Lochinvar 90 manual

Inst allation & Service Manual Models: 90,000 - 500,000 Btu/hr This manual supplies information for the installation, operation, and serv icing of the appliance. It is strongly reco mmended that this manual be reviewed complet ely before proceeding with an installation. P erform steps in the order given. Failure t o comply could r esult in se v[...]

2 Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention to the pr esence of hazards of var ious risk level s or to important information concerning the life of the product.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazardous situation whic h, if not avoided, w i[...]

3 Installation & Service Manual Please r ead bef or e pr oceeding NOTICE This is a gas appliance and should be installed by a lice nsed elect rician and/or certified gas supplier . Serv ice must be performed by a qualified serv ice installer , serv ice agency or the gas supplier .  W ARNING If the information in these instr uctions is not fo[...]

4 Installation & Service Manual Please r ead bef or e pr oceeding  W ARNING T o minimize the possibility of serious personal injur y , fir e, or damage to y our appliance, never violate the following safety rules: 1. Boilers and water heaters ar e heat producing appliances. T o av oid damage or injur y , do not st ore materials against the a[...]

5 Ra tings Maximum allo wed working pressur e is located on the rating plate. NOTICE Installation & Service Manual 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 W ater , MBH (Note 2) CBN315 158 315 258 224 CBN360 180 360 295 257 C[...]

6 Ra tings Installation & Service Manual Notes: 1. Copper -fins require special gas v enting. U se only the vent materials and methods specified in the Installation and Serv ice Man ual. 2. The Copper -fin 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 [...]

7 Installation & Service Manual T he Copper-fin - How it w or ks... 1. Control panel cov er The control panel c over pr ovides access to the thermostat, ignition module, and transformer . 2. Drain por t (not shown) Location from which the heat ex changer can be drained. 3. Flue outlet The flue outlet allows the c onnection of the vent pipe to t[...]

Installation & Service Manual 8 Models CWN270 Front View Model CWN399 (inside unit) Model CWN399 Front View Model CWN270 (inside unit) T he Copper-fin - How it w or ks... 3 1 10 9 11 5 21 15 16 22 6 12 8 4 14 23 7 13 1 3 10 16 15 21 5 11 9 6 7 13 23 4 22 14 12 8[...]

9 Installation & Service Manual T he Copper-fin - How it w or ks... (continued) Model CBN500 (inside unit) Model CBN500 Front View Models CBN399 (inside unit) Model CBN399 Front View 3 1 20 10 16 15 11 9 5 6 12 8 14 22 23 4 7 3 1 20 10 16 15 5 11 9 6 12 4 14 8 7 23 22[...]

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

11 Installation & Service Manual 1 Deter mine boiler location Figure 1-3_ Combustion Air Direct from Outside Combustion and v entilation air requir ements for con v entionall y v ented a ppliances Pr ovisions for combustion and ventilation air must be in acco rdance with the latest edition of the N ational Fuel Gas Code, ANSI Z223.1, in Canada,[...]

12 1 Deter mine boiler location Installation & Service Manual 4. If a sing le combustion air opening is pr ovided 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 t[...]

1 Deter mine boiler location (continued) 13 Installation & Service Manual 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[...]

14 Installation & Service Manual 2 V enting The distance of the vent terminal from adjac ent build ings, w indows that open and building open ings MUST comply with the latest edition of the National F uel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 In stal la tion Code for Gas Burn ing Applianc es and Equipment. V [...]

2 V enting (continued) 15 Installation & Service Manual Locate appliance as close as possible t o a chimney or gas vent. A void long horizontal runs of the vent pipe, 90° el bows, reductions and restrictions. Horizontal por tions of the venting syst em shall be suppor ted to prev ent sagging . Horizontal runs must slope up wards not less than [...]

16 2 V enting Installation & Service Manual 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 erm[...]

2 V enting (continued) 17 Installation & Service Manual Masonr y Chimney Installa tion A masonr y chimney must be properly siz ed for the installation of a gas fired appliance. 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 side[...]

