The EcoForce++™ Range

1.0 Display Codes

The Lochinvar EcoForce++ features a three-digit LED display on the front panel for setting desired water temperature and aiding diagnosis for firing issues.

1.1 Double Numbers

Displaying two numbers (e.g., 60) indicates normal operation, showing the setpoint. A illuminated green LED signifies the burner is active.

1.2 Diagnostic Codes

Permanently displayed codes indicate the water heater is waiting for a specific condition. Table 1.1 lists diagnostic codes, faults, and solutions.

1.3 Error Codes

Flashing codes on the LED display indicate a lockout requiring a reset via the control panel button. Table 1.2 lists error codes, causes, and solutions.

2.0 Introduction

The Lochinvar EcoForce++™ range comprises floor-standing direct gas-fired condensing water heaters. Each unit features a stainless steel radial burner assembly and heat exchanger for fully condensing operation, a stainless steel storage vessel, a bronze circulating pump, and interconnecting pipework.

The burner ignition sequence is fully electronic, incorporating spark ignition and flame rectification for flame supervision. The water heater's output is regulated by a variable speed combustion fan and gas/air ratio controls, allowing modulation down to 25% of rated output. An integral pump maintains constant water flow through the heat exchanger.

This equipment is designed for use with Group H Natural Gas (2nd Family) and LPG propane (3rd Family). Refer to Section 13 for propane firing details. The appliance must only be used with the gas for which it is designed and adjusted.

Installation must be performed by a competent person registered with an H.S.E. approved body, adhering to relevant Gas Safety and Building Regulations, and Health & Safety requirements. Failure to comply may result in prosecution.

For unvented (pressurised) systems, ensure all extra safety requirements for high or low-pressure conditions are met. The equipment is designed for direct connection to a flue system.

Ancillary Options:

• Unvented/Boosted Water System Kit (WH17)
• Condensate Neutralisation Kit (KIT2000)
• De-stratification Pump Kit (WH9)
• RCW Controller (E04-016-354)
• Flue System Components (Contact Lochinvar Limited)

2.1 Principal Parts

Figure 2.1 illustrates the principal parts of the water heater. Table 2.1 lists these components:

3.0 Technical Data

Table 3.1 provides detailed technical specifications for the EcoForce++ range.

*For Un-Vented systems only, Vented systems 8 bar.

Dimensions

Figure 3.1 shows dimensions for the EF+35/150+ model. Figure 3.2 shows dimensions for the EF+35/230+ and EF+55/230+ models. Dimensions marked (R) indicate recommended clearances for pipework and flue connections during installation.

4.0 General Requirements

The Lochinvar EcoForce++ condensing water heater is designed for reliable, long-term operation. Follow these instructions for optimal usage and efficiency. Read all instructions thoroughly before installation or use.

4.1 Related Documents

Installation must comply with The Gas Safety (Installation and Use) Regulations 1998, Building Regulations, I.E.E. Regulations, local water undertaking bylaws, and local gas distributor requirements. The following documents provide essential guidance:

• BS 5440-1: 2008: Installation and maintenance of flues and ventilation for gas appliances (up to 70kW net).
• BS 5440-2: 2009: Installation and maintenance of ventilation for gas appliances (up to 70kW net).
• BS 6644: 2005 + A1: 2008: Installation of gas-fired hot water boilers (70kW net to 1.8MW net).
• BS 6700: 1997: Design, installation, testing and maintenance of domestic water services.
• BS 6880: 1988 (Parts 1, 2, 3): Code of practice for low temperature hot water systems (>45kW).
• BS 7074: 1989 (Parts 1 & 2): Expansion vessels and ancillary equipment for sealed systems.
• BS 7671: 2008: Requirements for electrical installations (I.E.E. wiring regulations).
• CP 342: Part 2 1974: Code of practice for centralised hot water supply.
• IGE/UP/1: Edition 2: Installation pipework on industrial and commercial premises.
• IGE/UP/2: Edition 2: Gas installation pipework, boosters and compressors.
• IGE/UP/4: Edition 2: Commissioning of gas-fired plant.
• IGE/UP/10: Edition 3: Installation of flued gas appliances.
• Gas Safety (Installation and Use) Regulations 1998 (England, Scotland & Wales).
• CIBSE: Guide parts A, B and C.
• H.S.E. guidance: Automatically controlled steam and hot water boilers.
• Third edition of the 1956 Clean Air Act Memorandum on Chimney Heights.

