Lochinvar SNA285-125, SNR150-100, SNR200-100, SNA500-125, SNA400-125 User Manual

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Page 1

Installation & Service

Manual

Models: SNR150-100, SNR200-100,

SNA285-125, SNA400-125, AND

SNA500-125

This manual must only be used by a qualified heating installer / service technician. Read all instructions in this 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.

-- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

-- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your

building.

• Immediately call your gas supplier from a near by phone.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

-- Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

WARNING: If the information in these instructions is not

followed exactly, a fire or explosion may result causing property damage, personal injury or death.

SWH-I-S Rev D

Page 2

Contents

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . 3

Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THE SHIELD -- HOW IT WORKS . . . . . . . . . . . . . . . . . 4-6

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. DETERMINE WATER HEATER LOCATION

Closet and Alcove Installations . . . . . . . . . . . . . . . . . . . . 8

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10

Remove Water Heater from Wood Pallet . . . . . . . . . . . 10

Prevent Combustion Air Contamination . . . . . . . . . . . . 10

Removing Water Heater From Existing Common Vent . 11

Combustion & Ventilation Air Requirements . . . . . . . . . 11

2. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . 14

Venting and Combustion Air . . . . . . . . . . . . . . . . . . . . . 15

Requirements for Installation in Canada . . . . . . . . . . . . 15

Air Intake/Vent Connections . . . . . . . . . . . . . . . . . . . . . 16

Vent & Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. SIDEWALL DIRECT VENTING . . . . . . . . . . . . . . . . 18-24

4. VERTICAL DIRECT VENTING . . . . . . . . . . . . . . . . 25-28

5. CONVENTIONAL AND SIDEWALL VENTING . . . . 29

6. SYSTEM PIPING

General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Scalding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-34

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . 35

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . 36

Natural Gas Supply Pressure Requirements . . . . . . 36

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . 36

Propane Supply Pressure Requirements . . . . . . . . 36

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . 37

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . 38

8. FIELD WIRING

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 39

Power Cord Connection . . . . . . . . . . . . . . . . . . . . . . . . . 39

Runtime Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

10. START-UP

Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Inspect/fill Condensate System . . . . . . . . . . . . . . . . . . . . 43

Final Checks Before Starting the Water Heater . . . . . . . 44-46

11. OPERATING INFORMATION

How the Water Heater Operates . . . . . . . . . . . . . . . . . . . 47

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Water Heater Temperature Regulation . . . . . . . . . . . . . . 48

Adjustable Control Parameters . . . . . . . . . . . . . . . . . . . . 48

Saving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 49

The Shield Control Module . . . . . . . . . . . . . . . . . . . . . . . 50

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 53

Address Report Problems . . . . . . . . . . . . . . . . . . . . . 54

Inspect Water Heater Interior . . . . . . . . . . . . . . . . . . . 54

Clean Condensate Trap . . . . . . . . . . . . . . . . . . . . . . . 54

Check All Piping for Leaks . . . . . . . . . . . . . . . . . . . . . 54

Flue Vent System and Air Piping . . . . . . . . . . . . . . . . 55

Check Water System . . . . . . . . . . . . . . . . . . . . . . . . . 55

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . 55

Check Water Heater Relief Valve . . . . . . . . . . . . . . . 55

Inspect Ignition & Flame Sense Electrodes . . . . . . . . 56

Check Ignition Ground Wiring . . . . . . . . . . . . . . . . . . 56

Check All Water Heating Wiring . . . . . . . . . . . . . . . . . 56

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . 56

Perform Startup & Checks . . . . . . . . . . . . . . . . . . . . . 56

Check Burner Flames . . . . . . . . . . . . . . . . . . . . . . . . 56

Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . 57

Cleaning Water Heater Heat Exchanger . . . . . . . . . . 57

Oiled Bearing Circulators . . . . . . . . . . . . . . . . . . . . . . 57

13. TROUBLESHOOTING

Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Troubleshooting Chart - No Display . . . . . . . . . . . . . . 59

Checking Temperature Sensors . . . . . . . . . . . . . . . . . 60

Troubleshooting Chart - Noisy System . . . . . . . . . . . 61

Troubleshooting Chart - Fault Messages Displayed . 62-67

Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 68

Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 69

14. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Page 3

Please read before proceeding

Installer – Read all instructions, in this manual before installing. Perform steps in the order given.

Have this water 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.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

Water heater operation –

• Do not block flow of combustion or ventilation air to the water 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 water 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.

When calling or writing about the water heater – Please have the water heater model and serial number from the water heater rating plate.

Consider piping and installation when determining water heater location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death

-- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

-- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

-- Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

 WARNING

NOTICE

 WARNING

Installation & Service Manual

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.

When servicing the water heater –

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow the water heater to cool before performing maintenance.

Page 4

The Shield - How it works...

1. Access cover - front

Provides access to the gas train and heat exchanger.

2. Air intake adapter

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

3. Air pressure switch

The air pressure switch detects blocked inlet conditions.

4. Air shroud (500-125 Model Only_Not Shown)

The air shroud directs air and gas flow into the blower.

5. Blower

The blower pulls in air and gas through the venturi (item 5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

6. Burner (not shown)

Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a 5 to 1 firing rate.

7. Condensate drain connection

Connects the condensate drain line to 1/2" PVC.

8. Electronic Control Module

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

9. Electronic display

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

10. Flame inspection window

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

11. Flame sensor

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

12. Flue gas sensor (not shown)

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.

13. Gas connection pipe

Threaded pipe connection, either 1/2", 3/4", 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.

14. Gas shutoff switch (150-100 - - 285-125 Models Only)

An electrical switch designed to cut power from the gas valve to prevent gas flow to the burner.

15. Gas shutoff valve (400-125 -- 500-125 Models Only)

Manual valve used to isolate the gas valve from the gas supply.

16. Gas valve

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

17. Heat exchanger access cover

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

18. Heat exchanger inlet temperature sensor

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

19. Heat exchanger outlet temperature sensor

This sensor monitors heat exchanger outlet water temperature.

20. 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.

21. Ignition electrode

Provides direct spark for igniting the burner.

22. Line voltage junction box

The junction box contains the connection points for the line voltage power.

23. Low voltage connection board

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

24. Low voltage wiring connections (knockouts)

Conduit entryway for the low voltage connection board.

25. Power cord

Six foot cord allows for quick connection to 120V supply.

26. Pump

Circulates water between the tank and the heat exchanger.

27. Pump relay

Switches power to the pump.

28. Relief valve discharge pipe

Protects the heat exchanger from over pressure and temperature conditions. The relief valve is set at 150 PSI.

29. 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.

30. Tank sensor

Used by the control to monitor the temperature of the tank.

31. Top panel

Removable panel to gain access to the internal components.

32. Vent pipe connection

Allows for the connection of the PVC/CPVC vent pipe system to the water heater.

33. Venturi

The venturi controls air and gas flow into the burner.

34. Water heater drain valve

Location from which the water heater can be drained.

35. Water inlet

Copper sweat connection for cold water supply that returns water from the system to the heat exchanger, either 1-1/2" or 2", depending on the model.

36. Water outlet

Male NPT water connection that supplies hot water to the system, either 1-1/2" or 2", depending on the model.

Installation & Service Manual

Page 5

Front View - Models SNR150-100 -- SNA285-125

Left Side (inside unit) -- Models SNR150-100 SNA285-125

16 33

Right Side (inside unit) -- Models SNR150-100 - SNA285-125

The Shield - How it works... (continued)

Rear View - Models SNR150-100 -- SNA285-125

Models SNR150-100 -- SNA285-125

Installation & Service Manual

16 33

19 20

Page 6

The Shield - How it works...

Rear View - Model SNA400-125

Rear View - Model SNA500-125

Right Side (inside unit) - Model SNA500-125

Right Side (inside unit) - Model SNA400-125

Model SNA400-125

Model SNA500-125

Installation & Service Manual

Page 7

Ratings

Notes:

1. Shield water heaters require special gas venting. Use only the vent materials and methods specified in the Shield Installation and Service Manual.

2. Standard Shield water heaters are equipped to operate from sea level to 4,500 feet only with no adjustments. The water heater will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

3. High altitude Shield water heaters are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The water heater will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard models. A high altitude label (as shown in FIG. A) is also affixed to the unit.

Maximum allowed working pressure is located on the rating plate.

Model Number

Note: Change “N” to

“L” for L.P. gas models.

CSA

Input Modulation Btu/hr

(Note 2)

Water Content

Gallons

Water

Connections

Gas

Connections

Vent/Air Size

Min Max

(Note 1)

SNR150-100 30,000 - 150,000 92 1-1/2" 1/2" 3"

SNR200-100 40,000 - 199,999 93 1-1/2" 1/2" 3"

SNA285-125 57,000 - 285,000 124 2" 3/4" 4"

SNA400-125 80,000 - 399,999 125 2" 1" 4"

SNA500-125 100,000 - 500,000 126 2" 1" 4"

NOTICE

Figure A High Altitude Label Location

Installation & Service Manual

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

Page 8

The Shield water heater gas manifold and controls met safe lighting and other performance under tests specified in ANSI Z21.10.3 – latest edition.

Failure to keep water heater area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the water heater. Remove any

combustible materials, gasoline and other flammable liquids.

4. The Shield water heater must be installed so that gas

control system components are protected from dripping or spraying water or rain during operation or service.

 WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 9 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the water heater without removing it from the space.

Closet and alcove installations

This appliance requires a special venting system. The vent connection to the appliance must be made with the CPVC pipe section installed in the appliance. The field provided vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

NOTICE

 WARNING

1 Determine water heater location

Installation & Service Manual

A closet is any room the water heater is installed in which is less than 455 cubic feet for SNR150-100 and SNR200-100 models and 671 cubic feet for the SNA285-125 through SNA500-125 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 6 feet long, 6 feet wide, and 9 foot ceiling = 6 x 6 x 9 = 324 cubic feet. This would be considered a closet for a Shield Water Heater.

