Lochinvar 402 - 2072 Water connections, Inlet and outlet connections, Heat exchanger

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4 Water connections

Inlet and outlet connections

For ease of service, install unions on the water inlet and water outlet of the unit. The connection to the unit marked “Inlet” on the header should be used for return from the system. The connection on the header marked “Outlet” is to be connected to the supply side of the system.

Installation & Service Manual

Initial set-up of maximum water flow

On initial start-up of the Copper-fin II, the maximum water flow to the heat exchanger must be checked and manually limited with a valve or bypass before normal operation begins.

2" NPT WATER INLET

2" NPT WATER OUTLET

￿CAUTION

An appliance allowed to operate at return temperatures below the specified minimum setting may experience problems with the operating controls, safety switches, obstruction of the flue gas passages on the heat exchanger, incomplete combustion and possible flue gas spillage. Sustained operation at lower than specified water temperatures (140°F) may cause hazardous conditions that may result in personal injury or non-warrantable damage to the appliance.

INSPECTION

PLUGS

Figure 4-1_Water Connections - Models 402 - 752

2-1/2" NPT WATER INLET

2-1/2" NPT WATER OUTLET

INSPECTION

PLUGS

Figure 4-2_Water Connections - Models 992 - 2072

Heat exchanger

This appliance uses a finned copper tube heat exchanger to maximize the heat transfer process. The heat exchanger is mounted in the inner jacket of the appliance. A series of “V” shaped baffles are installed between the individual tubes to control the movement of the flue products over the finned copper surface and increase heat transfer. Water enters the heat exchanger and makes two passes over the area exposed to direct heat from the burner. A circulating pump MUST be installed to ensure proper water flow over the heat transfer surfaces during burner operation. Water temperatures in the heat exchanger are determined by water flow.

Water flow switch

A water flow switch is factory installed in the outlet on all heating boilers and water heaters. The flow switch must prove water flow before a trial for ignition can begin. The flow switch requires a minimum flow of 15 - 18 GPM on Models 402 - 752 and 26 GPM on Models 992 - 2072 to make the flow switch and start burner operation. A water flow switch meets most code requirements for a low water cutoff device on boilers requiring forced circulation for operation. A fault message, Flow Sw/ LWCO will be indicated in the Operator Interface on a low water flow condition as sensed by the flow switch.

Low water cutoff (if equipped)

If this boiler is installed above radiation level, a low water cutoff device must be installed at the time of boiler installation. An electronic low water cutoff is available as a factory supplied option on all models. The low water cutoff should be inspected every 6 months. A fault message, Flow Sw/LWCO will be indicated in the Operator Interface on a low water condition as sensed by the low water cutoff.

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Contents Models 402 Save this manual for future referenceContents Special instructions Please read before proceedingRemoval of Combustion Chamber Lining or Base Panels Safety information Owner warningCopper-fin II How it works Copper-fin II How it works Copper-fin II How it works Ratings Copper-fin =B=R RatingIndoor clearances from combustible construction Determine unit locationLocation of unit Freeze protectionHydronic systems anti-freeze Outdoor boiler installationLocation Combustion and ventilation airOutside Combustion Air Using Direct Venting Minimum Recommended Combustion AIR Supply to Equipment RoomExhaust fans Combustion air filterCAT IV Flue pipe materials VentingIdentify your appliance’s vent system CAT I Negative pressure non-condensingDirect Vent see Venting support General informationBarometric damper location Flue outlet piping Conventional negative draft venting seeNegative draft Common Venting SystemsVertical vent termination clearances and location Masonry chimney installationsInspection of a masonry chimney 1Vent Termination from Peaked Roof 10 ft. or Less From Ridge Length of air inlet pipe Vertical DirectAire venting seeCombustion air inlet piping Sidewall air inletCombined air inlet points Vertical Rooftop Air InletClearances Venting of flue products Directaire Kits Model Horizontal KIT Vertical KITSidewall venting termination Sidewall venting seeSidewall with fan Sidewall vent termination clearances and locationDrain tee installation Sidewall venting without fanModels 402 Horizontal DirectAire venting Powered Venting see Venting of flue productsFlue outlet piping Direct venting seeVertical DV venting termination Horizontal Vent Termination Clearances and Location Masonry chimney installationHorizontal DV venting termination Combustion air inlet pipingLength of air inlet pipe Connecting the air inlet pipe to the unitAir inlet piping materials Sealing PVC, CPVC, ABS, dryer vent, and flex duct vent pipeHorizontal combustion air inlet clearances Multiple sidewall direct vent installationsVertical and sidewall combustion air inlet Vertical Combustion Air Inlet ClearancesOutdoor vent/air inlet location Outdoor installation seeOutdoor vent cap kit Gas pressure test Connecting to gas supplyGas connections Gas connectionGas train and controls Combination gas valvesVenting of combination gas valves GAS Piping Size Chart Checking gas supply pressureInlet and outlet connections Water flow switchWater connections Heat exchangerPiping of the boiler system Heating boiler installationsRelief valve Water connections heating boilers onlyLow temperature bypass requirements Minimum boiler water temperaturesLow Temperature Return Water Systems LTV Valve Kits Model LTV Valve KITRadiant floor and snow melt heating systems Low system water volumeThree way valves in system Maximum Flow for Heating BoilerInstallation with a chilled water system Temperature / pressure gaugeTypical heating boiler installations DHW installationGPM Diameter4Primary/Secondary Piping of Multiple Boilers Floor Drain Heating Supply Loop 6Primary/Secondary Piping with Buffer Tank Boiler operating control module Installation must comply withElectrical connections AMP Draw DataLow voltage connections Line voltage connectionsEMS or remote thermostat connection DHW Domestic Hot Water thermostatLouver relay Louver proving switchAlarm contacts System supply sensor recommended useWiring of the cascade 4Low Voltage Field Wiring ConnectionsStart-up Placing the boiler in operation Check thermostat circuitsCheck vent and air piping Start the boiler1Lighting Instructions Set DHW operation Configuration of the cascadeSet clock How the appliance operates Operating informationGeneral How the control module operatesTemperature control Protection featuresOutdoor reset operation, if used boilers only Boiler temperature regulationCascade DAY Switching on Sequence DHW, Night Setback, and Ramp Delay operation with cascadeSequence of the cascade Sequence of operation Operation DisplayMENU/EXIT Display Screen ENTER/RESET Updown Copper-fin II control moduleUser Access modesInstaller To save parameters and exit programmingStatus display screens Inlet Shorted Inlet ***FInlet Open Syssup ***FSTG Demand Unit Pump DelayDHW Pump Delay FAN SpeedOperation of the cascade MIX VAL POS ** %Domestic water heaters Temperature Rise AT Full Rate Fire 90 GPM FlowModel Temperature Rise F Maximum Water FlowWater 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 Minimum Pump Performance Pump operationHeat exchanger Ft. HdMinimum water temperatures domestic hot water use Thermostat adjustment procedureDomestic water temperatures Cathodic protection Optional relief valveThermal expansion Location of Cold Water Supply Piping ConnectionsService technician Maintenance Maintenance and annual startupOwner maintenance Maintenance Check relief valve Inspect/replace hot surface igniter Check all wiringCheck control settings Ignition system checkoutCheck burner flame Inspect and clean burnerPerform start-up and checks Check flue gas passagewaysReview with owner Inspect and clean the heat exchangerOiled bearing circulators Connection diagram Digital HarnessSplay Diagram LadderFlow 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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