Lochinvar 2.5, 3.5 service manual Diagrams, Integrated Control

Page 58

Installation & Operation Manual

12 Diagrams

Figure 12-1Ladder Diagram

120VAC

 

 

JUNCTION BOX

NEUTRAL

 

 

 

 

TERMINAL STRIP

 

 

 

TERMINAL STRIP

120V SUPPLY "L"

 

 

 

120V SUPPLY "N"

 

INTEGRATED CONTROL

 

 

 

 

 

 

 

X1-3

1.5A EACH MAX

ON/OFF

 

 

 

 

SWITCH

 

 

 

X1-12

TERMINAL STRIP

 

 

 

 

 

X1-6

F2

F4

 

X1-1

 

 

 

 

 

 

 

 

3.15 A

5.0 A

SYSTEM PUMP

 

SYSTEM PUMP

 

RELAY

X1-2

CONTACTOR

 

 

 

 

 

 

 

 

 

 

 

 

BOILER PUMP

 

BOLIER PUMP

 

 

 

RELAY

X1-4

CONTACTOR

 

 

 

 

 

 

 

 

 

DHW PUMP

 

DHW PUMP

 

 

 

RELAY

X1-8

CONTACTOR

 

 

 

 

 

 

 

 

 

 

X2-4

SMALL BLOWER

 

 

 

 

RELAY

 

X10-1

 

SMALL GAS

X10-2

LARGE BLOWER

 

VALVE RELAY

RELAY

 

 

 

LARGE GAS

X10-3

 

 

 

 

VALVE RELAY

 

 

 

 

LARGE GAS

 

GAS

 

 

 

X10-6

VALVE

 

 

 

VALVE RELAY

 

 

 

(LARGE)

GAS

 

 

 

 

 

 

 

SMALL GAS

 

 

VALVE

 

 

X10-5

 

(SMALL)

 

 

VALVE RELAY

 

 

 

 

 

 

 

 

 

X10-4

 

 

 

 

 

 

X1-3

 

FLAME

 

 

 

 

 

SENSE 2

 

 

 

 

 

 

 

 

 

 

X1-7

 

SPARK

 

 

 

 

X1-10

SPARK

ROD

 

 

 

 

 

 

 

 

 

GENERATOR

 

 

 

 

 

 

 

 

 

 

 

X2-5

 

FLAME

 

 

 

 

 

SENSE 1

 

 

 

 

X6-3

 

 

X6-1

 

 

X11

X6-10

 

 

 

 

 

 

 

 

X2-5

 

 

USB

X13-4

 

 

 

 

 

 

 

 

 

 

INTERFACE

 

 

 

SMALL BLOWER

 

SMALL BLOWER

 

 

 

1

 

2

 

 

 

RELAY

 

 

 

LARGE BLOWER

 

 

LARGE BLOWER

 

 

3

1

 

2

 

RELAY

 

 

 

 

 

 

GROUND

INTEGRATED

CONTROL

X8-20

X8-10

X8-1

X7-8

X7-7

X8-13

X8-14

X8-12

X8-11

X8-5

X8-15

X8-6

X8-16

X8-7

X8-17

X8-1

X8-3

X8-8

X8-2

X8-4

X8-9

X7-1

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

 

 

 

LOW VOLTAGE

 

 

 

120 VAC

 

 

 

 

 

HIGH VOLTAGE

 

 

 

LARGE

 

 

 

 

CONNECTION BOARD

 

 

X4-1

X6-3

CN6-3

 

 

 

X4-2

X6-1

CN6-2

 

 

 

MODBUS

 

 

 

 

 

BOARD

X6-2

CN6-1

 

 

 

X4-3

17

SHIELD

 

 

 

 

 

CN3-6

18

A

MODBUS

 

 

19

B

OPTION

 

 

 

 

 

CN3-7

20

SHIELD

 

 

21

+

RATE

 

 

 

 

 

 

0-10V

-

OUT

 

 

CN3-14

22

 

 

23

+

BOILER

 

 

 

0-10V

-

PUMP OUT

 

 

CN3-13

24

 

 

25

SYSTEM RETURN

 

 

CN3-12

26

SENSOR

 

 

27

SYSTEM SUPPLY

 

 

 

 

 

CN3-11

28

SENSOR

 

 

29

TANK

 

 

 

 

 

CN3-10

30

SENSOR

 

 

31

OUTDOOR

CN3-4

CN3-9

32

SENSOR

33

+

BMS

 

 

 

0-10V

-

IN

 

 

CN3-8

34

 

 

35

+

SYSTEM

 

 

 

 

 

 

0-10V

-

PUMP IN

 

 

CN3-1

36

 

 

37

SHIELD

 

 

