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

    1 installation and service must be performed by a qualified service installer, service agency or the gas supplier. Factory warranty (shipped with appliance) does not apply to appliances improperly installed or improperly operated. Experience has shown that improper installation or system design, rat...

  • Page 2

    2 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. Your conventionally vented gas appliance must have a supply of fresh air circulating aro...

  • Page 3

    3 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. The pan must not restrict combustion air flow. Under no circumsta...

  • Page 4

    4 clearances from combustible construction: right side - 6" rear - 6" left side - 6" (24" suggested for service) front - (24" suggested for service) 45,000 - 180,000 btu models - 6" 199,000 - 500,000 btu models - alcove* top - (measured from draft hood) 45,000 - 180,000 btu models - 14" 199,000 - 50...

  • Page 5

    5 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 within 12" (30 cm) of the bottom of the enclosure. B. Vent...

  • 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 openings. The above require- ments are for the applianc...

  • Page 7

    7 mechanical room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance. Vent installations for connection to gas vents or chimneys must be in accordance with part 7, “venting of equipment,” of the latest edition of the natio...

  • Page 8

    8 any vent materials used must be listed by a nationally recognized test agency for use as vent material. Locate appliance as close as possible to chimney or gas vent. Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions. Horizontal portions of the venting system shal...

  • Page 9

    9 the vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof within a 10 foot (3.05m) radius of the termination. The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit. A vertical termination less th...

  • Page 10

    10 the venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) 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 11

    11 0.02 to 0.05 inches water to ensure proper operation. If draft exceeds the specified range, the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft. An induced draft fan must be interlocked into the appliance’s control circuit to s...

  • Page 12

    12 . Verify that the appliance is supplied with the type gas specified on the rating plate. This appliance is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation. Fi...

  • Page 13

    13 1. Safe operation of the appliance requires properly sized gas supply piping. See data in table f. 2. Gas pipe size may be larger than appliance gas connection. 3. Installation of a union is suggested for ease of service. 4. Install a manual main gas shutoff valve, outside of the appliance gas co...

  • Page 14

    14 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. Tubing installations must comply with approved standards and practices. Install piping to control 1. The gas line should be a separate...

  • Page 15

    15 4. Install a sediment trap in the supply line to the gas valve or manifold assembly (see figure 18). 5. Thread pipe the proper amount for insertion into gas valve or manifold inlet as shown in table-i. Do not thread pipe too far. Valve distortion or malfunction may result if the pipe is inserted ...

  • Page 16

    16 7. Turn the gas valve control knob to the “on” posi- tion. 8. Set the thermostat(s) to call for heat. 9. Observe gas regulator pressure when all burners are firing. See table e, manifold pressure for proper regulator pressure settings. 10. If adjustment is necessary, turn regulator adjustment scr...

  • Page 17

    17 to the “on” position when the pilot is established. Turn the gas valve control knob(s) to the “on” position on spark ignition models. . 8. Set the thermostat(s) to call for heat. 9. Observe the gas supply pressure with all burners firing. Ensure inlet pressure is within specified range. Check gas...

  • Page 18

    18 reversing the heat exchanger water connections a. Turn “off” power at the main disconnect switch and disconnect power wire from control panel. B. Turn “off” the external main manual gas shutoff valve. C. Disconnect water supply and return piping from heat exchanger. D. Remove temperature sensors ...

  • Page 19

    19 a water flow switch is available as a factory supplied 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 ignitio...

  • Page 20

    20 each unit has a combination gas valve(s) to control the 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 (m-9) is available as an option on intermittent pilot models. A two stage gas valve is ...

  • Page 21

    21 lower setting, approximately 5-15 degrees lower, for staged burner operation. Two stage burner control systems (m-9) are recommended for application on heating boilers only. Electrical connections this appliance is wired for 120 vac service. The appliance, when installed, must be electrically gro...

  • Page 22

    22 operator transformer mv mv/pv pv gnd 24v 24v th-w spark 1 2 3 4 5 6 7 8 9 high limit terminal board temperature adjustment operating temperature control an adjustable immersion operating control is located in the control panel. F-1 and f-9 control systems use a single operating control, m-9 contr...

  • Page 23

    23 the 45,000 thru 270,000 btu/hr heating boilers are equipped with a manual reset blocked vent and flame roll-out system. Temperature switches are located on the front of the burner tray and/or in the relief opening of the boiler’s built-in draft hood. Each switch has a red reset button. In the eve...

