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  4. COPPER-FIN 497 - 2067
  5. Installation And Service Manual

Lochinvar COPPER-FIN 497 - 2067 Installation And Service Manual

Manual is about: Gas Water heater

Summary of COPPER-FIN 497 - 2067

  • Page 1

    Installation & service manual models: 497 - 2067 save this manual for future reference. Cbx-cwx-i-s rev a this manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an ins...

  • Page 2: Contents

    Contents hazard definitions the following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Danger warning caution caution notice danger indicates an imminently hazardous ...

  • Page 3

    Installation & service manual 3 3 please read before proceeding notice this is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier. Warning if the information i...

  • Page 4

    4 please read before proceeding codes – the equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before instal...

  • Page 5

    5 the copper-fin - how it works... 1. Heat exchanger the heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process. 2. Inner combustion chamber do...

  • Page 6

    6 the copper-fin - how it works... 26 26 17 17 17 17 12 12 models 497 - 747 front view models 497 - 747 left side (inside unit) models 497 - 747 right side (inside unit) models 497 - 747 rear view 14 14 22 22 25 25 28 28 13 13 16 16 21 21 15 15 23 23 18 18 20 20 24 24 9 2 3 4 8 7 6 19 19 11 11 10 10...

  • Page 7

    7 installation & service manual the copper-fin - how it works... (continued) models 987 - 2067 left side (inside unit) models 987 - 2067 right side (inside unit) models 987 - 2067 rear view models 987 - 2067 front view 14 14 25 25 22 22 7 28 28 21 21 4 3 2 9 20 20 18 18 24 24 23 23 15 15 16 16 13 13...

  • Page 8: Ratings

    8 ratings maximum allowed working pressure is located on the rating plate. Notice copper-fin i=b=r rating model number note: change “n” to “l” for l.P. Gas models. Input mbh (note 4) min max gross output mbh (note 1) net i=b=r ratings water, mbh (note 2) cbn497 250 495 401 349 cbn647 350 645 522 454...

  • Page 9: Ratings

    9 ratings (continued) notes: 1. Copper-fins require special gas venting. Use only the vent materials and methods specified in the installation and service manual. 2. The copper-fin is orificed for operation up to 2000 feet altitude. The ap pli ance will be derated 4% per 1000 feet above 2000 feet el...

  • Page 10: Determine Unit Location

    10 1 determine unit location locating the unit 1. Maintain all clearances from combustible construction when locating unit. See clearances from combustible construction, this page. 2. Locate the unit so that if water connections should leak, water damage will not occur. When such locations cannot be...

  • Page 11: Determine Unit Location

    1 determine unit location (continued) 11 table 1a combustible floor kits model kit number 497 cfk3302 647 cfk3303 747 cfk3304 caution although these units are csa international design- certifi ed for outdoor installations, such installations are not recommended in areas where the danger of freezing ...

  • Page 12: Determine Unit Location

    12 1 determine unit location table 1b minimum recommended combustion air supply to equipment room model number *outside air from 2 openings directly from outdoors *outside air from 1 opening directly from outdoors, in 2 inside air from 2 ducts delivered from outdoors inside air from 2 ducts delivere...

  • Page 13: Determine Unit Location

    13 combustion air filter this unit has a standard air filter located at the combustion air inlet. This filter helps ensure clean air is used for the combustion process. Check this filter every month and replace when it becomes dirty. The filter size on models 497 - 747 is 12" x 12" x 1" (30.5cm x 30...

  • Page 14: Determine Unit Location

    14 1 determine unit location this unit has four combustion air options. 1. Outside combustion air, no ducts you can direct outside combustion air to this unit using either one or two permanent openings (see fig. 1-5). One opening the opening must have a minimum free area of one square inch per 3000 ...

  • Page 15: Determine Unit Location

    1 determine unit location (continued) 15 3. Combustion air from an interior space you can direct combustion air to this unit using air from an adjoining interior space. You must provide two openings from the boiler room to the adjoining room. Each of the two openings must have a net free area of one...

  • Page 16: Venting

    General information you must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the national fuel gas code...

  • Page 17: Venting

    17 2 venting (continued) barometric damper location any venting system option that requires a barometric damper must adhere to the following directions for optimum performance. The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit’...

  • Page 18: Venting

    2 venting 18 1. Conventional negative draft venting notice before installing a venting system, follow all venting clearances and requirements found in the venting, general information section, page 16. Figure 2-5_conventional negative draft vertical venting with combustion air louvers this option us...

  • Page 19: Venting

    19 2 venting (continued) common venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances r...

  • Page 20: Venting

    2 venting 20 2. Outdoor installation venting units are self-venting and can be used outdoors when installed with the optional outdoor caps. These caps mount directly to the unit and cover the flue outlet and combustion air inlet openings. No additional vent piping is required. Combustion air supply ...

  • Page 21: Venting

    21 2 venting (continued) the optional outdoor vent kit is available from the appliance manufacturer. The outdoor kit part numbers are listed by unit size. See table 2b for kit numbers. You can install the outdoor vent cap and combustion air inlet panel(s) on the unit (see fig.’s 2-6 and 2-7). Outdoo...

