TEMPERATURE/PRESSURE Gauge

Lochinvar 1, 000 through 2 TEMPERATURE/PRESSURE Gauge, Typical Heating Boiler Installations

Page 68

This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the outlet side of the boiler bypass piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in °F. The temperature/pressure gauge is provided to meet code requirements. Water temperatures can be more accurately monitored from the data provided in the Command Display.

TYPICAL HEATING BOILER

INSTALLATIONS

General Plumbing Rules

1.Check all local codes.

2.For serviceability of boiler, always install unions.

3.Always pipe pressure relief valve to an open drain.

4.Locate system air vents at highest point of system.

5.Expansion tank must be installed near the boiler and on the suction side of the system pump.

6.Support all water piping.

9.Check system pressure. Ensure a minimum of 12 PSI and not more than the rated pressure of the relief valve.

10.Review the installed gas piping from the meter to the boiler. Ensure that the gas pipe, meter and any regulators are adequately sized.

11.Review the field wiring and electrical service for both the boiler controls and pump. Ensure that the electrical service(s) is adequately sized.

12.Review wiring to an energy management system and wiring to any remote temperature sensors.

Boiler Set-Up

13.Ensure that the boiler and piping system are full of water. Bleed all air from the secondary loop and bypass piping on the boiler.

14.Check system for any water leaks.

15.Check system for installation of glycol or water treatment.

16.Turn on power to the primary system pump and the integral boiler secondary pump and verify operation.

PLACING THE BOILER

IN OPERATION

Pre-Start Check List

1.Review the location of the boiler, clearances from combustible surfaces and available service clearances.

2.Review the installed Vent System. Ensure that all vent components are Category IV material with adequate clearance from combustibles.

3.Ensure that the boiler condensate drain and all vent

system condensate drains are properly routed to an acceptable floor drain or neutralization system.

4.Ensure that an optional condensate neutralization

system is properly installed if required by codes.

5.Review the vent termination point for proper location and clearances.

6.Ensure that proper volumes of combustion and ventilation air are provided to the mechanical room. If a separate combustion air pipe is used, ensure that it is properly sized, sealed and terminated.

7.Review the water piping from the boiler to the system. The boiler must be installed in a primary/ secondary piping system. Review the diameter and equivalent length of the installed piping to and from the boiler to ensure proper flow.

8.Ensure that a properly sized primary system pump is installed with an expansion tank.

Boiler Operational Checks

17.Turn the boiler main power switch to the “ON” position and the run/stop switch to the “STOP” position.

18.Verify operation of the Excel 10 and Command Display.

19.Program the adjustable points from the Command Display.

20.Turn the run/stop switch to the “RUN” position to start boiler operation. Note: The bypass must go through the synchronization process before start-up begins.

21.Push the resets for low water level, high water temperature and flame failure.

22.	Carefully follow the bypass adjustment procedure
	to set maximum flow to the boiler at 90 GPM. Verify
	by checking temperature rise while burner is firing at
	100% of rated input.

23.Install a manometer on the gas supply to the boiler and verify minimum gas supply pressure as the burner fires at 100% of rated input.

24.Verify operation of safeties as necessary (low water cut-off, high limit, gas pressure, etc.).

25.Turn the run/stop switch to the “STOP” position.

26.Verify that all adjustable points in the Command Display are set as required.

27.Reconnect any wiring disconnected during the boiler set-up.

