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  5. Installation And Service Manual

Lochinvar 1,260,000 Installation And Service Manual

Manual is about: HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 399,999 - 2,070,000 Btu/hr MODELS

Summary of 1,260,000

  • 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

    Installation and service manual 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 quali...

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    Hydronic heating boilers and domestic water heaters 4 safety information 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. 1. This unit is o...

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

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    Hydronic heating boilers and domestic water heaters 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. Maint...

  • Page 7

    Installation and service manual 7 base for combustible floors there are no manufactured combustible floor base kits available for 990,000 - 2,070,000 btu models. See table-a below for floor base kits that are available. You must construct a base for combustible floor installation. Install unit over ...

  • Page 8

    Hydronic heating boilers and domestic water heaters 8 installation continued shut-down and draining if for any reason, the unit is to be shut off, the following precautionary measures must be taken: 1. Shut off gas supply. 2. Shut off water supply. 3. Shut off electrical supply. 4. Drain the unit co...

  • Page 9

    Installation and service manual 9 fig. 4 metal panel covering side combustion air inlet fig. 5 moving air filter/bracket assembly from rear of unit to side combustion air options this unit has four combustion air options. 1. Outside combustion air, no ducts you can direct outside combustion air to t...

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    Hydronic heating boilers and domestic water heaters 10 installation continued fig. 7 outside combustion air - two openings 2. Outside combustion air, using ducts you can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room. Each of the two openings mus...

  • Page 11

    Installation and service manual 11 exhaust fans any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and/or cause a down draft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardo...

  • Page 12

    Hydronic heating boilers and domestic water heaters 12 installation continued fig. 11 vent termination from peaked roof more than 10’ from ridge fig. 12 vent termination from flat roof 10’ or less from parapet wall fig. 13 vent termination from flat roof more than 10’ from parapet wall sidewall vent...

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    Installation and service manual 13 input flue air inlet btu/hr size size* 399,999 6" 6" 500,000 6" 6" 650,000 8" 8" 750,000 8" 8" 990,000 10" 10" 1,260,000 12" 12" 1,440,000 12" 12" 1,800,000 14" 12" 2,070,000 14" 12" * minimum diameter for air inlet pipe. Installer may increase diameter one pipe si...

  • Page 14

    Hydronic heating boilers and domestic water heaters 14 installation continued fig. 15 air inlet cap for sidewall termination to prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance requirements in the latest edition of the na...

  • Page 15

    Installation and service manual 15 if the air inlet cap is within a 10-foot (3.05m) radius of the flue outlet, the point of termination for the combustion air inlet cap must be at least 3 feet (0.91m) below the point of flue gas termination (vent cap). Do not install the combustion air inlet cap clo...

  • Page 16

    Hydronic heating boilers and domestic water heaters 16 installation continued 1. Conventional negative draft venting fig. 17 conventional negative draft vertical venting with combustion air louvers this option uses type-b double-wall flue outlet piping. The blower brings in combustion air. The buoya...

  • Page 17

    Installation and service manual 17 3. If possible, close all building doors and windows. Close all doors between the space in which the appliances remaining connected to the common venting system are located and other building spaces. 4. Turn on clothes dryers and any other appliances not connected ...

  • Page 18

    Hydronic heating boilers and domestic water heaters 18 installation continued the vertical directaire™ vent system requires you to install two vent pipes directly to the unit; one vertical pipe with a rooftop termination for the flue products and one pipe for combustion air. For this venting option,...

  • Page 19

    Installation and service manual 19 * the svk kits include a dv box adapter and sidewall air inlet cap. The vdk kits include a dv box adapter and a rooftop air inlet cap. 3. Sidewall venting this option uses a powered vent assembly which pulls the flue products out of the stack. This fan generates a ...

  • Page 20

    Hydronic heating boilers and domestic water heaters 20 installation continued the following is a detailed explanation of sidewall venting without an external power vent fan installation requirements. Flue outlet piping venting guidelines if using this venting option, a sealed al29-4c venting system ...

  • Page 21

    Installation and service manual 21 masonry chimney installation a masonry chimney must be properly sized for the installation of a high efficiency gas-fired appliance. Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exter...

