Lochinvar 90 Gas connections, Gas Supply Gas Pressure Test, Gas Connection, Manifold Pressure

Page 19

Installation & Service Manual

3Gas connections

Gas Supply

 

 

 

 

 

 

Gas Pressure Test

 

 

 

 

 

 

 

 

 

 

Verify that the appliance is supplied with

the type gas

1.

The appliance must be disconnected from the gas supply

specified on the rating plate. This appliance is orificed for

 

piping system during any pressure testing of that system at

operation up to 2000 feet altitude. The appliance will be

 

a test pressure in excess of 1/2 PSIG (3.5kPa).

 

 

derated 4% per 1000 feet above 2000 feet elevation. Consult

2.

The appliance must be isolated from the gas supply piping

the factory for installations above 2000 feet elevation. Field

 

system by

closing

a manual

shutoff valve during

any

conversions for operation at high altitude must be performed

 

 

pressure testing of

the gas

supply

piping

system

at

test

by certified personnel only. The appliance will be marked to

 

 

pressures equal to or less than 1/2 PSIG (3.5kPa).

 

 

indicate suitability for high altitude operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS SUPPLY PRESSURE: Measured at the inlet pressure tap

3. The appliance and its gas connection must be leak-tested

 

before placing it in operation.

 

 

 

 

 

 

 

 

 

located upstream of the combination gas valve(s) see

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIG.’s 3-5 and 3-6, page 23.

 

 

 

 

 

 

Gas Connection

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE - 3A

 

 

 

 

1.

Safe operation of the appliance requires properly sized gas

 

GAS SUPPLY PRESSURE

 

 

 

supply piping.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.

Gas pipe size may be larger than appliance gas connection.

 

 

 

 

Natural Gas

LP Gas

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Max. (Inches Water Column)

 

 

 

 

 

 

3.

Installation of a union is suggested for ease of service, see

 

14

 

 

14

 

 

 

 

 

 

FIG. 3-1 on page 20.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Min. (Inches Water Column)

 

*4.5

 

 

11

 

4.

Install a manual

main gas

shutoff

valve, outside

of

the

 

 

 

 

 

 

 

 

 

Min. (Inches Water Column)

 

**5.0

 

 

11

 

 

 

 

 

 

appliance gas connection and before the gas valve or

 

 

 

 

 

 

 

 

 

 

manifold connection, when local codes require.

 

 

*Models 90,000 - 360,000 Btu/hr Only

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

**Models 399,999 - 500,000 Btu/hr Only

5.

A trap (drip leg) MUST be provided by the installer in

Maximum inlet

gas pressure

must not

exceed the value

 

the inlet of the

gas connection to the

appliance,

see

 

FIG. 3-1 on page 20.

 

 

 

 

 

 

 

 

 

 

 

specified. Minimum value listed is for the purposes of input

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adjustment.

 

 

 

 

 

 

 

 

6.

The combination gas valve has an integral vent limiting

MANIFOLD PRESSURE: Measured at the pressure tap on

 

device and

 

does

 

not require

 

 

venting to atmosphere,

 

outside the building.

 

 

 

 

 

 

 

 

 

 

 

the downstream side of the combination gas valve(s) (see

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIG.’s 3-5 and 3-6, page 23). The gas regulator settings for

7.

Optional gas controls may require routing of bleeds and

single stage and two stage operation are factory set to supply

 

vents to the atmosphere,

outside

the building

when

proper manifold pressure for normal operation. To check

 

 

required by local codes.

 

 

 

 

 

 

 

 

 

 

 

manifold pressure, see Manifold Adjustment Procedure. Do

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

not increase manifold pressure beyond

specified pressure

 

 

 

 

 

 

 

TABLE - 3C

 

 

 

 

settings shown below in Table 3B.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FITTINGS TO EQUIVALENT STRAIGHT PIPE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE - 3B

 

 

 

 

 

 

 

 

 

Diameter Pipe (inches)

 

 

 

 

 

MANIFOLD PRESSURE

 

 

 

3/4

 

1

 

1 1/4

1 1/2

 

2

 

3

 

4

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Single and Two-Stage

 

 

Two Stage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Input Gas

 

 

 

 

 

Equivalent Length of Straight Pipe (feet)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Full or High Fire Settings

 

Low Fire Settings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Btu/hr

 

 

 

2

 

2

 

3

 

4

 

5

 

10

 

14

20

 

Natural Gas

 

 

LP Gas

 

Natural Gas

 

LP Gas

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

90,000 - 180,000

3.5"

 

10"

 

 

0.9"

 

2.5"

 

 

 

 

 

 

TABLE - 3D

 

 

 

 

199,999

2.9"

 

7.5"

 

 

0.9"

 

2.5"

 

 

 

 

 

 

GAS CONNECTIONS

 

 

 

 