Manufacturer's notes do not override statutory obligations.

5.0 Water Quality

Water supply quality impacts heater efficiency. Water hardness should not exceed 205ppm CaCO3, and TDS should not exceed 350ppm. Contact Lochinvar Limited if these limits are exceeded.

6.0 Location

6.1 Plant Room Requirements

The EcoForce++ must be installed in a room with appropriate ventilation. For Type C appliances (room-sealed), combustion air is ducted from outside, so no additional ventilation is needed for combustion. However, if installed in a compartment or hot environment, cooling ventilation is required (refer to Section 9). For Type B appliances, ventilation for both cooling and combustion is necessary (refer to Section 9).

6.2 General Requirements

Avoid storing corrosive chemicals (aerosols, solvents, refrigerants, cleaning agents) near the appliance or air intake to prevent heat exchanger corrosion and poor combustion. This practice invalidates the warranty.

The appliance must be installed on a level surface capable of supporting its weight. Ensure that combustible materials near the appliance or flue do not exceed 65°C; use insulation if necessary. Position the appliance to prevent water damage from leaks; use a drain pan if unavoidable, ensuring it is adequately drained and does not obstruct airflow.

6.3 Clearances

The chosen location must accommodate the flue system and air supply. Adequate space for servicing and air circulation is essential. Refer to Figures 3.1 and 3.2 for dimensions and clearances, and BS5440 or BS6644 for further details.

6.4 Condensate Drain

The condensate drain has a ¾" flexible hose. Connect it to a suitable drain, ensuring a continuous downward slope of at least 3° (50mm per metre). The Water Resources Act requires trade effluent discharge between pH 6.5 and 10.0. A condensate neutralisation kit is available from Lochinvar Limited if this pH cannot be achieved.

7.0 Gas Supply

The Lochinvar EcoForce++ is suitable for Natural Gas (G20 - 20mbar) and LPG propane (G31 - 37mbar). Details for Natural Gas are provided; refer to Section 13 for LPG.

7.1 Service Pipes

Consult the local gas distributor regarding gas supply availability. Do not use an existing service pipe without prior consultation.

7.2 Meters

The gas distributor will install a new meter. Existing meters should be checked for adequacy.

7.3 Gas Supply Pipes

Install supply pipes per IGE/UP/2. Pipework must be adequately sized. Purge and test the installation per IGE/UP/1. Refer to Section 13 for LPG pipework guidance.

7.4 Boosted Supplies

If a gas pressure booster is used, it must include a low-pressure cut-off switch at the booster inlet. Consult the local gas distributor.

7.5 Plant-Room Control Valve

A clearly identified, accessible manual valve for plant-room isolation must be fitted in the gas supply line.

7.6 Equipment Gas System Leak Check

Install an approved gas inlet appliance isolating valve and union. Ensure the valve is OFF. While the equipment is leak-tested at the factory, transit and installation can disturb fittings. A further tightness test is required during commissioning. Avoid leak detection fluid near electrical parts.

8.0 Flue System

Figure 8.1 shows flue terminal positions with minimum distances detailed in Table 8.1.

8.1 Flue System General Requirements

Refer to BS5440-1, BS6644, and IGE/UP/10 for detailed flue system recommendations.

8.2 Approved Flue System

The approved flue system is for internal use only. For external routes, consult a flue system manufacturer. The heater connects to a concentric flue system; a conversion kit is needed for conventional flue. For Type C (Balanced Flued) appliances, use the purpose-designed adaptive concentric flue system. For Type B (Conventional Flued) appliances, use Stainless Steel or Polypropylene flue pipe rated above 120°C. Aluminium flue pipe must not be used.

