Lochinvar 497 - 2067 service manual Copper-fin How it works

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Installation & Service Manual

The Copper-fin - How it works...

1. Heat exchanger

16. Low voltage connection board

The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process.

The low voltage connection board provides a location to tie in all of the low voltage contacts to the appliance. This is where most of the external safety devices are connected to the unit such as the louver proving switch.

2.Inner combustion chamber door

The inner combustion chamber door is a galvanized steel door which allows access for service, maintenance, and removal of the heat exchanger from inside the combustion chamber.

3.Blower

The blower pulls in air and injects air into the individual burners along with gas from the gas manifold where the mix is burned in the combustion chamber.

4.Gas valve

The gas valve allows the proper amount of gas to pass into the burner for combustion. The gas valve is biased with pressure from the combustion chamber to assist in regulation of the gas flow.

5.System / tank temperature sensor (not shown)

When connected, this sensor can be used as a system sensor or a tank sensor.

6.Inlet temperature sensor

This sensor monitors inlet water temperature. If selected as the controlling sensor, the appliance will maintain the set point temperature based on the reading at this sensor.

7.Temperature and pressure gauge (boiler only)

The temperature and pressure gauge monitors the outlet temperature of the appliance as well as the system water pressure.

8.Diagnostic display

The diagnostic display consists of six (6) lamps used to show all the major steps of operation and control malfunctions.

9.Burner

The burner is a ported stainless steel construction which uses a gas air mix to operate at a fixed input. Banks of burners are turned on or off to vary the firing rate.

10.Water outlet (system supply)

The water outlet is a pipe connection that supplies water to the system with connections for a flow switch (see #25), a relief valve (see #22), and a temperature and pressure gauge (boilers only) (see #7).

11.Water inlet (system return)

The water inlet is a pipe connection that receives water from the system and delivers it to the heat exchanger.

12.Gas supply pipe

The gas supply pipe on this appliance is 1 1/4'' diameter (Models 497 - 747) and 2" diameter (Models 987 - 2067) NPT. Please reference the National Fuel Gas Code charts for connection details.

13.Two-Stage Electronic Temperature Control

The electronic temperature control provides two-stage (high / low fire) operation by monitoring system demand.

14.Air intake

Fresh air for combustion is drawn through a filter provided at the air intake, located at either the rear or right side of the appliance.

15.Line voltage terminal strip

The line voltage terminal strip provides a location to connect all of the line voltage (120 VAC) contact points to the unit.

17.Front doors - upper and lower

The front doors provide access to the gas train as well as the blower, burners and other key components for service and maintenance.

18.Hot surface igniter (HSI)

The hot surface igniter is a device that is used to ignite the air/gas mixture as well as monitor the performance of the flame during operation. This device acts as a flame sense electrode.

19.Flame inspection window (sight glass)

The flame inspection windows, located on either side of the appliance, allow for visual inspection of the burners and flame during operation.

20.Gas shut off valve (downstream test cock)

The downstream test cock (when supplied) is in the gas train to ensure complete shut off of the gas to the burner in case of maintenance, inspection, or testing of the valve.

21.Manual high limit

Device that monitors the outlet water temperature to ensure safe operation. If the temperature exceeds its setting (field adjustable), it will break the control circuit, shutting the appliance down.

22.Relief valve

The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Boilers operate on pressure only and are shipped from the factory at a rating of 50 PSI. Water heaters operate on temperature and pressure and are shipped standard as 150 PSI and 210°F (98.9°C).

23.Power switch

The power switch is used to engage and disengage power to the appliance on the 120 VAC circuit.

24.Air pressure switch

The air pressure switch is a safety device which ensures proper blower operation. The air pressure switch is wired in series with the low voltage control circuit in such a way that if the fan does not engage or shuts down prematurely the device will break the control circuit and the unit will shut down.

25.Flow switch

The flow switch is a safety device that ensures flow through the heat exchanger during operation. This appliance is low mass and should never be operated without flow. The flow switch makes contact when flow is detected and allows the unit to operate. If flow is discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down.

26.Drain port(s)

Location from which the heat exchanger can be drained.

