Lochinvar SOLUTION 260000 manual

Inst allation & Service Manual Models: 45,000 - 260,000 Btu/hr This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this man ual be revi ewed c ompletely before proc eeding w ith an installation. P erform steps in the order given. Failure t o comply could result in sev[...]

2 Hazar d definitions The following defined terms are used thr oug hout this manual t o br ing attention t o the presence of hazards of various risk le v el s or to important information concerning the life of the pr oduct.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazardous situation whic h, if not avoided,[...]

3 Installation & Service Manual Please r ead bef or e proceeding NOTICE This is a gas appliance and should be installed by a lice nsed elect rician and/or certified gas supplier . Ser vice must be performed by a qualified serv ice installer , serv ice agency or the gas supplier .  W ARNING If the information in these instructions is not foll[...]

4 Installation & Service Manual Please r ead bef or e proceeding  W ARNING T o minimize the possibility of serious personal injur y , fire, or damage to your appliance, never violate the following safety rules: 1. Boilers are heat producing applianc es. T o av oid damage or injur y , do not st ore materials against the appliance or the vent-[...]

5 Ra tings Notes: 1. The ratings are based on standard test pr ocedures prescribed by the U nited States Depart ment of Energ y . 2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allow[...]

T he Solution - Ho w it wor ks... 1. Control panel cov er The control panel c over pr ovides access to the thermostat, ig nition module, and tr ansformer . 2. Burner (not shown) The burner is a cylindrical stainless steel tube used to regulate burner flame. 3. Drain por t Location from which the heat ex changer can be drained. 4. Flue outlet The fl[...]

Models 45,000 - 90,000 Btu/hr Front View Models 45,000 - 90,000 Left Side (inside unit) Models 45,000 - 90,000 Right Side (inside unit) Models 45,000 - 90,000 Rear View T he Solution - Ho w it wor ks... (continued) 11 22 14 23 21 25 9 16 7 18 12 6 24 1 10 19 8 3 17 15 5 4 20 Installation & Service Manual 7[...]

8 Installation & Service Manual T he Solution - Ho w it wor ks... Models 135,000 - 260,000 Btu/hr Left Side (inside unit) Models 135,000 - 260,000 Btu/hr Right Side (inside unit) Models 135,000 - 260,000 Btu/hr Rear View Models 135,000 - 260,000 Btu/hr Front View 10 1 19 3 8 15 17 5 4 20 22 21 9 14 25 23 11 3 3 7 18 12 24 6[...]

Installation & Service Manual 1 Deter mine boiler location NOTICE Clearances from c ombustible construction are noted on the applianc e rating plate. Location of unit 1. Locate the appliance so that if water connections should leak, water damage will not occur . W hen such locations cannot be av oided, it is r ecommended that a suitable drain p[...]

Installation & Service Manual 10 Figure 1-3_ Combustion Air Direct from Outside Combustion and v entilation air requir ements f or conv entionally vented appliances Pr ovisions for combustion and ventilation air must be in acco rdance with, Air for Combustion and V entilation, of the latest edition of the National F uel Gas Code, ANSI Z223.1, i[...]

4. If a single combustion air opening is provided to bring combustion air in dir ectly from the outdoors, the opening must be sized based on a minimum fr ee area of one square inch per 3000 Btu/hr (7 cm 2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6). Figure 1-6_ Combustion Air from Outside[...]

Installation & Service Manual 12 T ABLE - 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPL Y TO EQUIPMENT R OOM Input Btu/hr *Outside Air from 2 Openings Directly from Outdoors *Outside Air from 1 Opening Directly from Outdoors, in 2 *Outside Air from 2 Ducts Deliver ed from Outdoors **Inside Air from 2 Ducts Deliver ed from Interior Space To p Open[...]

Installation & Service Manual 13 2 V enting A Con ventional Negativ e Draft V enting System The negativ e draft in a conv entional vent in stal la tion must be within the range of a negative 0.02 t o 0.05 inches water column to ensure pr oper op erat ion. All draft read ings are made while the appliance is in stable op er a tion (appro ximately[...]

Locate appliance as close as possible t o a chimney or gas vent. A void long horizontal runs of the v ent pipe, 90° el bows, reductions and restrictions. Horizontal por tions of the venting syst em shall be suppor ted to pr event sagging. Horizontal runs must slope up wards not less than 1/4 inch per foot (21 mm/m) from the appliance t o the vent [...]

