Lochinvar COPPER-FIN 497 - 2067 manual

Installation & Service Manual Models: 497 - 2067 Save this manual for future reference. CBX-CWX-I-S Rev A This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an installation. Perform steps in the order given. F[...]

Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.  DANGER  WARNING  CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which, if not avoided, will [...]

Installation & Service Manual 3 3 Please read before proceeding NOTICE This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier.  WARNING If the information in these instructions is not followed exact[...]

4 Please read before proceeding Codes – The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. In the absence of such require[...]

5 The Copper-fin - How it works... 1. Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process. 2. Inner combustion chamber door The inner combustion chamber door is a galvaniz[...]

6 The Copper-fin - How it works... 26 26 17 17 17 17 12 12 Models 497 - 747 Front View Models 497 - 747 Left Side (inside unit) Models 497 - 747 Right Side (inside unit) Models 497 - 747 Rear View 14 14 22 22 25 25 28 28 13 13 16 16 21 21 15 15 23 23 18 18 20 20 24 24 9 2 3 4 8 7 6 19 19 11 11 10 10 1 Installation & Service Manual[...]

7 Installation & Service Manual The Copper-fin - How it works... (continued) Models 987 - 2067 Left Side (inside unit) Models 987 - 2067 Right Side (inside unit) Models 987 - 2067 Rear View Models 987 - 2067 Front View 14 14 25 25 22 22 7 28 28 21 21 4 3 2 9 20 20 18 18 24 24 23 23 15 15 16 16 13 13 8 6 19 19 11 11 10 10 7 1 12 12 17 17 17 17 2[...]

8 Ratings Maximum allowed working pressure is located on the rating plate. NOTICE Copper-fin I=B=R Rating Model Number Note: Change “N” to “L” for L.P. gas models. Input MBH (Note 4) Min Max Gross Output MBH (Note 1) Net I=B=R Ratings Water, MBH (Note 2) CBN497 250 495 401 349 CBN647 350 645 522 454 CBN747 350 745 603 524 CBN987 360 985 798[...]

9 Ratings (continued) Notes: 1. Copper-fins require special gas venting. Use only the vent materials and methods specified in the Installation and Service Manual. 2. The Copper-fin is orificed for operation up to 2000 feet altitude. The ap pli ance will be derated 4% per 1000 feet above 2000 feet el e va tion. Consult the factory for installations [...]

10 1 Determine unit location Locating the unit 1. Maintain all clearances from combustible construction when locating unit. See Clearances from Combustible Construction, this page. 2. Locate the unit so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, install a suitable drain pan that is wel[...]

1 Determine unit location (continued) 11 TABLE 1A COMBUSTIBLE FLOOR KITS Model Kit Number 497 CFK3302 647 CFK3303 747 CFK3304  CAUTION Although these units are CSA International design- cer ti fi ed for outdoor installations, such installations are not recommended in ar eas where the danger of freezing exists. Y ou must provide proper fr eeze p[...]

12 1 Determine unit location TABLE 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Model Number *Outside Air from 2 Openings Directly from Outdoors *Outside Air from 1 Opening Directly from Outdoors, in 2 Inside Air from 2 Ducts Delivered from Outdoors Inside Air from 2 Ducts Delivered from Interior Space Top Opening, in 2 Bottom Ope[...]

13 Combustion air filter This unit has a standard air filter located at the combustion air inlet. This filter helps ensure clean air is used for the combustion process. Check this filter every month and replace when it becomes dirty. The filter size on Models 497 - 747 is 12" x 12" x 1" (30.5cm x 30.5cm x 2.5cm) and 16" x 16&quo[...]

14 1 Determine unit location This unit has four combustion air options. 1. Outside Combustion Air, No Ducts You can direct outside combustion air to this unit using either one or two permanent openings (see FIG. 1-5). One Opening The opening must have a minimum free area of one square inch per 3000 Btu input (7 cm 2 per kW). You must locate this op[...]

1 Determine unit location (continued) 15 3. Combustion Air from an Interior Space You can direct combustion air to this unit using air from an adjoining interior space. You must provide two openings from the boiler room to the adjoining room. Each of the two openings must have a net free area of one square inch per 1000 Btu input (22cm² per kW), b[...]

General information You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest ed ition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of C[...]

17 2 Venting (continued) Barometric damper location Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance. The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit’s flue outlet. The barometric damper MUST NOT be[...]

2 Venting 18 1. Conventional negative draft venting NOTICE Before installing a venting system, follow all venting clearances and requirements found in the Venting, General Information section, page 16. Figure 2-5_ Conventional negative draft vertical venting with combustion air louvers This option uses Type-B double-wall flue outlet piping. The blo[...]

