Lochinvar 495 manual

INST ALLA TION AND SER VICE MANU AL Sav e this manual f or futur e reference.  WARNING : If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or loss of life. – Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other a[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 2 Table of Contents General Product Information . . . . . . . . . . . . . . . . . . . . . . . . .3 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Codes . . . . . . . . . . . [...]

GENERAL PRODUCT INFORMATION Special Instr uctions This manual supplies information for the installation, operation and servicing of the appliance. Read and understand this manual completely before installing unit. Installation and service must be performed by a qualified service installer , service agency , or the gas supplier . Unpacking Upon rece[...]

3. Boilers and water heaters are heat producing appliances. T o avoid damage or injury , do not store materials against the appliance or the vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components. Follow all clearances from combustibles contained in this manual. 4[...]

Installa tion and Ser vice Manual 5 Figure 1 – Fr ont and Rear View Rear V iew Front V iew PRODUCT IDENTIFICATION[...]

INSTALLATION This unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9 and ANSI Z21.10.3/CSA 4.3. L OCA TING UNIT 1. Maintain all clearances from combustible construction when locating unit. See Clearances fr om Combustible [...]

base for combustible floor installation. Install unit over a base of hollow clay tiles or concrete blocks from 8" to 12" thick and extending at least 24" beyond the unit sides. Place tiles or blocks so that the holes line up horizontally to provide a clear passage through the tiles or blocks. Place a 1/2" fireproof millboard ove[...]

INSTALLATION Continued F reeze Pr otection f or a Heating Boiler System (if r equired) 1. Use only properly diluted inhibited glycol antifreeze designed for hydronic systems. Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible.  WARNING : Do not use undiluted or automotive type antifreez[...]

Combustion Air Options  CA UTION : Under no circumstances should the mechanical room ever be under a negative pressure. Particular care should be t aken where exhaust fans, attic fans, clothes dryers, compressors, air handling unit s, etc., t ake away air from the unit. 1. Outside Combustion Air , No Ducts Y ou can direct outside combustion air [...]

INSTALLATION Continued Figure 9 - Combustion Air fr om Interior Space All dimensions are based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be w[...]

Y ou must locate the air inlet termination elbow at least 12" (30cm) above the roof or above normal snow levels. Keep the vent cap clear of snow , ice, leaves, and debris to avoid blocking the flue. Figure 10 - V ent T ermination from Peaked Roof - 10' or Less From Ridge IMPORT ANT : V ent terminations are not shown in Figures 10, 1 1, 12[...]

INSTALLATION Continued Input Flue Btu/hr Size 495,000 6" 645,000 8" 745,000 8" 985,000 10" 1,255,000 12" 1,435,000 12" 1,795,000 14" 2,065,000 14" V ent System Options This unit has two venting options. 1. Conventional Negative Draft V enting This option uses a vertical rooftop flue termination. Combustion ai[...]

1. Con v entional Ne gativ e Dr aft V enting IMPORT ANT : Before installing a venting system, follow all venting clearances and requirement s found in the V enting, General Information section, p age 10. Figure 14 - Conventional Negative Draft V ertical V enting with Combustion Air Louvers This option uses T ype-B double-wall flue outlet piping. Th[...]

INSTALLATION Continued 4. T urn on clothes dryers and any other appliances not connected to the common venting system. T urn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. 5. Close fire place dampers. 6. Place in operation the unit being inspected. Follow t[...]

Outdoor V ent/Air Inlet Loca tion Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain a minimum clearance of 3" (76mm) to combustible surfaces and a minimum of 3" (76mm) clearance to the air inlet. T o avoid a blocked air inlet or blocked flue condition, keep the air inlet, fl[...]

INSTALLATION Continued CONNECTING TO GAS SUPPLY Only supply the gas type specified on the unit's rating plate. This unit is orificed for operation up to 2000 feet altitude. If installing above 2000 feet elevation, consult the appliance manufacturer . INLET PRESSURE : Measure inlet pressure at the inlet pressure tap located upstream of the comb[...]

