Lochinvar 497 - 2067 service manual Contents

Page 2

Contents

HAZARD DEFINITIONS

2

PLEASE READ BEFORE PROCEEDING

3-4

SAFETY INFORMATION

4

THE COPPER-FIN -- HOW IT WORKS

5-7

RATINGS

8-9

1. DETERMINE UNIT LOCATION

 

Locating the Unit

10

Indoor Clearances from Combustible Construction

10

Freeze Protection

11-12

Prevent Combustion Air Contamination

11-13

Combustion Air Options

14-15

2. VENTING

 

General Venting Information

16-17

Vent System Options

 

Conventional Negative Draft Venting

18-19

Masonry Chimney Installation and Inspection

19

Outdoor Installation Options

20-21

3. GAS CONNECTIONS

 

Connecting to Gas Supply

22

Gas Pressure Test

22

Gas Piping

22

Gas Connections / Gas Train and Controls

23

Combination Gas Valves

24

Checking Gas Supply Pressure

24-25

Gas Manifold Pressure Adjustment

25-26

4. WATER CONNECTIONS

 

Inlet & Outlet Connections

27

Relief Valve

27

Heating Boiler Installations

27-29

Low Temperature Return Water Systems

30

Primary/Secondary Piping of a Single Boiler

31

Primary/Secondary Piping of Multiple Boilers

32

Boiler w/Low Temperature Bypass Piping

33

Primary/Secondary Piping with Buffer Tank

34

Installation with a Chilled Water System

35

Typical Heating Boiler Installations

35

Boiler Flow Rate / Bypass Requirements

35-36

Temperature/Pressure Gauge and Water Treatment

36

5. ELECTRICAL CONNECTIONS

 

Connecting to Electrical Supply

37

EMS Connections

38

Terminal Strip Connection Options

38

Temperature Controls

 

 

Temperature Adjustment

39

Outdoor Reset Option

40

Temperature Control Sensors

41-42

Hot Surface Ignition System

42-43

Operation and Diagnostic Lights

44

6. STARTUP

 

 

Operating and Safety Instructions

45

Check Water Chemistry

46

Freeze Protection (when used)

46

Fill and Test Water System

46

Purge Air from Water System

46

Check for Gas Leaks / Thermostat Circuit(s)

47

Check Vent and Air Piping

47

Placing the Boiler in Operation

47

7. DOMESTIC WATER HEATERS

 

 

General

48

Water Velocity Control

48

Pipe Size Requirements

 

 

Typical Water Heater Piping w/ Storage Tank

49

Single Water Heater Piping w/Two Storage Tanks ...

50

Multiple Water Heater Piping w/One Storage Tank

... 51

Multiple Water Heater Piping w/Multi. Storage Tanks. 52

Water Chemistry

53

Circulating Pump/ Performance

53

Heat Exchanger

54

Potable Hot Water Temperature Controls

54

Location of Cold Water Supply Piping Connections

55

High Water Temperature Limit Control

56

Optional Relief Valve

56

Thermal Expansion and Cathodic Protection

56

8. MAINTENANCE

 

 