 

 

 

CN3-2

38

A

CASCADE

 

 

39

B

 

 

 

 

 

 

 

 

 

CN3-3

40

SHIELD

 

 

 

 

 

 

 

CN3-4

 

 

 

-T

 

 

 

 

 

INLET SENSOR

 

 

 

 

 

-T

 

 

 

 

 

OUTLET SENSOR (S9)

 

 

 

 

-T

 

 

 

 

 

OUTLET SENSOR (S1)

 

 

 

 

-T

 

 

 

 

 

FLUE SENSOR

 

 

 

 

 

-T

 

 

 

 

 

FLUE SENSOR (S10)

 

 

 

 

-T

 

 

 

 

 

X1-1

 

 

X1-2

3

 

 

 

 

MODBUS

 

 

 

 

 

X1-3

FLUE DAMPER

 

 

 

 

 

 

 

 

TRANSFORMER

 

FLUE DAMPER

 

 

 

1

M

2

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

24V

 

 

 

 

 

TRANSFORMER

 

 

 

 

J3-6

 

J3-5

LWCO

TEST

J3-3

 

J3-2

PROBE

SWITCH

 

 

 

 

 

LWCO RESET

J2-1

LWCO

J3-4

 

BOARD

 

 

 

 

 

 

 

 

J2-2

 

 

 

 

 

 

INTEGRATED

 

 

 

 

X6-5

CONTROL

 

 

 

 

 

 

GPS1

GPS2

GPS3

X6-15

 

 

 

 

 

 

 

BLOWER PROVING

 

 

 

X3-3

SWITCH (LARGE)

 

X6-12

 

 

BLOWER PROVING

 

 

 

X3-4

 

 

 

 

SWITCH (SMALL)

 

X13-1

 

X3-1

 

 

 

 

 

BLOCKED FLUE

 

X6-6

 

X3-2

SWITCH

 

 

BLOCKED DRAIN

 

X5-1

 

 

SWITCH

 

 

 

 

 

 

 

X5-7

 

X6-11

 

 

 

X5-2

 

X6-2

 

 

 

X5-8

 

X6-14

 

 

 

X5-3

 

 

 

"X5"

 

X5-9

 

X6-13

 

 

 

 

 

BLOCK WIRING

 

X5-4

 

X6-4

IS MODEL

 

 

DEPENDANT

 

 

 

 

 

 

 

X5-10

 

 

 

 

 

X5-5

 

 

 

 

 

X5-41

 

 

 

 

 

X5-6

 

 

 

 

 

X5-12

 

 

 

 

X7-5

PRE-MIX SENSOR 1 (S11)

 

 

 

 

-T

 

 

 

 

X7-2

PRE-MIX SENSOR 1 (S13)

 

 

 

 

-T

 

 

 

 

X7-6

PRE-MIX SENSOR 2 (S12)

 

 

 

 

-T

 

 

 

 

 

PRE-MIX SENSOR 2 (S14)

 

 

 

 

X6-18

1

 

 

 

 

 

SMALL BLOWER

 

 

 

X6-9

2

 

 

 

 

X6-17

4

 

 

 

 

X6-8

5

 

 

 

 

 

1

 

 

 

 

X13-2

LARGE BLOWER

 

 

 

2

 

 

 

 

X13-3

4

 

 

 

 

 

5

 

 

 

 

X4

 

 

 

 

 

RIBBON CABLE

 

LCD

 

 

 

CN1

CN3

 

 

 

DISPLAY

 

 

 

 

 

 

 

SMALL

DU941

 

 

CONNECTION BOARD

 

 

 

CN1-4

 

 

 

 

 

CN1-5

 

 

 

 

 

CN1-6

1

ALARM

 

 

 

CN1-12

2

CONTACTS

 

 

 

3

RUN-TIME

 

 

 

CN1-10

4

CONTACTS

 

 

 

5

TANK

 

 

 

 

 

 

 

CN1-11

6

THERMOSTAT

 

 

 

7

R

 

 

 

 

8

ENABLE

 

 

 

CN1-9

W

 

 

 

9

LOUVER

 

 

 

CN1-8

10

PROVING

 

 

 

11

24 VAC LOUVER

 

 

 

CN1-7

12

RELAY COIL

 

 

 

13

AUX

 

 

 

CN1-1

14

SWITCH 1

 

 

 

15

AUX

 

 

HIGH LIMIT

CN1-2

16

SWITCH 2

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

CN1-3

 

 

 

 

Notes:

 

 

 

 

 

1.All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2.If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions : Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3.Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

