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Lochinvar 000 - 260 Boiler User Manual

1. 2 Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer s warranty see Boiler Flow Rates and Temperature Rise for flow requirements Improper installation adjustment alteration service or maintenance can result in severe personal injury death or substantial property damage Refer to this manual for assistance or additional information consult a qualified installer service agency or the gas supplier Checking equipment Upon receiving equipment check for signs of shipping damage Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on the packing slip with those actually received In case there is damage or a shortage immediately notify the carrier Do not use this appliance if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced A Owner warning NOTE Retain this manual for future reference The information contained in this manual is intended for use by qualified professional installers service technicians or gas suppliers Consult your local expert for proper installation or service procedures Consult and follow all local Building and IMPORTANT Fire Regula
2. 21 22 23 24 25 Installation amp Service Manual Sight Glass The sight glass provides a view of the burner surface burner flame and the pilot flame Temperature and pressure gauge The temperature and pressure gauge monitors the outlet temperature of the appliance as well as the system water pressure Temperature sensor This sensor monitors inlet water temperature If selected as the controlling sensor the appliance will maintain the setpoint at this sensor Terminal strip The boiler is equipped with a terminal strip on the left side of the unit to allow easy connection to contact points Top panel Removable panel to gain access to the internal components Thermostat The thermostat monitors the water temperature via a temperature sensor and will initiate a call for heat when the water temperature drops below the setpoint plus the differential on the thermostat Transformer The transformer reduces 120 VAC supply voltage to 24 VAC for the control circuit Water inlet system return The water inlet is a 1 1 2 pipe connection that receives water from the system and delivers it to the heat exchanger Water outlet system supply The water outlet is a 1 1 2 pipe connection that supplies water to the system with connections for a flow switch a relief valve and a temperature and pressure gauge Gas manifold pipe Delivers gas from the gas valve to the main burners through a number of orifices
3. 36 Outdoor Air Reset Option 000008 38 Additional Temperature Controls 38 Blocked Vent and Flame Roll Out Flame Interlock Switch 39 6 STARTUP Initial Startup TET 40 Lighting Instructions for Spark Ignition Pilot Models M9 40 Safety Shutoff Test for Spark Ignition Pilot System 41 Intermittent Pilot Spark Ignition System M9 42 Freeze Protection SbassesiuexedozstikswedakdueesbE Ebesuda 42 Water Treatment 22 eccenceecdaueeseuaeeeessecds chesnut 42 7 MAINTENANCE Maintenance and Annual Startup 43 48 8 TROUBLESHOOTING 49 9 DIAGRAMS eller 50 A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate A CAUTION n CAUTION NOTICE CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage SOLUTION Installation amp Service Manual 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
4. Reset button low water cutoff e Remove and wash burners Check appliance piping gas and Every water for leaks 6 months Operate relief valve Shut appliance down unless End boiler used for domestic hot of season water months 43 7 Maintenance A WARNING SOLUTION Installation amp Service Manual Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the appliance Failure to perform the service and maintenance could result in damage to the appliance or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage A WARNING The appliance should be inspected annually only by a qualified service technician maintenance and care of the appliance designated in Table 7A and explained on the following pages must be In addition the performed to assure maximum appliance efficiency and reliability Failure to service and maintain the appliance and system could result in equipment failure A WARNING Electrical shock hazard Turn off power to the appliance before any service operation on the appliance except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death AN CAUTION Label all wires prior to disconnection when servicing controls Wiring erro
5. SOLUTION Installation amp Service Manual 4 Lochinvar The Solution How it works continued Models 45 000 90 000 Right Side inside unit Models 45 000 90 000 Left Side inside unit SOLUTION Installation amp Service Manual Lochinvar The Solution How it works Models 135 000 260 000 Btu hr Front View SS NS T p By 7 3 p Z A gt 4 KEN E i WN Models 135 000 260 000 Btu hr Right Side inside unit Models 135 000 260 000 Btu hr Left Side inside unit SOLUTION Installation amp Service Manual I 4 Lochinvar 1 Determine boiler location Location of unit Recommended Service Clearances Left 24 1 Locate the appliance so that if water connections should Front 24 leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any a of its components Ui TOP 2 The appliance must be installed indoors where it is protected from exposure to wind rain and weather 3 Theappliance must be installed so that the ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator repl