The combination gas valves have an integral vent limiting device and does not require venting to atmosphere outside the building. The unit will not operate properly if the reference hose is removed or a vent to atmosphere is installed. Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required[...]

INSTALLATION Continued W ater heater models do not have downstream test valves, but the rest of the gas train is represented by Figure 19. Combination Gas V alves These units fire in up to 2 stages of burner input. Each stage of burner operation has a combination gas valve or series of gas valves to cycle the gas supply on and off and regulate gas [...]

9. If gas pressure is out of range, contact your gas utility , gas supplier , qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control. 10. If gas supply pressure is within normal range, remove the gas manometer and replace the pressure tap fittings in the gas control as indicated in the f[...]

20 INSTALLATION Continued Figure 21 - Measuring Manifold Gas Pr essure 2. T urn the power switch located in the lower left corner behind the control panel access door to the “O” or “OFF” position. 3. Remove the top front jacket access panels to access the gas valve(s). 4. Locate the reference hose on the first gas valve which goes from the [...]

Figure 22 - W ater Connections R elief V alv e This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure V essel Code, Section IV ("Heating Boilers"). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. Place no other valve between the relief valve and the uni[...]

INSTALLATION Continued Figure 23A - Models 495,000 - 745,000 Btu/hr Contr ol Panel Component Location Drawing Figure 23B - Models 985,000 - 2,065,000 Btu/hr Control Panel Component Location Drawing Exter nal EMS Connection to T er minal Strip for Stage Firing Control of Bur ners This unit is equipped with a factory installed terminal strip for conn[...]

Figure 24A - S tand Alone Operation - Models 985,000 - 2,065,000 Btu/hr Only Figure 24B - Remote On/Off Boiler or W ater Heater - Models 985,000 - 2,065,000 Btu/hr Only Figure 24C - T wo-S tage (High/Low Fire) Boiler or W ater Heater - Models 985,000 - 2,065,000 Btu/hr Only Figure 24D - Field-Installed Safety Devices - Models 985,000 - 2,065,000 Bt[...]

INSTALLATION Continued Circulator Pump R equir ements 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. T wo heat exchanger head-loss charts (Figur[...]

The installer must ensure that the boiler has adequate flow without excessive temperature rise. Low system flow can result in overheating of the boiler water which can cause short burner ON cycles, system noise and in extreme cases, a knocking flash to steam. These conditions indicate the need to increase boiler flow by installation of a larger cir[...]

INSTALLATION Continued Sludge formed as the result of excessive oxygen in the system can restrict water flow resulting in a premature boiler failure. Any boiler damage due to excessive oxygenation is non- warrantable. Figure 28 - Boiler with Low T emperature Bypass Piping Installation with a Chilled W ater System Pipe refrigeration systems in paral[...]

Boiler Flow Ra te  CA UTION : The maximum flow rate for models 495,000 - 745,000 Btu/hr is 60 GPM and 90 GPM on 985,000 - 2,065,000 models. Do not exceed the maximum flow rate of the heating boiler . If higher flow rates are required through the boiler , an optional Cupro-Nickel heat exchanger is available. When using a Cupro-Nickel heat exchang[...]

INSTALLATION Continued 8. Recheck all air vents as described in step 4. 9 . Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged and not water logged. 10. Start the boiler accordi[...]

Figure 31 - Contr ol Panel Cover Figure 32 - ON/OFF Switch 8. T urn the manual gas cock clockwise to the “OFF” position. 9. W ait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow “B” in the safety information. If you do not smell gas, go on to the next step. 10. Turn the manual gas cock counterclockwise to the “ON” [...]

OPERATION Continued Figure 34 - Locating T emperature Contr ol T emper a tur e Control Settings There are three setting knobs on the temperature control unless your unit is specified as a boiler only with an outdoor air reset option. If your unit is a boiler only with an outdoor air reset option, there are additional controls for this option. They [...]

