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⚠
⚠ WARNING:
If the information in
this manual is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or loss of life.
-- This water heater MUST NOT be installed
in any location where gasoline or flammable
vapors are likely to be present.
-- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
near by phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
• Installation and service must be performed
by a qualified installer, service agency, or
the gas supplier.
CBX-CWX-I-S_100160893_2000001309_Rev T
Installation & Service Manual
Models: 497 - 2067
⚠ WARNING:
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual be reviewed completely before proceeding
with an installation. Perform steps in the order
given. Failure to comply could result in severe
personal injury, death, or substantial property
damage.
Save this manual for future reference.
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Table of Contents
Related Manuals for Lochinvar Copper-Fin 2067
Summary of Contents for Lochinvar Copper-Fin 2067
- Page 1 ⚠ CBX-CWX-I-S_100160893_2000001309_Rev T Installation & Service Manual Models: 497 - 2067 ⚠ WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. -- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS ........... 2 Terminal Strip Connection Options ......40-41 PLEASE READ BEFORE PROCEEDING ....3-4 Temperature Controls SAFETY INFORMATION ..........4 Temperature Adjustment ..........41 THE COPPER-FIN -- HOW IT WORKS ....... 5-7 Outdoor Reset Option ..........42 RATINGS................ -
Page 3: Please Read Before Proceeding
Installation & Service Manual Please read before proceeding Special instructions Apply enough water to the combustion chamber This is a gas appliance and should be installed NOTICE lining to prevent airborne dust. by a licensed electrician and/or certified gas supplier. -
Page 4: Safety Information
Installation & Service Manual Please read before proceeding Safety information ⚠ Owner warning – To minimize the possibility of serious ⚠ WARNING personal injury, fire or damage to your The information contained in this manual is intended for use unit, never violate the following safety by qualified professional installers, service technicians, or gas rules. -
Page 5: The Copper-Fin - How It Works
Installation & Service Manual The Copper-fin - How it works... Heat exchanger 16. Low voltage connection board The heat exchanger allows system water to flow through specially The low voltage connection board provides a location to tie in designed tubes for maximum heat transfer. The glass lined all of the low voltage contacts to the appliance. - Page 6 Installation & Service Manual The Copper-fin - How it works... Models 497 - 747 Rear View Models 497 - 747 Front View Models 497 - 747 Right Side (inside unit) Models 497 - 747 Left Side (inside unit)
- Page 7 Installation & Service Manual The Copper-fin - How it works... (continued) Models 987 - 2067 Rear View Models 987 - 2067 Front View Models 987 - 2067 Left Side (inside unit) Models 987 - 2067 Right Side (inside unit)
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Page 8: Ratings
Installation & Service Manual Ratings Copper-fin Other Specifications AHRI Rating Vent Size Model Number Gross AHRI Boiler Water Input Water Ratings Output Content Connections Connections Water, (Note 3) Gallons (Note 4) Note: Change “N” to “L” for L.P. gas models. (Note 2) (Note 1) 2"... - Page 9 Installation & Service Manual Ratings (continued) LOW LEAD CONTENT Copper-fin Specifications Model Number Vent Size Input Water Water Connections Gas Connections Content Gallons Note: Change “N” to (Note 1) “L” for L.P. gas models CWN497 2" 1 1/4" 6" CWN647 2"...
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Page 10: Determine Unit Location
Installation & Service Manual Determine unit location Installation Indoor clearances from combustible construction Th is unit meets the safe lighting performance criteria with the Maintain minimum specified clearances for adequate gas manifold and control assembly provided, as specifi ed in the operation. -
Page 11: Freeze Protection
Installation & Service Manual Determine unit location (continued) Outdoor boiler installation TABLE 1A COMBUSTIBLE FLOOR KITS Adequate hydronic system antifreeze must be used. A snow Model Kit Number screen should be installed to prevent snow and ice accumulation around the unit or its venting system. 100136977 Shut-down and draining 100136978... - Page 12 Installation & Service Manual Determine unit location Freeze Protection for a Heating Boiler Combustion and Ventilation Air System (if required) Provisions for combustion and ventilation air must be Do not use undiluted or automotive type in accordance with Section 5.3, Air for Combustion and ⚠...
- Page 13 Installation & Service Manual Determine unit location (continued) Figure 1-3_Combustion air filter_ Models 497 - 747 Figure 1-4_Combustion air filter_ Models 987 - 2067 During construction the air filter should be checked more frequently to ensure it does not become clogged NOTICE with construction dirt and debris.
