Lochinvar 402 - 2072 operation manual Please read before proceeding, Special instructions

Page 3

Installation & Operation Manual

Please read before proceeding

Special instructions

NOTICE

This is a gas appliance and should be installed

by a licensed electrician and/or certified gas

 

 

supplier. Service must be performed by a

 

qualified service installer, service agency or

 

the gas supplier.

Apply enough water to the combustion chamber lining to prevent airborne dust.

Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.

￿WARNING

￿WARNING

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for assistance or additional information, consult a qualified installer, service agency or the gas supplier.

• NIOSH stated First Aid:

Eye: Irrigate immediately.

Breathing: Fresh air.

￿ WARNING The combustion chamber insulation in this

appliance contains ceramic fiber material.

Ceramic fibers can be converted to cristobalite

in very high temperature applications.

The International Agency for Research on

Cancer (IARC) has concluded, “Crystalline

silica in the form of quartz or cristobalite

from occupational sources is carcinogenic

to humans (Group 1).” Normal operating

temperatures in this appliance are below the

level to convert ceramic fibers to cristobalite.

Abnormal operating conditions would have

Checking equipment –

Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on packing slip with those actually received. In case there is damage or a shortage, immediately notify the carrier.

to be created to convert the ceramic fibers in

this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines.

Do not use this appliance if any part has been under water. 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.

NOTICE

The ceramic fiber material used in this

appliance is an irritant; when handling or

 

 

replacing the ceramic materials it is advisable

 

that the installer follow these safety guides.

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS:

Avoid

breathing

dust

and

contact

with

skin

and eyes.

 

 

 

 

 

 

 

• Use

NIOSH certified

dust respirator

(N95).

This type of respirator is based on the OSHA

requirements for cristobalite at the time this

document

was

written.

Other

types

of

respirators

may

be needed

depending

on

the

job

site conditions. Current NIOSH recommendations

can

be

found

on

the

NIOSH

website

at

h t t p : / / w w w . c d c . g o v / n i o s h / h o m e p a g e . h t m l . NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

Warranty –

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Experience has shown that improper installation or system design, rather than faulty equipment, is the cause of most operating problems.

1.Excessive water hardness causing a lime/scale build-up in the copper tube is not the fault of the equipment and is not covered under the manufacturer’s warranty (see Water Treatment and Water Chemistry).

2.Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer’s warranty (see Boiler Flow Rates and Temperature Rise for flow requirements).

• Wear long-sleeved, loose fitting clothing, gloves,

 

 

3

and eye protection.

 

 

