1. DL manuals
  2. Lochinvar
  3. Water Heater
  4. 000 BTU/HR
  5. Installation And Service Manual

Lochinvar 000 BTU/HR Installation And Service Manual

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

Summary of 000 BTU/HR

  • Page 1

    Installation and service manual save this manual for future reference. 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. – do not store or use gasoline or other flammable vapors and liquids in...

  • Page 2

    Hydronic heating boilers and domestic water heaters 2 table of contents general product information . . . . . . . . . . . . . . . . . . . . . . . . .3 special instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 3

    General product information special instructions this manual supplies information for the installation, operation and servicing of the appliance. Read and understand this manual completely before installing unit. Installation and service must be performed by a qualified service installer, service ag...

  • Page 4

    3. Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components. Follow all clearanc...

  • Page 5

    Installation and service manual 5 figure 1 – front and rear view rear view front view product identification.

  • Page 6

    Installation this unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ansi standards for gas-fired units, ansi z21.13/csa 4.9 and ansi z21.10.3/csa 4.3. Locating unit 1. Maintain all clearances from combustible construction when ...

  • Page 7

    Base for combustible floor installation. Install unit over a base of hollow clay tiles or concrete blocks from 8" to 12" thick and extending at least 24" beyond the unit sides. Place tiles or blocks so that the holes line up horizontally to provide a clear passage through the tiles or blocks. Place ...

  • Page 8

    Installation continued freeze protection for a heating boiler system (if required) 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 is possible. Warning : do not ...

  • Page 9

    Combustion air options caution : under no circumstances should the mechanical room ever be under a negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., take away air from the unit. 1. Outside combustion air, no duct...

  • Page 10

    Installation continued figure 9 - combustion air from interior space all dimensions are 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 louver...

  • Page 11

    You must locate the air inlet termination elbow at least 12" (30cm) above the roof or above normal snow levels. Keep the vent cap clear of snow, ice, leaves, and debris to avoid blocking the flue. Figure 10 - vent termination from peaked roof - 10' or less from ridge important: vent terminations are...

  • Page 12

    Installation continued input flue btu/hr size 495,000 6" 645,000 8" 745,000 8" 985,000 10" 1,255,000 12" 1,435,000 12" 1,795,000 14" 2,065,000 14" vent system options this unit has two venting options. 1. Conventional negative draft venting this option uses a vertical rooftop flue termination. Combu...

  • Page 13

    1. Conventional negative draft venting important: before installing a venting system, follow all venting clearances and requirements found in the venting, general information section, page 10. Figure 14 - conventional negative draft vertical venting with combustion air louvers this option uses type-...

  • Page 14

    Installation continued 4. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. 5. Close fire place dampers. 6. Place...

  • Page 15

    Outdoor vent/air inlet location keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain a minimum clearance of 3" (76mm) to combustible surfaces and a minimum of 3" (76mm) clearance to the air inlet. To avoid a blocked air inlet or blocked f...

  • Page 16

    Installation continued connecting to gas supply only supply the gas type specified on the unit's rating plate. This unit is orificed for operation up to 2000 feet altitude. If installing above 2000 feet elevation, consult the appliance manufacturer. Inlet pressure : measure inlet pressure at the inl...

  • Page 17

    The combination gas valves have an integral vent limiting device and does not require venting to atmosphere outside the building. The unit will not operate properly if the reference hose is removed or a vent to atmosphere is installed. Optional gas controls may require routing of bleeds and vents to...

  • Page 18

    Installation continued water heater models do not have downstream test valves, but the rest of the gas train is represented by figure 19. Combination gas valves these units fire in up to 2 stages of burner input. Each stage of burner operation has a combination gas valve or series of gas valves to c...

  • Page 19

    9. If gas pressure is out of range, contact your gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control. 10. If gas supply pressure is within normal range, remove the gas manometer and replace the pressure tap f...

  • Page 20

    20 installation continued figure 21 - measuring manifold gas pressure 2. Turn the power switch located in the lower left corner behind the control panel access door to the “o” or “off” position. 3. Remove the top front jacket access panels to access the gas valve(s). 4. Locate the reference hose on ...

  • Page 21

    Figure 22 - water connections relief valve 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. Place no other valve b...