High-Fire Of fset The temperature control operates a two-stage firing system. The two stages are High-Fire and Low-Fire. High-Fire operates all burners while Low-Fire operates approximately one-half of the burners. The High-Fire knob specifies the number of degrees below set point that the High-Fire stage shuts down. At that point, the unit will co[...]

OPERATION Continued T emper a tur e Control Sensor s 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 W ater T emperature Sensor 2. Multi-Purpose T emp[...]

R emote Mounting of Sensor Y ou must mount the outside air temperature sensor outside the building. T o mount remote sensors, follow the guidelines below . T ake care to correctly wire sensors to the unit. Erratic temperature readings can be caused by poor wiring practices. T wist the wires between the unit and the remote sensor . T urn wires at le[...]

OPERATION Continued Hot Surface Ignition Control Module Ignition Module Lockout Functions The ignition module may lockout in either a hard-lockout condition, requiring pushing of the reset button to recycle the control, or a soft-lockout condition which may recycle after an approximate five-minute waiting period. This soft-lockout condition is inte[...]

OPERA TION AND DIA GNOSTIC 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 left end of the unit. Figure 40 - Operation/Diagnostic Lights Installa tion and Ser vice Manual 35 Code Sequence Condition Constant ON System O[...]

DOMESTIC WATER HEATERS This section applies only to those units used to supply potable hot water for domestic use. The hot water supply boiler 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 installati[...]

Installa tion and Ser vice Manual Wa ter Chemistr y The required temperature rise and the standard pump sizing are based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm. Consult the appliance manufacturer when heating potable water exceeding these specifications. Heatin[...]

DOMESTIC WATER HEATERS Continued 6 90° elbows 2 ball valves 2 unions 1 cold water tee Not more than 45 feet of straight pipe. IMPORT ANT : For every elbow and tee in excess of those shown above, deduct 5 feet from maximum allowable straight pipe in heater to t ank circulating loop. Minimum Pump P erfor mance This is based on heating potable water [...]

Installa tion and Ser vice Manual 39 Remember , no water heating system provides exact temperatures at all times. Let the system operate a few days at your desired settings to determine correct settings for your needs. 1. These units are equipped with an operating temperature control. 2. The control set points are preset to a low test setting when [...]

CLEANING AND MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations. V erify proper operation after servicing.  CA UTION : Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Appliance Ar ea Keep appliance area clear and free from combustibl[...]

Installa tion and Ser vice Manual 41 Heat Ex changer 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 40. 3. Di[...]

CLEANING AND MAINTENANCE CONTINUED Figure 43 - Air Pr essure Switch Figure 44 - Adjusting Air Shutter Set Up Procedure T o the left of the fan is an air pressure switch with a large and a small tube delivering pressure from points inside the unit (see Figure 43). The pressure in the lar ge tube is the chamber pressure. The pressure in the small tub[...]

Installa tion and Ser vice Manual 43 Adjustment Procedure: 1,435,000, 1,795,000 and 2,065,000 Btu/hr Models 1. Remove the upper front jacket panels from the unit to access the upper chamber . 2. Slightly loosen the screws that attach the fan transition box to the metal base (see Figure 46). 3. Locate the air shutter at the rear of the fan duct (see[...]

CLEANING AND MAINTENANCE CONTINUED A faulty hot surface igniter or ignition module must be replaced with an identical part. A specification igniter and ignition module for this specific unit is available from your local distributor . Do not use general purpose field replacement ignition modules or igniters. Ignition System Check out 1. T urn of f g[...]

29. Burners are now firing for approximately 50% of the heater ’ s input. 30. 24V AC is supplied from the second stage of the electronic temperature control across the 2C and 2NO terminals on the terminal strip on to a control to a relay . 31. The control relay switches the fan on the 985,000 - 2,065,000 Btu/hr models to high speed and energizes [...]

