1. DL manuals
  2. Lochinvar
  3. Boiler
  4. 0
  5. Installation and service manual

Lochinvar 0 Installation and service manual

Manual is about: Power-Fin 4:1 HOT WATER HEATING BOILERS DOMESTIC HOT WATER SUPPLY BOILERS

Summary of 0

  • Page 1

    Fig. 1 front view 1,500,000 - 2,000,000 btu/hr models installation and service must be performed by a qualified service installer, service agency or the gas supplier. Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated. Experience has shown that i...

  • Page 2

    Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the boiler, 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 sho...

  • Page 3

    Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 installation requirements location . . . . . . . . . . ....

  • Page 4

    The information contained in this manual is intended for use by qualified professional installers, service technicians or gas suppliers. Consult your local expert for proper installation or service procedures. A gas appliance that draws combustion air from the equipment room where it is installed mu...

  • Page 5

    Fig. 3 clearances from combustible construction - front maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the fig. 4 clearances from ...

  • Page 6

    6 the equipment room must be provided with properly sized openings to assure adequate combustion air and proper ventilation when the unit is installed with a basic category iv venting system. Fig. 5 combustion air direct from outside 1. If air is taken directly from outside the building with no duct...

  • Page 7

    All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12 inches (30 cm) ...

  • Page 8

    A construction air filter is provided with the appliance as shipped. An air filter is provided for installation on the combustion air inlet located at the rear of the appliance. This filter is for temporary use only on an appliance that must be operated for temporary heat or hot water when a buildin...

  • Page 9

    Sidewall. All appliances are shipped from the factory equipped for category iv venting. The optional direct vent and directaire venting systems will require the installation of specific vent kits and venting materials. The following is a detailed explanation of the installation requirements for each...

  • Page 10

    Result in a hazardous condition where flue gases spill into an occupied living space. Consult the induced draft fan manufacturer to size the induced draft fan and to determine the diameter of the common vent pipe required for a combined vent installation. The flue from this category iv appliance mus...

  • Page 11

    The venting system shall terminate at least 4 feet (1.2 m) below, 4 feet (1.2 m) horizontally from, or 1 foot (30 cm) above any door, window or gravity air inlet into any building. Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent can not termi...

  • Page 12

    Follow all general category iv vent termination clearances. Fig. 13 vent termination from peaked roof - 10' or less from ridge fig. 14 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 (0.61 m) above the h...

  • Page 13

    Fig. 17 sidewall venting installation the connection from the appliance flue outlet to the sidewall vent cap must be made with listed type category iv vent materials and accessories. The installer must supply suitable vent pipe material. The sidewall vent cap is available from the appliance manufact...

  • Page 14

    The sidewall vent termination must be at least 8 feet (2.4 m) horizontally from any combustion air intake located above the sidewall termination cap. Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent can not terminate below grade. The vent shal...

  • Page 15

    Select air inlet pipe material from the following specified materials: pvc, cpvc or abs (6", 7"or 8" i.D.)* dryer vent or sealed flexible duct (not recommended for roof top air inlet) galvanized steel vent pipe with joints and seams sealed as specified below. Type "b" double wall vent with joints an...

  • Page 16

    Fig. 20 vertical direct vent installation with rooftop combustion air inlet follow all requirements in the general category iv venting sections for proper installation and of venting flue products vertically to the outdoors. All other general installation requirements must be followed. The direct ve...

  • Page 17

    Multiple vertical direct vent installations fig. 22 multiple vertical direct vent installations the combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (0.91 m) clearance below the closest vertical flue outlet if within 10 feet (3.05 m). Multiple flue outl...

  • Page 18

    The part numbers for the required sidewall air inlet cap kit are listed by unit size. The manufacturer, in accordance with csa/cga requirements, must furnish the sidewall air inlet cap. Each kit includes the special combustion air inlet cap for installation on an exterior sidewall. The sidewall air ...

  • Page 19

    A directaire vent system is a category iv flue installed with a separate combustion air pipe to the outdoors. The directaire vent system terminates the flue and the combustion air inlet pipe in different pressure zones. The directaire vent system may terminate the flue and combustion air in any one ...

