Lochinvar EGS-I&S-01 Supplement

EGS-I&S-01
1
SINGLE-WALL INDIRECT
WATER HEATER
For your family’s comfort, safety, and convenience, we
recommend this water heater be installed and serviced
by a plumbing professional.
TABLE OF CONTENTS
IMPORTANT INFORMATION ..................................1
GENERAL INFORMATION .......................................3
PRE-INSTALLATION..................................................4
WATER CONNECTIONS ............................................6
ELECTRICAL CONNECTIONS ................................8
OPERATING INSTRUCTIONS ..................................8
MAINTENANCE .........................................................10
TROUBLESHOOTING GUIDE ................................12
IMPORTANT INFORMATION
Thefollowingtermsareusedthroughoutthismanualtobring
attention to the presence of hazards of various risk levels,
or to important information concerning product life.
INSTALLATION & SERVICE MANUAL
WARNING
To avoid damage or injury, there must be no
materials stored against the indirect water heater
and proper care shall be taken to avoid unnecessary
contact (especially by children) with the indirect
water heater.
•Do not store or use gasoline or other flammable
liquids in the vicinity of this water heater or any
other appliance.
The equipment must be installed in accordance with
those installation regulations required in the area
wheretheinstallationistobemade.Theseregulations
must be carefully followed in all cases. Authorities
having jurisdiction shall be consulted before
installations are made.
All wiring on water heaters installed in the USA must
be in accordance with the National Electrical Code and/
or local regulations; or in Canada, installed in
accordance with the Canadian Electrical Code and/or
local regulations.
DANGER
Indicatesan imminently hazardoussituation, which,
if not avoided, will result in death, serious injury, or
substantial property damage.
CAUTION
Indicatesa potentially hazardous situation, which, if
not avoided, could result in death, serious injury, or
substantial property damage.
NOTICE
Indicates special instructions on installation,
operation or maintenance, which are important but
not related to personal injury hazards.
WARNING
Indicatesa potentially hazardous situation, which, if
notavoided, may result in moderate,or minor injury
or property damage.
DANGER
DO NOT store or use gasoline or other flammable,
combustible,or corrosive vapors and/or liquids in the
vicinity of this or any other appliance.
IF YOU SMELL GAS:
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not
use any telephone in your building.
Immediately call your gas supplier from a
telephone in another building. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier, call
the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL
THE LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than
air and will remain at floor level if there is a leak.
Basements, crawl spaces, closets, and areas below
ground level will serve as pockets for accumulation
of leaking gas.
This water heater is supplied with an adjustable
thermostat to control water temperature. Hot water
temperaturesrequired for automaticdishwasher and
laundryuse can cause scald burns resulting inserious
personal injury and/or death. The temperature at
which injury occurs varies with the person’s age and
the time of exposure. The slower response time of
disabled persons increases the hazards to them.
NEVER allow small children to use a hot water tap
or to draw their own bath water. NEVER leave a
child or disabled person unattended in a bathtub or
shower.

EGS-I&S-01
2
WARNING
Installation is not complete unless a pressure and
temperature relief valve is installed into the side of
the water heater. See the Water Connections section
of this manual for details.
Thiswater heater contains very hotwater under high
pressure.Do not unscrew anypipe fittings or attempt
to disconnect any components of this water heater
without positively assuring the water is cool and has
no pressure. Always wear protective clothing and
equipment when installing, starting up, or servicing
this water heater to prevent scald injuries. Do not
rely on the pressure and temperature gauges to
determinethe temperature and pressure of the water
heater. This water heater contains components that
becomeveryhot.Donottouchanycomponentsunless
they are cool.
Improper installation, adjustments, alteration,
service or maintenance can cause property damage,
personal injury or loss of life. Failure to follow all
instructions in the proper order can cause personal
injuryordeath.Readandunderstandallinstructions,
including all those contained in component
manufacturer’smanuals,whichareprovidedwiththe
appliance before installing, starting-up, operating,
maintaining, or servicing this appliance. Keep this
manualand literature in legible condition and posted
neartheappliancefor reference by owner and service
technician.