  • Page 22

    Hydronic heating boilers and domestic water heaters 22 installation continued fig. 23a horizontal directaire installation (illustration with sidewall venter and sidewall combustion air) combustion air supplied from outdoors must be free of contaminants (see combustion and ventilation air , page 8). ...

  • Page 23

    Installation and service manual 23 drain tee installation a drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee must be installed as the first fitting after the horizontal ell on the top of the unit (see fig. 23b). Pl...

  • Page 24

    Hydronic heating boilers and domestic water heaters 24 installation continued horizontal dv venting termination horizontal venting uses the unit’s internal combustion air blowers to force the flue products out of the horizontally- terminated flue. You must purchase a horizontal direct vent kit from ...

  • Page 25

    Installation and service manual 25 for venting versatility, you can move the air filter assembly and dv box adapter to the right side of the unit. Remove the metal panel on the unit’s right side (see fig. 25). Remove the filter/bracket assembly from the rear of the unit. Attach the filter/bracket as...

  • Page 26

    Hydronic heating boilers and domestic water heaters 26 installation continued you must locate the combustion air cap and the flue gas outlet on the same roof top surface (vertical direct vent system) or sidewall surface (horizontal direct vent system) and in the same pressure zone as the vent termin...

  • Page 27

    Installation and service manual 27 combustion air supply must be free of contaminants (see combustion and ventilation air , page 8). To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section. Outdoor vent/air inlet location keep venting area...

  • Page 28

    Hydronic heating boilers and domestic water heaters 28 installation continued connecting to gas supply only supply 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....

  • Page 29

    Installation and service manual 29 fig. 28 gas line connection 2. Use new, properly threaded black iron pipe free from chips. If you use tubing, make sure the ends are cut square, deburred and clean. Make all tubing bends smooth and without deformation. Avoid flexible gas connections. Internal diame...

  • Page 30

    Hydronic heating boilers and domestic water heaters 30 installation continued water heater models do not have downstream test valves, but the rest of the gas train is represented by figure 29. Combination gas valves these units fire in multiple stages of burner input. Each stage of burner operation ...

  • Page 31

    Installation and service manual 31 check burner performance by cycling the system while you observe burner response. Burners should ignite promptly. Flame pattern should be stable, see burner flames , page 56. Turn system off and allow burners to cool, then cycle burners again to ensure proper ignit...

  • Page 32

    Hydronic heating boilers and domestic water heaters 32 installation continued 4. Locate the reference hose on the second gas valve which goes from the vent fitting on the gas valve to a barbed fitting on the deck of the unit (see fig. 31). 5. Remove the flexible cap from the barbed fitting on the “t...

  • Page 33

    Installation and service manual 33 fig. 32 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...

  • Page 34

    Hydronic heating boilers and domestic water heaters 34 installation continued 1. Use only type-t wire [63°f (35°c) rise] on all wiring between the unit and field-installed devices. 2. Enclose line voltage wire exterior to the unit in approved conduit or approved metal-clad cable. 3. The pump must ru...

  • Page 35

    Installation and service manual 35 example : the boiler inlet temperature is 160°f (71°c) and the boiler outlet temperature is 180°f (82°c), this means that there is a 20°f (11°c) temperature rise across the boiler. Heat exchanger pressure drop chart fig. 34 pressure drop chart 399,999 - 750,000 fig...

  • Page 36

    Hydronic heating boilers and domestic water heaters 36 installation continued fig. 36 primary/secondary piping of a single boiler fig. 37 primary/secondary piping of multiple boilers low temperature return water systems any non-condensing boiler and venting system will develop operational problems w...

  • Page 37

    Installation and service manual 37 radiant floor and snow melt heating systems this type of heating boiler application operates in a low temperature range which requires a boiler bypass as described under low temperature return water systems . A non-metallic rubber or plastic tubing installed in a r...

  • Page 38

    Hydronic heating boilers and domestic water heaters 38 installation continued boiler flow rate if higher flow rates are required through the boiler, an optional cupro-nickel heat exchanger is available. Consult the factory for specific application requirements. The heat exchanger is generally capabl...

  • Page 39

    Installation and service manual 39 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 and not water logged. 10. Start the bo...

