Lochinvar 402 - 2072 operation manual Connection diagram, Digital Harness

Page 76

Installation & Operation Manual

10 Connection diagram

 

FIELD WIRING

 

1

+

ALARM

 

 

 

OPT. ALARM HARNESS

 

 

 

 

 

 

 

 

 

LOW VOLT HARNES

TO MONITORING DEVICE

 

+

CONTACTS

 

 

 

 

PR

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

+

 

 

 

 

 

 

 

 

 

4

PR

 

 

 

 

 

 

 

 

DIGITAL HARNESS

TO MONITORING DEVICE

 

3

RUNTIME

 

 

 

 

BL

2

 

 

 

 

 

 

 

 

 

+

CONTACTS

 

 

 

 

5

P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPEN

4

+

OPEN

WAY-3 VALVE

 

 

 

 

Y

3

 

 

 

 

 

 

 

 

 

 

 

 

 

3-WAY

24V

 

5

 

CN4

 

 

6

P

 

 

G

12

 

 

 

 

 

 

 

 

 

VALVE

 

COMMON

6

+

COM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CLOSE

 

+

CLOSE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STAGE #1

 

7

+

S1

 

 

 

 

 

BR

1

 

 

 

 

 

GY

10

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

 

7

BR/W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

S1

 

 

 

 

 

 

 

 

 

BK/W

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

7 GY

 

 

 

F2

 

 

 

CONNECT

STAGE #3

 

12

+

S2

 

STAGING

 

 

 

 

 

9

R/BK

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

+

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F4

 

 

 

 

TO

STAGE #2

 

10

+

S2

 

 

 

 

 

R/O

3

8

R

 

 

BK

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#19

 

 

 

 

13

+

S3

 

 

 

 

 

T/W

4

10

R/W

 

 

P

4

3

W

 

 

 

 

 

 

 

(LOUVER

STAGE #4

 

+

 

 

 

 

 

 

 

 

 

 

BR/W

2

X1

 

 

 

 

 

 

RELAY)

 

14

S4

 

 

 

 

 

Y

5

 

 

1 PR

 

 

 

 

 

 

 

 

 

 

 

 

15

+

S4

 

 

 

CN5

 

11

GY

 

 

 

 

 

 

 

 

 

 

 

LOUVERS

M

 

COM

 

+

LOUVER PROVINGFIELD

 

BL

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19

+

COIL

 

 

 

 

12

W/BK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROVE

 

16

+

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LINE

 

 

17

+

LOUVER RELAYWIRING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NEU

 

 

20

+

TANK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AQUASTAT

 

+

AQUASTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTR

 

 

 

 

 

 

CN3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F5

 

TANK

 

SENSOR

 

22

+

TANK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

23

+

SENSOR

 

 

 

Y

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

SHIELD

CASCADE

 

 

 

6

R/W

 

 

 

BK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24

CN6

 

BR/W

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

SHIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UNITS

 

 

 

 

25

+

A

 

 

 

 

 

 

 

7

BR

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

26

+

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FROM

 

0-10V DC IN

27

+

 

 

 

 

 

 

 

 

8

Y/G

 

 

GY/W

2

 

 

 

 

 

 

 

 

 

28

+0-10V

 

 

 

 

BL

4

 

 

1

X2

 

 

 

 

 

 

 

BMS

 

COMMON

29

+

-BMS IN

 

 

 

 

9

BL/BK

 

GY/W

 

 

 

 

 

 

 

 

TO

 

0-10V DC OUT

+

+0-10V

 

 

 

 

PR

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30

 

 

 

 

10

O/R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BMS

 

COMMON

31

+

-RATE OUT

 

 

 

 

 

 

 

 

 

 

 

 

F6

 

 

 

 

 

 

MOD

 

 

 

 

+

 

 

 

CN1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

32

SHIELD

MODBUS

 

MODULE

 

 

 

Y

3

 

 

 

 

 

 

 

 

 

 

 

 

BMS

 

 

 

 

34

+

SHIELD

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

BUS

 

