1. DL manuals
  2. Lochinvar
  3. Water Heater
  4. 000 - 500
  5. Installation And Service Manual

Lochinvar 000 - 500 Installation And Service Manual

Manual is about: 90,000 - 500,000 Btu/hr

Summary of 000 - 500

  • Page 1

    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, ...

  • Page 2

    Warranty ..................................................................................1 safety warnings ......................................................................1 codes ..................................................................................3 location .......................

  • Page 3

    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. In the ab...

  • Page 4

    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" all units have been approved fo...

  • 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 2 per kw). This opening must be located with in 12" (30cm)...

  • Page 6

    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 p...

  • Page 7

    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 livi...

  • 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. Use the n...

  • Page 9

    Fig. 10 vent termination from peaked roof 10’ or less from ridge 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 th...

  • Page 10

    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. Frozen condensate on the vent cap can result in a bl...

  • Page 11

    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. A vent...

  • Page 12

    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 13

    7. Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes. 13 btu/hr distance from meter (in feet) input 0-50 51 - 100 101 - 200 201 - 300 301 - 500 45,000 1/2" 1/2" 3/4" 1" 1 1/4" 75,000 1/2" 3/4" 1" 1 1/4" 1 1/4" 90,000 1/...

  • Page 14

    Fig. 16 gas line connection all gas connections must be made with pipe joint com pound resistant to the action of liquefied pe tro leum and natural gas. All piping must comply with local codes. Tubing installations must com ply with ap proved standards and practices. Reference figure 16 for a typica...

  • Page 15

    Fig. 17 wrench 8. For l.P. Gas, consult your l.P. Gas supplier for expert installation. Fig. 18 manifold pressure adjustment 1. Turn the power “off” at the main dis con nect switch. 2. Turn gas valve control knob to “pilot” po si tion on standing pilot models. Ensure that the stand ing pilot remains...

  • Page 16

    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...

  • Page 17

    20. Set the thermostat to call for heat. The appliance is now ready to operate. Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly. Flame pattern should be stable, see “main te nance-normal flame pattern.” turn system off and allow burner...

  • Page 18

    Fig. 23a relief valve - water heater fig. 23b relief valve - boiler this appliance is supplied with a relief valve(s) sized in accordance with asme boiler and pressure ves sel code, section iv (“heating boilers”). The re lief valve(s) is mounted directly into the heat ex chang er inside the header. ...

  • Page 19

    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. 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 boil...

  • Page 20

    Fig. 26 intermittent pilot system f9/m9 control panel fig. 27 control panel assembly 500,000 btu/hr operating temperature control locating temperature control remove the control panel door on the front of the unit in order to locate and access the temperature control. Temperature control settings th...

  • Page 21

    Set point the set point knob specifies the target outlet water temperature in degrees, fahrenheit. After the water temperature reaches the set point, the temperature control shuts off the burners. Differential the differential specifies the number of degrees below the set point that the control will...

  • Page 22

    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 electri...

  • Page 23

    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...

  • Page 24

    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 meas...

  • Page 25

    25 3. Set the thermostat to the lowest setting (off). 4. Turn off all electrical power to the appliance. 5. 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 6. Wait five (5) minutes to clear out any gas, then smell for ga...

  • Page 26

    26 1. Set the thermostat to the off position. 2. Turn off all electric power to the appliance if service is to be performed. 3. Turn the gas control knob on the gas valve clockwise to the “off” position. Do not force. Fig. 36 pilot with thermocouple and spark ignition 1. With the main burners on and...

  • Page 27

    27 1. Stop! Read the safety information first. 2. Remove the control panel door. 3. Set the thermostat to the lowest setting (off). 4. Turn off all electrical power to the appliance. 5. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the p...

  • Page 28

    28 11. If ignition system fails to operate properly, re pair work must be performed by a qualified serviceman or installer. 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, person...

  • Page 29

    5. Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system. 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 exchang...

  • Page 30

    Removal of combustion chamber lining or base panels: • avoid breathing dust and contact with skin and eyes. • use niosh certified dust respirator (n95) (http://www.Cdc.Gov/niosh/homepage.Html). • lightly mist with water (only those areas being handled) the combustion chamber lining or base insulatio...

