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  4. Efficiency-Pac EW 150 -- 300
  5. Installation & Service Manual

Lochinvar Efficiency-Pac EW 150 -- 300 Installation & Service Manual

Summary of Efficiency-Pac EW 150 -- 300

  • Page 1

    Low lead content installation & service manual models: ew150 - 300 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, ...

  • Page 2: Contents

    2 contents please read before proceeding ...................... 3 hazard definitions ...................................................... 3 safety warnings and codes ........................................3 1. Determine water heater location location .................................................

  • 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...

  • Page 4

    4 installation & service manual 1 determine water heater location installation 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 regulations shall be carefully followed in all cases. Authorities h...

  • Page 5

    5 installation & service manual 1 determine water heater location (continued) 6. The appliance must not be installed on carpet or other combustible material other than wood flooring. 7. Outdoor models require the installation of an optional outdoor kit. Instructions for mounting the parts in the kit...

  • Page 6

    6 installation & service manual 1 determine water heater location 2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 btu/hr (11cm 2 p...

  • Page 7

    7 installation & service manual 1 determine water heater location (continued) 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 l...

  • Page 8: General Venting

    8 2 general venting installation & service manual general vent installations for connection to gas vents or chimneys must be in accordance with part 7, “venting of equipment,” of the latest edition of the national fuel gas code, ansi z223.1, in canada, the latest edition of can/cga b149 installation...

  • Page 9: General Venting

    9 2 general venting (continued) installation & service manual the vertical vent terminal should exhaust outside the building at least 2 feet (61 cm) above the highest point of the roof within a 10 foot (3.05 m) radius of the termination. The vertical termination must be a minimum of 3 feet (91 cm) a...

  • Page 10: General Venting

    10 2 general venting installation & service manual this appliance has five venting options. They are: 1. Conventional negative draft venting conventional negative draft venting with vertical termination. 2. E+ with a vertical conventional vent e+vent with a vertical conventional vent for flue produc...

  • Page 11: General Venting

    11 2 general venting (continued) installation & service manual the vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes. Locate appliances as close...

  • Page 12: General Venting

    12 2 general venting installation & service manual 6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to there previous condi...

  • Page 13: General Venting

    13 2 general venting (continued) installation & service manual figure 2-7 e+ vent with roof top air vertical roof top air inlet the air inlet cap for the vertical roof top air inlet is assembled from components purchased locally. The air inlet cap consist of two 90° ells installed at the point of te...

  • Page 14: General Venting

    14 2 general venting installation & service manual air inlet pipe materials the air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from those specified in this section. Select air inlet pipe material from the following specified materials: pvc or cpvc (4", 5" or ...

  • Page 15: General Venting

    15 2 general venting (continued) installation & service manual vent kits the sidewall e+vent kit must be ordered from the manufacturer for single appliance installations with sidewall air inlet. The part number for each kit is listed by appliance size. Each kit includes a sidewall combustion air inl...

  • Page 16: General Venting

    16 2 general venting installation & service manual flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces shoul...

  • Page 17: General Venting

    17 2 general venting (continued) installation & service manual figure 2-11 sidewall direct vent caps flue outlet air inlet sidewall direct vent kits the sidewall direct vent kit must be ordered from the appliance manufacturer. The part number for each kit is listed by appliance size. Each kit includ...

  • Page 18: General Venting

    18 2 general venting installation & service manual notice the use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air. Warning using other vent or air intake materials, failure ...

  • Page 19: General Venting

    19 2 general venting (continued) installation & service manual danger failure to properly seal all vent joints and seams may result in flue gas spillage and carbon monoxide causing severe personal injury or death. The connection from the vent to the vent termination outside the building must be made...

  • Page 20: General Venting

    20 2 general venting installation & service manual flue outlet air inlets air inlets 3’ min 3’ min figure 2-14 installation of multiple direct vent caps multiple sidewall direct vent installations the combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (91...

  • Page 21: General Venting

    21 2 general venting (continued) installation & service manual table 2d direct vent flue and air pipe sizes input btu/hr direct vent flue size* air inlet pipe** sidewall e+ vent kit 150,000 4" 4" hdk3013 199,999 4" 4" hdk3013 250,000 5" 5" hdk3014 300,000 5" 5 hdk3014 *minimum diameter, installer ma...

  • Page 22: General Venting

    22 2 general venting installation & service manual air inlet pipe materials select air inlet pipe material from the following specified materials: pvc or cpvc (4", 5" or 6" i.D.)* dryer vent galvanized steel vent pipe with joints and seams sealed as specified below. Type “b” double wall vent with jo...

  • Page 23: General Venting

    23 2 general venting (continued) installation & service manual combustion air inlet combustion air supply pipes can not be combined into a single pipe for multiple appliance installations. Combustion air supplied from outdoors must be free of contaminants (see combustion and ventilation air). To pre...

  • Page 24: General Venting

    24 2 general venting installation & service manual warning outdoor models must be installed outdoors and must use the vent cap supplied by the manufacturer. Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors. All covers, doors and jacket pane...

  • Page 25: Gas Connections

    25 3 gas connections installation & service manual gas supply verify appliance is supplied with type gas specified on rating plate. This appliance is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for ins...

  • Page 26: Gas Connections

    26 3 gas connections installation & service manual gas connection 1. Safe operation of appliance requires properly sized gas supply piping. See data below. 2. Gas pipe size may be larger than heater connection. 3. Installation of a union is suggested for ease of service. 4. Install a manual main gas...