Page 9

OPEN FRONT

1" MINIMUM CLEARANCE

AROUND HOT WATER

PIPES AND VENT PIPE

Figure 1-2 Alcove Installation - Minimum Required Clearances

Figure 1-1 Closet Installation - Minimum Required Clearances

 WARNING

For closet installations, CPVC material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

1 Determine water heater location (continued)

RECOMMENDED SERVICE CLEARANCES:

Top - 18" (457 mm) Right Side - 24" (610 mm) Front - 24" (610 mm)

RECOMMENDED SERVICE CLEARANCES:

Top - 18" (457 mm) Right Side - 24" (610 mm) Front - 24" (610 mm)

Installation & Service Manual

 WARNING

For alcove installations, CPVC material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

1" MINIMUM CLEARANCE

AROUND HOT WATER PIPES AND VENT PIPE

VENTILATING AIR OPENING

CLOSED DOOR

VENTILATING AIR OPENING

AREAOF EACH OPE

1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES

NING

Page 10

Do not install the water heater on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

When local codes require compliance with NSF 5, the heater must be sealed to the floor with a food grade silicone to prevent debris and harborage of vermin under the heater.

If flooding is possible, elevate the water heater sufficiently to prevent water from reaching the water heater.

Flooring and foundation

Flooring

The Shield water heater is approved for installation on combustible flooring, but must never be installed on carpeting.

Prevent combustion air contamination

Install air inlet piping for the Shield water heater as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, for products and areas which may cause contaminated combustion air.

Ensure that the combustion air will not contain any of the contaminants in Table 1A. Contaminated combustion air will damage the water heater, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

 WARNING

1 Determine water heater location

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

Remove water heater from wood pallet

1. Remove the sides and the top of the crate.

2. Remove the blocks on the base of the crate to allow for easier removal.

3. The water heater can then be slid off the base of the crate for installation.

Do not drop the water heater or bump the jacket on the floor or pallet. Damage to the water heater can result.

NOTICE

Installation & Service Manual

Page 11

When removing a water heater from existing common vent system:

Do not install the Shield water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

At the time of removal of an existing water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

 DANGER

 WARNING

1 Determine water heater location (continued)

Combustion and ventilation air requirements for appliances drawing air from the equipment room

Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.

Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown above.

Multiple appliances may be installed in a modular water heater installation. Multiple appliances may be installed side by side with no clearance between adjacent appliances because this appliance is approved for zero clearance from combustible surfaces.

Consult the Ve nt i ng section of this manual for specific installation instructions for the appropriate type of venting system that you will be using.

Installation & Service Manual

Page 12

1 Determine water heater location

Figure 1-3_Combustion Air Direct from Outside

1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room (see FIG. 1-3):

(a) Combustion air opening, with a minimum free

area of one square inch per 4000 Btu/hr input (5.5 cm

per kW). This opening must be located within 12" (30 cm) of the bottom of the enclosure.

(b) Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu/hr input (5.5 cm

per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.

Figure 1-4_Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm

per kW) of input (see FIG. 1-4).

Figure 1-6_Combustion Air from Outside - Single Opening

3. If air is taken from another interior space, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm

per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-5).

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6).

Figure 1-5_Combustion Air from Interior Space

Installation & Service Manual

IF NECESSARY FOR

TIGHT CONSTRUCTION

Page 13

1 Determine water heater location (continued)

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

Model

Number

FIG. 1-3 FIG. 1-4 FIG. 1-5 FIG. 1-6

*Outside Air from

2 Openings Directly from

Outdoors

*Outside Air from

2 Ducts Delivered from

Outdoors

**Inside Air from

2 Ducts Delivered from Interior

Space

*Outside Air from 1 Opening Directly from Outdoors, in

To p

Opening, in

Bottom

Opening, in

To p

Opening, in

Bottom

Opening, in

To p

Opening, in

Bottom

Opening, in

SNR150-100

(246 cm2)

(484 cm2)

150

(968 cm2)

150

(968 cm2)

(323 cm2)

SNR200-100

(323 cm

)

(323 cm

)

100

(646 cm

)

100

(646 cm

)

200

(1,291 cm

)

200

(1,291 cm

)

(433 cm

)

SNA285-125

(465 cm2)72(465 cm2)

143

(923 cm2)

143

(923 cm2)

285

(1,839 cm2)

285

(1,839 cm2)

(613 cm2)

SNA400-125

100

(646 cm2)

100

(646 cm2)

200

(1,291 cm2)

200

(1,291 cm2)

400

(2,581 cm2)

400

(2,581 cm2)

134

(865 cm2)

SNA500-125

125

(807 cm2)

125

(807 cm2)

250

(1,613 cm2)

250

(1,613 cm2)

500

(3,226 cm2)

500

(3,226 cm2)

167

(1,078 cm

)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the water heater only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected. If a fan is used to supply combustion air to the equipment room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance.

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B149.1. Check all local code requirements for combustion air.

All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12" (30cm) of the ceiling and one must be within 12" (30cm) of the floor of the equipment room. Each opening must have net free area as specified in the chart above (Table 1B). Single openings shall commence within 12" (30cm) of the ceiling.

 CAUTION

Under no circumstances should the equipment room ever be under negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.

Installation & Service Manual

Page 14

Figure 2-1 Vertical Direct Venting (Two-Pipe Vertical

Termination) - See page 25 for more details

Figure 2-2 Sidewall Direct Venting (Two-Pipe Sidewall Termination) - See page 18 for more details

Figure 2-3 Concentric Vertical Termination - See page 27 for more details

Figure 2-4 Concentric Sidewall Termination - See page 22 for more details

Direct venting options

2 General venting

Installation & Service Manual

Page 15

Vent piping materials

Use only the materials listed in Table 2A below for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Table 2A Vent Pipe and Fittings

Venting and combustion air

 DANGER

The Shield water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

 WARNING

NOTICE

 WARNING

For closet and alcove installations, CPVC material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

NOTICE

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.

4. The 3" Concentric Vent Kit available from Lochinvar (see Section 3 – Sidewall Termination – Optional Concentric Ve n t) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Shield Water Heater. Both kits are listed to the ULC-S636 standard for use in Canada.

All vent pipe materials and fittings must comply with the following:

Item Material

Standards for installation in:

United States Canada

Vent pipe and fittings

PVC schedule 40 ANSI/ASTM D1785

CPVC and PVC venting must be

ULC-S636 Certified. IPEX is an

approved manufacturer in Canada

supplying vent material listed to

ULC-S636.

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM F441

Pipe cement/primer

PVC ANSI/ASTM D2564

IPEX System 636

Cements & Primers

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

2 General venting (continued)

Installation & Service Manual

Page 16

Air intake/vent connections

1. Combustion Air Intake Connector (FIG.’s 2-5 and 2-6)

- Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG.’s 2-5 and 2-6) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

VENT

AIR

3" CPVC PIPE INSTALLED IN THE WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Figure 2-5 Near Water Heater Venting Models SNR150-100 - SNR200-100

Figure 2-6 Near Water Heater Venting Models SNA285-125 - SNA500-125

The Shield water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 2B below.

Model Air Intake Vent

SNR150-100 -- SNR200-100 3 inches 3 inches

SNA285-125 -- SNA500-125 4 inches 4 inches

Table 2B Air Intake/Vent Piping Sizes

Increasing or decreasing combustion air or vent piping is not authorized.

NOTICE

2 General venting

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

Installation & Service Manual

Models SNA400-125 and SNA500-125 will de-rate 1.75% per 25 feet of vent when installed as direct vent or 0.75% per 25 feet of vent when drawing combustion air from the room.

Models SNR150-100 through SNA285-125 will de-rate up to 1% per 25 feet of vent pipe when installed as direct vent, but will not de-rate when drawing combustion air from the room.

AIR

VENT

4" CPVC PIPE INSTALLED IN THE WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Page 17

2 General venting (continued)

Vent, air piping and termination:

The Shield water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the water heater, they can form strong acids. The acid can eat through the water heater wall, causing serious damage and presenting a possible threat of flue gas spillage or appliance water leakage into the building.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the water heater combustion air inlet, have your installer pipe the water heater combustion air and vent to another location, per this manual.

If the water heater combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the water heater or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

Removing from existing vent

Follow the instructions in Section 1, page 11 of this manual when removing a water heater from an existing vent system.

Vent and air piping

Vent and air system:

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Shield water heater using any other means.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only PVC or CPVC and fittings, with primer and cement specifically designed for the material used.

NOTICE

 WARNING

Model

Kit

Number

Equivalent

Vent Length

SNR150-100 -- SNR200-100 CVK3003 3 feet

SNA285-125 CVK3007 3 feet

SNA400-125 CVK3007 5 feet

SNA500-125 CVK3007 30 feet

Table 2C Equivalent Vent Lengths

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:

Ve n t = 12 equivalent feet minimum / 100 equivalent feet maximum

Combustion Air (when used) = 12 equivalent feet minimum / 100 equivalent feet maximum

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.

Installation & Service Manual

Page 18

3 Sidewall direct venting

Vent/air termination – sidewall

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

 WARNING

NOTICE

 WARNING

Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 17 of this manual.

2. You must consider the surroundings when terminating

the vent and air: a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

 WARNING

Sidewall vent and air inlet terminations must terminate in the same pressure zone.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

Figure 3-1A Sidewall Termination of Air and Vent

Model Kit Number Vent Size

SNR150-100 -- SNR200-100 KIT30045 3 inch vent

SNA285-125 -- SNA500-125 KIT30046 4 inch vent

Table 3A Sidewall Vent Kits

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 3-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential water heater shutdown.

Figure 3-1B Alternate Sidewall Termination of Air and Vent w/Field Supplied Fittings

 WARNING

If using the alternate sidewall termination:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 3-1B. This arrangement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG.3-1B.

Installation & Service Manual

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVERHANG

12"

MIN

Page 19

Vent/air termination – sidewall

3 Sidewall direct venting (continued)

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

12"

MIN.

