FIGURE 3.2 PLANT-ROOM INSTALLATION CLEARANCES (mm)

Page 10

4.0 GENERAL REQUIREMENTS

The Lochinvar EcoShield condensing water heater has been designed to operate trouble free for many years. These instructions should be followed closely to obtain the maximum usage and efficiency of the equipment.

PLEASE read the instructions fully before installing or using the appliance.

4.1 RELATED DOCUMENTS

It is law that all gas appliances are installed by competent persons, in accordance with The Gas Safety (Installation and Use) Regulations 1998. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that this law is complied with.

The installation of the equipment MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, I.E.E. Regulations and the bylaws of the local water undertaking. The installation should also be in accordance with any relevant requirements of the local gas distributor and local authority.

In addition the installation should follow the relevant guidance offered in the following documents. It is not practical to list all relevant information but emphasis is placed on the following documents, as failure to comply with the guidance given will almost certainly result in an unsatisfactory installation:

BS EN 1858: 2003 Chimneys. Components. 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 gases). Specification for installation and maintenance of ventilation for gas appliances

BS 6644: 2005 Specification for Installation of gas-fired hot water boilers of rated inputs between 70kW + A1:2008 (net) and 1.8MW (net) (2nd and 3rd family gasses)

BS 6700: 1997 Design, installation, testing and maintenance of services supplying water for

domestic use within buildings and their curtilages

BS 6880: 1988 Code of practice for low temperature hot water systems of output greater than 45kW Parts 1, 2 and 3

BS 7074: 1989 Application, selection and installation of expansion vessels and ancillary equipment

for

Parts 1and 2 sealed systems

BS 7671: 2008 Requirements for electrical installations, I.E.E. wiring regulations Seventeenth

edition

CP 342: Code of practice for centralised hot water supply-buildings other than dwellings Part 2 1974

IGE/UP/1: Installation pipework on industrial and commercial premises Edition 2

IGE/UP/2: Gas installation pipework, boosters and compressors on industrial and commercial Edition 2 premises

IGE/UP/4: Commissioning of gas-fired plant on industrial and commercial premises Edition 2

Page 11

IGE/UP/10: Installation of flued gas appliances in industrial and commercial premises Edition 3

Gas Safety (Installation and Use) Regulations 1998

CIBSE: Guide parts A, B and C

H.S.E. guidance Automatically controlled steam and hot water boilers note PM5:

Third edition of the 1956 Clean Air Act Memorandum on Chimney Heights

Manufacturer's notes must not be taken in any way as overriding statutory obligations.

5.0 WATER QUALITY

Water supply quality may adversely affect the efficiency and performance of water heaters and hot water systems. The situation can intensify where higher temperatures or demands exist.

Water hardness should not exceed 205ppm CaCO3 and TDS (Total Dissolved Solids) of untreated water should not exceed 350ppm. If these values are exceeded, contact Lochinvar Limited for further guidance.

6.0 LOCATION

6.1 PLANT ROOM REQUIREMENTS

The Lochinvar EcoShield may only be installed in a room that complies with the appropriate ventilation requirements.

The Lochinvar EcoShield can be used as a type C13, C33, C43 or C53 appliance. Due to its room sealed design, ventilation allowances for combustion air are not necessary, provided the minimum clearances and service clearances as detailed in Figure 3.2 are observed. If the appliance is to be installed in a compartment or a hot environment, the minimum clearances detailed in Figure 3.1 should be observed. In addition to this or to comply with the recommendations in BS6644, ventilation for cooling purposes must be fitted. For further guidance, please 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 exchanger and flue system may occur if air for combustion contains certain chemical vapours. Such corrosion may result in poor combustion and create a risk of asphyxiation. Aerosol propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals are corrosive. Products of this sort should not be stored near the water heater or outside by the air intake (if applicable). The fitting of this equipment in a situation where aerosols or other chemicals may be entrained into the combustion air will invalidate the warranty.

The equipment must be installed on a level surface that is capable of adequately supporting its weight (when filled with water) and any ancillary equipment. The operation of the equipment must not cause the temperature of any combustible material in the vicinity of the equipment and its flue to exceed 65°C. If such a situation is unavoidable, appropriate insulation should be provided.

Locate the equipment so that if the appliance or any connecting pipework should leak, water damage will not occur. When such locations cannot be avoided it is recommended that a suitable drain pan be installed under the equipment. The pan should be adequately drained but must not restrict the combustion or ventilation airflow.

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6.3 CLEARANCES

The location chosen for the equipment must permit the provision for a satisfactory flue system and, where necessary, an adequate air supply. The location must also provide adequate space for servicing and air circulation around each unit. This includes any electrical trunking laid across the floor and to the appliance.

See Figure 3.1 & Figure 3.2 for dimensions/clearances. Further details regarding locations are given in BS5440 or

BS6644 as appropriate.

6.4 CONDENSATE DRAIN

The condensate drain is located on the rear of the water heater. It is fitted with a ½” PVC tee and union, this should be connected to an appropriate condensate drain, sloping continuously away from the water heater at an angle of at least 3 (50mm per metre).

The Water Resources Act requires that trade effluent is discharged to municipal sewers between pH 6.5 and 10.0. If it is determined that these levels cannot be achieved, an in-line condensate neutralisation kit is available from Lochinvar Limited. This unit is capable of neutralising 4000 litres of condensate to a pH of 7.0 before releasing it to a drain.

7.0 GAS SUPPLY

The Lochinvar EcoShield range is suitable for use on second and third family gasses 2H - G20 - 20mbar and 3P G31 - 37mbar. Details relating to Natural 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 connected to the service pipe by the local gas distributor contractor. An existing gas meter should be checked, preferably by the gas distributor, to ensure that it is adequate to deal with the rate of gas supply required.

7.3 GAS SUPPLY PIPES

Supply pipes must be fitted in accordance with IGE/UP/2. Pipework from the meter to the equipment must be of adequate size. The complete installation must be purged and tested as described in IGE/UP/1. Refer to Section

14 LPG FUEL for information on LPG pipework installation guidance.

7.4 BOOSTED SUPPLIES

Where it is necessary to employ a gas pressure booster, the controls must include a low-pressure cut-off switch at the booster inlet. The local gas distributor must be consulted before a gas pressure booster is fitted. For details of how to connect a low-pressure cut-off switch, please refer to Section 11 Electrical Supply

7.5 PLANT-ROOM CONTROL VALVE

A manual valve for plant-room isolation must be fitted in the gas supply line. It must be clearly identified and readily accessible for operation, preferably by an exit.

Page 13

7.6 EQUIPMENT GAS SYSTEM LEAK CHECK

Location

Description

SHW45-325CE SHW60-325CE

SHW85-435CE SHW115-435CE SHW145-435CE

Directly below an opening, air brick, opening windows etc.

300

2000

Above an opening, air brick, opening windows etc.

300

1000

Horizontally to an opening, air brick, opening windows etc.

300

1000

Below a gutter or sanitary pipework

Below the eaves

200

Below a balcony or car port roof

200

From a vertical drain or soil pipe

150

From an internal or external corner

300

Above ground, roof or balcony level

300

From a surface facing the terminal

600

1000

From a terminal facing the terminal

1200

2000

From an opening in the car port (e.g. door, window) into the dwelling

1200

Vertically from a terminal on the same wall

1500

Horizontally from a terminal on the same wall

300

600

From a vertical structure on the roof

300

Above intersection with the roof

300

An approved gas-inlet appliance isolating valve and union should be installed for each unit in a convenient and safe position and be clearly marked. Ensure that the gas-inlet appliance isolating valve is in

the OFF position. Although the equipment receives a gas leak check and gas train component integrity check prior to leaving the factory, transit and installation may cause disturbance to unions, fittings and components. During commissioning a further test for tightness should be carried out on the equipment gas pipework and components.