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Page 14: Combustion Air Options
Installation & Service Manual Determine unit location Combustion Air Options Two Openings The combustion air opening must have a minimum free area of one square inch per 4000 Btu input (5.5cm² per kW). You Under no circumstances should a mechanical ⚠... - Page 15 Installation & Service Manual Determine unit location (continued) Exhaust Fans 3. Combustion Air from an Interior Space You can direct combustion air to this unit using air from an Any fan or equipment which exhausts ⚠ WARNING adjoining interior space. You must provide two openings from air from the boiler room may deplete the the boiler room to the adjoining room.
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Page 16: Venting
Installation & Service Manual Venting General information You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building codes. -
Page 17: Vent System Options
Installation & Service Manual Venting (continued) Figure 2-4_Vent termination from flat roof - 10 ft. or more Figure 2-3_Vent termination from flat roof - 10 ft. or from parapet wall less from parapet wall Units which are shut down or will not operate may experience freezing due to convective air flow in flue ⚠... -
Page 18: Conventional Negative Draft Venting
Installation & Service Manual Venting Barometric damper location Negative draft Any venting system option that requires a barometric The negative draft in a conventional vent installation must be damper must adhere to the following directions for optimum within the range of 0.02 to 0.08 inches w.c. to ensure proper performance. -
Page 19: Masonry Chimney Installation And Inspection
Installation & Service Manual Venting (continued) Masonry chimney installation Common venting systems may be too large when an existing unit is removed. A masonry chimney must be properly sized for the installation At the time of removal of an existing appliance, the following of a high efficiency gas-fired appliance. - Page 20 Installation & Service Manual Venting Figure 2-7 Other than Direct Vent Terminal Clearances Table 2B Other than Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony 6 in (15 cm) for appliances <...
- Page 21 Installation & Service Manual Venting (continued) Table 2B Other than Direct Vent Terminal Clearances (continued) 6 in (15 cm) for appliances < 10,000 Btuh 4 ft (1.2 m) below or to side of opening; 1 ft Clearance to nonmechanical air supply (3kW), 12 in (30 cm) for appliances >...
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Page 22: Outdoor Installation Options
Installation & Service Manual Venting 2. Outdoor installation venting Before installing a venting system, follow Multiple outdoor unit installations require NOTICE NOTICE all venting clearances and requirements 48'' (1.22m) clearance between each vent found in the Venting, General Information cap. Locate the outdoor cap at least 48'' section, page 16. - Page 23 Installation & Service Manual Venting (continued) DIR #2000597290 00 DIR #2000597290 00 Figure 2-8_Outdoor vent kit installed on Models Figure 2-9_Outdoor vent kit installed on Models 497 - 747 987 - 2067 Outdoor vent kit Th e optional outdoor vent kit is available from the appliance manufacturer. Th e outdoor kit part numbers are listed by unit size. See Table 2C for kit numbers.
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Page 24: Gas Connections Connecting To Gas Supply
Installation & Service Manual Gas connections Gas piping Connecting to gas supply Verify that the appliance is supplied with the type of gas specified To safely operate this unit, you must properly size the gas on the rating plate. This appliance is configured for operation supply piping. -
Page 25: Gas Connections / Gas Train And Controls
Installation & Service Manual Gas connections (continued) Gas connection TABLE 3B SUGGESTED GAS PIPE SIZE FOR All gas connections must be made with pipe joint compound SINGLE UNIT INSTALLATIONS resistant to the action of liquefied petroleum (L.P.) and natural gases. All piping must comply with local codes and ordinances. Distance from Meter (in feet) Piping installations must comply with approved standards and MODEL... -
Page 26: Combination Gas Valves
Installation & Service Manual Gas connections Combination gas valves Checking gas supply pressure These units fire in multiple stages of burner input. Each stage Use the following procedure to check gas supply pressure. of burner operation has a combination gas valve(s) to cycle the gas supply on and off and regulate gas to the burners. -
Page 27: Gas Manifold Pressure Adjustment
Installation & Service Manual Gas connections (continued) Gas manifold pressure adjustment 10. If gas supply pressure is within normal range, remove the gas manometer and replace the pressure tap fittings in the gas control as indicated by the following steps. The gas valves are referenced to the fan NOTICE pressurized chamber by a hose connected... - Page 28 Installation & Service Manual Gas connections 12. If adjustment is necessary, remove the regulator 15. Read the value on the manometer/magnahelic and cover screw on the gas valve. Note: If the gas valve compare it to the values in TABLE- 3E. under adjustment is located on a manifold assembly 16.