19 2 Venting (continued) Common venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to the common venting system ar[...]

2 Venting 20 2. Outdoor installation venting Units are self-venting and can be used outdoors when installed with the optional outdoor caps. These caps mount directly to the unit and cover the flue outlet and combustion air inlet openings. No additional vent piping is required. Combustion air supply must be free of contaminants (see Combustion and V[...]

21 2 Venting (continued) The optional outdoor v ent kit is available fr om the appliance manufa cturer . The outdoor kit par t numbers ar e listed by unit siz e. See T able 2B for kit numbers. Y ou can install the outdoor vent cap and c ombustion air inlet panel(s) on the unit (see FIG. ’ s 2-6 and 2-7). Outdoor vent kit 3' 3' 3' 3[...]

3 Gas connections 22 Connecting to gas supply Verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 2000 feet altitude. Consult factory for installations above 2000 feet elevation. Inlet gas pressure: Measured at the inlet pressure tap on the appliance gas manifold[...]

23 3 Gas connections (continued) Gas connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum (L.P.) and natural gases. All piping must comply with local codes and ordinances. Piping installations must comply with approved standards and practices. 1. Make sure gas line is a separate line di[...]

3 Gas connections 24 Combination gas valves These units fire in multiple stages of burner input. Each stage of burner operation has a combination gas valve(s) to cycle the gas supply on and off and regulate gas to the burners. Each combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves. T[...]

NOTICE The gas valves are referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the front inside portion of the jacket. Reference the drawings in this section for component and connection points for pressure measurement. The referenced chamber pressure must be s[...]

3 Gas connections 26 12. If adjustment is necessary, remove the regulator cover screw on the gas valve. Note: If the gas valve under adjustment is located on a manifold assembly monitored by an igniter, the unit may shut down and recycle when the regulator cover screw is removed. This is normal. 13. Turn the regulator adjustment screw “clockwise?[...]

27 4 Water connections Inlet and outlet connections For ease of service, install unions on the water inlet and water outlet of the unit. The connection to the unit marked “Inlet” on the header should be used for return from the system. The connection on the header marked “Outlet” is to be connected to the supply side of the system. NEED NEW[...]

4 Water connections 28 Boiler circulator requirements This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation. Pump selection is critical to achieve proper operation. A pump should be selected to achieve proper system design water temperature rise. Pipe diameter and length are critical to en[...]

29 4 Water connections (continued) A buffer tank is an effective way to enhance a small system load and increase heating system efficiency (see FIG. 4-8 on page 34 of this manual). Buffer tanks add water volume to the system and act as a flywheel to absorb the additional Btu’s provided by the boiler when only a single zone of a large system is ca[...]

4 Water connections 30 Low temperature return water systems Any non-condensing boiler and venting system will develop operational problems when exposed to inlet water temperatures below 140°F. Lochinvar offers a low temperature protection valve (LTV) that is factory preset to maintain 140°F inlet water to the boiler regardless of the system retur[...]

TO FLOOR DRAIN HEAT ING SUPPLY LOOP TO EX PANSION TANK AND M AKEUP W ATER SYSTEM HEATING RETURN LOOP 12" MAX 31 4 Water connections (continued) Figure 4-5_ Primary/secondary piping of single boiler Installation & Service Manual COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Number of Units GPM Diameter (in.) 1 60 2 1/2 COMMON MANIFOLD SIZE [...]

32 4 Water connections Installation & Service Manual Figure 4-6_ Primary/secondary piping of multiple boilers SECONDARY BOILER PUMP FROM SYSTEM 12" OR 4X PIPE DIAM ETERS AIR SEPARATOR MAKE-UP WA TE R PRESSURE RELI EF VALVE EXPAN SION TANK LOW W ATER CUT-OFF (OPTIONAL) TO SYSTEM SYSTEM PUM P COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Num[...]

33 H EA EA TI TI NG SUPP LY LY LOOP TO FLOOR DR DR AIN MIX ING VALVE TO EXPANSIO N TANK A ND ND M AKE AKE UP W ATER SYSTEM HEA TI TI NG RET UR UR N L OO OO P 12” 12” MAX Figure 4-7_ Boiler with low temperature bypass *Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipmen[...]

