Manuals / Lochinvar / Household Appliance / Plumbing Product

Lochinvar 402 - 2072 operation manual CFX-CHX-I-ORev A 6/11

Models: 402 - 2072

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Revision Notes: Revision A (ECO #C08226) initial release.

CFX-CHX-I-O Rev A

6/11

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Lochinvar 402 - 2072 operation manual CFX-CHX-I-ORev A 6/11

Contents

Save this manual for future reference CFX-CHX-I-ORev AInstallation & Operation Manual Models: 402 - Contents Hazard definitionsDANGER CAUTION CAUTION NOTICEWarranty – Installation & Operation ManualPlease read before proceeding Special instructionsSafety information Owner warning –Prevention of freezing – CodesThe Copper-finII - How it works Installation & Operation ManualModels 402 - 752 Front View Models 402 - 752 Rear ViewModels 402 - 752 Right Side inside unit Models 402 - 752 Left Side inside unitThe Copper-finII - How it works... continued Models 992 - 2072 Front ViewModels 992 - 2072 Rear View Models 992 - 2072 Right Side inside unitRatings NOTICE NotesOther Specifications Installation & Operation Manual1 Determine unit location TABLE - 1ALocation of unit Indoor clearances from combustible constructionOutdoor boiler installation 2. Outside Combustion Air, Using DuctsLocation Hydronic systems anti-freeze4. Outside Combustion Air - Using Direct Venting 1 Determine unit location continuedFigure 1-5_OutsideCombustion Air Through Ducts Installation & Operation ManualExhaust fans Combustion air filterFigure 1-6 MetalPanel Covering Side Combustion Air Inlet2 Venting BEFORE YOU BEGINIdentify your appliance’s vent system CAT IV Flue pipe materialsInstallation & Operation Manual 2 VentingGeneral information TABLE - 2AVenting support Barometric damper locationConventional negative draft venting - see page Negative draftFlue outlet piping Common Venting SystemsMasonry chimney installations Vertical vent termination clearances and locationInspection of a masonry chimney Installation & Operation ManualInstallation & Operation Manual 2 VentingFigure 2-1_VentTermination from Peaked Roof - 10 ft. or Less From Ridge NOTICEVertical DirectAire venting - see page Combustion air inlet pipingLength of air inlet pipe Sidewall air inletVertical Rooftop Air Inlet Combined air inlet pointsClearances Figure 2-7_RooftopCombustion Air InletFigure 2-8_VerticalDirectAire Installation TABLE - 2Bw/Rooftop Combustion Air Inlet Venting of flue productsSidewall venting - see page Sidewall with fanSidewall venting termination Sidewall vent termination clearances and locationDrain tee installation Sidewall venting without fanFigure 2-9_SidewallVent - Models 402 - 752 Only Installation & Operation ManualW/POWER FAN ASSY TABLE - 2CSIDEWALL VENT KITS MAX. VENTTABLE - 2D Venting of flue productsHORIZONTAL DIRECTAIRE KITS Installation & Operation ManualDirect venting - see page Flue outlet pipingVertical DV venting termination Installation & Operation ManualMasonry chimney installation TABLE - 2EHorizontal DV venting termination DIRECT VENT KITSConnecting the air inlet pipe to the unit Air inlet piping materialsLength of air inlet pipe Figure 2-11_AttachingDV Box Adapter to UnitMultiple sidewall direct vent installations Vertical and sidewall combustion air inletFigure 2-13_VerticalRooftop Air Inlet Horizontal combustion air inlet clearancesOutdoor installation - see page Figure 2-14_Outdoorvent cap installedVenting TABLE - 2FConnecting to gas supply 3 Gas connectionsGas pressure test Gas connectionCombination gas valves TABLE 3BTABLE - 3C Gas train and controls3 Gas connections continued TABLE - 3DChecking gas supply pressure Installation & Operation ManualWater flow switch Installation & Service Manual4 Water connections Inlet and outlet connectionsHeating boiler installations Circulator pump specificationsPump delay operation 4 Water connections continuedMinimum boiler water temperatures Low