This water heater requires regular maintenance and
service to operate safely. Follow the instructions
contained in this manual. Installation, maintenance,
and service must be performed only by an
experienced, skilled, and knowledgeable installer or
service agency.
NOTICE
Insulation blankets are not required for this water
heater. This water heater meets or exceeds the
ASHRAE/IES 90.1b standards with respect to
insulation and standby loss requirements.
CAUTION
The maximum boiler water supply temperature to
the indirect heat exchanger must not exceed 240°F
(116°C).
WARNING
It is the responsibility of the installing contractor to
see that all controls are correctly installed and are
operatingproperly when the installation iscomplete.
DO NOT operate the water heater with jumpered
or absent controls or safety devices.
DO NOT tamper with or alter the water heater and/
or controls.
DO NOT operate the water heater if any external
part has been under water. Immediately call a
qualified service technician to inspect the appliance
and to replace any part of the control system that
was under water.
This water heater is suitable for installation on
combustible flooring. DO NOT install this water
heater on carpeting.
DO NOT operate this water heater without first
being certain it is filled with water.
Flammable items, pressurized containers, or any
other potential fire hazardous articles must never
be placed on or adjacent to the heater. Containers of
flammable gases should not be stored or used in the
same room with this water heater.
Hydrogengascan be produced in anoperatingwater
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 that the water faucet be
openedfor several minutes atthe kitchen sink before
you use any electrical appliance that is connected to
the hot water system. If hydrogen is present, there
will be unusual sounds such as air escaping through
the pipes as hot water begins to flow. Do not smoke
or have open flame near the faucet at the time it is
open.

EGS-I&S-01
3
TEMPERATURE AND PRESSURE
RELIEF VALVE
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER — The heat exchanger (coil) has
1" NPT female fittings.
These water heaters with single-wall heat exchangers meets
the Uniform Plumbing Code for installation in all potable
water systems provided that:
•The boiler water (including additives) is
practically non-toxic, having toxicity rating of
class of 1 as listed in Clinical Toxicology of
Commercial Products.
•The boiler water pressure is limited to
maximum 30 psig by approved relief valve.
•The heat transfer medium is potable water or
contains only substances that are recognized
as safe by the U.S. Food and Drug
Administration (FDA).
•The pressure of the heat transfer medium is
maintained less than the normal minimum
operating pressure of the potable water system.
•The equipment is permanently labeled to
indicate that only additives recognized as safe
by the FDA shall be used in the heat transfer
medium.
WARNING
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.For protection
against excessive temperatures and pressure, install
temperature and pressure protective equipment required
by local codes, but not less than a combination
temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment
or materials as meeting the requirements of the Standard
for Relief Valves and Automatic Gas Shutoff Devices
for Hot Water Supply Systems, ANSI Z21.22 and
the Standard CAN1-4.4 Temperature, Pressure,
Temperature and Pressure Relief Valves and Vacuum
Relief Valves. The combination temperature and
pressure relief valve must be marked with a maximum
set pressure not to exceed the maximum working
pressure of the water heater. The combination
temperature and pressure relief valve must also have an
hourly rated temperature steam BTU discharge capacity
not less than the hourly rating of the water heater. The
supplied combination temperature and pressure relief
valve, when properly installed and unrestricted, will
discharge the maximum input produced by a 240°F
(116°C) boiler supply temperature. A lower boiler
supply temperature will reduce the input required to be
discharged in the event of excessive potable water
temperatures.
Install the combination temperature and pressure relief
valve into the opening provided and marked for this
purpose on the water heater.
Some models may already be equipped or supplied with
a temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve
complies with local codes. If the temperature and
pressure relief valve does not comply with local codes,
replace it with one that does.
NOTICE
If the boiler takes longer to heat up from a cold start
than the water availability as noted above, hot water
shortage may occur.