V er tical V ent T er mina tion Clear ances Figure 2-2_ V ent T ermination from Peaked Roof 10' or Less from Ridge Figure 2-4_ V ent T ermination from Flat Roof 10' or Less from Parapet Wall Figure 2-3_ V ent T ermination from Peaked Roof More than 10' from Ridge Figure 2-5_ V ent T ermination from Flat Roof More Than 10' from P[...]

Installation & Service Manual 16 Masonr y Chimney Installation A masonr y chimney must be pr operly sized for the installation of a gas fired applianc e. V enting of an appliance into a cold or o versized masonry chimney can result in op er a tion al and safety problems. Ext er ior masonry chim neys, with one or more sides exposed to c old out [...]

Installation & Service Manual 17 The vent damper is a useful t ool for saving energ y when installed inside the living space where air can cir cu late freely around the applianc e. The v ent damper w ill not sa ve as much, if an y , energy if it is installed in locations such as: - U nheated garage - Attic - Crawlspac e - M echanical room that [...]

18 3 Gas connections Installation & Service Manual Gas Supply V erify that the appliance is supplied with the ty pe 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 abov e 2000 feet el e va tion. Consult the factory for installations above 20[...]

3 Gas connections (continued) 19 Installation & Service Manual T ABLE - 3E GAS PIPING SIZE CHAR T N ominal Iron Pipe Size Inches Length of Pipe in Str aight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 13.5 Inc hes W ater Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch W ater Column (Based on N A [...]

Installation & Service Manual 20 APPLY W RENCH FROM TOP OR BOTTOM OF GAS CONTROL TO EITHER SHADED AREA APPLY W RENCH TO FLANGE ONLY WH EN F L AN GE IS NOT USED W HEN FLANGE IS USED Figure 3-2_ Wrench 8. For L.P . gas, consult your L.P . gas supplier for expert installation. IMPORT ANT U pon completion of an y piping con nec tions to the gas sys[...]

Installation & Service Manual 21 Checking Gas Supply Pressur e MANOME TER GAS SUPPLY PRESSUR E GAS VALVE Figure 3-4_ Gas Supply Pressure 1. T urn the power “OFF” at the main dis con nect switch. 2. T urn gas valve co ntrol knob to the “OFF” position. 3. Shut off gas supply at the manual valve in the gas piping to the appliance. If fuel [...]

Combination Gas V alv es W IRING TERMI NALS PRESSURE REGU LATOR ADJUSTMENT (UNDER CAP SCRE W ) INLET PRESSURE TAP G A S CONTROL K NOB PILOT OUTLET OUTLET PRESSURE TAP Figure 3-5_ M9 Gas V alve V enting of Combination Gas V alves The combination gas val ve regulator used on all mod els is equipped with an integral vent limiting orifice. The vent lim[...]

R elief V alv e RELIEF VALVE Figure 4-1_ Relief V alve This appliance is supplied with a relief val ve(s) sized in acco rdance with ASME Boiler and Pr essure V es sel Code, Section IV (“Heating Boilers ”). The r e lief valv e(s) is mounted directly into the heat e x chang er inside the header (see FIG. 4-1). T o pre vent water damage, the dis c[...]

Low W ater Cutoff (if equipped) A hot water boiler installed abov e radiation level must be provided with a low water cut off dev ice either as part of the unit or installed at the time the boiler is installed. An electronic low wat er cutoff is a vailable as a kit on all units. Low wat er cutoffs should be in spect ed e v er y six months, includin[...]

9. Inspect the liquid level in the e xpansion tank. The system must be full and under normal operating pressure t o ensure proper water lev el in the expansion tank. Ensure that diaphragm t ype ex pan sion tanks are properly charged and not wat er logged. 10. Star t the boiler acc ording to the Section 6 - “Start-Up Instructions” in this manual[...]

Hot wat er pip ing must be suppor ted by suitable hangers or floor stands, NOT by the boiler . Copper pipe systems will be subject to considerable expansion and c on t rac tion. Rigid pipe hangers could allo w the pipe to slide in the hanger resulting in noise transmitted into the system. Padding is recommended on rigid hangers installed with a cop[...]

