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SBR-I-S Rev B
Installation & Service Manual
Models: 45,000 - 260,000 Btu/hr
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 SOLUTION 260000
Summary of Contents for Lochinvar SOLUTION 260000
- Page 1 SBR-I-S Rev B Installation & Service Manual Models: 45,000 - 260,000 Btu/hr 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.
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Page 2: Table Of Contents
Low Temperature Bypass Requirements ... . . 28 Boiler Flow Rates ......28 Primary / Secondary Piping . -
Page 3: Please Read Before Proceeding
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). WARNING Improper Service must be Checking equipment –... -
Page 4: Please Read Before Proceeding
Controls and Safety Devices for Automatically 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 the authority having jurisdiction, the installation must comply with the Canadian Association Code, CAN/CGA- B149.1 and/or B149.2 and/or local codes. -
Page 5: Ratings
Ratings Solution Boiler I=B=R Rating Input Model Number Note: Change “N” to (Note 4) “L” for L.P. gas models. CBN045 CBN075 CBN090 CBN135 CBN180 CBN215 CBN260 Maximum allowed working pressure is located on the rating plate. NOTICE Notes: 1. The ratings are based on standard test procedures prescribed by the United States Department of Energy. -
Page 6: The Solution --How It Works
19. Terminal strip The boiler is equipped with a terminal strip on the left side of the unit to allow easy connection to contact points. 20. Top panel Removable panel to gain access to the internal components. - Page 7 The Solution - How it works... Models 45,000 - 90,000 Btu/hr Front View Models 45,000 - 90,000 Right Side (inside unit) (continued) Models 45,000 - 90,000 Rear View Models 45,000 - 90,000 Left Side (inside unit) Installation & Service Manual...
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Page 8: The Solution --How It Works
Installation & Service Manual The Solution - How it works... Models 135,000 - 260,000 Btu/hr Front View Models 135,000 - 260,000 Btu/hr Rear View Models 135,000 - 260,000 Btu/hr Left Side (inside unit) Models 135,000 - 260,000 Btu/hr Right Side (inside unit) -
Page 9: Determine Boiler Location
Determine boiler location Location of unit 1. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. -
Page 10: Combustion And Ventilation Air
Determine boiler location Combustion ventilation requirements for conventionally vented appliances Provisions for combustion and ventilation air must be in accordance with, Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes. - Page 11 Determine boiler location Figure 1-6_Combustion Air from Outside Single Opening If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm opening must be located within 12"...
- Page 12 (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.
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Page 13: Venting
Venting A Conventional Negative Draft Venting System The negative draft in a conventional vent in stal la tion must be within the range of a negative 0.02 to 0.05 inches water column to ensure proper operation. All draft read ings are made while the appliance is in stable op er a tion (approximately 2 to 5 minutes). - Page 14 Venting Locate appliance as close as possible to a chimney or gas vent. Avoid long horizontal runs of the vent pipe, 90° el bows, reductions and restrictions. Horizontal por tions of the venting system shall be supported to prevent sagging. Horizontal runs must slope up wards not less than 1/4 inch per foot (21 mm/m) from the appliance to the vent terminal.