  • Page 22: Gas Connections

    3 gas connections 22 connecting to gas supply verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 2000 feet altitude. Consult factory for installations above 2000 feet elevation. Inlet gas pressure: measured at th...

  • Page 23: Gas Connections

    23 3 gas connections (continued) gas connection all gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum (l.P.) and natural gases. All piping must comply with local codes and ordinances. Piping installations must comply with approved standards and prac...

  • Page 24: Gas Connections

    3 gas connections 24 combination gas valves these units fire in multiple stages of burner input. Each stage of burner operation has a combination gas valve(s) to cycle the gas supply on and off and regulate gas to the burners. Each combination valve consists of a gas regulator and two valve seats to...

  • Page 25: Gas Connections

    Notice the gas valves are referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the front inside portion of the jacket. Reference the drawings in this section for component and connection points for pressure meas...

  • Page 26: Gas Connections

    3 gas connections 26 12. If adjustment is necessary, remove the regulator cover screw on the gas valve. Note: if the gas valve under adjustment is located on a manifold assembly monitored by an igniter, the unit may shut down and recycle when the regulator cover screw is removed. This is normal. 13....

  • Page 27: Water Connections

    27 4 water connections inlet and outlet connections for ease of service, install unions on the water inlet and water outlet of the unit. The connection to the unit marked “inlet” on the header should be used for return from the system. The connection on the header marked “outlet” is to be connected ...

  • Page 28: Water Connections

    4 water connections 28 boiler circulator 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...

  • Page 29: Water Connections

    29 4 water connections (continued) a buffer tank is an effective way to enhance a small system load and increase heating system efficiency (see fig. 4-8 on page 34 of this manual). Buffer tanks add water volume to the system and act as a flywheel to absorb the additional btu’s provided by the boiler...

  • Page 30: Water Connections

    4 water connections 30 low temperature return water systems any non-condensing boiler and venting system will develop operational problems when exposed to inlet water temperatures below 140°f. Lochinvar offers a low temperature protection valve (ltv) that is factory preset to maintain 140°f inlet wa...

  • Page 31: Water Connections

    To floor drain heating supply loop to expansion tank and makeup water system heating return loop 12" max 31 4 water connections (continued) figure 4-5_primary/secondary piping of single boiler installation & service manual common manifold size (min.) models: 497 - 747 number of units gpm diameter (i...

  • Page 32: Water Connections

    32 4 water connections installation & service manual figure 4-6_primary/secondary piping of multiple boilers secondary boiler pump from system 12" or 4x pipe diameters air separator make-up water pressure relief valve expansion tank low water cut-off (optional) to system system pump common manifold ...

  • Page 33: Water Connections

    33 hea eati ting supply ly loop to floor dr drain mixing valve to expansion tank and nd make akeup water system heati ting retur urn loo oop 12” 12” max figure 4-7_boiler with low temperature bypass *please note that these illustrations are meant to show system piping concept only, the installer is ...

  • Page 34: Water Connections

    34 1" temperature and pressure gauge automatic air eliminator/vent system outlet system sensor location system inlet buffer tank drain pump commom manifold must be sized to accommodate combined flow rate for all boilers figure 4-8_primary/secondary piping with buffer tank *please note that these ill...

  • Page 35: Water Connections

    35 4 water connections (continued) 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 ...

  • Page 36: Water Connections

    36 4 water connections 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 will help to ensure that the bo...

  • Page 37: Electrical Connections

    37 5 electrical connections connecting to electrical supply this unit is wired for 120 vac service. The unit, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the ...

  • Page 38: Electrical Connections

    38 5 electrical connections external ems connection to terminal strip for stage firing control of burners this unit is equipped with a factory installed terminal strip for connection of an energy management system (ems) to the burner stages. The ems terminal strip is located in the unit’s control pa...

  • Page 39: Electrical Connections

    39 5 electrical connections (continued) temperature adjustment note: the temperature controller is preset at the factory with test settings. You may need to adjust the settings to meet your specific needs. Return water temperatures must not be less than 140°f. If lower return water temperatures are ...

  • Page 40: Electrical Connections

    40 5 electrical connections setpoint the set point knob specifies the target 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 t...

  • Page 41: Electrical Connections

    41 5 electrical connections (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 fo...

  • Page 42: Electrical Connections

    42 5 electrical connections remote mounting of a 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. ...

  • Page 43: Electrical Connections

    43 5 electrical connections (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 is wired from the ignition module status led and mounted on the front diagnostic panel. The flashing...

  • Page 44: Electrical Connections

    44 5 electrical connections 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 front of the unit. Table 5d status led diagnostic codes code sequen...

  • Page 45: Startup

    45 6 startup figure 6-1_operating instructions installation & service manual for your safety read before operating a. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. Before operating smell all around the appliance a...

  • Page 46: Startup

    46 6 startup check/control water chemistry do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies ...

  • Page 47: Startup

    6 startup (continued) installation & service manual check thermostat circuit(s) 1. Disconnect the two external wires connected to the enable terminals on the connection board. 2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit...

