Lochinvar 000 - 500 Installation And Service Manual
Hydronic heating boilers and domestic water heaters 45,000 - 500,000 btu/hr
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Table of Contents
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INSTALLATION AND SERVICE MANUAL
HYDRONIC HEATING BOILERS and
IMPORTANT:
This is a gas appliance and should be installed by a
licensed electrician and/or certified gas supplier.
Service must be performed by a qualified service
installer, service agency or the gas supplier.
WARRANTY
Installation and service must be performed by a
qual i fied service installer, service agency or the gas
supplier.
Factory warranty (shipped with appliance) does not
apply to appliances improperly installed or im prop er ly
operated.
Experience has shown that improper installation or
system design, rather than faulty equipment, is the
cause of most operating problems.
1. Excessive water hardness causing a lime
buildup in the copper tube is not the fault of
the equipment and is not covered under the
manufacturer's warranty (see
2. Excessive pitting and erosion on the inside of
the copper tube may be caused by too much
water velocity through the tubes and is not
covered by the manufacturer's warranty (see
flow re quire ments).
SPECIAL INSTRUCTIONS TO OWNER
Note:
Retain this manual for future reference.
This manual supplies information for the in stal la tion,
operation and servicing of the appliance. It is strong ly
recommended that this manual be re viewed com plete ly
before proceeding with an in stal la tion.
DOMESTIC WATER HEATERS
45,000 - 500,000 Btu/hr MODELS
).
Improper Installation, Adjustment,
Alteration, Service or Main te nance
can cause injury or prop er ty dam age.
Refer to this man u al. For as sis tance or
additional information consult a qualified
installer, service agen cy or the gas supplier.
CHECKING EQUIPMENT
Upon receiving equipment, check for signs of ship ping
damage. Pay particular attention to parts ac com pa ny ing
the appliance which may show signs of being hit or
otherwise being mis han dled. Verify total num ber of
pieces shown on packing slip with those ac tu al ly
received.
In case there is damage or a short age,
immediately notify carrier.
DO NOT
Use this appliance if any part has been
under water. The possible damage to a flooded
appliance can be extensive and present numerous
safety hazards. Any ap pli ance that has been un der
water must be re placed.
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.
for
This appliance MUST NOT be installed in any
location where gasoline or flammable vapors are
likely to be present, unless the installation is such to
eliminate the probable ignition of gasoline or
flammable vapors.
• 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
neighbors 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.
RSB-i&s-05
WARNING
WARNING
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Table of Contents
Related Manuals for Lochinvar 000 - 500
Summary of Contents for Lochinvar 000 - 500
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Page 1: Warranty
INSTALLATION AND SERVICE MANUAL HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 45,000 - 500,000 Btu/hr MODELS IMPORTANT: This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier. -
Page 2: Table Of Contents
Placing Boiler in Operation ...36 Temperature Rise Chart ...37 Boiler Temperature Control ...38 Remote Thermostat Control Connection ...38 Power Venter Connection...38 Domestic Water Heater...38 Water Velocity Control ...39 Temperature Rise ...39 Water Chemistry ...40 Pump Operation ...40 Risk of Scald Warnings...42 Troubleshooting ...44... -
Page 3: Codes
CODES The equipment shall be installed in accordance with installation regulations in force in the local area where the installation is to be made. These reg u la tions shall be carefully followed in all cases. Au thor i ties having jurisdiction shall be consulted be fore installations are made. -
Page 4: Clearances
CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Clearances from Combustible Construction: Right Side - 6" Rear - 6" Left Side - 18" (24" suggested for service) Front - 18" (24" suggested for service) Top - (measured from the top of the unit) 45,000 - 180,000 Btu/hr Models - 14" 199,999 - 500,000 Btu/hr Models - 29"... - Page 5 FIG. 5 Combustion Air Direct from Outside 1. If air is taken directly from outside the building with no duct, provide two permanent openings: a. Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5cm per kW).
- Page 6 Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Open ings. Table A lists the re quire ments for the ap pli ance only, additional gas fired appliances located in the same room will require an increase in the net free area to supply adequate...
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Page 7: Conventional Venting
EXHAUST FANS: Any fan or equipment which ex - hausts air from the room where the appliance is installed may deplete the combustion air supply and/or cause a down draft in the venting system, spilling flue products into the room. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected im -... - Page 8 On a conventionally vented, negative draft ap pli ance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type “B” double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter.