Care must be taken not to allow leak detection fluid on or near any electrical parts or connections.

8.0 FLUE SYSTEM

FIGURE 8.1: FLUE TERMINAL POSITIONS

TABLE 8.1 FLUE TERMINAL MINIMUM DISTANCES

Page 14

8.1 FLUE SYSTEM GENERAL REQUIREMENTS

Detailed recommendations for the flue system are given in BS5440-1 for equipment of rated input not exceeding 70kW net, BS6644 for equipment above 70kW net and IGE/UP/10 for equipment of rated input above 54kW net. The following notes are intended to give general guidance only.

8.2 APPROVED FLUE SYSTEM

The approved flue system is not suitable for use external to the building. If external routes cannot be avoided, a flue system manufacturer should be consulted to supply a suitable alternative.

When used as a Type C (balanced flue) appliance, the approved, purpose designed adaptive flue system should be used. For further details, please contact Lochinvar Limited.

When used as a Type B (conventional flue) appliance, a suitable flue system constructed of Stainless Steel or Polypropylene with a temperature rating in excess of 120C should be used. Aluminium flue pipe must not be

used on this appliance as it may lead to premature failure of the heat exchanger and will invalidate the warranty.

8.3 INSTALLATION PRECAUTIONS

 The approved flue system is rated to 120C max. To prevent the exhaust temperature exceeding this,

the appliance is supplied with a flue gas temperature sensor. This must be fitted during the

installation of the flue system. Failure to do so may lead to severe personal injury, death or substantial property damage.

 The heater must not be operated unless the complete flue system is installed. This includes the water

heater connections, 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 taken to ensure that the internal sealing ring is seated correctly.  Due to the close tolerances in the flue system, it may be necessary to use a twisting action to fit the

joints together. No lubrication other than water should be used.

8.4 MAXIMUM LENGTH

Details of maximum flue lengths can be found in Table 3.1 Technical Data

8.5 FLUE DISCHARGE

The flue system must ensure safe and efficient operation of the equipment to which it is attached, protect the combustion process from wind effects and disperse the products of combustion to open external air.

The flue must terminate in a freely exposed position and be so situated as to prevent the products of combustion entering any opening in a building.

Under certain operating and weather conditions, the EcoShield heater may generate a plume at the terminal. Consideration should be given to the nuisance this may cause and the terminal should be sited accordingly.

For further information on terminal locations, please refer to Figure 8.1 and Table 8.1.

8.6 CONDENSATE DRAIN

If the flue system rises at an angle of at least 3 (50mm per metre), no additional condensate drain will be required. Failure to provide an adequate rise in the flue system may lead to pooling of condensate which may lead to premature failure of the flue system.

Page 15

8.7 CONCENTRIC FLUE CONNECTION ASSEMBLY

ITEM

DESCRIPTION

Flue Gas Test Point

Concentric Adaptor

80mm Dia x 500mm Length

90 Elbow

Air Intake Transition

Intake Connection Reducer

Exhaust Transition

"X"

8.7.1 SHW45-325CE & SHW60-325CE

FIGURE 8.2 FLUE CONNECTION DETAILS SHW45-325CE & SHW60-325CE

TABLE 8.2 FLUE CONNECTION DETAILS SHW45-325CE & SHW60-325CE

FIGURE 8.3 CUTTING ITEM 3 TO LENGTH

Page 16

To install the flue connection to the SHW45-325CE & SHW60-325CE water heaters the following procedure

ITEM

DESCRIPTION

Flue Gas Test Point

Concentric Adaptor

100mm Dia x 500mm Length

90 Elbow

Exhaust Transition

Intake Connection

Air Intake Transition

should be followed:

1. Insert the exhaust transition (Item 7 in Figure 8.2) into the exhaust port on the heater.

2. Insert the flue temperature sensor (supplied with the water heater) into the location hole on the exhaust

transition.

NOTE: IF THE FLUE TEMPERATURE SENSOR IS NOT FITTED, THE FLUE GAS MAY EXCEED THE MAXIMUM TEMPERATURE RATING OF THE FLUE AND CAN LEAD TO SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

3. Insert the air intake transition (Item 5 in Figure 8.2) into the intake connection reducer (Item 6) and

tighten the worm drive clip.

4. To the bottom (exhaust) connection of the concentric adaptor (Item 2 in 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 500mm length and cut the measured distance from the plain end. (See Figure

8.3)

8. Reassemble and fit to the heater.

9. Fit the flue gas test point (Item 1 in Figure 8.2) and clamp using its locking band.

8.7.2 SHW85-435CE, SHW115-435CE & SHW145-435CE

FIGURE 8.4 FLUE CONNECTION DETAILS SHW85-435CE – SHW145-435CE

TABLE 8.3 FLUE CONNECTION DETAILS SHW85-435CE – SHW145-435CE

Page 17

FIGURE 8.5 CUTTING ITEM 3 (1) TO LENGTH

"X"

To install the flue connection to the SHW85-435CE, SHW115-435CE & SHW145-435CE water heaters the following procedure should be followed:

1. Insert the exhaust transition (Item 5 in Figure 8.4) into the exhaust port on the heater.

2. Insert the flue temperature sensor (supplied with the water heater) into the location hole on the exhaust

transition.

NOTE: IF THE FLUE TEMPERATURE SENSOR IS NOT FITTED, THE FLUE GAS MAY EXCEED THE MAXIMUM TEMPERATURE RATING OF THE FLUE AND CAN LEAD TO SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

3. To the bottom (exhaust) connection of the concentric adaptor (Item 2 in Figure 8.4) fit one of the 100mm

dia. x 500 lengths (Item 3) followed by one of the 90 elbows (Item 4).

4. Offer the assembly to the heater, ensuring the concentric adaptor is vertical, and measure the distance

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 500mm length

followed by one of the 90 elbows.

8. To the air intake transition, fit the final 90 elbow followed by the final 100mm dia. x 500mm length.

Measure and cut the 100mm dia. x 500mm lengths to suit the installation.

9. Reassemble and fit to the heater.

10. Fit the flue gas test point (Item 1 in Figure 8.4) and clamp using its locking band.

8.8 FLUE TERMINAL INSTALLATION

8.8.1 TYPE B

When the heater is installed as a Type B23 appliance, the flue system should be installed in accordance with the flue manufacturer’s specific instructions.

A kit of components to facilitate conventional fluing of the appliance is available from Lochinvar Limited.

Page 18

1. Insert the exhaust transition into the exhaust port of the heater.

2. Insert the flue temperature sensor into the location hole on the exhaust transition.

NOTE: IF THE FLUE TEMPERATURE SENSOR IS NOT FITTED, THE FLUE GAS MAY EXCEED THE MAXIMUM TEMPERATURE RATING OF THE FLUE AND CAN LEAD TO SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

3. Insert the air intake transition into the intake connection and tighten the worm drive clip.

4. Insert the air inlet grille into the air inlet transition.

8.8.2 TYPE C

When the heater is installed as a Type C13 appliance, the flue system should be installed as follows:

1. Determine the location of the flue terminal, taking into account minimum distances as detailed in Figure

8.1, Table 8.1 and the relevant British Standards.