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Page 15: Vertical Vent Termination Clearances
Venting (continued) Vertical Vent Termination Clearances 10' OR LESS 2' MIN RIDGE Figure 2-2_Vent Termination from Peaked Roof 10' or Less from Ridge MORE THAN 10' RIDGE Figure 2-3_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. -
Page 16: Masonry Chimney Installation
Venting Masonry Chimney Installation A masonry chimney must be properly sized for the installation of a gas fired appliance. Venting of an appliance into a cold or oversized masonry chimney can result in op er a tion al and safety problems. chim neys, with one or more sides exposed to cold out door tem per a tures, are more likely to have venting problems. -
Page 17: Automatic Vent Damper
300,000 Btu/hr must have the vent damper prop er ly installed and the vent damper wire harness plugged into the ter mi nal block on the side of the control panel to allow the boiler to function. Larger input heating boilers will have a jumper plug installed in the ter mi nal block to allow operation without a damper. -
Page 18: Gas Connections Gas Supply
Gas connections 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. Consult the factory for installations above 2000 feet elevation. -
Page 19: Gas Piping
Gas connections 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 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 2,000 1,900 1,700 1,540 1,400 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130... -
Page 20: Gas Manifold Pressure Adjustment Procedure
Gas connections WHEN FLANGE APPLY WRENCH TO FLANGE ONLY APPLY WRENCH FROM TOP OR BOTTOM OF GAS CONTROL TO EITHER SHADED AREA Figure 3-2_Wrench For L.P. gas, consult your L.P. gas supplier for expert installation. Upon completion IMPORTANT con nec tions to the gas system, leak test all gas con nec tions with a soap solution while system... -
Page 21: Checking Gas Supply Pressure
Gas connections Checking Gas Supply Pressure GAS SUPPLY PRESSURE MANOMETER GAS VALVE Figure 3-4_Gas Supply Pressure Turn the power “OFF” at the main dis con nect switch. Turn gas valve control knob to the “OFF” position. Shut off gas supply at the manual valve in the gas piping to the appliance. -
Page 22: Combination Gas Valves
Gas connections Combination Gas Valves PRESSURE REGULATOR ADJUSTMENT WIRING TERMINALS (UNDER CAP SCREW) INLET PRESSURE TAP S CONTROL KNOB Figure 3-5_M9 Gas Valve Each unit has a combination gas valve to control the gas supply to the burners. The com bi na tion valve con sists of a gas regulator and two valve seats to meet the requirements for redundant gas valves. -
Page 23: Water Connections
The flow rate required is a function of the diameter of pipe and tee used for installation. Ensure that the pump installed on the boiler will supply adequate flow to make the flow switch con tacts and operate the boil er. -
Page 24: Low Water Cutoff (If Equipped)
A hot water boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed. An electronic low water cutoff is available as a kit on all units. -
Page 25: Piping Of The Boiler System
The boiler cir cu lat ing pump, air sep a ra tor, expansion Operate the system, tank and oth er components required for proper installation must be purchased locally. - Page 26 The boiler circulating pump must be field supplied. The boiler circulator pump must operate con tin u ous ly while the boiler is firing. Pump selection is critical to achieve proper op er a tion. A pump should be selected to achieve proper system design water temperature rise.
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Page 27: Performance Loop
A primary/secondary piping system uses a dedicated pump to supply flow to the boiler only. This pump is sized based on de sired boiler flow rate, boiler head loss and head loss in the sec ond ary system piping only. The secondary pump, in -... -
Page 28: Low Temperature Bypass Requirements
A bypass as shown in FIG. 4-5 (see page 33) must be piped into the system at the time of installation. Full Flow Application It is acceptable for the Solution boiler to be installed in a full flow application, as long as the following requirements are met: The performance loop is in place and functional. -
Page 29: Primary / Secondary Piping
Water connections Primary / Secondary Piping Figure 4-4_Primary / Secondary Piping of a Single Boiler BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR SYSTEM BALL VALVE (TYPICAL) EXPANSION TANK (continued) PRESSURE REDUCING VALVE PRESSURE GAUGE SEPARATOR NOT TO EXCEED... - Page 30 Water connections Primary / Secondary Piping Figure 4-5_Single Boiler - Primary / Secondary with Low Temperature Bypass BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR SYSTEM BALL VALVE (TYPICAL) EXPANSION TANK PRESSURE REDUCING VALVE PRESSURE GAUGE SEPARATOR NOT TO EXCEED...
- Page 31 NOT TO EXCEED 12" APART BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) Y-STRAINER (RECOMMENDED) UNION (TYPICAL) TEMPERATURE / PRESSURE GAUGE PRESSURE BOILER 2 RELIEF VALVE (LEADER 1) (continued) PRESSURE PRESSURE REDUCING VALVE GAUGE BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR...