Figure 3-2 Clearance to Gravity Air Inlets

FORCED AIR

INLET

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

Figure 3-3A Clearance to Forced Air Inlets

5. Maintain clearances as shown in FIG.’s 3-1A thru 3-3B, pages 18 and 19. Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from

any door or window or any other gravity air inlet.

b. Air inlet must terminate at least 12 inches above

grade or snow line; at least 12 inches below the vent termination; and the vent pipe must not extend more than 24 inches vertically outside the building.

c. Do not terminate closer than 4 feet horizontally

from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Figure 3-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings

Figure 3-2B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings

Figure 3-3B Alternate Clearance to Forced Air Inlets w/Field Supplied Fittings

Installation & Service Manual

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER INTAKE AIR

CONNECTION

BIRD

SCREEN

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

COUPLING

12” MIN 15” MAX

BIRD SCREEN

12”

MIN

Page 20

3 Sidewall direct venting

VENT PIPING

GALVANIZED

THIMBLE

VENT CAP

AIR PIPING

WALL PLATE

VENT PLATE

Figure 3-4A Sidewall Termination Assembly

Prepare wall penetrations

1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.

Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

Vent pipe penetration: a. Cut a hole for the vent pipe. For either

combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

2. Install the vent and air intake piping through the wall into the vent plate openings. Seal all gaps between the pipes and wall. Use RTV silicone sealant to seal the air pipe. Use the glue (cement/primer) listed in Table 2A on page 15 to seal the vent pipe.

3. Mount and secure the vent plate to the wall using stainless steel screws. Seal around the plate to the wall assuring no air gaps.

4. Assemble the vent cap to the vent plate (see FIG. 3-4A). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.

5. Seal all wall cavities.

Figure 3-4B Alternate Sidewall Termination Assembly w/Field Supplied Fittings

Prepare wall penetrations (Alternate Field Supplied Option)

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either

combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole as shown in FIG. 3-4B.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when passing

through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Termination and fittings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG. 3-1A, page 18.

2. Maintain the required dimensions of the finished termination piping as shown in FIG. 3-1A, page 18.

3. If using the alternate sidewall termination do not extend exposed vent pipe outside of the building more than what is shown in this document. Condensate could freeze and block vent pipe.

Installation & Service Manual

Page 21

3 Sidewall direct venting (continued)

Vent/air termination – sidewall

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Multiple vent/air terminations

1. When terminating multiple Shield water heaters terminate each vent/air connection as described in this manual (FIG. 3-5A).

 WARNING

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 3-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Shield water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT / AIR

TERMINATION

VENT

AIR

Figure 3-5A Multiple Vent Terminations (must also comply with Figure 3-1A)

Figure 3-5B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 3-1B)

Installation & Service Manual

Page 22

3 Sidewall direct venting

Figure 3-7 Kit Contents_CVK3003 - SNR150-100 -SNR200-100

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 3-6).

2. The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 17 of this manual.

3. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate

damage to exterior finishes.

4. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

5. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.

a. Cement the Y concentric fitting to the larger kit pipe

(FIG.’s 3-7 and 3-8).

b. Cement the rain cap to the smaller diameter kit pipe

(FIG.’s 3-7 and 3-8).

Figure 3-8 Kit Contents_CVK3007 - SNA285-125 -SNA500-125

Sidewall termination – optional concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3" diameter Models SNR150-100 - SNR200-100 and #CVK3007 for 4" diameter - Models SNA285-125 - SNA500-125). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as shown in FIG. 3-6.

The required combustion vent pipe materials are listed in Table 2A, on page 15 of this manual.

Figure 3-6 Concentric Sidewall Termination

Installation & Service Manual

RAIN CAP

6" (152 MM) TO 4" (102 MM) REDUCER

6" (152 MM) DIA.

4" (102 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

"FLEXIBLE" PIPE COUPLING

Page 23

Sidewall termination – optional concentric vent

Figure 3-9 Concentric Vent Dimensional Drawing Models SNR150-100 -- SNR200-100 / CVK3003

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 3-11).

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 3-11 Rain Cap to Vent Pipe Alternate Assembly

6. Install the Y concentric fitting and pipe assembly through the structure’s hole.

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

7. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for #CVK3003 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

8. Secure the assembly to the structure as shown in FIG. 3-12 using field-supplied metal strapping or equivalent support material.

Ensure termination location clearance dimensions are as shown in FIG. 3-6.

NOTICE

 WARNING

NOTICE

Figure 3-10 Concentric Vent Dimensional Drawing Models SNA285-125 -- SNA500-125 / CVK3007

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied SDR-26 PVC (D2241) pipe for CVK3003 and standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 3-9 and 3-10).

If assembly depth needs to be reduced, dimension D can be as short as possible.

NOTICE

3 Sidewall direct venting (continued)

Installation & Service Manual

"A"

(152 MM)

"B" DIA.

"G"

(76 MM)

(537 MM)

"H" DIA.

(254 MM) (194 MM)

"D"

"F"

(168 MM)

(76 MM)

"C" DIA.

"B" DIA. PVC VENT / EXHAUST

ABC DE FGH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

(1524 MM)

(102 MM)

"E"

Page 24

3 Sidewall direct venting

Sidewall termination – optional concentric vent

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 3-13). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 3-13. The vent terminations must be at least 36 inches away from the first two (2) terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension A in FIG. 3-13 represents the distance between pipes or rain shields, as touching or a 2 inch maximum separation.

Figure 3-13 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation

Figure 3-12 Concentric Vent Sidewall Attachment

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 3-12 for proper pipe attachment.

10. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

CAUTION

Note: CVK3003 shown for illustration purposes.

Installation & Service Manual

Page 25

4 Vertical direct venting

Vent/air termination – vertical

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 17 of this manual.

2. The vent must terminate at least 3 feet above the highest

place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an up-turned coupling

as shown in FIG. 4-1. The top of the coupling must be at least 1 foot above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake.

Figure 4-1 Vertical Termination of Air and Vent

5. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

 WARNING

NOTICE

 WARNING

Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone.

Installation & Service Manual

Page 26

4 Vertical direct venting

Vent/air termination – vertical

Prepare roof penetrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either

combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole.

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 4-1, page 25.

4. Follow all local codes for isolation of vent pipe when

passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent

pipe and air pipe.

Termination and fittings

1. Prepare the vent termination coupling and the air

termination elbow (FIG. 4-1) by inserting the bird screens provided with the water heater. Bird screens are provided for either 3" (Models SNR150-100 -SNR200-100) or 4" (Models SNA285-125 -SNA500-125) fittings.

2. The air piping must terminate in a down-turned 180°

return bend as shown in FIG. 4-1. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

3. The vent piping must terminate in an up-turned

coupling as shown in FIG. 4-1. The top of the coupling must be at least 1 foot above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake.

4. Maintain the required dimensions of the finished

termination piping as shown in FIG. 4-1.

5. Do not extend exposed vent pipe outside of building

more than shown in this document. Condensate could freeze and block vent pipe.

Multiple vent/air terminations

1. When terminating multiple Shield water heaters, terminate each vent/air connection as described in this manual (FIG. 4-2).

Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another water heater for U.S. installations (see FIG. 4-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Shield water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

Figure 4-2 Vertical Terminations with Multiple Water Heaters

Figure 4-3 Alternate Vertical Terminations with Multiple Water Heaters

 WARNING

Installation & Service Manual

Page 27

4 Vertical direct venting (continued)

Vertical termination – optional concentric vent

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 4-4.

Field supplied pipe and fittings are required to complete the installation.

The required combustion air and vent pipe fittings are listed in Table 2A, on page 15 of this manual.

Vertical termination installation

1. Determine the best location for the termination kit (see FIG. 4-4).

2. The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 17 of this manual.

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 3-11, page 23).

3. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

4. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG.’s 3-7 and 3-8, page 22).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG.’s 3-7 and 3-8, page 22).

c. Do not attach a U-Bent to the rain cap. Doing so could

cause recirculation (see FIG. 4-5).

Figure 4-4 Concentric Vertical Termination

NOTICE

 WARNING

Figure 4-5 Do Not Install U-Bent to Rain Cap

Installation & Service Manual

Page 28

4 Vertical direct venting

Vertical termination – optional concentric vent

Figure 4-6 Concentric Vent Roof Installation

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 4-4, page 27.

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe for #CVK3003 and standard schedule 40 PVC for #CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 3-9 and 3-10, page 23).

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

7. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting for #CVK3003 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

8. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-6 for proper pipe attachment.

9. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-7. The vent terminations must be at least 36 inches away from the first two (2) terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension A in FIG. 4-7 represents the distance between pipes or rain shields, as touching or a 2 inch maximum separation.

Figure 4-7 Concentric Vent and Combustion Air Vertical Termination (Dimension A as Touching or 2 inches Maximum Separation)

5. Install the Y concentric fitting pipe assembly up through the structure’s hole and field supplied roof boot/flashing.

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

6. Secure the assembly to the roof structure as shown below in FIG. 4-6 using field supplied metal strapping or equivalent support material.

 WARNING

NOTICE

Note: CVK3003 shown for illustration purposes.

Installation & Service Manual

Page 29

The Shield water heater may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. The vent pipe may terminate either vertically (FIG. 5-1) above the roof line in a conventional vent manner or on a sidewall (FIG. 5-2).

Follow the requirements in the General Venting, Sidewall Direct Venting, and Vertical Direct Venting sections for vent material specifications, vent length requirements, and vent termination requirements.

Combustion and ventilation air must be supplied to the equipment room per the requirements on page 15 of this manual for proper operation of the Shield water heater when utilizing the single pipe method.

Figure 5-1 Vertical Direct Venting w/Room Air

Figure 5-2 Sidewall Direct Venting w/Room Air

5 Conventional and sidewall venting

Installation & Service Manual

Page 30

6 System piping

System water piping methods

Observe a minimum of one inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

2. If this water heater is installed in a closed water supply system, such as the one having a backflow preventer in the cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion. Warranties do not cover damages from thermal expansion such as pressure bulges and/or deformities. Your water supplier or local plumbing inspector should be contacted on how to control this situation.

3. After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows through the faucets, close them and check all water connections for possible leaks.

4. Never operate the water heater without first being certain it is filled with water.

Scalding

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.

 WARNING

Failure to install and maintain a new, listed temperature and pressure relief valve will release the manufacturer from any claim, which might result from excessive temperature and pressures.

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.

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 the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance, which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have an open flame near the faucet at the time it is open.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-2 thru 6-4), which will guide you through the installation of the Shield water heater.

1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. The COLD water inlet and HOT water outlet are identified on the water heater. Make the proper plumbing connections between the water heater and the plumbing system to the building. Install a shutoff valve in the cold water supply line.

