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100283650_2000541395_Rev L
™
F I R E T U B E
Epic Fire Tube Boiler and Combi
Installation & Service Manual
EPC 110 - 199 & EPB 80 - 199
Series 100 - 101 & 110 - 111
⚠WARNING
This manual must only be used
by a qualified heating installer
/ service technician. Read all
instructions, in this manual before
installing. 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 Epic 100 Series
Summary of Contents for Lochinvar Epic 100 Series
- Page 1 100283650_2000541395_Rev L ™ F I R E T U B E Epic Fire Tube Boiler and Combi Installation & Service Manual EPC 110 - 199 & EPB 80 - 199 Series 100 - 101 & 110 - 111 ⚠WARNING This manual must only be used by a qualified heating installer / service technician.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS .............. 2 Chilled Water System ................ 33 PLEASE READ BEFORE PROCEEDING ......3 Freeze Protection Fluids ..............33 THE EPIC FIRE TUBE -- HOW IT WORKS ......4-5 General Piping Information ............. 33 RATINGS ................... 6 Near Boiler Piping Components ............. 34 1. -
Page 3: Please Read Before Proceeding
Installation & Service Manual ™ F I R E T U B E Please read before proceeding Installer – Read all instructions, in this DO NOT install units in rooms or ⚠WARNING ⚠WARNING manual before installing. Perform steps environments that contain corrosive in the order given. -
Page 4: The Epic Fire Tube - How It Works
Installation & Service Manual ™ F I R E T U B E The Epic Fire Tube - How it works... 1. Heat exchanger 17. Boiler control module Allows system water to flow through specially designed The boiler control responds to internal and external signals coils for maximum heat transfer, while providing and controls the blower, gas valve, and pumps to meet the protection against flue gas corrosion. - Page 5 Installation & Service Manual ™ F I R E T U B E The Epic Fire Tube - How it works... (continued) NOTICE The Epic Combi Boiler is shown throughout the manual unless otherwise noted. Bottom View - Boiler Only FRONT LEFT RIGHT...
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Page 6: Ratings
Installation & Service Manual ™ F I R E T U B E Ratings LOW LEAD CONTENT Other Specifications AHRI Rating AFUE Input AHRI DHW Water SH Water Heating Capacity Model Number Connections Ratings Connections Vent/Air Boiler Water Water, Size Content Gallons Connections Note: Change “N”... -
Page 7: Determine Boiler Location
Installation & Service Manual ™ F I R E T U B E Determine boiler location Installation must comply with: DO NOT install the boiler in a room likely to freeze. • Local, state, provincial, and national codes, laws, regulations, and ordinances. This appliance is certified as an indoor ⚠WARNING •... - Page 8 Installation & Service Manual ™ F I R E T U B E Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, ⚠WARNING polypropylene, or stainless steel 1" MINIMUM CLEARANCE vent material MUST BE used in AROUND VENT PIPE 6"...
