Lochinvar EGS030 Service Manual
INSTALLATION & SERVICE MANUAL
SINGLE-WALL INDIRECT
WATER HEATER
WARNING
To avoid damage or injury, there must be no
materials stored against the indirect water heater
and proper care shall be taken to avoid unnecessary
contact (especially by children) with the indirect
water heater.
• Do not store or use gasoline or other flammable
liquids in the vicinity of this water heater or any
other appliance.
For your family’s comfort, safety, and convenience, we
recommend this water heater be installed and serviced
by a plumbing professional.
EGS-I&S-01
WARNING
Indicates a potentially hazardous situation, which, if
not avoided, may result in moderate, or minor injury
or property damage.
CAUTION
Indicates a potentially hazardous situation, which, if
not avoided, could result in death, serious injury, or
substantial property damage.
NOTICE
Indicates special instructions on installation,
operation or maintenance, which are important but
not related to personal injury hazards.
TABLE OF CONTENTS
IMPORTANT INFORMATION ..................................1
GENERAL INFORMATION ....................................... 3
PRE-INSTALLATION..................................................4
WATER CONNECTIONS ............................................6
ELECTRICAL CONNECTIONS ................................8
OPERATING INSTRUCTIONS ..................................8
MAINTENANCE ......................................................... 10
TROUBLESHOOTING GUIDE ................................ 12
IMPORTANT INFORMATION
The equipment must be installed in accordance with
those installation regulations required in the area
where the installation is to be made. These regulations
must be carefully followed in all cases. Authorities
having jurisdiction shall be consulted before
installations are made.
All wiring on water heaters installed in the USA must
be in accordance with the National Electrical Code and/
or local regulations; or in Canada, installed in
accordance with the Canadian Electrical Code and/or
local regulations.
The following terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels,
or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation, which,
if not avoided, will result in death, serious injury, or
substantial property damage.
DANGER
DO NOT store or use gasoline or other flammable,
combustible, or corrosive vapors and/or liquids in the
vicinity of this or any other appliance.
IF YOU SMELL GAS:
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not
use any telephone in your building.
Immediately call your gas supplier from a
telephone in another building. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier, call
the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL
THE LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than
air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets, and areas below
ground level will serve as pockets for accumulation
of leaking gas.
This water heater is supplied with an adjustable
thermostat to control water temperature. Hot water
temperatures required for automatic dishwasher and
laundry use can cause scald burns resulting in serious
personal injury and/or death. The temperature at
which injury occurs varies with the person’s age and
the time of exposure. The slower response time of
disabled persons increases the hazards to them.
NEVER allow small children to use a hot water tap
or to draw their own bath water. NEVER leave a
child or disabled person unattended in a bathtub or
shower.
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EGS-I&S-01
WARNING
Installation is not complete unless a pressure and
temperature relief valve is installed into the side of
the water heater. See the Water Connections section
of this manual for details.
This water heater contains very hot water under high
pressure. Do not unscrew any pipe fittings or attempt
to disconnect any components of this water heater
without positively assuring the water is cool and has
no pressure. Always wear protective clothing and
equipment when installing, starting up, or servicing
this water heater to prevent scald injuries. Do not
rely on the pressure and temperature gauges to
determine the temperature and pressure of the water
heater. This water heater contains components that
become very hot. Do not touch any components unless
they are cool.
Improper installation, adjustments, alteration,
service or maintenance can cause property damage,
personal injury or loss of life. Failure to follow all
instructions in the proper order can cause personal
injury or death. Read and understand all instructions,
including all those contained in component
manufacturer’s manuals, which are provided with the
appliance before installing, starting-up, operating,
maintaining, or servicing this appliance. Keep this
manual and literature in legible condition and posted
near the appliance for reference by owner and service
technician.
This water heater requires regular maintenance and
service to operate safely. Follow the instructions
contained in this manual. Installation, maintenance,
and service must be performed only by an
experienced, skilled, and knowledgeable installer or
service agency.
CAUTION
WARNING
It is the responsibility of the installing contractor to
see that all controls are correctly installed and are
operating properly when the installation is complete.