- Page 9 VENTING TERMINATION FIG. 10 Vent Termination from Peaked Roof 10’ or Less from Ridge MORE THAN 10' RIDGE 2' MIN CHIMNEY FIG. 11 Vent Termination from Peaked Roof More Than 10’ from Ridge The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the high est point of the roof within a 10 foot (3.05m) radius of the termination.
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Page 10: Masonry Chimney Installations
To avoid a blocked vent condition, keep the vent cap clear of snow, ice, leaves, debris, etc. Flue gases will form a white plume in winter. Plume could obstruct window view. Flue gas condensate can freeze on exterior sur fac es or on the vent cap. -
Page 11: Automatic Vent Damper
AUTOMATIC VENT DAMPER This heating boiler is design certified for use with the automatic vent damper (FIG. 15) part number printed on the boiler’s rating plate. A vent damper must be installed on all residential heating boilers with inputs of less than 300,000 Btu/hr to comply with minimum efficiency requirements. -
Page 12: Gas Supply
GAS SUPPLY Verify that the appliance is supplied with the type gas spec i fied on the rating plate. This appliance is orificed for operation up to 2000 feet altitude. The ap pli ance will be derated 4% per 1000 feet above 2000 feet el e va - tion. - Page 13 1 1/2" 1 1/2" 1 1/2" 2" 1 1/2" 2" 1 1/2" 2" 45,000 - 135,000 180,000 - 315,000 360,000 - 500,000 201 - 300 301 - 500 1" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4"...
- Page 14 MULTIPLE APPLIANCE INSTALLATIONS Nominal Iron Pipe Size, Inches 1 1/4 1,400 1 1/2 2,150 1,500 1,210 1,020 4,100 2,820 2,260 1,950 2 1/2 6,460 4,460 3,610 3,100 11,200 7,900 6,400 5,400 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 13.5 Inches Water Col umn (0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on the calorific value of Natural Gas, 1025 Btu/ft @ 0.60 Specific Gravity)
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Page 15: Manifold Pressure Adjustment
FIG. 17 Wrench For L.P. gas, consult your L.P. gas supplier for expert installation. IMPORTANT Upon completion of any piping con nec tions to the gas system, leak test all gas con nec tions with a soap solution while system Immediately repair any leaks found in the gas train Do Not or related components. -
Page 16: Supply Pres Sure Measurement
14. Repeat the adjustment procedure for the sec ond gas valve on the 500,000 Btu/hr model. 15. Turn the gas valve control knob(s) to “ON” position. 16. Turn the power “ON” at the main dis con nect switch. The appliance is now ready to op er ate. If manifold pressure can not be properly adjusted, use the following procedure to check gas supply pressure with a manometer connected to the inlet pressure tap on... -
Page 17: Gas Valves
Red Reset Button Knob FIG. 20 F1 Gas Valve 90,000 - 270,000 Btu/hr Models FIG. 21 F9 Gas Valve 90,000 - 500,000 Btu/hr Models Turn system FIG. 22 M9 Gas Valve 45,000 - 399,999 Btu/hr Models Each unit has a combination gas valve(s) to control the gas supply to the burners. -
Page 18: Relief Valve
CAUTION Avoid contact with hot discharge water. WATER FLOW SWITCH (IF EQUIPPED) FIG. 24A Water Flow Switch Water Heater - Side Connections FLOW SWITCH FIG. 24B Water Flow Switch Boiler - Top Connections A water flow switch is available as a factory sup plied option on all heating boilers and water heaters. -
Page 19: Electrical Connections
A water flow switch meets most code re quire ments for a low-water cut off device on boil ers requiring forced cir cu la tion for operation. TABLE I MINIMUM FLOW RATE REQUIRED TO ACTUATE FLOW SWITCH Pipe Size GPM Flow Rate 1 1/2"... -
Page 20: Temperature Adjustment
FIG. 26 Intermittent Pilot System F9/M9 Control Panel FIG. 27 Control Panel Assembly 500,000 Btu/hr TEMPERATURE ADJUSTMENT Operating Temperature Control NOTE: The temperature controller is pre-set at the factory with test settings. You may need to adjust the settings to meet your specific needs. - Page 21 Boilers with the outdoor air reset option also have an outside air temperature sensor. Water Heater Application Water heater units are shipped with two sensors; the inlet water temperature sensor and the multi-purpose temperature sensor to be used as a tank sensor.