  • Page 48: Domestic Water Heaters

    48 7 domestic water heaters this section applies only to those units used to supply potable hot water for domestic use. The water heater must be installed with a storage tank. This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes...

  • Page 49: Domestic Water Heaters

    49 7 domestic water heaters (continued) outlet cold water supply building hot water supply relief valve lock-temp storage tank drain building return inlet relief valve mixing valve figure 7-1_typical water heater piping with storage tank installation & service manual common manifold size (min.) mode...

  • Page 50: Domestic Water Heaters

    50 outlet cold water supply building hot water supply relief valve lock-temp storage tank drain building return inlet mixing valve figure 7-2_single water heater piping with two storage tanks 7 domestic water heaters installation & service manual common manifold size (min.) models: 497 - 747 number ...

  • Page 51: Domestic Water Heaters

    Installation & service manual 51 7 domestic water heaters (continued) relief valve building hot water supply cold water supply building return mixing valve drain min 4" common manifold size lock-temp storage tank figure 7-3_multiple water heater piping with a single storage tank common manifold size...

  • Page 52: Domestic Water Heaters

    Relief valve building hot water supply cold water supply building return mixing valve drain min 4" common manifold size lock-temp storage tank figure 7-4_multiple water heater piping with multiple storage tanks 52 7 domestic water heaters installation & service manual common manifold size (min.) mod...

  • Page 53: Domestic Water Heaters

    7 domestic water heaters (continued) table 7c pipe sizing chart 497 - 747 987 - 2067 number of units common pipe size (min.) number of units common pipe size (min.) 1 2'' 1 2 1/2'' 2 3'' 2 4'' 3 3'' 3 4'' 4 4'' 4 5'' 5 5'' 5 6'' 6 5'' 6 6'' water chemistry the required temperature rise and the stand...

  • Page 54: Domestic Water Heaters

    54 minimum pump performance this is based on heating potable water with a hardness of 5 to 25 grains per gallon and/or total dissolved solids not exceeding 350 ppm. See water chemistry, page 53. Table 7d minimum pump performance model gpm ft/hd 497 - 747 55 10 987 - 2067 90 15 heat exchanger this is...

  • Page 55: Domestic Water Heaters

    7 domestic water heaters (continued) storing the water at a higher temperature and thermostatically mixing the water increases the available quantity of mixed hot water, greatly reducing the possibility of condensate forming on the heat exchanger or in the venting system and helps prevent water born...

  • Page 56: Domestic Water Heaters

    56 7 domestic water heaters high water temperature limit control the unit is equipped with an adjustable setting, auto-reset high water temperature limit control. The hot water heater temperature limit control has a maximum limit setting of 200°f (93°c). If water temperature exceeds the set point, t...

  • Page 57: Maintenance

    57 8 maintenance listed below are items that must be checked to ensure safe, reliable operations. Verify proper installation after servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Caution appliance area keep applianc...

  • Page 58: Maintenance

    58 8 maintenance 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 in burner removal ...

  • Page 59: Maintenance

    59 8 maintenance (continued) air pressure switch figure 8-2_air pressure switch adjustment procedure models 497 - 1257: 1. Remove the upper front jacket panels from the unit to access the upper chamber. 2. Locate the air shutter on the side of the fan housing (see fig. 8-3). Turn the adjustment scre...

  • Page 60: Maintenance

    60 8 maintenance transition box screws figure 8-5_loosening the transition box screws, models 1437, 1797 and 2067 only increase air pressure decrease air pressure figure 8-6_adjusting the air shutter servicing a hot surface igniter and ignition module this unit uses a proven hot surface ignition mod...

  • Page 61: Maintenance

    8 maintenance (continued) 9. 24vac is supplied to the intermittent alarm field safety contacts, b1 and b2. 10. 24vac is supplied to the water flow switch. 11. 24vac is supplied to the th terminals on the ignition module. 12. As power is applied to the th terminals on the ignition module, 120vac is s...

  • Page 62: Glossary

    62 9 glossary power supply (ac120vac/60hz) 120vac/60hz/1ph power connects to black (line) and white (neutral) wires located within an electrical wiring box located on the left side of the unit. A green chassis grounding wire is also provided for connection to earth ground. On/off rocker switch the b...

  • Page 63: Glossary

    63 9 glossary (continued) once the ignition module sees a 24vac input from the pressure switch, it runs the blower for approximately 15 seconds in order to purge the combustion chamber of any unburned fuel/air mixture. Trial for ignition (ignition module function) once the ignition module has comple...

  • Page 64: Diagrams

    64 10 diagrams ladder diagram installation & service manual.

  • Page 65: Diagrams

    65 10 diagrams (continued) ladder diagram (continued) 0987-2067 0497-747 installation & service manual.

  • Page 66: Diagrams

    66 10 diagrams connection diagram installation & service manual.

  • Page 67: Diagrams

    67 10 diagrams (continued) connection diagram (continued) installation & service manual.

  • Page 68

    Revision notes: revision a (eco #c07390) initial release. Cbx-cwx-i-s rev a 3/11.