6. 1 210 1 020 923 830 200 Water Column and a pressure drop of 0 5 Inch 666 63 Water Column Based on NAT 2 4 100 2 820 2 260 1 950 1 720 1 560 1 440 1 330 1 250 1 180 1 100 GAS 1025 Btu hr per Cubic 21 2 6 460 4 460 3 610 3 100 2 720 2 460 2 310 2 100 2 000 1 900 1 700 1 540 1 400 1 300 Foot of Gas and se 11 200 7 900 6 400 5 400 4 870 4 410 4 000 3 800 3 540 3 300 3 000 2 720 2 500 2 340 gg 23 500 16 100 13 100 11 100 10 000 9 000 8 300 7 690 7 380 6 870 6 150 5 640 5 130 4 720 Gas Piping GAS VALVE GAS SHUTOFF VALVE TRAP DRIP LEG Figure 3 1 Gas Line Connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes Tubing installations must comply with approved standards and practices Reference FIG 3 1 for a typical installation Install Piping to Control l The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are cut squared deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide proper volume
7. Local codes may require a back flow preventer or actual disconnect from city water supply when glycol antifreeze is added to the system Water Treatment In hard water areas water treatment should be used to reduce the introduction of minerals to the system Minerals in the water can collect in the heat exchanger tubes and cause noise on operation Excessive build up of minerals in the heat exchanger can cause a non warrantable failure SOLUTION Installation amp Service Manual Lochinvar 7 Maintenance Maintenance and annual startup Table 7A Service and Maintenance Schedules Owner maintenance see the User s Information Manual for instructions Service technician see the following pages for instructions General Check appliance area Address reported problems Check pressure temperature Inspect interior clean and vacuum if gauge necessary Check for leaks water gas flue Examine venting system Check system water pressure system piping expansion tank Check control settings Check wiring and connections Flame inspection stable uniform Check flue gas passageways Monthly e Check vent piping Inspect and clean the burners Perform start up checkout and NECN TECE VANE performance verification per Section 6 Start up n H lt H o l lt lt If combustion or performance indicate need Clean heat exchanger Periodically Test low water cutoff if used
8. each set point adjustment to ensure proper operation Room Thermostat or Remote Thermostat Connection to Terminal Strip A room thermostat or remote temperature control may be connected to the boiler The room thermostat should be installed on an inside wall away from the influences of drafts hot or cold water pipes lighting fixtures televisions sun rays or fireplaces Follow the manufacturers instructions supplied with the thermostat for proper installation and adjustment The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection FIG 5 1 34 SOLUTION Installation amp Service Manual amp Lochinvar Remove the jumper between the R and W terminals on the terminal strip Refer to the chart in this section Table 5A to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the R and W terminals on the terminal strip Connection to the terminal strip will allow the room thermostat to make and break the 24VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requirements Set the boiler operating temperature control as described in this section Figure 5 1_ Terminal Strip Connections TABLE 5A TERMINAL STRIP WIRING Wire Gauge Masinuna Allowable Length Auxiliary Device Connection to Terminal Strip A terminal connection strip is provided for ease
9. 4 Install 250 x 032 insulated female quick connect terminals to the end of the wires Feed the wires through the access hole located on the back of the unit and secure the connectors to the thermostat connections Sys Tank CN5 and CN6 located in the upper right hand of the thermostat Turn on the electrical power and the main manual gas shutoff to the appliance Replace the side access panel Fire the appliance and resume operation ACCESS HOLE CONNECT THE MEASURED WIRE TO THE SENSOR WIRE Figure 5 4 Installation of Remote Sensors D Electrical connections Outdoor Air Reset Option For boilers ordered with the Outdoor Air Reset option there is an additional control FIG 5 5 There are three setting knobs for Shutdown Outdoor Air Max and Ratio There is also a switch to turn the outdoor air shutdown feature On or Off An O A Sensor is also included 9 O A SENSOR ENABLE swi DISABLE O A SHUTDOWN 40 70 SHUTDOWN Figure 5 5_Optional Outdoor Air Reset Control Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the unit from operating Outdoor Air Max O A Max The O A Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting When the outdoor air temperature is above the specified setting the unit will not function in the O A Reset Mode but will continue to run at the selected set p
10. 5kPa The appliance and its gas connection must be leak tested before placing it in operation Gas Connection Safe operation of the appliance requires properly sized gas supply piping See data in Table 3C Gas pipe size may be larger than appliance gas connection Installation of a union is suggested for ease of service see FIG 3 1 on page 19 Install a manual main gas shutoff valve outside of the appliance gas connection and before the gas valve or manifold connection when local codes require A trap drip leg MUST be provided by the installer in the inlet of the gas connection to the appliance see FIG 3 1 on page 19 The combination gas valve has an integral vent limiting device and does not require venting to atmosphere outside the building Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes TABLE 3C FITTINGS TO EQUIVALENT STRAIGHT PIPE Diameter Pipe inches Paneth p poe e ee Equivalent Length of Straight Pipe feet TABLE 3D GAS CONNECTIONS Btu hr Pipe Size INPUT P 3 Gas connections continued SOLUTION Installation amp Service Manual TABLE 3E GAS PIPING SIZE CHART Nominal Iron Pipe Length of Pipe in Straight Feet Maximum Size Capacity of Pipe in Thousands of nos ao 29 o 4o so e 7o so 90 10 15 9 punc for gas pressures 128 121 113 of 13 5 Inches 1 1 2 2 150 1 500