2. Taking care to protect the appliance from debris and dust, drill a hole in the desired location. The

diameter of the hole should be no more than 10mm greater than the diameter of the air supply pipe of the terminal.

3. Determine the required length of the terminal and cut as necessary.

NOTE: When determining the required length for the flue terminal, the outer wall plate or rosette should be flush

to the wall. (See Figure 8.6)

NOTE: Once cut; remove all burrs and sharp edges.

4. Insert the terminal into the drilled hole. The terminal section should be installed level or 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

pipes as necessary.

FIGURE 8.6 HORIZONTAL TERMINAL INSTALLATION

8.8.3 TYPE C

When the heater is installed as a Type C33 appliance, the flue system should be installed as follows:

1. Confirm that the roof flashing is correct for the type of roof through which the terminal is to be installed.

(See Figure 8.7)

2. Determine the desired location for the flue terminal, taking into account minimum distances as detailed

in Figure 8.1, Table 8.1 and the relevant British Standards.

3. Taking care to protect the appliance from debris and dust, drill a hole in the desired location. The

diameter of the hole should be no more than 10mm greater than the diameter of the air supply pipe of the terminal.

NOTE: The hole should be drilled from the outside to ensure that no damage is done to the roofing material.

Extra care should be taken to ensure that the hole is drilled vertically.

4. Install the roof flashing and secure as appropriate.

5. Carefully insert the roof terminal through the roof flashing and hole in the roof.

NOTE: When inserting the roof terminal do not support or turn the terminal using the cap.

6. Ensure the terminal is vertical using a spirit level.

Page 19

7. Fit the support bracket around the terminal and secure using appropriate fixings. Do not tighten the

Model No.

Mass Rate @ 100% (@ 9% CO2) (G20)

Mass Rate @ 23%

(@ 9% CO2) (G20)

Mass Rate @ 100%

(@ 10.5% CO2) (G31)

Mass Rate @ 23%

(@ 10.5% CO2) (G31)

SHW45-325CE

16.0

3.7

16.7

3.8

SHW60-325CE

22.3

5.1

23.2

5.3

SHW85-435CE

30.4

7.0

31.6

7.3

SHW115-435CE

42.5

9.8

44.2

10.2

SHW145-435CE

53.2

12.2

55.4

12.7

support bracket

8. Install the remainder of the flue system working progressively away from the water heater supporting the

pipes as necessary.

9. Once the flue system is fully installed, tighten the clamp to secure the terminal in place.

FIGURE 8.7 VERTICAL TERMINAL ROOF FLASHINGS FOR SYNTHETIC, FLAT AND TILED ROOFS

FIGURE 8.8 INSTALLING TERMINAL THROUGH ROOF FLASHING

8.8.4 TYPE C

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

TABLE 8.4 FLUE GAS MASS RATES

Page 20

8.8.5 TYPE C

Model

Gross

Input

(kW)

Net

Input

(kW)

Ventilation

(Room)

(cm2)

Compartment

(Direct to Outside)

(To Internal Space)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

SHW45-325CE

43.9

39.6

165

200

400

800

SHW60-325CE

58.6

52.8

230

265

530

1060

Model

Gross

Input (kW)

Net Input (kW)

Plant Room

Enclosure

Low

Summer Use

Medium

Summer Use

High

Summer Use

Low

Summer Use

Medium

Summer Use

High

Summer Use

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

SHW85-435CE

83.5

75.3

152

304

228

380

304

456

380

760

456

836

532

912

SHW115-435CE

117.2

105.6

212

424

318

530

424

636

530

1060

636

1166

742

1272

SHW145-435CE

146.5

132.0

264

528

396

660

528

792

660

1320

792

1452

924

1584

When installing the heater as a Type C53 appliance, it should be noted that the terminals must not be installed on opposite sides of the building or closer than 500mm apart (centre to centre).

To install a Type C53 terminal or air inlet, the procedure for either a Type C13 (horizontal) or a Type C33 (vertical) terminal should be followed noting that the annular space of the terminal should be sealed off

8.9 FLUE TERMINAL GUARDING

If a horizontal flue terminal is to be fitted less than 2 metres from ground level or in a location where it can be touched from a window, door or balcony, a terminal guard must be fitted. An approved terminal guard, Lochinvar Part No. FTG0001 is available; please contact Lochinvar Limited for further information.

The terminal guard is constructed from plastic-coated mild steel and is suitable for use on condensing appliances only. The guard should be installed centrally around the terminal ensuring a gap of at least 50mm between the guard and terminal is maintained.

9.0 AIR SUPPLY

The following information is based on single water 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 requirements are as follows:

TABLE 9.1 COMBUSTION VENTILATION REQUIREMENTS SHW45-325CE – SHW60-325CE

TABLE 9.2 COMBUSTION VENTILATION REQUIREMENTS SHW85-435CE – SHW145-435CE

Page 21

9.2 COOLING VENTILATION

Model

Input

(Gross)

Input

(Net)

Enclosure/Compartment

Internal Space/Boiler Room

(Direct to Outside)

(To Internal Space)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

SHW45-325CE

43.9

39.6

200

400

N/A

SHW60-325CE

58.6

52.8

265

530

N/A

SHW85-435CE

83.5

75.3

380

760

152

SHW115-435CE

117.2

105.6

530

1060

212

SHW145-435CE

146.5

132.0

660

1320

264

When used as a type C appliance, cooling ventilation should be provided as follows:

TABLE 9.3 COOLING VENTILATION REQUIREMENTS

When used as a type B appliance, provision for cooling ventilation is included in the combustion ventilation allowance.

10.0 WATER CONNECTIONS

10.1 GENERAL

Recommendations for the water circulation system are given in BS6644 and CP 342. The following notes are of particular importance.

1. Circulating pipework not forming part of the useful heating surface should be insulated. Cisterns,

expansion vessels and pipework situated in areas exposed to freezing conditions should also be insulated.

2. Drain valves must be located in accessible positions that will permit draining of the entire system

including the unit and any additional storage vessel.

3. Tapping sizes for 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 arrangement provided that a vent pipe in accordance with CP 342, BS6644 or BS6700 as appropriate is fitted. The minimum static head requirement for an open vented system is 1.0 bar.

10.3 UNVENTED SYSTEM ARRANGEMENT

NOTE: IT IS STRONGLY RECOMMENDED THAT UNVENTED HOT WATER SYSTEMS BE

INSTALLED BY AN APPROVED INSTALLER.

If the Lochinvar EcoShield is to be used in an unvented arrangement, the system should follow the guidance given in BS6700 and must comply with the Building Regulations 1992: Part G3. A kit of components that have been suitably sized for the unvented operation of the appliance is available from Lochinvar Limited. For further information, contact Lochinvar Limited.

10.3.1 TEMPERATURE AND PRESSURE RELIEF VALVE

A temperature and pressure relief valve is provided in the unvented water system kit. This valve has a lift pressure of 7 bar and a lift temperature of 90°C. The valve must be fitted to the relief valve tapping located on the rear of the appliance.

The storage vessel relief valve connection should not be used for any other purpose.

