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  5. Installation And Operating Manual

Lochinvar POWER VENTED GAS HEATERS Installation And Operating Manual

Manual is about: WITH HOT SURFACE IGNITION

Summary of POWER VENTED GAS HEATERS

  • Page 1

    Residential gas water heaters installation and operating manual 1210 324084-001 keep this manual in the pocket on heater for future reference whenever maintenance adjustment or service is required. Power vented gas models with hot surface ignition not for use in manufactured (mobile) homes • for you...

  • Page 2: Table of Contents

    2 www.Lochinvar.Com table of contents table of contents 2 safe installation, use and service 3 general safety 4 introduction 6 qualifi ed installer or service agency . . . . . . . . . . . . 6 preparing for the installation . . . . . . . . . . . . . . . . . . 6 installation requirements for the commo...

  • Page 3

    Www.Lochinvar.Com 3 your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazar...

  • Page 4: General Safety

    4 www.Lochinvar.Com general safety.

  • Page 5: General Safety

    Www.Lochinvar.Com 5 general safety installation: do not install the water heater where flammable products will be stored or used. Vapors from flammable liquids may explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline, solvents or adhe- sives i...

  • Page 6: Introduction

    6 www.Lochinvar.Com thank you for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations found in this installation and operating manual: csa - canadian standards association ansi - american national standards institute nfpa -...

  • Page 7

    Www.Lochinvar.Com 7 commonwealth of massachusetts for all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or op...

  • Page 8

    8 www.Lochinvar.Com • if your water heater will be installed in the commonwealth of massachusetts, refer to the following graphic during installation and during modifications to the water supply system. In remove a must be vertical to ir bubbles e out coil air handler to air handler shut-off valve *...

  • Page 9: Typical Installation

    Www.Lochinvar.Com 9 get to know your water heater - gas models (list referencing figures 1-7) typical installation 1. Vent termination elbow with rodent screen 2. *vent pipe 3. *vent pipe coupling (if required) 4. *vent pipe elbow (long radius) 5. Blower high limit switch (see figure 6) 6. T&p valve...

  • Page 10

    10 www.Lochinvar.Com 32 34 36 33 38 39 37 35 40 41 natural gas and propane main burner with igniter assembly for 40k to 50k btu/hr models figure 3 32 34 36 33 38 39 37 35 40 41 natural gas and propane main burner with igniter assembly for 60k to 75k btu/hr models figure 4 17 figure 5 25 23 24 22 5 2...

  • Page 11: Danger

    Www.Lochinvar.Com 11 water piping - mixing valve usage mixing valves water temperature over 125°f (52°c) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. Tempe...

  • Page 12

    12 www.Lochinvar.Com some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infi rm and the physically/mentally disabled. Table 1 (published by u.S. Government memorandum, 1978) shows the approximate time-to-burn relationship for norm...

  • Page 13: Warning

    Www.Lochinvar.Com 13 figure 13 electrical requirements & wiring diagram failure to do so can result in death or electrical shock. Replace all parts and panels before operating. Disconnect power before servicing. Electric shock hazard warning before plugging in the water heater, always make sure: the...

  • Page 14: Safety Lockouts

    14 www.Lochinvar.Com this water heater has several lockout features designed to prevent the heater from operating in unsafe conditions. High limit controls (tco) thermostat/water temperature this feature is a part of the gas control valve/thermostat (see figure 1, item 10) and limits the maximum wat...

  • Page 15: Caution

    Www.Lochinvar.Com 15 facts to consider about the location carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not fo...

  • Page 16: Warning

    16 www.Lochinvar.Com read instruction manual before installing, using or servicing water heater. • do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • avoid all ignition sources if you smell gas. • do not expose water heater control to...

  • Page 17: Warning

    Www.Lochinvar.Com 17 if this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken from outside thes...

  • Page 18

    18 www.Lochinvar.Com method used to provide fresh air to the confi ned space and the total btu/hr input rating of all appliances installed in the space. Direct vent appliances other appliances installed in a direct vent confi guration that derive all air for combustion from the outdoor atmosphere th...

  • Page 19

    Www.Lochinvar.Com 19 figure 19 4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than 3” (76mm) (see figure 20). Figure 20 5. Alternatively a singl...

  • Page 20: Danger

    20 www.Lochinvar.Com water piping water temperature over 125°f (52°c) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. Temperature limiting devices such as mix...

  • Page 21

    Www.Lochinvar.Com 21 combo heating this section serves as a guide for the installation and use of “combo” heating systems utilizing a domestic water heater that has been specifi cally approved for such use. It is written for those knowledgeable in the required trades and professionals involved in th...

  • Page 22: Caution

    22 www.Lochinvar.Com closed water systems water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure-reducing valves, check valves, and back fl ow preventers. Devices such as these cause the water system to b...

  • Page 23: Warning

    Www.Lochinvar.Com 23 temperature-pressure relief valve • temperature-pressure relief valve must comply with ansi z21.22-csa4.4 and asme code. • properly sized temperature- pressure relief valve must be installed in opening provided. • do not plug, block, or cap the discharge line. • failure to follo...