Image 68

Contents

IFB/IFW-i&s-05 WarrantySpecial Instructions To Owner Table of Contents Checking Equipment Do notWhat to do if YOU Smell GAS Owner WarningInstallation Procedure Location of Unit Recommended Service ClearancesTable a Clearances from Combustible ConstructionCombustion Air Direct from Outside Table B Minimum Recommended CombustionAIR Supply to Mechanical Room 500 in2 3226 cm2 667 in2 4303 cm2 000 in2 12,903 cm2Construction AIR Filter Construction Air FilterConstruction AIR Filter Kits Table C VentingTable D Category IV Flue Pipe SizesCategory IV Positive Pressure Venting System Category IV VentingCategory IV Flue Pipe Materials Venting Guidelines for a Category IV VentExceed a maximum of 100 equivalent feet 30.5 m in length Drain Tee InstallationGeneral Category IV Vent Termination Clearances Masonry Chimney Installations Vertical Venting TerminationsSidewall Venting Terminations Table ESidewall Vent Cap Kits Sidewall VentLocation of a Sidewall Vent Termination Direct Vent INTELLI-VENT SystemsTable F Direct Vent and Intelli-Vent Flue Air Inlet Pipe SizesAir Inlet Length of Air Inlet PipeVertical Direct Vent Systems Combined Combustion Air Inlet PointsMultiple Vertical Direct Vent Installations Horizontal Direct VentLocation of a Sidewall Air Inlet Cap Sidewall Combustion AIR InletTable G Multiple Horizontal Direct Vent Installations These areTable H Combined Air Inlet PointsMaximum Length of an Intelli-Vent System Air Inlet Sidewall Input Flue Pipe Btu/hr SizeHorizontal INTELLI-VENT with Vertical Combustion AIR Air Inlet Sidewall Input Flue PipeBtu/hr Size Cap Kit 500,000 SVK3026Vertical Combustion Horizontal INTELLI-VENT AIR Inlet Location of a Rooftop Air Inlet CapTable J GAS Supply GAS Pressure Test Table KGAS Connection Table LRecommended Gas Pipe Size Single Appliance Installations Multiple Appliance Installations Gas Pipe Size ChartTable M Table NGAS Manifold Pressure Adjustment Install Piping to ControlGAS Piping Checking GAS Supply PressureChecking Manifold GAS Pressure Water Connections Water ConnectionsMinimum Pipe Size Requirements Secondary Heat Exchanger Primary Heat ExchangerInlet and Outlet Connections Integral Bypass Bypass Valve SynchronizationBypass Piping Assembly Integral CirculatorOptional Intermittent Pump Operation Bypass Initial Set-up of Maximum Water FlowMinimum Water Temperatures Btu/hr Input Temperature RiseTable P Bypass OperationWater Flow Switch Table QLOW Water Cutoff GAS Train and ControlsRelief Valve Diaphragm GAS Valve Ratio GAS ValveJacket Assembly Electrical ConnectionsAccess to Components and Controls Front Control Panel LocationsVariable Frequency Drive Transformer and Relay LocationsExcel High GAS Pressure Switch LOW GAS Pressure Switch OptionalLOW AIR Pressure Switch Be used as a diagnostic indicator Temperature Adjustment Default Values Pre-programmed in the ExcelTable S To Activate the Manual OverridePassword Function Configuring Command DisplayTable T Display Default Values Accessing the SIX Changeable Points from Command DisplayCalculated Set Point Total Run TimeSet Point Temp Sequencing TypeCommand Display Data Screen Status Points Table UStatus Point Operational Modes Hot Surface Igniter OnOutdoor Reset Function Selections Optional on Heating Boilers OnlyMultiple Appliance Installations Efficiency Optimized with Time EqualizationTable W Singly Terminated FTT Network Bus Topology SpecificationsInterfacing Multiple Appliances Wire Termination for E-Bus Connection Additional Components Used to Interface Multiple AppliancesHigh Water Temperature Limit Control Typical Building Management System DiagramIgnition Module Lockout Functions Service PartsHOT Surface Ignition System Diagnostic Status Indication Table YIgnition and Control Timings Table ZOPERATION/DIAGNOSTIC LIGHTS, Resets and Switches IndicatorBurner Table AACombustion AIR Blower Combustion Air Blower and Transition ChamberCondensate Management System OptionalTable BB Condensate Drain Location On RearReplenishing the Neutralizer Condensate TestingCondensate Trap Installation Install Condensate Trap Lighting InstructionsTo Turn OFF GAS to Appliance Ignition System CheckoutSequence of Operation Heat Transfer ProcessMaintenance End of SequenceBurner Removal and Cleaning Burner MaintenanceBurner Cleaning Procedure Location of Primary Heat ExchangerSecondary Heat Exchanger Inspection Lubrication Freeze Protection Heating Boiler Installations Freeze Protection for a Heating Boiler System If RequiredWater Treatment Water Connections Heating Boilers onlyPrimary Loop Circulator Pump Specifications Piping LengthsBoiler Circulator Pump Limitations Circulator Pump OperationMinimum Boiler Water Temperatures PRIMARY/SECONDARY Boiler PipingBoiler Temperature Rise Chart Table DD Table CCMaximum Flow for Heating Boiler Btu/hr Input Maximum FlowPlacing the Boiler Operation TEMPERATURE/PRESSURE GaugeTypical Heating Boiler Installations Boiler Operation Installation with a Chilled Water SystemBoiler Operating Temperature Control Water Velocity Control Typical Water Heater Piping with Storage TankMaximum Flow Rate Btu/hr Input Table EETable FF Water Chemistry Piping Multiple Unit Installations Single Water Heater Piping with Two Storage TanksTable GG Pump OperationHeat Exchanger Common ManifoldThermostat Settings Table HHCathodic Protection Optional Relief ValveThermal Expansion Ladder Diagram PWM Wiring Diagram

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Lochinvar 1, 000 through 2 TEMPERATURE/PRESSURE Gauge, Typical Heating Boiler Installations