Page 22

10.3.2 RELIEF VALVE DISCHARGE PIPEWORK

500mm MAXIMUM

TUNDISH

METAL DISCHARGE PIPE (D1) FROM TEMPERATURE RELIEF VALVE TO TUNDISH

SAFETY DEVICE (e.g. TEMPERATURE RELIEF VALVE)

METAL DISCHARGE PIPE (D2) FROM TUNDISH, WITH CONTINUOUS FALL

FIXED GRATING

TRAPPED GULLY

DISCHARGE IDEALLY BELOW FIXED GRATING

300mm MINIMUM

It is important that any discharge water does not collect in the discharge pipe-work and can run freely to the tundish. The Tundish should be mounted in a vertical and visible position located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e.g. the temperature relief valve.

The discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, be of metal and:

a) Be at least one pipe size larger than the nominal outlet size of the safety device unless its total

equivalent hydraulic resistance exceeds that of a straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on. Bends must be taken into

account in calculating the flow resistance. An alternative approach for sizing discharge pipes would be to follow BS6700 Specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

b) Have a vertical section of pipe at least 300mm long, below the tundish before any elbows or bends in the

pipework.

c) Be installed with a continuous fall. d) Have discharges visible at both the tundish and the final point of discharge but where this is not possible

or is practically difficult there should be clear visibility 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 wire cage or similar guard is positioned to prevent contact whilst maintaining

visibility.

III. Discharges at a high level; e.g. into a metal hopper and metal down pipe with the end of the discharge

pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature

discharges of water and 3m from any plastic guttering systems that would collect such discharges

(tundish visible).

IV. Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should

be limited to not more than 6 systems so that any installation can be traced reasonably easily. The single

common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe

to be connected. If unvented hot water storage systems are installed where discharges from safety

devices may not be apparent i.e. in dwellings occupied by blind, infirm or disabled people, consideration

should be given to the installation of an electronically operated device to warn when discharge takes

place.

FIGURE 10.1 RELIEF VALVE DISCHARGE PIPEWORK

Page 23

10.3.3 EXPANSION VESSEL SIZING

Stored Temp.

C

0.005

0.006

0.008

0.010

0.012

0.015

0.017

Stored Temp.

C

0.020

0.023

0.026

0.030

0.031

0.033

0.037

Model

Normal Supply Voltage

External Fuse Rating

Power Consumption

SHW45-325CE

230V AC

50 Hz

1 PH

10 Amps

431 W

SHW60-325CE

459 W

SHW85-435CE

646 W

SHW115-435CE

932 W

SHW145-435CE

961 W

The following information is based on an inlet pressure of 3.5 bar. If a different inlet pressure is to be used, please consult BS6700.

V V = S V * e

0.45

Where: V V = Vessel Volume S V = System Volume e = Coefficient of Expansion (See Table 10.1)

TABLE 10.1 COEFFICIENT OF EXPANSION OF WATER AT 3.5 BAR INLET PRESSURE

11.0 ELECTRICAL SUPPLY

Wiring external to the equipment must be installed in accordance with the I.E.E. Regulations and any local regulations that apply.

TABLE 11.1 ELECTRICAL SUPPLY REQUIREMENTS

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 EcoShield is compatible with the following control and safety systems:

 Gas pressure switch (e.g. gas booster under pressure/over pressure safety switch)  Auxiliary safety system proving switch (e.g. fan dilution system proving switch)

In addition to this, the Lochinvar EcoShield can give the following signals:

 Volt-free “burner on” (runtime) signal  Volt-free “lock-out” (alarm) signal  24VAC auxiliary device enable signal (e.g. to start fan dilution system)

11.1.1 REMOTE ENABLING

When remote control of an EcoShield water heater is required and controlled using a Building Management System (B.M.S.) the factory fitted wiring between the low-voltage connection strip and the tank temperature sensor

Page 24

should be interrupted using a suitable relay. The burner control interprets the break in the wiring as a very high

MAINS

230V~50Hz

PUMP OUTPUTS 190 WATTS MAX

PRIMARY

DE-STRAT

RETURN

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 and Neutral connections should be used to energise a suitable contactor.

PRIMARY

230 VAC Live, Neutral and Earth connections for a primary circulation pump starter. NOTE: On all EcoShield the primary pump is pre-wired internally.

MAINS

Connections for a 230V ~ 1 ph 50Hz power supply. NOTE: the power supply cable should be secured using the anchor supplied or an equivalent.

TO INTERNAL TANK SENSOR

B.M.S. ENABLE WIRING B.M.S. FAULT SIGNAL WIRING

B.M.S. ENABLE RELAY

AUX. DEVICE PILOT SUPPLY

24VAC

GND

AUX. DEVICE PROVING

GAS PRESSURE SWITCH

FLOW SWITCH

ALARM CONTACTS

RUNTIME CONTACTS

TANK SENSOR

SHIELD GROUND

0-10VDC EXTERNAL GND CONTROL

TANK THERMOSTAT

A B SHIELD GROUND

SEQUENCING

LOW WATER

CUTOFF

CN1

CN2

CN3

CN4

CN5

temperature within the storage vessel and shuts the burner down if it is firing or prevents a firing sequence occurring if it is not.

It should be noted that the design of the control board interprets the very high recorded temperature as a fault and automatically closes the alarm contacts to indicate that an error has occurred; this can cause nuisance alarms in systems that log fault occurrences or have remote alarm sounders.

To prevent the B.M.S. registering unnecessary faults it is recommended that the B.M.S. enables the water heater via a two-pole relay. The second pole of the relay should then be used to interrupt the fault signal wiring, therefore preventing the fault signal when the heater is disabled.

For further details, please see the wiring diagram below.

FIGURE 11.1 ENABLE WIRING

11.2 HIGH VOLTAGE CONNECTOR STRIP

FIGURE 11.2 HIGH VOLTAGE CONNECTION STRIP

TABLE 11.2 HIGH VOLTAGE CONNECTION TERMINAL DETAILS

Page 25

11.3 LOW VOLTAGE CONNECTOR STRIP

AUX. DEVICE PILOT SUPPLY

24VAC

GND

AUX. DEVICE PROVING

GAS PRESSURE SWITCH

FLOW SWITCH

ALARM CONTACTS

RUNTIME CONTACTS

TANK SENSOR

SHIELD GROUND

0-10VDC EXTERNAL GND CONTROL

TANK THERMOSTAT

A B SHIELD GROUND

SEQUENCING

LOW WATER

CUTOFF

CN1

CN2

CN3

CN4

CN5

CONNECTION

NOTES

1-2

EXTERNAL CONTROL

When the heater is to be controlled by a 0-10V DC analogue output from a Building Management System (BMS), the 0V line should be connected to pin 1 and the 0-10V line should be connected to pin 2.

3-6

SEQUENCING

This facility is not used on the EcoShield water heater.

7-8

TANK SENSOR

This sensor controls the temperature of the storage vessel and is factory wired. If time control is required, this wiring should be interrupted. (See Section 11.1.1: REMOTE ENABLING for further details.)

9-10

TANK THERMOSTAT

This facility is not used on the EcoShield water heater.

11-12

RUNTIME CONTACTS

An internal volt free contact across pins 11 &1 2 will close in the event of the burner operating. This connection can be used by a BMS to monitor the operation of the heater.

13-14

ALARM CONTACTS

An internal volt free contact across pins 13 & 14 will close in the event of the heater locking out. This connection can be used by a BMS to monitor the operation of the heater.

15-16

FLOW SWITCH

This facility is not used on the EcoShield water heater.

17-18

GAS PRESSURE SWITCH

If a gas pressure switch is 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 auxiliary deice safety circuit wiring installed. If there is no continuity across the terminals the heater will not fire.