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Page 29: Water Connections
Installation & Service Manual Water connections Inlet and outlet connections Water flow switch For ease of service, install unions on the water inlet and water A water flow switch is factory installed in the outlet piping on outlet of the unit. The connection to the unit marked “Inlet” all heating boilers and water heaters. - Page 30 Installation & Service Manual Water connections Water connections (heating boilers only) Circulator pump specifications Inlet and outlet water connections on Models 497 - 747 Maximum operating pressure for the pump must exceed have 2'' NPT and on Models 987 - 2067 the inlet and outlet system operating pressure.
- Page 31 Installation & Service Manual Water connections (continued) Minimum boiler water temperatures Pump Maintenance: Inspect the pump every six (6) months and oil as necessary. Use SAE 30 non-detergent oil or lubricant Inlet water temperatures below the specified minimum of specified by the pump manufacturer. 140°F (60°C) can excessively cool the products of combustion resulting in condensation on the heat exchanger.
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Page 32: Low Temperature Return Water Systems
140°F. Lochinvar offers a low temperature protection system temperature. A remote low temperature range operator valve (LTV) that is factory preset to maintain 140°F inlet water is recommended to control the boiler operation based on the to the boiler regardless of the system return water temperature. -
Page 33: Primary/Secondary Piping Of A Single Boiler
Installation & Service Manual Water connections (continued) Figure 4-5_Primary/secondary piping of single boiler COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Models: 987 - 2067 Diameter Diameter Number of Units Number of Units (in.) (in.) 2 1/2 HEATING Y-STRAINER RETURN... -
Page 34: Primary/Secondary Piping Of Multiple Boilers
Installation & Service Manual Water connections Figure 4-6_Primary/secondary piping of multiple boilers COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 987 - 2067 Models: 497 - 747 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2 EXPANSION PRESSURE TANK... -
Page 35: Boiler W/Low Temperature Bypass Piping
Installation & Service Manual Water connections (continued) Figure 4-7_Boiler with low temperature bypass COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Models: 987 - 2067 Diameter Diameter Number of Units Number of Units (in.) (in.) 2 1/2 MIXING Y-STRAINER HEATING... -
Page 36: Primary/Secondary Piping With Buffer Tank
Installation & Service Manual Water connections Figure 4-8_Primary/secondary piping with buffer tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 987 - 2067 Models: 497 - 747 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2 PUMP Y-STRAINER 1"... -
Page 37: Installation With A Chilled Water System
Installation & Service Manual Water connections (continued) Installation with a chilled water TABLE - 4C system BOILER TEMPERATURE RISE AT MAXIMUM FLOW Temperature Rise at Full Rate Fire Pipe refrigeration systems in parallel. Install duct coil Maximum Flow downstream at cooling coil. Where the hot water heating Model Temperature Rise °F boiler is connected to a heating coil located in the air handling... -
Page 38: Temperature/Pressure Gauge And Water Treatment
Installation & Service Manual Water connections Boiler bypass requirements Do not use petroleum based stop leak ⚠ CAUTION products. All system leaks must be repaired. The installer must ensure that the boiler is supplied with The constant addition of make-up water can adequate flow without excessive temperature rise. -
Page 39: Electrical Connections Connecting To Electrical Supply
Installation & Service Manual Electrical connections Connecting to electrical supply ELECTRICAL SHOCK HAZARD – For your ⚠ WARNING safety, turn off electrical power supply before This unit is wired for 120 VAC service. The unit, when making any electrical connections to avoid installed, must be electrically grounded in accordance with possible electric shock hazard. -
Page 40: Line Voltage Connections
Installation & Service Manual Electrical connections Line voltage connections wiring connections. This remote ON/OFF control will provide an Enable/Disable signal to the unit and allow the unit to 1. Connect 120 VAC power wiring to the line voltage operate based on the stage set points, until the remote ON/ terminal strip in the junction box, as shown in FIG. -
Page 41: Temperature Controls
Installation & Service Manual Electrical connections (continued) Temperature control settings Figure 5-6_Remote on/off water heater There are three setting knobs on the temperature control unless SYSTEM/TANK your unit is specified as a boiler only with an outdoor air reset SENSOR option. -
Page 42: Outdoor Reset Option
Installation & Service Manual Electrical connections TABLE 5B Figure 5-11_Optional outdoor reset control Maximum Setpoint Determination OUTDOOR OUTDOOR Max. SHUTDOWN SENSOR Setpoint SHUTDOWN Connected Connected 230° Connected 190° Connected 200° 160° Anytime that OJ1 is the only jumper cut, a NOTICE new overlay is required under the Set Point knob on the temperature controller because... -
Page 43: Temperature Control Sensors
Installation & Service Manual Electrical connections (continued) Ratio The sensor must be connected to two wires provided on the side of the appliance with the water connections (FIG. 5-12). It will The Ratio knob allows the control over the reset ratio to be used be necessary to add additional wire to reach from the appliance during Outdoor Air Reset. - Page 44 Installation & Service Manual Electrical connections Outdoor air Temperature sensor Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment The outside air temperature sensor will only be used for boiler exists. Shielded cable is recommended on all cable runs of systems.