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Contents Save this manual for future reference Models 402Contents Please read before proceeding Special instructionsRemoval of Combustion Chamber Lining or Base Panels Owner warning Safety informationCopper-fin II How it works Copper-fin II How it works Copper-fin II How it works Copper-fin =B=R Rating RatingsFreeze protection Determine unit locationLocation of unit Indoor clearances from combustible constructionCombustion and ventilation air Outdoor boiler installationLocation Hydronic systems anti-freezeMinimum Recommended Combustion AIR Supply to Equipment Room Outside Combustion Air Using Direct VentingCombustion air filter Exhaust fansCAT I Negative pressure non-condensing VentingIdentify your appliance’s vent system CAT IV Flue pipe materialsDirect Vent see General information Venting supportBarometric damper location Common Venting Systems Conventional negative draft venting seeNegative draft Flue outlet pipingMasonry chimney installations Vertical vent termination clearances and locationInspection of a masonry chimney 1Vent Termination from Peaked Roof 10 ft. or Less From Ridge Sidewall air inlet Vertical DirectAire venting seeCombustion air inlet piping Length of air inlet pipeVertical Rooftop Air Inlet Combined air inlet pointsClearances Directaire Kits Model Horizontal KIT Vertical KIT Venting of flue productsSidewall vent termination clearances and location Sidewall venting seeSidewall with fan Sidewall venting terminationSidewall venting without fan Drain tee installationModels 402 Venting of flue products Horizontal DirectAire venting Powered Venting seeDirect venting see Flue outlet pipingVertical DV venting termination Combustion air inlet piping Masonry chimney installationHorizontal DV venting termination Horizontal Vent Termination Clearances and LocationSealing PVC, CPVC, ABS, dryer vent, and flex duct vent pipe Connecting the air inlet pipe to the unitAir inlet piping materials Length of air inlet pipeVertical Combustion Air Inlet Clearances Multiple sidewall direct vent installationsVertical and sidewall combustion air inlet Horizontal combustion air inlet clearancesOutdoor installation see Outdoor vent/air inlet locationOutdoor vent cap kit Gas connection Connecting to gas supplyGas connections Gas pressure testCombination gas valves Gas train and controlsVenting of combination gas valves Checking gas supply pressure GAS Piping Size ChartHeat exchanger Water flow switchWater connections Inlet and outlet connectionsWater connections heating boilers only Heating boiler installationsRelief valve Piping of the boiler systemLTV Valve Kits Model LTV Valve KIT Minimum boiler water temperaturesLow Temperature Return Water Systems Low temperature bypass requirementsMaximum Flow for Heating Boiler Low system water volumeThree way valves in system Radiant floor and snow melt heating systemsDHW installation Temperature / pressure gaugeTypical heating boiler installations Installation with a chilled water systemDiameter GPM4Primary/Secondary Piping of Multiple Boilers Floor Drain Heating Supply Loop 6Primary/Secondary Piping with Buffer Tank AMP Draw Data Installation must comply withElectrical connections Boiler operating control moduleDHW Domestic Hot Water thermostat Line voltage connectionsEMS or remote thermostat connection Low voltage connectionsSystem supply sensor recommended use Louver proving switchAlarm contacts Louver relay4Low Voltage Field Wiring Connections Wiring of the cascadeStart-up Start the boiler Check thermostat circuitsCheck vent and air piping Placing the boiler in operation1Lighting Instructions Configuration of the cascade Set DHW operationSet clock How the control module operates Operating informationGeneral How the appliance operatesProtection features Temperature controlBoiler temperature regulation Outdoor reset operation, if used boilers onlyCascade DHW, Night Setback, and Ramp Delay operation with cascade DAY Switching on SequenceSequence of the cascade Operation Display Sequence of operationCopper-fin II control module MENU/EXIT Display Screen ENTER/RESET UpdownTo save parameters and exit programming Access modesInstaller UserStatus display screens Syssup ***F Inlet ***FInlet Open Inlet ShortedFAN Speed Unit Pump DelayDHW Pump Delay STG DemandMIX VAL POS ** % Operation of the cascadeMaximum Water Flow Temperature Rise AT Full Rate Fire 90 GPM FlowModel Temperature Rise F Domestic water heatersWater chemistry 1Typical Water Heater Piping with Storage Tank 2Single Water Heater Piping with Two Storage Tanks 3Multiple Water Heater Piping with a Single Storage Tank 4Multiple Water Heater Piping with Multiple Storage Tanks Ft. Hd Pump operationHeat exchanger Minimum Pump PerformanceThermostat adjustment procedure Minimum water temperatures domestic hot water useDomestic water temperatures Location of Cold Water Supply Piping Connections Optional relief valveThermal expansion Cathodic protectionMaintenance Maintenance and annual startup Service technicianOwner maintenance Maintenance Ignition system checkout Check all wiringCheck control settings Check relief valve Inspect/replace hot surface igniterCheck flue gas passageways Inspect and clean burnerPerform start-up and checks Check burner flameInspect and clean the heat exchanger Review with ownerOiled bearing circulators Digital Harness Connection diagramSplay Ladder DiagramFlow Switch
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402 - 2072 specifications

The Lochinvar 402 - 2072 is a versatile and highly efficient boiler designed to meet the heating demands of modern residential and commercial applications. This model stands out due to its innovative technologies, advanced features, and a high level of reliability, making it an ideal choice for consumers looking for an enduring and economical heating solution.

One of the primary characteristics of the Lochinvar 402 - 2072 is its impressive energy efficiency. With an exceptional annual fuel utilization efficiency (AFUE) rating, this boiler ensures minimal energy waste, allowing homeowners and business operators to save significantly on their energy bills. The model incorporates advanced condensing technology that enables it to extract heat from the combustion gases, maximizing heat transfer and reducing emissions.

The Lochinvar 402 - 2072 is built with a robust stainless steel construction that enhances durability and resilience against corrosion and other environmental factors. This material not only prolongs the lifespan of the unit but also contributes to its outstanding thermal efficiency. Additionally, the boiler's compact design allows for flexible installation options, making it suitable for various spaces, including tight utility rooms and basements.

Equipped with a user-friendly control interface, the Lochinvar 402 - 2072 allows for easy monitoring and adjustment of settings. Its advanced digital display provides real-time data on system performance, ensuring the operator can maintain optimal performance and efficiency.

Another noteworthy feature is the unit's quiet operation. The design includes sound-dampening insulation and high-efficiency circulators, keeping noise to a minimum, which is an essential trait for both residential and commercial settings.

The Lochinvar 402 - 2072 is also designed with safety in mind. It incorporates multiple safety features including an automated vent damper, low water cutoff, and a comprehensive control system that monitors various operating conditions. This proactive approach to safety ensures that potential issues are identified and addressed before they become critical.

In conclusion, the Lochinvar 402 - 2072 boiler presents an exceptional combination of efficiency, durability, and user-friendly features. Its advanced condensing technology, stainless steel construction, and focus on safety make it a leading choice in the competitive boiler market, catering to the heating needs of a diverse range of applications while ensuring environmental responsibility. For those in search of a dependable and efficient heating solution, the Lochinvar 402 - 2072 is certainly worth considering.
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