Lochinvar 500, 90 service manual Contents

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Contents

HAZARD DEFINITIONS

2

PLEASE READ BEFORE PROCEEDING

3-4

RATINGS

5-6

THE COPPER-FIN--HOW IT WORKS

7-9

1. DETERMINE UNIT LOCATION

 

Locate of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Clearances from Combustible Construction . . . . . . . . . . .10 Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . 11-13

2. VENTING

A Conventional Negative Draft Venting System . . . . . . . 14-15

Vertical Vent Termination Clearances . . . . . . . . . . . . . . . 16

Masonry Chimney Installation . . . . . . . . . . . . . . . . . . . . . 17

Inspection of a Masonry Chimney . . . . . . . . . . . . . . . 17

Automatic Vent Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. GAS CONNECTIONS

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Gas Manifold Pressure Adjustment Procedure . . . . . . . . 21

Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . 22

Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. HYDRONIC PIPING

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Water Flow Switch (if equipped) . . . . . . . . . . . . . . . . . . . 24 Low Water Cutoff (if equipped) . . . . . . . . . . . . . . . . . . . . 25 Typical Heating Boiler Installations . . . . . . . . . . . . . . . . . 25-26 Piping of the Boiler System . . . . . . . . . . . . . . . . . . . . . . . 26 Water Connections Heating Boilers Only . . . . . . . . . . . . 27 Circulator Pump Requirements . . . . . . . . . . . . . . . . . . . . 27 Circulator Pump Specifications . . . . . . . . . . . . . . . . . . . 27 Circulator Pump Operation (Heating Boilers Only) . . . . 27 Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . . . . 28 Low Temperature Bypass Requirements . . . . . . . . . . . . . 28 Three Way Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 4-6_Prim. / Sec. Piping of a Single Boiler . . . 30 Figure 4-7_Prim. / Sec. Piping w/Low Temp. Bypass 31 Figure 4-8_Multiple Boilers Zoned w/Circulators . . . . 32

5. ELECTRICAL CONNECTIONS

Boiler Operating Temperature Control . . . . . . . . . . . . . . . 33 Room Thermostat or Remote Thermostat Connection . . 33 Power Venter Connection to Terminal Strip . . . . . . . . . . . 33 Pump Wiring for a Heating Boiler . . . . . . . . . . . . . . . . . . 34 Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 34 Temperature Control Settings . . . . . . . . . . . . . . . . . . . . . 35 Maximum Set Point Determination . . . . . . . . . . . . . . . . . 35 Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . . . 36 Additional Temperature Controls . . . . . . . . . . . . . . . . . . . 38-39 Blocked Vent and Flame Roll-Out / Flame Interlock Switch . 39

6. STARTUP

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lighting Instructions for Standing Pilot Models (F1) . . . . 40-42 Safety Shutoff Test for Standing Pilot Ignition System . . 42 Lighting Instructions for Spark Ignition Pilot Models (F9/M9) . 43-44 Safety Shutoff Test for Spark Ignition Pilot System . . . . . . 44 Intermittent Pilot Spark Ignition System (F9/M9) . . . . . . . . . 44-45 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7. DOMESTIC WATER HEATERS

Water Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Required Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . 46

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Softened Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 7-1_Single Water Heater Piping w/Single Tank . . 48

Figure 7-2_Single Water Heater Piping w/Multiple Tanks 49

Figure 7-3_Multiple Water Heater Piping w/Single Tank . 50

Remote Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 51

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Thermostat Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52

Optional Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8. MAINTENANCE

 

