Lochinvar CP-5M-4/08 manual

Installation and service must be performed by a qual i fied service installer , service agency or the gas supplier . Factory warranty (shipped with appliance) does not apply to appliances improperly installed or im prop er ly operated. Experience has shown that improper installation or system design, rather than faulty equipment, is the cause of mo[...]

W arranty ..................................................................................1 Safety W arnings ......................................................................1 Codes ..................................................................................3 Location ....................................................................[...]

The equipment shall be installed in accordance with installation regulations in force in the local area where the installation is to be made. These reg u la tions shall be carefully followed in all cases. Au thor i ties having jurisdiction shall be consulted be fore installations are made. In the absence of such requirements, the in stal - la tion [...]

Clearances from Combustible Construction: Right Side - 6" Rear - 6" Left Side - 18" (24" suggested for service) Front - 18" (24" suggested for service) T op - (measured from the top of the unit) 45,000 - 180,000 Btu/hr Models - 14" 199,999 - 500,000 Btu/hr Models - 29" All units have been approved for alcove [...]

FIG . 5 Combustion Air Dir ect from Outside 1. If air is taken directly from outside the building with no duct, provide two permanent openings: a. Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5cm 2 per kW). This opening must be located with in 12" (30cm) of the floor . b. V entilation air opening[...]

6 Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Open ings. T able A lists the re quire ments for the ap pli ance only , additional gas fired appliances lo[...]

EXHAUST F ANS: Any fan or equipment which ex - hausts air from the room where the appliance is installed may deplete the combustion air supply and/or cause a down draft in the venting system, spilling flue products into the room. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition tha[...]

On a conventionally vented, negative draft ap pli ance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed T ype “B” double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter . Use the National Fuel Gas Code venting tables for dou[...]

FIG . 10 V ent T ermination from Peaked Roof 10’ or Less from Ridge FIG . 1 1 V ent T ermination from Peaked Roof More Than 10’ from Ridge The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the high est point of the roof within a 10 foot (3.05m) radius of the termination. The vertical termination[...]

T o avoid a blocked vent condition, keep the vent cap clear of snow , ice, leaves, debris, etc. Flue gases will form a white plume in winter . Plume could obstruct window view . Flue gas condensate can freeze on exterior sur fac es or on the vent cap. Frozen condensate on the vent cap can result in a blocked vent condition. Flue gas condensate can [...]

This heating boiler is design certified for use with the automatic vent damper (FIG . 15) part number printed on the boiler ’ s rating plate. A vent damper must be installed on all residential heating boilers with inputs of less than 300,000 Btu/hr to comply with minimum efficiency requirements. A vent damper is factory supplied with residential [...]

V erify that the appliance is supplied with the type gas spec i fied on the rating plate. This appliance 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 above 2000 feet elevation. Field conversions for operation at high altitud[...]

7. Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes. 13 Btu/hr DIST ANCE FROM METER (In Feet) INPUT 0-50 51 - 100 101 - 200 201 - 300 301 - 500 45,000 1/2" 1/2" 3/4" 1" 1 1/4" 75,000 1/2" 3/4" 1" 1 1/4" 1 1/4" 90,000 1[...]

FIG . 16 Gas Line Connection All gas connections must be made with pipe joint com pound resistant to the action of liquefied pe tro leum and natural gas. All piping must comply with local codes. T ubing installations must com ply with ap proved standards and practices. Reference Figure 16 for a typical installation. Install Piping to Control 1. The[...]

FIG . 17 W rench 8. For L.P . gas, consult your L.P . gas supplier for expert installation. FIG . 18 Manifold Pressur e Adjustment 1. T urn the power “OFF” at the main dis con nect switch. 2. T urn gas valve control knob to “PILOT” po si tion on standing pilot models. Ensure that the stand ing pilot remains on. If the pilot goes out, follow[...]

14. Repeat the adjustment procedure for the sec ond gas valve on the 500,000 Btu/hr model. 15. T urn the gas valve control knob(s) to “ON” position. 16. Turn the power “ON” at the main dis con nect switch. The appliance is now ready to op er ate. If manifold pressure can not be properly adjusted, use the following procedure to check gas sup[...]

20. Set the thermostat to call for heat. The appliance is now ready to operate. Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly . Flame pattern should be stable, see “Main te nance-Normal Flame Pattern.” T urn system off and allow burners to cool, then cycle burners again to en su[...]

