Lochinvar 500, 90 Safety Shutoff Test for Spark Ignition Pilot System, Freeze Protection

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Installation & Service Manual

6Start-up

To Turn Off Gas to Appliance

1.Set the thermostat to the OFF position.

2.Turn off all electric power to the appliance if service is to be performed.

3a. 90,000 - 135,000 and 399,999 - 500,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the “OFF” position. Do not force.

3b. 180,000 - 360,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob. Depress the knob and continue rotation to the “OFF” position. Do not force.

Should overheating occur or the gas fail to ￿ WARNING shut off, turn off the external manual gas

valve to the appliance.

Safety Shutoff Test for Spark Ignition Pilot System

1.Turn “OFF” gas supply to the appliance.

2.Turn thermostat to highest setting.

3.Turn electric power “ON”.

4.Pump relay pulls in to start pump.

5.The ignition will begin sparking at the pilot.

6.The ignition module will lock out after the 90 second trial for ignition period on the 90,000 through 399,999 Btu/hr models and after the 15 second trial for ignition period on the 500,000 Btu/hr model.

7.Immediately call a qualified serviceman or installer to repair an ignition system that fails to lock out and properly shut down burner operation.

8.After successful completion of the test, readjust the thermostat to normal setting.

9.Turn “ON” gas supply.

10.Turn power “OFF” then “ON” to reset ignition module.

11.If ignition system fails to operate properly, repair work must be performed by a qualified serviceman or installer.

Intermittent Pilot Spark Ignition System (F9/M9)

The ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty ignition module must be replaced with a new module.

Ignition and Control Timings

F1 Standing Pilot Models (thermocouple supervised)

Pilot Flame Failure Response Time - 180 Seconds Maximum

F9 Intermittent Spark Ignition Pilot Models

Pilot Trial for Ignition Period - 90 Seconds (90,000 through 399,999 Btu/hr models)

Pilot Trial for Ignition Period - 15 Seconds (500,000 Btu/hr model)

Pilot Failure Response Time - 0.8 Seconds at less than 1.0 µA flame current

Pump Delay Timing (Standard on Water Heaters and Optional on Boilers) - 30 Seconds after burner shutdown

Freeze Protection

1.For water heaters and boilers that utilize the pump delay option, 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.

2.Location - Heating boilers and water heaters must be located in a room having a temperature safely above freezing [32°F(0°C)].

3.Caution - A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing. The cold outside air pulled down the flue may freeze a heat exchanger. This condition must be corrected to provide adequate freeze protection.

4.Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Follow the manufacturers instructions. DO NOT use undiluted or automotive type antifreeze.

5.A snow screen should be installed to prevent snow and ice accumulation around the appliance venting system in cold climates.

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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 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 PressureTwo Stage Burner Control System Combination Gas ValvesVenting of Combination Gas Valves Relief Valve Water Flow Switch if equippedHydronic piping 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 connectionsOperating Temperature Control Temperature AdjustmentPump Wiring for a Heating Boiler 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 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 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 ModelsPump Operation Water ChemistrySoftened Water Systems 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 ChecksInspection and Cleaning Procedure Inspect and Clean BurnerHeat Exchanger / Burner Access 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 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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