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Page 45: Hot Surface Ignition System
The igniter is extremely fragile, be very ⚠ CAUTION careful when removing. A faulty or damaged hot surface igniter MUST BE replaced with a Lochinvar PLT3400 igniter. Do not use general purpose field replacement igniters. Hot surface ignition control module Ignition Module Lockout Functions... -
Page 46: Operation And Diagnostic Lights
Installation & Service Manual Electrical connections Operation and diagnostic lights TABLE 5E The diagnostic control panel has up to 6 indicating and Status LED Diagnostic Codes diagnostic lights to show all major steps of operation and Code control sensed malfunctions. This panel is located on the front Condition Lights Sequence of the unit. -
Page 47: Startup
Installation & Service Manual Startup Figure 6-1_Operating instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition If you cannot reach your gas supplier, call the fire department. -
Page 48: Check Water Chemistry
Installation & Service Manual Startup Pre-Commissioning Cleaning Boiler water 1. Prior to fill and start-up, flush the entire heating system. Do not use petroleum based cleaning or CAUTION sealing compounds in the boiler system. 2. Clean the entire heating system with an approved pre- Gaskets and seals in the system may be commissioning cleaner (comparable to Sentinel X300 damaged. -
Page 49: Fill And Test Water System
Installation & Service Manual Startup (continued) Fill and test water system Use glycol only if needed for freeze protection. Propylene glycol is the recommended freeze protection. 1. Fill system only after ensuring the water meets the requirements of this manual. Make sure to flush the boiler system before adding glycol. -
Page 50: Check For Gas Leaks / Thermostat Circuit(S)
Installation & Service Manual Startup Check for gas leaks Boiler operation Before starting the boiler, and during initial ⚠ WARNING operation, smell near the floor and around the Verify that all adjustable points in the Operator boiler for gas odorant or any unusual odor. Interface are set as required. -
Page 51: Domestic Water Heaters
Installation & Service Manual Domestic water heaters This section applies only to those units used to supply potable hot water for domestic use. The water heater must be installed with a storage tank. This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and service sections apply to these instructions. -
Page 52: Typical Water Heater Piping W/ Storage Tank
Installation & Service Manual Domestic water heaters Figure 7-1_Typical water heater piping with storage tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Models: 987 - 2067 Diameter Diameter Number of Units Number of Units (in.) (in.) 2 1/2 2 1/2... -
Page 53: Single Water Heater Piping W/Two Storage Tanks
Installation & Service Manual Domestic water heaters (continued) Figure 7-2_Single water heater piping with two storage tanks COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Models: 987 - 2067 Diameter Diameter Number of Units Number of Units (in.) (in.) 2 1/2... -
Page 54: Multiple Water Heater Piping W/One Storage Tank
Installation & Service Manual Domestic water heaters Figure 7-3_Multiple water heater piping with a single storage tank COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 987 - 2067 Models: 497 - 747 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2... - Page 55 Installation & Service Manual Domestic water heaters (continued) Figure 7-4_Multiple water heater piping with multiple storage tanks COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.) Models: 987 - 2067 Models: 497 - 747 Diameter Diameter Number of Units Number of Units (in.) (in.) 3 1/2...