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Page 9: Provide Air Openings To Room
Installation & Service Manual ™ F I R E T U B E Determine boiler location (continued) Residential garage installation If you do not provide the recommended NOTICE service clearances shown, it may not be Precautions possible to service the boiler without removing it from the space. -
Page 10: Corrosive Contaminants And Sources
Installation & Service Manual ™ F I R E T U B E Determine boiler location When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new boiler: Products to avoid: Failure to follow all instructions can result ⚠WARNING Spray cans containing chloro/fluorocarbons in flue gas spillage and carbon monoxide... -
Page 11: Removing A Boiler From Existing Common Vent
Installation & Service Manual ™ F I R E T U B E Determine boiler location (continued) When removing a boiler from existing common vent system: Do not install the Epic Fire Tube into a g. Any improper operation of the common venting system ⚠... -
Page 12: Prepare Boiler
Installation & Service Manual ™ F I R E T U B E Prepare boiler Remove boiler from wood pallet 1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow the boiler to cool 1. -
Page 13: Mounting The Boiler
Installation & Service Manual ™ F I R E T U B E Prepare boiler Mount the wall bracket using the 2 1/4" lag bolts (continued) provided. Make sure the top edge of the bracket is away After converting to LP, check combustion from the wall. -
Page 14: General Venting
Installation & Service Manual ™ F I R E T U B E General venting Direct venting options - Sidewall Vent DIR #2000534592 00 DIR #2000534593 00 Figure PVC/CPVC Concentric Sidewall Figure 3-1 Two-Pipe Sidewall Termination - See Termination - See page 25 for more details page 22 for more details Direct venting options - Vertical Vent DIR #2000534588 00... -
Page 15: Install Vent And Combustion Air Piping
Installation & Service Manual ™ F I R E T U B E General venting (continued) Install vent and combustion air piping The Epic Fire Tube vent and air piping can be installed through The Epic Fire Tube must be vented and ⚠... -
Page 16: Sizing
Installation & Service Manual ™ F I R E T U B E General venting Sizing ⚠WARNING Using air intake materials other than those specified can result in personal injury, The Epic Fire Tube uses model specific combustion air intake death or property damage. -
Page 17: Optional Room Air
Installation & Service Manual ™ F I R E T U B E General venting (continued) Optional room air Please read the information given in Table 1A, page 10, Optional room air is intended for NOTICE listing contaminants and areas likely to contain them. commercial applications. -
Page 18: Pvc/Cpvc
Installation & Service Manual ™ F I R E T U B E General venting PVC/CPVC: Work from the boiler to vent or air termination. Do This product has been approved for use with the PVC/CPVC not exceed the lengths given in this manual for the air vent materials listed in Table 3D. -
Page 19: Polypropylene
Installation & Service Manual ™ F I R E T U B E General venting (continued) Polypropylene: The installer must use a specific vent NOTICE starter adapter at the flue collar connection, This product has been approved for use with polypropylene supplied by the vent manufacturer to vent with the manufacturers listed in Table 3E. -
Page 20: Stainless Steel Vent
Installation & Service Manual ™ F I R E T U B E General venting Stainless steel vent: Installation of a stainless steel vent system NOTICE should adhere to the stainless steel vent This product has been approved for use with stainless steel manufacturer’s installation instructions using the manufacturers listed in Table 3G. -
Page 21: Sidewall Direct Venting Vent/Air Termination - Sidewall
Installation & Service Manual ™ F I R E T U B E Sidewall direct venting Vent/air termination – sidewall If using the sidewall termination: Follow instructions below when 3. The air piping must terminate in a down-turned elbow ⚠WARNING determining vent location to avoid as shown in FIG. - Page 22 Installation & Service Manual ™ F I R E T U B E Sidewall direct venting Figure 4-2A Clearance to Gravity Air Inlets w/Field Vent/air termination – sidewall Supplied Fittings Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR COUPLING...
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Page 23: Prepare Wall Penetrations
Installation & Service Manual ™ F I R E T U B E Sidewall direct venting (continued) Prepare wall penetrations Figure 4-5A Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1A) Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. -
Page 24: Sidewall Termination - Optional Concentric Vent
Installation & Service Manual ™ F I R E T U B E Sidewall direct venting Sidewall termination – optional concentric vent Description and usage 3. Cut one (1) hole (5 inch diameter for #100140480 The manufacturer offers optional concentric combustion air installations or 4 inch diameter for #100140485 installations) and vent pipe termination kits (Factory Kit #100140480 - 3"... - Page 25 Installation & Service Manual ™ F I R E T U B E Sidewall direct venting (continued) Sidewall termination – optional concentric vent models Figure 4-8 Concentric Vent Dimensional Drawing Instead of cementing the smaller pipe to NOTICE 5. Install the Y concentric fitting and pipe assembly through the rain cap, a field-supplied stainless steel the structure’s hole.
- Page 26 Installation & Service Manual ™ F I R E T U B E Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-10 Concentric Vent Sidewall Attachment Multiventing sidewall terminations DO NOT use field-supplied couplings to CAUTION extend pipes. Airflow restriction will occur When two (2) or more direct vent appliances are vented near and may cause intermittent operation.