  • Page 22

    Installation continued figure 23a - models 495,000 - 745,000 btu/hr control panel component location drawing figure 23b - models 985,000 - 2,065,000 btu/hr control panel component location drawing external ems connection to terminal strip for stage firing control of burners this unit is equipped wit...

  • Page 23

    Figure 24a - stand alone operation - models 985,000 - 2,065,000 btu/hr only figure 24b - remote on/off boiler or water heater - models 985,000 - 2,065,000 btu/hr only figure 24c - two-stage (high/low fire) boiler or water heater - models 985,000 - 2,065,000 btu/hr only figure 24d - field-installed s...

  • Page 24

    Installation continued circulator pump requirements 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 r...

  • Page 25

    The installer must ensure that the boiler has adequate flow without excessive temperature rise. Low system flow can result in overheating of the boiler water which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. These conditions indicate the need to in...

  • Page 26

    Installation continued sludge formed as the result of excessive oxygen in the system can restrict water flow resulting in a premature boiler failure. Any boiler damage due to excessive oxygenation is non- warrantable. Figure 28 - boiler with low temperature bypass piping installation with a chilled ...

  • Page 27

    Boiler flow rate caution : the maximum flow rate for models 495,000 - 745,000 btu/hr is 60 gpm and 90 gpm on 985,000 - 2,065,000 models. Do not exceed the maximum flow rate of the heating boiler. If higher flow rates are required through the boiler, an optional cupro-nickel heat exchanger is availab...

  • Page 28

    Installation continued 8. Recheck all air vents as described in step 4. 9. Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged a...

  • Page 29

    Figure 31 - control panel cover figure 32 - on/off switch 8. Turn the manual gas cock clockwise to the “off” position. 9. Wait five (5) minutes to clear out any gas. If you smell gas, stop! Follow “b” in the safety information. If you do not smell gas, go on to the next step. 10. Turn the manual gas...

  • Page 30

    Operation continued figure 34 - locating temperature control temperature control settings there are three setting knobs on the temperature control 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 ar...

  • Page 31

    High-fire offset the temperature control operates a two-stage firing system. The two stages are high-fire and low-fire. High-fire operates all burners while low-fire operates approximately one-half of the burners. The high-fire knob specifies the number of degrees below set point that the high-fire ...

  • Page 32

    Operation continued temperature control sensors this is a two-stage temperature control that controls the burner ignition, pump, and alarm functions. This temperature controller can measure up to three different sensor inputs, depending upon how the unit is set up. They are as follows: 1. Inlet wate...

  • Page 33

    Remote mounting of sensor you must mount the outside air temperature sensor outside the building. To mount remote sensors, follow the guidelines below. Take care to correctly wire sensors to the unit. Erratic temperature readings can be caused by poor wiring practices. Twist the wires between the un...

  • Page 34

    Operation continued hot surface ignition control module ignition module lockout functions the ignition module may lockout in either a hard-lockout condition, requiring pushing of the reset button to recycle the control, or a soft-lockout condition which may recycle after an approximate five-minute w...

  • Page 35

    Operation and diagnostic lights the diagnostic control panel has up to 6 indicating and diagnostic lights to show all major steps of operation and control sensed malfunctions. This panel is located on the left end of the unit. Figure 40 - operation/diagnostic lights installation and service manual 3...

  • Page 36

    Domestic water heaters this section applies only to those units used to supply potable hot water for domestic use. The hot water supply boiler must be installed with a storage tank. This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions,...

  • Page 37

    Installation and service manual 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 appliance manufacturer when heating potabl...

  • Page 38

    Domestic water heaters continued 6 90° elbows 2 ball valves 2 unions 1 cold water tee not more than 45 feet of straight pipe. Important: for every elbow and tee in excess of those shown above, deduct 5 feet from maximum allowable straight pipe in heater to tank circulating loop. Minimum pump perform...

  • Page 39

    Installation and service manual 39 remember, no water heating system provides exact temperatures at all times. Let the system operate a few days at your desired settings to determine correct settings for your needs. 1. These units are equipped with an operating temperature control. 2. The control se...

  • Page 40

    Cleaning and maintenance listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing. Caution : label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Appliance area keep ap...