  • Page 40

    Hydronic heating boilers and domestic water heaters 40 installation continued set the control set point(s) to the desired operating water temperature. Observe the boiler discharge temperature after each set point adjustment to ensure proper operation. See programming temperature control , page 43 fo...

  • Page 41

    Installation and service manual 41 operation for your safety read before operating a. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. Before operating, smell around the appliance area for g...

  • Page 42

    Hydronic heating boilers and domestic water heaters 42 operation continued c. Use only your hand to turn the gas control lever. Never use tools. If the lever will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosio...

  • Page 43

    Installation and service manual 43 to turn off gas to appliance 1. Open the front access panel to access control panel. 2. Turn power switch to “off” position. 3. Turn the manual gas cock clockwise to the “off” position. Fig. 45 combination gas valve programming temperature control note : the temper...

  • Page 44

    Hydronic heating boilers and domestic water heaters 44 operation continued note: * indicates the setting is only available in the advanced access level ** units listed in kbtu adjust menu setting descriptions boil max maximum boiler target supply temperature [either 200°f (93°c) or 250°f (121°c)]. S...

  • Page 45

    Installation and service manual 45 stg mode used to distinguish between single and dual ignition module appliances. Applies only on 650,000, 750,000, and 990,000 btu/hr models. Outdr dsgn design outdoor air temperature used in the heat loss calculations. Boil start starting temperature of the boiler...

  • Page 46

    Hydronic heating boilers and domestic water heaters 46 operation continued scroll through the different settings by pressing the “select” button. Change settings by pressing either the “+” button or the “–” button. If no buttons are pushed after a few seconds, the control will time-out and return to...

  • Page 47

    Installation and service manual 47 system sensor: this is used for boiler applications. This sensor will control the water temperature within the building loop. Staging logic there are two different types of staging logic used in the temperature control; proportional (step) staging logic and pid sta...

  • Page 48

    Hydronic heating boilers and domestic water heaters 48 operation continued to program settings for mode 1 operation, press in and hold the three programming buttons for 3 seconds. The screen will change from the view menu to the adjust menu. “adjust” will appear in the upper right corner of the scre...

  • Page 49

    Installation and service manual 49 3. Do not locate temperature sensor wiring near electric motors. 4. Do not locate temperature sensor wiring near welding equipment. 5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller. 6. Do not mount senso...

  • Page 50

    Hydronic heating boilers and domestic water heaters 50 operation continued diagnostic status indication the ignition module has an led which indicates the status of the safety circuits. A remote ignition module status indicating light(s) is wired from the ignition module status led and mounted on th...

  • Page 51

    Installation and service manual 51 ignition and control timings proven pilot hot surface ignition system m-9 on 990,000 through 2,070,000 btu/hr models with two hot surface ignition modules. Hot surface ignition module timings (nominal) prepurge: 15 seconds hot surface igniter heat-up time: 25- 35 s...

  • Page 52

    Hydronic heating boilers and domestic water heaters 52 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 use...

  • Page 53

    Installation and service manual 53 potable water exceeding these specifications. Heating of high hardness and/or high total dissolved solids water will require a larger circulating pump, an optional cupro-nickel heat exchanger and a revised temperature rise specification based on the water chemistry...

  • Page 54

    Hydronic heating boilers and domestic water heaters 54 domestic water heaters continued this pump is sized based on installation of a single storage tank and heater in close proximity. If the number of fittings and straight pipe exceeds the quantities shown in this section, a larger pump will be req...

  • Page 55

    Installation and service manual 55 4. The temperature set points for all stages should be set at the same temperature when supplying potable hot water for domestic use. 5. Stage firing is achieved by setting the differentials at approximately 3°f, 5°f, 7°f and 9°f for stages 1, 2, 3, and 4. Stage fi...

  • Page 56

    Hydronic heating boilers and domestic water heaters 56 cleaning and maintenance listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing. Appliance area keep appliance area clear and free from combustible materials, gasoline and other fl...

  • Page 57

    Installation and service manual 57 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 58

    Hydronic heating boilers and domestic water heaters 58 cleaning and maintenance continued adjusting differential air pressure the following is a recommended method for setting the differential air pressure ( Δ p) for each fan. Fig. 56 adjusting air shutter 399,999 - 750,000 btu/hr models fig. 57 loo...