Circulator Pump Specifications 1. Maximum operating pressur e for the pump must ex ceed system operating pressure. 2. Maximum wate r temperature should not ex c eed nameplate rating. 3. Cast iron cir culators may be used for closed loop systems. 4. A properly sized e xpansion tank must be in stalled near the boiler and located on the suction side o[...]

Full Flow Application It is acc eptable for the Solution boiler to be installed in a full flow application, as long as the following requirements ar e met: 1. The perfor mance loop is in plac e and functional. 2. The system flow is not lower than the minim um boiler flow . 3. The boiler setpoint is 140°F or hig her . 4. If water temperatur e is be[...]

Primar y / Secondar y Piping SOLUTION BOILER BACKFLOW PREVENTER PRESSURE REDUCING VALV E PRESSURE GAUGE TEMPERATUR E / PRESSURE GAUGE AIR SEPARATOR EXPANSIO N TANK BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POIN T (TYPICAL) MA KE U P W A TER FROM SYSTEM 12" NOT TO EXCEED APA RT BOILER CIRCULATO R SYSTEM CIRCULATOR TO SYST[...]

Figure 4-5_ Single Boiler - Primary / Secondary with Low T emperature Bypass SOLUTION BOILER BACKFLOW PREVENTER PRESSURE REDUCING VAL VE PRESSURE GAUGE TEMPERATUR E / PRESSURE GAUGE AIR SEPARATOR EXPANSIO N TANK BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POIN T (TYPICAL) MA KE U P W A TER FROM SYSTEM 12" NOT TO EXCEED A P[...]

Primar y / Secondar y Piping Figure 4-6_ Multiple Boilers Zoned with Circulators BOILER 1 (LEADER) INDIRECT DHW TA NK ANTI-SCALD MIXIN G VALVE COLD W ATER IN TEMPERATURE / PRESSURE GAUGE AIR SEPARATOR ZONE #1 ZONE #2 ZONE #3 ZONE #4 BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POINT (TYPICAL) MAKE UP W AT ER HOT W ATER OUT BOILE[...]

SOLUTION BOILER BACKFLOW PREVENTER PRESSURE REDUCING VALV E PRESSURE GAUGE TEMPERATUR E / PRESSURE GAUGE AIR SEPARATOR EXPANSIO N TANK BALL VALV E (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE MA KE U P W A TER FROM SYSTEM SYSTEM CIRCULATOR TO SYSTEM SYSTEM SU PPLY SENSOR DRAIN Y-STRAI NER (RECOM MENDED) Figure 4-7_ Single Boiler Full System Flow[...]

Installation & Service Manual 33 SOLUTION BOILER BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE TEMPERATURE / PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE MAK E UP W ATE R FRO M SYSTE M BOILER CIRCULATOR SYSTEM CIRCULATOR TO SYSTE M SYSTEM SUPPLY SENSOR DRAIN Y-STRAINER (RECOM[...]

34 Installation & Service Manual 5 Electrical connections This appliance is wired for 120 V AC serv ic e. The appliance, when installed, must be electrically g round ed in accordanc e with the requirements of the authority having jurisdic tion or in the absence of such re quir e ments, w ith the latest edition of the N ational Electr ical Code [...]

35 Installation & Service Manual 5 Electrical connections (continued) Pump W iring for a Hea ting Boiler The heating boiler circulating pump must be pur chased locally . The max i mum load for the pump sw itc hed by the internal pump rela y must not exc eed 1 HP . The current draw for a field installed 120 V A C pump MUST be add ed to the boile[...]

Maximum Set P oint Deter mination The maximum set point for the contr ol is factor y set. Boilers can be set to 240°F max. These maximum set points are established b y cutting the OJ1 and OJ2 jumpers located on the right side of the temperature controller . The maximum set point is determined as shown below in T able 5C. T ABLE - 5C MAXIMUM SET PO[...]

5 Electrical connections (continued) 37 Installation & Service Manual Out door Air T emperature Sensor The outside air temperature sensor will only be used for boiler systems. The outside air sensor is optional. This sensor allows y ou to tie boiler operation to the outdoor air temperature. A s outside temperatures drop , the c ontrol will incr[...]

Installation & Service Manual 38 Outdoor Air R eset Option For boilers or dered with the Outdoor Air R eset option, ther e is an additional control (FIG. 5-5). There ar e three setting knobs for Shutdo w n, Outdoor Air Max., and Ratio. There is also a switch to turn the outdoor air shut down feature On or Off. An O .A. Sensor is also included. [...]