Hot water availability is based off drawing 80% of
the heated tank volume at 4 gallons per minute flow
rate.
The maximum heat transfer through the coil (heat
input) of the water heater at 240°F boiler water supply
temperature and 210°F potable water temperature is
94,100 Btu/hr for residential models and 180,300 Btu/
hr for commercial models. Potable water temperature
is limited to below 210 °F and nominal water-
containing capacity is below 120 gallons for all single-
wall indirect models.
Accordingly, per Part HLW-101.2, Section IV of the
ASMEBoilerandPressureVesselCode,allLochinvar
Single-wall Indirect products are exempted from
compliance with the code.

EGS-I&S-01
4
NOTE: Any claims for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee.
IMPORTANT DECISIONS REQUIRED
BEFORE INSTALLATION
SIZING
1. Boiler DOE Heating Capacity – The Single-wall
Indirect water heater will provide the rated
performance only if used in conjunction with a
boiler with a DOE heating capacity (Boiler Output)
minimum of 220,000 Btu/hr. If the boiler has less
capacity, the output of the tank will be reduced. To
determine the approximate reduction in output from
the tank use the following formula:
New Rating = (maximum first hour rating) x
Actual Boiler Output Capacity
Minimum Boiler Output Capacity
For example, what would the 140°F first hour rating be if
model EGS050 was installed with a boiler having a DOE
heating capacity of 180,000 BTU/hr?
Answer:
New Rating
= 297 gal/hr x (180,000 BTU/h)/(220,000 BTU/hr)
= 297 gal/hr x 0.818 = 243 gal/hr
2. Circulator Sizing – Refer to Table below for the
corresponding pressure drop through the coil for
the given model. Calculate the pressure drop of
all straight pipe and fittings on the supply and
return of the water heater at the selected flow
rate. Add the piping/fitting pressure drop to the
pressure drop through the water heater coil. Select
a circulator that will provide an appropriate flow
rate at the combined pressure drop.
ADJUSTABLE AQUASTAT – The temperature may
be adjusted from 80°F to 160°F. The aquastat (thermostat)
was adjusted to 120°F before the heater was shipped from
the factory. It is recommended that lower temperatures be
used to avoid the risk of scalding. Refer to the “Warnings”
and the section on SCALDING “under – Operating
Instructions.” It is further recommended, in all cases, that
the water temperature be set for the lowest temperature that
satisfies your hot water needs. This will also provide the
most energy efficient operation of the water heater and
minimizes scale formation.
Setting the water heater temperature at 120°F will reduce
the risk of scalds. Some states require settings to specific
lower temperatures.
SACRIFICIAL ANODES—Three sacrificial anode rods
have been installed in the tank head to extend tank life. The
anode rods should be inspected annually to determine the
amount of sacrificial decay and replaced when necessary to
prolong tank life. Water conditions in your area will
influence the time interval for inspection and replacement
of the anode rod. The use of a water softener may increase
the speed of anode consumption. More frequent inspection
of the anode is needed when using softened (or phosphate
treated) water. Contact the plumbing professional who
installed the water heater or the manufacturer listed on the
rating plate for anode replacement information.
PRE-INSTALLATION
INSPECT SHIPMENT carefully for any signs of damage.
If damage is noted, do not install the product. Contact the
shipper or manufacturer listed on rating plate. All equipment
is carefully manufactured, inspected, and packed. Our
responsibility ceases upon delivery of the packaged heater
to the carrier in good condition.
WARNING
Install a discharge line so that water discharged from the
temperature and pressure relief valve will exit within six
(6) inches above, or any distance below, the structural
floor and cannot contact any live electrical part. The
discharge line is to be installed to allow for complete
drainage of both the temperature and pressure relief valve
and the discharge line. The discharge opening must not
be subjected to blockage or freezing. DO NOT thread,
plug, or cap the discharge line. It is recommended that a
minimum clearance of four (4) inches be provided on
the side of the water heater for servicing and maintenance
of the combination temperature and pressure relief valve.