 

 

 

33

A

 

 

 

 

 

MODBUS

 

 

 

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

B

 

 

 

 

 

 

 

 

2

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

35 CN2

 

 

 

 

 

CONNECTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POOL

 

 

 

 

 

 

OUTDOOR

 

 

 

 

 

 

 

 

 

 

4

 

PR

 

 

 

 

 

 

 

 

SAFETY

 

OUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SUPPLY BK

DOOR10K

1

+

SENSOR

 

20K

POOLSUP SENSOR

 

 

 

 

 

 

 

 

2

 

P

 

 

 

 

 

 

 

 

 

 

R

AIR

 

3

+

SENSOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

2

+

 

10K

 

 

 

 

 

 

 

 

 

3

 

PR

X3

 

 

 

 

 

10K/20K

 

10K

 

 

 

SYS SUPPLY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

4

+

 

10K 10K

 

 

Y

1

5

BK

 

 

1

 

P

 

 

 

 

 

 

 

 

POOL/BOILER

10K

 

+

SYS RETURN

 

 

 

P

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

6

W/R

 

 

 

 

 

 

 

 

 

 

 

 

 

FROM

0-10V DC IN

6

+

SENSOR10K

CN1

 

 

 

 

 

 

 

 

X10

 

 

 

 

 

 

PUMP

7

+

0-10V SYS

 

 

 

 

 

 

7

R/BK

 

 

 

 

 

 

X12

 

 

 

 

 

OUTPUT

COMMON

+

- PUMP IN

 

 

 

 

 

 

8

BK/R

 

 

 

 

 

 

 

 

 

 

X9

 

 

 

 

 

8

CN2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOILER/POOL HEATER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SAFETY

10K/20K

 

 

 

G

4

2

BK

 

 

 

 

4

Y

 

 

 

 

 

 

 

DISPLAY

 

OUTLET

 

 

 

 

 

 

W

3

 

 

W/BK 2

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

R

 

 

W

 

3

 

 

 

 

 

 

 

 

SENSOR

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INLET

 

10K

 

 

 

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SENSOR

 

 

 

 

 

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

24V COM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAIN POWER HARNESS

 

 

 

 

G

 

 

Y

 

S3/S4

 

BL

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24V

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

R/O

4

 

 

 

 

 

 

 

 

 

 

 

OPT. MODBUS HARNESS

 

CONTROLLER

GROUND

 

 

2

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R/W

5

IND-DHW PUMP

 

 

 

W

 

 

 

 

 

 

 

 

XFMR

 

 

 

 

 

 

S1/S2

3

Y

R

 

 

 

BK

1

 

 

1 BK

 

 

 

 

 

 

 

 

 

1

 

6

 

RELAY COIL

 

 

 

 

 

 

 

120V 60VA 24V

Y

2

 

 

 

2 Y

 

 

BL

 

 

 

 

 

 

P

 

G 2

 

 

3 W

 

 

3

 

Y

4

 

R

 

 

120V

 

 

 

 

 

 

 

W

3

 

 

 

 

 

BL 3

 

 

BL

 

Y

2

 

 

SYSTEM PUMP

 

 

 

W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

R/BK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

RELAY COIL R

 

 

PR

 

 

 

 

 

 

 

 

 

 

CKT. BREAKER

 

 

Y

6

 

 

 

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

1

GY

 

 

GY

1

 

1HP

 

UNIT

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

GY

 

 

GY

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BR

 

BR

 

 

 

GY/W

3

 

 

MAX

PUMP

 

 

 

BR

 

 

 

 

 

 

 

 

 

 

 

 

 

4

G

 

 

G

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GY/W

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BK

 

 

BR/

 

 

 

 

 

 

6

IGNITER

 

 

120V/60Hz NEUTRAL

 

 

W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

120V

 

 

 

W

1

BK

 

 

 

 

SUPPLY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LINE

 

 

BK

 

 

 

 

BK

 

 

W

 

 

AC

 

 

 