LADDER DIAGRAM

LBL20281 REV A

58

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Image 58
Page 57 Page 59
Contents Save this manual for future reference Contents When servicing boiler Please read before proceedingCrest How it works BlowersCrest How it works Models 1.5 2.0 2.5 3.0 Ratings Crest Ahri RatingDetermine boiler location Installation must comply withRecommended clearances for service access Before locating the boiler, checkVent and air piping Provide air openings to roomFlooring and foundation Prevent combustion air contaminationProducts to avoid When using an existing vent system to install a new boilerAreas likely to have contaminants When removing a boiler from existing common vent system Remove boiler from wood pallet 7Combustion Air from Outside Single Opening Minimum Recommended Combustion AIR Supply to Equipment Room Direct venting General ventingOptional room air Install vent and combustion air piping Air inlet pipe materialsApproved Stainless Steel Vent Manufacturers Make Model Air intake/vent connectionsRemoving from existing vent Common venting Determine location Vertical direct ventingVent/air termination vertical Prepare roof penetrationsMultiple vent/air terminations 4Alternate Vertical Terminations with Multiple BoilersSidewall direct venting Vent/air termination sidewallPrepare wall penetrations 2Clearance to Doors and WindowsRoom air 4Multiple Vent Terminations must also comply with FigureHydronic piping Model Circulator sizing20F 40F 60F Near boiler piping components Ball Valve Multiple Boilers Common Header Primary / Secondary Flow For all equipment and detailing required by local codes AIR Seperator Drain Port Typical System Supply Sensor Gas connections Connecting gas supply pipingModel Gas Inlet Size Natural gas Propane GasGAS Piping Size Chart Check inlet gas supplyGas valve replacement Gas PressureInstallation must comply with Field wiringLine voltage connections Louver proving switch EnableOutdoor temperature sensor Low voltage connectionsWiring of the cascade Auxiliary switch 1Alarm contacts System supply sensorWiring FieldCondensate disposal Condensate drainCheck/control water chemistry Freeze protection when usedStart-up Fill and test water systemInspect condensate system Check for gas leaksCheck thermostat circuits Inspect/check condensate lines and fittingsIf boiler does not start correctly Final checks before starting the boilerStart the boiler Check system and boilerFor Your Safety Read Before Operating Set space heating operation Gas Natural Gas Propane ValveConfiguration of the cascade Verify HWG circulator mode Set HWG target temperatureSet clock Operating information GeneralProtection features Boiler temperature regulation Outdoor reset operation, if usedCascade Sequence of operation Crest control module Home Screen2Main Menu Screen Owner maintenance Maintenance Maintenance and annual startupService technician See the Crest User’s Information Manual for InstructionsMaintenance Check expansion tank Flue vent system and air pipingCheck water system Check boiler relief valveCheck control settings Check ignition ground wiringCheck all boiler wiring Check flame signalHandling ceramic fiber materials Cleaning boiler heat exchangerReview with owner Niosh stated First AidDiagrams Integrated Control2Wiring Diagram
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3, 2, 3.5, 2.5 specifications

The Lochinvar 2, 3, 3.5, and 2.5 models are a standout lineup in the realm of commercial and residential water heating solutions. Known for their advanced technology and high efficiency, these units cater to a wide range of applications, ensuring optimal performance and reliability.

One of the key features of the Lochinvar models is their robust construction. Each unit is designed to withstand rigorous operational demands while providing excellent thermal efficiency. They are equipped with stainless steel heat exchangers, which offer superior resistance to corrosion and extend the lifespan of the equipment. This durability is essential for both commercial and residential settings where demand can vary significantly.

The Lochinvar 2, 3, 3.5, and 2.5 models utilize innovative control systems that enhance their operational efficiency and user convenience. The built-in Smart Control technology allows for easy monitoring and adjusting of system parameters, ensuring that users can maintain optimal performance with minimal effort. This feature is especially beneficial in commercial settings where large volumes of hot water are required, as it enables users to effectively manage their energy consumption.

Energy efficiency is another hallmark of the Lochinvar lineup. With high-efficiency ratings, these models help reduce energy costs significantly, making them an environmentally friendly option for heating water. The use of advanced combustion technology ensures that these units can deliver maximum heat output with minimal fuel consumption.

Additionally, the Lochinvar models are designed with safety and reliability in mind. They feature multiple safety controls and diagnostics that alert users to potential issues before they escalate, providing peace of mind. The integration of advanced venting options allows for flexible installation configurations, accommodating various building layouts and space requirements.

In summary, the Lochinvar 2, 3, 3.5, and 2.5 models define modern water heating technology with their combination of durability, efficiency, and advanced features. With their innovative design and user-friendly controls, they meet the demanding needs of both commercial and residential users, making them a top choice in the water heater market. Whether for new installations or replacements, these units deliver reliable performance and value.
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