FIG . 23A Relief V alve - W ater Heater FIG . 23B Relief V alve - Boiler This appliance is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure V es sel Code, Section IV (“Heating Boilers”). The re lief valve(s) is mounted directly into the heat ex chang er inside the header . T o pre vent water damage, the dis - ch[...]

A water flow switch meets most code re quire ments for a low-water cut off device on boil ers requiring forced cir cu la tion for operation. A hot water boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed. An electronic low water cutoff is[...]

FIG . 26 Intermittent Pilot System F9/M9 Control Panel FIG . 27 Control Panel Assembly 500,000 Btu/hr Operating T emperature Control Locating T emperature Control Remove the control panel door on the front of the unit in order to locate and access the temperature control. T emperature Control Settings There are three setting knobs on the temperatur[...]

Set Point The Set Point knob specifies the target outlet 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 to drop before it bri[...]

5. Make sure good mechanical connections are made to the sensor , any interconnecting wiring and the controller . 6. Do not mount sensor with leadwire end pointing up in an area where condensation can occur . 7. Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists. Shielded cable [...]

Manual Reset High W ater T emperature Limit Control ( S tandard Fixed Settings on W ater Heaters and Optional Adjustable Settings on Boilers and W ater Heaters ) W ater heaters are supplied with a fixed setting, manual reset high water temperature limit control. This manual reset temperature limit control has a fixed limit setting of 230°F (1 10°[...]

On boilers, the pump will operate whenever the “W” terminal is energized. B. Location - The appliance should be located within a room having a temperature safely above freezing [32°F(0°C)]. C. Shutdown and Draining - If, for any rea son, the appliance is shut off, the following pre cau tion ary measures must be taken: 1. Shut off gas supply ,[...]

25 3. Set the thermostat to the lowest setting (OFF). 4. T urn off all electrical power to the appliance. 5. Turn the gas control knob on the gas valve clockwise to the “OFF” position. FIG . 33 F1 Gas V alve 90,000 - 270,000 Btu/hr Models 6. W ait five (5) minutes to clear out any gas, then smell for gas, including near the floor . If you smell[...]

26 1. Set the thermostat to the OFF position. 2. T urn off all electric power to the appliance if service is to be performed. 3. T urn the gas control knob on the gas valve clockwise to the “OFF” position. Do not force. FIG . 36 Pilot with Thermocouple and Spark Ignition 1. W ith the main burners on and firing, un screw the thermocouple connect[...]

27 1. STOP! Read the safety information first. 2. Remove the control panel door . 3. Set the thermostat to the lowest setting (OFF). 4. T urn off all electrical power to the appliance. 5. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. 6a. 45,000 - 135,000 and 399,999 -[...]

28 1 1. If ignition system fails to operate properly , re pair work must be performed by a qualified serviceman or installer . The ignition module is not repairable. Any mod i fi ca tion or repairs will invalidate the warranty and may create hazardous conditions that result in prop er ty damage, personal injury , fire, explosion and/or toxic gases.[...]

5. Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system. In hard water areas, water treatment should be used to reduce the introduction of minerals to the sys tem. Minerals in the water can collect in the heat exchanger tubes and cause noise on operation. Excessive b[...]

REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS: • A void breathing dust and contact with skin and eyes. • Use NIOSH certified dust respirator (N95) (http://www .cdc.gov/niosh/homepage.html). • Lightly mist with water (only those areas being handled) the combustion chamber lining or base insulation to prevent airborne fibers. • Remove[...]

o. Check “V” baffles on top of the heat ex chang er . Remove and clean if necessary . p. Remove soot from the heat exchanger with a stiff bristle brush. Soot may also be re moved from the heat exchanger by washing thoroughly with detergent and water . Remove the heat exchanger before using water for cleaning. Rinse thoroughly and dry before re-[...]

FIG . 39 Gas T rain 45,000 - 399,999 Btu/hr Models FIG . 40 Gas T rain 500,000 Btu/hr Model The drawings in this section show typical heating boil er piping installations. Before beginning the in stal - la tion, consult local codes for specific plumb ing re quire ments . The installation should provide unions and valves at the inlet and outlet of t[...]

1. Maximum operating pressure for the pump must exceed system operating pressure. 2. Maximum water temperature should not ex ceed nameplate rating. 3. Cast iron circulators may be used for closed loop systems. 4. A properly sized expansion tank must be in stalled near the boiler and located on the suction side of the pump. Boilers are equipped with[...]

FIG . 43 Primary/Secondary Piping of a Single Boiler Heating boilers with inputs of 315,000 - 500,000 Btu/hr or larg er installed on multiple zone systems are rec om - mend ed to be installed with a primary/sec ond ary piping sys tem as shown in Figure 43. A pri ma ry/secondary pip ing system may also be in stalled on smaller input boil ers to ensu[...]