Electronic T emperature Contr oller (Operator) A 2-stage electronic temperature controller is provided on the unit and it serves to maintain a user selectable temperature set point. Ultimately , the temperature controller delivers 24V AC to the ignition module and pressure switch when it senses heat mode is desired. It also activates the pump relay[...]

47 SCHEMATIC DIAGRAM MODELS 495,000 - 745,000 BTU/HR J3 5 4 6 3 2 1 O.C . J1 J2 3 2 1 J4 P OP E R A T OR INLE T PROBE SYS/ TA N K SET POINT CN1 CN 2 CN 3 CN 4 CN 5 CN 6 CN 7 CN 8 CN9 OF F DIF FERE NTI AL HIGH- FI RE OFFSET SHUTDO WN O .A. MAX. RATIO O.A . DISABLE SHU TD OWN ON SENSO R ENABLE CN 1 IN L ET SENSOR BK BK SYSTEM / T ANK SENSO R PR PR 3 [...]

48 WIRING DIAGRAMS - MAIN UNIT CONNECTIONS MODELS 495,000 - 745,000 BTU/HR PO WER SWI TCH 120 VA C TRI AL 24 VA C HEAT IN G 24 VAC F LAM E FAI LURE BK W GY GY O Y BL PR H I- L IMIT C N O N C C 2 1 AUX H I-LIMIT OPTI ON A L C N O N C C 21 14 5 9 10 12 15 36 8 7 13 BK / W 11 BK O R R BK IN L E T SENSO R H HI - LIMITS - P WR SW J U MPERED IF NO T PRO [...]

49 WIRING DIAGRAMS - MAIN UNIT CONNECTIONS MODELS 495,000 - 745,000 BTU/HR (CONTINUED) LBL20007 R EV A 1 2 3 4 1 2 1 2 W BK 120VAC POW ER TO LOUV E R OR DAMPER BK BK OP T I ON B OX "A " LOUV ER/ DAMPE R 120 VAC R ELAY 4 6 2 BK BR C W 10 11 12 14 15 13 1 2 4 5 9 10 11 12 14 15 36 8 71 3 1 2 4 5 9 10 11 12 36 8 7 24 VAC G BL Y BK SPLI CE 8 [...]

50 CN9 TES T SWIT CH T RESE T T PROB E ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 2C 2NO STAGE # 2 HIG H FIRE B3 B1 B2 FIEL D SUPPLIED SAFETY DE VICES INTERMIT TENT ALARMS A1 A2 1C 1N O 24 VAC 120 VAC - + HI- LIMIT Line BL BR ON /OF F POW ER SWI TCH BK AUX . HI- LIMIT OP ER A TOR S2 / FS F2 F1 LIN E S1 RESE TS T/ W O BK NEU IGNIT ER TRIA L GY 5 4 1 2 3 11 - + - + BL/[...]

51 WIRING DIAGRAM - CONTROL BOX CONNECTIONS MODELS 985,000 - 2,065,000 BTU/HR FLAME FAI L ENAB LE RELAY 24 V OPTI ON AL ALARM ENABLE RELAY 24 V BK W S2/F S F2 F1 S1 NEU 4 2 3 - + - + IGN ITION MOD UL E TH 10 PI 9 8 24COM RESE T 7 24VAC 6 MV 5 PS 4 M/S FF 1 LIN E STG #1 Y PR Y P BL PR/ BK Y P 1 2 3 PR/ BK OP TION A L PR Y BL 5 4 3 2 1 5 4 3 2 1 RUNT[...]

Revision 4 (CB-CW(E)-i&s-04) reflects changes made to the O.A. section. Revision 5 (CB-CW(E)-i&s-05) reflects changes made to text on Page 21 and the LBLs on pages 47-51. Revision 6 (ECO #C02870) reflects the addition of a mixing valve to FIG . 41 (page 37) and edits made to the scald warnings. CB-CW(E)-i&s-06 CP-5M-1/09[...]