Table of Contents
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The Mini Copper-Fin® range
High Efficiency Gas Fired Water Heaters and
Boilers
Installation, Commissioning and
Maintenance Instructions
Models:
MCW91CE
MCW136CE
MCW181CE
MCW226CE
MCW271CE
MCW316CE
MCW361CE
MCW401CE
MCW501CE
MCB91CE
MCB136CE
MCB181CE
MCB226CE
MCB271CE
MCB316CE
MCB361CE
MCB401CE
MCB501CE
INS0023 Issue No 6 | August 2011
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Table of Contents
Related Manuals for Lochinvar Mini Copper-Fin MCW91CE
Summary of Contents for Lochinvar Mini Copper-Fin MCW91CE
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Page 1: Maintenance Instructions
The Mini Copper-Fin® range High Efficiency Gas Fired Water Heaters and Boilers Installation, Commissioning and Maintenance Instructions Models: MCW91CE MCW136CE MCW181CE MCW226CE MCW271CE MCW316CE MCW361CE MCW401CE MCW501CE MCB91CE MCB136CE MCB181CE MCB226CE MCB271CE MCB316CE MCB361CE MCB401CE MCB501CE INS0023 Issue No 6 | August 2011... -
Page 2: Table Of Contents
Table of Contents INTRODUCTION ..............................................4 PRINCIPAL PARTS ..............................................5 TECHNICAL DATA ..............................................7 GENERAL REQUIREMENTS ..........................................9 RELATED DOCUMENTS ..........................................9 WATER QUALITY ..............................................10 LOCATION ................................................10 PLANT ROOM VENTILATION ........................................10 GENERAL REQUIREMENTS ......................................... 10 CLEARANCES ..............................................10 GAS SUPPLY ................................................. - Page 3 14.0 MAINTENANCE ..............................................28 14.1 GENERAL ............................................... 28 14.2 MAINTENANCE SCHEDULE ......................................... 29 14.2.1 ADDITIONAL REQUIREMENTS FOR WATER HEATERS ............................29 14.3 DRAINING THE WATER SYSTEM ........................................ 29 14.4 WATER HEATER SERVICING ........................................29 14.4.1 REMOVING SCALE AND SEDIMENT FROM THE STORAGE VESSEL ........................29 14.4.2 SACRIFICIAL MAGNESIUM ANODES ..................................
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Page 4: Introduction
INTRODUCTION The Lochinvar Mini Copper-Fin range is a floor standing direct gas fired water heater or boiler. The • equipment comprises a copper finned tube heat exchanger surrounded with a high density, light weight refractory insulation. A durable outer steel jacket assembly provides structural integrity and easy disassembly. -
Page 5: Principal Parts
PRINCIPAL PARTS FIGURE 2.1 EXPLODED DIAGRAM FIGURE 2.2 EXPLODED DIAGRAM – CONTROL PANEL ASSEMBLY... - Page 6 FIGURE 2.3 EXPLODED DIAGRAM – HEAT EXCHANGER FIGURE 2.4 EXPLODED DIAGRAM - GAS MANIFOLD ASSEMBLY ITEM DESCRIPTION ITEM DESCRIPTION Main burner bar Control thermostat Pilot burner assembly Terminal strip Burner manifold On/off switch Main burner injector Heat exchanger Gas inlet flange ‘V’...
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Page 7: Technical Data
TECHNICAL DATA Model Number MC91CE MC136CE MC181CE MC226CE MC271CE MC316CE MC361CE MC401CE MC501CE GENERAL DATA Input (gross) - kW 26.4 39.6 52.8 65.9 79.1 92.3 105.5 117.2 146.5 Input (net) - kW 23.8 35.6 47.0 59.4 71.3 83.1 95.1 105.6 132.0 Output - kW (80°/60°) 20.8... - Page 8 RECOMMENDED CLEARANCES E DIA GAS CONNECTION OUTLET INLET (TO CENTRE OF GAS INLET) RECOMMENDED CLEARANCES FIGURE 3.1: DIMENSIONS Dimension Description MC91CE MC136CE MC181CE MC226CE MC271CE MC316CE MC361CE MC401CE MC501CE Overall height of heater Overall width of heater 1130 1334 Overall depth of heater Centreline of flue Flue diameter Height of gas inlet...