Do not place a valve between the combination
temperature and pressure relief valve and the tank!
NOTICE
Increasing the boiler DOE heating capacity above
220,000 Btu/hr will not increase the rating of the
water heater. Ratings are based on 180°F boiler
water.

EGS-I&S-01
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2. Non-Priority – Boiler output is divided between
space heating and domestic hot water heating.
Delivery of domestic hot water can be reduced
during simultaneous space and domestic hot water
heating operations, depending on such factors as
boiler output, boiler over-sizing, number of space
heating zones calling for heat, and the ratio of
domestic hot water load to space heating load.
COMPONENT LOCATION
Appliance Location
1. Boiler Location – Locate the Single-wall Indirect
as close to the boiler as practical.
2. Fixture Locations – For fastest delivery of hot
water, place the Single-wall Indirect close to
points of use.
SYSTEM ZONE CONTROL
The Single-wall Indirect water heater must be installed
as a zone separate from the space heating system. The
domestic hot water zone’s piping and circulator must be
sized for a minimum flow rate with all zones in use and
a maximum flow rate with only the water heater in use.
For this reason, the preferred method of zone control is
with circulators.
1. Circulators – With space heating zones using
circulators, the Single-wall Indirect should be
added as an additional zone with a circulator.
2. Zone Valves – Select a valve with a low-pressure
drop to assure adequate flow through the water
heater.
3. Hybrid – The space heating zone can be zoned
using zone valves and the Single-wall Indirect
zoned with a circulator.
DOMESTIC HOT WATER PRIORITY
Two options are available, Priority and Non-Priority.
1. Priority – Demand for space heating is
interrupted or postponed until the domestic hot
water demand is satisfied. This option provides
maximumdelivery of domestic hot water. Priority
is recommended when:
a) Boiler net output is 100,000 Btu per hour or
less, or
b) When boiler output required to satisfy
domestic hot water demand is at least 50%
of the boiler output required to satisfy space
heating demand, or
c) When an interruption in space heating can
be tolerated during a long domestic hot
water draw.
CAUTION
This water heater must be located in an area where
leakage of the tank, water line connections, or the
temperature and pressure relief valve will not result
in damage to the area adjacent to the water heater or
to lower floors of the structure. When such locations
cannot be avoided, a suitable drain pan must be
installedunderthewaterheater. Thedrainpandepth
must be suitable for draining and collecting water,
andhave a minimum lengthand width of at leastfour
(4) inches measured from the jacket of the water
heater. The drain pan, as described above, can be
purchased from your plumbing professional. The
drain pan must be piped to an adequate drain. The
piping must be at least ¾”in diameter and pitched
for proper drainage.
CAUTION
Donotdrop water heater. Do notbumpwater heater
jacket against floor.
Clearance from Combustible Materials
Top Sides Front Rear
0" 0" 0" 0"
Table 2 – Combustible Material Clearances
Recommended Service Clearances
Non-Piping Front Rear T & P Relief
Side (Aquastat) Valve Side
4" 16" 0" 4"
Table 3 – Service Clearances
Table 1: Water Heater Performance
EGS030 5.5 14.2 1.3
EGS040 7.5 14.2 1.3
EGS050 9.0 14.2 1.3
EGS065 11.0 14.2 1.3
EGS080 13.5 14.2 1.3
EGS120 20.8 14.2 1.3
Model Hot Water
Availability
(Minutes)
Coil Heat
Transfer
Area (Sq Ft)
Pressure Drop
at 12 GPM
(Feet of Head)

EGS-I&S-01
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INSTRUCTIONS FOR
POTABLE CONNECTIONS
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. After the pressure has been relieved, close
the faucet. The COLD water inlet and HOT water
outlet are identified on the top of the water heater.
Make the proper plumbing connections between the
water heater and the plumbing system to the house.
Install a shut-off valve in the cold water supply line.