215,000 - 399,999

3.5"

 

10"

 

 

0.9"

 

2.5"

 

 

 

 

Btu/hr

 

 

 

 

 

 

Pipe Size

 

 

 

 

 

 

 

 

 

 

INPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

500,000

3.5"

 

10"

 

 

N/A

 

N/A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

90,000 - 135,000

 

 

 

 

 

 

1/2"

 

 

 

(two valves)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

180,000 - 315,000

 

 

 

 

 

 

3/4"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

360,000 - 500,000

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19

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Contents Models 90,000 500,000 Btu/hr Contents Checking equipment Please read before proceedingCodes Copper-fin =B=R Rating RatingsCopper-fin Specifications Gas connection pipe Copper-fin How it worksModels CWN270 Front View Model CWN399 Front View 422 Location of unit Determine unit location3Combustion Air Direct from Outside Determine boiler location6Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room Conventional Negative Draft Venting System VentingVent Pipe Sizes Venting Less from Ridge From Parapet Wall Vertical Vent Termination ClearancesNumber Masonry Chimney InstallationVent Materials Sidewall Venting7CB with Vent Damper and Vent Damper Terminal Block Automatic Vent DamperManifold Pressure Gas connectionsGas Supply Gas Pressure Test Gas ConnectionGas Piping Install Piping to ControlClockwise to raise regulator gas pressure, counterclockwise Gas Manifold Pressure Adjustment Procedure4Gas Supply Pressure Checking Gas Supply PressureVenting of Combination Gas Valves Combination Gas ValvesTwo Stage Burner Control System Hydronic piping Water Flow Switch if equippedRelief Valve General Plumbing Rules Typical Heating Boiler InstallationsLow Water Cutoff if equipped Minimum Required Flow For Heating BoilerPiping of the Boiler System System Temperature Rise ChartCirculator Pump Requirements Heat Exchanger Pressure Drop ChartCirculator Pump Specifications Water Connections Heating Boilers OnlyPrimary/Secondary Boiler Piping Boiler Flow Rates Three Way Valves4Primary / Secondary Piping of a Single Boiler Primary / Secondary PipingNot to Exceed 4 Pipe DIA or MAX. of 12 Apart 8Multiple Boilers Zoned with Circulators Electrical connections Terminal Strip WiringBoiler Operating Temperature Control Power Venter Connection to Terminal StripPump Wiring for a Heating Boiler Temperature AdjustmentOperating Temperature Control Maximum Set Point Determination Locating Temperature ControlTemperature Control Settings Maximum SET Point DeterminationOutdoor Air Temperature Sensor Temperature Control SensorsInlet Water Temperature Sensor Multi-Purpose Temperature SensorInstallation of a Remote Sensor Boiler Application Outdoor Air Reset OptionInstallation of a Tank Sensor Water Heater Application Additional Temperature Controls Manual Reset High Water Temperature Limit Control Blocked Vent and Flame Roll-Out / Flame Interlock SwitchStart-up Pre-start ChecklistInitial Start-up 1Gas Valve 90,000 270,000 Btu/hr Models Lighting InstructionsTo Turn OFF GAS to Appliance Safety Shutoff Test For Standing Pilot Ignition SystemOperating Instructions To Turn Off Gas to Appliance Safety Shutoff Test for Spark Ignition Pilot SystemIntermittent Pilot Spark Ignition System F9/M9 Freeze ProtectionFreeze Protection for a Heating Boiler System if required Water TreatmentDomestic Water Heaters 90,000 500,000 Btu/hr Models Required Temperature RiseRequired Temperature Rise Domestic water heatersSoftened Water Systems Water ChemistryPump Operation 1Single water heatersingle tank 2Single water heatermultiple tank 3Multiple water heatersingle tank Heat Exchanger Remote Sensor InstallationThermostat Settings Minimum Pump Performance5Danger Warning Cathodic Protection Water Flow Switch if equippedPressure Only Relief Valve Thermal ExpansionSee the User’s Information Manual for instructions Maintenance and annual startupService technician Owner maintenanceMaintenance Check Relief Valve Check Expansion TankPerform Start-up and Checks Check All WiringCheck Control Settings Combustion Air AdjustmentHeat Exchanger / Burner Access Inspect and Clean BurnerInspection and Cleaning Procedure Water Circulating Pump Pilot Flame Adjustment ProcedureClear Area Inspection of Heat Exchanger WaterwaysGas Train and Controls Review with ownerTroubleshooting Pilot or replace 90,000 270,000 Btu/hr Models DiagramsSchematic Diagram F1 Unit Wiring Diagram F1 UnitWiring Diagram F9 Unit Schematic Diagram F9 Unit315,000 399,999 Btu/hr Models Diagrams Diagrams Page Revision a ECO #C06290 initial release CFA-I-S Rev a 09/10
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