Lochinvar Standard Hi-Power Installation Manual
1
INSTALLATION AND SERVICE MANUAL
SHP-I&S-02
COMMERCIAL ELECTRIC WATER HEATERS
52, 82, 119 Gallon, 9 kW - 54kW Input Models
FIG. 1 Front View Vertical Round Models
Installation and service must be performed by Qualified
Service Personnel Only.
WARRANTY
Factory warranty (shipped with unit) does not apply to
units improperly installed or improperly operated.
Experience has shown that improper installation or system
design, rather than faulty equipment, is the cause of most
operating problems.
1. Excessive water hardness causing a lime/scale build-up
in the heater and/or on the immersion heating elements
is not the fault of the equipment and is not covered
under the manufacturer's warranty. (See Water
Treatment and Water Chemistry)
2. Do not energize electrical system before the heater is
completely filled with water. Damage caused to the
immersion heating elements by dry fire is not covered
under the manufacturer's warranty. Follow start up
procedure in the manual.
3. Water heater corrosion and component failure caused
by air-borne chemical vapors is not covered under the
manufacturer's warranty.
4. Corrosion damage caused by current leakage due to
improper grounding of electrical systems or electronic
components to the storage tank and related piping is not
covered by the manufacturer's warranty.
5. Under no circumstance will the manufacturer be liable
for consequential damages resulting from the
installation or use of this equipment.
6. Correct installation procedure and local codes must be
adhered to.
SPECIAL INSTRUCTIONS
TO OWNER
NOTE:
Retain this manual for future reference.
WARNING:
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE can
cause injury or property damage. Refer to this
manual. For assistance or additional information,
consult a qualified installer, service agency or the
electric utility.
This manual supplies information for the installation,
operation and servicing of the appliance. It is strongly
recommended that this manual be reviewed completely
before proceeding with an installation.
CHECKING EQUIPMENT
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying
the water heater, which may show signs of being hit or
otherwise being mishandled. Verify total number of pieces
shown on packing slip with those actually received. In case
there is damage or a shortage, immediately notify carrier.
DO NOT USE THIS APPLIANCE 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.
2
WARNING:
CONTENTS
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Checking the Equipment . . . . . . . . . . . . . . . . . . . . . . . . .1
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation Requirements
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Drain Pan Requirements . . . . . . . . . . . . . . . . . . . . . . . . .3
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Tank Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Service
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Wire Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Jacket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Standard and Optional Controls . . . . . . . . . . . . . . . . . . .7
Components and Controls
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuses and Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Surface Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Immersion Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . . . .10
Risk of Scald Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .10
Temperature Limit Control . . . . . . . . . . . . . . . . . . . . . .11
Immersion Heating Elements . . . . . . . . . . . . . . . . . . . .12
Start-Up Procedure
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Filling the Water Heater . . . . . . . . . . . . . . . . . . . . . . . . .12
Start-Up Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Maintenance
T&P Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Flushing the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Sediment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Scale Removal - Elements . . . . . . . . . . . . . . . . . . . . . . . .15
Trouble Shooting
Not Enough Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . .16
Water Is Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Water Heater Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life. Do
not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other
appliance.
OWNER WARNING:
The information contained in this manual is
intended for use by qualified professional installers,
service technicians or the electric utility. Consult
your local expert for proper installation or service
procedures.
IMPORTANT:
Consult and follow local Electrical Codes, Building
and Fire Regulations and other Safety Codes that
apply to this installation. Consult local codes
officials and electric utility company to authorize
and inspect all field installed electrical connections.
CAUTION
Be sure to turn off power when working on or near
the electrical system of the water heater. Never touch
electrical components with wet hands or when
standing in water. When replacing fuses, always use
the correct size for the circuit. Do not test electrical
system before the water heater is completely filled
with water. Follow the start-up procedure.
WARNING:
To minimize the possibility of serious personal
injury, fire or damage to your appliance, never violate
the following safety rules.
1. Always keep the area around your appliance free of
combustible materials, gasoline, and other flammable
liquids and vapors.
2. Never cover your appliance, lean anything against it,
store trash or debris near it, stand on it or in any way
block the access to your appliance.