18 2 V enting Installation & Service Manual Automa tic V ent Damper This heating boiler is design certified for use w ith the automatic vent damper (FIG. 2-7) part number printed on the boiler’ s rating plate. A vent damper is optional on heating boilers abo ve 360,000 Btu/hr . A utomatic vent dampers ar e not required or fur nished on potabl[...]

19 Installation & Service Manual 3 Gas connections Gas Supply V er ify that the appliance is supplied with the ty pe gas spec i fied on the rating plate. This applianc e is or ificed for operation up to 2000 feet altitude. The ap pli ance w ill be derated 4% per 1000 feet abov e 2000 feet el e va tion. Consult the factory for installations abov[...]

20 3 Gas connections Installation & Service Manual T ABLE - 3E MUL TIPLE APPLIANCE INST ALLA TIONS 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 Inches W ater Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch W ate[...]

3 Gas connections (continued) 21 Installation & Service Manual APPL Y WRENCH TO FLANGE ONL Y WHEN FLANGE IS USED APPL Y WRENCH FROM BOTTOM OF GAS CONTROL TO EITHER SHADED AREA WHEN FLANGE IS NOT USED Figure 3-2_ Wrench 8. For L.P . gas, consult y our L.P . gas supplier for expert installation. IMPORT ANT U pon completion of any piping con nec t[...]

22 Installation & Service Manual Checking Gas Supply Pressur e GAS VALVE MANO MET ER GAS SUPPLY PR ESSURE UNION Figure 3-4_ Gas Supply Pressure 1. T urn the power “OFF” at the main dis con nect switch. 2. T urn gas valve c ontrol knob(s) to the “OFF” position. 3. The 500,000 Btu/hr model will have tw o gas valves. T urn the gas valv e c[...]

3 Gas connections (continued) 23 Installation & Service Manual Combination Gas V alves W IRING T ERMINALS PRESSURE REGU LATOR A DJUSTMEN T (UNDER CAP SCRE W ) INLET PRESSURE TAP GAS CONTROL KNOB PILOT OUTLET OUTLET PRESSURE TAP PRESSURE REGULATOR A DJUSTMENT (UNDER CAP SCREW) INLET PRESSURE TAP RED RESET BUTTON PILOT OUTLET OUTLET PRESSURE TAP [...]

24 4 Hy dr onic piping Installation & Service Manual RELIEF V AL VE Figure 4-1_ Relief V alve - CBN315-500 This appliance is supplied with a relief valv e(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 hea[...]

4 Hy dr onic piping (continued) 25 Installation & Service Manual A water flo w sw itch meets most code r e quire ments for a low-water cut off dev ice on boil ers requir ing forced cir cu la tion for operation. 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 e[...]

26 4 Hy dr onic piping Installation & Service Manual 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 y pe ex pan sion tanks are properly charged and not wat er logged. 10. Start the boiler accor ding to t[...]

4 Hy dr onic piping (continued) 27 Installation & Service Manual Hot wat er pip ing must be suppor ted by suitable hangers or floor stands, NOT by the boiler . Copper pipe syst ems w ill be subject to considerable expansion and c on trac tion. Rigid pipe hangers could allo w the pipe to slide in the hanger resulting in noise transmitted into th[...]

28 4 Hy dr onic piping Installation & Service Manual PUMP INST ALLA TION AND MAIN TE N ANCE: The boiler circulating pump must be pur chased lo cal ly . F or installation and maintenance information on the circulat or pump, refer to the pump man u fac tur ers in st ruc tion package included with the pump. The installer must ensure that the boile[...]

4 Hy dr onic piping (continued) 29 Installation & Service Manual Low T emperature Bypass Requirements This piping is like a primary/secondar y boiler installation with a bypass in the secondary boil er piping . Inlet water temperatur es below 140°F (60°C) can ex cessiv ely cool the prod ucts of combustion r e sult ing in condensation on the h[...]

30 4 Hy dr onic piping Installation & Service Manual Primar y / Secondar y Piping EXPANSION TA NK AIR SE PARAT OR PRESSURE REDUCING VALVE BACK FLOW PREV ENTER BALL VALVE (TYPICAL) UNION (TYPICA L) PRESSURE RELIE F VALVE FLOW CHECK VALVE (TY PICAL) BOILER TEMPERA TURE / PRES SURE GAUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOIL ER CIRCU LAT[...]