  • Page 24: Warning

    24 www.Lochinvar.Com note: the purpose of a temperature-pressure relief valve is to prevent excessive temperatures and pressures in the storage tank. The t&p valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed sy...

  • Page 25: Warning

    Www.Lochinvar.Com 25 make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch w. C. (3.5 kpa) for natural gas and propane gas. The minimum inlet gas pressure shown on the rating plate is that which will permit fi ring at rated input...

  • Page 26: Caution

    26 www.Lochinvar.Com dirt or foreign material in the gas supply line, a sediment trap (sometimes called a dirt leg) must be incorporated in the piping. The sediment trap must be readily accessible. Install in accordance with the “gas piping” section. Refer to the current edition of the national fuel...

  • Page 27

    Www.Lochinvar.Com 27 termination clearances sidewall power vent inside corner detail fixed closed operable fixed closed operable vent terminal air supply inlet area where is not permitted gas meter / regulator c b b b b b j a k m f b l e d i v v v v v v v v v v x x x g a figure 29 vent terminal clea...

  • Page 28

    28 www.Lochinvar.Com blower assembly installation 1. This power vented water heater comes with blower assembly installed (see figure 30). 2. After unit is set in place, make sure blower assembly is still mounted securely. Make sure there is no damage to blower. Hose connection port for condensate dr...

  • Page 29

    Www.Lochinvar.Com 29 or any region that experiences hot summers. Ambient conditions hotter than 110°f (43°c) require that the venting material be either cpvc or polypropylene. Areas that can experience high ambient environments include closets, alcoves, areas under staircases, attics-especially in m...

  • Page 30

    30 www.Lochinvar.Com exhaust venting this heater is designed to exhaust the products of combustion (fl ue gases) to the outdoors using a sealed piping system. Table 2 lists the allowable vent materials and sizing information. Figure 34 shows the general venting layout while figures 38-42 show variou...

  • Page 31

    Www.Lochinvar.Com 31 venting terminations and sizing refer to figure 34 and table 2 for vent pipe materials and sizing. Examples of the vent terminations are shown in figures 35 & 36. If the installation requires a vent riser, suitable drainage must be provided to ensure condensation does not accumu...

  • Page 32

    32 www.Lochinvar.Com calculating equivalent feet water heater model heater input (btu/hr) vent size (inside diam) pressure switch setting maximum equivalent vent length minimum equivalent vent length 40 & 50 gal. 40,000 2” (50mm) - 0.27 in. W.C. 50 ft. (15.2m) + termination elbow 7 ft. (2.1m) + term...

  • Page 33: Caution

    Www.Lochinvar.Com 33 venting instructions 1. Plan the venting layout starting at the vent termination and work back toward the heater. Take into consideration the style and position of the vent termination, the vent pipe routing, elbows and connectors required and the necessary support hangers. 2. V...

  • Page 34: Caution

    34 www.Lochinvar.Com termination may be 90° elbow 3” (76mm) min. Length roof line a vent used in a special venting system with positive vent pressure and passing through a roof shall extend at least 18” (457mm) above the highest point where it passes through the roof surface and any other obstructio...

  • Page 35: Warning

    Www.Lochinvar.Com 35 4” vent pipe 3” rubber coupling (supplied) 3” vent pipe, 75mm (3 in.) max length 3”-4” adapter (field supplied) blower configuration for hi-input heater connected to 4” venting. Figure 42 blower exhaust direction the blower assembly may be rotated 90 degree clockwise or counterc...

  • Page 36: Warning

    36 www.Lochinvar.Com cement: the cement should be a bodied cement of approximately 500 to 1600 centipoise viscosity containing 10-20% (by weight) virgin pvc material solvated with tetrahydrofuran (thf). Small quantities of dimethyl formamide (dmf) may be included to act as a retarding agent to exten...

  • Page 37: Warning

    Www.Lochinvar.Com 37 d. Inspection, cleaning, priming visually inspect the inside of the pipe and fi tting sockets and remove all dirt, grease or moisture with a clean dry rag. If wiping fails to clean the surfaces, a chemical cleaner must be used. Check for possible damage such as splits or cracks ...

  • Page 38

    38 www.Lochinvar.Com installation checklist note: use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Vent termination horizontal 12 in. (305mm) min. Above grade/snow level. Away from corners, other vents, windows etc. Vertical exha...

  • Page 39: Operating Instructions

    Www.Lochinvar.Com 39 read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner viewport is not missing or damaged. Make sure the tank is completely fi lled with water before operating the water heater. The gas control valve/thermostat has an ...

  • Page 40: Danger

    40 www.Lochinvar.Com it is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisfi es your hot-water needs. This will also provide the most energy effi cient o...

  • Page 41

    Www.Lochinvar.Com 41 gas control valve/thermostat on/off switch temperature setting dial 155°f 70°f 130°f 140°f 150°f 120°f 110°f figure 49 temperature dial setting approximate temperature °f (°c) time to induce a 2nd and 3rd degree burn to adult skin very hot 155 (68) less than 1 second c 150 (65) ...