27.Manual shutoff valve (not shown)

Manual valve used to isolate the unit from the gas supply.

28.Flue pipe

A pipe like enclosure that is placed over an appliance to improve natural upward convection of heat and thereby increase the dissipating ability of the appliance.

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Contents Save this manual for future reference What to do if YOU Smell GASContents Please read before proceeding WarrantySpecial instructions Checking equipmentOwner warning Safety informationPrevention of freezing CodesCopper-fin How it works Copper-fin How it works Models 987 2067 Front View Models 987 2067 Rear View Copper-fin =B=R Rating RatingsCopper-fin Specifications Determine unit location InstallationLocating the unit Indoor clearances from combustible constructionShut-down and draining Outdoor boiler installationFreeze protection Pump operationCombustion and Ventilation Air Freeze Protection for a Heating Boiler System if requiredMinimum Recommended Combustion AIR Supply to Equipment Room NumberCombustion air filter 3Combustion air filter Models 497Outside Combustion Air, No Ducts Outside Combustion Air, Using DuctsCombustion Air Options Combustion Air from an Interior Space Exhaust FansGeneral information VentingVenting support Vertical vent termination clearances and locationFlue Pipe Sizes Model Flue Size Vent system optionsBarometric damper location Negative draft Conventional negative draft ventingFlue outlet piping Common venting systemsInspection of a masonry chimney Masonry chimney installationOutdoor vent/air inlet location Outdoor installation ventingOutdoor Vent Kits Model Pump Cover Without Pump Cover Outdoor vent kitGas connections Connecting to gas supply Gas pipingGas pressure test Inlet GAS Pressure Natural ModelGas connection Suggested GAS Pipe Size for Single Unit InstallationsGas train and controls Fittings to Equivalent Straight PipeCombination gas valves GAS Piping Size ChartVenting of combination gas valves Checking gas supply pressure3Measuring gas supply pressure at combination gas valve Gas manifold pressure adjustmentNat. Gas 4Measuring manifold gas pressureWater 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 System Temperature Rise Chart Low temperature return water systemsRadiant floor and snow melt heating systems LTV Valve Kits Model LTV Valve KITGPM Common Manifold Size Min Models 497 Number of UnitsDiameter 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 Typical heating boiler installations Installation with a chilled water systemBoiler flow rate General plumbing rulesBoiler bypass requirements Temperature / pressure gaugeFilling the system Water treatmentElectrical connections Connecting to electrical supplyAMP Draw Data VACTerminal strip connection options BurnersLocating the temperature control Temperature adjustmentTemperature control settings OJ1 OJ2Outdoor reset option Remote sensor for pump delay Temperature control sensorsPlacement of sensors Boiler applicationHot surface ignition system Remote Wire Connection Wire Gauge Max. Allowable LengthRemote mounting of a sensor Hot surface igniter and ignition control moduleIgnition and control timings Diagnostic Status IndicationSequence Constant Ignition Operation and diagnostic lightsStage 2 on SixOFF StartupCheck/control water chemistry Freeze protection when usedFill and test water system Purge air from water systemCheck thermostat circuits Check for gas leaksCheck vent and air piping Start the boilerWater velocity control Domestic water heatersInitial set-up of maximum water flow Maximum Water Flow1Typical water heater piping with storage tank 2Single water heater piping with two storage tanks Models 497 Number of Units Common Manifold Size Min4Multiple water heater piping with multiple storage tanks Pipe Sizing Chart 497 987 Required temperature risePipe size requirements Water chemistryDomestic water temperature Potable hot water temperature control settingsMinimum pump performance Heat exchangerLocation of cold water supply piping connections Optional relief valve High water temperature limit controlThermal expansion Cathodic protectionMaintenance Combustion and ventilation air Adjustment procedure Models 497 Servicing a hot surface igniter and ignition module Sequence of operationIgnition system checkout OverviewEnd of sequence Heat transfer processGlossary Trial for Ignition Ignition Module Function Pump Delay Electronic Thermostat FunctionIgniter Controlled by Ignition Module Hi-Lo Fire RelayLadder diagram DiagramsDiagrams 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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