4 Hy dr onic piping (continued) 31 Installation & Service Manual Figure 4-5_ Single Boiler - Primary / Secondary with Low T emperature Bypass EXPANSION T ANK AIR SE PARAT OR PRES SURE REDU CING VALVE BACK FLOW PREV ENTER BALL VALVE (TYPICAL) UNION (TYPI CAL) PRESSURE RE LIEF VALVE FLOW CHECK VALVE (TY PICAL) BOILER TEMPERA TURE / PRES SURE GAUG[...]

32 4 Hy dr onic piping Installation & Service Manual Primar y / Secondar y Piping Figure 4-8_ Multiple Boilers Zoned with Circulators EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) PRESSURE RELIEF VALVE (TYPICAL) FLOW CHECK VALVE (TYPICAL) INDIRE CT DHW TA NK BOILER 1 PRESSURE GAUGE DRAIN ( TYPICAL[...]

5 Electrical connections 33 Installation & Service Manual This appliance is wired for 120 V AC service. The applianc e, when installed, must be electr ically ground ed in accor dance with the requirements of the authority having jur isdiction or in the absence of such re quire ments, with the latest edition of the N ational Electr ical Code ANS[...]

34 5 Electrical connections Installation & Service Manual 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 itched b y the internal pump rela y must not exc eed 1 HP . The current dra w for a field installed 120 V AC pump MUST be add ed to the boiler’ s cur r[...]

5 Electrical connections (continued) 35 Installation & Service Manual Locating T emper ature Control Re move the contr ol panel door on the front of the unit in order to locat e and access the temperature c ontrol. T emper ature Control Settings Re move the contr ol panel door on the front of the unit unless your unit is specified as a boiler o[...]

36 5 Electrical connections Installation & Service Manual T emperature Control Sensors This is a two-stage temperatur e control (M9/F9) that contr ols the burner ignition and pump functions. This temperatur e controller can measur e up to three different sensor inputs, depending upon how the unit is set up . They ar e as follows: 1. Inlet W ate[...]

5 Electrical connections (continued) 37 Installation & Service Manual Inst allation of a Remote Sensor (Boiler Application) 1. T urn OFF the main electrical power and the main manual gas shutoff to the appliance. 2. Remov e the side access panel from the applianc e to gain access t o the thermostat. 3. Locate the sensor in the kit. Determine th[...]

38 5 Electrical connections Installation & Service Manual Shut down The Shutdo w n knob specifies the outdoor air lock out temperature at which the c ontrol would prevent the unit fr om operating. Out door Air Max (O.A. Max) The O .A. Max knob allo ws a reset up to the maximum outdoor air te mper ature specified b y this knob setting . W hen th[...]

5 Electrical connections (continued) 39 Installation & Service Manual Manual Reset High W ater T emperature Limit Control (St andard Fixed Settings on Boilers and Water Heaters with Optional Adjustable Settings) W ater heaters are supplied with a fix ed setting, manual r eset high water temperature limit c ontrol. This manual reset temperature [...]

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 wat er heaters and boilers with the system pump delay option, the operating temperature co ntrol w ill energize the pump relay which energizes the pump on a call for heat. The operating temperature contro[...]

6 Star t-up (continued) 41 Installation & Service Manual Lighting Instr uctions 1. ST OP! Read the safety information (page 40). 2. Re move the contr ol panel door . 3. Set the thermostat to the low est setting (OFF). 4. T urn off all electrical power to the applianc e. 5. T urn the gas control knob on the gas valv e clockwise to the “OFF” [...]

42 6 Star t-up Installation & Service Manual 10. U se the loop end of the wire lighting wand, shipped with the instruction pack age, to hold the match and reac h the pi lot. An acc ess slot is provided in the lower fr ont jacket panel, beside the burner , t o inser t the lighting wand and match t o the pilot. Lift the pilot co ver (FIG. 6-3) to[...]

