Manuals / Lochinvar / Household Appliance / Boiler

Lochinvar 000 through 2 warranty 1/09-Printedin U.S.A

Models: 000 through 2 1

1 80

Page 80

Revision Notes: Rev. 4 (IFB/IFW-i&s-04) reflects additional text on Page 39, changes made to Figures 47 & 48, Table AA (Page 51), and LBLs on Pages 77-79.

Revision 5 (ECO #C02870) reflects changes made to the scald section, pages 70, 73, and 75, the addition of a mixing valve to the piping diagrams (FIG’s 83 - 86), edits made to FIG. 80 (pg. 66), and a title change on FIG.’s 3 and 4 on page 4.

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Lochinvar 000 through 2 warranty 1/09-Printedin U.S.A

Contents

WARRANTY SPECIAL INSTRUCTIONS TO OWNERINSTALLATION AND SERVICE MANUAL Intelli-FinTABLE OF CONTENTS Water Heater/Domestic Hot Water Supply BoilerCHECKING EQUIPMENT DO NOTWHAT TO DO IF YOU SMELL GAS OWNER WARNINGINSTALLATION PROCEDURE LOCATION OF UNIT RECOMMENDED SERVICE CLEARANCESTABLE - A Clearances from Combustible ConstructionCOMBUSTION AND VENTILATION AIR REQUIREMENTS FOR APPLIANCES DRAWING AIR FROM THE EQUIPMENT ROOMFIG. 5 Combustion Air Direct from Outside FIG. 6 Combustion Air Through DuctsTABLE - B Minimum Recommended Combustion AIR SUPPLY TO MECHANICAL ROOMCONSTRUCTION AIR FILTER FIG. 9 Construction Air FilterCONSTRUCTION AIR FILTER KITS TABLE - C VENTINGTABLE - D The Category IV Flue Pipe Sizes InputA CATEGORY IV POSITIVE PRESSURE VENTING SYSTEM Category IV VentingCategory IV Flue Pipe Materials Venting Guidelines for a Category IV VentFIG. 12 Drain Tee Drain Tee InstallationGeneral Category IV Vent Termination Clearances MASONRY CHIMNEY INSTALLATIONS VERTICAL VENTING TERMINATIONS10 OR LESS 2 MINSIDEWALL VENTING TERMINATIONS TABLE - E Sidewall Vent Cap KitsSidewall Vent Cap KitLOCATION OF A SIDEWALL VENT TERMINATION DIRECT VENT AND INTELLI-VENTSYSTEMS3 MIN 4 MINTABLE - F Direct Vent and Intelli-VentFlue and Air Inlet Pipe SizesAir Inlet Length of Air Inlet PipeCombined Combustion Air Inlet Points DANGERVERTICAL DIRECT VENT SYSTEMS VERTICAL COMBUSTION AIR INLET Multiple Vertical Direct Vent InstallationsHORIZONTAL DIRECT VENT SIDEWALL COMBUSTION AIR INLET TABLE - GFlue Sidewall AirMultiple Horizontal Direct Vent Installations INTELLI-VENTSYSTEMSTABLE - H VERTICAL INTELLI-VENTWITH SIDEWALL COMBUSTION AIRCombined Air Inlet Points Maximum Length of an Intelli-VentSystemHORIZONTAL INTELLI-VENTWITH VERTICAL COMBUSTION AIRTABLE - VentVERTICAL COMBUSTION HORIZONTAL INTELLI-VENTAIR INLET WITH SIDEWALL COMBUSTION AIRTABLE - J SIDEWALL COMBUSTION AIR INLETFlue Air InletSettings at Full Fire GAS SUPPLYGAS PRESSURE TEST TABLE - K Inlet Gas PressureSingle Appliance Installations TABLE - M Recommended Gas Pipe SizeTABLE - N TABLE - OGAS MANIFOLD PRESSURE ADJUSTMENT Install Piping to ControlGAS PIPING CHECKING GAS SUPPLY PRESSURECHECKING MANIFOLD GAS PRESSURE WATER CONNECTIONS MANIFOLD GAS PRESSURE– – – – = FIELD CONNECTED AIR INLET GAS WATER OUTLET WATER INLETSECONDARY HEAT EXCHANGER PRIMARY HEAT EXCHANGERInlet and Outlet Connections Minimum Pipe Size RequirementsINTEGRAL BYPASS BYPASS VALVE - SynchronizationBYPASS PIPING ASSEMBLY INTEGRAL CIRCULATOROptional Intermittent Pump Operation BYPASS - Initial Set-upof Maximum Water FlowTABLE - P Temperature Rise At Full Rate Fire MINIMUM WATER TEMPERATURESTemperature Rise Bypass Manually Fully ClosedTABLE - Q Minimum Inlet Water Temperatures WATER FLOW SWITCHTemperature LOW WATER CUTOFF If EquippedRELIEF VALVE DIAPHRAGM GAS VALVERATIO GAS VALVE FIG. 43 Ratio Gas ValveJACKET ASSEMBLY Venting of Gas Valves and Pressure SwitchesELECTRICAL CONNECTIONS TABLE - RACCESS TO COMPONENTS AND CONTROLS FIG. 47 Front Control Panel LocationsVARIABLE FREQUENCY DRIVE FIG. 48 Transformer and Relay LocationsFIG. 