Maintenance and Annual Startup

54-60

9. TROUBLESHOOTING

61-62

10. DIAGRAMS

.63-66

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

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

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Contents Models 90,000 500,000 Btu/hr Contents Please read before proceeding Checking equipmentCodes Ratings Copper-fin =B=R RatingCopper-fin Specifications Copper-fin How it works Gas connection pipeModels CWN270 Front View Model CWN399 Front View 422 Determine unit location Location of unitDetermine boiler location 3Combustion Air Direct from Outside6Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room Vent Pipe Sizes VentingConventional Negative Draft Venting System Venting Vertical Vent Termination Clearances Less from Ridge From Parapet WallSidewall Venting Masonry Chimney InstallationVent Materials NumberAutomatic Vent Damper 7CB with Vent Damper and Vent Damper Terminal BlockGas Connection Gas connectionsGas Supply Gas Pressure Test Manifold PressureInstall Piping to Control Gas PipingGas Manifold Pressure Adjustment Procedure Clockwise to raise regulator gas pressure, counterclockwiseChecking Gas Supply Pressure 4Gas Supply PressureTwo Stage Burner Control System Combination Gas ValvesVenting of Combination Gas Valves Relief Valve Water Flow Switch if equippedHydronic piping Minimum Required Flow For Heating Boiler Typical Heating Boiler InstallationsLow Water Cutoff if equipped General Plumbing RulesSystem Temperature Rise Chart Piping of the Boiler SystemWater Connections Heating Boilers Only Heat Exchanger Pressure Drop ChartCirculator Pump Specifications Circulator Pump RequirementsPrimary/Secondary Boiler Piping Three Way Valves Boiler Flow RatesPrimary / Secondary Piping 4Primary / Secondary Piping of a Single BoilerNot to Exceed 4 Pipe DIA or MAX. of 12 Apart 8Multiple Boilers Zoned with Circulators Power Venter Connection to Terminal Strip Terminal Strip WiringBoiler Operating Temperature Control Electrical connectionsOperating Temperature Control Temperature AdjustmentPump Wiring for a Heating Boiler Maximum SET Point Determination Locating Temperature ControlTemperature Control Settings Maximum Set Point DeterminationMulti-Purpose Temperature Sensor Temperature Control SensorsInlet Water Temperature Sensor Outdoor Air Temperature SensorInstallation of a Tank Sensor Water Heater Application Outdoor Air Reset OptionInstallation of a Remote Sensor Boiler Application Additional Temperature Controls Blocked Vent and Flame Roll-Out / Flame Interlock Switch Manual Reset High Water Temperature Limit ControlInitial Start-up Pre-start ChecklistStart-up Lighting Instructions 1Gas Valve 90,000 270,000 Btu/hr ModelsSafety Shutoff Test For Standing Pilot Ignition System To Turn OFF GAS to ApplianceOperating Instructions Freeze Protection Safety Shutoff Test for Spark Ignition Pilot SystemIntermittent Pilot Spark Ignition System F9/M9 To Turn Off Gas to ApplianceWater Treatment Freeze Protection for a Heating Boiler System if requiredDomestic water heaters Required Temperature RiseRequired Temperature Rise Domestic Water Heaters 90,000 500,000 Btu/hr ModelsPump Operation Water ChemistrySoftened Water Systems 1Single water heatersingle tank 2Single water heatermultiple tank 3Multiple water heatersingle tank Minimum Pump Performance Remote Sensor InstallationThermostat Settings Heat Exchanger5Danger Warning Thermal Expansion Water Flow Switch if equippedPressure Only Relief Valve Cathodic ProtectionOwner maintenance Maintenance and annual startupService technician See the User’s Information Manual for instructionsMaintenance Check Expansion Tank Check Relief ValveCombustion Air Adjustment Check All WiringCheck Control Settings Perform Start-up and ChecksInspection and Cleaning Procedure Inspect and Clean BurnerHeat Exchanger / Burner Access Inspection of Heat Exchanger Waterways Pilot Flame Adjustment ProcedureClear Area Water Circulating PumpReview with owner Gas Train and ControlsTroubleshooting Pilot or replace Wiring Diagram F1 Unit DiagramsSchematic Diagram F1 Unit 90,000 270,000 Btu/hr Models315,000 399,999 Btu/hr Models Schematic Diagram F9 UnitWiring Diagram F9 Unit Diagrams Diagrams Page Revision a ECO #C06290 initial release CFA-I-S Rev a 09/10
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