6 Star t-up (continued) 43 Installation & Service Manual Lighting Instr uctions for Spar k Ignition Pilot Models (F9/M9) Models 90,000 through 500,000 Btu/hr Input FOR Y OUR SAFETY READ BEFORE OPERA TING  W ARNING If you do not follow these instructions exactly , a fir e or explosion may r esult causing property damage, personal injur y or l[...]

44 6 Star t-up Installation & Service Manual T o T ur n Of f Gas to A ppliance 1. Set the thermostat to the OFF position. 2. T urn off all elect ric power t o the appliance if ser vice is to be performed. 3a. 90,000 - 135,000 and 399,999 - 500,000 Btu/hr models, rotate the gas c ontrol knob on the gas valv e clockw ise to the “OFF” position[...]

6 Star t-up (continued) 45 Installation & Service Manual 6. Shut-do w n and Draining - If for an y rea son, the appliance is to be sh ut off, the following precautionary measures must be tak en: (a) Shut off gas supply . (b) Shut off water supply . (c) Shut off elect rical supply . (d) Dr ain the unit complet ely . Remov e one threaded plug or [...]

46 7 Domestic wa ter hea ter s Installation & Service Manual Domestic Wa ter Heaters 90,000 - 500,000 Btu/hr Models This section applies only to those units used to sup ply direct fired domestic hot water and installed with a storage tank(s). The use of a properly sized pump and the c ontrol of water velocity , as e x plained in the W ater V el[...]

7 Domestic wa ter hea ter s (continued) 47 Installation & Service Manual Wa ter Chemistr y The required t emperature rise and the standard pump sizing are based on the heating of potable water with chemistr y within the specified limits. Caution should be used when heating water softened t o less than 5 gr ains per gallon. Many commer cial wate[...]

48 Installation & Service Manual 7 Domestic wa ter hea ter s Figure 7-1_ Single water heater_single tank FLOW CHECK VALVE (TYPICAL) EX PANSION TANK TH ERMOMET ER COLD W ATER SUPPL Y HOT W ATER SUP PLY BUILDI NG RETURN DRAIN TEMP ERATURE & PRESSURE RELIEF VALVE (TYPICAL) FLOW SW ITCH WA TE R H EA TE R CIRCULATOR ST ORA GE TANK WA T E R HEATE[...]

49 Installation & Service Manual 7 Domestic wa ter hea ter s (continued) Figure 7-2_ Single water heater_multiple tank FLOW CHECK VALVE (TYPICAL) BALL VALVE (TYPICAL) EXPANSION TANK THER MOMET ER COLD W ATER SUPPLY HOT W ATER SUPPLY BUILDI NG RETURN DRAIN (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) FLOW SW ITCH W ATER HEATER CIR[...]

50 7 Domestic wa ter hea ter s Installation & Service Manual Figure 7-3_ Multiple water heater_single tank THER MOMETER HOT WATER SUPPLY DRAIN TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) FLOW SW ITCH ( TYPICAL ) WAT ER HEATER CIRCULATOR ( TYPICAL) STORA GE TANK WAT E R HEATER UNION (TYPICAL) BALL VALVE (TYPICAL) Y-STRAINER [RECOMMENDED] ([...]

7 Domestic wa ter hea ter s (continued) 51 Installation & Service Manual Minimum Pump P erfor mance Based on heating potable water with a hardness of 8 to 25 grains per gallon and total dissolved solids not e xceeding 350 ppm. See “W ater Chemist r y” , page 47. BTU/hr INPUT GPM Ft. Hd. 90,000 - 500,000 30 8 R emote Sensor Installation W at[...]

52 Installation & Service Manual 7 Domestic wa ter hea ter s  CAUTION Setting the temperature select or to high er settings provides hotter wate r , whic h in creas es the risk of scald injur y . The manufacturer r ecommends the use of a prop er ly sized thermostatic mixing valve t o supply do mes tic hot water at temperatures less than 140?[...]

53 Installation & Service Manual 7 Domestic wa ter hea ter s (continued) Figure 7-8_ Relief V alve - Water heater Figure 7-9_ Water Flow Switch, W ater heater R elief V alv e RELIEF VA LV E FLOW SWITCH FLOW This appliance is supplied with a relief valv e sized in acco rdance with ASME Boiler and Pr essure V es sel Code, Section IV (“Heating B[...]