  • Page 24

    24 pre-start checklist 1. Inspect the burners to be sure they are properly aligned. 2. Inspect the pilot gas line, thermocouple leads, ignition leads and wire connections to gas valve to be sure none were damaged during shipment. 3. Check to ensure that gas connections have been made properly and th...

  • Page 25

    25 5. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. If you smell gas, stop! Follow “b” in the safety information. If you don’t smell gas go on to the next step. 6. Find the pilot - follow the metal tube from the gas valve to the pilot. The pilot is located...

  • Page 26

    26 to turn off gas to appliance 1. Set the thermostat to the lowest setting. 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. Safety shutoff test for standing pilot ignition sys...

  • Page 27

    27 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 neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire departme...

  • Page 28

    28 6. Wait five (5) minutes to clear out any gas then smell for gas, including near the floor. If you smell gas, stop! Follow “b” in the safety information. If you don’t smell gas go on to the next step. 7a. 45,000 - 135,000 and 399,000 - 500,000 btu/hr models, rotate the gas control knob on the gas...

  • Page 29

    29 intermittent pilot, spark ignition system (f-9/m-9) the ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty ignition module mus...

  • Page 30

    30 freeze protection for a heating boiler system (if required) 1. Use only properly diluted inhibited glycol anti- freeze designed for hydronic systems. Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible. 2. A solution of 50% propylene glyc...

  • Page 31

    31 air is provided to the burners by the gas injection pressure into the venturi of the burners. The burners do not have an adjustable air shutter. Adequate combustion air must be supplied to the mechanical room to ensure proper burner operation. Check frequently to be sure the flow of combustion an...

  • Page 32

    32 block burner ports and cause non-warrantable failure. Use extreme care when operating an appliance for temporary heat during new construction. The burners will probably require a thorough cleaning before the appliance is placed in service. H. Check the heat exchanger surface for sooting. The exte...

  • Page 33

    33 b. Turn inner adjustment screw clockwise to decrease or counterclockwise to increase pilot 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. Replace pilot adjustment cover screw on valve. Tighte...

  • Page 34

    34 only heating boilers with inputs of 45,000-180,000 btu/hr have 1-1/4" npt inlet and outlet connections, heating boilers with inputs of 225,000-500,000 btu/hr have 1-1/2" npt inlet and outlet connections. Caution: field installed reducing bushings may decrease flow re- sulting in boiler noise or f...

  • Page 35

    35 pump installation and maintenance: the boiler circulating pump must be purchased locally. For installation and maintenance information on the circulator pump, refer to pump manufacturers instruction package included with the pump. The installer must ensure that the circulating pump installed with...

  • Page 36

    36 increase in flow that may be required is based on the type and percentage of glycol added to the boiler system. Consult the manufacturer of the glycol for additional recommendations when using a glycol and water fill for your boiler system. The installer must ensure that the boiler has adequate f...

  • Page 37

    37 the basic guide for minimum flow in this boiler is based on a 40°f temperature rise in most installations. Lower flow and a higher temperature rise is acceptable if the boiler system is specifically designed for the characteristics of a higher temperature rise. A system not specifically designed ...

  • Page 38

    38 placing the boiler in operation filling the system: all air must be purged from the system for proper operation. An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve. 1. Close all drain c...

  • Page 39

    Installation with a chilled water system pipe refrigeration systems in parallel. Install duct coil downstream at cooling coil. Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation, the boiler piping ...

  • Page 40

    40 remove the jumper between the r and w terminals on the terminal strip. Refer to the chart in this section to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the r and w terminals on the terminal strip. Connection to the ter...

  • Page 41

    41 water velocity control important - to ensure proper velocity through the heat exchanger, it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet. This must be done on initial installation and periodically rechecked. With the correct temperature rise across ...

  • Page 42

    42 water chemistry the required temperature rise and the standard pump sizing are based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm. Consult the manufacturer when heating potable water exceeding these specifications....

  • Page 43

    43 the standard pump selection is based on the following pipe and fittings from the unit to the storage tank: 6 - 90° elbows 2 - ball valves 2 - unions 1 - cold water tee plus the following length of straight pipe based on the heater size: 90,000 thru 360,000 btu/hr models not more than 45 feet of s...

  • Page 44

    44 the manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 140°f. Storing the water at a higher temperature and thermostatically mixing the water will increase the available quantity of mixed hot water, greatly reduce t...

  • Page 45

    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 contr...

  • Page 46: Notes

    46 notes.

  • Page 47: Notes

    47 notes.

  • Page 48

    Cp-5m-2/04-printed in u.S.A..