3
CODES
The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These shall be carefully followed
in all cases. Authorities having jurisdiction shall be
consulted before installations are made. In the absence of
such requirements, the installation shall conform to the
latest edition of the National Electrical Code, NFPA 70.
When the appliance is installed in Canada, it must conform
to the CAE C22.1, Canadian Electrical Code, Part 1 and/or
local Electrical Codes.
APPROVALS
This complete appliance is design certified and Listed by
Underwriters Laboratories as a commercial storage electric
water heater. This water heater bears the UL certification
for the United States as tested under the Standard for
Electric Booster and Commercial Storage Tank Water
Heaters, UL1453 and C-UL in Canada as tested under the
Standard for Construction and Test of Electric Storage Tank
Water Heaters, CAN/CSA-C22.2 No. 110-M90.
INSTALLATION PROCEDURE
LOCATION OF UNIT
1. 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
unit. Under no circumstances is the manufacturer to be
held responsible for water damage in connection with
this unit, or any of its components.
2. Insure that the appliance is located near an acceptable
drain so that the vessel can be properly drained when
performing service or maintenance. The drain must
also
provide adequate drainage in the event of leakage from
the tank or related piping. The drain must prevent water
damage to the adjacent area and lower floors of the
structure.
3. The appliance must be installed so that the electrical
components are protected from water (dripping,
spraying, etc.) during appliance operation and service
(replacing of fuses, elements, etc.)
4. Appliances located in a garage or parking structure shall
be installed so that the jacket and all piping shall be
located or protected so that it is not subject to physical
damage by a moving vehicle.
5. The appliance must be installed on a level floor. Shim
the base as necessary if leveling is required.
6. The floor on which the appliance is installed must be
capable of supporting the total weight of the water
heater when completely filled with water. Combustible
floor locations may be used. Maintain required
clearances from combustible surfaces.
7. The appliance must not be installed on carpet.
8. The appliance must be installed indoors where it is
protected from exposure to wind, rain and weather.
9. Locate the appliance as close as possible to the point of
major hot water usage, the water piping and branch
electrical circuit wiring.
10. Insulate water piping to control heat loss and possible
condensation.
11. The appliance must be located in an area that is not
subject to freezing. The ambient temperature of the
space where the appliance is installed must not go below
32°F (0°C) or above 104°F (40°C).
CAUTION
This water heater, as well as all water heaters will
eventually leak. Installation of the water heater
should be accomplished in such a manner that if the
tank, piping or any connections should leak, the flow
of water will not cause damage to the structure. For
this reason, it is not advisable to install the water
heater in an attic or upper floor. When such
locations cannot be avoided, a suitable drain pan
must be installed under the water heater. Drain pans
may be fabricated or purchased from your plumbing
wholesaler. The drain pan must be piped to an
adequate drain. Under no circumstances is the
manufacturer to be held liable for any water damage
in connection with this water heater.
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CLEARANCES FROM
COMBUSTIBLE CONSTRUCTION
FIG. 2 Clearances from Combustible Construction
TABLE - A
CLEARANCES FROM
COMBUSTIBLE CONSTRUCTION:
Right Side - 0"
Rear - 0"
Left Side - 0"
Front - 18" (45cm) for service access to controls and
heating elements
Top - 12" (30cm) suggested for service access to
piping and water connection
Hot Water Pipes 1" (25.4mm)
Maintain minimum specified clearances for adequate
operation. All installations must allow sufficient space for
servicing the electrical components, water pipe
connections, piping and other auxiliary equipment, as well
as the appliance.
Multiple appliances may be installed in a modular water
heater installation. Multiple appliances may be installed
side by side with no clearance between the sides of adjacent
appliance. This appliance is approved for zero clearance
from side combustible surfaces and no service access is
required from the sides on most models.
MOUNTING
The water heater should be mounted to the floor following
applicable architectural and local code requirements or
accepted standards for the specific site and model
purchased. In areas prone to seismic activity, it is
recommended that the water heater be mounted to the
floor according to recommended procedures for the site. In
some geographic areas, additional strapping or braces may
be required, consult local codes for specific requirements.