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Page 22: Temperature Limit Control
5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller. 6. Do not mount sensor with leadwire end pointing up in an area where condensation can occur. 7. Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists. -
Page 23: Blocked Vent And Flame Roll-Out System
Manual Reset High Water Temperature Limit Control ( Standard Fixed Settings on Water Heaters and Optional Adjustable Settings on Boilers and Water Heaters Water heaters are supplied with a fixed setting, manual reset high water temperature limit control. This manual reset temperature limit control has a fixed limit setting of 230°F (110°C). -
Page 24: Lighting Instructions
On boilers, the pump will operate whenever the “W” terminal is energized. B. Location - The appliance should be located within a room having a temperature safely above freezing [32°F(0°C)]. C. Shutdown and Draining - If, for any rea son, the appliance is shut off, the following pre cau tion ary measures must be taken: 1. - Page 25 Set the thermostat to the lowest setting (OFF). Turn off all electrical power to the appliance. Turn the gas control knob on the gas valve clockwise to the “OFF” position. FIG. 33 F1 Gas Valve 90,000 - 270,000 Btu/hr Models Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor.
- Page 26 TO TURN OFF GAS TO APPLIANCE Set the thermostat to the OFF position. Turn off all electric power to the appliance if service is to be performed. Turn the gas control knob on the gas valve clockwise to the “OFF” position. Do not force. WARNING Should overheating occur or the gas fail to shut off, turn off the external manual gas valve to the...
- Page 27 OPERATING INSTRUCTIONS STOP! Read the safety information first. Remove the control panel door. Set the thermostat to the lowest setting (OFF). Turn off all electrical power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand.
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Page 28: Ignition & Control Timings
11. If ignition system fails to operate properly, re pair work must be performed by a qualified serviceman or installer. INTERMITTENT PILOT SPARK IGNITION SYSTEM (F9/M9) The ignition module is not repairable. Any mod i fi ca tion or repairs will invalidate the warranty and may create hazardous conditions that result in prop er ty damage, personal injury, fire, explosion and/or toxic gases. -
Page 29: Maintenance
Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system. WATER TREATMENT In hard water areas, water treatment should be used to reduce the introduction of minerals to the sys tem. Minerals in the water can collect in the heat exchanger tubes and cause noise on operation. -
Page 30: Inspection Cleaning Procedure
INSPECTION CLEANING PROCEDURE WARNING The combustion chamber lining in this appliance contains ceramic fiber materials. Ceramic fibers can transform into cristobalite (crystalline silica) when exposed to temperatures above 2192°F (1200°C) dependent upon the length of exposure time.* The International Agency for Research on Cancer (I.A.R.C.) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans."**... - Page 31 o. Check “V” baffles on top of the heat ex chang er. Remove and clean if necessary. p. Remove soot from the heat exchanger with a stiff bristle brush. Soot may also be re moved from the heat exchanger by washing thoroughly with detergent and water.
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Page 32: Gas Train
Heating Boilers with inputs of 45,000 - 260,000 Btu/hr have 1 1/2" NPT inlet and outlet connections. Heating boilers with inputs of 315,000 - 500,000 Btu/hr have 2" NPT. All water heaters have 2" NPT. Cau tion: Field installed reducing bushings may de crease flow re sult ing in boiler noise or flashing to steam. -
Page 33: Pressure Drop Chart
TABLE - L HEAT EXCHANGER PRESSURE DROP CHART FOOT HEAD LOSS CIRCULATOR PUMP SPECIFICATIONS Maximum operating pressure for the pump must exceed system operating pressure. Maximum water temperature should not ex ceed nameplate rating. Cast iron circulators may be used for closed loop systems. - Page 34 BOILER PIPING FIG. 43 Primary/Secondary Piping of a Single Boiler Heating boilers with inputs of 315,000 - 500,000 Btu/hr or larg er installed on multiple zone systems are rec om - mend ed to be installed with a primary/sec ond ary piping sys tem as shown in Figure 43.