2. If this water heater is installed in a closed water
supply system, such as one having a back-flow
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
expansions such as pressure bulges and/or
deformities. A properly sized expansion tank will
alleviate most problems. 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 steady streams of water flow through the
faucets, close them and check all water connections
for possible leaks.
Additional Recommended
Components
1. Shut-off Valves – Allows isolation of water heater
from domestic water system and/or boiler system
during service.
2. Unions – Allows water heater movement during
service if adequate clearance cannot be provided.
3. Thermal Expansion Tank – If the water heater is
installed in a closed water supply system, such as one
having a back-flow preventer in the cold water line,
provide thermal expansion control. Contact the water
supplier or local plumbing inspector for additional
information
MOVE THE WATER HEATER TO A PERMANENT
POSITION BY SLIDING OR WALKING.
WATER CONNECTIONS
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.
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. HYDROGEN GAS
IS EXTREMELY FLAMMABLE. To prevent the
possibility of injury under these conditions, we
recommendthehotwaterfaucetbeopenedfor several
minutes at the kitchen sink before you use any
electrical appliance that is connected to the hot water
system.Ifhydrogenispresent,there will be an unusual
sound such as air escaping through the pipes as hot
waterbeginstoflow. Donotsmokeorhave open flame
near the faucet at the time it is open.
Keep clear of the 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.
WARNING
Do not plug the inlet and outlet tappings
of tankless heater left installed in the boiler.
WARNING
Temperature and pressure relief valve discharge
piping must be piped near the floor to eliminate
potential of severe burns. Do not pipe in any area
where freezing could occur. Do not install any shut-
off valves, plugs or caps to the temperature and
pressure relief valve or piping.
CAUTION
If sweat fittings are to be used, DO NOT apply
heat to the nipples on top of the water heater.
Sweat the tubing to the adapter before fitting
the adapter to the water connections. It is
imperativethat heat is notappliedto the nipples
containing a plastic liner.

EGS-I&S-01
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4. NEVER OPERATE THE WATER HEATER
WITHOUT FIRST BEING CERTAIN THAT IT
IS FILLED WITH WATER.
INSTRUCTIONS FOR
BOILER CONNECTIONS
The Single-wall Indirect connection labeled “To Boiler
Return” should be piped to the boiler return piping as close
to the boiler as possible and especially after any flow control
or check valves in the space heating return piping. The use
of a union and a shut-off valve is recommended. The use of
a flow control or check valve is required to prevent back
flow through the water heater during operation of the space
heating system. Pipe and fittings between the boiler and
Single-wall Indirect should be ¾” diameter or larger.
CONNECT WATER BOILER
SUPPLY PIPING
1. For a space heating system that utilizes
ZONE VALVES, refer to Figure 1. The Single-
wall Indirect connection labeled “FROM BOILER
SUPPLY”should be piped to the boiler supply
piping. Mount the circulator making sure the flow
arrow points toward the water heater. The use of
Shut-off valves and unions are recommended for
future service convenience. The use of an air
separator and vent is recommended to eliminate air
in the system. Pipe and fittings between the boiler
and Single-wall Indirect must be ¾” diameter or
larger.
CAUTION
Maximum boiler water supply temperature to the
indirect heat exchanger must not exceed 240°F
(116°C).
Figure 1 - Water Boiler Piping with Zone Valves
Figure 2 - Water Boiler Piping with Circulators
2. For a space heating system that utilizes CIRCULATORS,
refer to Figure 2. The Single-wall Indirect connection
labeled “FROM BOILER SUPPLY” should be piped to
the boiler supply piping. Mount the circulator making
sure the flow arrow points toward the water heater. The
use of shut-off valves and unions are recommended for
future service convenience. The use of an air separator
and vent is recommended to eliminate air in the system.
Pipe and fittings between the boiler and Single-wall
Indirect must be ¾” diameter or larger.