21-22

AUX. DEVICE PILOT SUPPLY

When the heater gets a call for heat, a 24VAC supply becomes present on pin 22. Used in conjunction with the ground pin (pin 21), these terminals can be used to send a signal to energise an auxiliary device such as a fan dilution system or mechanical ventilation system.

FIGURE 11.3 LOW VOLTAGE CONNECTION STRIP

TABLE 11.3 LOW VOLTAGE CONNECTION TERMINAL DETAILS

11.4 ELECTRICAL CONNECTIONS

Cable routing to the High Voltage and Low Voltage Connection Strips can be achieved by removing the appropriate knockouts on the back panel of the heater. All connections should be secured using an appropriate cord anchorage. One cord anchor is supplied with the heater for securing the mains supply to the unit. If additional controls and ancillaries are to be used, the appropriate knockout should be removed and an anchor such as RS Components part number 607-897 plus locking nut 607-910 should be fitted.

If a knockout is removed by mistake, the resulting hole must be blocked with an appropriate anchor, plug or grommet to prevent accidental access to the live parts within the heater.

11.5 FUSES

The EcoShield has five internal fuses. F1 will automatically reset, F2 – F5 are slow blow fuses, located and rated as follows:

Page 26

FIGURE 11.3 FUSE RATINGS AND LOCATIONS

The water heater has three spare fuses in a plastic bag attached to the 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

11.7 WIRING DIAGRAM

diagrams to troubleshoot unit.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using

W R

VENT

N.O.

230V SUPPLY

DE-STRAT PUMP

RETURN PUMP

PRIMARY PUMP

TR1

COM

24 VAC

CN5-2

CN5-4

CN5-3

HIGH VOLTAGE SPARK LEADCAUTION

HI-LIMIT

AUTO RESET

CONTROL

EXTERNAL

X6-6

X6-2

CN4-13

CN4-7

X6-1

CN4-5

THERMOSTAT

TANK

X6-8

CN4-8

SUPPLY

PILOT

DEVICE

AUX.

X3-2

X3-4

X3-3

X3-1

CONTACTS

RUN-TIME

CONTACTS

ALARM

CN4-4

CN4-10

CN4-12

CN4-11

X6-10

X6-5

X6-4

X6-3

X6-9

CN4-2

CN4-3

CN4-9

CN4-1

CN4-6

CN5-1

CUT-OFF

WATER

LOW

PROVING

DEVICE

AUX.

SWITCH

PRESSURE

GAS

SWITCH

FLOW

SHIELD

X1-4

X1-6

X1-2

X1-5

X1-3

CN3

CONNECTION BOARD

RS485

0-10V

SENSOR

TANK

3542

BELL JUMPER

CN3

CN4

CN5

CN2

CN1

22 21 20 19 18 17 16 15 14 13 12 11 10

or ribbon cables 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 same wire gauge (AWG) and rated for a

1. All wiring must be installed in accordance with I.E.E Regulations and any local regulations that apply.

Notes:

CN4-14

INTERFACE

HIGH VOLTAGE

LOW VOLTAGE 230 VAC

X5-10

X5-4

X5-3

X5-11

X5-14

X5-7

X5-9

X5-2

X5-1

X5-8

DRAIN

BLOCKED

HI-LIMIT

MANUAL RESET

SENSOR

FLUE

SENSOR

OUTLET

SENSOR

INLET

W R

W/R

ROD

SPARK

ROD

FLAME

VALVE

GAS

X1-7

X2-1

X2-2

VALVE

SOLENOID

X1-1

FAN

INTEGRATED CONTROL

X5-12

X5-6

X5-13

X5-5

X1-8

DISPLAY

BOX DEPICTS

OPTIONAL ITEMS

JUNCTION

BOX

TERMINAL STRIP

ON/OFF SWITCH

L GND N

GND

FIGURE 11.4 WIRING DIAGRAM

Page 28

11.8 LADDER DIAGRAM

INTERFACE

8 7 6 5 4 3 2

X4-2

CN3-2

CONTROL

EXTERNAL

SHIELD

RS485

0-10V

SENSOR

TANK

X4-5

CN3-5

RIBBON CABLE

X5-9

X5-2

X5-1

X5-8

X3-2

X3-4

X3-3

X3-1

CONTACTS

RUN-TIME

CONTACTS

ALARM

CN4-4

CN4-10

CN4-12

CN4-11

CONTROL

INTEGRATED

X4-10

X4-1

X4-3

X4-4

X4-6

X4-8

X4-7

X4-9

SENSOR

FLUE

SENSOR

OUTLET

SENSOR

INLET

CONNECTION BOARD

DISPLAY

CN3-10

CN3-1

CN3-3

CN3-4

CN3-6

CN3-8

CN3-7

CN3-9

RETURN

RETURN PUMP

RELAY

DE-STRAT PUMP

RELAY

PRIMARY PUMP

RELAY

X1-2

X1-4

X1-3

STRIP

PRIMARY

PUMP

STRIP

DE-STRAT PUMP "L"

PRIMARY PUMP "L"

PUMP "L"

DE-STRAT

PUMP

RETURN

PUMP

DE-STRAT PUMP "N"

PRIMARY

PUMP "N"

TERMINAL TERMINAL

GND

230VAC

TERMINAL STRIP

230V SUPPLY "L"

NEUTRAL

TERMINAL STRIP 230V SUPPLY "N"

GROUND

JUNCTION BOX

GND

2. See wiring diagram for additional notes.

are connected or a fault condition is present.

vary from those shown 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

HIGH VOLTAGE SPARK LEADCAUTION

HIGH VOLTAGE

LOW VOLTAGE 230 VAC

CONTROL

INTEGRATED

INTEGRATED CONTROL

ROD

SPARK

FLAME ROD

X1-7

TR1

1.25A

3.5A

X5-12

X5-6

X5-13

X5-5

RELAY

GAS VALVE

X2-1

X5-4

X5-10

X5-3

X5-11

HI-LIMIT

AUTO RESET

SWITCH

DRAIN

BLOCKED

X6-10

CN4-2

PROVING

AUX. DEVICE

24VAC

PILOT SUPPLY

AUX. DEVICE

SWITCH

PRESSURE

HIGH GAS

SWITCH

PRESSURE

LOW GAS

BOARD

CONNECTION

X6-4 CN4-9

X5-14

HIGH LIMIT

MANUAL RESET

CONTROL

INTEGRATED

X6-5

X6-1

X6-6

X6-9

CN4-3

CN4-5

CN4-13

CN4-6

BOARD

CONNECTION

BOARD

CONNECTION

THERMOSTAT

TANK

CN5-4

CN5-2

LWCO

CN5-3

BOARD

CONNECTION

SWITCH

FLOW

X1-8

BOX

JUNCTION

CN5-1

CN4-7

BOARD

CONNECTION

CN4-1

CN4-8

X6-7

X5-7

X6-3

X6-8

X1-5

VLAVE

SOLENOID

VALVE

VENT

JUNCTION BOX

FAN

X1-1

RELAY

BLOWER

X1-6

SWITCH

ON / OFF

24 VAC

230 VAC

OPTIONAL ITEMS

BOX DEPICTS

FAN

FIGURE 11.5 LADDER DIAGRAM

Page 29

12.0 USER CONTROL INTERFACE

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

12.3 SEQUENCE OF OPERATION

OPERATION

DISPLAY

1. Upon a call for heat, the control turns on the appropriate

pumps.

WHR: Standby OUT: 61.4C (65)

2. The control connects 230 VAC to the fan. The fan does

not run at this time.