Figure 6-1 Scald Warning

Installation & Service Manual

Wa te r temperatures over 125°F (52°C) can cause severe burns instantly or death from scalds. Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting the thermostat at the water heater.

Feel water before bathing or showering.

Te m perature limiting valves are available, consult local plumbing supplier.

Page 31

6 System piping (continued)

See the *piping illustrations included in this section, FIG.’s 6-2 thru 6-4 for suggested guidelines in piping the Shield water heater.

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

NOTICE

Piping components

Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-2 thru 6-4.

Water heater isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the water heater.

Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

Unions:

Field supplied. Recommended for unit serviceability.

Temperature and pressure relief valve:

Factory supplied on water heaters. The temperature and pressure relief valve is sized to ASME specifications.

Water chemistry

The water must be treated if it is not between 5 to 25 grains per gallon or above 350 ppm of total dissolved solids. Hardness exceeding 25 grains or 350 ppm can cause non-warrantable premature failure of the heat exchanger. Water with a hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing nonwarrantable damage to the pump and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions.

The following chart (Table 6A) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F 1 1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1 1/2 seconds

155°F About 1 second

Table 6A Approximate Time / Temperature Scald Chart

The Shield water heater is designed for heating potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm.

NOTICE

Installation & Service Manual

Delta T

If the temperature rise or difference between the HEX IN and HEX OUT is greater than 30°, scaling of the heat exchanger has already begun. A de-liming solution should be used that is acceptable for use with potable water to remove the scale. The local water utility should be consulted for appropriate water treatments.

No valves shall be placed between the relief valve, heat exchanger, or tank. The relief valve shall be piped to a suitable drain as close as possible to the heater with no reducing couplings or other restrictions. The piping must be sloping away from the heater at all times.

The heater is equipped with 3/4" CPVC (SDR11) pipe and elbow connections. If local codes prohibit the use of CPVC, the CPVC pipe, elbow, and 3/4" NPT adapter can be replaced with a copper equivalent.

 CAUTION

Page 32

6 System piping

Figure 6-2 Single Unit

Installation & Service Manual

COLD WATER

SUPPLY

EXPANSION

TAN K

FLOW CHECK VALVE

(TYPICAL)

BUILDING

RETURN

SYSTEM

CIRCULATOR

MIXING VALVE

BALL VALVE

(TYPICAL)

UNION

HOT WATER

SUPPLY

Page 33

6 System piping (continued)

Figure 6-3 Multiple Units

Installation & Service Manual

COLD WATER

SUPPLY

EXPANSION

TAN K

BUILDING

RETURN

FLOW CHECK VALVE

SYSTEM

CIRCULATOR

BALL VALVE

(TYPICAL)

MIXING

VALV E

UNION

(TYPICAL)

HOT WATER

SUPPLY

Page 34

6 System piping

Figure 6-4 Two Temperature - Single Unit

Installation & Service Manual

THERMOMETER

(TYPICAL)

180° HOT

WATER

SUPPLY

140° HOT

WATER

SUPPLY

LOW TEMPERATURE

BUILDING RETURN

COLD

EXPANSION

WATER

SUPPLY

FLOW CHECK VALVE (TYPICAL)

BALL VALVE (TYPICAL)

MIXING VALVE

TANK

UNION (TYPICAL)

HIGH TEMPERATURE

BUILDING RETURN

Page 35

7 Gas connections

Connecting gas supply piping

1. Install ground joint union for servicing, when required.

2. On Models SNR150-100 -- SNA285-125 install a manual shutoff valve in the gas supply piping outside water heater jacket when required by local codes or utility requirements.

3. In Canada – When using manual main shutoff valves, it must be identified by the installer.

Figure 7-1 Gas Supply Piping - Models SNR150-100 -SNA285-125

4. Support piping with hangers, not by the water heater or its accessories.

Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Figure 7-2 Gas Supply Piping - Models SNA400-125 -SNA500-125

5. Purge all air from the gas supply piping.

6. Before placing the water heater in operation, check the water heater and its gas connection for leaks.

a. The appliance must be disconnected from the gas

supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply

piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak

tested before placing it in operation.

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the water heater or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

7. Use pipe sealing compound compatible with propane gases.

Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

Installation & Service Manual

GAS SUPPLY

DRIP LEG

UNION

MANUAL GAS SHUT OFF VALVE (FIELD SUPPLIED)

MANUAL GAS

SHUTOFF VALVE

(FACTORY SUPPLIED ON

MODELS SNA400-125 --

SNA500-125)

GAS SUPPLY

DRIP LEG

UNION

Page 36

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

Shield water heaters are typically shipped ready to fire on natural gas. Check the water heater rating plate to determine which fuel the water heater is set for. In order to operate on LP gas contact the factory, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at water heater (FIG. 7-3), using one wrench to prevent the water heater gas line connection from turning. Failure to support the water heater gas connection pipe to prevent it from turning could damage gas line components.

Figure 7-3 Inlet Pipe with Backup Wrench

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on rated water heater input (divide by 1,000 to obtain cubic feet per hour). a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas piping of 0.50 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or

with water heater on.

• Minimum 4 inches w.c. with gas flowing (verify during

water heater startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum.

Propane gas:

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with water heater on.

• Minimum 8 inches w.c. with gas flowing (verify during water heater startup).

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

 WARNING

Shield water heaters are typically shipped ready to fire on natural gas. Check water heater rating plate to determine which fuel the water heater is set for. In order to operate on LP gas contact the factory, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

 WARNING

Ensure that the high gas pressure regulator is at least 10 feet upstream of the appliance.

7 Gas connections

Installation & Service Manual

USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING

Page 37

Nominal

Iron Pipe

Size (Inches)

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet for 1/2 PSI

100

125

150

175

200

1/2

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4

369

256

205

174

155

141

128

121

113

106

697

477

384

328

292

267

246

236

210

200

179

164

149

138

1-1/4

1400

974

789

677

595

543

502

472

441

410

369

333

308

287

1-1/2

2150

1500

1210

1020

923

830

769

707

666

636

564

513

472

441

4100

2820

2260

1950

1720

1560

1440

1330

1250

1180

1100

974

871

820

2-1/2

6460

4460

3610

3100

2720

2460

2310

2100

2000

1900

1700

1540

1400

1300

11200

7900

6400

5400

4870

4410

4000

3800

3540

3330

3000

2720

2500

2340

23500

16100

13100

11100

10000

9000

8300

7690

7380

6870

6150

5640

5130

4720

Table 7A Natural Gas Pipe Size Chart

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Disconnect power from the appliance.

2. Shut off gas to the appliance.

3. Loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG.’s 7-4 thru 7-6.

4. Slowly turn on the gas supply at the field installed manual gas valve.

 WARNING

5. Reconnect power to the appliance.

6. Adjust the temperature set point on the control panel of the electronic control module to call for heat.

7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Disconnect power from the appliance.

12. Shut off the gas to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap.

Check inlet gas supply

NOTICE

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your water heater to fire at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane (when configured for LP), requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

 WARNING

7 Gas connections (continued)

 WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

14. Reconnect gas to the appliance.

15. Reconnect power to the appliance.

16. Adjust the temperature set point on the control panel of

the electronic control module to the desired water temperature so the appliance will call for heat.

Installation & Service Manual

Page 38

7 Gas connections

Gas pressure

The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Shield water heater. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Figure 7-4 Inlet Gas Supply Check - Models SNR150/100

-- SNA285-125

Figure 7-5 Inlet Gas Supply Check - Model SNA400/125

Figure 7-6 Inlet Gas Supply Check - Model SNA500/125

Failure to follow all precautions could result in fire, explosion, or death!

 WARNING

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the venturi and blower.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Installation & Service Manual

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

DETAIL

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

DETAIL

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

DETAIL

Page 39

8 Field wiring

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with the water heater must be replaced, use only type 105°C wire or equivalent.

The water heater must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Power cord connection

This water heater is designed to operate with 120 VAC and 60 Hz power supply. If allowed by local codes, connect the power cord provided with the heater to a GFI protected outlet on a separate circuit and breaker. Ensure the circuit cannot be interrupted by a switch used to control lights or other appliances.

If local codes do not allow for the use of the power cord, remove the cord from the junction box found on the side of the control support bracket (FIG. 8-2) and attach conduit to the junction box. Route the wires out of the appliance to a GFI protected outlet on a separate circuit and breaker.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

 WARNING

NOTICE

 CAUTION

Figure 8-1 Routing Field Wiring

Auxiliary device proving switch

1. When the operation of an external limit needs to be verified before the water heater fires, remove the jumper wire from terminals X & B and connect them to the contacts on the external limit (FIG. 8-3).

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the water heater, as shown in FIG. 8-1.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-3 on page 40 of this manual and the water heater wiring diagram.

Runtime contacts

The electronic control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat.

Alarm contacts

The electronic control closes another set of contacts whenever the water heater is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the water heater is down. Note that the alarm contacts will close momentarily after each call for heat.

Installation & Service Manual

Figure 8-2 Remove Power Cable

Use of an extension cord is NOT allowed. If a suitable electrical outlet is not within reach of the supplied power cord, a new receptacle must be installed or the power cord must be replaced with hard conduit as described above.

 WARNING

LOW VOLTAGE WIRING KNOCKOUTS

JUNCTION BOX

Page 40

8 Field wiring

Figure 8-3 Low Voltage Field Wiring Connections

BUILDING

MANAGMENT

SYSTEM

ALARM BELL

LOW WATER

CUTOFF

Installation & Service Manual

Page 41

8 Field wiring (continued)

Figure 8-4 Control Inputs/Outputs

TANK SENSOR

LOW VOLTAGE

CONNECTION

BOARD

INLET TEMPERATURE

SENSOR

OUTLET TEMPERATURE /

HIGH LIMIT SENSOR

FLUE GAS SENSOR

FLAME SENSOR

LOW WATER CUTOFF

BLOCKED DRAIN SWITCH

DI SPL AY PAN EL

CONTROL BOARD

BLOCKED AIR INLET PRESSURE SWITCH

INPUTS

OUTPUTS

Installation & Service Manual

LOW VOLTAGE

CONNECTION

BOARD

CONTROL BOARD

ALARM BELL (ALARM CONTACTS)

RUNTIME CONTACTS

WHR PUMP

IGNITER

BLOWER

GAS VALVE

DI SPL AY PAN EL

Page 42

9 Condensate disposal

Condensate drain

1. This water heater is a high efficiency appliance that produces condensate.

2. Slope condensate tubing down and away from the water heater into a drain or condensate neutralizing filter. Condensate from the Shield water heater will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.