5 Electrical connections (continued) 39 Installation & Service Manual Block ed V ent and Flame Roll-Out / Flame Inter lock Switc h BLOCKED VENT SWITCH INVERTED TO SHOW RESET UNDERNEATH DRAFT HOOD FRONT OF UNIT Figure 5-7_ Blocked V ent Switch Location HEX FILLER BRA CKET OUTER AIR DEFLECTOR DETAIL A FLAME ROLL-OUT SWITCH / INTERLOCK SWITCH UPPE[...]

40 6 Star t-up Installation & Service Manual Initial Star t-up Follo w the Lighting Instructions on the label applied to the appliance. A. On boilers with the system pump delay option, the operating temperature contr ol w ill energize the pump rela y which energ izes the pump on a call for heat. The operating temperature control will de- energi[...]

6 Star t-up (continued) 41 Installation & Service Manual Operating Instr uctions 1. ST OP! Read the safety information first. 2. Re move the contr ol panel door . 3. Set the thermostat to the lo west setting (OFF). 4. T urn off all electrical power to the applianc e. 5. This appliance is equipped with an ig nition device which automatically lig[...]

Installation & Service Manual 42 Ignition and Control Timings M9 Intermittent Spark Ignition Pilot Mod els Pilot T rial for Ignition Period - 90 Sec onds Pilot Failure R esponse Time - 0.8 Sec onds at less than 1.0 µA flame current Pump Dela y Timing (Optional on Boilers) - 30 Seconds aft er burner shut down F reeze Pr otection 1. For boilers [...]

43 Installation & Service Manual Maintenance and annual star tup Ser vice technician (see the following p ages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water , gas, flue) • Examine venting system • Check system water pressure/system piping/expansion t [...]

Follo w the ser vice and maintenance pr ocedures giv en throughout this manual and in component literatur e shipped with the appliance. F ailure to perform the serv ice and maint enance could result in damage t o the appliance or system. Failure t o follow the directions in this manual and co mponent literature could result in severe personal injur[...]

7 Maintenance (continued) 45 Installation & Service Manual Check Expansion T ank 1. Expansion tanks pro vide space for water to mov e in and out as the heating system water e xpands due to temperature incr ease or contracts as the water cools. T anks may be open, closed, diaphr agm or bladder ty pe. See Section 4 - W ater Connections for sugges[...]

46 Installation & Service Manual Check All Wiring 1. Inspect all wiring, making sure wires ar e in good condition and secur ely attached. Check Control Settings 1. A djust settings if necessary . See Section 5 - Electr ical Connections for adjustment procedur es. 2. Check settings of external limit controls (if any) and adjust if necessary . Ch[...]

7 Maintenance (continued) 47 Installation & Service Manual  A void breathing dust and c ontact w ith skin and eyes. • Use NIOSH c ert ified dust r espir at or (N95). This type of respirator is based on the OSHA requir ements for cristobalite at the time this document was written. Other ty pes of respirators may be needed depending on the j[...]

Installation & Service Manual 48 s. Ensure that all burner ports are cleaned to remo ve any soot. See Inspection and Cleaning Procedure , page 47. t. Carefully re-install the heat ex changer , “V” baffles, jacket panels, and wires. u. Reassemble all gas and water piping. T est for gas leaks. v . Cy cle the appliance and check for prop er op[...]

49 Installation & Service Manual 8 T r oubleshooting Step 1: Step 2: Step 3: Is the spark ignitor sparking? No Yes Check continuity on the spark cable. Check for 24 VAC on the 24v terminal (gray wire) on the i g nition module. No Is there 24 VAC (purple wire) on the 4-pin connector plug on the tem p erature controller? Yes Replace ignition modu[...]

50 Installation & Service Manual Schema tic Diag ram - M9 Unit 45,000 - 260,000 Btu/hr Models W iring Diag r am - M9 Unit 45,000 - 260,000 Btu/hr Models 9 Diag r ams[...]

51 Notes[...]

Revision A (ECO #C03746) initial release. Revision B (ECO #C06868) update the pressure drop chart (T able 4C) to reflect the correct models and change out the reference to the two blues wires to SYS/T ANK contacts under System Sensor on page 36 (ECR03727). SBR-I-S Rev B 1 1/10[...]