Lochinvar 500, 90 service manual Initial Start-up, Pre-start Checklist

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6Start-up

Initial Start-up

Follow the Lighting Instructions on the label applied to the appliance.

A.On water heaters and boilers with the system pump delay option, the operating temperature control will energize the pump relay which energizes the pump on a call for heat. The operating temperature control will de-energize the pump relay approximately 30 seconds after the call for heat ends. If either the inlet sensor or the optional multi-purpose temperature sensor reads below 40°F, the pump relay will turn ON. When the temperature rises above 50°F the pump relay will turn OFF.

On boilers, the pump will operate whenever the “W” terminal is energized.

B.Location - The appliance should be located within a room having a temperature safely above freezing [32°F(0°C)].

C.Shutdown and Draining - If, for any reason, the appliance is shut off, the following precautionary measures must be taken:

1.Shut off gas supply,

2.Shut off water supply.

3.Shut off electrical supply.

4.Drain the heat exchanger completely. Remove one 3/8" NPT plug or bulbwell from the inlet side and one from the outlet side of the front header of the heat exchanger.

5.Drain the pump. Remove the 3/4" plug in the bypass loop.

Pre-start Checklist

1.Inspect the burners to be sure they are properly aligned.

2.Inspect the pilot gas line, thermocouple leads, ignition leads and wire connections to the gas valve to be sure none were damaged during shipment.

3.Check to ensure that gas connections have been made properly and the gas line is purged of air.

4.Check to ensure that water connections are tight and the appliance and piping system have been properly filled.

5.Ensure that discharge from the relief valve has been piped to a floor drain.

6.Verify that properly sized combustion and ventilation air openings are provided and not obstructed in any way.

Installation & Service Manual

7.Check carefully for gas leaks.

8.Read the appliance’s safety warnings, lighting instructions and check out procedure carefully, before firing the system.

Lighting Instructions for Standing Pilot Models (F1) Models 90,000 through 270,000 Btu/hr Input

FOR YOUR SAFETY READ BEFORE

OPERATING

￿WARNING If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

A.This appliance has a pilot which must be ignited by hand. When lighting the pilot, follow these instructions exactly.

B.BEFORE OPERATING, smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor.

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.

C.Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D.Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance. 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.

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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 Conventional Negative Draft Venting System VentingVent Pipe Sizes Venting Vertical Vent Termination Clearances Less from Ridge From Parapet WallMasonry Chimney Installation Vent MaterialsSidewall Venting NumberAutomatic Vent Damper 7CB with Vent Damper and Vent Damper Terminal BlockGas connections Gas Supply Gas Pressure TestGas Connection Manifold PressureInstall Piping to Control Gas PipingGas Manifold Pressure Adjustment Procedure Clockwise to raise regulator gas pressure, counterclockwiseChecking Gas Supply Pressure 4Gas Supply PressureVenting of Combination Gas Valves Combination Gas ValvesTwo Stage Burner Control System Hydronic piping Water Flow Switch if equippedRelief Valve Typical Heating Boiler Installations Low Water Cutoff if equippedMinimum Required Flow For Heating Boiler General Plumbing RulesSystem Temperature Rise Chart Piping of the Boiler SystemHeat Exchanger Pressure Drop Chart Circulator Pump SpecificationsWater Connections Heating Boilers Only 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 Terminal Strip Wiring Boiler Operating Temperature ControlPower Venter Connection to Terminal Strip Electrical connectionsPump Wiring for a Heating Boiler Temperature AdjustmentOperating Temperature Control Locating Temperature Control Temperature Control SettingsMaximum SET Point Determination Maximum Set Point DeterminationTemperature Control Sensors Inlet Water Temperature SensorMulti-Purpose Temperature Sensor Outdoor Air Temperature SensorInstallation of a Remote Sensor Boiler Application Outdoor Air Reset OptionInstallation of a Tank Sensor Water Heater Application Additional Temperature Controls Blocked Vent and Flame Roll-Out / Flame Interlock Switch Manual Reset High Water Temperature Limit ControlStart-up Pre-start ChecklistInitial Start-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 Safety Shutoff Test for Spark Ignition Pilot System Intermittent Pilot Spark Ignition System F9/M9Freeze Protection To Turn Off Gas to ApplianceWater Treatment Freeze Protection for a Heating Boiler System if requiredRequired Temperature Rise Required Temperature RiseDomestic water heaters Domestic Water Heaters 90,000 500,000 Btu/hr ModelsSoftened Water Systems Water ChemistryPump Operation 1Single water heatersingle tank 2Single water heatermultiple tank 3Multiple water heatersingle tank Remote Sensor Installation Thermostat SettingsMinimum Pump Performance Heat Exchanger5Danger Warning Water Flow Switch if equipped Pressure Only Relief ValveThermal Expansion Cathodic ProtectionMaintenance and annual startup Service technicianOwner maintenance See the User’s Information Manual for instructionsMaintenance Check Expansion Tank Check Relief ValveCheck All Wiring Check Control SettingsCombustion Air Adjustment Perform Start-up and ChecksHeat Exchanger / Burner Access Inspect and Clean BurnerInspection and Cleaning Procedure Pilot Flame Adjustment Procedure Clear AreaInspection of Heat Exchanger Waterways Water Circulating PumpReview with owner Gas Train and ControlsTroubleshooting Pilot or replace Diagrams Schematic Diagram F1 UnitWiring Diagram F1 Unit 90,000 270,000 Btu/hr ModelsWiring 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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