49 Internal Control Panel Location FIG. 50 Variable Frequency DriveLOW AIR PRESSURE SWITCH PRESSURE SWITCHEXCEL BLOWERbe used as a diagnostic indicator TEMPERATURE ADJUSTMENT Default Values Pre-programmedin the ExcelCOMMAND DISPLAY TABLE - SPASSWORD FUNCTION CONFIGURING THE COMMAND DISPLAYTABLE - T DISPLAY DEFAULT VALUES ACCESSING THE SIX CHANGEABLE POINTS FROMVISIBLE FROM THE SCREEN OF THE COMMAND DISPLAYPOINTS FROM INFORMATION FIG. 56a Command Display Data Screen FIG. 56b Command Display Data ScreenFIG. 56c Command Display Data Screen FIG. 56d Command Display Data ScreenStatus Point Operational Modes STATUS POINTSTABLE - U Optional on Heating Boilers Only OUTDOOR RESET FUNCTION SELECTIONSStatus Point Alarm Modes MULTIPLE APPLIANCE INSTALLATIONS SEQUENCING OPTIONSCLOSED VIEW COMPONENTWire to the terminal blocks as follows INTERFACING MULTIPLE APPLIANCESTABLE - W TABLE -Wire Requirements ADDITIONAL COMPONENTS USED TO INTERFACEMULTIPLE APPLIANCES FIG. 60 Wire Termination for E-BusConnectionHIGH WATER TEMPERATURE LIMIT CONTROL FIG. 62 High Water Temperature ControlService Parts HOT SURFACE IGNITION SYSTEMIGNITION CONTROL MODULE Ignition Module Lockout FunctionsIgnition Module Status LED Diagnostic Codes Diagnostic Status IndicationTABLE - Y Ignition and Control Timings TABLE - ZOPERATION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHES Diagnostic Lights and SwitchesIndicator BURNERCOMBUSTION AIR BLOWER ORIFICEMOUNTING TRANSITIONACCESS PLATE Approximate Maximum Condensate VolumesCONDENSATE MANAGEMENT SYSTEM Optional TABLE - BBReplenishing the Neutralizer Condensate TestingCondensate Trap Installation LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATINGTO TURN OFF GAS TO APPLIANCE IGNITION SYSTEM CHECKOUTTURN TO OFF POSITION LIGHTING INSTRUCTIONSSEQUENCE OF OPERATION Heat Transfer ProcessMAINTENANCE End of SequenceBURNER REMOVAL AND CLEANING D. BURNER MAINTENANCEFIG. 77 Location of Primary Heat Exchanger Burner Cleaning ProcedureE.CHANGING THE HOT SURFACE IGNITER FIG. 78 Location of Secondary Heat Exchanger G. SECONDARY HEAT EXCHANGER INSPECTIONF.PRIMARY HEAT EXCHANGER INSPECTION H. LUBRICATION I. COMBUSTION AND VENTILATION AIRJ. CONTROL CIRCUIT VOLTAGE K. COMBUSTION AIR MEASUREMENTFREEZE PROTECTION L. COMBUSTIBLE MATERIALSHEATING BOILER INSTALLATIONS WATER TREATMENTWATER CONNECTIONS HEATING BOILERS ONLY PIPING OF THE BOILER SYSTEMPRIMARY LOOP CIRCULATOR PUMP SPECIFICATIONS PIPING LENGTHSBOILER CIRCULATOR PUMP LIMITATIONS CIRCULATOR PUMP OPERATION Heating Boilers OnlyMINIMUM BOILER WATER TEMPERATURES PRIMARY/SECONDARY BOILER PIPINGTO SYSTEM TO EXPANSION TANK AND MAKEUP WATER SYSTEM 12” MAX FROM SYSTEMBOILER TEMPERATURE RISE CHART TABLE - DD Minimum Inlet Water TemperaturesTemperature Rise at Full Rate Fire TABLE - CCTEMPERATURE/PRESSURE GAUGE TYPICAL HEATING BOILER INSTALLATIONSPLACING THE BOILER IN OPERATION General Plumbing RulesBoiler Operation INSTALLATION WITH A CHILLED WATER SYSTEMBOILER OPERATING TEMPERATURE CONTROL WATER VELOCITY CONTROL DOMESTIC HOT WATER SUPPLY BOILERWATER HEATERS DOMESTIC HOT WATER SUPPLY BOILERSTemperature Rise At Full Rate Fire TABLE - EETABLE - FF Maximum Flow RateWATER CHEMISTRY PIPING - MULTIPLE UNIT INSTALLATIONS MIXING VALVE BUILDING HOT WATER SUPPLYRELIEF VALVE TO DRAIN LOCK-TEMP STORAGE TANK COLD WATER SUPPLY DRAIN BUILDING RETURNHot Water Supply Boiler Installations Temperature RiseTABLE - GG PUMP OPERATIONTHERMOSTAT SETTINGS MINIMUM WATER TEMPERATURESTABLE - APPROXIMATE TIME / TEMPERATURE RE TABLE - HHOPTIONAL RELIEF VALVE THERMAL EXPANSIONCATHODIC PROTECTION HIGH WATER TEMPERATURE LIMIT CONTROLWARNING:To Ladder Diagram1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models REAR WIRING CONTROLLERCONV HI-LIMITWiring Diagram continued SWITCH1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models LBL90002 REV A1/09-Printedin U.S.A

1/09-Printed in U.S.A.