Lochinvar 90, 500 Heat Exchanger Pressure Drop Chart, Water Connections Heating Boilers Only

Page 27

Installation & Service Manual

4Hydronic piping (continued)

Hot water piping must be supported by suitable hangers or floor stands, NOT by the boiler. Copper pipe systems will be subject to considerable expansion and contraction. Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system. Padding is recommended on rigid hangers installed with a copper system. The boiler pressure relief valve must be piped to a suitable floor drain. See the relief valve section on page 24 of this manual.

￿ CAUTION

A leak in a boiler system will cause the

system to intake fresh water constantly,

 

 

which will cause the tubes to accumulate

 

a lime/scale build up. This will cause a

 

NON-WARRANTABLE FAILURE.

Water Connections Heating Boilers Only

All water heaters and heating boilers with inputs of 315,000 - 500,000 Btu/hr have 2" NPT.

￿CAUTION Field installed reducing bushings may decrease flow resulting in boiler noise or

flashing to steam.

Circulator Pump Requirements

This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation. The boiler circulating pump must be purchased locally. The boiler circulator pump must operate continuously while the boiler is firing. Pump selection is critical to achieve proper operation. A pump should be selected to achieve proper system design water temperature rise. A heat exchanger pressure drop chart (Table 4C) is provided to assist in proper pump selection. Also provided is a System Temperature Rise Chart (Table 4B). This table provides GPM and boiler head-loss at various temperature rises for each boiler based on Btu/hr input. Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing. Example: The boiler inlet temperature is 160°F and the boiler outlet temperature is 180°F, this means that there is a 20°F temperature rise across the boiler.

TABLE - 4C

HEAT EXCHANGER PRESSURE DROP CHART

 

7

 

CB500

 

 

 

 

 

 

6

 

 

 

 

 

 

CB360

 

 

5

 

 

 

FT/HD

4

CB

315

 

 

CB399

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

2

1

0

0

5

10

15

20

25

30

35

Gallons per Minute

Circulator Pump Operation (Heating Boilers Only)

Boilers are equipped with a relay for controlling the circulation pump for the hot water loop. The relay turns ON and OFF in response to the “W” input from the wall thermostat or zone control.

The field installed boiler pump MUST NOT exceed 1 h.p. For continuous pump operation, wire the system pump to the 120V supply. The pump should be connected at the junction box as shown in FIG. 4-3.

120V

SUPPLY

TO

UNIT

Circulator Pump Specifications

1.Maximum operating pressure for the pump must exceed system operating pressure.

2.Maximum water temperature should not exceed nameplate rating.

3.Cast iron circulators may be used for closed loop systems.

4.A properly sized expansion tank must be installed near the boiler and located on the suction side of the pump.

TO

CIRCULATION

PUMP

Figure 4-3_Boiler Wiring - Circulation Pump to Junction Box

27

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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 Venting Conventional Negative Draft Venting SystemVent 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 PressureCombination Gas Valves Venting of Combination Gas ValvesTwo Stage Burner Control System Water Flow Switch if equipped Hydronic pipingRelief 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 StripTemperature Adjustment Pump Wiring for a Heating BoilerOperating 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 SensorOutdoor Air Reset Option Installation of a Remote Sensor Boiler ApplicationInstallation 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 SwitchPre-start Checklist Start-upInitial 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 heatersWater Chemistry Softened Water SystemsPump 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 AdjustmentInspect and Clean Burner Heat Exchanger / Burner AccessInspection 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 UnitSchematic Diagram F9 Unit Wiring 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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