Temperature Return Water SystemsLow temperature bypass requirements TABLE 4ALow system water volume TABLE - 4BThree way valves in system Radiant floor and snow melt heating systemsTemperature / pressure gauge Typical heating boiler installationsInstallation with a chilled water system DHW installationInstallation & Operation Manual 4 Water connections continuedCOMMON MANIFOLD SIZE Min Models: 402, 502, 652, & NOTICEInstallation & Service Manual 4 Water connections3 1/2 NOTICEInstallation & Operation Manual 4 Water connections continuedCOMMON MANIFOLD SIZE Min Models: 402, 502, 652, & NOTICE4 Water connections NOTICE NOTICEInstallation & Operation Manual Installation must comply with 5 Electrical connectionsTABLE - 5A Boiler operating control moduleFigure 5-1_LineVoltage Field Wiring Connections Figure 5-2_RoutingField WiringFigure 5-3_RemoteON/OFF Wire Connection Line voltage connectionsLouver proving switch Alarm contacts5 Electrical connections continued Louver relayWiring of the cascade Figure 5-4_LowVoltage Field Wiring ConnectionsInstallation & Operation Manual 5 Electrical connectionsFreeze protection when used 6 Start-upCheck/control water chemistry Fill and test water systemSet space heating set point temperature Check thermostat circuitsCheck vent and air piping Placing the boiler in operation6 Start-up continued Figure 6-1_LightingInstructionsInstallation & Operation Manual Set outlet target temperature boiler only Set tank target temperatureConfiguration of the cascade NOTICE0 - 10V input set point or power 7 Operating information continuedGeneral How the appliance operatesTemperature control Protection featuresRamp delay boiler only Outdoor air reset boiler onlyBoiler temperature regulation Outdoor reset operation, if used boilers onlyRun-timeand alarm outputs Service reminderSequence of the cascade Installation & Operation ManualSWITCHING ON SEQUENCE 7 Operating informationSequence of operation OPERATIONDISPLAY Installation & Operation ManualENTER/RESET Copper-finII control moduleFigure 7-1_ControlPanel - Operator Interface MENU/EXITAccess modes InstallerUser Installation & Operation ManualStatus display screens Status Display ScreensScreen # Display ShowsStatus Display Screens cont’d Display showsInstallation & Operation Manual 7 Operating information continuedScreen Screen #5Screen #6 Screen #7Screen #10 Screen #11Operation of the cascade 7 Operating information continued8 Domestic water heaters TABLE - 8ATABLE - 8B Installation & Operation ManualWater chemistry Installation & Operation Manual8 Domestic water heaters NOTICEInstallation & Operation Manual 8 Domestic water heatersNOTICE BUILDING HOT WATER SUPPLY RELIEF VALVE LOCK-TEMP8 Domestic water heaters continued Installation & Operation ManualNOTICE BUILDING HOT WATER SUPPLYCOLD 8 Domestic water heatersNOTICE Installation & Operation Manual 8 Domestic water heaters continuedNOTICE MIXING VALVE BUILDING HOT WATER SUPPLY RELIEFTABLE 8C TABLE DPump operation Heat exchangerThermostat adjustment procedure Minimum water temperatures domestic hot water useDomestic water temperatures Installation & Operation ManualOptional relief valve Thermal expansionCathodic protection Figure 8-5_DangerWarning9 Maintenance Maintenance and annual startup Service technicianOwner maintenance Table 9A_Service and Maintenance Schedules9 Maintenance Address reported problemsInspect appliance area Inspect appliance interior9 Maintenance continued Check all wiringCheck control settings Check relief valveInspect and clean burner Perform start-upand checksCheck burner flame Check flue gas passagewaysInspect and clean the heat exchanger Review with ownerOiled bearing circulators 9 Maintenance continued10 Connection diagram DISPLAYInstallation & Operation Manual MAIN POWER HARNESS10 Connection diagram continued Installation & Operation ManualSPLAY DANGERdiagram InstallationLadder ManualJ3-6 continuedCFX-CHX-I-ORev A 6/11