 If the unit is equipped with a flow switch or low

water cut-off, it must close before the control powers up the fan.

 If the unit is equipped with a manual reset high

limit it must be closed before the control powers up the fan.

 If the unit is equipped with a gas pressure switch,

it must close at this time.

 If there is an auxiliary device connected to the

unit, the unit will then provide 24 VAC to its enable relay. If the auxiliary device has a proving switch, it must close before the sequence continues.

WHR: Standby OUT: 61.4C (65)

3. The control then starts a 10 second prepurge cycle.

WHR: PREPURGE OUT: 61.5C (65)

4. Once the prepurge cycle is complete, and the blocked

drain and auto-reset high 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 burner again. If the burner does not light after 4 trials, the control will lockout for 1 hour and then try another set of 4 trials. On the SHW145-435CE the unit will lockout until manually reset.

WHR: POSTPURGE, PREPURGE OUT: 61.5C (65)

6. If the control detects a flame before the trial for ignition

ends, it begins to modulate the burner in order to maintain the set point.

WHR: RUN 20% RATE OUT: 62.6C (65)

7. Once the call for heat is satisfied, the control will turn off

the burner. The fan will remain on for the 10-second postpurge cycle. The primary pump will continue to run for its respective pump delay time, and then turn off.

WHR: POSTPURGE OUT: 64.5C (65)

8. Primary pump switches off.

WHR: Standby OUT: 64.8C (65)

Page 31

12.4 STATUS DISPLAY SCREENS

Status Display Screens

By using the Previous/Next (◄, ►) arrow keys on the user interface control panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display:

Screen

Display shows:

Description

WHR: OFF

The unit has been turned OFF by the Enter/Reset button on the user interface control panel.

STANDBY

The unit has not received a call for heat from its from a tank sensor.

PREPURGE

The unit has initiated a 10 second purge period on a call for heat.

IGNITION

The unit has begun a 5 second spark period to ignite the main burner.

RUN***% RATE

The unit has fired and is running at the displayed percentage.

POSTPURGE

The call for heat has been satisfied and the unit runs the fan for an additional 10 seconds to clear the combustion chamber and flue system of residual combustion products.

SERVICE

The unit has been placed in a temporary mode that will allow the unit to fire at 100% of rate for the purpose of combustion analysis.

OUT:***.*C

The heat exchanger outlet temperature is displayed.

OPEN

The control does not detect the outlet sensor.

SHORTED

The outlet sensor wires or the sensor itself has become shorted.

Press the Next ► arrow key on the user control interface panel to access Screen 2

IN: ***.*C

The heat exchanger inlet temperature is displayed.

OPEN

The control does not detect the inlet sensor

SHORTED

The inlet sensor wires or the sensor itself has become shorted.

RISE: ***.*C

The difference between the inlet temperature and the outlet temperature.

Press the Next ► arrow key on the user control interface panel to access Screen 3.

FLUE: ***.*C

The control will display the flue temperature.

OPEN

The control 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 4.

FAN SPD: ****RPM

The control will display the actual fan motor RPM.

FLAME SIG: **.*UA

The control will display the flame signal in dc micro amps.

Press the Next ► arrow key on the user control interface panel to access Screen 5.

WHR CFH: OFF

The control has not received a call for heat from the tank sensor.

The control has received a call for heat from the tank sensor.

WHR PUMP: OFF

The control has not received a DHW call for heat and has not powered the primary pump.

The control has received a DHW call for heat and has powered the primary pump.

DELAY

The primary call for heat has been satisfied and the DHW pump is running for a fixed time to remove any residual heat.

Press the Next ► arrow key on the user control interface panel to access Screen 6.

NOT USED: N/A

Not used.

0-10V IN: **.VDC

The control will display a 0-10Vdc signal received from a Building Management System (BMS) connected to the unit.

Press the Next ► arrow key on the user control interface panel to access Screen 7.

PMP: Off

The burner control has not received a call for heat from the tank sensor and has not powered the primary pump.

PMP: On

The burner control has received a call for heat from the tank sensor and has powered the primary pump.

PMP: Delay

The call for heat has been satisfied and the primary pump is running for a fixed time to remove any residual heat.

Press the Next ► arrow key on the User control interface panel to roll back to Screen 1. At any point if you wish to access an earlier screen, press the Previous ◄ arrow key on the User control interface panel.

Page 32

13.0 COMMISSIONING AND TESTING

13.1 ELECTRICAL INSTALLATION

Notes on the requirements for electrical installation are provided in Section 11: ELECTRICAL SUPPLY. A schematic drawing of the control circuit is shown in Figure 11.4

13.2 GAS INSTALLATION

For design see Section 7: GAS SUPPLY. See Section 2.0: PRINCIPAL PARTS for details on the position of the gas connection.

13.3 WATER CONNECTIONS

For design see Section 10: WATER CONNECTIONS

The system should be thoroughly flushed out with cold water without any circulating pump in position. Ensure all the valves are open.

If a building return pump is to be fitted, it should be fitted before the system is filled and air locks cleared. Check the system for leaks and repair as necessary. If the system is configured in an unvented arrangement, check the expansion vessel cushion pressure.

13.4 COMMISSIONING THE EQUIPMENT

13.4.1 GENERAL CHECKS PRIOR TO LIGHTING

A person deemed competent MUST be responsible for the commissioning of this equipment. Before attempting to commission any equipment, ensure that 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 matter, tested for soundness and purged.

5. The condensate drain is installed correctly and the condensate trap is filled with water.

NOTE: If the condensate trap is not filled before use, products of combustion may escape and can lead to severe personal injury or death

13.4.2 EQUIPMENT CHECKS PRIOR TO LIGHTING

This unit has been designed for a nominal gas inlet pressure of 20 mbar when used on natural gas. Information relating to propane firing can be found in Section 14: LPG FUEL

1. Gas supply is connected but turned to the “off” position. Any unions or fittings are correctly tightened,

test points are closed and the flame sense electrode lead is connected correctly. Ensure the ceramic

sheath around the flame sense electrode is not cracked or broken.

2. Ensure electricity supply is connected.

3. Check that the internal circulating pump is fully bled.

Page 33

13.4.3 PROCEDURE FOR INITIAL LIGHTING

Model No.

CO2

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

IF THE UNIT IS TO OPERATE ON LPG REFER TO SECTION 14 BEFORE PROCEEDING

1. Ensure that the gas-inlet appliance isolating valve, provided by the installer, is in the “off” position.

2. Press the power rocker switch, positioned on the back of the appliance to bring the equipment on.

3. Press the Enter/Reset button on the user control interface panel to initiate the burner.

4. The combustion fan should ramp up to full speed to purge the combustion chamber and then drop back

to half rate in order to light. The spark generator should create a spark, visible through the burner sight

glass. As the gas-inlet appliance isolating valve is closed, the controls should go to a flame failure

condition after four ignition attempts (SHW45-325CE – SHW115-435CE) or one ignition attempt

(SHW145-435CE). If the above occurs correctly, open the gas-inlet appliance isolating valve and reset

the unit by depressing the Enter/Reset button on the control panel.

5. The combustion fan will repeat the pre-purge procedure and attempt to light. Once a flame is

established, the LCD display will change to display the rate at which it is firing.

6. Allow the system to reach temperature to check operation of the control sensors.

7. Once the unit has reached temperature and shut down, check that the flame has extinguished.

13.4.4 GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS

The Lochinvar EcoShield series are supplied with a preset gas/air ratio inlet assembly. This must not be tampered with. Any attempt to adjust the gas valve or venturi will invalidate the warranty.