8.3 Installation Precautions

The approved flue system is rated to 120°C. The heater must not operate without a complete flue system installed. If discharging at low level, use a flue guard. Avoid long external flue runs to prevent condensate freezing. Ensure flue system sealing rings are correctly seated. Use a twisting action for joints; only water lubrication is permitted.

8.4 Maximum Length – Concentric Flue

Maximum flue length is determined by component resistance, not exceeding 200Pa. Table 8.2 lists component resistances. Table 8.3 provides a worked example for EF+35/230+.

8.5 Maximum Length – Conventional Flue

Maximum flue length must not exceed 150Pa. Table 8.4 lists component resistances. Table 8.5 provides a worked example for EF+55/230+.

8.6 Flue Discharge

The flue system must ensure safe operation, protect combustion from wind, and disperse combustion products. A plume may form under certain conditions; site the terminal accordingly. The terminal must be in a freely exposed position, preventing combustion products from entering the building.

8.7 Flue Terminal Installation

8.7.1 Type B23 (Conventional Flue)

Conversion details are in the kit. Install per flue manufacturer's instructions.

8.7.2 Type C13 (Horizontal Balanced Flue)

Install the flue terminal considering minimum distances (Figure 8.1, Table 8.1, British Standards). Drill a hole no more than 10mm larger than the air supply pipe. Cut the terminal to length, ensuring the wall plate is flush. Remove burrs. Insert the terminal level or with a fall to the outside (max 10mm/metre). Ensure the air intake is at the bottom. Seal the void with water-resistant sealant. Fit wall plates. Install the rest of the flue system progressively.

8.7.3 Type C33 (Vertical Balanced Flue)

Confirm roof flashing suitability. Determine terminal location using minimum distances. Drill hole carefully from outside, ensuring verticality. Install roof flashing. Insert terminal through flashing, ensuring it is vertical. Fit support bracket. Install remaining flue system. Tighten terminal clamp.

8.8 Flue Terminal Guarding

If a horizontal flue terminal is less than 2 metres from ground level or accessible from a window/door/balcony, a terminal guard is required. Position it centrally and secure it.

8.9 Condensate Drain

For flue runs under 6 metres with a minimum 3° rise, no additional drain is needed. For runs over 6 metres, an inline condensate drain and trap are recommended, connected per Section 6.4.

9.0 Air Supply

Information is for single water heater installations. For multiple units, consult BS5440-2 or BS6644.

9.1 Combustion Ventilation

For Type C appliances, combustion air is ducted from outside. For Type B appliances, Table 9.1 details combustion ventilation requirements for room or direct-to-outside air supply.

9.2 Cooling Ventilation

For Type C appliances installed in compartments, Table 9.2 specifies cooling ventilation requirements. For Type B appliances, cooling ventilation is included in the combustion ventilation allowance.

10.0 Water Connections

10.1 Installation Schematic Drawings

Figures 10.1 and 10.2 show schematic drawings for 1x and 2x EcoForce++ Open Vented Supply systems. Figures 10.3 and 10.4 show schematic drawings for 1x and 2x EcoForce++ Unvented Supply systems, detailing components like pressure reducing valves, non-return valves, expansion vessels, and relief valves.

These are examples; Lochinvar Limited can provide suitable schematics for different applications. Fit isolation valves to cold-water inlet and hot water draw-off connections for maintenance. The appliance has 1 ½" B.S.P. water connections.

10.2 Open Vented System Arrangement

An open vented system requires a vent pipe per CP 342, BS6644, or BS6700, with a minimum static head of 0.2 bar. Refer to Figures 10.1 and 10.2.

10.3 Unvented System Arrangement

Note: Unvented hot water systems must be installed by an approved installer. Follow BS6700 and Building Regulations (Part G3 in England/Wales, P5 in N. Ireland, P3 in Scotland). Unvented operation kits are available from Lochinvar Limited.