A Neutralizer Kit is available from the factory (KIT3087).

3. Leave the top of the 1/2 inch tee OPEN (FIG. 9-1). This is needed as a vacuum break.

4. Do not expose condensate line to freezing temperatures.

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

5. A condensate removal pump is required if the water heater is below the drain. When installing a condensate pump, select one approved for use with condensing water heaters and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage. The switch should be wired to the auxiliary device proving switch terminals on the low voltage connection board.

NOTICE

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the water heater tee, resulting in potential water damage to property.

Figure 9-1 Condensate Disposal

Installation & Service Manual

1/2” (12.7 mm) PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

NEUTRALIZER KIT

FLOOR DRAIN OR

DRAIN PAN

Page 43

10 Start-up

Chlorine concentration less than 200 ppm

1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the water heater to directly heat swimming pool or spa water.

4. At initial fill and during water heater startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

Check for gas leaks

Before starting the water heater, and during initial operation, smell near the floor and around the water heater for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the water heater enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

Figure 10-1 Condensate Trap

 WARNING

Propane water heaters only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate PVC fittings and condensate trap.

Fill condensate trap with water

1. Remove the PVC cap retaining screw from the PVC cap (FIG. 10-1).

2. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 10-1).

3. Fill with fresh water until the water begins to pour out of the drain.

4. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

5. Replace the retaining screw.

 WARNING

The condensate trap (FIG. 10-1) must be filled with water during all times of water heater operation to avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

 WARNING

Final checks before starting the water heater

 Read this manual to familiarize yourself with electronic

control module operation. Read pages 45 and 46 for proper steps to start the water heater.

 Verify the water heater and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 43

and 44 have been completed.

 Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap). Replace the cap. Press the cap onto the trap until the cap makes contact with the drain. Replace the retaining screw.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Installation & Service Manual

2" PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING SCREW

CONDENSATE FROM

HEAT EXCHANGER

CONDENSATE DRAIN

REMOVABLE CAP

TO CLEAN OUT TRAP

Page 44

10 Start-up

Start the water heater

1. Read and follow the Operating instructions in FIG.’s 10-2 and 10-3, pages 45 and 46.

If water heater does not start correctly

1. Check for loose connections, blown fuse or service switch off.

2. Is external limit control (if used) open? Is water temperature above 200°F?

3. Is tank set point set below tank temperature?

4. Is gas turned on at meter and water heater?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the Troubleshooting section of this manual.

Check system and water heater

 Check water piping

1. Check system piping for leaks. If found, shut down the water heater and repair immediately. (See WARNINGS on pages 43 and 44 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause hot water distribution problems and noise.

 Check vent piping and air piping

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

 Check gas piping

1. Check around the water heater for gas odor following the procedure on page 35 of this manual (Connecting Gas Supply Piping).

If you discover evidence of any gas leak, shut down the water heater at once. Find the leak source with a bubble test and repair immediately. Do not start the water heater again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check flame and combustion

1. Press the SHUTDOWN button on the display until HTR:Off appears in the display window.

2. Remove the screws securing the top panel to the unit. Remove the panel from the unit to gain access to the flue sensor.

3. Locate the flue sensor in the top of the vent connection. Remove the flue sensor and grommet from the unit.

Note:

Combustion measurements will be made at this

point.

4. Press the SHUTDOWN button on the display until HTR:Standby appears in the display window.

5. Locate the pinhole button above the “r” in the Lochinvar logo on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the water heater into Service Mode. In Service Mode the water heater will fire at ignition speed and will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.

7. Once the water heater has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 10A. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range, reference the Troubleshooting section of this manual for possible causes and corrective actions.

 WARNING

Table 10A Flue Products Chart

8. Once the combustion analysis is complete, press the SHUTDOWN button on the display board (FIG. 11-1) to take the water heater out of Service Mode. The water heater will go to shutdown and the display will show HTR:Off.

9. Replace the flue sensor and grommet into the vent connection.

10. Replace the top panel on the unit.

11. Place the Shield water heater back into normal operation.

You must replace the flue sensor to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

Installation & Service Manual

Page 45

Figure 10-2 Operating Instructions - Models SNR150-100 -- SNA285-125

10 Start-up (continued)

Installation & Service Manual

Page 46

Figure 10-3 Operating Instructions - Models SNA400-125 -- SNA500-125

10 Start-up

Installation & Service Manual

Page 47

11 Operating information

General

How the water heater operates

The Shield water heater combines an advanced stainless steel heat exchanger, electronic control module, and tank that allows fully condensing operation. The blower pulls in air and pushes flue products out of the heat exchanger and flue piping. The control module regulates blower speed to control the water heater firing rate. The gas valve senses the amount of air flowing into the water heater and allows only the right amount of gas to flow. An internal pump circulates the water between the tank and heater and mixes the incoming water to provide maximum efficiency.

Temperature control

Modulation

The Shield water heater is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the hot water draw and various other temperature limitations.

Night setback

The controller may be programmed to reduce the tank set point during a certain time each day. A start and stop time can be programmed for each day of the week.

Flame current support

To prevent nuisance shutdowns when the water heater is firing at minimum rates, the control will increase fan speed when the flame signal drops too low.

Protection features

Outlet temperature, flue temperature, and temperature rise limiting

The heat exchanger outlet temperature is monitored by the heat exchanger outlet temperature sensor. When the heat exchanger outlet temperature exceeds 190°F, the unit will reduce the fan speed. If the heat exchanger outlet water temperature exceeds 198°F the control will shut the unit down until it cools off.

The control module monitors the flue temperature by a sensor located in the flue exhaust. If the flue temperature exceeds 215°F the control will reduce the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the heat exchanger inlet and the heat exchanger outlet sensors. If this difference exceeds 25°F the control will reduce the fan speed. If the temperature difference exceeds 30°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 25°F and the minimum off time has expired.

Freeze protection

DO NOT install the water heater in a room likely to freeze.

The following integral feature of the electronic control module provides some protection for the water heater.

• The electronic control module provides freeze-up protection as follows when the water heater water temperature drops below 45°F:

• Below 45°F, the internal pump operates constantly.

• Below 37°F, the burner turns on.

• The burner and pump will turn off if water heater water temperature rises above 45°F.

This feature of the electronic control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the water heater.

 CAUTION

Monitor external limits

Connections are provided on the connection board for external limits. The electronic control module will shut off the burner and inhibit relighting whenever an external limit opens.

Runtime and alarm outputs

The water heater provides dry contacts for indicating when the water heater is running, and when it is unable to operate.

Error logging

The control will hold in memory the last 10 faults. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences will be held in memory.

Installation & Service Manual

Page 48

Water heater temperature regulation

Operating temperature (target)

The electronic control module senses water temperature in the tank and regulates water heater ignition and firing rate to achieve a target temperature. The target temperature can be set between 60°F and 185°F.

High limit operations

When the heat exchanger outlet temperature exceeds 203°F, high limit action occurs. The burner shuts down until the heat exchanger outlet water cools down, and requires manual reset of the control before operation will resume. To reset control, push the RESET key on the display.

Low water cutoff protection

1. The electronic control module uses sensing of both heat exchanger supply and return temperatures. If the flow rate is too low or either temperature too high, the control module modulates and shuts the burner down. This ensures water heater shutdown in the event of low water or low flow conditions in the heat exchanger.

Adjustable control parameters

To access the control parameters, press the MENU button on the display. When finished, press the MENU button again to return to the status display. Use the NEXT and PREVIOUS buttons to select the parameter you wish to change.

Date and time

The control uses an internal clock for the night setback feature and for logging of events. For these features to work correctly, the clock must be set when the water heater is first installed or anytime the water heater has been powered off for more than 30 days. The date and time are displayed as “MM:DD:YY W hh:mm”. MM = month, DD = date, YY = year, W = day (1 = Monday, 2 = Tuesday, etc.), hh = hour (24 hour time; 2:00 PM = 14:00), mm = minutes.

Tank Differential

Once the tank set point is satisfied, the tank temperature must drop below the set point by this amount before the heater will fire again. The temperature range of this parameter is 3.6°F to 18°F. The default value is 6.3°F.

Temperature units (°F/°C)

The control can be configured to display temperature in either °C or °F. This setting can be changed by the user or the installer. The default is °F.

Night setback temperature

Once the internal clock has been set correctly, the night setback feature can be used to program a lower tank set point. The temperature range for this parameter is 32°F to 140°F. The feature is turned off with a setting of 32°F. The default value is 32°F.

Night setback times

If the night setback temperature is set to anything other than 32°F, the night setback feature becomes active. This will require start and stop times to be programmed for the days that reduced temperatures are required. Each day of the week (Sunday through Saturday) will have an ON and OFF time.

Night setback can be programmed to skip certain days of the week, and to remain active throughout certain days of the week. To skip a day, set the ON and OFF times for that day to any time before 12:00 (noon), and equal to each other. Night setback will become inactive at the OFF time on the previous day, and remain inactive until the ON time on the following day. To have night setback remain active throughout an entire day, set the ON and OFF times to any time after 12:00 (noon), and equal to each other. Night setback will become active at the ON time on the previous day, and remain active until the OFF time on the following day.

Saving parameters

To save parameters:

Press the ENTER/RESET button.

To keep parameter settings only for a current operating cycle:

Press the MENU/EXIT button 1 time to return to the status display.

11 Operating information

NOTICE

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Tank set point

When a HW call for heat becomes active, the control will use the tank set point to determine the firing rate of the water heater based on the actual water temperature. The temperature range of this parameter is 60°F to 185°F. The default value is 125°F.

