Lochinvar ER152, ER202, ER252, ER302, ER402 User Manual
Service Manual
Models: ER152, ER202,
ER252, ER302, and ER402
This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the EnergyRite
Installation and Operation Manual,
before installing. Perform steps in the
order given. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
WARNING
Save this manual for future reference.
2
Service Manual
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please read before proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
What is in this manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Access Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Access Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner removal and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Heat exchanger cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Combustion air shutter adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Facts about water chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heat exchanger inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Prevention of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting Chart - No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting Chart - Noisy System . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Chart - Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . 25
Gas Manifold Pressure Adjustment Procedure . . . . . . . . . . . . . . . . . . . . 28
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but
not related to personal injury or property damage.
Please read before proceeding
Installer – Read all instructions,
including this manual and the
EnergyRite Installation and Operation
Manual, before installing. Perform steps
in the order given.
User – This manual is for use only by a
qualified heating installer/service
technician. Refer to the EnergyRite
User’s Information Manual for your
reference.
Have this pool heater serviced/inspected
by a qualified service technician at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the pool
heater – Please have the pool heater model
and serial number from the pool heater
rating plate.
Consider piping and installation when
determining pool heater location (see the
EnergyRite Installation and Operation
Manual).
Any claims for damage or shortage in
shipment must be filed immediately against
the transportation company by the
consignee.
Service Manual
3
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be
converted to cristobalite in very high temperature applications. The International Agency for Research on
Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from
occupational sources is carcinogenic to humans (Group 1).”:
Avoid breathing dust and contact with skin and eyes.
• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA
requirements for cristobalite at the time this document was written. Other types of respirators may
be needed depending on the job site conditions. Current NIOSH recommendations can be found on
the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,
manufacturers, and phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent airborne dust.
Remove the combustion chamber lining from the pool heater and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
WARNING
NOTICE
WARNING
4
Service Manual
Please read before proceeding
When servicing pool heater –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow the pool heater to cool
before performing maintenance.
Pool heater operation –
• Do not block flow of combustion or ventilation air to
the pool heater.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this pool heater if any part has been under
water. The possible damage to a flooded appliance can
be extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Pool heater water –
• Do not use petroleum-based cleaning or sealing
compounds in the pool heater system. Gaskets and
seals in the system may be damaged. This can result in
substantial property damage.
• Do not use “homemade cures” or “pool heater patent
medicines”. Serious damage to the pool heater,
personnel, and/or property may result.
Service Manual
5
What is in this manual?
Service
The EnergyRite display
• Display panel readout, buttons and their functions
Control module inputs
• Control module inputs and options
Control module outputs
• Control module outputs and options
General
• How the pool heater operates
• How the control module operates
Control panel menu access
• Accessing service and setup mode and locating menus
Maintenance
• Service and maintenance schedules
• Inspect pool heater area and pool heater interior
• Check all piping for leaks
• Check air openings
• Flue vent system and air piping
• Check water system
• Check pool heater relief valve (if applicable)
• Inspect ignition electrode
• Check ignition ground wiring
• Check all pool heater wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• General maintenance
• Cleaning heat exchanger
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor table
• Troubleshooting table - Fault messages displayed on
pool heater interface
• Gas manifold pressure adjustment procedure
• Checking gas supply pressure
1
Service
6
Service Manual
The EnergyRite display
1
Service
(continued)
Service Manual
7
Control inputs
1
Service
8
Service Manual
Control outputs
1
Service
(continued)
Service Manual
9
General Operation
How the pool heater operates
The EnergyRite uses a copper finned tube heat exchanger
and an electronic control module. The blower provides
both primary and secondary air to the burners and forces
the flue products out of the combustion chamber and into
the vent system. The combination gas valve both regulates
the manifold pressure and provides gas to the manifold,
which then supplies the burners. The control and gas
supply system is a fixed rate and only performs ON/OFF
operation.
How the control module operates
The EnergyRite control monitors the inlet sensor which is
indicative of pool/spa water temperature. The control will
begin an ignition sequence when the water temperature has
dropped below the set point minus the differential. It will
also monitor all safety circuits and will terminate or prevent
an ignition cycle if a safety circuit is open. In addition, the
control will monitor the outlet temperature and will
terminate a call for heat if the outlet temperature gets too
high.
1
Service
10
Service Manual
Access setup menu
Table 1A Use this procedure to access the Setup Menu from the display panel
The pool heater will continue to operate while the Setup Menu
is being accessed. To adjust settings, press the MENU button
until the desired screen is displayed. Use the UP and DOWN
buttons to adjust the setting within the screen. By pressing the
MENU or POOL/SPA button the new setting will be stored into
memory and the next screen will be displayed.
When adjusting “set passcode” the 4 individual digits can be
adjusted. The digit on the far left will be active first. Use the UP
and DOWN buttons to adjust the digit. Once the MENU
button is pushed, that digit is stored into memory and the next
digit to the right is active. Continue on until all digits have been
adjusted.
After 1 minute of inactivity, all settings are stored and the
control will exit the Setup Menu. To manually exit the Setup
Menu at any time, press the POOL/SPA button once.
Setup menu descriptions
Pool/spa remote
This setting allows the user to enable or disable the remote
capability of switching from pool to spa. The default setting is
disable.
There are three (3) options under this menu: T Stat, Switch, and
Disable.
T Stat - Select this option when the heater is used in
conjunction with a two wire remote system which includes its
own thermostat. This option will automatically set the set point
to 104° (max.) and all messages on the display will become
generic (i.e. no references to pool or spa). Where there is no call
for heat the pool heater will remain in Standby Mode.
Switch - Select this option when the heater is used in
conjunction with a three wire remote system, also known as a
three-way switch. The remote will control the pool heater if it is
in Pool, Spa, or Standby Mode and will utilize the thermostat on
the heater. When there is no call for Pool or Spa Mode, the pool
heater will remain in Standby Mode.
When in T Stat or Switch Mode, the user can turn the control
“OFF” by pressing the POOL/SPA button on the display.
Disable - This is the default setting. When this option is selected
the heater will ignore all inputs on R, Ws, and Wp. The heater
will not recognize any of the remotes.
For additional wiring instructions consult the third party remote
manufacturer along with the EnergyRite Installation and
Operation Manual.
Differential
This setting allows the user to choose how far below set point the
water temperature must drop before the control will initiate a
call for heat. The range of adjustment is from 1°F to 15°F. The
default setting is 2°F.
Temperature scale
This setting allows the user the choice of showing the displayed
temperature in degrees Fahrenheit or degrees Celsius. The
default setting is Fahrenheit.
Restore defaults
This setting allows the user to restore the factory default settings
for the Setup Menu and temperature settings.
Set passcode
This setting allows the user to set a personal passcode that would
be required to lock and unlock the keypad. See Keypad Lockout
on page 12 of this manual. The default passcode is 1234.
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