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Page 27: Vertical Direct Venting Vent/Air Termination - Vertical
Installation & Service Manual ™ F I R E T U B E Vertical direct venting Vent/air termination – vertical Follow instructions below when ⚠WARNING Figure 5-1A PVC/CPVC/Polypropylene Vertical determining vent location to avoid Termination of Air and Vent possibility of severe personal injury, death or substantial property damage. -
Page 28: Prepare Roof Penetrations
Installation & Service Manual ™ F I R E T U B E Vertical direct venting Vent/air termination – vertical Prepare roof penetrations Figure 5-2 Vertical Terminations with Multiple Boilers Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. -
Page 29: Vertical Termination - Optional Concentric Vent
Installation & Service Manual ™ F I R E T U B E Vertical direct venting (continued) Vertical termination – optional concentric vent Description and usage 2. Cut one (1) hole (5 inch diameter for #100140480 installations The manufacturer offers an optional concentric combustion or 4 inch diameter for #100140485 installations) into the air and vent pipe termination kit. - Page 30 Installation & Service Manual ™ F I R E T U B E Vertical direct venting Vertical termination – optional concentric vent DO NOT use field-supplied couplings to Do not operate the appliance with CAUTION ⚠WARNING extend pipes. Airflow restriction will occur. the rain cap removed or recirculation of combustion products may occur.
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Page 31: Alternate Vertical Concentric Venting
Installation & Service Manual ™ F I R E T U B E Vertical direct venting (continued) Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an Figure 5-8 Concentric Vent Example 1 existing unused venting system;... - Page 32 Installation & Service Manual ™ F I R E T U B E Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase FLUE EXHAUST AIR INLET...
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Page 33: Hydronic Piping
Installation & Service Manual ™ F I R E T U B E Hydronic piping System water piping methods General piping information All boiler piping must contain an oxygen The Epic Fire Tube is designed to function in a closed loop IMPORTANT barrier. -
Page 34: Near Boiler Piping Components
DHW and space heating. top right side of the boiler (images in this manual show relief valve installed). Lochinvar offers the Squire which is a series of indirect 8. Boiler purge valve: water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger. - Page 35 Installation & Service Manual ™ F I R E T U B E Hydronic piping (continued) Figure 6-1 Pressure Drop vs. Flow_COMBI ONLY Table 6A Temperature Rise Applications_Combi Only EPC110 EPC150 Delta T FT/HD Eq Ft of 1" Pipe Delta T FT/HD Eq Ft of 1"...
- Page 36 Installation & Service Manual ™ F I R E T U B E Hydronic piping Figure 6-2 Single Boiler - Primary / Secondary Piping_COMBI ONLY PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER MAKE UP WATER SEPARATOR SYSTEM SUPPLY SENSOR MAY SUBSTITUTE LOW LOSS HEADER (OPTIONAL) FROM SYSTEM...
- Page 37 Installation & Service Manual ™ F I R E T U B E Hydronic piping (continued) Figure 6-3 Single Temperature Zoned with Circulators_COMBI ONLY ZONE #1 PRESSURE PRESSURE ZONE #2 ZONE #3 ZONE #4 GAUGE REDUCING VALVE BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL)
- Page 38 Installation & Service Manual ™ F I R E T U B E Hydronic piping Figure 6-4 Multiple Boilers - Single Temperature Zoned with Circulators_COMBI ONLY Number of Units Model Required Pipe Sizes 1 1/2" 2" 2" 2 1/2" 2 1/2" 3"...
- Page 39 Installation & Service Manual ™ F I R E T U B E Hydronic piping (continued) Figure 6-5 Single Temperature Piped with Air Handler_COMBI ONLY HANDLER AIR SEPARATOR BALL VALVE (TYPICAL) Y-STRAINER (RECOMMENDED) DRAIN POINT (TYPICAL) BOILER MAKE UP WATER PRESSURE REDUCING VALVE PRESSURE...
- Page 40 Installation & Service Manual ™ F I R E T U B E Hydronic piping Figure 6-6 Pressure Drop vs. Flow_BOILER ONLY NK080 NK110 35.000 30.000 30.000 25.000 25.000 20.000 20.000 15.000 15.000 10.000 10.000 5.000 5.000 0.000 0.000 FLOWRATE (GPM) FLOWRATE (GPM) NK150 NK199...