54 Installation & Service Manual 8 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 [...]

8 Maintenance (continued) 55 Installation & Service Manual Follo w the ser vice and maintenance proc edures given thr oughout this manual and in component literature shipped with the appliance. F ailure to perform the serv ice and maintenanc e could result in damage to the appliance or system. Failure t o follow the directions in this manual an[...]

56 8 Maintenance 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, diaphragm or bladder t ype. See Section 4 - H ydronic Piping for suggested best locati[...]

Installation & Service Manual 8 Maintenance (continued) 57 Check All Wiring 1. Inspect all wiring , making sure wires are in good condition and secur ely attached. Check Control Settings 1. Adjust settings if necessar y . See Section 5 - Electr ical Connections for adjustment procedur es. 2. Check settings of external limit controls (if any) an[...]

58 8 Maintenance Installation & Service Manual  A void breathing dust and c ontact w ith skin and eyes. • Use NIOSH c ert ified dust respirator (N95). This ty pe of respirator is based on the OSHA requir ements for cristobalite at the time this document was written. Other ty pes of respirators ma y be needed depending on the jobsite condit[...]

8 Maintenance (continued) 59 Installation & Service Manual p. Check “V” baffles on top of the heat ex chang er . Re move and clean if necessar y . q. Remov e soot from the heat ex changer w ith a stiff bristle brush. Soot ma y also be re moved from the heat ex changer by washing thoroughly with detergent and water . R emove the heat ex chan[...]

8 Maintenance 60 Installation & Service Manual IMPORT ANT U pon completion of any testing on the gas system, leak test all gas connections with a soap solution while main bur ners are operating. I m me di ate ly repair an y leak found in the gas train or re lat ed comp on ent s. Do N ot operate an appliance with a leak in the gas train, valv es[...]

9 T r oubleshooting 61 Installation & Service Manual T r oubleshooting Guide: 315,000 - 500,000 Btu/hr Models - Boiler s 90,000 - 500,000 Btu/hr Wa ter Heaters F9/M9 Step 1: Step 2: Step3: Is t he sp ar k ignitor sparking? No Yes Check continuity on the spark cable. Check for 24 VAC on the 24v terminal (gray wire) on the ignition module No Is t[...]

9 T r oubleshooting 62 Installation & Service Manual Step 1: Step 2: Step 3: Is the pilot lit? Yes Is the gas valve getting 24VAC to the MV terminal? Yes Check gas pressure and make sure the gas valve knob is on No Check gas pressure. Check the pilot assembl y and thermocouple. Clean the thermocouple and pilot or replace. No Is there 24 VAC (pu[...]

10 Diag r ams 63 Installation & Service Manual Schema tic Diag r am - F1 Unit 90,000 - 270,000 Btu/hr Models W iring Dia g ram - F1 Unit 90,000 - 270,000 Btu/hr Models[...]

10 Diag r ams 64 Installation & Service Manual Schema tic Diag r am - F9 Unit 315,000 - 399,999 Btu/hr Models W iring Dia g ram - F9 Unit 315,000 - 399,999 Btu/hr Models[...]

65 Installation & Service Manual 10 Diag r ams (continued) Schema tic Diag r am - M9 Unit 315,000 - 399,999 Btu/hr Models BO X D EPI C T S O PT I O N A L I TE M S 120V LINE 120 NEUTRAL GROUND 24VDC RELAY CIRCULATION PUMP MOT 120V TRANSFORMER 24V CN1-1 OPERATOR CN1-2 1 LOW W ATER 2 CUTOFF 5 VENT DAMPE R 3 RW THERMOSTAT LO W WAT ER CUTOFF 3 4 ROL[...]

66 Schema tic Diag r am - F9/M9 Unit 500,000 Btu/hr Models W iring Dia g ram - F9/M9 Unit 500,000 Btu/hr Models 10 Diag r ams Installation & Service Manual[...]

67 Notes[...]

Revision A (ECO #C06290) initial release. CF A-I-S Rev A 09/10[...]