Proper mounting will help to make the water heater less
susceptible to seismic damage.
FIG. 3 Water Connections
WATER CONNECTIONS
NOTE:
Before making any connections to the cold water
inlet or hot water outlet, insure that all piping is clean
and free of material or scale. This can usually be
accomplished by "blowing out the pipe." Any foreign
material or scale entering the water heater can
adversely affect operation and performance.
NOTE:
When using copper tubing, solder tubing to an
adapter before attaching to the threaded nipple
connection provided on the water heater. Soldering
directly to the threaded connection may harm a
lining in the nipple or damage the tank lining.
5
INLET AND OUTLET CONNECTIONS
For ease of service, install unions on the cold water inlet
and hot water outlet of the water heater. The cold water
inlet connection is located on the lower left front side of the
water heater. A manual shutoff valve should be installed
upstream on the cold water source as an isolation device.
The hot water outlet connection is located on the top center
of the water heater. A manual shutoff valve should be
installed downstream on the hot water outlet source as an
isolation device in case the water heater must be
disconnected from the system.
STORAGE TANK
This appliance uses a glass lined steel storage tank to store
the heated water for use. The storage tank is constructed
in accordance with the requirements of the Underwriters
Laboratory Listing for a commercial electric water heater.
The tank is furnished with threaded connections for cold
water inlet, hot water outlet, a relief valve and a drain
connection. The storage tank has a hand hole for ease of
inspection, cleanout and service. The interior of the
storage tank is glass lined and fired to 1600˚F (871˚C) to
insure a molecular fusing of glass and steel to protect the
steel base metal against corrosion. A magnesium anode is
standard to help prevent dissipation of the tank material by
electrolytic action.
RELIEF VALVE
This water heater is supplied with a temperature and
pressure relief valve(s) sized in accordance with ASME
Boiler and Pressure Vessel Code, Section IV. Some water
heaters may be supplied with an optional pressure only
relief valve. The relief valve(s) is installed in the vertical
position and mounted in the tapping provided in the
storage tank. No valve is to be placed between the relief
valve, and the water heater. To prevent water damage, the
discharge from the relief valve must be piped to a suitable
floor drain for disposal when relief occurs. No reducing
couplings or other restrictions shall be installed in the
discharge line. The discharge line shall allow complete
drainage of the valve and line. Relief valves should be
manually operated at least once a year. A relief valve that
fails to completely reseat and continues to discharge water
must be immediately replaced with a new, properly sized,
temperature and pressure relief valve.
CAUTION
Avoid contact with hot discharge water. Insure that
no one is in front of or around the relief valve
discharge line. Make sure that the extremely hot
water manually discharged from the relief valve will
not cause bodily injury or property damage.
THERMAL EXPANSION
OF WATER
A relief valve that discharges periodically may be due to
thermal expansion in a closed system. Many water systems
are equipped with pressure reducing valves, check valves or
back flow preventers which may cause the water system to
be closed. As water is heated it will expand in volume due
to thermal expansion. The system must make allowance for
this expansion. If an expansion tank is not provided in the
system, water pressure may increase to the point where the
water heater's temperature and pressure relief valve opens
to relieve the excess pressure. The temperature and
pressure relief valve is not intended for the constant relief of
thermal expansion. This is an unacceptable condition and
must be corrected. Do not plug or cap the relief valve
discharge! A properly sized expansion tank is typically
installed in the potable water system to relieve the pressure
built up by thermal expansion of heated water. Consult
your local plumbing contractor and plumbing wholesaler
for assistance in properly selecting an expansion tank for
your system.
As the water heater operates, there may be noises generated
by the expansion and contraction of the metal parts of the
water heater and related piping. These noises may occur
during periods of heat up or cool down. They do not
represent harmful or dangerous conditions.
CATHODIC PROTECTION
Hydrogen gas can be produced in a hot water system that
has not been used 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 be open for several
minutes at a sink close to the water heater 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 pipe as the hot
water begins to flow. There should be no smoking or open
flames near the faucet at the time it is open.
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