  • Page 20

    Fig. 28 air inlet cap for sidewall termination the air inlet cap for the sidewall air inlet must be purchased from the appliance manufacturer. The part numbers for the required sidewall air inlet cap kit are listed by unit size. The appliance manufacturer, in accordance with csa/cga requirements, mu...

  • Page 21

    The flue and air inlet duct sizes for a horizontal directaire installation with rooftop combustion air inlet are listed by unit size. The sidewall vent cap must be purchased from the appliance manufacturer as a vent kit. *piping from the appliance to the air inlet cap may be either 7" or 8" connecti...

  • Page 22

    Follow all requirements in the general category iv venting sections for proper installation and of venting flue products horizontally to the outdoors. All other general installation requirements must be followed. The directaire system requires the installation of an additional pipe to supply combust...

  • Page 23

    Incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products that can cause personal injury, death or property damage. Verify that the appliance is supplied with type gas sp...

  • Page 24

    Fig. 34 gas line connection with sediment trap and manual main gas shut-off valve all gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas. All piping must comply with local codes and ordinances. Tubing installations must comply with ap...

  • Page 25

    4. Run pipe or tubing to the units gas inlet. If tubing is used, obtain a tube to pipe coupling to connect the tubing to the units gas inlet. 5. Install a sediment trap in the supply line to the units gas inlet. (see fig. 34) 6. Remove seal over gas inlet to the appliance 7. Apply a moderate amount ...

  • Page 26

    10. If gas supply pressure is within normal range, proceed to remove gas manometer and replace pressure tap fittings in the gas piping to the appliance. 11. Turn the power switch to “off” position. 12. Shut off gas supply at the manual gas cock in the gas piping to the appliance. If fuel supply is l...

  • Page 27

    3. Set the diagnostic information center to a setpoint which will fire the burner at 100% of rated input. 4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer. The sum of these two readings as they are effected by the two gas pressu...

  • Page 28

    Fig. 38 heat exchanger this appliance uses a finned copper tube heat exchanger to maximize the heat transfer process. The heat exchanger is mounted in the inner jacket on the front side of the appliance. The heat exchanger is composed of two circular, glass lined, and cast iron headers with 24 verti...

  • Page 29

    This unit is supplied with a relief valve(s) sized in accordance with asme boiler and pressure vessel code, section iv ("heating boilers"). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. No valve is to be placed between the relief valve, and the unit. ...

  • Page 30

    Provided on the valve assembly to indicate the position of the valve seat. Operation of the gas valve in combination with the combustion air blower allows the burner input rate to vary from 25% to 100% based on temperature demand. There is no need for an additional upstream constant gas pressure reg...

  • Page 31

    1. All wiring between the appliance and field installed devices shall be made with type t wire [63 o f (35 o c) rise]. 2. Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable. 3. The circulating pump must run continuously when appliance is bei...

  • Page 32

    32 fig. 46 component and auxiliary controls connections fig. 44 internal control panel component access drawing fig. 45 transformer, circuit boards and relay locations display and indicating leds slide forward electronic temperature control circuit board transformer low water cutoff (optional) reset...

  • Page 33

    A component, transformer and relay mounting control panel is located along the right front control panel, along the right side of the exterior jacket panel. This panel contains a 75 va transformer to drop 120 vac to 24 vac for internal control operation, an optional electronic low water cut-off, vfd...

  • Page 34

    High and/or low gas pressure switches are available as an option on this appliance. The high gas pressure switch is used to monitor the maximum gas supply pressure supplied to the gas train. If gas pressure exceeds the maximum setting of the pressure switch, the appliance will shut down and a gas pr...

  • Page 35

    The electronic temperature control may have default values for the control points specified at the time the appliance is tested at the factory. Job site specific values may be programmed into the control at the time the appliance is commissioned for start-up. Fig. 51 external diagnostic information ...

  • Page 36

    Setpoint differential: on water heaters and boilers, this is the number of degrees that the water temperature must fall below the setpoint temperature before a call for heat initiates. On boilers, this is also the number of degrees that the water temperature must rise above the setpoint temperature ...