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Page 32: Full System Flow
Water connections Full System Flow Figure 4-7_Single Boiler Full System Flow BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR SYSTEM BALL VALVE (TYPICAL) EXPANSION TANK PRESSURE REDUCING VALVE PRESSURE GAUGE SEPARATOR UNION (TYPICAL) TEMPERATURE / PRESSURE DRAIN GAUGE... -
Page 33: Full System Flow
Water connections Full System Flow Figure 4-8_Single Boiler Full System Flow with Low Temperature Bypass BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR SYSTEM BALL VALVE (TYPICAL) EXPANSION TANK (continued) PRESSURE REDUCING VALVE PRESSURE GAUGE SEPARATOR 3-WAY VALVE W/BYPASS PIPE... -
Page 34: Electrical Connections
Turn the con trol set point dial to the desired operating water tem per a ture. Observe the boiler discharge tem per a ture after each set point adjustment to ensure prop er operation. -
Page 35: Pump Wiring For A Heating Boiler
Temperature Control Settings Remove the control panel door on the front of the unit in unless your unit is specified as a boiler only with an outdoor air reset option. If your unit is a boiler only with an outdoor air reset option, there are additional controls for this option. -
Page 36: Maximum Set Point Determination
System Sensor Depending upon how your unit is set up, this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications. Connect this sensor to the SYS/TANK contacts on the control board. - Page 37 As outdoor temperatures rise, the control will decrease the temperature to the selected set point of the boiler. You can set the control to shut the boiler off when a desired outdoor air temperature level is reached.
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Page 38: Outdoor Air Reset Option
1.0° drop in outdoor air temperature up to the maximum set point temperature. If the outdoor design and boiler design temperatures are known, the Ratio setting can be calculated using the following formula: Ratio = (boiler design temperature - operator set point) (O.A. -
Page 39: Blocked Vent And Flame Roll-Out / Flame Interlock Switch
In the event the system has actuated to shut off the main burner gas supply, wait for the boiler to cool, then press the red reset to return the boiler to operation. Op er a tion of a blocked vent and/or flame roll-out / interlock switch usually... -
Page 40: Startup Initial Startup
Start-up Initial Start-up Follow the Lighting Instructions on the label applied to the appliance. A. On boilers with the system pump delay option, the operating temperature control will energize the pump relay which energizes the pump on a call for heat. -
Page 41: Operating Instructions
Start-up (continued) 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. -
Page 42: Intermittent Pilot Spark Ignition System (M9)
This condition must be cor rect ed to provide adequate freeze protection. Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Follow the manufacturers instructions. -
Page 43: Owner Maintenance
• Check relief valve • Test low water cutoff (if used) • Reset button (low water cutoff) • Check appliance piping (gas and water) for leaks • Operate relief valve • Shut appliance down (unless boiler used for domestic hot water) -
Page 44: Address Reported Problems
2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI). 3. Watch the system pressure as the boiler heats up (during heat transfer, testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem. -
Page 45: Check Expansion Tank
– not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage. - Page 46 Maintenance Check All Wiring 1. Inspect all wiring, making sure wires are in good condition and securely attached. Check Control Settings 1. Adjust settings if necessary. See Section 5 - Electrical Connections for adjustment procedures. 2. Check settings of external limit controls (if any) and adjust if necessary.
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Page 47: Inspection And Cleaning
Maintenance Avoid breathing dust and contact with skin and eyes. • Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on jobsite conditions. -
Page 48: Review With Owner
Check frequently to be sure the flow of com bus tion and ventilation air to the boiler is not obstructed. Inspection of Heat Exchanger Waterways Appliances operated in hard water areas should have periodic inspections of the tubes to be sure that no sediment or scale accumulates on the heat transfer sur fac es. -
Page 49: Troubleshooting
Troubleshooting Troubleshooting Guide: M9 Solution Boilers Step 1: Is the spark ignitor sparking? Is the pilot Step 2: staying on? Step 3: Is the gas valve getting 24 VAC to the MV terminal? Check gas pressure and make sure gas valve knob is on. -
Page 50: Diagrams
Installation & Service Manual Diagrams Schematic Diagram - M9 Unit Wiring Diagram - M9 Unit 45,000 - 260,000 Btu/hr Models 45,000 - 260,000 Btu/hr Models... - Page 51 Notes...
- Page 52 Revision A (ECO #C03746) initial release. Revision B (ECO #C06868) update the pressure drop chart (Table 4C) to reflect the correct models and change out the reference to the two blues wires to SYS/TANK contacts under System Sensor on page 36 (ECR03727).
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