  • Page 27: Gas Connections

    27 3 gas connections (continued) installation & service manual apply wrench from top or bottom of control figure 3-2 wrench to support gas valve for piping connection 7. Remove seal over control inlet. 8. Connect pipe to control inlet. Use wrench to square ends of the control. 9. For lp gas, consult...

  • Page 28: Gas Connections

    28 3 gas connections installation & service manual figure 3-4 gas manifold pressure adjustment 10. Remove the 1/8" hex plug, located on the “outlet” side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge (see fig. 3-4). Minimum range of scale should be up ...

  • Page 29: Gas Connections

    29 3 gas connections (continued) installation & service manual 4 3 2 0 1 2 3 1 4 8 7 6 5 5 6 7 8 manometer gas valve note if the regulator cover screw it not in place and tight, the appliance will not function properly. 20. Turn the power switch to the “off” position. 21. Turn gas valves and manual ...

  • Page 30: System Piping

    30 installation & service manual 4 system piping figure 4-1 connection to the appliance inlet and outlet connections for ease of service, install unions on inlet and outlet of the appliance. The connection to the appliance marked “inlet” on the header should be used for return from the system. The c...

  • Page 31: System Piping

    31 installation & service manual 4 system piping (continued) each appliance has a combination gas valve to cycle the gas supply on and off to the burners. The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves. The valve has a gas cont...

  • Page 32: System Piping

    32 installation & service manual 4 system piping 2. Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchanger. This is a non-warrantable failure. Temperature rise must be properly adjusted to achieve the specified flow rate. Tab...

  • Page 33: System Piping

    33 installation & service manual water 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 sh...

  • Page 34: System Piping

    34 installation & service manual 4 system piping incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the heat exchanger and operational problems. The cold water supply piping must be installed in the discharge pipi...

  • Page 35: Electrical Connections

    35 installation & service manual 5 electrical connections this appliance is wired for 120 vac service. The appliance, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition...

  • Page 36: Electrical Connections

    Installation & service manual 5 electrical connections maximum set point determination the maximum set point for the control is factory set. Water heaters are set to 190°f max., and specialty state and local codes to 200°f. These maximum set points are established by cutting the oj1 and oj2 jumpers ...

  • Page 37: Electrical Connections

    37 installation & service manual 5 electrical connections (continued) notice ground the cable shield at the connection to the temperature control only. Do not ground the shielded cable at the sensor end. To maintain temperature accuracy, sensor wires should be 18 awg two conductor (18/2). Use shield...

  • Page 38: Operation and Startup

    Installation & service manual 6 operation and startup 1. Stop! Read the safety information above. 2. Turn off all electrical power to the appliance. 3. Remove the upper front access panel 4. Turn the power switch on the inside of the cabinet to “off” position. 5. Set the thermostat to the lowest set...

  • Page 39: Operation and Startup

    39 installation & service manual 6 operation and startup (continued) figure 6-2 operation and diagnostic lights the unit has a lighted on/off power switch on the outer cabinet (left side) and five (5) led indicators on the electronic ignition control module to monitor the units operation. Table 6a i...

  • Page 40: Operation and Startup

    40 installation & service manual 6 operation and startup maintenance listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing. Caution label all wires prior to disconnection when servicing controls. Wiring erros can cause improper and da...

  • Page 41: Operation and Startup

    41 installation & service manual 6 operation and startup (continued) g. If the appliance does not function properly after manually setting the air shutter, use a magnahelic or slope gauge to set the air shutter based on differential air pressure. H. Install a tee in each of the hoses connecting the ...

  • Page 42: Operation and Startup

    42 installation & service manual 6 operation and startup removal of combustion chamber lining or base panels: • avoid breathing dust and contact with skin and eyes. • use niosh certified dust respirator (n95) (http://www.Cdc.Gov/niosh/hompage.Html). • lightly mist with water (only those areas being ...

  • Page 43: Diagrams

    Installation & service manual 43 7 diagrams thermostat w1 r1 transformer igniter ign mod p5 air blower combustion a off on power switch l1 (hot) l2 to 120 vac power supply 24 vac 120 vac lwco lwco 6 2 lbl2 0019 rev a * if equ ipped pump delay 24vdc pump delay mrhl r2 w2 hfgv x b gas valve c no nc c ...

  • Page 44: Ct P

    44 installation & service manual tr a n s f o r m e r on-off sw it c h l o w air no nc c pump * r1 w1 a x swi t c h termi n al board igni t e r blower bc lim it gas v a l v e igni t ion module bk bk/w bk/w w gr w gr bl or/r bl or y r/w r/or r/bk t r y y gr w y bl bk w br w gy gy r/bk gas v a l v e h...

  • Page 45: Troubleshooting

    45 installation & service manual step 1 with 120 vac power to appliance, turn on power switch, switch lights up? 120 vac power to unit? No check 120 vac power supply. No yes check wiring to switch? Yes check 120 vac thru switch? No check wiring connections. No replace switch. Yes step 2 ignition con...

  • Page 46: Troubleshooting

    46 installation & service manual step 9 no check wiring connections. No yes replace igniter/sensor. Yes step 10 no yes gas valve open? Yes step 11 igniter "led" turns off & valve "led" stays on? Step 12 yes igniter / sensor warms up and glows red. 120 vac at igniter/sensor? No replace module. Igniti...

  • Page 47: Notes

    47 notes.

  • Page 48

    Revision a (eco c15343) initial release. Revision b (change #500000694) reflects the addition of non-metallic venting information to page 14. Ew-i-s rev b_dir #2000003735_mm #100207764 06/15.