- Page 41 Installation & Service Manual ™ F I R E T U B E Hydronic piping (continued) Figure 6-7 Single Boiler - Primary / Secondary Piping_BOILER ONLY PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER MAKE UP WATER SEPARATOR SYSTEM SUPPLY SENSOR MAY SUBSTITUTE LOW LOSS HEADER (OPTIONAL) FROM...
- Page 42 Installation & Service Manual ™ F I R E T U B E Hydronic piping Figure 6-8 Single Temperature Zoned with Circulators_BOILER ONLY ZONE #1 PRESSURE PRESSURE ZONE #2 ZONE #3 ZONE #4 GAUGE REDUCING VALVE BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL) MAKE UP WATER...
- Page 43 Installation & Service Manual ™ F I R E T U B E Hydronic piping (continued) Figure 6-9 Multiple Boilers - Single Temperature Zoned with Circulators_BOILER ONLY Number of Units Model Required Pipe Sizes 1 1/4" 1 1/2" 2" 2" 2 1/2"...
- Page 44 Installation & Service Manual ™ F I R E T U B E Hydronic piping Figure 6-10 Single Temperature Piped Full Flow_BOILER ONLY PRESSURE PRESSURE GAUGE REDUCING VALVE BACKFLOW PREVENTER MAKE UP WATER HANDLER AIR SEPARATOR EXPANSION TANK BALL VALVE (TYPICAL) Y-STRAINER (RECOMMENDED)
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Page 45: Domestic Water Piping
Installation & Service Manual ™ F I R E T U B E Domestic water piping (Combi Only) Water chemistry Scalding Any damage or failure resulting from improper water This combi heater can deliver scalding temperature water chemistry, or heating anything other than potable water. at any faucet in the system. -
Page 46: Dhw Pressure Drop Chart
Installation & Service Manual ™ F I R E T U B E Domestic water piping (Combi Only) Table 6E DHW Pressure Drop Chart DHW PRESSURE DROP Combi Sequence of operation Th e cold domestic water enters the plate heat exchanger through the DHW inlet connection, fl ow switch, and strainer. -
Page 47: Domestic Water Piping Diagrams
Installation & Service Manual ™ F I R E T U B E Domestic water piping (Combi Only) (continued) Figure 6-11 Combi DHW Piping BOILER EXPANSION TANK UNION (TYPICAL) PRESSURE RELIEF VALVE (REQUIRED, FIELD SUPPLIED) ASSE 1070 ANTI-SCALD FLOW MIXING VALVE CHECK (REQUIRED) TEMPERATURE /... - Page 48 Installation & Service Manual ™ F I R E T U B E Domestic water piping (Combi Only) Figure 6-12 DHW Recirculation w/Dedicated Return BOILER Note: Aquastat for DHW recirculation pump or thermostatic shut off valve must be used to stop recirculation water fl...
- Page 49 Installation & Service Manual ™ F I R E T U B E Domestic water piping (Combi Only) (continued) Figure 6-13 DHW Piping w/Recirculation Return Through Cold Line BOILER Note: Aquastat recirculation pump or thermostatic shut off valve must be used to stop recirculation water fl...
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Page 50: Gas Connections Connecting Gas Supply Piping
Installation & Service Manual ™ F I R E T U B E Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 2. Support piping with hangers, not by the boiler or its to pipe gas to the boiler. -
Page 51: Natural Gas
Installation & Service Manual ™ F I R E T U B E Gas connections (continued) Natural gas: Failure to apply pipe sealing compound ⚠WARNING as detailed in this manual can result Pipe sizing for natural gas in severe personal injury, death, or substantial property damage. -
Page 52: Check Inlet Gas Supply
Installation & Service Manual ™ F I R E T U B E Gas connections Table 7A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size... -
Page 53: Gas Pressure
Installation & Service Manual ™ F I R E T U B E Gas connections (continued) Gas Pressure 13. Shut off the gas supply at the manual gas valve in the gas piping to the appliance. The gas pressure must remain between 4 inches w.c. (natural), 14. -
Page 54: Field Wiring
Installation & Service Manual ™ F I R E T U B E Field wiring Installation must comply with: For field wiring on Combi units, reference NOTICE the Combi Installation and Service 1. National Electrical Code and any other national, state, Manual provided with the unit. - Page 55 Installation & Service Manual ™ F I R E T U B E Field wiring (continued) System supply sensor Thermostat (field supplied) 1. By installing the system supply sensor as shown in the 1. Connect the room thermostat or end switch (isolated Hydronic Piping section of this manual, the temperature of contact only) to the room thermostat as shown in FIG.'s the primary supply can be controlled.
- Page 56 Installation & Service Manual ™ F I R E T U B E Field wiring Figure 8-4 Low Voltage Field Wiring Connections_BOILER ONLY...
- Page 57 Installation & Service Manual ™ F I R E T U B E Field wiring (continued) Figure 8-5 Low Voltage Field Wiring Connections_COMBI ONLY...
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Page 58: Condensate Disposal Condensate Drain
Installation & Service Manual ™ F I R E T U B E Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. This boiler is a high efficiency appliance that produces authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. - Page 59 Installation & Service Manual ™ F I R E T U B E Start-up 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.
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Page 60: Startup
Installation & Service Manual ™ F I R E T U B E Start-up Use glycol only if needed for a freeze protection fluid. Fill and test water system Propylene glycol is the recommended freeze protection 1. Fill system only after ensuring the water meets the fluid. - Page 61 Installation & Service Manual ™ F I R E T U B E Start-up (continued) Check for gas leaks Check thermostat circuit(s) Before starting the boiler, and during 1. Disconnect the external wire connected to the room ⚠WARNING initial operation, smell near the floor and thermostat terminal on the connection board.
- Page 62 Installation & Service Manual ™ F I R E T U B E Start-up Final checks before starting the boiler Check gas piping 1. Check around the boiler for gas odor following the Read this manual to familiarize yourself with boiler procedure on page 63 of this manual.
- Page 63 Installation & Service Manual ™ F I R E T U B E Start-up (continued) Figure 10-2 Operating Instructions Move switch to the “OFF” position.
- Page 64 Installation & Service Manual ™ F I R E T U B E Start-up Epic Fire Tube control module Use the control panel (FIG. 10-3) to set temperatures, operating conditions, and monitor boiler operation. Figure 10-3 Control Panel DISPLAY RESET BUTTON WINDOW - Indicates that the unit has a Space Heating demand.
- Page 65 Installation & Service Manual ™ F I R E T U B E Start-up (continued) Setup wizard MAX SH SETPT • Th e MAX SH SETPT should be set to the highest space heating water set point that can be used for the specifi c Th e Epic Fire Tube control has a Setup Wizard feature that can space heating system.
- Page 66 Installation & Service Manual ™ F I R E T U B E Start-up DHW SETPT Th e Epic Fire Tube includes a Service Mode feature that can be used to force the unit to run at a particular • Th is is the desired set point temperature of fi ring rate.
- Page 67 Installation & Service Manual ™ F I R E T U B E Start-up (continued) ► ▼ Verify space heat circulator operation 3. Press the buttons (simultaneously) for 5 seconds to enter Service Mode. Note: Diverter valve used on Combi models only. 4.
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Page 68: Operating Information General
Installation & Service Manual ™ F I R E T U B E Operating information General Parameters in the set points menu: SH SETPT (COLD DAY) How the boiler operates • Space heating water set point temperature, or the The Epic Fire Tube uses an advanced stainless steel heat space heating water set point temperature when exchanger and electronic control module that allows fully outdoor temperature is at the cold day setting if... -
Page 69: Control Inputs And Outputs
Installation & Service Manual ™ F I R E T U B E Operating information (continued) Parameters in the installer menu: Enter the installer password GENERAL Submenu To enter the installer password, use the ▲ and ▼ buttons to • MAX SH SETPT – also found in OUTDOOR RESET change the value of the fi rst digit to 5, then press ►... - Page 70 Installation & Service Manual ™ F I R E T U B E Operating information DHW Priority (Boiler) Combi diverter valve (Combi Only) The Smart System control allows the connection of a DHW The Epic Fire Tube is factory equipped with a diverter valve thermostat or tank sensor to the low voltage board.
- Page 71 Installation & Service Manual ™ F I R E T U B E Operating information (continued) Outdoor air reset Outdoor Air Shutdown The Epic Fire Tube uses an advanced non-linear outdoor Outdoor air shutdown specifi es the outdoor air temperature at reset curve to improve system efficiency by reducing the which the Space Heating demand is blocked.
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Page 72: Cascade
Installation & Service Manual ™ F I R E T U B E Operating information Cascade The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the When multiple Epic Fire Tubes are installed, they can be control will reduce the maximum fan speed. - Page 73 Installation & Service Manual ™ F I R E T U B E Operating information (continued) Low voltage blocking The blower and gas valve require a minimum amount of voltage in order to operate properly. If an ignition attempt is made when the line voltage is temporarily low (such as during a brownout), the control could enter a manual reset lockout.
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Page 74: Sequence Of Operation
Installation & Service Manual ™ F I R E T U B E Operating information Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pumps. The LWCO must close. 2. Once the LWCO has closed, the auxiliary limit switch must close. - Page 75 Installation & Service Manual ™ F I R E T U B E Operating information (continued) Sequence of operation (continued) OPERATION DISPLAY 6. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command.
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Page 76: Maintenance Maintenance And Annual Startup
Installation & Service Manual ™ F I R E T U B E Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the Epic Fire Tube User’s Information Manual (see the following pages for instructions) for instructions) General: •... - Page 77 Installation & Service Manual ™ F I R E T U B E Maintenance (continued) Follow the Service and maintenance procedures given throughout this manual and in component literature ⚠WARNING shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.
- Page 78 Installation & Service Manual ™ F I R E T U B E Maintenance Check fill water meter 2. After following the warning directions in this manual, if the relief valve weeps or will not seat properly, replace the 1. Check fill water meter for water usage. If the amount relief valve.
- Page 79 Installation & Service Manual ™ F I R E T U B E Maintenance (continued) Handling ceramic fiber materials Figure 12-2 Burner Assembly REMOVAL OF COMBUSTION CHAMBER LINING TOP PLATE The combustion chamber insulation in ⚠WARNING this appliance contains ceramic fiber material.
- Page 80 • Follow the “To Turn Off Gas to Appliance” instructions 1. Shut down boiler: for the boiler in Section 10 - Startup of the Lochinvar • Follow the “To Turn Off Gas to Appliance” instructions Combi Boiler Installation and Operation Manual.
- Page 81 Installation & Service Manual ™ F I R E T U B E Maintenance (continued) 3. Allow the unit to progress through its normal diagnostics Figure 12-3 Remove flow sensor and DHW flow and pre-purge programming. switch assembly 4. Allow the unit to fire and operate until the temperatures stabilize.
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Page 82: Troubleshooting
Installation & Service Manual ™ F I R E T U B E Troubleshooting Check control module fuses If this boiler may be frozen, DANGER ⚠ immediately shut off power and gas to the appliance and contact ALWAYS check control module fuses NOTICE the factory for further instructions. - Page 83 Installation & Service Manual ™ F I R E T U B E Troubleshooting (continued) Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature.
- Page 84 Installation & Service Manual ™ F I R E T U B E Troubleshooting Table 13-2 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Supply problem. Natural • Refer Section Connections pressures should be between 4 inches w.c. detailed information concerning the gas supply. and 14 inches w.c.
- Page 85 Installation & Service Manual ™ F I R E T U B E Troubleshooting (continued) Table 13-3 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The control module has detected parameter • Replace control module. settings that are corrupted.
- Page 86 • Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping for the proper piping methods for the Lochinvar Combi Boiler. • Check 120 vac to boiler pump motor on a call for heat.