DO NOT operate the water heater with jumpered
or absent controls or safety devices.
DO NOT tamper with or alter the water heater and/
or controls.
DO NOT operate the water heater if any external
part has been under water. Immediately call a
qualified service technician to inspect the appliance
and to replace any part of the control system that
was under water.
This water heater is suitable for installation on
combustible flooring. DO NOT install this water
heater on carpeting.
DO NOT operate this water heater without first
being certain it is filled with water.
Flammable items, pressurized containers, or any
other potential fire hazardous articles must never
be placed on or adjacent to the heater. Containers of
flammable gases should not be stored or used in the
same room with this water heater.
Hydrogen gas can be produced in an operating water
heater that has not had water drawn from the tank
for a long period of time (generally two weeks or
more). Hydrogen gas is extremely flammable. To
prevent the possibility of injury under these
conditions, we recommend that the water faucet be
opened for several minutes at the kitchen sink before
you use any electrical appliance that is connected to
the hot water system. If hydrogen is present, there
will be unusual sounds such as air escaping through
the pipes as hot water begins to flow. Do not smoke
or have open flame near the faucet at the time it is
open.
The maximum boiler water supply temperature to
the indirect heat exchanger must not exceed 240°F
(116°C).
NOTICE
Insulation blankets are not required for this water
heater. This water heater meets or exceeds the
ASHRAE/IES 90.1b standards with respect to
insulation and standby loss requirements.
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EGS-I&S-01
TEMPERATURE AND PRESSURE
RELIEF VALVE
WARNING
Keep clear of the combination temperature and
pressure relief valve discharge line outlet. The
discharge may be hot enough to cause scald injury. The
water is under pressure and may splash.For protection
against excessive temperatures and pressure, install
temperature and pressure protective equipment required
by local codes, but not less than a combination
temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment
or materials as meeting the requirements of the Standard
for Relief Valves and Automatic Gas Shutoff Devices
for Hot Water Supply Systems, ANSI Z21.22 and
the Standard CAN1-4.4 Temperature, Pressure,
Temperature and Pressure Relief Valves and Vacuum
Relief Valves. The combination temperature and
pressure relief valve must be marked with a maximum
set pressure not to exceed the maximum working
pressure of the water heater. The combination
temperature and pressure relief valve must also have an
hourly rated temperature steam BTU discharge capacity
not less than the hourly rating of the water heater. The
supplied combination temperature and pressure relief
valve, when properly installed and unrestricted, will
discharge the maximum input produced by a 240°F
(116°C) boiler supply temperature. A lower boiler
supply temperature will reduce the input required to be
discharged in the event of excessive potable water
temperatures.
NOTICE
If the boiler takes longer to heat up from a cold start
than the water availability as noted above, hot water
shortage may occur.
Hot water availability is based off drawing 80% of
the heated tank volume at 4 gallons per minute flow
rate.
The maximum heat transfer through the coil (heat
input) of the water heater at 240°F boiler water supply
temperature and 210°F potable water temperature is
94,100 Btu/hr for residential models and 180,300 Btu/
hr for commercial models. Potable water temperature
is limited to below 210 °F and nominal watercontaining capacity is below 120 gallons for all singlewall indirect models.
Accordingly, per Part HLW-101.2, Section IV of the
ASME Boiler and Pressure Vessel Code, all Lochinvar
Single-wall Indirect products are exempted from
compliance with the code.
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER — The heat exchanger (coil) has
1" NPT female fittings.
These water heaters with single-wall heat exchangers meets
the Uniform Plumbing Code for installation in all potable
water systems provided that:
Install the combination temperature and pressure relief
valve into the opening provided and marked for this
purpose on the water heater.
Some models may already be equipped or supplied with
a temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve
complies with local codes. If the temperature and
pressure relief valve does not comply with local codes,
replace it with one that does.
• The boiler water (including additives) is
practically non-toxic, having toxicity rating of
class of 1 as listed in Clinical Toxicology of
Commercial Products.