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Page 35: Bypass Requirements
LOW TEMPERATURE BYPASS REQUIREMENTS This piping is like a primary/secondary boiler installation with a bypass in the secondary boil er piping. Inlet water temperatures below 140°F (60°C) can excessively cool the prod ucts of combustion re sult ing in condensation on the heat exchanger and in the flue. -
Page 36: Placing Boiler In Operation
TABLE - M MINIMUM REQUIRED FLOW FOR HEATING BOILER Input Btu/hr GPM Flow 45,000 75,000 90,000 135,000 180,000 215,000 260,000 315,000 360,000 399,999 500,000 NOTE: Minimum flow is based on a 40°F tem per a ture rise across the boiler. Minimum flow may not prove a flow switch installed in the boiler piping. -
Page 37: Temperature Rise Chart
10. Start the boiler according to the in this manual. Operate the system, including the pump, boiler and radiation units, for one hour. 11. Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. -
Page 38: Boiler Temperature Control
16 GA 18 GA DOMESTIC WATER HEATERS 90,000 - 500,000 Btu/hr MODELS This section applies only to those units used to sup ply direct fired domestic hot water and installed with a storage tank(s). The use of a properly sized pump and... -
Page 39: Water Velocity Control
If they do not, an adjustment must be made to your final calculation. Turn the water heater on and allow time for the temperature to stabilize. Record the difference between the inlet and outlet temperatures. This difference will be the “tem per a ture rise.”... -
Page 40: Water Chemistry
STORAGE TANK Softened water will DRAIN FIG. 49 Typical Water Heater Piping with Storage Tank COMMON WATER MANIFOLD SIZE FOR MULTIPLE HOT WATER SUPPLY BOILER Pipe sizing chart provides minimum pipe size for com mon manifold piping and tank tappings to in - sure ad e quate flow. - Page 41 Based on heating potable water with a hardness of 8 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm. See BTU/hr INPUT 90,000 - 500,000 REMOTE SENSOR INSTALLATION INSTRUCTIONS Water heaters are provided with an extra temperature sensor that MUST BE field installed.
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Page 42: Risk Of Scald Warnings
(2) Higher stored water temperature in creas es the ability of the water heater to supply desired quantities of hot water, however remember:... - Page 43 THERMAL EXPANSION A relief valve which discharges periodically may be due to thermal expansion in a closed system. A hot water supply boiler installed in a closed sys tem, such as one with a backflow preventer or check valve in stalled in the cold water supply, shall be provided with means to control expansion.
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Page 44: Troubleshooting
45,000 - 500,000 Btu/hr Models - Boilers & Water Heaters F9/M9 Is the spark STEP 1: igniter sparking? Is the pilot STEP 2: staying ON? STEP 3: Is the gas valve getting 24VAC? TROUBLESHOOTING GUIDE Check continuity of the spark cable. - Page 45 90,000 - 270,000 Btu/hr Models - Water Heaters F1 STEP 1: Is the pilot lit? Is the gas valve STEP 2: getting 24VAC? STEP 3: Unit is running. TROUBLESHOOTING GUIDE Check for gas. Check the pilot assembly and thermocouple. Check the gas valve for proper operation.
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Page 46: Wiring Diagrams
Schematic Diagram - F1 Unit Wiring Diagram - F1 Unit 90,000 - 270,000 Btu/hr Models 90,000 - 270,000 Btu/hr Models... - Page 47 Schematic Diagram - F9 Unit Wiring Diagram - F9 Unit 90,000 - 399,999 Btu/hr Models 90,000 - 399,999 Btu/hr Models...
- Page 48 Schematic Diagram - M9 Unit Wiring Diagram - M9 Unit 45,000 - 399,999 Btu/hr Models 45,000 - 399,999 Btu/hr Models...
- Page 49 Wiring Diagram - F9/M9 Unit Schematic Diagram - F9/M9 Unit 500,000 Btu/hr Models 500,000 Btu/hr Models...
- Page 50 NOTES...
- Page 51 NOTES...
- Page 52 Revision 4 (RSB-i&s-04) reflects the removal of the inlet pipe and installing the inlet sensor inside the header. Revision 5 (RSB-i&s-05) reflects changes made to the O.A. section. RSB-i&s-05 CP-5M-4/08...