Lochinvar 497 - 2067 Boiler bypass requirements, Temperature / pressure gauge, Filling the system

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Installation & Service Manual

4 Water connections

Boiler bypass requirements

The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded. The bypass will help to ensure that the boiler can be supplied with adequate water flow. Flow rates exceeding the maximum recommended flow will result in erosion of the boiler tubes. A typical bypass with a valve as shown in FIG. 4-6 will allow control of boiler flow.

Temperature / pressure gauge

This boiler is equipped with a dial type temperature / pressure gauge. This gauge is factory installed in the outlet side of the boiler piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in degrees Fahrenheit. The temperature / pressure gauge is provided to meet code requirements. Water temperatures can be more accurately monitored from the data provided in the digital display in the Operator Interface.

Filling the system

All air must be purged from the system for proper operation. An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve.

1.Close all drain cocks and air vents.

2.Open the makeup water valve and slowly fill the system.

3.If a makeup water pump is employed, adjust the pressure to provide a minimum of 12 psi at the highest point in the system. If a pressure regulator is also installed in the line, it should be adjusted to the same pressure.

4.Close all valves. Purge one circuit at a time as follows: A. Open one circuit drain valve and let the water drain for at least five minutes. Ensure that

there are no air bubbles visible in the water stream before closing the drain valve.

B. Repeat this procedure for each circuit.

5.Open all valves after all circuits have been purged. Make sure there are no system leaks.

CAUTION Do not use petroleum based stop leak products. All system leaks must be repaired.

The constant addition of make-up water can cause damage to the boiler heat exchanger due to scale accumulation. Scale reduces flow and heat transfer, causing overheating of the heat exchanger.

6.Run the system circulating pump for a minimum of 30 minutes with the boiler turned off.

7.Open all strainers in the system and check for debris.

8.Recheck all air vents as described in step 4.

9.Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged and not water logged.

10.Start the boiler according to the operating instructions in this manual. Operate the system, including the pump, boiler and radiation units, for one hour.

11.Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. Recheck pressure charge on diaphragm type tanks.

12.Shut down the entire system and vent all radiation units and high points in the system.

13.Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris. Reopen the water makeup valve.

14.Verify system pressure with the boiler pressure gauge before beginning regular operation.

15.Within three days of startup, recheck and bleed all air vents and the expansion tank using these instructions.

Water treatment

In hard water areas, water treatment should be used to reduce the introduction of minerals to the system. Minerals in the water can collect in the heat exchanger tubes and cause noise on operation. Excessive build up of minerals in the heat exchanger can cause a non-warrantable failure.

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Contents What to do if YOU Smell GAS Save this manual for future referenceContents Warranty Please read before proceedingSpecial instructions Checking equipmentSafety information Owner warningPrevention of freezing 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 Installation Determine unit locationLocating the unit Indoor clearances from combustible constructionOutdoor boiler installation Shut-down and drainingFreeze protection Pump operationFreeze Protection for a Heating Boiler System if required Combustion and Ventilation AirMinimum Recommended Combustion AIR Supply to Equipment Room Number3Combustion air filter Models 497 Combustion air filterOutside Combustion Air, Using Ducts Combustion Air OptionsOutside Combustion Air, No Ducts Exhaust Fans Combustion Air from an Interior SpaceVenting General informationVenting support Vertical vent termination clearances and locationVent system options Barometric damper locationFlue Pipe Sizes Model Flue Size Conventional negative draft venting Negative draftFlue outlet piping 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 CoverConnecting to gas supply Gas piping Gas connectionsGas pressure test Inlet GAS Pressure Natural ModelSuggested GAS Pipe Size for Single Unit Installations Gas connectionGas train and controls Fittings to Equivalent Straight PipeGAS Piping Size Chart Combination gas valvesVenting of combination gas valves Checking gas supply pressureGas manifold pressure adjustment 3Measuring gas supply pressure at combination gas valve4Measuring manifold gas pressure Nat. GasWater connections Pressure Drop Chart Water connections heating boilers onlyBoiler circulator requirements Minimum boiler water temperatures Low system water volumeRun Cycle Output Minimum System Load Temp. Rise 8.33 60 Min Low temperature return water systems System Temperature Rise ChartRadiant floor and snow melt heating systems LTV Valve Kits Model LTV Valve KITCommon Manifold Size Min Models 497 Number of Units GPMDiameter 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 Installation with a chilled water system Typical heating boiler installationsBoiler flow rate General plumbing rulesTemperature / pressure gauge Boiler bypass requirementsFilling the system Water treatmentConnecting to electrical supply Electrical connectionsAMP Draw Data VACBurners Terminal strip connection optionsTemperature adjustment Locating the temperature controlTemperature control settings OJ1 OJ2Outdoor reset option Temperature control sensors Remote sensor for pump delayPlacement of sensors Boiler applicationRemote Wire Connection Wire Gauge Max. Allowable Length Hot surface ignition systemRemote mounting of a sensor Hot surface igniter and ignition control moduleDiagnostic Status Indication Ignition and control timingsOperation and diagnostic lights Sequence Constant IgnitionStage 2 on SixStartup OFFFreeze protection when used Check/control water chemistryFill and test water system Purge air from water systemCheck for gas leaks Check thermostat circuitsCheck vent and air piping Start the boilerDomestic water heaters Water velocity controlInitial set-up of maximum water flow 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 Required temperature rise Pipe Sizing Chart 497 987Pipe size requirements Water chemistryPotable hot water temperature control settings Domestic water temperatureMinimum pump performance Heat exchangerLocation of cold water supply piping connections High water temperature limit control Optional relief valveThermal expansion Cathodic protectionMaintenance Combustion and ventilation air Adjustment procedure Models 497 Sequence of operation Servicing a hot surface igniter and ignition moduleIgnition system checkout OverviewHeat transfer process End of sequenceGlossary Pump Delay Electronic Thermostat Function Trial for Ignition Ignition Module FunctionIgniter Controlled by Ignition Module 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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