2

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BK/W

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHASSIS

ON/OFF

 

 

 

PUMP RELAY

 

 

 

4

BK/R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

GROUND

 

 

G

 

 

 

 

GROUND

SWITCH

 

 

 

120VAC COIL

 

 

 

 

 

 

MAIN UNIT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

76

Image 76
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 RatingDetermine unit location Location of unitIndoor clearances from combustible construction Freeze protectionOutdoor boiler installation LocationHydronic systems anti-freeze Combustion and ventilation airOutside Combustion Air Using Direct Venting Minimum Recommended Combustion AIR Supply to Equipment RoomExhaust fans Combustion air filterVenting Identify your appliance’s vent systemCAT IV Flue pipe materials CAT I Negative pressure non-condensingDirect Vent see Venting support General informationBarometric damper location Conventional negative draft venting see Negative draftFlue outlet piping 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 Vertical DirectAire venting see Combustion air inlet pipingLength of air inlet pipe Sidewall air inletCombined air inlet points Vertical Rooftop Air InletClearances Venting of flue products Directaire Kits Model Horizontal KIT Vertical KITSidewall venting see Sidewall with fanSidewall venting termination 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 Masonry chimney installation Horizontal DV venting terminationHorizontal Vent Termination Clearances and Location Combustion air inlet pipingConnecting the air inlet pipe to the unit Air inlet piping materialsLength of air inlet pipe Sealing PVC, CPVC, ABS, dryer vent, and flex duct vent pipeMultiple sidewall direct vent installations Vertical and sidewall combustion air inletHorizontal combustion air inlet clearances Vertical Combustion Air Inlet ClearancesOutdoor vent/air inlet location Outdoor installation seeOutdoor vent cap kit Connecting to gas supply Gas connectionsGas pressure test Gas connectionGas train and controls Combination gas valvesVenting of combination gas valves GAS Piping Size Chart Checking gas supply pressureWater flow switch Water connectionsInlet and outlet connections Heat exchangerHeating boiler installations Relief valvePiping of the boiler system Water connections heating boilers onlyMinimum boiler water temperatures Low Temperature Return Water SystemsLow temperature bypass requirements LTV Valve Kits Model LTV Valve KITLow system water volume Three way valves in systemRadiant floor and snow melt heating systems Maximum Flow for Heating BoilerTemperature / pressure gauge Typical heating boiler installationsInstallation with a chilled water system DHW installationGPM Diameter4Primary/Secondary Piping of Multiple Boilers Floor Drain Heating Supply Loop 6Primary/Secondary Piping with Buffer Tank Installation must comply with Electrical connectionsBoiler operating control module AMP Draw DataLine voltage connections EMS or remote thermostat connectionLow voltage connections DHW Domestic Hot Water thermostatLouver proving switch Alarm contactsLouver relay System supply sensor recommended useWiring of the cascade 4Low Voltage Field Wiring ConnectionsStart-up Check thermostat circuits Check vent and air pipingPlacing the boiler in operation Start the boiler1Lighting Instructions Set DHW operation Configuration of the cascadeSet clock Operating information GeneralHow the appliance operates 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 moduleAccess modes InstallerUser To save parameters and exit programmingStatus display screens Inlet ***F Inlet OpenInlet Shorted Syssup ***FUnit Pump Delay DHW Pump DelaySTG Demand FAN SpeedOperation of the cascade MIX VAL POS ** %Temperature Rise AT Full Rate Fire 90 GPM Flow Model Temperature Rise FDomestic 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 Pump operation Heat exchangerMinimum Pump Performance Ft. HdMinimum water temperatures domestic hot water use Thermostat adjustment procedureDomestic water temperatures Optional relief valve Thermal expansionCathodic protection Location of Cold Water Supply Piping ConnectionsService technician Maintenance Maintenance and annual startupOwner maintenance Maintenance Check all wiring Check control settingsCheck relief valve Inspect/replace hot surface igniter Ignition system checkoutInspect and clean burner Perform start-up and checksCheck burner flame 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.