CONNECT STEAM BOILER
SUPPLY PIPING
Figure 3 represents a typical steam boiler connection
diagram. Refer to the boiler installation manual or contact
the boiler manufacturer for an appropriate piping diagram.
The use of a union, shut-off valves, and a drain valve is
recommended for future service convenience. The use of
an in-line “Y”-style strainer is required to prevent
accumulation of sludge in the water heater’s coil.
Figure 3 – Typical Steam Boiler Connections
(connections available below the water line)

EGS-I&S-01
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FILL BOILER SYSTEM
1. On new boiler installations, do not purge the boiler
or space heating system through the water heater.
During any boiler or space heating system flushing,
cleaning, or purging, the water heater should be
isolated to avoid possible attack on the carbon steel
coil by chemical additives.
2. Purge air from boiler/water heater piping.
3. Check system for leaks. Repair as necessary.
ELECTRICAL CONNECTIONS
Install electric wiring in accordance with National Electric
Code or the Canadian Electrical Code and local regulations.
See the boiler’s installation manual for wiring diagrams.
The Single-wall Indirect is supplied with an aquastat
temperature control. This aquastat must be installed in the
aquastat well location of the water heater. Refer to Figure
4. Remove the cover and loosen the clamping screws. Insert
DANGER
Positively assure all electrical connections are
unpowered before attempting installation or service
of electrical components or connections of the water
heateror building. Lock out all electrical boxes with
padlock once power is turned off.
WARNING
Wheninstalled,the water heater must be electrically
grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical
Code, ANSI/NFPA 70, and /or the CSA C22.1
Electric Code.
Failureto properly wire electrical connectionsto the
water heater may result in serious physical harm.
Electricalpower may be from morethan one source.
Make sure all power is off before attempting any
electrical work.
Figure 4 - Aquastat Control
the aquastat capillary bulb to the well bottom as shown and
screw the aquastat clamp securely in the well groove. The
aquastat acts as a thermostat for zone control and should be
wired accordingly. Refer to the boiler or zone control
manufacturer’s instructions if any additional wiring is
required. The control is factory set at 120°F and care should
be made to not rotate this dial while wiring the control. Once
electrical connections are complete, secure the aquastat
cover back in place. AT NO TIME SHOULD WATER
HEATER OPERATION TAKE PLACE WITHOUT
THE COVER ON THE CONTROL.
OPERATING INSTRUCTIONS
SYSTEM START-UP
Follow boiler installation instructions to place boiler in
operation.
SEQUENCE OF OPERATIONS
1. Aquastat senses stored water temperature drops below
desired setting.
a. Domestic hot water priority only: Normally
closed contacts open to interrupt space heating.
NOTICE
Typicalsteamboiler without connections available
below the water line is not recommended due to
insufficient water temperature, especially during
warmer months when the space heating system is
not operational. Boiler water temperature at the
bottom of a steam boiler can be 50°F lower than
theboiler’s water temperature limit settingduring
such periods.
WARNING
Water heaters are heat-producing appliances. To avoid
damage or injury there must be no materials stored against
the water heater, and proper care must be taken to avoid
unnecessary contact (especially by children) with the
water heater. UNDER NO CIRCUMSTANCES SHALL
FLAMMABLE MATERIALS, SUCH AS GASOLINE
OR PAINT THINNER BE USED OR STORED IN THE
VICINITY OF THE WATER HEATER OR IN ANY
LOCATION FROM WHICH FUMES COULD REACH
THE WATER HEATER.
Installation or service of this water heater requires
ability equivalent to that of a licensed tradesman in
the field involved. Plumbing and electrical work are
required.

EGS-I&S-01
9
WARNING
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.
Bysetting the aquastaton this waterheater to obtain
an increased water temperature, you may create the
potential for scald injury. To protect against injury,
you should install an ASSE approved mixing valve
(a device to limit the temperature of water to protect
against scald injury via mixing hot and cold water
supply) in the water system. This valve will reduce
point of discharge temperature in branch supply
lines. Such valves are available from the
manufacturerofthiswaterheateroralocalplumbing
supplier.Pleaseconsultwithaplumbingprofessional.