Combustion figures should be as follows:

TABLE 13.1 NATURAL GAS COMBUSTION FIGURES

If the combustion figures are not within the range specified, contact Lochinvar Limited for further guidance.

Combustion figures for Propane firing can be found in Section 14 LPG FUEL.

13.5 TEMPERATURE ADJUSTMENT PROCEDURE

With the heater firing, the setpoint can be adjusted using the Up and Down buttons on the user interface control panel. Once the desired setpoint is displayed, the Enter/Reset button should be pressed to store the value. The setpoint should be adjusted to ensure that the water is stored at 60°C and distributed at 50°C within 1 (one) minute at all outlets. Care is needed to avoid much higher temperatures because of the risk of scalding. At 50°C the risk of scalding is small for most people, but the risk increases rapidly with higher temperatures and for longer exposure times. The risk to young children and to those with a sensory or mobility loss will be greater. Where a significant scalding risk has been identified, the use of thermostatic mixing valves on baths and showers should be considered to reduce temperature, these need to be placed as close to the point of use as possible.

13.6 INSTALLATION NOISE

If care has been taken to follow the manufacturer’s instructions there should be no discernible noise from the equipment. The allied pump motor may have a level of sound that could lead to consideration for acoustic insulation, but care must be taken not to impede ventilation or airflow to the pump motor.

Page 34

14.0 LPG FUEL

Model

Part No.

Stamp

Size

SHW45-325CE

ORF2022

150

4.98  0.025

SHW60-325CE

ORF2023

210

5.56  0.025

SHW85-435CE

ORF2024

285

6.76  0.025

SHW115-435CE

ORF2025

7.2

7.20  0.02

SHW145-435CE

ORF20003

9.5

9.50  0.02

NOTE! IT IS STRONGLY RECOMMENDED THAT, ON LPG INSTALLATIONS, GAS DETECTION EQUIPMENT IS FITTED. THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE APPLIANCE AND AT LOW LEVEL. IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE APPLIANCE IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL. THIS APPLIANCE MUST NOT BE LOCATED BELOW GROUND E.G. IN A CELLAR

14.1 RELATED DOCUMENTS

In addition to those documents listed in Section 4.1: RELATED DOCUMENTS within the main body of the

installer’s guide the gas installation should also comply with the guidance offered in the following documents.

BS 5482-1: 2005 Code of practice for domestic butane and propane gas burning installations.

Part 1: Installations at permanent dwellings, residential park homes and commercial

premises, with installation pipework sizes not exceeding dn25 for steel and dn28 for corrugated stainless steel or copper.

The operation of the EcoShield range on LPG-Propane (3rd Family) 3P is similar to that on Natural Gas (2nd

Family) 2H and the design and installation details described in the main body of the installer’s guide should be

followed.

14.2 CONVERSION TO LPG

This process must be carried out in the order stated. Failure to follow the following procedure may lead to non-warrantable damage to the water heater. The conversion MUST be carried out by 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.

TABLE 14.1 LPG ORIFICE MARKINGS

If the water heater is already installed and operational, you must turn off the gas supply, turn off the power supply and allow the water heater to cool before proceeding. The conversion procedure is as follows:

14.2.1 SHW45-325CE – SHW85-435CE

1. Remove the top and front access covers from the unit.

2. Remove the impulse tube and wiring plug from the gas valve.

3. Remove the three cap-head screws securing the gas valve to the venturi (Figure 14.1).

4. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk

is correct for the water heater (see Table 14.1). Place the orifice into the black rubber grommet in the

side of the gas valve ensuring the orifice and grommet are seated correctly (Figure 14.1).

5. Reposition the gas valve against the venturi and replace the cap-head screws (Figure 14.1) securing

the valve to the venturi.

6. Refit the impulse tube and wiring plug to the gas valve.

Page 35

7. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the

water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the

unit in the lower left corner.

8. Replace the top and front access covers.

FIGURE 14.1 CONVERSION PROCEDURE SHW45-325CE – SHW80-435CE

14.2.2 SHW115-435CE

1. Remove the top and front access covers from the unit.

2. Remove the impulse tube and wiring plug from the gas valve.

3. Remove the three screws securing the venturi to the fan.

NOTE: When separating the venturi from the fan, take care not to damage the O-ring inside the fan (Figure

14.2).

4. Remove the four cap-head screws securing the gas valve to the venturi (Figure 14.2).

5. Locate the propane orifice disk from the 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 (Figure 14.2) securing

the valve to the venturi.

8. Inspect the O-ring inside the fan. Handle the O-ring with care, do not damage. Reposition the venturi

against the fan and replace the screws securing the venturi to the fan (Figure 14.2).

9. Refit the impulse tube and wiring plug to the gas valve.

10. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the

water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the

unit in the lower left corner.

11. Replace the top and front access covers.

Page 36

FIGURE 14.2 CONVERSION PROCEDURE SHW115-435CE

14.2.3 SHW145-435CE

1. Remove the top and front access covers from the unit.

2. Remove the gas valve and manifold from the unit via the unions on each end (Figure 14.3).

3. Remove the three screws mounting the injector plate on the air shroud (Figure 14.3).

4. Remove the four screws securing the manifold adapter to the injector plate taking care not to damage

the O-ring.

5. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk

is correct for the water heater (see Table 14.1 LPG Orifice Markings).

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 shroud and replace the three injector plate mounting screws.

9. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the

water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the

unit in the lower left corner.

10. Replace the top and front access covers.

FIGURE 14.3 CONVERSION PROCEDURE SHW145-435CE

Page 37

14.3 LPG COMMISSIONING AND TESTING

Model No.

CO2

SHW45-325CE

10.5% 0.5%

<100 ppm

SHW60-325CE

10.5% 0.5%

<100 ppm

SHW85-435CE

10.5% 0.5%

<100 ppm

SHW115-435CE

10.5% 0.5%

<100 ppm

SHW145-435CE

10.5% 0.5%

<100 ppm

The commissioning procedure on LPG is similar to that when the heater is firing on Natural Gas. As such, the same procedure should be followed taking in to account the following information:

14.3.1 LPG PRESSURE ADJUSTMENT AND COMBUSTION CHECKS

The Lochinvar EcoShield series are supplied with a preset gas/air ratio inlet assembly. This must not be tampered with. Any attempt to adjust the gas valve or venturi will invalidate the warranty.

Combustion figures should be as follows:

TABLE 14.3 LPG COMBUSTION FIGURES

If the combustion figures are not within the range specified, contact Lochinvar Limited for further guidance.

15.0 MAINTENANCE

15.1 GENERAL

KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS AND FLAMMABLE VAPOURS AND LIQUIDS.

A competent person should check and ensure that the flue, its support and terminal, the ventilation to the boiler house, safety valve, drain, pressure gauge etc. are in a serviceable and working condition and still comply with the relevant standards and codes of practice, as detailed in Section 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 the state of the flue and burner. Results of the flue gas analysis should be compared with previously measured values to identify a possible loss of efficiency.

15.2 MAINTENANCE SCHEDULE

The water heater has a built in function that reminds the user that routine maintenance is due. As a default, this is set to 12 months, 10,000 operational hours or 10,000 ignition cycles. Lochinvar Limited recommend that this is the maximum service interval however in hard water areas, it may be necessary to reduce this time period to ensure correct operation of the heater and associated equipment.

15.3 BURNER INSPECTION

The heat exchanger has a sight glass for inspection of the flame picture.