10.3.1 Expansion Vessel Sizing

Use the formula VV = SV * e / 0.45, based on an inlet pressure of 3.5 bar. Table 10.1 provides coefficients of expansion for water at different temperatures.

10.4 De-Stratification

A de-stratification pump is recommended for systems without a circulated building return to ensure even temperature distribution. Kits are available from Lochinvar Limited.

10.5 Integral Pump

The unit has an integral pump set to its highest setting; do not adjust it. If water flow drops and the temperature differential is too high, the heater will shut down. If this occurs four times, it will lock out, limiting output to 50% upon reset to protect the heat exchanger. Contact Lochinvar Limited for assistance.

11.0 Electrical Supply

External wiring must comply with I.E.E. Regulations and local regulations. Table 11.1 lists electrical supply requirements.

Warning: This appliance must be earthed. Ensure wiring is checked by a competent person. A 230V AC, single phase, 50 Hz supply is required. An isolator with at least 3mm contact separation in all poles, serving only this equipment, must be fitted close to the appliance. The double pole switch must be readily accessible.

11.1 Connector Strip

Figure 11.1 shows the connector strip. Table 11.2 details pin connections and notes:

11.2 Fuses

The EcoForce++ has four internal fuses; three auto-resetting and one 3.15A fuse on the main control board.

11.3 Arc Welding Precautions

Isolate the appliance from the mains supply during arc welding on connecting pipework.

11.4 Ancillary Equipment

11.4.1 RCW Controller

Install the RCW controller per its guide. Connect using screened two-core cable. For correct operation, modify wiring as follows: Isolate supply, remove front and PCB covers, disconnect yellow wires from pins 5&6, connect plug to blue socket on PCB, fit bridging plug (Figure 11.3) to transition socket, refit covers.

11.5 Wiring Diagrams

Figures 11.4 and 11.5 show standard and RCW mode wiring diagrams, including component labels (K0-K19) and their corresponding wire colours.

12.0 Commissioning and Testing

12.1 Electrical Installation

Refer to Section 11 for electrical installation requirements and Figures 11.4/11.5 for control circuit schematics.

12.2 Gas Installation

Refer to Section 7 for Gas Supply and Figures 3.1/3.2 for gas connection positions.

12.3 Water Connections

Refer to Section 10 for Water Connections. Flush the system with cold water, ensuring all valves are open. If a return pump is fitted, install it before filling and clearing airlocks. Check for leaks and expansion vessel pressure (if unvented).

12.4 Commissioning the Equipment

12.4.1 General Checks Prior to Lighting

Commissioning must be done by a competent person aware of the procedure. Perform these checks:

1. Ensure flueway passages are clear.
2. Verify adequate plant room ventilation (if required).
3. Confirm the system is fully charged with water, all valves are open, and the building return pump (if fitted) is circulating.
4. Check gas supply pipework is clear, tested, and purged.
5. Ensure the condensate drain is correctly installed and the condensate trap is filled. Note: An unfilled condensate trap can lead to severe injury or death from combustion products.

12.4.2 Equipment Checks Prior to Lighting

The unit is designed for a 20 mbar natural gas inlet pressure. For propane, see Section 13. Checks include:

1. Gas supply connected but OFF. Unions tightened, test points closed, ignition electrode lead connected and ceramic sheath intact.
2. Electricity supply connected.
3. Integral circulating pump is fully bled.

12.4.3 Procedure for Initial Lighting

Note: For LPG, refer to Section 13.2 first.

1. Ensure the gas inlet appliance isolating valve is OFF.
2. Press the power rocker switch to turn the equipment ON.
3. Depress the recessed button below the computer interface port to enter service mode.
4. The combustion fan will purge the chamber, then reduce speed for ignition. A spark should be visible. With the gas valve closed, a flame failure condition will occur after four attempts.
5. If correct, open the gas inlet appliance isolating valve, reset the unit, and place it back in service mode.
6. The fan will purge again and attempt ignition. The green 'Burner On' lamp illuminates when a flame is established.
7. Depress the service mode button again to shut down. Verify the main flame has extinguished.