2. Aquastat satisfied.
a. Aquastat contacts open, turning off domestic hot
water circulator and de-energizing relay.
b. Normally open contacts open, stopping boiler
operation.
c. Domestic hot water priority only: Normally
closed contacts close, returning boiler control
to space heating.
WATER TEMPERATURE ADJUSTMENT
1. The aquastat controls the maximum water temperature
in the tank. The differential is a fixed 5°F with a 160°F
maximum setting, set at the factory to 120°F.
Table 4 details the approximate 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.
2. For the most energy efficient operation, adjust the
aquastat for the minimum water temperature necessary
to meet domestic hot water needs. Refer to Figure 6.
Use a small flat screwdriver to rotate the temperature
dial through the hole directly below the temperature
indication window. The temperature setting is aligned
with the notch in this window. IT IS NOT
NECESSARY TO REMOVE THE COVER TO
ADJUSTTHE TEMPERATURE SETTING. THE
AQUASTAT COVER SHOULD NEVER BE
REMOVED WITHOUT ELECTRICITY BEING
FIRST DISCONNECTED.
APPROXIMATE
TIME/TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F More than 5 minutes
125°F 1 ½ 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 ½ seconds
155°F About 1 second
Table 4 – Scald Relationships
Figure 5 - Scald Warning
Figure 6 - Aquastat Control

EGS-I&S-01
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CAUTION
Beforemanually operating thevalve, make sure
that a drain line has been attached to the valve
todirect thedischargeto anopendrain. Failure
totake this precaution could mean contact with
extremelyhot water discharging from the valve
during this checking operation.
3. After the water heater completes a heat-up cycle, check
the water temperature at a faucet. Allow enough water
to flow to ensure that the water temperature reflects
the tank temperature. Adjust the water heater’s
temperature setting as necessary.
a. Adjusting to a lower temperature setting will not
immediately affect water temperature. Draw
sufficient water or allow the water heater to sit
until a heat-up cycle is initiated. Repeat step 3.
b. Adjusting to a higher temperature may not
immediately affect water temperature. If a heat-
up cycle begins, return to step 3. If a heat-up
cycle does not begin, draw sufficient water or
allow the water heater to sit until a heat-up cycle
is initiated. Repeat step 3.
MAINTENANCE
The Single-wall Indirect is intended to provide a service
life of many years. Components that require service,
however, may be subject to failure. Failure to use the correct
procedures or parts in these circumstances may make the
water heater unsafe.
The owner should arrange to have the following inspections
and simple maintenance procedure performed by qualified
service personnel at the frequencies suggested.
1. Boiler and Domestic Water Piping (Annual) – Check
all piping for signs of leakage at joints, unions, and
shut-off valves. Repair as needed.
2. Temperature-Pressure Relief Valve (Annual)- The
temperature-pressure relief valve should be checked
to ensure that it is in operating condition. To check
the relief valve, lift the lever at the end of the valve
several times. The valve should seat properly and
operate freely. If water does not flow, remove and
inspect for obstructions or corrosion. Replace with a
new valve of the recommended size as necessary. Do
not attempt to repair the valve, as this could result in
improper operation and a tank explosion. In areas with
poor water conditions, it may be necessary to inspect
the temperature-relief valve more often than once a
year.
If the temperature–pressure relief valve on the heater
discharges periodically or continuously, it may be due to
thermal expansion of water in a closed water supply system,
or it may be due to a faulty relief valve. Thermal expansion
is the normal response of water when it is heated. In a closed
system, thermal expansion will cause the system pressure
to build until the relief valve actuation pressure is equaled.
Then the relief valve will open, allowing some water to
escape, slightly lowering the pressure. Contact your water
supplier or local plumbing inspector on how to control this
situation.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE
AND PRESSURE RELIEF VALVE. THIS IS NOT A
SOLUTION AND CAN CREATE A HAZARDOUS
SITUATION.
