Lochinvar 90, 500 service manual Please read before proceeding, Checking equipment

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Installation & Service Manual

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 Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for assistance or additional information, consult a qualified installer, service agency or the gas supplier.

￿WARNING

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

Checking equipment –

Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on the packing slip with those actually received. In case there is damage or a shortage, immediately notify the carrier.

What to do if you smell gas –

•Do not try to light any appliance.

•Do not touch any electric switch; do not use any phone in your building.

•Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

Warranty –

Installation and service must be performed by a qualified service installer, service agency or the gas supplier.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Experience has shown that improper installation or system design, rather than faulty equipment, is the cause of most operating problems.

1.Excessive water hardness causing a lime/scale build-up in the copper tube is not the fault of the equipment and is not covered under the manufacturer’s warranty (see Water Treatment and Water Chemistry).

2.Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer’s warranty (see Boiler Flow Rates and Temperature Rise for flow requirements).

Do not use this appliance if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

￿Owner warning –

NOTE: Retain this manual for future reference.

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.

Consult and follow all local Building and IMPORTANT Fire Regulations and other Safety Codes

that apply to this installation. Consult your local gas utility company to authorize and inspect all gas and flue connections.

Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting.

Should overheating occur or the gas supply ￿ WARNING fail to shut off, do not turn off or disconnect

the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

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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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