12.4.4 Gas Pressure Adjustment and Combustion Checks

Use a CO2 measuring device for optimal setting. Figure 12.1/13.1 shows the gas valve.

1. Enter 'Service Mode' via the switch below the communication interface port.
2. Turn the set point dial fully clockwise for maximum fan speed.
3. Adjust screw 2 for 8.8% CO2 (± 0.3%). Clockwise reduces CO2; anti-clockwise increases it.
4. Turn the set point dial fully anti-clockwise for minimum fan speed.
5. Adjust screw 1 for 8.5% CO2 (± 0.3%). Clockwise increases CO2; anti-clockwise reduces it.
6. Turn the set point dial fully clockwise and re-check high fire combustion. Adjust as needed.
7. Depress the service switch to return to normal operating mode.
8. Record combustion data.

Propane combustion figures are in Section 13.

12.5 Temperature Adjustment Procedure

Set point should ensure water is stored at 60°C and distributed at 50°C within one minute at all outlets. Avoid higher temperatures due to scalding risk, especially for children and those with sensory/mobility issues. Consider thermostatic mixing valves for baths/showers if a significant scalding risk exists.

12.6 Installation Noise

Proper installation should result in no discernible noise. The pump motor may produce sound requiring acoustic insulation, but ensure ventilation/airflow is not impeded.

13.0 LPG Fuel

Note: For LPG installations, fit gas detection equipment at low level near the appliance. Ensure the housing space has adequate high and low-level ventilation. Do not locate the appliance below ground (e.g., in a cellar).

13.1 Related Documents

In addition to Section 4.1 documents, comply with BS 5482-1: 2005 for domestic butane and propane gas burning installations.

EcoForce++ operation on LPG is similar to Natural Gas. Follow the main installer's guide details.

13.2 Conversion and Commissioning Procedure

Follow this sequence for initial switch-on to avoid non-warrantable damage. Conversion requires gas valve adjustment (see Figure 13.1).

1. Ensure gas inlet isolating valve is OFF.
2. Turn the power rocker switch ON.
3. Enter service mode via the recessed button.
4. Fan purges, then attempts ignition. Flame failure occurs after four attempts if the gas valve is closed.
5. Isolate electrical supply. Turn screw 2 clockwise until it stops, then two full turns anti-clockwise.
6. Turn main power ON, press reset, and enter service mode.
7. If no fire after three attempts, turn screw 2 a further half turn anti-clockwise.
8. Turn set point dial fully clockwise for maximum fan speed.
9. Adjust screw 2 for 9.8% CO2 (± 0.3%).
10. Turn set point dial fully anti-clockwise for minimum fan speed.
11. Adjust screw 1 for 9.5% CO2 (± 0.3%).
12. Turn set point dial fully clockwise and re-check high fire combustion. Adjust as needed.
13. Depress the service switch to return to normal mode.
14. Record combustion data. Mark dust cap with an anti-tamper indicator.

14.0 Maintenance

14.1 General

Keep the appliance area clear of combustibles, vapours, and liquids. A competent person should check the flue, support, terminal, ventilation, safety valve, drain, and pressure gauge annually. Servicing is recommended every 12 months for trouble-free operation. Controls and safety features require annual checks.

Flue gas CO2 and temperature measurements indicate burner and flue condition. Compare results with previous measurements.

14.2 Maintenance Schedule

Water impurities (soil, sand, scale) can form sediment. Scale accumulation reduces efficiency and lifespan. Water softening reduces hardness but may not remove all scale. Regular de-scaling is recommended.

14.3 Burner Inspection

Use the sight glass to inspect the flame picture at high and low fire. Note: The area may be hot.