3. Anode Inspection and Replacement - This water
heater is equipped with multiple sacrificial anodes.
Anodes protect the glass-lined tank from corrosion
by sacrificing themselves through electrolysis. When
the anode material is consumed, there is no more
protection and corrosion of the tank accelerates.
Inspection of the anode every year allows you to
identify a spent anode and replace. Replace the anode
when its diameter is 3/8 of an inch, or every other
year, which ever is first. Aggressive, very hot and
softened water causes rapid consumption of the
anode, requiring frequent inspections. Anodes are
available from your distributor or from the
manufacturer listed on the rating plate.
To inspect or replace an anode:
The anodes on this water heater are easily accessible
from the top of the heater making replacement simple
and quick.
a. Turn the water heater electricity off for the
zone containing the Single-wall Indirect.
Flow water until the discharge is cool or
allow enough time for the potable water to
cool naturally. Connect a hose to the drain
valve. Locate the hose’s discharge in an area
where any remaining hot water will not
cause any damage or injury.

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11
b. Open the drain valve to flush any sediment
out of the bottom to the heater.
c. Shut off the cold water supply. Make sure
all hot water fixtures and circulating pumps
are turned off.
d. Wait for water flow from the hose to stop.
Remove the anode using a socket of the
appropriate size. Do not use an impact
wrench.
e. Inspect and replace the anode as required.
Use pipe tape or sealant when reinstalling
the anode.
f. Close the drain valve. Open a hot water
fixture to allow air to escape. Open the cold
water supply to the heater and allow the tank
to fill.
g. Check your anode and drain valve for leaks.
h. Turn the water heater electricity on for the
zone containing the Single-wall Indirect.
4. Sediment (Annual, but harsh water quality may
dictate morefrequent service)- Depending on water
conditions, a varying amount of sediment may
collect in the tank. Levels requiring service are
indicated by a small temperature difference in the
supply and return lines (See also “Scale” below).
Repeated flushing usually clears such material. As
a preventive measure, water should be drawn from
the tank at the drain valve until it runs clear.
5. Scale (Annual)- Hard water may cause scale to
build-up on the outside of the heat exchanger coil.
A water softener will prevent this problem (See also
“Sediment” above). Symptoms would be reduced
recovery capacity or reduced temperature
differential between boiler supply and return lines.
Repeated flushing should resolve the problem.

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TROUBLE SHOOTING GUIDE
PROBLEM CAUSE SOLUTION
Boiler does not operate Refer to boiler installation instructions
Check main service switch
Check fused disconnect
Circulator does not operate Check power supply
Replace as necessary
Improper aquastat setting calibration Turn tank aquastat to appropriate or setting
Zone valve does not open (if used) Check power supply
Replace as necessary
Electrical problem (relay, wiring, etc.) Check fuse and replace
Check circuit breaker andreset (if applicable)
Check power supply
Scale build-up If boiler, circulator, and tank are operating
satisfactorily, coil may have scale coating.
See Maintenance
Clogged cold water filter or Clean or replace filter or strainer
boiler supply strainer (if used)
Aquastat set too high Lower aquastat setting. See Operating Instructions
Improper system plumbing Compare to plumbing in Water Connections
Improper system wiring Compare to wiring in Electrical Connections
Aquastat setting too low Adjust aquastat to higher setting.
See Operating Instruction
Undersized boiler with no Rewire for priority
priority to domestic hot water
Peak use of hot water is greater Determine peak usage and compare to tank capacity
than tank storage capacity
Faulty tank aquastat Replace aquastat
Excessive demand Reduce demand or consider larger tank
Faulty aquastat Replace aquastat
Boiler high limit set too low Increase boiler high limit setting
No hot water
at faucet
Water at
faucet too
hot
Insufficient
hot water
Boiler cycles
more per day
in summer
2/06-Printed in USA