Burner Flames

57

Burner Removal and Cleaning Procedures

57-58

Adjusting Differential Air Pressure

58-59

Servicing a Hot Surface Igniter / Ignition Module

60

Sequence of Operation Overview

60-61

9. GLOSSARY

62-63

10. DIAGRAMS

64-67

Revision Notes

Back Cover

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

NOTICE

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 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 What to do if YOU Smell GAS Save this manual for future referenceContents Special instructions WarrantyPlease read before proceeding Checking equipmentPrevention of freezing Safety informationOwner warning CodesCopper-fin How it works Copper-fin How it works Models 987 2067 Front View Models 987 2067 Rear View Ratings Copper-fin =B=R RatingCopper-fin Specifications Locating the unit InstallationDetermine unit location Indoor clearances from combustible constructionFreeze protection Outdoor boiler installationShut-down and draining Pump operationMinimum Recommended Combustion AIR Supply to Equipment Room Freeze Protection for a Heating Boiler System if requiredCombustion and Ventilation Air Number3Combustion air filter Models 497 Combustion air filterOutside Combustion Air, No Ducts Outside Combustion Air, Using DuctsCombustion Air Options Exhaust Fans Combustion Air from an Interior SpaceVenting support VentingGeneral information Vertical vent termination clearances and locationFlue Pipe Sizes Model Flue Size Vent system optionsBarometric damper location Flue outlet piping Conventional negative draft ventingNegative draft Common venting systemsMasonry chimney installation Inspection of a masonry chimneyOutdoor installation venting Outdoor vent/air inlet locationOutdoor vent kit Outdoor Vent Kits Model Pump Cover Without Pump CoverGas pressure test Connecting to gas supply Gas pipingGas connections Inlet GAS Pressure Natural ModelGas train and controls Suggested GAS Pipe Size for Single Unit InstallationsGas connection Fittings to Equivalent Straight PipeVenting of combination gas valves GAS Piping Size ChartCombination gas valves Checking gas supply pressureGas manifold pressure adjustment 3Measuring gas supply pressure at combination gas valve4Measuring manifold gas pressure Nat. GasWater connections Boiler circulator requirements Pressure Drop ChartWater connections heating boilers only Run Cycle Output Minimum System Load Temp. Rise 8.33 60 Min Minimum boiler water temperaturesLow system water volume Radiant floor and snow melt heating systems Low temperature return water systemsSystem Temperature Rise Chart LTV Valve Kits Model LTV Valve KITDiameter Common Manifold Size Min Models 497 Number of UnitsGPM Common Manifold Size Min Models 987 Number of Units6Primary/secondary piping of multiple boilers 7Boiler with low temperature bypass 8Primary/secondary piping with buffer tank Boiler flow rate Installation with a chilled water systemTypical heating boiler installations General plumbing rulesFilling the system Temperature / pressure gaugeBoiler bypass requirements Water treatmentAMP Draw Data Connecting to electrical supplyElectrical connections VACBurners Terminal strip connection optionsTemperature control settings Temperature adjustmentLocating the temperature control OJ1 OJ2Outdoor reset option Placement of sensors Temperature control sensorsRemote sensor for pump delay Boiler applicationRemote mounting of a sensor Remote Wire Connection Wire Gauge Max. Allowable LengthHot surface ignition system Hot surface igniter and ignition control moduleDiagnostic Status Indication Ignition and control timingsStage 2 on Operation and diagnostic lightsSequence Constant Ignition SixStartup OFFFill and test water system Freeze protection when usedCheck/control water chemistry Purge air from water systemCheck vent and air piping Check for gas leaksCheck thermostat circuits Start the boilerInitial set-up of maximum water flow Domestic water heatersWater velocity control Maximum Water Flow1Typical water heater piping with storage tank 2Single water heater piping with two storage tanks Common Manifold Size Min Models 497 Number of Units4Multiple water heater piping with multiple storage tanks Pipe size requirements Required temperature risePipe Sizing Chart 497 987 Water chemistryMinimum pump performance Potable hot water temperature control settingsDomestic water temperature Heat exchangerLocation of cold water supply piping connections Thermal expansion High water temperature limit controlOptional relief valve Cathodic protectionMaintenance Combustion and ventilation air Adjustment procedure Models 497 Ignition system checkout Sequence of operationServicing a hot surface igniter and ignition module OverviewHeat transfer process End of sequenceGlossary Igniter Controlled by Ignition Module Pump Delay Electronic Thermostat FunctionTrial for Ignition Ignition Module Function Hi-Lo Fire RelayDiagrams Ladder diagramDiagrams Connection diagram Connection diagram

497 - 2067 specifications

Lochinvar 497 - 2067 is a highly efficient and versatile condensing boiler that is designed to meet the diverse heating needs of residential and commercial applications. Known for its impressive performance and advanced technology, the Lochinvar 497 - 2067 has garnered a reputation as a reliable choice among heating professionals.

One of the standout features of the Lochinvar 497 - 2067 is its impressive thermal efficiency. The boiler boasts an efficiency rating of up to 95% AFUE (Annual Fuel Utilization Efficiency), allowing users to significantly reduce their energy costs while minimizing environmental impact. This efficiency is facilitated by its innovative condensing technology, which captures and reuses heat from exhaust gases for optimal performance.

The Lochinvar 497 - 2067 is equipped with a robust stainless steel heat exchanger designed to handle high temperatures and ensure long-lasting performance. The heat exchanger’s design maximizes heat transfer, while its corrosion-resistant properties guarantee durability over time. This contributes to the boiler's overall longevity and serviceability, reducing the need for frequent replacements.

Control is another critical feature of the Lochinvar 497 - 2067. The boiler comes with an advanced control system that enables easy management of system operations. Users can take advantage of features such as outdoor reset control, which adjusts the temperature of the boiler based on external weather conditions, enhancing system efficiency and comfort.

In terms of safety, the Lochinvar 497 - 2067 incorporates several cutting-edge safety features, including a flame detection system and multiple safety shut-off devices. These safeguards help to ensure the safe operation of the boiler, providing peace of mind to users and heating professionals alike.

Another important characteristic is the compact design of the Lochinvar 497 - 2067, which allows for flexible installation in various settings, including tight spaces. Its lightweight structure further simplifies the installation process, making it a practical choice for contractors.

In summary, the Lochinvar 497 - 2067 is an exceptional high-efficiency condensing boiler that combines advanced technology, durability, and ease of use. With its impressive thermal efficiency, superior heat exchanger design, advanced control systems, and enhanced safety measures, it stands out as a top choice for those seeking reliable heating solutions. This boiler not only meets but exceeds modern demands for energy efficiency and performance, solidifying its position in the market.
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