• The boiler water pressure is limited to
maximum 30 psig by approved relief valve.
• The heat transfer medium is potable water or
contains only substances that are recognized
as safe by the U.S. Food and Drug
Administration (FDA).
• The pressure of the heat transfer medium is
maintained less than the normal minimum
operating pressure of the potable water system.
• The equipment is permanently labeled to
indicate that only additives recognized as safe
by the FDA shall be used in the heat transfer
medium.
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EGS-I&S-01
ADJUSTABLE AQUASTAT – The temperature may
be adjusted from 80°F to 160°F. The aquastat (thermostat)
was adjusted to 120°F before the heater was shipped from
the factory. It is recommended that lower temperatures be
used to avoid the risk of scalding. Refer to the “Warnings”
and the section on SCALDING “under – Operating
Instructions.” It is further recommended, in all cases, that
the water temperature be set for the lowest temperature that
satisfies your hot water needs. This will also provide the
most energy efficient operation of the water heater and
minimizes scale formation.
Setting the water heater temperature at 120°F will reduce
the risk of scalds. Some states require settings to specific
lower temperatures.
WARNING
Install a discharge line so that water discharged from the
temperature and pressure relief valve will exit within six
(6) inches above, or any distance below, the structural
floor and cannot contact any live electrical part. The
discharge line is to be installed to allow for complete
drainage of both the temperature and pressure relief valve
and the discharge line. The discharge opening must not
be subjected to blockage or freezing. DO NOT thread,
plug, or cap the discharge line. It is recommended that a
minimum clearance of four (4) inches be provided on
the side of the water heater for servicing and maintenance
of the combination temperature and pressure relief valve.
Do not place a valve between the combination
temperature and pressure relief valve and the tank!
NOTE: Any claims for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee.
IMPORTANT DECISIONS REQUIRED
BEFORE INSTALLATION
SIZING
1. Boiler DOE Heating Capacity – The Single-wall
Indirect water heater will provide the rated
performance only if used in conjunction with a
boiler with a DOE heating capacity (Boiler Output)
minimum of 220,000 Btu/hr. If the boiler has less
capacity, the output of the tank will be reduced. To
determine the approximate reduction in output from
the tank use the following formula:
New Rating = (maximum first hour rating) x
Actual Boiler Output Capacity
Minimum Boiler Output Capacity
For example, what would the 140°F first hour rating be if
model EGS050 was installed with a boiler having a DOE
heating capacity of 180,000 BTU/hr?
Answer:
New Rating
= 297 gal/hr x (180,000 BTU/h)/(220,000 BTU/hr)
= 297 gal/hr x 0.818 = 243 gal/hr
SACRIFICIAL ANODES—Three sacrificial anode rods
have been installed in the tank head to extend tank life. The
anode rods should be inspected annually to determine the
amount of sacrificial decay and replaced when necessary to
prolong tank life. Water conditions in your area will
influence the time interval for inspection and replacement
of the anode rod. The use of a water softener may increase
the speed of anode consumption. More frequent inspection
of the anode is needed when using softened (or phosphate
treated) water. Contact the plumbing professional who
installed the water heater or the manufacturer listed on the
rating plate for anode replacement information.
PRE-INSTALLATION
INSPECT SHIPMENT carefully for any signs of damage.
If damage is noted, do not install the product. Contact the
shipper or manufacturer listed on rating plate. All equipment
is carefully manufactured, inspected, and packed. Our
responsibility ceases upon delivery of the packaged heater
to the carrier in good condition.
NOTICE
Increasing the boiler DOE heating capacity above
220,000 Btu/hr will not increase the rating of the
water heater. Ratings are based on 180°F boiler
water.
2. Circulator Sizing – Refer to Table below for the
corresponding pressure drop through the coil for
the given model. Calculate the pressure drop of
all straight pipe and fittings on the supply and
return of the water heater at the selected flow
rate. Add the piping/fitting pressure drop to the
pressure drop through the water heater coil. Select
a circulator that will provide an appropriate flow
rate at the combined pressure drop.
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