Lochinvar 402 - 2072 operation manual Copper-fin II How it works

Page 5

Installation & Operation Manual

The Copper-fin II - How it works...

1.Heat exchanger

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.

2.Heat exchanger access cover

The heat exchanger access cover 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 and injects air into the individual burners along with gas from the gas manifold where the mix is burned inside the combustion chamber.

4.Gas valve

The gas valves (reference) have a dual purpose; changing the gas supply pressure to manifold pressure, and the reference side of the gas valve is designed to allow chamber pressure to change the volume of gas through the valve and measured as net manifold pressure. This is not a design to compensate for gas supply pressure issues.

5.System / tank temperature sensor (not shown)

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

6.Outlet/limit temperature sensor

This sensor monitors the outlet water temperature. If

selected as the controlling sensor and a system supply sensor is not connected, the appliance will maintain set point by adjusting the firing rate of the unit according to this sensor.

7.Inlet temperature sensor

This sensor monitors inlet water temperature. If selected as

the

controlling sensor

and a system return sensor

is

not connected, the

appliance will maintain set point

by adjusting the firing rate of the unit according to this sensor.

8.Temperature and pressure gauge (boilers only)

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

9.Electronic display

The electronic display consists of 6 buttons and a two-line 16-character liquid crystal display used to monitor the operation of the heater as well as enter and view the programming of the main control board.

10.Burner

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

15.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.

16.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.Low voltage connection board(s)

The low voltage connection board provides a location to connect all of the low voltage devices to the appliance. This is where most of the external safety controls are connected.

18.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.

19.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.

20.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.

21.Gas shut off valve (downstream test cock) (boiler only)

The downstream test cock is provided 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.

22.Manual reset high limit sensor

This device 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. Manual reset is performed through the display.

23.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).

24.Power switch

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

25.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.

11.Water outlet (system supply)

The water outlet is a 2 or 2 1/2" (depending on model) pipe connection that supplies water to the system with connections for a flow switch (see #26), a relief valve (see #23), and a temperature and pressure gauge (boilers only) (see #8).

12.Water inlet (system return)

The water inlet is a 2 or 2 1/2" (depending on model) pipe connection that receives water from the system and delivers it to the heat exchanger.

26.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.

27.Drain port(s)

The drain ports are located underneath the front header.

13.Gas supply pipe

The gas supply pipe on this appliance is 1 1/4 or 2" (depending on model) diameter NPT. Please reference the National Fuel Gas Code charts for connection details.

28.Manual shutoff valve (not shown)

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

14. SMART SYSTEM Control Module

The SMART System Control Module is the main control for the appliance. This module contains the programming that operates the blower, gas valve, and pumps in addition to other

programmable features.

 

5

 

 

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Contents Save this manual for future reference Models 402Contents Removal of Combustion Chamber Lining or Base Panels Please read before proceedingSpecial instructions 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 RatingsLocation of unit Determine unit locationIndoor clearances from combustible construction Freeze protectionLocation Outdoor boiler installationHydronic systems anti-freeze Combustion and ventilation airMinimum Recommended Combustion AIR Supply to Equipment Room Outside Combustion Air Using Direct VentingCombustion air filter Exhaust fansIdentify your appliance’s vent system VentingCAT IV Flue pipe materials CAT I Negative pressure non-condensingDirect Vent see Barometric damper location General informationVenting support Negative draft Conventional negative draft venting seeFlue outlet piping Common Venting SystemsInspection of a masonry chimney Masonry chimney installationsVertical vent termination clearances and location 1Vent Termination from Peaked Roof 10 ft. or Less From Ridge Combustion air inlet piping Vertical DirectAire venting seeLength of air inlet pipe Sidewall air inletClearances Vertical Rooftop Air InletCombined air inlet points Directaire Kits Model Horizontal KIT Vertical KIT Venting of flue productsSidewall with fan Sidewall venting seeSidewall venting termination Sidewall vent termination clearances and locationSidewall venting without fan Drain tee installationModels 402 Venting of flue products Horizontal DirectAire venting Powered Venting seeVertical DV venting termination Direct venting seeFlue outlet piping Horizontal DV venting termination Masonry chimney installationHorizontal Vent Termination Clearances and Location Combustion air inlet pipingAir inlet piping materials Connecting the air inlet pipe to the unitLength of air inlet pipe Sealing PVC, CPVC, ABS, dryer vent, and flex duct vent pipeVertical and sidewall combustion air inlet Multiple sidewall direct vent installationsHorizontal combustion air inlet clearances Vertical Combustion Air Inlet ClearancesOutdoor vent cap kit Outdoor installation seeOutdoor vent/air inlet location Gas connections Connecting to gas supplyGas pressure test Gas connectionVenting of combination gas valves Combination gas valvesGas train and controls Checking gas supply pressure GAS Piping Size ChartWater connections Water flow switchInlet and outlet connections Heat exchangerRelief valve Heating boiler installationsPiping of the boiler system Water connections heating boilers onlyLow Temperature Return Water Systems Minimum boiler water temperaturesLow temperature bypass requirements LTV Valve Kits Model LTV Valve KITThree way valves in system Low system water volumeRadiant floor and snow melt heating systems Maximum Flow for Heating BoilerTypical heating boiler installations Temperature / pressure gaugeInstallation with a chilled water system DHW installationDiameter GPM4Primary/Secondary Piping of Multiple Boilers Floor Drain Heating Supply Loop 6Primary/Secondary Piping with Buffer Tank Electrical connections Installation must comply withBoiler operating control module AMP Draw DataEMS or remote thermostat connection Line voltage connectionsLow voltage connections DHW Domestic Hot Water thermostatAlarm contacts Louver proving switchLouver relay System supply sensor recommended use4Low Voltage Field Wiring Connections Wiring of the cascadeStart-up Check vent and air piping Check thermostat circuitsPlacing the boiler in operation Start the boiler1Lighting Instructions Set clock Configuration of the cascadeSet DHW operation General Operating informationHow the appliance operates How the control module operatesProtection features Temperature controlCascade Boiler temperature regulationOutdoor reset operation, if used boilers only Sequence of the cascade DHW, Night Setback, and Ramp Delay operation with cascadeDAY Switching on Sequence Operation Display Sequence of operationCopper-fin II control module MENU/EXIT Display Screen ENTER/RESET UpdownInstaller Access modesUser To save parameters and exit programmingStatus display screens Inlet Open Inlet ***FInlet Shorted Syssup ***FDHW Pump Delay Unit Pump DelaySTG Demand FAN SpeedMIX VAL POS ** % Operation of the cascadeModel Temperature Rise F Temperature Rise AT Full Rate Fire 90 GPM FlowDomestic water heaters 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 Heat exchanger Pump operationMinimum Pump Performance Ft. HdDomestic water temperatures Thermostat adjustment procedureMinimum water temperatures domestic hot water use Thermal expansion Optional relief valveCathodic protection Location of Cold Water Supply Piping ConnectionsOwner maintenance Maintenance Maintenance and annual startupService technician Maintenance Check control settings Check all wiringCheck relief valve Inspect/replace hot surface igniter Ignition system checkoutPerform start-up and checks Inspect and clean burnerCheck burner flame Check flue gas passagewaysOiled bearing circulators Inspect and clean the heat exchangerReview with owner 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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