This piping is like a primary/secondary boiler installation with a bypass in the secondary boil er piping. Inlet water temperatures below 140°F (60°C) can excessively cool the prod ucts of combustion re sult ing in condensation on the heat exchanger and in the flue. Condensation can cause operational prob lems, bad combustion, sooting, flue gas s[...]

General Plumbing Rules 1. Check all local codes. 2. For serviceability of the boiler , always install unions. 3. Always pipe pressure relief valves to an open drain. 4. Locate system air vents at the highest point of the system. 5. Expansion tank must be installed near the boil er and on the suction side of the pump. 6. Support all water piping. Fi[...]

10 . Start the boiler according to the “S tart-Up Instructions” in this manual. Operate the system, including the pump, boiler and radiation units, for one hour . 1 1. Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. Recheck pres sure charge on diaphragm type tanks. 12. [...]

The operating temperature control is located in the control panel, behind the control panel front ac cess door . The sensing element for the operator is placed in a bulb well installed in the heat exchanger . Carefully observe the dis charge water temperature on the initial boiler on cycles. The exact temperature set point is based on your system?[...]

This section contains specific instructions for those units used to supply domestic hot water . All warn ings, cau tions, notes and instructions in the gen er al installation and service sections apply to these instructions. W ater heat ers are designed for installation with a storage tank. The use of a properly sized pump and the control of water [...]

The required temperature rise and the standard pump sizing are based on the heating of potable water with chemistry within the specified limits. Caution should be used when heating water softened to less than 5 grains per gallon. Many commercial water softeners reduce hardness to 0 grains which may result in long term problems in the system. Soften[...]

3. The pump must run continuously when the burners are firing. 4. Lubricate the pump to the manufacturers rec om men - da tions. P um p d am age due to inadequate lu bri ca - tion is non-warrantable. 5. A standard water heater/hot water supply boiler is furnished with a 1/6 HP , 120 V AC, 3.6 AMP circulating pump to be mounted on the units in let w[...]

42 your gas supplier for local re quire ments governing the tem per a ture setting. Re mem ber , no water heating sys tem will provide exact tem per a ture at all times. Allow a few days of operation at this setting to de ter mine the correct temperature set ting consistent with your needs. Incorrect piping of the cold water supply to the sys tem m[...]

A relief valve which discharges periodically may be due to thermal expansion in a closed system. A hot water supply boiler installed in a closed sys tem, such as one with a backflow preventer or check valve in stalled in the cold water supply , shall be provided with means to control expansion. Con tact the water sup pli er or local plumbing inspec[...]

44 Is the spark igniter sparking? NO Check continuity of the spark cable. Check for 24V AC on the TH terminal (gray wire) on the ignition module. Is the pilot staying ON? STEP 1: STEP 2: Check the pilot tube for gas. Check for draft. NO NO YES Replace ignition module. Is there 24 V AC (purple wire) on the 4-pin connector plug on the temperature con[...]

45 TROUBLESHOOTING GUIDE 90,000 - 270,000 Btu/hr Models - W ater Heaters F1 Is the pilot lit? NO Check for gas. Check the pilot assembly and thermocouple. Check the gas valve for proper operation. Clean and replace. Is the gas valve getting 24V AC? STEP 1: STEP 2: NO Is there 24 V AC (purple wire) on the 4- pin connector plug on the temperature con[...]

46 Schematic Diagram - F1 Unit 90,000 - 270,000 Btu/hr Models Wiring Diagram - F1 Unit 90,000 - 270,000 Btu/hr Models[...]

47 Schematic Diagram - F9 Unit 90,000 - 399,999 Btu/hr Models Wiring Diagram - F9 Unit 90,000 - 399,999 Btu/hr Models[...]

48 Schematic Diagram - M9 Unit 45,000 - 399,999 Btu/hr Models Wiring Diagram - M9 Unit 45,000 - 399,999 Btu/hr Models[...]

49 Schematic Diagram - F9/M9 Unit 500,000 Btu/hr Models Wiring Diagram - F9/M9 Unit 500,000 Btu/hr Models[...]

50 NOTES[...]

51 NOTES[...]

52 Revision 4 (RSB-i&s-04) reflects the removal of the inlet pipe and installing the inlet sensor inside the header . Revision 5 (RSB-i&s-05) reflects changes made to the O.A. section. RSB-i&s-05 CP-5M-4/08[...]