34 1" TEMPERATUR E AND PRESSU RE GAUGE AUTOMATIC AIR ELIMINATOR /VENT SYSTEM OUTLET SYSTEM SENSOR LOCATION SYSTEM INLET BUFFER TANK DRAIN PUMP COMMOM MANIFO LD MUST BE SIZE D TO ACCOM MODATE CO MBINED FLOW RATE FOR ALL BOILERS Figure 4-8_ Primary/secondary piping with buffer tank *Please note that these illustrations are meant to show system p[...]

35 4 Water connections (continued) Installation with a chilled water system Pipe refrigeration systems in parallel. Install duct coil downstream at cooling coil. Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation, the boiler piping system must be [...]

36 4 Water connections The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded. The bypass will help to ensure that the boiler can be supplied with adequate water flow. Flo[...]

37 5 Electrical connections Connecting to electrical supply This unit is wired for 120 VAC service. The unit, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the National Electrical Code ANSI/NFPA No. 70. When th[...]

38 5 Electrical connections External EMS connection to terminal strip for stage firing control of burners This unit is equipped with a factory installed terminal strip for connection of an energy management system (EMS) to the burner stages. The EMS terminal strip is located in the unit’s control panel. Ensure that all wiring used for connection [...]

39 5 Electrical connections (continued) Temperature adjustment Note: The temperature controller is preset at the factory with test settings. You may need to adjust the settings to meet your specific needs. Return water temperatures must not be less than 140°F. If lower return water temperatures are required, follow the instructions for Low Tempera[...]

40 5 Electrical connections Setpoint The Set Point knob specifies the target water temperature in degrees, Fahrenheit. After the water temperature reaches the set point, the temperature control shuts off the burners. Differential The Differential specifies the number of degrees below the set point that the control will allow the water temperature t[...]

41 5 Electrical connections (continued) Temperature control sensors This is a two-stage temperature control that controls the burner ignition, pump, and alarm functions. This temperature controller can measure up to three different sensor inputs, depending upon how the unit is set up. They are as follows: 1. Inlet Water Temperature Sensor 2. Multi-[...]

42 5 Electrical connections Remote mounting of a sensor You must mount the outside air temperature sensor outside the building. To mount remote sensors, follow the guidelines below. Take care to correctly wire sensors to the unit. Erratic temperature readings can be caused by poor wiring practices. Twist the wires between the unit and the remote se[...]

43 5 Electrical connections (continued) Diagnostic Status Indication The ignition module has an LED which indicates the status of the safety circuits. A remote Ignition Module Status indicating light is wired from the ignition module Status LED and mounted on the front diagnostic panel. The flashing operation of this light indicates the diagnostic [...]

44 5 Electrical connections Operation and diagnostic lights The diagnostic control panel has up to 6 indicating and diagnostic lights to show all major steps of operation and control sensed malfunctions. This panel is located on the front of the unit. TABLE 5D Status LED Diagnostic Codes Code Sequence Condition Constant ON System OK, no faults pres[...]

45 6 Startup Figure 6-1_ Operating instructions Installation & Service Manual FOR YOUR SAFET Y READ BEFORE OPERAT ING A. This appliance is equipped with an ignition device which autom atically l ights the burner. Do not try to light the burner by hand. B. BEFORE OPERA TING smell all around the appliance area for gas. Be sure to smell next to th[...]

46 6 Startup Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard water areas (above 7 grains hardness). Ch[...]

6 Startup (continued) Installation & Service Manual Check thermostat circuit(s) 1. Disconnect the two external wires connected to the enable terminals on the connection board. 2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading[...]

48 7 Domestic water heaters This section applies only to those units used to supply potable hot water for domestic use. The water heater must be installed with a storage tank. This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and [...]

49 7 Domestic water heaters (continued) OUTLET COLD WA T E R SUPPLY BUIL DING HOT W ATER SUPPLY RELIE F VALVE LOCK-TEMP STORAGE TANK DRAIN BUILDI NG RETURN INLET RELIE F VALVE MIXING VALVE Figure 7-1_ Typical water heater piping with storage tank Installation & Service Manual COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Number of Units GPM Dia[...]

50 OUTLET COLD WA T ER SUPPLY BUILDI NG HOT W ATER SUPPLY RELIE F VALVE LOCK-TEMP STORAGE TANK DRAIN BUILDING RETURN INLET MIXING VALVE Figure 7-2_ Single water heater piping with two storage tanks 7 Domestic water heaters Installation & Service Manual COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Number of Units GPM Diameter (in.) 1 60 2 1/2 C[...]

Installation & Service Manual 51 7 Domestic water heaters (continued) RELI EF VALVE BUIL DING HOT WA TE R SUPPLY COLD WA TE R SUPPLY BUIL DING RET URN MIXING VALVE DRAIN MIN 4" COMMON MANIFO LD SIZE LOCK-TEM P STORAGE TANK Figure 7-3_ Multiple water heater piping with a single storage tank COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Numb[...]