  • Page 37

    Fig. 52 diagnostic information center display panel (1) press the select key until the desired adjustable item's led is illuminated and its' current setting is displayed. (2) within 5 seconds of releasing the select key, press either an up or down key to increase or decrease the displayed setpoint v...

  • Page 38

    These functions are shown in the screens of the diagnostic information center. Where noted, these settings are changeable from the diagnostic information center to configure boiler operation to the building heat load and weather conditions in a specific geographic area. The controller has a method t...

  • Page 39

    Without having to unnecessarily re-enter the limited access mode before completing controller and display settings. The following are the feature settings that can be changed with the limited access feature: pump modes: when the limited access mode is first entered, "pu" will be indicated in the dis...

  • Page 40

    A manual reset high limit control is located on the inside of the left front control panel, behind the display. The setting of this control knob limits maximum discharge water temperature. A red reset button, located beside the knob, must be pushed whenever water temperature has exceeded the setpoin...

  • Page 41

    Fig. 55 install condensate trap fig. 56 hot surface ignition control module this appliance uses a proven hot surface ignition control system. The operation of the electronic control module for the hot surface igniter proves the presence of an ignition source much like a proven standing pilot before ...

  • Page 42

    Ignition module will pause for a fixed time period. The timed length of the pause is based on the type of fault sensed by the control module. At the end of this timed pause, the ignition module will attempt a new trial for ignition sequence. If the soft lockout fault condition has subsided or has be...

  • Page 43

    This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the primary heat exchanger. There is a unique burner for each one of the three models. Burners may not be changed between different btu/hr input models. The burner consists of a round mounti...

  • Page 44

    1. Stop - read the safety information. 2. Set the setpoint temperature function of the diagnostic information center to the lowest setting. 3. Turn off all electrical power to the appliance. 4. This appliance is equipped with an ignition device, which automatically lights the burner. 5. Do not try t...

  • Page 45

    11. If the appliance will not operate, follow the instructions "to turn off gas to appliance" and call your service technician or gas supplier. 1. Set the setpoint temperature function of the diagnostic information center to the lowest setting. 2. Turn off all electric power to the appliance if serv...

  • Page 46

    19. Variable ratio gas valve senses the pressure from the combustion air blower and supplies gas to the orifice and into the blower inlet to pre-mix. 20. The gas/air mixture is forced into the burner and out of the burner ports under pressure. 21. Hot surface igniter lights the gas/air mixture and t...

  • Page 47

    A. Normal flame: a normal flame at 100% of burner input is blue, with slight yellow tips, a well defined flame and no flame lifting. B. Yellow tip: yellow tipping can be caused by blockage or partial obstruction of air flow to the burner. C. Yellow flames: yellow flames can be caused by blockage of ...

  • Page 48

    8. Remove the sensing tubes from the air ratio gas valve to the combustion air blower. 9. Remove the 6 nuts holding the blower assembly to the blower and remove the blower assembly. 10. Disconnect the power wires to the hot surface igniter. 11. Remove the hot surface igniter. The hot surface igniter...

  • Page 49

    6. Heat exchanger inspection fig. 66 location of heat exchanger inside of jacket 1. Turn off all power to the appliance. 2. Turn off main gas to appliance. 3. Remove the front outer jacket door. 4. Remove the front, upper inner jacket door. 5. Check the heat exchanger surface for soot. If soot is pr...

  • Page 50

    9. Control circuit voltage this appliance uses a transformer to supply a low voltage control circuit. The voltage on the secondary side should be 24 to 28 vac when measured with a voltmeter. A secondary voltage of 18 vac or less supplied to 24 vac components may cause operational problems. 10. Conde...

  • Page 51

    3. Set the command display to a setpoint which will fire the burner at 100% of rated input. 4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer. The sum of these two readings as they are effected by the two air pressures is the dif...

  • Page 52

    1. Use only properly diluted inhibited glycol antifreeze designed for hydronic systems. Inhibited propylene glycol is recommended for systems where incidental contact with drinking water or any potable water is possible. 2. A solution of 50% antifreeze will provide maximum protection of approximatel...