  • Page 42: Caution

    42 www.Lochinvar.Com start up conditions condensate whenever the water heater is fi lled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensate. This usually happens when: a. A new water heater is fi lled with c...

  • Page 43: Warning

    Www.Lochinvar.Com 43 “air” in hot-water faucets • flammable hydrogen gases may be present. • keep all ignition sources away from faucet when turning on hot water. Explosion hazard warning hydrogen gas: hydrogen gas can be produced in a hot-water system that has not been used for a long period of tim...

  • Page 44: Warning

    44 www.Lochinvar.Com general upkeep make it a habit to look around the heater, the vent piping, and the hot and cold water pipes. Do not allow any material to be piled up against the heater. Do not place any object on top of the vent pipes. Every 3 – 6 months or as necessary: clean lint from blower,...

  • Page 45

    Www.Lochinvar.Com 45 accessing the blower wheel through the outlet, use the paint brush to brush off the outer edge of the blower wheel to dislodge the dirt stuck on the blades and the inside of the housing. Rotate the wheel until all blades are clear. Note: the wheel is a balanced component. Do not...

  • Page 46: Danger

    46 www.Lochinvar.Com combustion chamber and burner cleaning in the event your burner or burner air openings require cleaning, call your service agency to remove and clean the burner and correct the problem that required the burner to be cleaned. Housekeeping • do not obstruct combustion air openings...

  • Page 47: Danger

    Www.Lochinvar.Com 47 installing anode rod: use tefl on ® tape or an approved pipe sealant on threads of the new anode rod. Place the anode rod in the spud (top of the tank) and turn clockwise until the threads are hand tight. Using a ratchet and 1-1/16” socket tighten down water tight. Open a nearby...

  • Page 48: Warning

    48 www.Lochinvar.Com temperature-pressure relief valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty. Thermal expansion tanks must be installed on all closed water systems. • temperature-pressure re...

  • Page 49: Leakage Checkpoints

    Www.Lochinvar.Com 49 service if a condition persists or you are uncertain about the operation of the water heater contact a service agency. Use this guide to check a “leaking” water heater. Many suspected “leakers” are not leaking tanks. Often the source of the water can be found and corrected. If y...

  • Page 50: Reference Parts Listing

    50 www.Lochinvar.Com reference parts listing replacement parts may be ordered through your plumber or the local distributor. When ordering replacement parts, always have the following information ready: model, serial and product number type of gas item number parts description 1. Vent termination el...

  • Page 51

    Www.Lochinvar.Com 51 32 34 36 33 38 39 37 35 40 41 natural gas and propane main burner with igniter assembly for 40k to 50k btu/hr models flare nut** * figure 59 32 34 36 33 38 39 37 35 40 41 natural gas and propane main burner with igniter assembly for 60k to 75k btu/hr models flare nut** * figure ...

  • Page 52: Troubleshooting Guidelines

    52 www.Lochinvar.Com these guidelines should be utilized by a qualifi ed service agent. Problem possible cause(s) corrective action burner flame too high air inlets blocked insuffi cient secondary air orifi ce too large 1. 2. 3. Unblock inlet air openings provide ventilation to water heater replace ...

  • Page 53

    Www.Lochinvar.Com 53 problem possible cause(s) corrective action condensation filling the new water heater for the fi rst time m o i s t u r e f r o m t h e p r o d u c t s o f combustion water dripping from blower assembly undersized water heater 1. 2. 3. 4. Normal operation: the condensation shoul...

  • Page 54

    54 www.Lochinvar.Com problem possible cause(s) corrective action blower runs continuously 1. Air pressure switch not closing due to insuffi cient draft – check for: a. Vent piping blocked b. Piping length too long c. Clogged/dirty blower 2. Disconnected, torn or blocked pressure switch hose from air...

  • Page 55

    Www.Lochinvar.Com 55 ignition state and timing ignition state timing pre-purge 5 seconds (ng models) 15 seconds (lp models) hot surface igniter (hsi) warmup 10 seconds ignition activation period (iap) 3.5 seconds maximum flame recognition period (frp) 0.5 second trial for ignition iap + frp flame st...

  • Page 56

    56 www.Lochinvar.Com this page intentionally left blank. May be used for notes or to record other installation information..

  • Page 57

    Www.Lochinvar.Com 57 this page intentionally left blank. May be used for notes or to record other installation information..

  • Page 58: Limited Warranty

    58 www.Lochinvar.Com limited warranty limited warranty residential gas limited warranty this warranty is applicable to the original owner only in accordance with the warranty terms and conditions specifi ed below. The warrantor will furnish the original owner, 1) a re- placement water heater of equi...

  • Page 59

    Www.Lochinvar.Com 59 limitation on implied warranties implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied war-...

  • Page 60

    300 maddox simpson parkway lebanon, tn 37090 phone: 615-889-8900 • fax: 615-547-1000 technical services email: 2tech@lochinvar.Com www.Lochinvar.Com copyright © 2011 lochinvar llc. All rights reserved..