RELI EF VALVE BUIL DING HOT WA TE R SUPPLY COLD WA TE R SUPPLY BUIL DING RETURN MIXING VALVE DRAIN MIN 4" COMMON MANIFO LD SIZE LOCK-TEMP STORAGE TANK Figure 7-4_ Multiple water heater piping with multiple storage tanks 52 7 Domestic water heaters Installation & Service Manual COMMON MANIFOLD SIZE (Min.) Models: 497 - 747 Number of Units G[...]

7 Domestic water heaters (continued) TABLE 7C Pipe Sizing Chart 497 - 747 987 - 2067 Number of Units Common Pipe Size (Min.) Number of Units Common Pipe Size (Min.) 1 2'' 1 2 1/2'' 2 3'' 2 4'' 3 3'' 3 4'' 4 4'' 4 5'' 5 5'' 5 6'' 6 5'' 6 6&a[...]

54 Minimum pump performance This is based on heating potable water with a hardness of 5 to 25 grains per gallon and/or total dissolved solids not exceeding 350 ppm. See Water Chemistry , page 53. TABLE 7D Minimum Pump Performance Model GPM FT/HD 497 - 747 55 10 987 - 2067 90 15 Heat exchanger This is a highly sophisticated heat exchanger, designed [...]

7 Domestic water heaters (continued) Storing the water at a higher temperature and thermostatically mixing the water increases the available quantity of mixed hot water, greatly reducing the possibility of condensate forming on the heat exchanger or in the venting system and helps prevent water born bacteria growth. Some states may require a lower [...]

56 7 Domestic water heaters High water temperature limit control The unit is equipped with an adjustable setting, auto-reset high water temperature limit control. The hot water heater temperature limit control has a maximum limit setting of 200°F (93°C). If water temperature exceeds the set point, the limit will break the control circuit and shut[...]

57 8 Maintenance Listed below are items that must be checked to ensure safe, reliable operations. Verify proper installation after servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.  CAUTION Appliance area Keep appliance area clear and free from combustible materia[...]

58 8 Maintenance Heat exchanger cleaning 1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. 2. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning, page 57. 3. Disconnect wiring from t[...]

59 8 Maintenance (continued) AIR PRESSURE SWITCH Figure 8-2_ Air pressure switch Adjustment procedure Models 497 - 1257: 1. Remove the upper front jacket panels from the unit to access the upper chamber. 2. Locate the air shutter on the side of the fan housing (see FIG. 8-3). Turn the adjustment screw on the air shutter to open or close the shutter[...]

60 8 Maintenance TRANSITION BOX SCREW S Figure 8-5_ Loosening the transition box screws, Models 1437, 1797 and 2067 only INCREASE AIR PRESSURE DECREASE A IR PRESSURE Figure 8-6_ Adjusting the air shutter Servicing a hot surface igniter and ignition module This unit uses a proven hot surface ignition module and a hot surface igniter. The hot surface[...]

8 Maintenance (continued) 9. 24VAC is supplied to the intermittent alarm field safety contacts, B1 and B2. 10. 24VAC is supplied to the water flow switch. 11. 24VAC is supplied to the TH terminals on the ignition module. 12. As power is applied to the TH terminals on the ignition module, 120VAC is switched from the F2 terminal to start the combusti[...]

62 9 Glossary Power Supply (AC120VAC/60Hz) 120VAC/60Hz/1PH power connects to black (line) and white (neutral) wires located within an electrical wiring box located on the left side of the unit. A green chassis grounding wire is also provided for connection to earth ground. ON/OFF Rocker Switch The black line voltage wire runs directly to a single p[...]

63 9 Glossary (continued) Once the ignition module sees a 24VAC input from the pressure switch, it runs the blower for approximately 15 seconds in order to purge the combustion chamber of any unburned fuel/air mixture. Trial for Ignition (Ignition Module Function) Once the ignition module has completed its prepurge period, it turns on the hot surfa[...]

64 10 Diagrams Ladder diagram Installation & Service Manual[...]

65 10 Diagrams (continued) Ladder diagram (continued) 0987-2067 0497-747 Installation & Service Manual[...]

66 10 Diagrams Connection diagram Installation & Service Manual[...]

67 10 Diagrams (continued) Connection diagram (continued) Installation & Service Manual[...]

Revision Notes: Revision A (ECO #C07390) initial release. CBX-CWX-I-S Rev A 3/11[...]