  • 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. Remove the heat exchanger before using water for cl...

  • Page 32

    Fig. 39 gas train 45,000 - 399,999 btu/hr models fig. 40 gas train 500,000 btu/hr model the drawings in this section show typical heating boil er piping installations. Before beginning the in stal - la tion, consult local codes for specific plumb ing re quire ments . The installation should provide ...

  • Page 33

    1. Maximum operating pressure for the pump must exceed system operating pressure. 2. Maximum water temperature should not ex ceed nameplate rating. 3. Cast iron circulators may be used for closed loop systems. 4. A properly sized expansion tank must be in stalled near the boiler and located on the s...

  • Page 34

    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. A pri ma ry/secondary pip ing system may als...

  • Page 35

    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. Condensation can cause operationa...

  • Page 36

    General plumbing rules 1. Check all local codes. 2. For serviceability of the boiler, always install unions. 3. Always pipe pressure relief valves to an open drain. 4. Locate system air vents at the highest point of the system. 5. Expansion tank must be installed near the boil er and on the suction ...

  • Page 37

    10. Start the boiler according to the “start-up instructions” 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. Recheck pres...

  • Page 38

    The operating temperature control is located in the control panel, behind the control panel front ac cess door. The sensing element for the operator is placed in a bulb well installed in the heat exchanger. Carefully observe the dis charge water temperature on the initial boiler on cycles. The exact...

  • Page 39

    This section contains specific instructions for those units used to supply domestic hot water. All warn ings, cau tions, notes and instructions in the gen er al installation and service sections apply to these instructions. Water heat ers are designed for installation with a storage tank. The use of...

  • Page 40

    The required temperature rise and the standard pump sizing are based on the heating of potable water with chemistry within the specified limits. Caution should be used when heating water softened to less than 5 grains per gallon. Many commercial water softeners reduce hardness to 0 grains which may ...

  • Page 41

    3. The pump must run continuously when the burners are firing. 4. Lubricate the pump to the manufacturers rec om men - da tions. Pump damage due to inadequate lu bri ca - tion is non-warrantable. 5. A standard water heater/hot water supply boiler is furnished with a 1/6 hp, 120 vac, 3.6 amp circulat...

  • Page 42

    42 your gas supplier for local re quire ments governing the tem per a ture setting. Re mem ber, no water heating sys tem will provide exact tem per a ture at all times. Allow a few days of operation at this setting to de ter mine the correct temperature set ting consistent with your needs. Incorrect...

  • Page 43

    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. Con t...

  • Page 44

    44 is the spark igniter sparking? No check continuity of the spark cable. Check for 24vac on the th terminal (gray wire) on the ignition module. Is the pilot staying on? Step 1: step 2: check the pilot tube for gas. Check for draft. No no yes replace ignition module. Is there 24 vac (purple wire) on...

  • Page 45

    45 troubleshooting guide 90,000 - 270,000 btu/hr models - water heaters f1 is the pilot lit? No check for gas. Check the pilot assembly and thermocouple. Check the gas valve for proper operation. Clean and replace. Is the gas valve getting 24vac? Step 1: step 2: no is there 24 vac (purple wire) on t...

  • Page 46

    46 schematic diagram - f1 unit 90,000 - 270,000 btu/hr models wiring diagram - f1 unit 90,000 - 270,000 btu/hr models.

  • Page 47

    47 schematic diagram - f9 unit 90,000 - 399,999 btu/hr models wiring diagram - f9 unit 90,000 - 399,999 btu/hr models.

  • Page 48

    48 schematic diagram - m9 unit 45,000 - 399,999 btu/hr models wiring diagram - m9 unit 45,000 - 399,999 btu/hr models.

  • Page 49

    49 schematic diagram - f9/m9 unit 500,000 btu/hr models wiring diagram - f9/m9 unit 500,000 btu/hr models.

  • Page 50: Notes

    50 notes.

  • Page 51: Notes

    51 notes.

  • Page 52

    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.