1. Enter service mode.
2. Heater should shut down and relight.
3. Turn temperature adjustment fully clockwise for maximum rate. Check flame.
4. Turn temperature adjustment fully counter-clockwise for minimum rate. Check flame.
5. Press service button to exit service mode.

14.4 Burner Removal

If the flame picture is unacceptable, remove and clean the burner:

1. Isolate electrical and gas supplies. Allow to cool.
2. Disconnect ignition electrode wiring.
3. Disconnect power, control leads, and earth wire from the combustion fan.
4. Apply release oil to the 6 studs around the burner door edge.
5. Remove the 6 retaining nuts.
6. Withdraw the heat exchanger front plate and burner assembly.
7. Clean the burner with a vacuum cleaner brush attachment.

Reassembly is the reverse. Ensure gaskets (front plate, fan connection, burner door insulation, rear wall insulation) are in good condition or replaced. Note: Pay special attention to the combustion chamber rear wall insulation; replace if deteriorated.

14.5 Cleaning the Heat Exchanger

To clean the heat exchanger:

1. Remove burners (as above).
2. Vacuum heating surfaces.
3. Inspect heat exchanger for clear 1mm flueways between coils.
4. Brush remaining debris with a non-metallic brush, avoiding insulation damage.

Note: A cleaning kit (KIT30063) is available from Lochinvar Limited. Ensure all deposits are removed. Rinse with fresh water. Remove and clean the condensate water trap. Refit the condensate drain and recharge with 1 litre of water. Reinstall the burner and restart per Section 12.4.3.

14.6 Draining the Water Heater

Drain the heater if exposed to freezing temperatures or for maintenance. Turn off electrical disconnect. Connect a hose to the drain valve. Discharge safely. Close cold water inlet. Open a hot water outlet to vent. Open the drain valve. Purge the heat exchanger with an air compressor. Leave the drain valve open for extended shutdowns.

14.7 Removing Scale and Sediment from the Storage Vessel

Drain the system. Remove the outer cover plate and cleanout opening cover/gasket. Carefully remove scale/sediment, avoiding damage to the cold water injection system. Inspect and replace the cleanout plate gasket if necessary. Reinstall gasket and plate.

14.8 Refilling the System

Close the drain valve. Open a hot water fixture to vent air. Open the cold water supply to fill. Isolate gas supply, then reinstate electrical supply. Once air is purged from the heat exchanger, follow initial lighting instructions (Section 12.4.3). Check for water leaks.

14.9 Other Checks

14.9.1 Relief Valves (If Fitted)

Annually, check the temperature and pressure relief valve and safety valve by lifting the lever or turning the screw cap. They should operate freely and seat properly. If water does not flow, inspect for obstructions or corrosion and replace if necessary.

14.9.2 Flue System

Examine the exhaust and air intake system annually. Check for obstructions, deterioration, foreign material, and leakage at connections. Reseal as required. Ensure ventilation grilles comply with current regulations.

14.10 Troubleshooting

Tables provide lockout codes, common complaints, possible causes, and solutions.

14.10.1 Faults and Complaints

Table 14.1 lists error codes and their possible causes (page references). Table 14.2 lists common complaints and their possible causes (page references).

14.10.2 Possible Causes

Table 14.3 lists detailed possible causes for various operational issues, numbered 1 through 29.

14.10.3 Solutions

Table 14.4 provides corresponding solutions for the issues listed in Table 14.3, numbered 1 through 29.

15.0 ErP Specification Data Sheet

Table 15.0 presents the ErP specifications for the EcoForce++ models, including Load Profile, Energy Efficiency, Daily Consumption (Electricity and Fuel), Mixed Water V40, NOx Emissions, and Sound Power Level.

16.0 User Instructions

Upon completion of installation and commissioning, the owner or representative should be informed about the appliance's operation and safety devices. A practical demonstration is recommended. Incorrect use may cause injury and void the warranty. The Installation, Commissioning and Maintenance Instructions should be kept for reference. Users are strongly advised to read the separate User Guide.