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Page 9: General Requirements
GENERAL REQUIREMENTS The Lochinvar Mini Copper-Fin has been designed to operate trouble free for many years. These instructions should be followed closely to obtain the maximum usage and efficiency of the equipment. PLEASE read the instructions fully before installing or using the appliance. -
Page 10: Water Quality
LOCATION 6.1 PLANT ROOM VENTILATION The Lochinvar Mini Copper-Fin may only be installed in a room that complies with the appropriate ventilation requirements. For further details, please refer to Section 9: AIR SUPPLY or to BS5440-2 or BS6644 as appropriate. -
Page 11: Gas Supply
GAS SUPPLY The Lochinvar Mini Copper-Fin range is suitable for use on second and third family gasses 2H - G20 - 20mbar and 3P - G31 - 37mbar. Details relating to Natural Gas (2H) appear below; for details relating to Propane (3P) please refer to Section 13: LPG FUEL. -
Page 12: Flue System
A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all draught flue installations. If this dimension cannot be achieved please contact Lochinvar Limited for further guidance. The weight of the flue must be adequately supported by securing clips and not by the appliance. -
Page 13: Multiple Flue Installation
8.4 MULTIPLE FLUE INSTALLATION Common flues may be used on multiple installations only if all the heaters are of the same burner • system and fuel type and should be sized to ensure complete evacuation of the flue products from the installation. -
Page 14: Mechanical Ventilation
1.35 ± 0.18 (with or without draught stabilisers) TABLE 9.3 MECHANICAL VENTILATION FLOW RATES Worked Example – Mechanical inlet/natural discharge: Lochinvar MC361CE Heat input (net): = 95.1 kW = 95.1 x 2.8 m = 266.28 m Minimum combustion air flow rate:... - Page 15 Worked Example – Mechanical inlet/mechanical discharge (minimum combustion air flow rate): Lochinvar MC361CE Heat input (net): = 95.1 kW = 95.1 x 2.8 m = 266.28 m Minimum combustion air flow rate: Difference between inlet and extract air (maximum value): = 95.1 x (2.07 + 0.18) m...
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Page 16: Water Connections
INSTALLED BY AN APPROVED INSTALLER. If the Lochinvar Mini Copper-Fin is to be used in an unvented arrangement, the system should follow the guidance given in BS6700 and must comply with The Building Regulations: Part G3. A kit of components that have been suitably sized for the unvented operation of the appliance is available from Lochinvar Limited. -
Page 17: Expansion Vessel Sizing
Glandless (canned rotor) pumps are not recommended by Lochinvar Limited due to the fact that in hard water areas, scale can build up within the rotor and failure can occur, not only of the pump but also the heater itself. -
Page 18: Pipework Size
Total System Pressure Model Differential - K Flow – l/s Loss - Metre H MCW91CE 2.44 2.44 MCW136CE 2.44 MCW181CE 2.44 MCW226CE 2.44 MCW271CE 2.44 MCW316CE 2.44 MCW361CE 2.44 MCW401CE 2.44 MCW501CE TABLE 10.2 WATER HEATER FLOW RATES To ensure proper velocity through the heat exchanger, it is necessary to balance the temperature rise across the heat exchanger from inlet to outlet. -
Page 19: Heating Boilers
10.2.2 OPEN VENTED SYSTEM ARRANGEMENT The Lochinvar Mini Copper-Fin can be used in an open vented arrangement provided that a vent pipe in accordance with CP342 or BS6644 as appropriate is fitted. The minimum static head requirement for an open vented system is 0.5 bar. -
Page 20: Expansion Vessel Sizing
10.2.6 PRIMARY CIRCULATING PUMPS The Lochinvar Mini Copper-Fin boiler may need a primary pump to ensure correct flow through the boiler and a secondary pump to circulate water around the heating system. Pump selection must ensure that the flow rate through the unit is in accordance with that stated in Table 10.4. -
Page 21: Pool Heating
FLOW SWITCH The Lochinvar Mini Copper-Fin range of equipment is based on a low water content copper heat exchanger. In order to ensure a long life expectancy it is important that the burner does not fire if the main circulating pump fails. -
Page 22: Electrical Connections
11.1 ELECTRICAL CONNECTIONS Access to the electrical connections is achieved by taking off the removable panel next to the controls positioned on the left hand side of the equipment. Connections to the equipment should pass through one of the 20mm knock out wiring gland covers provided. -
Page 23: Wiring Diagram
11.4 WIRING DIAGRAM BK/W BR/W Y/GR Y/GR Y/GR TERMINAL STRIP ROCKER SWITCH OVERHEAT LIMIT RESET LIMIT THERMOSTAT OPERATING THERMOSTAT TTB DEVICE FLAME FAILURE RESET IGNITION SEQUENCE CONTROLLER PILOT ASSY. GAS VALVE 11 RUN RELAY 12 FAULT RELAY (TIME DELAY) FIGURE 11.2 WIRING DIAGRAM MC91CE –... - Page 24 BK/W BR/W Y/GR Y/GR R/BK R/BK Y/GR Y/GR R/BK Y/GR BL TERMINAL STRIP FLAME FAILURE RESET R/BK ROCKER SWITCH IGNITION SEQUENCE CONTROLLER OVERHEAT LIMIT RESET PILOT ASSY. LIMIT THERMOSTAT GAS VALVES OPERATING THERMOSTAT RUN RELAY TTB DEVICE FAULT RELAY (TIME DELAY) FIGURE 11.3 WIRING DIAGRAM MC501CE...