Installation & Service Manual

Page 49

11 Operating information (continued)

OPERATION DISPLAY

1. When the tank temperature falls below the set point minus the differential, the control will start the burner.

HTR: Standby TANK: 123.8F(129)

2. The control connects 120 VAC to the blower. The blower does not run at this time.

• The manual reset high limit must be closed before the control

powers up the blower.

• The control starts the internal pump.

• If there is an external limit connected to the heater, it must be

closed.

HTR: Standby TANK: 123.8F(129)

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

HTR: PREPURGE TANK: 123.9F(129)

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

HTR: IGNITION TANK: 123.9F(129)

5. If the control does not detect flame by the end of the trial for ignition, the control performs a 10 second postpurge, another prepurge and tries to light the burner again. If the burner does not light after 4 trials, the control locks out for 1 hour and then tries another set of 4 trials.

HTR: POSTPURGE, PREPURGE TANK: 123.9F(129)

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.

HTR: RUN 20% RATE TANK: 124.8F(129)

7. Once the tank temperature goes 3 - 4°F above the set point, the control will turn off the burner. The blower will remain on for the 10 second postpurge cycle. The internal pump will continue to run for its pump delay time, then turn off.

HTR: POSTPURGE

TANK: 127.4F(129)

8. Burner off.

HTR: Standby

TANK: 124.7F(129)

Sequence of operation

Installation & Service Manual

Page 50

Shield control module

Figure 11-1 Control Panel

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation.

11 Operating information

Installation & Service Manual

• Press once to go into Menu Mode

• Press again to exit Menu Mode

• Press to toggle between digits when entering the hour, minutes, etc., or when entering date and time

Page 51

11 Operating information (continued)

Status Display Screens

By using the Previous/Next (, ) arrow keys on the electronic control module display panel, you can navigate through the five (5) 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

HTR: OFF

The unit has been turned OFF by the Enter/Reset button on the electronic control module display panel.

Standby

The unit has not received a call for heat.

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 vent system of residual flue 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.

TANK:***.*F

The tank temperature is displayed.

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 electronic control module display to access Screen #2.

HEX IN: ***.*F

The temperature at the inlet to the heat exchanger is displayed.

Open

The control does not detect the heat exchanger inlet sensor.

Shorted

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

HEX OUT: ***.*F

The temperature at the outlet of the heat exchanger is displayed.

Open

The control does not detect the heat exchanger outlet sensor.

Shorted

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

Press the Next  arrow key on the electronic control module display to access Screen #3.

Status display screens

Installation & Service Manual

Page 52

11 Operating information

Status Display Screens (cont’d)

Screen Display shows: Description

RISE: ***.*F

The control will display the temperature difference between the outlet and inlet of the heat exchanger.

FLUE: ***.*F

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 shorted.

Press the Next  arrow key on the electronic control module display 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 microamps.

Press the Next  arrow key on the electronic control module display to access Screen #5.

FAULT 01 MM:DD:YY (fault)

FAULT 01 hh:mm (fault)

This screen allows the user to view the last 10 faults. The most recent fault is shown first. The top line of the display shows the fault number, and alternates between the date of the fault (MM:DD:YY) and the time (hh:mm). The bottom line shows cause of the fault. To view earlier faults, press the UP key. To review later faults, press the DOWN key.

Installation & Service Manual

Page 53

12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and fill with fresh

water

• Check for leaks (water, gas, flue,

condensate)

• Verify flue and air lines in good condition

and sealed tight

• Check system water pressure/system

piping/expansion tank

• Check control settings

• Check ignition and flame sense electrodes

(sand off any deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and

performance verification per Section 10 in this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high fire)

• Clean the heat exchanger if flue

temperature is more than 54°F above return water temperature.

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

ANNUAL START-UP

Owner maintenance

Daily

• Check water heater area

Monthly

• Check vent piping

• Check air piping

• Check relief valve

• Check condensate drain system

Every

6 months

• Check water heater piping (gas and water) for leaks

• Operate relief valve

Installation & Service Manual

Page 54

12 Maintenance

Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

The water heater should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the water heater designated in Table 12A and explained on the following pages must be performed to assure maximum water heater efficiency and reliability. Failure to service and maintain the water heater and system could result in equipment failure.

Electrical shock hazard – Turn off power to the water heater before any service operation on the water heater except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect water heater area

1. Verify that water heater area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the water heater intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual.

Inspect water heater interior

1. Remove the front access cover and inspect the interior of the water heater.

Eliminate all system or water heater leaks. Leaking water may cause severe property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Check all piping for leaks

The condensate trap must be filled with water during all times of water heater operation to avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

 WARNING

Figure 12-1 Condensate Trap

Clean condensate trap

1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

2. Replace the clean out cap.

3. Fill with fresh water until the water begins to pour out of

the drain.

4. Resume operation.

Installation & Service Manual

2" PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING SCREW

CONDENSATE DRAIN

CONDENSATE FROM

HEAT EXCHANGER

REMOVABLE CAP

TO CLEAN OUT TRAP

Page 55

12 Maintenance (continued)

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that water heater vent discharge and air intake are clean and free of obstructions.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold fill pressure for the system. Verify it is

correct (must be a minimum of 12 PSI).

3. Watch the system pressure as the water heater heats up

(during testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect automatic air vents and air separators. Remove

air vent caps and briefly push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in and

out as the water expands due to temperature increase or contracts as the water cools. Tanks must be approved for potable water systems. See Section 6 - System Piping for suggested best location of expansion tanks.

Check water heater relief valve

1. Inspect the relief valve and lift the lever to verify flow.

Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - System Piping before proceeding further.

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the water heater relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the water heater until a new relief valve has been installed.

2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

 WARNING

Installation & Service Manual

Page 56

12 Maintenance

Inspect ignition and flame sense electrodes

1. Remove the ignition and flame sense electrodes from the water heater heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect water heater ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all water heater wiring

1. Inspect all water heater wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the control module display to Parameter Mode and check all settings. Adjust settings if necessary. See Section 1 of this manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Perform start-up and checks

1. Start water heater and perform checks and tests

specified in Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating

pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire, turn off water heater and allow water heater to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 below.

4. When replacing the burner, ensure gasket is in good condition and positioned correctly (FIG. 12-2).

Figure 12-2 Burner Assembly

Check flame signal

1. At high fire the flame signal shown on the display should be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode.

3. See Section 3 - Troubleshooting for other procedures to deal with low flame signal.

Review with owner

1. Emphasize the need to perform the maintenance schedule specified in this manual.

2. Remind the owner of the need to call a licensed contractor should the water heater or system exhibit any unusual behavior.

Installation & Service Manual

Page 57

12 Maintenance (continued)

Cleaning heat exchanger

1. Shut down water heater:

• Follow the “To Turn Off Gas to Appliance” instructions for the water heater on pages 45 and 46.

• Do not drain the water heater unless it will be exposed to freezing temperatures.

2. Allow time for the water heater to cool to room temperature if it has been firing.

3. Remove the blower assembly (gas air/arm) from the heat exchanger access cover. Set bolts aside.

4. Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

5. Remove the heat exchanger access cover, cover gasket(s) and chamber insulation assembly.

The water heater contains ceramic fiber materials. Use care when handling these materials per instructions listed on this page. Failure to comply could result in severe personal injury.

6. Use a vacuum cleaner to remove any accumulation on the

water heater heating surfaces. Do not use any solvent.

7. Finish cleaning using a clean cloth dampened with warm

water.

8. Install access cover gasket, chamber insulation assembly and

cover.

9. Secure nuts on the studs. DO NOT overtighten.

10. Re-install the blower assembly (gas air/arm) using the bolts

set aside in Step 3.

11. Close isolation valves on piping to isolate water heater from

system. Attach a hose to the water heater drain and flush water heater thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the water heater.

12. When the water heater has been flushed, restore water

heater to operation.

13. Perform start-up and check-out procedures listed in Section

10 - Start-up.

Oiled bearing circulators

1. The circulator shipped with the Shield water heater is waterlubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

 WARNING

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber door 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.ht ml. 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 water 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

Installation & Service Manual

Page 58

13 Troubleshooting

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the water heater before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage.

Never jumper (bypass) any device except for momentary testing as outlined in the Troubleshooting chart. Severe personal injury, death, or substantial property damage can result.

Before troubleshooting:

1. Have the following items: a. Voltmeter that can check 120 VAC, 24 VAC, and

12 VDC. b. Continuity checker. c. Contact thermometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to water heater.

3. Make sure the tank is calling for heat.

4. Make sure all external limit controls are installed and operating.

Check the following:

1. Wire connectors to control module and connection board are securely plugged in.

2. Gas pressures:

• Maximum: 14 inches w.c. (natural and LP) with no flow (lockup) or with water heater on

• Minimum: 4 inches w.c. (natural), 8 inches w.c. (LP) with gas flowing (verify during water heater startup)

Check control module fuses

ALWAYS check control module fuses before replacing control module or any major components (blower, etc.). If one of these fuses is blown, it can prevent the control module or other components from operating.

1. Turn OFF power to the water heater at the external disconnect switch.

2. Remove top access cover.

3. Remove the control module cover.

4. Inspect fuses F2, F3, F4, and F5, see FIG. 13-1 below.

Figure 13-1 Control Module Fuses

5. The water heater is shipped with three (3) spare fuses in a plastic bag attached to the control module cover.

6. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4 are 3.15 amps, and F5 is 5 amps).

Note: Fuses F2 - F5 are all slow blow fuses.

Do not jumper fuse or replace with any fuse except as specified. Failure to comply could result in severe personal injury, death, or substantial property damage.

7. Install control module cover and top access cover after fuse inspection.

8. Restore power to the water heater at the external disconnect switch and verify water heater operation (Section 10 Start-up) after completing water heater service.

 WARNING

NOTICE

 WARNING

Installation & Service Manual

F4 - 3.15 AMP FUSE

GAS VALVE

F5 - 5 AMP FUSE

PUMPS

F2 - 3.15 AMP FUSE

24V SUPPLY

F3 - 1.25 AMP FUSE

MAIN BOARD

Page 59

13 Troubleshooting (continued)

Table 13A Troubleshooting Chart - No Display

FAULT CAUSE CORRECTIVE ACTION

No Display

- No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker.

• Check wiring harness connection between display board and main control board. Connect harness at both points.