  • Page 53

    This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation. Pump selection is critical to achieve proper operation. A pump should be selected to achieve proper system design water temperature rise. A system pump may provide full flow through the...

  • Page 54

    The boiler primary piping system must have a circulator installed in the main system loop to carry the heated boiler water to the point of use in the main system. Multiple boilers may also be installed with a primary/secondary manifold system. Multiple boilers should be connected to the common manif...

  • Page 55

    The boiler. Constant water flow through the boiler must be provided at all times when the boiler is operating. The boiler's operating temperature sensor can be remote mounted in a bulbwell installed in the system water flow to control boiler operation at a low temperature range. The lowest temperatu...

  • Page 56

    Fig. 72 boiler bypass piping for high flow systems the installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded. The bypass wil...

  • Page 57

    This boiler is equipped with a dial type temperature/ pressure gauge. This gauge is factory installed in the outlet side of the boiler piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in degrees fahrenheit. The temperature/pressure gauge is provi...

  • Page 58

    14. Review wiring to an energy management system and wiring to any remote temperature sensors. Boiler set-up 15. Ensure that the boiler and piping system are full of water. Bleed all air from the boiler and related piping. 16. Check system for any water leaks. 17. Check system for installation of gl...

  • Page 59

    In a bulbwell installed in the inlet side of the heat exchanger top header. The outlet sensor is located in a bulbwell on the outlet side of the heat exchanger top header. Carefully observe the discharge water temperature on the initial cycles. The location of the temperature sensor may generally re...

  • Page 60: Domestic

    Fig. 75 typical water heater piping with storage tank this section contains specific instructions for those appliances used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and service sections apply to these instructions. Hot water supply boil...

  • Page 61

    If higher flow rates are required through the water heater, an optional cupro-nickel heat exchanger is available. Consult the factory for specific application requirements. The heat exchanger is capable of operating within the design flow rates required for the water heater, storage tank(s) and conn...

  • Page 62

    Be heated. Water with a hardness of less than 5 grains per gallon will usually have a low ph which can be aggressive and corrosive causing non-warrantable damage to the heater, pump and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system because heate...

  • Page 63

    1. The water heater or hot water supply boiler must have properly sized circulating pump. This pump is sized to circulate water between the heater and storage tank only. 2. The pump is sized to the heater input and water chemistry specifications noted in “water chemistry." 3. The diameter and length...

  • Page 64

    This is a highly sophisticated heat exchanger designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build-up of impurities. The straight-line, four pass design of the tubes sends water into the headers at a properly rated velocity. The ...

  • Page 65

    The maximum temperature setpoint that can be programmed into the electronic temperature controller from the diagnostic information center for water heater operation is 200°f (93°c). The control is factory pre-set at approximately 120°f (48.9°c). Facilities with small children or invalids may require...

  • Page 66

    Fig. 80 high water temperature limit control a manual reset high limit control is located on the inside of the right front control panel, behind the display. The setting of this control knob limits maximum discharge water temperature. The water heater or hot water supply boiler temperature limit con...

  • Page 67

    67 fig. 81 component location drawing - front fig. 82 component location drawing - rear fig. 83 component location drawing - top electrical junction box water inlet combustion air inlet gas supply water outlet flue outlet drains ratio gas valve control panel blower motor vfd combustion air blower tr...

  • Page 68: Wiring Diagram

    68 wiring diagram 1,500,000, 1,700,000 and 2,000,000 btu/hr models low voltage transformer 75 or 100va.

  • Page 69: Wiring Diagram

    69 wiring diagram (continued) 1,500,000, 1,700,000 and 2,000,000 btu/hr models.

  • Page 70: Ladder Diagram

    70 ladder diagram 1,500,000, 1,700,000 and 2,000,000 btu/hr models.

  • Page 71: Ladder Diagram

    71 ladder diagram (continued) 1,500,000, 1,700,000 and 2,000,000 btu/hr models.

  • Page 72

    Cp-5m-10/05-printed in u.S.A..