  • Page 59

    Installation and service manual 59 6. Adjust the air shutter on the right fan until the differential pressure is nominally 1.1-1.3 inches water column. 7. Once the adjustment procedure is complete, reattach the caps to the tees in the hoses to the pressure switches and check all tubing and wire conn...

  • Page 60

    Hydronic heating boilers and domestic water heaters sequence of operation continued manual reset high-limit thermostat a manual reset high limit thermostat is provided as backup for the electronic adjustable temperature controller. An adjustable dial thermostat will trip and require resetting should...

  • Page 61

    Installation and service manual 61 are energized. This does not interfere with the safety functionality of either pressure switch or the ignition modules. Ignition (ignition module function) once the trial for ignition period has been completed, the ignition module sends 24vac to the gas valves on o...

  • Page 62

    Hydronic heating boilers and domestic water heaters 62 check the flow switch and tekmar pins #15 and #16 for 24vac. Step 1 does the power switch provide power to the unit? Check the switch for proper operation. Check the line voltage. No yes check 24vac at th (orange wire) on the ignition module. Ye...

  • Page 63

    Installation and service manual 63 step 1 does the power switch provide power to the control panel? Check the switch and/or the line voltage. Step 1 does the power switch provide power to the check the switch and/or the line voltage. No yes combustion air blowers come on. No is there 24vac at b2 on ...

  • Page 64

    Hydronic heating boilers and domestic water heaters 64 wiring box connections - wiring diagram a 399,999 - 750,000 btu/hr models pr br 12 3 56 4 24 vac xf m r . Ele c tr o n ic co nt ro ll er d ispl a y bo ard al ar m e n ab le re la y 24 v senso r co nn ec to r ci r c ui t br e a ke r 120v 24v op t...

  • Page 65

    Installation and service manual 65 ladder diagram 399,999 - 750,000 btu/hr models nc nc no alarm inputs 1, 2, & 3 join here s2/ fs - + f2 f1 neu line s1 o r pressure switch reset purge gy gy pump relay bk stage #2 stage #1 16 15 18 17 20 19 heat dem #1 el ec tr o n ic te mp era tu r e co nt r ol le ...

  • Page 66

    Hydronic heating boilers and domestic water heaters 66 wiring box connections - wiring diagram b 399,999 - 750,000 btu/hr models.

  • Page 67

    Installation and service manual 67 wiring box connections - wiring diagram b (continued) 399,999 - 750,000 btu/hr models.

  • Page 68

    Hydronic heating boilers and domestic water heaters 68 ladder diagram 990,000 - 2,070,000 btu/hr models 24 vac control j3 5 4 6 1 2 3 o.C. J1 j2 3 2 1 j4 p o nc br/ w alarm inputs 1, 2, 3 & 4 join here s2/fs f2 f1 line s1 o/w pressure switch #2 reset purge y p t/w s2/ fs - + f2 f1 neu line s1 o g r ...

  • Page 69

    Installation and service manual 69 wiring diagram a 990,000 - 2,070,000 btu/hr models j3 5 4 6 1 2 3 o.C. J1 j2 3 2 1 j4 p bk /w br ff 12 3 5 6 4 4 5 6 1 2 3 24 vac xf m r . El ectro n ic co nt ro ll er di spl a y bo a r d al a r m en a b le r e la y 24 v pr ess u r e sw it c h pro v in g re la y 2 ...

  • Page 70

    Hydronic heating boilers and domestic water heaters 70 wiring box connections - wiring diagram b connections 990,000 - 2,070,000 btu/hr models.

  • Page 71

    Installation and service manual 71 diagram b connections 990,000 - 2,070,000 btu/hr models (continued).

  • Page 72

    Revision 6 (cf-ch(e)-i&s-06) reflects changes made to text on page 33 and the lbls on pages 64-65, 68-69. Revision 7 (eco c02822) reflects moving fig. 22a (page 20) to page 23 and adding aire-lock to the title. Revision 8 (eco #c02870) reflects the addition of a mixing valve to fig. 54 (page 53) and...