- Bad display board. • Replace board.

- Bad main control board. • Replace the main control board.

- Blown fuse. • Replace fuse F3 on the main control board, see page 58 of this manual.

No Burner

Operation

- Tank temperature set point satisfied. • Review temperature setting.

- Unit locked out on fault. • Consult display for specific fault. Refer to fault descriptions on page 62 of this manual for corrective actions.

Unit Does Not

Modulate

Above 50%

- Flue sensor open.

• Verify that the flue sensor is located in the flue outlet.

• Check wiring connections at the flue sensor.

• Check the resistance of the flue sensor and compare to Table 3C on page 60 of this manual.

Installation & Service Manual

Page 60

13 Troubleshooting

Table 13B - Inlet/Outlet Tank Sensor Resistance vs. Temperature

Temperature °F

Resistance Ω

Temperature °F

Resistance Ω

50 18,780 158 1,990

68 12,263 176 1,458

86 8,194 194 1,084

104 5,592 212 817

122 3,893 -- --

140 2,760 -- --

Table 13C - Flue Temperature Sensor Resistance vs. Temperature

Temperature °F

Resistance Ω

Temperature °F

Resistance Ω

68 14,773 176 1,707

86 9,804 194 1,266

104 6,652 212 952

122 4,607 230 726

140 3,252 248 560

158 2,337 -- --

Checking temperature sensors

The water heater temperature sensors (inlet water, outlet water, tank water, and flue) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.

Installation & Service Manual

Page 61

13 Troubleshooting (continued)

Table 13D Troubleshooting Chart - Noisy System

FAULT CAUSE CORRECTIVE ACTION

Noisy

Operation

- Supply gas problem. Natural gas pressures should be between 4 inches w.c. and 14 inches w.c. LP gas pressures should be between 8 inches w.c. and 14 inches w.c.

• Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.

- Gas/air mixture problem.

• Refer to the Gas Valve Adjustment Procedure on

page 69 of this manual for the proper gas valve setting. Verify that the vent/air intake lengths do not exceed the maximum listed in the General Venting section.

- Dirty/damaged burner.

• Refer to page 56 in this manual for the burner removal

and inspection procedure. Clean or replace the burner as necessary.

- Low water flow through the heat exchanger.

• Refer to Section 6 - System Piping for minimum flow

rates.

- Air in the piping system. • Properly purge all air from the piping system.

No Pump

Operation

- Blown fuse.

• Replace fuse F5 on the control board, see page 58 of

this manual.

- Faulty pump. • Replace pump.

- Faulty pump relay. • Replace pump relay.

- Internal fault on control board. • Replace main control board.

Relief Valve

Opening

- System pressure exceeds relief valve setting.

• Lower the system pressure below the 150 PSI rating of the supplied relief valve.

Installation & Service Manual

Page 62

13 Troubleshooting

Table 13E Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Flame

Sequence

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The flame detector circuit is seeing a flame signal while no flame is present.

• Check supply voltage for proper polarity.

• Check external wiring for voltage feedback.

• Check the flame rod and make sure it is clean.

• Check the internal wiring for bad connections.

• Replace main control board.

No Flame Ign

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The unit has failed to prove main burner ignition after four (4) attempts.

• Inspect spark electrode and associated wiring for damage and connection. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Check for proper electrical grounding of the unit.

• Check incoming supply gas pressure. Natural gas pressures should be between 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.

• Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged.

• Verify that the vent/air intake pipes are correctly installed and that there are no obstructions.

• Check for 24 VAC to the gas valve at the 2-pin connection on the side of the main control board during the ignition attempt. If no voltage is present, replace the main control board.

• If 24 VAC is present at the main control board, check the wiring between the main control board and the gas valve. Replace the wiring if necessary. Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point. The main control board can detect if the gas valve is not connected and will display the GV / Relay Fail fault.

• If 24 VAC is present, check the outlet of the valve to ensure the valve is flowing gas. With a manometer connected to the outlet tap of the gas valve, when the unit is in the prepurge period, there should be a negative pressure present. When the valve is energized a change in pressure should occur. If the pressure change does not occur, the gas valve is not opening. Replace the gas valve.

• Inspect flame sensor and associated wiring. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Inspect the burner. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Replace the main control board.

Installation & Service Manual

Page 63

13 Troubleshooting (continued)

Table 13E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

No Flame

Running

(will require a manual

reset once the

condition has been

corrected. Press the

RESET button on the

display to reset.)

The unit was running and lost the flame signal. This condition occurred four (4) straight times.

• Inspect spark electrode and associated wiring for damage and connection. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Check for proper electrical grounding of unit.

• Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged.

• Verify that the vent/air intake pipes are installed correctly and there are no obstructions.

• Check for 24 VAC to the gas valve at the 2-pin connection on the side of the main control board during the ignition attempt. If no voltage is present, replace the main control board.

• Inspect flame sensor and associated wiring. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Inspect the burner. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Replace the main control board.

GV/Relay

Fail

(will require a manual

reset once the

condition has been

corrected. Press the

RESET button on the

display to reset.)

The main control board did not detect the gas valve.

• Ensure gas valve switch is ON (Models SNR150-100 and SNA285-125).

• Check wiring harness connection at the gas valve and

at the main control board.

• Replace the gas valve wire harness.

• Replace the gas valve.

• Replace the main control board.

Installation & Service Manual

Page 64

13 Troubleshooting

Table 13E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Manual Reset

High Limit

(will require a manual

reset once the condition has been corrected. Press the RESET button on the

display to reset.)

The outlet water temperature has exceeded the fixed setting of the manual reset high limit.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the water heater is piped properly into the heating system. Refer to Section 6 - System Piping for the proper piping methods for the Shield water heater.

• Check 120 VAC to water heater pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.

• Replace the main control board if necessary.

• If 120 VAC is present on a call for heat and the water heater pump is not operating, replace the pump.

• Check resistance of water sensors and compare to Table 13B on page 60 of this manual. Replace sensor if necessary.

Fan Low

Fan Speed Low

(will require a manual

reset once the condition has been corrected. Press the RESET button on the

display to reset.)

The actual fan RPM is 30% lower than what is being called for.

• Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 2 - General Venting for proper lengths.

• Check for obstruction or blockage in the vent/air intake pipes or at terminations.

• Check the wiring connections at the fan and at the main control board.

• Replace the fan.

• Replace the main control board.

Blown fuse.

• Replace fuse F4 on the control board, see page 58 of this manual.

APS

Open

(will require a manual

reset once the condition has been corrected. Press the RESET button on the

display to reset.)

Air pressure switch contacts are open.

• Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals.

• Air intake lengths exceed the maximum allowed lengths. Refer to Section 2 - General Venting for

proper lengths.

• Check for obstruction or blockage in the air intake pipes or at terminations.

• Check reference hoses connected to the air pressure switch for blockage or obstruction.

• Inspect the burner. Reference page 56 of this manual for removal and cleaning procedures. Replace if necessary.

• Inspect the heat exchanger. Reference page 57 of this manual for removal and cleaning procedures. Replace if necessary.

• Faulty air pressure switch. Replace switch.

Installation & Service Manual

Page 65

13 Troubleshooting (continued)

Table 13E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Fan High

Fan Speed High

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

The actual fan RPM is 30% higher than what is being called for.

• Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 2 - General Venting for proper lengths.

• Check for obstruction or blockage in the vent/air intake pipes or at terminations.

• Check the wiring connections at the fan and at the main control board.

• Replace the fan.

• Replace the main control board.

Sensor Open

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Either the heat exchanger inlet water, heat exchanger outlet water or tank temperature sensor has been disconnected.

S1 = Outlet Sensor S2 = Inlet Sensor

• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare the resistance to the tables on page 60 of this manual.

• Replace the sensor if necessary.

Sensor Shorted

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Either the heat exchanger inlet water heat exchanger outlet water or tank temperature sensor has been shorted.

S1 = Outlet Sensor S2 = Inlet Sensor

• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare the resistance to the tables on page 60 of this manual.

• Replace the sensor if necessary.

External Limit

Switch

(will retry after 5

minutes. RESET may be

pressed after condition is

corrected.)

An optional remote limit switch is not making.

• Check function of remote devices.

• Check for loose or misplaced jumper if external limit switch is not installed.

Temp O/Shoot

The flue temperature has exceeded the set parameters for the water heater.

• Inspect the heat exchanger. Reference page 57 of this manual for the procedure on how to clean the flue side of the heat exchanger.

• Inspect the flue sensor and associated wiring. Measure the resistance of the flue sensor and compare to Table 13C on page 60 of this manual. Replace the sensor if necessary.

• Verify that the vent/air intake pipes are properly installed and that there are no obstructions.

• Replace the main control board.

Installation & Service Manual

Page 66

13 Troubleshooting

Table 13E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Temp O/Shoot

(continued)

The temperature rise across the heat exchanger has exceeded the set parameters for the water heater.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the water heater is piped properly into the heating system. Refer to Section 6 - System Piping for the proper piping methods for the Shield water heater.

• Check for 120 VAC to the water heater pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board. Replace the main control board if necessary.

• If 120 VAC is present on a call for heat and the water heater pump is not operating, replace the pump.

• Verify that the water heater pump is set to the proper speed or that the pump is the proper size. Reference Section 6 - System Piping for water heater pump specifications.

Heat exchanger outlet water temperature has exceeded the maximum outlet water temperature.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the water heater is piped properly into the heating system. Refer to Section 6 - System Piping for the proper piping methods for the Shield water heater.

• Check for 120 VAC to the water heater pump motor on a call for heat. If voltage is not present, check wiring back to the main control board. Replace the main control board if necessary.

• If 120 VAC is present on a call for heat and the water heater pump is not operating, replace the pump.

• Replace the main control board.

Parameters

Progr

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

After downloading parameters from a laptop, the main control board must be reset.

• Press the ENTER/RESET button on the display panel.

Blocked Drain

(will retry after 5

minutes. RESET may be

pressed after condition is

corrected.)

The blocked drain switch has detected excessive condensate build up inside the unit.

• Check condensate tube from unit to floor drain for proper installation and obstructions.

• Inspect condensate trap for blockage. Clean if necessary.

• Check for loose wiring connection at wire harness plug.