NOTE: If the appliance has been in recent operation, this area may be hot. Appropriate precautions should be taken to prevent personal injury.

To check the flame picture at high and low fire, the following procedure should be followed:

1. Place the water heater into service mode. This is done by depressing the small button below the

Enter/Reset button for 5 seconds.

Page 38

2. The heater should shut down and relight.

3. Depress the service button momentarily, this should ramp the water heater up to full rate.

4. Check the flame condition.

5. Depress the service button momentarily, this should ramp the water heater down to low rate.

6. Check the flame condition.

7. Press and hold the service button for 5 seconds to take the unit out of service mode.

15.4 BURNER REMOVAL

If it has been determined that the flame picture is unacceptable, the burner can be removed and cleaned using the following procedure:

1. Isolate the electrical and gas supplies to the heater.

2. Allow the boiler to cool down.

3. Disconnect the wiring connections to the ignition electrode.

4. Disconnect the power and control connection leads and earthing wire from the combustion fan.

5. Apply a suitable release oil to the 6 studs around the edge of burner door.

6. Remove the 6 retaining nuts around the edge of the burner door.

NOTE: Once loosened, the nuts should be removed by hand. If any of the nuts seize, the nut should

gently be re-tightened and additional release oil used.

7. Withdraw the heat exchanger front plate and burner assembly from the heat exchanger complete with

the combustion fan.

8. With the burner assembly away from the boiler, the burner can be gently cleaned with the brush

attachment of a vacuum cleaner.

The reassembly procedure is the reverse of the above taking care to ensure that the for the heat exchanger front plate sealing gasket, the combustion fan connection gasket, the burner door insulation and the combustion chamber rear wall insulation are in 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 accumulation on the heating surfaces.

3. Inspect the heat exchanger to ensure that the 1 mm flueway is clear between all coils.

4. If any debris is still present, brush the heat exchanger with a non-metallic brush taking care not to

damage the insulation panel on the rear wall of the heat exchanger.

NOTE: A kit of components to aid with cleaning the heat exchanger is available from Lochinvar Limited.

For models SHW45-325CE – SHW115-435CE use part number KIT30063, for model SHW145-

435CE use part number KIT30064. NOTE: It is very important to inspect and remove all deposits from the heat exchanger. If all deposits

cannot be removed from the heat exchanger, contact Lochinvar Limited for further guidance.

5. Once the heat exchanger has been brushed it should be rinsed with fresh water to remove all residues.

6. Remove the condensate water trap and clean out any debris.

7. Refit the condensate drain and fully recharge by pouring 1 litre of water through the heat exchanger

coils.

8. Reinstall the burner.

9. Restart the heater as detailed in Section 13.4.3: PROCEDURE FOR INITIAL LIGHTING.

15.6 DRAINING THE WATER HEATER SYSTEM

Maintenance and service procedures for the storage vessel require draining the water heater. The water heater must also be drained if it is to be shut down and exposed to freezing temperatures.

1. Turn off the water heater electrical disconnect switch.

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2. Connect a hose to the system drain valve.

3. Locate hose’s discharge in an area where hot water will not cause any damage or injury.

4. Close the cold-water inlet valve to water heater system.

5. Open a nearby hot water outlet to vent the system.

6. Open the drain valve.

7. If the water heater is being drained for an extended shutdown, it is suggested the drain valve be left

open during this period.

NOTE: The heat exchanger cannot be completely drained of water without purging with compressed air at a pressure of 1 bar.

15.7 STORAGE VESSEL: INSPECTION AND CLEANING

1. Drain the heater. Refer to Section 15.6: DRAINING THE WATER HEATER SYSTEM.

2. Remove outer cover plate from lower side of water heater jacket.

3. Remove cover and gasket from cleanout opening.

4. Remove scale or sediment using care not to damage the vitreous enamel lining.

5. Inspect cleanout plate gasket and replace if necessary.

6. Install gasket and cleanout plate. Draw plate up square by tightening screws evenly.

15.8 SACRIFICIAL ANODES: INSPECTION AND REPLACEMENT

If the Correx non-sacrificial anode protection system is used, there is no requirement to check the condition of the anodes.

The tank is protected against corrosion by means of two sacrificial anodes fitted in the front of the storage vessel. The rate at which the anodes are eroded is dependent on the quality 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 should be paid to the

ends of each anode to ensure excessive localised depletion has not occurred.

4. When refitting the inspected or replaced anode, a suitable jointing compound should be applied to the

threads of the anode to prevent water leakage.

15.9 REFILLING THE SYSTEM

1. Close the drain valve.

2. Open a hot water fixture to allow air to escape.

3. Open the cold water supply to water heater and allow the tank to fill.

4. Follow the lighting instructions as detailed in Section 13.4.3: PROCEDURE FOR INITIAL LIGHTING.

5. Check for water leakage.

15.10 OTHER CHECKS

15.10.1 RELIEF VALVE

At least once a year, the temperature and pressure relief valve and safety valve should be checked to ensure that they operate correctly. To check the valves, the manual override levers should be operated several times. The valves should seat properly and operate freely.

If water does not flow, drain the heater, remove the inoperative valve and inspect for obstructions or corrosion. Replace with a new valve of the recommended size as necessary.

15.10.2 FLUE SYSTEM

Examine the exhaust and air intake system every 12 months. Points of inspection are as follows:

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1. Check for obstructions and/or deterioration of flue pipe and terminal. Replace immediately where

needed.

2. Check the terminal for any foreign material and remove as necessary

3. Check all flue system connections for leakage and reseal as required.

4. Check that ventilation grilles comply with current regulations.

15.10.3 CONDENSATE NEUTRALISATION KIT

If fitted, the condensate neutralisation kit will require replacing after 12 months of operation. Please refer to the item specific instructions for further details.

16.0 USER CONTROL INTERFACE SETTINGS

16.1 ENTERING THE INSTALLER CODE

To access the user control the following procedure should be followed:

1. If the heater is operating, press the Enter/Reset button to turn the unit off.

2. Press and hold the Menu/Exit button for 5 seconds. At this point the display will change to show:

Enter Menu Code:

0000

3. Press the UP button 9 times. The display should now show:

Enter Menu Code:

0009

4. Press the Previous button 2 times. The display should now show:

Enter Menu Code:

0009

5. Press the Up button 3 times. The display should now show:

Enter Menu Code:

0309

6. Press the Previous button. The display 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 then accessed using the

Enter/Reset button.

16.2 MENU SET D FUNCTIONS

16.2.1 RESET LAST 10 ERRORS

The last 10 errors logged can be cleared using this parameter. To carry out this function, the Enter/Reset button.

16.2.2 SERVICE MODE DELAY

By pressing the pin button on the front of the display for five (5) seconds, the control will be placed in Service Mode. This will override all other heat demands. The Service Mode allows the installer to set the unit to either maximum firing rate or minimum firing rate for the purpose of combustion analysis. The delay sets the length of time the water heater will stay in the Service Mode if no keys have been pressed before going back to its original state. The time range of this parameter can be adjusted between 0 and 40 minutes using the Up and Down buttons. Once the desired time period has been set, the Enter/Reset button should be pressed to store the value. The default time delay is 20 minutes.

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16.3 MENU SET E WHR SETTINGS

16.3.1 TANK SETPOINT

When a DHW call for heat becomes active, the control will use the tank setpoint to determine the firing rate of the water heater based on the actual water temperature. The desired temperature can be adjusted in ½ 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.

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