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Page 25: Commissioning And Testing
12.0 COMMISSIONING AND TESTING 12.1 ELECTRICAL INSTALLATION Notes on the requirements for electrical installation are provided in Section 11: ELECTRICAL SUPPLY. Schematic drawings of the control circuit are shown in Figure 11.2 and 11.3. 12.2 GAS INSTALLATION For design see Section 7: GAS SUPPLY. See Figure 3.1 for details on the position of the gas connection. 12.3 WATER CONNECTIONS For design see Section 10: WATER CONNECTIONS... -
Page 26: Procedure For Initial Lighting
12.4.3 PROCEDURE FOR INITIAL LIGHTING IF THE UNIT IS TO OPERATE ON LPG REFER TO SECTION 13: LPG FUEL BEFORE PROCEEDING Ensure that the gas inlet appliance isolating valve, provided by the installer, is in the ‘off’ position. Remove the control cover (located above the water flow and return header). Set the thermostat to a temperature above that of the system water. -
Page 27: Water Heater Temperature Adjustment Procedure
12.5 WATER HEATER TEMPERATURE ADJUSTMENT PROCEDURE The temperature selector knob of the operator thermostat will be adjusted to its lowest setting when dispatched from the factory. The operating thermostat setting should be adjusted to ensure that the water is stored at 60°C and distributed at 50°C within 1 (one) minute at all outlets. -
Page 28: Propane Injectors
Section 4: GENERAL REQUIREMENTS. Servicing is recommended at intervals no greater than 12 months, preferably by a Lochinvar appointed person, to ensure trouble free operation. Even if a tank maintenance schedule is determined to be less than annually, it is important that all controls and safety features are checked for correct operation on an annual basis. -
Page 29: Maintenance Schedule
14.2 MAINTENANCE SCHEDULE Equipment installed in a dusty or dirty contaminated atmosphere may require maintaining more frequently than on an annual basis. When installed in a dusty or dirty environment, the combustion system should be checked at 3 month intervals to then determine the maintenance period required. Non-combustible particular matter such as dust can block the ports of the burners and cause non-warrantable failures. -
Page 30: Cleaning The Heat Exchanger
Enamel lined storage vessels are protected against corrosion by sacrificial anodes. The rate at which the anodes are depleted is dependent on the quality of the water, therefore it is important that the anodes are inspected as follows: Drain the water system. Refer to Section 14.3: DRAINING WATER SYSTEM. Remove the plastic covers to expose the anode retaining plugs. -
Page 31: Refilling The System
16. Check the condition of the copper tubes to ensure each tube has not warped or annealed. If there are any signs of damage to the heat exchanger it should be replaced. 17. If it is necessary to replace the heat exchanger, undo the self-tapping screws on the outer casing adjacent to the header to open up the withdrawal opening. -
Page 32: Other Checks
This device shall not be put out of operation due to the seriousness of untimely interference. If required, this device should only be replaced with a genuine Lochinvar part. 14.9... -
Page 33: User Instructions
15.0 USER INSTRUCTIONS Once the installation and commissioning is complete, the equipment owner or their representative should be made aware of the lighting and operating instructions. A practical demonstration should be given describing each functional step. Incorrect use may result in injury and will also invalidate the warranty. The installers guide should be handed over and kept in a safe place for easy reference. - Page 34 NOTES NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________...
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