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Page 56: Pipe Size Requirements
Installation & Service Manual Domestic water heaters Required temperature rise TABLE 7C Pipe Sizing Chart Based on heating potable water with a hardness of 5 to 20 grains per gallon and/or total dissolved solids not 497 - 747 987 - 2067 exceeding 350 ppm, see Water Chemistry, this page. -
Page 57: Heat Exchanger
Installation & Service Manual Domestic water heaters (continued) Potable water temperature Minimum pump performance control settings This is based on heating potable water with a hardness of 5 to 25 grains per gallon and/or total dissolved solids not Domestic water temperature exceeding 350 ppm. -
Page 58: Location Of Cold Water Supply Piping Connections
Installation & Service Manual Domestic water heaters Storing the water at a higher temperature and thermostatically The High-Fire stage will be delayed by NOTICE mixing the water increases the available quantity of mixed hot approximately 10 seconds to allow a water, greatly reducing the possibility of condensate forming soft start of the water heater. -
Page 59: High Water Temperature Limit Control
Installation & Service Manual Domestic water heaters (continued) High water temperature limit control The unit is equipped with an adjustable setting, auto-reset high water temperature limit control. The hot water heater temperature limit control has a maximum limit setting of 200°F (93°C). -
Page 60: Maintenance
Installation & Service Manual Maintenance Listed below are items that must be checked to ensure safe, Lifting Flames: The usual causes for lifting flames are over reliable operations. Verify proper installation after servicing. firing the burner(s), excessive primary air, or high draft. Label all wires prior to disconnection when If you observe improper flame patterns, examine the venting ⚠... -
Page 61: Adjusting Differential Air Pressure
Installation & Service Manual Maintenance (continued) Combustion and ventilation air Heat exchanger cleaning Combustion air filter While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be See Combustion Air Filter, page 13. cleaned and problem corrected. Proceed as follows. Air flow Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning,... - Page 62 Installation & Service Manual Maintenance Adjust the air shutter until the air chamber pressure is Figure 8-2_Air pressure switch nominally 1.35 - 1.45 inches water column. See FIG. 8-4 for installations up to 2000 feet altitude. Contact the factory for high altitude settings. Once the adjustment procedure is complete, reattach the cap to the tee in the hose and check all tubing and wire connections for a snug fit.
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Page 63: Servicing A Hot Surface Igniter / Ignition Module
Installation & Service Manual Maintenance (continued) Ignition system checkout Figure 8-5_Loosening the transition box screws, Models 1437, 1797 and 2067 only Turn off gas supply to unit. Turn electric power on. Adjust the set point on the temperature control to a setting above water temperature or to the highest safe setting. - Page 64 Installation & Service Manual Maintenance Heat transfer process 24VAC is supplied to the intermittent alarm field safety contacts, B1 and B2. 28. Heated products of combustion pass over the heat 10. 24VAC is supplied to the water flow switch. exchanger transferring heat to the water. 11.
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Page 65: Glossary & Notes
Installation & Service Manual Maintenance Maintenance and annual startup Table 8A_Service and Maintenance Schedules Owner maintenance Service technician (see the Copper-fin User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check appliance area •... - Page 66 Installation & Service Manual Glossary Power Supply Safety Device Terminals (AC120VAC/60Hz) The safety device terminals ensure that no power can be 120VAC/60Hz/1PH power connects to black (line) and white delivered to the ignition module unless factory/field-installed (neutral) wires located within an electrical wiring box located safety devices such as flow switches and gas pressure switches on the left side of the unit.
- Page 67 Installation & Service Manual Glossary Post-Purge Once the ignition module sees a 24VAC input from the pressure switch, it runs the blower in order to purge the (Ignition Module Function) combustion chamber of any unburned fuel/air mixture. When 24VAC is removed from the ignition module’s thermostat Trial for Ignition input, the module turns off the gas valves and maintains the blower in order to allow the combustion chamber to be purged...
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Page 68: Diagrams
Installation & Service Manual Diagrams Ladder diagram... - Page 69 Installation & Service Manual Diagrams (continued) Ladder diagram (continued)
- Page 70 Installation & Service Manual Diagrams Connection diagram...
- Page 71 Installation & Service Manual Diagrams (continued) Connection diagram (continued)
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Page 72: Revision Notes
Revision Notes: Revision A (ECO #C07390) initial release. Revision B (ECO C09691) reflects the update of AHRI and ASME logos on pages 8 and 9. Revision C (ECO C12077) reflects the update of ignition timing information on pages 40, 43, 61 and 63 as well as the update of heat exchanger information on page54.