• Bad blocked drain switch. Replace switch.

Installation & Service Manual

Page 67

13 Troubleshooting (continued)

Table 13E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Service Blk

While the unit is in Service Mode, the outlet temperature has exceeded 185°F.

• Establish a draw to remove HW heat from the water heater.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the water heater is piped properly into the heating system. Refer to Section 6 - System Piping for the proper piping methods for the Shield water heater.

• Check 120 VAC to the water heater pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board. Replace the main control board if necessary.

• If 120 VAC is present on a call for heat and the water heater pump is not operating, replace the pump.

• Verify that the water heater pump is set to the proper speed or that the water heater pump is the proper size. Reference Section 6 - System Piping for water heater pump specifications.

Low 24 VAC

120 VAC input to the main control board has dropped below 80 VAC.

• Check 120 VAC supply to the transformer.

• Check wiring connections at the low voltage terminal strip.

• Check the wire size/length to remote devices.

• Replace the transformer.

Watch Dog Error

The main control board has detected an internal fault.

• Replace the main control board.

Write EEProm

The main control board has detected an internal fault.

• Replace the main control board.

CRC Parameters

The main control board has detected an internal fault.

• Replace the main control board.

Installation & Service Manual

Page 68

13 Troubleshooting

Combustion Analysis Procedure

1. Press the SHUTDOWN button on the display until HTR:Off appears in the display window.

2. Remove the screws securing the top panel to the unit. Remove the panel from the unit to gain access to the flue sensor.

3. Locate the flue sensor in the top of the vent connection. Remove the flue sensor and grommet from the unit. Note: Combustion measurements will be made at this point.

4. Press the SHUTDOWN button on the display until HTR:Standby appears in the display window.

5. Locate the pinhole button above the “r” in the Lochinvar

logo on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the water heater into Service Mode. In Service Mode the water heater will fire at ignition speed and will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole

left by the removal of the flue temperature sensor.

7. Once the water heater has modulated up to full fire, measure

the combustion. The values should be in the range listed in Table 13G. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range, reference the chart below for possible causes and corrective actions.

Table 13F Troubleshooting Chart - Combustion Levels

POSSIBLE CAUSE CORRECTIVE ACTION

Vent/Air Intake Length

or Obstruction

• Refer to Section 2 - General Venting for the proper venting and air intake methods for the Shield water heater.

• Check for obstructions at the vent/air intake terminals.

Gas Supply Pressure

• Refer to Section 7 - Gas Connections for the proper gas supply for the Shield water heater.

Dirty/Damaged Burner

• Refer to page 56 of this manual for burner removal and cleaning procedures.

• Replace burner if necessary.

Gas Valve Adjustment

• Refer to page 69 of this manual for the gas valve adjustment procedure.

Table 13G Flue Products

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

9. Replace the flue sensor and grommet into the vent connection.

10. Replace the top panel on the unit.

11. Place the Shield water heater back into normal operation.

You must replace the flue sensor to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Installation & Service Manual

Page 69

13 Troubleshooting (continued)

Gas valve adjustment procedure

If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.)

Models SNR150-100 -- SNA285-125

Locate the throttle adjustment screw on the side of the venturi valve (FIG. 13-2). Using a screwdriver, turn the screw a 1/4 turn clockwise to decrease CO2levels or a 1/4 turn

counterclockwise to increase CO2levels. After performing one adjustment on the valve, follow the Combustion Analysis

Procedure on page 68 of this manual to measure the combustion.

If combustion is still not within the specified range, repeat the procedure. This procedure SHOULD NOT be performed more than four (4) times. If after four (4) adjustments and the combustion is still not within the specified range, revisit the possible causes in Table 13F on page 68 or replace the gas valve.

Figure 13-2 Gas Valve Adjustment: Models SNR150-100 -- SNA285-125

Figure 13-4 Gas Valve Adjustment: Model SNA500-125

Model SNA400-125

Locate the throttle adjustment screw on the top of the gas valve, see FIG. 13-3. Using a screwdriver, turn the screw 1/8 turn counterclockwise to increase CO2levels or 1/8 turn

clockwise to decrease CO2levels. After one adjustment on the valve, follow the Combustion Analysis Procedure on page

68 of this manual to measure the combustion.

Model SNA500-125

Locate the throttle adjustment screw on top of the gas valve, see FIG. 13-4. Using a screwdriver, turn the screw a 1/4 turn counterclockwise to increase CO

levels or a 1/4 turn clockwise

to decrease CO

levels. After one adjustment on the valve,

follow the Combustion Analysis Procedure on page 68 of this manual to measure the combustion.

Figure 13-3 Gas Valve Adjustment: Model SNA400-125

Installation & Service Manual

THROTTLE DJUSTMENT

SCREW

THROTTLE DJUSTMENT

SCREW

THROTTLE

DJUSTMENT

SCREW

Page 70

14 Diagrams

Figure 14-1 Ladder Diagram

Installation & Service Manual

120VAC

MANUAL RESET

INTERFACE

TAN K

SENSOR

EXTERNAL

CONTROL

TERMINAL STRIP 120V SUPPLY "L"

X1-6

X1-8

JUNCTION

BOX

X5-7

X6-7

X6-2

CN2-6

CN2-12

HIGH LIMIT

RUN-TIME

CONTACTS

ALARM

CONTACTS

INTEGRATED CONTROL

1.25A

3.5A

CONNECTION

X5-14

DISPLAY

0-10V

PUMP RELAY

3.5A

120 VAC

24 VAC

BOARD

INTEGRATED

CONTROL

INLET

SENSOR

OUTLET SENSOR

FLUE

SENSOR

CONNECTION BOARD

CN4-1

CN4-4

CN4-5

CN4-2

DHW PUMP

RELAY

BLOWER

RELAY

CN5-1

X1-3

X1-1

X1-5

X6-8

X6-3

CN2-5X6-4

RIBBON CABLE

CN4-11

CN4-12

CN4-10

CN4-4

CN3-8

CN3-6

CN3-10

CN3-4

JUNCTION BOX

DHW

PUMP "L"

DHW

TERMINAL

CONNECTION

BOARD

PUMP

STRIP

PUMP

RELAY COIL

CN5-3

LOW GAS

PRESSURE

SWITCH

CN4-6 CN4-3

INTEGRATED

CONTROL

X5-8

X5-1

X5-2

X5-9

X3-1

X3-3

X3-4

X3-2

X4-8

X4-6

X4-10

X4-4

TERMINAL STRIP 120V SUPPLY "N"

GND

DHW

PUMP "N"

TERMINAL

STRIP

BLOWER

JUNCTION BOX

LWCO

HIGH GAS

PRESSURE

SWITCH

CN2-4

CN2-10

CN5-2

CN5-4

EXTERNAL

LIMIT

BLOCKED

AUTO RESET

NEUTRAL

DRAIN

SWITCH

HI-LIMIT

GAS VALVE

BLOWER

SPARK

ROD

CONNECTION

BOARD

AIR PRESSURE

SWITCH

GROUND

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

INTEGRATED

CN2-11

X6-9

CN2-3

X6-5

CN2-9

X6-10

X5-11

X5-4

X5-3

X5-10

X2-2

GAS VALVE

X2-1

X5-5

X5-13

X5-6

X5-12

TR1

X1-7

FLAME ROD

CONTROL

RELAY

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possible, switches are shown without utilities (gas, water or electricity) connected to t he unit. As such, actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present.

2. See wiring diagram for additional notes.

LADDER DIAGRAM LBL20026 REV A

Page 71

14 Diagrams (continued)

Figure 14-2 Wiring Diagram

Installation & Service Manual

INTERFACE

EXTERNAL

LIMITS

ALARM

CONTACTS

RUN-TIME

CONTACTS

DISPLAY

CONNECTION BOARD

CN1

CN2

CN2-9

CN2-3

CN2-7

CN2-1

CN2-8

CN2-2

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

INTEGRATED CONTROL

X1-5

X6-10

X6-5

X3-4

X3-2

X3-1

X3-3

X1-3

X1-6

X1-8

X1-1

BLOWER

PUMP

RELAY

DISCONNECT POWER

BEFORE SERVICING

JUNCTION

BOX

GND

TERMINAL STRIP

WARNING

BOX DEPICTS

OPTIONAL ITEMS

GND

DHW PUMP

120V SUPPLY

245

X5-5

X5-13

X5-6

X5-12

X5-7

X5-14

X5-11

X5-3

X5-4

X5-10

X5-8

X5-1

X5-2

X5-9

X2-2

X2-1

X1-7

TR1

OR/BK

W/R

FLAME ROD

SPARK

ROD

OR/BK

OR OR

GAS VALV E

MANUAL RESET HI-LIMIT

AIR PRESSURE SWITCH

BLOCKED DRAIN

AUTO RESET HI-LIMIT

INLET SENSOR

OUTLET SENSOR

FLUE SENSOR

LOW

WATER

CUT-OFF

PRESSURE

SWITCH

TAN K

SENSOR

EXTERNAL

CONTROL

GAS

24 VAC

COM

0-10V

CN5

CN5-1

CN5-3

CN5-4

CN5-2

CN4-3

CN4-6

CN4-1

CN4-4

CN4-5

CN4-2

CN4

CN2-6

CN2-12

CN2-11

CN2-4

CN2-10

CN2-5

CN3

X6-2

X6-7

X6-9

X6-3

X6-8

X6-4

CAUTION HIGH VOLTAGE SPARK LEAD

Notes:

1. All wiring must be installed in accordance with: local, stat

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 minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or o

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

e, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

of a non-approved spark lead

ther components.

WIRING DIAGRAM LBL20025 REV A

Page 72

Revision Notes: Revision A (ECO #C02299) initial release.

Revision B (ECO #C02870) reflects the addition of a mixing valve to the piping diagrams (FIG.’s 6-2 and 6-3, pgs. 32 - 34).

Revision C (ECO #C02738) reflects edits made to the Gas Valve Adjustment Procedure for Model SNA400-125 on page 69.

Revision D (ECO #C03223) reflects edits made to the high altitude section on page 7.

SWH-I-S Rev D

3/09

Lochinvar SNA285-125, SNR150-100, SNR200-100, SNA500-125, SNA400-125 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual