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Lochinvar 45,000—500,000 Btu/hr Models Installation And Service Manual

Water heater/domestic hot water supply boiler
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Download this manual See also: User's Information Manual
INSTALLATION AND SERVICE MANUAL
Water Heater/Domestic Hot Water Supply Boiler
Installation and service must be performed by a
qualified service installer, service agency or the gas
supplier.
WARRANTY
Factory warranty (shipped with appliance) does not
apply to appliances improperly installed or improperly
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 Water Treatment
and Water Chemistry).
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
Boiler Flow Rates and Temperature Rise for
flow requirements).
SPECIAL INSTRUCTIONS TO OWNER
NOTE:
Retain this manual for future reference.
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.
WARNING:
Improper Installation, Adjustment,
Alteration, Service or Maintenance
can cause injury or property damage.
Refer to this manual. For assistance or
additional information consult a qualified
installer, service agency or the gas supplier.
Hot Water Heating Boiler
45,000—500,000 Btu/hr Models
1
CHECKING EQUIPMENT
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying
the appliance which may show signs of being hit or
otherwise being mishandled. Verify total number of
pieces shown on packing slip with those actually
received.
In case there is damage or a shortage,
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 appliance that has
been under water must be replaced.
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.
The 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.
— 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
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.
RB/RW-i&s-07

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Summary of Contents for Lochinvar 45,000—500,000 Btu/hr Models

  • Page 1: Warranty Safety Warnings

    RB/RW-i&s-07 INSTALLATION AND SERVICE MANUAL Hot Water Heating Boiler Water Heater/Domestic Hot Water Supply Boiler 45,000—500,000 Btu/hr Models Installation and service must be performed by a CHECKING EQUIPMENT qualified service installer, service agency or the gas supplier. Upon receiving equipment, check for signs of shipping damage.

  • Page 2: Table Of Contents

    USER WARNING CONTENTS The information contained in this manual is Warranty intended for use by qualified professional installers, Safety Warnings ..............1 service technicians or gas suppliers. Consult your Codes ..................2 local expert for proper installation or service Location ..................3 procedures. Clearances................4 Combustion/Ventilation Air Requirements ......4 IMPORTANT:...

  • Page 3: Location Of Unit

    Safety Code for Controls and Safety Devices for Auto- LOCATION OF UNIT matically Fired Boilers, ASME CSD-1. All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code, Section IV. Where required by Locate the appliance so that if water connections the authority having jurisdiction, the installation must should leak, water damage will not occur.

  • Page 4: Clearances

    Clearances Models 199,000–500,000 29" Combustion Floor Base 6" FIG. 5B FIG. 4 CLEARANCES FROM TABLE - A COMBUSTIBLE CONSTRUCTION COMBUSTIBLE FLOOR BASE KITS Input BTU/hr Kit Number Clearances from Combustible Construction: 45,000 CFK3045 75,000 CFK3090 Right Side - 6" Rear - 6" 90,000 CFK3090 Left Side - 6"...
  • Page 5 Combustion Air from Interior Space Combustion Air Direct from Outside FIG. 6 FIG. 8 1. If air is taken directly from outside the building If air is taken from another interior space that is with no duct, provide two permanent openings: adequately ventilated, each of the two openings specified above should have a net free area of one a.
  • Page 6 TABLE - B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO MECHANICAL ROOM Combustion Air Source Input Outside Air*/2 Outside Air*/1 Inside Air/2 Btu/hr Openings Openings Openings 45,000 12 in 15 in 100 in 75,000 19 in 25 in 100 in 90,000 23 in 30 in 100 in...

  • Page 7: Conventional Venting

    mechanical room, the installer must make sure that it A CONVENTIONAL NEGATIVE DRAFT does not cause drafts which could lead to nuisance VENTING SYSTEM operational problems with the appliance. The negative draft in a conventional vent installation must be within the range of a negative 0.02 to 0.05 VENTING inches water to insure proper operation.
  • Page 8 Any vent materials used must be listed by a nationally exhaust fans, such as range hoods and bathroom recognized test agency for use as vent material. exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Locate appliance as close as possible to chimney or gas Close fireplace dampers.
  • Page 9 VENTING TERMINATION Vent Termination from Flat Roof 10’ or Less from Parapet Wall Vent Termination from Peaked Roof 10’ or Less from Ridge FIG. 11 FIG. 13 Vent Termination from Peaked Roof Vent Termination from Flat Roof More Than 10’ from Ridge More Than 10’...

  • Page 10: Masonry Chimney Installation

    The venting system shall terminate at least 4 feet (1.2m) Inspection of a Masonry Chimney below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above any door, window or gravity air inlet into any A masonry chimney must be carefully inspected to building.

  • Page 11: Automatic Vent Damper

    0.02 to 0.05 inches water to ensure proper operation. If The vent damper is a useful tool for saving energy when draft exceeds the specified range, the fan must be installed inside the building envelope where air can adjusted or the installation of a barometric damper in circulate freely around the appliance.

  • Page 12: Gas Supply

    Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment. MANIFOLD PRESSURE: Measured at the pressure tap on the downstream side of the combination gas valve(s). The gas regulator on the appliance’s combination gas valve(s) is adjustable to supply proper manifold pressure for normal operation.
  • Page 13 TABLE GAS CONNECTION FITTINGS TO EQUIVALENT 1. Safe operation of the appliance requires STRAIGHT PIPE properly sized gas supply piping. See data in Table F. Diameter Pipe (inches) 3/4" 1" 1 1/4" 1 1/2" 2" 3" 4" 5" 2. Gas pipe size may be larger than appliance gas connection.
  • Page 14 TABLE- H MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING SIZE CHART Nominal Length of Pipe in Straight Feet 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 1,720 1,560 1,440 1,330 1,250 1,180 1,100 2 1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100...

  • Page 15: Manifold Pressure Adjustment

    Install a sediment trap in the supply line to the gas GAS MANIFOLD PRESSURE valve or manifold assembly (see Figure 18). ADJUSTMENT PROCEDURE Thread pipe the proper amount for insertion into gas valve or manifold inlet as shown in Table-I. DO NOT THREAD PIPE TOO FAR.

  • Page 16: Supply Pressure Measurement

    Turn the gas valve control knob to the “ON” posi- CHECKING GAS SUPPLY PRESSURE tion. Set the thermostat(s) to call for heat. Observe gas regulator pressure when all burners are firing. See Table E, Manifold Pressure for proper regulator pressure settings. 10.

  • Page 17: Water Connections

    to the “ON” position when the pilot is established. 19. Set the thermostat(s) to call for heat. Turn the gas valve control knob(s) to the “ON” appliance is now ready to operate. position on spark ignition models. . IMPORTANT: Set the thermostat(s) to call for heat. Upon completion of any testing on the gas system, leak test all gas connections with a soap solution Observe the gas supply pressure with all burners...
  • Page 18 h. Remove heat exchanger by sliding out toward REVERSING THE HEAT EXCHANGER front of the appliance. Use caution to prevent WATER CONNECTIONS damage to burners, refractory, pilot, spark igniter (if equipped) or wiring. I. Turn heat exchanger so inlet/outlet header is on the right and slide back into unit.

  • Page 19: Relief Valve

    A water flow switch is available as a factory supplied RELIEF VALVE option on all heating boilers, hot water supply boilers and water heaters. The flow switch should be wired in series with the 24 VAC power to the gas valve (red wire) on standing pilot models and in series with the 24 VAC power to the ignition module (purple wire to 24V terminal on module) on intermittent pilot models.

  • Page 20: Gas Valve

    Each unit has a combination gas valve(s) to control the COMBINATION GAS VALVES gas supply to the burners. The 399,000 and 500,000 Btu/hr models have two combination gas valves to supply gas to the burners. Two stage burner operation F-1 Gas Valve Models 045–135 (M-9) is available as an option on intermittent pilot Outlet Wiring...

  • Page 21: Electrical Requirements

    lower setting, approximately 5-15 degrees lower, for TABLE - K staged burner operation. Two stage burner control AMP DRAW DATA systems (M-9) are recommended for application on 45,000 thru 500,000 Btu/hr Models heating boilers only. MAXIMUM FIRING TOTAL AMPS CONTROLS @ 120 VAC ELECTRICAL CONNECTIONS F-1 Standing Pilot (Single Stage...

  • Page 22: Temperature Adjustment

    The high water temperature limit sensor is mounted in INTERMITTENT PILOT SYSTEM - F9 the outlet side of the front header. CONTROL PANEL Manual Reset High Water Temperature Limit Control (Optional) The appliance may be supplied with a fixed setting, HIGH LIMIT manual reset high water temperature limit control.
  • Page 23 FLAME ROLL-OUT SWITCH INITIAL START-UP 45,000 BTU MODELS Follow instructions on the label applied to the top of the appliance. Burner A. Pump Operation - MOST IMPORTANT - This appliance is designed for continuous pump Burner operation when the burners are firing. Tray heating boiler may cycle the pump by using the pump control relay located in the control panel...

  • Page 24: Lighting Instructions

    WHAT TO DO IF YOU SMELL GAS PRE-START CHECKLIST Inspect the burners to be sure they are properly Do not try to light any appliance. aligned. Do not touch any electric switch; do not use any Inspect the pilot gas line, thermocouple leads, phone in your building.
  • Page 25 F-1 GAS VALVE - MODELS 045-135 USING LIGHTING WAND TO ALSO SEE FIG. 26 LIGHT STANDING PILOT OUTLET SIDE FIG. 35 FIG. 37 Wait five (5) minutes to clear out any gas, then Turn the control knob on the gas valve smell for gas, including near the floor.
  • Page 26 The main gas valve should extinguish the burners TO TURN OFF GAS TO APPLIANCE immediately after removal of the thermocouple. Set the thermostat to the lowest setting. If burners do not extinguish, immediately follow steps “TO TURN Turn off all electric power to the appliance if APPLIANCE”.

  • Page 27: Operating Instructions

    F-9 GAS VALVE - MODELS 045-135 WHAT TO DO IF YOU SMELL GAS ALSO SEE FIG. 27 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 neighbor’s phone.
  • Page 28 3a. 45,000 - 135,000 and 399,000 - 500,000 Btu/hr M-9 GAS VALVE models, rotate the gas control knob on the gas ALSO SEE FIG. 28 valve clockwise to the “OFF” position. Do not force. 3b. 180,000 - 360,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob.

  • Page 29: Ignition & Control Timings

    Pump Operation - MOST IMPORTANT - This INTERMITTENT PILOT, appliance is designed for continuous pump SPARK IGNITION SYSTEM (F-9/M-9) operation when the burners are firing. If the system pump does not run continuously an additional pump must be installed to provide constant circulation The ignition module is not repairable.

  • Page 30: Maintenance

    CAUTION: FREEZE PROTECTION FOR A HEATING Label all wires prior to disconnection when servicing BOILER SYSTEM (If Required) controls. Wiring errors can cause improper and dangerous operation. Use only properly diluted inhibited glycol anti- Examine the venting system at least once a year. freeze designed for hydronic systems.

  • Page 31: Burner Cleaning

    air is provided to the burners by the gas injection materials it is advisable that the installer follow these safety guides. pressure into the venturi of the burners. burners do not have an adjustable air shutter. REMOVAL OF COMBUSTION CHAMBER LINING Adequate combustion air must be supplied to the OR BASE PANELS: mechanical room to ensure proper burner...

  • Page 32: Heat Exchanger Inspection

    block burner ports and cause non-warrantable failure. q. Reassemble all gas and water piping. Test for Use extreme care when operating an appliance for gas leaks. temporary heat during new construction. The burners r. Cycle the appliance and check for proper will probably require a thorough cleaning before the operation.

  • Page 33: Gas Train

    b. Turn inner adjustment screw clockwise to GAS TRAIN decrease or counterclockwise to increase pilot 399,000–500,000 Btu/hr MODELS flame. c. If difficulty is experienced in adjusting the pilot flame, a tee may be installed in the pilot line from the gas valve to the pilot burner. d.

  • Page 34: Heating Boiler

    Maximum water temperature should not exceed WATER CONNECTIONS nameplate rating. HEATING BOILERS ONLY Cast iron circulators may be used for closed loop ONLY systems. Heating Boilers with inputs of 45,000-180,000 Btu/hr have 1-1/4" NPT inlet and outlet connections, Heating A properly sized expansion tank must be installed Boilers with inputs of 225,000-500,000 Btu/hr have near the boiler and located on the suction side of 1-1/2"...

  • Page 35: Typical Piping

    PUMP INSTALLATION AND MAINTENANCE: The PRIMARY/SECONDARY boiler circulating pump must be purchased locally. For BOILER PIPING installation and maintenance information on the circulator pump, refer to pump manufacturers instruction package included with the pump. PRIMARY/SECONDARY PIPING OF A SINGLE BOILER MAKE-UP WATER BOILER BYPASS REQUIREMENTS...

  • Page 36: Low Temperature Systems

    increase in flow that may be required is based on the condensation on the heat exchanger and in the flue. type and percentage of glycol added to the boiler Condensation can cause operational problems, bad system. Consult the manufacturer of the glycol for combustion, sooting, flue gas spillage and reduced additional recommendations when using a glycol and service life of the vent system and related components.

  • Page 37: Boiler Flow Rates

    The installation of a three way valve on this boiler is not The basic guide for minimum flow in this boiler is based generally recommended because most piping methods on a 40°F temperature rise in most installations. Lower allow the three way valve to vary flow to the boiler. This flow and a higher temperature rise is acceptable if the boiler is a low mass, high efficiency unit which requires boiler system is specifically designed for the...

  • Page 38: Temperature Rise Chart

    TABLE - N SYSTEM TEMPERATURE RISE CHART Based on Boiler Output in Btu/hr Btu/hr 10° T 20° T 30° T 40° T 50° T Input Output Ft/hd GPM Ft/hd Ft/hd GPM Ft/hd GPM Ft/hd 45,000 36,900 75,000 61,500 12.3 90,000 73,800 14.9 135,000...
  • Page 39 NOTE: INSTALLATION WITH A CHILLED Do not use petroleum based stop leak products. All system leaks must be repaired. WATER SYSTEM The constant addition of make-up water can cause damage to the boiler heat exchanger due to scale accumulation. Scale reduces flow and heat trans- fer, causing overheating of the heat exchanger.

  • Page 40: Boiler Temperature Control

    Remove the jumper between the R and W terminals on BOILER OPERATING the terminal strip. Refer to the chart in this section to TEMPERATURE CONTROL determine maximum allowable length and wire gauge The operating temperature control is located in the recommended to connect the switching contacts of the control panel, behind the control panel front access door.

  • Page 41: Water Velocity Control

    Common manifold piping for multiple unit instal- WATER VELOCITY CONTROL lations will require larger minimum pipe sizes and tank tappings to ensure proper flow, see Table Q. IMPORTANT - To ensure proper velocity through the Multiple unit installations may also require a larger heat exchanger, it is necessary to regulate the circulating pump to achieve the specified flow temperature rise across the heat exchanger from inlet to...

  • Page 42: Water Chemistry

    TABLE - Q WATER CHEMISTRY COMMON WATER MANIFOLD SIZE FOR The required temperature rise and the standard pump MULTIPLE HOT WATER SUPPLY BOILER sizing are based on the heating of potable water with a INSTALLATIONS hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm.

  • Page 43: Pump Requirements

    The standard pump selection is based on the following THERMOSTAT SETTINGS pipe and fittings from the unit to the storage tank: The thermostat is adjusted to a low test setting 6 - 90° elbows 2 - ball valves when shipped from the factory. 2 - unions 1 - cold water tee Set the thermostat to the lowest settings which will...

  • Page 44: Risk Of Scald Warnings

    HIGH WATER TEMPERATURE CAUTION: LIMIT CONTROL Setting the temperature selector to higher settings provides hotter water, which increases the risk of scald injury. The unit may be equipped with either a fixed setting, manual-reset high water temperature limit control or an adjustable setting, auto-reset high water temperature The manufacturer recommends the use of a properly limit.
  • Page 45 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 system, such as one with a backflow preventer or check valve installed in the cold water supply, shall be provided with means to control expansion.
  • Page 46 NOTES...
  • Page 47 NOTES...
  • Page 48 CP-5M-2/04-Printed in U.S.A.

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