  • Page 41

    Installation and service manual 41 heat exchanger cleaning 1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. 2. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 ...

  • Page 42

    Cleaning and maintenance continued figure 43 - air pressure switch figure 44 - adjusting air shutter set up procedure to the left of the fan is an air pressure switch with a large and a small tube delivering pressure from points inside the unit (see figure 43). The pressure in the large tube is the ...

  • Page 43

    Installation and service manual 43 adjustment procedure: 1,435,000, 1,795,000 and 2,065,000 btu/hr models 1. Remove the upper front jacket panels from the unit to access the upper chamber. 2. Slightly loosen the screws that attach the fan transition box to the metal base (see figure 46). 3. Locate t...

  • Page 44

    Cleaning and maintenance continued a faulty hot surface igniter or ignition module must be replaced with an identical part. A specification igniter and ignition module for this specific unit is available from your local distributor. Do not use general purpose field replacement ignition modules or ig...

  • Page 45

    29. Burners are now firing for approximately 50% of the heater’s input. 30. 24vac is supplied from the second stage of the electronic temperature control across the 2c and 2no terminals on the terminal strip on to a control to a relay. 31. The control relay switches the fan on the 985,000 - 2,065,00...

  • Page 46

    Electronic temperature controller (operator) a 2-stage electronic temperature controller is provided on the unit and it serves to maintain a user selectable temperature set point. Ultimately, the temperature controller delivers 24vac to the ignition module and pressure switch when it senses heat mod...

  • Page 47

    47 schematic diagram models 495,000 - 745,000 btu/hr j3 5 4 6 3 2 1 o.C. J1 j2 3 2 1 j4 p op e r a t or in l e t pr o b e s ys/ ta n k se t p o in t cn1 cn 2 cn 3 cn 4 cn 5 cn 6 cn 7 cn 8 cn 9 of f di f f e r e n t ia l hi g h -f ir e of f s e t s hut d o w n o .A. M a x . Ra t io o. A . Di s abl e ...

  • Page 48

    48 wiring diagrams - main unit connections models 495,000 - 745,000 btu/hr power switch 120 vac trial 24 vac heating 24vac flame failure bk w gy gy o y bl pr hi-limit c no nc c 2 1 aux hi-limit optional c no nc c 2 1 1 4 5 9 10 12 15 3 6 8 7 13 bk/w 11 bk o r r bk inlet sensor h hi-limits - pwr sw j...

  • Page 49

    49 wiring diagrams - main unit connections models 495,000 - 745,000 btu/hr (continued) lbl20007 rev a 1 2 3 4 1 2 1 2 w bk 120vac power to louver or damper bk bk option box "a" louver/damper 120 vac relay 4 6 2 bk br c w 10 11 12 14 15 13 1 2 4 5 9 10 11 12 14 15 3 6 8 7 13 1 2 4 5 9 10 11 12 3 6 8 ...

  • Page 50

    50 cn 9 te s t sw it c h t re s e t t pr o b e ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 2c 2no sta g e # 2 hi g h f ir e b3 b1 b 2 f iel d s u pp l ied s a f e t y de v ice s in t e r m it t e n t a l arm s a1 a2 1c 1 n o 24 vac 12 0 va c - + hi -l im it li ne bl br on /o f f po w e r sw it c h bk au x . Hi - li m i...

  • Page 51

    51 wiring diagram - control box connections models 985,000 - 2,065,000 btu/hr fla m e fa il en a b l e r e l a y 24 v op t ion a l al arm e n abl e re l a y 24 v bk w s2 /f s f2 f1 s1 ne u 4 2 3 - + - + ign it ion mo d u l e th 10 pi 9 8 24co m re s e t 7 24v ac 6 mv 5 ps 4 m/ s ff 1 li n e st g # 1...

  • Page 52

    Revision 4 (cb-cw(e)-i&s-04) reflects changes made to the o.A. Section. Revision 5 (cb-cw(e)-i&s-05) reflects changes made to text on page 21 and the lbls on pages 47-51. Revision 6 (eco #c02870) reflects the addition of a mixing valve to fig. 41 (page 37) and edits made to the scald warnings. Cb-cw...