- Page 87 Installation & Service Manual ™ F I R E T U B E Troubleshooting (continued) Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect spark electrode and associated wiring for damage and connection.
- Page 88 Refer to Section 6A - Hydronic Piping the setting of the manual reset high limit. has been corrected. for the proper piping methods for the Lochinvar Combi Press the RESET button Boiler. on the display to reset.) • Check 120 vac to boiler pump motor on a call for heat.
- Page 89 • Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping The temperature rise across the heat for the proper piping methods for the Lochinvar Combi exchanger has exceeded the set parameters Boiler. for the boiler.
- Page 90 Installation & Service Manual ™ F I R E T U B E Troubleshooting Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION • Check 120 vac supply to the transformer. •...
- Page 91 Installation & Service Manual ™ F I R E T U B E Troubleshooting (continued) Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT CAUSE CORRECTIVE ACTION • Verify DHW flow is at least 0.4 gpm. •...
- Page 92 Installation & Service Manual ™ F I R E T U B E Troubleshooting Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT CAUSE CORRECTIVE ACTION • Wait until DHW demand has ended, then combi unit should provide heated water to the space heating A DHW demand is present.
- Page 93 • Check for obstructions at the vent/air intake terminals. Gas Supply Pressure • Refer to Section 7 - Gas Connections for the proper gas supply for the Lochinvar Fire Tube. • Refer to page 79 of this manual for burner removal.
- Page 94 Installation & Service Manual ™ F I R E T U B E Troubleshooting Figure 13-2 Gas Valve Adjustment_Layout 1 SCREW CAP MUST BE REMOVED TO ACCESS BIAS/OFFSET ADJUSTMENT SCREW THROTTLE ADJUSTMENT SCREW (REQUIRES 2.5 MM DIR #2000577164 00 HEX KEY) Figure 13-3 Gas Valve Adjustment_Layout 2 THROTTLE ADJUSTMENT...
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Page 95: Diagrams
Installation & Service Manual ™ F I R E T U B E Diagrams Figure 14-1 Combi Models Only: Ladder Diagram (Standard) 120VAC NEUTRAL GROUND JUNCTION BOX 120V SUPPLY "L" 120V SUPPLY "N" INTEGRATED CONTROL SYSTEM PUMP "L" SYSTEM PUMP X1-6 RELAY X1-2... -
Page 96: Wiring Diagram (Standard)_Combi Only
Installation & Service Manual ™ F I R E T U B E Diagrams Figure 14-2 Combi Models Only: Wiring Diagram (Standard) DISPLAY LOW VOLTAGE 120 VAC HIGH VOLTAGE INTEGRATED CONNECTION BOARD CONTROL JUNCTION X1-3 BOX DEPICTS OPTONAL ITEMS SHIELD CASCADE X1-2 SHIELD... -
Page 97: Ladder Diagram (Standard)_Boiler Only
Installation & Service Manual ™ F I R E T U B E Diagrams (continued) Figure 14-3 Boiler Models Only: Ladder Diagram (Standard) 120VAC NEUTRAL GROUND JUNCTION BOX 120V SUPPLY "L" 120V SUPPLY "N" INTEGRATED CONTROL SYSTEM SYSTEM PUMP PUMP "L" SYSTEM X1-6 PUMP... -
Page 98: Wiring Diagram (Standard)_Boiler Only
Installation & Service Manual ™ F I R E T U B E Diagrams Figure 14-4 Boiler Models Only: Wiring Diagram (Standard) DISPLAY LOW VOLTAGE 120 VAC HIGH VOLTAGE CONNECTION BOARD JUNCTION BOX DEPICTS OPTONAL ITEMS X1-3 PUMP SHIELD CASCADE X1-4 BOILER PUMP... - Page 99 Installation & Service Manual ™ F I R E T U B E Notes...
- Page 100 Revision A (PCP #3000024821 / CN #500014945) initial release. Revision B (PCP #3000026706 / CN #500016345) reflects an update to the low voltage field wiring connections images on pages 56 and 57. Revision C (PCP #3000027055 / CN #500016866) reflects the removal of references to an external flow switch.