11. 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 Start the boiler according to the Section 6 Start Up Operate the system including the pump boiler and radiation units for one Instructions in this manual hour Recheck the water level in the expansion tank If it exceeds half the tank volume open the tank to reduce the water level Recheck pressure charge on diaphragm type tanks Shut down the entire system and vent all radiation units and high points in the system Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris Reopen the water makeup valve Verify system pressure with the boiler pressure gauge before beginning regular operation Within three days of start up recheck and bleed all air vents and the expansion tank using these instructions SOLUTION Installation amp Service Manual Piping of the Boiler System The drawings in this section see FIG s 4 7 thru 4 11 show typical heating boiler piping installations Before beginning the installation consult local codes for specific plumbing requirements The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for service The boiler circulating pump air separat
12. PRESSURE Measured at the inlet pressure tap located upstream of the combination gas valve s see FIG 3 5 page 22 TABLE 3A GAS SUPPLY PRESSURE Natural Gas Max Inches Water Column pa 14 Min Inches Water Column Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment MANIFOLD PRESSURE Measured at the pressure tap on the downstream side of the combination gas valve s see FIG 3 5 page 22 The gas regulator settings for single stage and two stage operation are factory set to supply proper manifold pressure for normal operation To check manifold pressure see Manifold Adjustment Procedure Do not increase manifold pressure beyond specified pressure settings shown below in Table 3B TABLE 3B MANIFOLD PRESSURE Single and Full or High Fire Settings Natural LP Gas Natural LP Gas Gas Gas Input Gas Btu hr Low Fire Settings Lom ps pw pw Lm pee 0 pw p Deme s par pu am Fusco ss or pun p SOLUTION Installation amp Service Manual Gas Pressure Test IL The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5kPa The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3
13. check for corrosion or deterioration Immediately correct any problems observed in the venting system 15 2 Venting Masonry Chimney Installation A masonry chimney must be properly sized for the installation of a gas fired appliance Venting of an appliance into a cold or oversized masonry chimney can result in operational and safety problems Exterior masonry chimneys with one or more sides exposed to cold outdoor temperatures are more likely to have venting problems The temperature of the flue gases from an appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft This will result in condensing of flue gases damage the masonry flue tile insufficient draft and possible spillage of flue gases into an occupied living space Carefully inspect all chimney systems before installation If there is any doubt about the sizing or condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system Inspection of a Masonry Chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue gases A clay tile lined chimney must be structurally sound straight and free of misaligned tile gaps between liner sections missing sections of liner or any signs of condensate drainage at the breaching or clean out If there is any doubt about the condition of a masonry chimney it must be relined An unlined masonry chimney
14. conditions that result in property damage personal injury fire explosion and or toxic gases A faulty ignition module must be replaced with a new module Ignition and Control Timings M9 Intermittent Spark Ignition Pilot Models Pilot Trial for Ignition Period 90 Seconds Pilot Failure Response Time 0 8 Seconds at less than 1 0 pA flame current Pump Delay Timing Optional on Boilers 30 Seconds after burner shutdown Freeze Protection 1 For boilers with the pump delay option if either the inlet sensor or the optional multi purpose temperature sensor reads below 40 F the pump relay will turn ON When the temperature rises above 50 F the pump relay will turn OFF 2 Location Heating boilers must be located in a room having a temperature safely above freezing 32 F 0 C 3 Caution A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing The cold outside air pulled down the flue may freeze a heat exchanger This condition must be corrected to provide adequate freeze protection 4 Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze Follow the manufacturers instructions DO NOT use undiluted or automotive type antifreeze 5 A snow screen should be installed to prevent snow and ice accumulation around the appliance venting
15. flow Flow rate can be determined by measuring the temperature rise through the boiler The basic guide for minimum flow in this boiler is based on a 40 F temperature rise in most installations Lower flow and a higher temperature rise is acceptable if the boiler system 1s specifically designed for the characteristics of a higher temperature rise A system not specifically designed for a higher temperature rise may experience overheating of the boiler water This can cause short burner on cycles system noise and in extreme cases a knocking flash to steam These conditions can lead to operational problems and non warrantable failures of the boiler High temperature rise systems must be designed by a qualified engineer SOLUTION Installation amp Service Manual Lochinvar 4 Water connections continued Primary Secondary Piping Figure 4 4 Primary Secondary Piping of a Single Boiler PRESSURE REDUCING VALVE C PRESSURE BACKFLOW pd GAUGE PREVENTER Iu 3 LANN LI LI MAKE UP WATER SYSTEM SUPPLY AIR SENSOR SEPARATOR SYSTEM CIRCULATOR T PRONI o 5 q BH 5 SYSTEM SYSTEM N je NOT TO EXCEED 12 APART au T BALL VALVE TYPICAL M BOILER EXPANSION CIRCULATOR TANK DRAIN POINT TYPICAL Y STRAINER RECOMMENDED UNION TYPICAL TEMPERATURE PRESSURE GAUGE DRAIN PRESSURE RELIEF VALVE SOLUTION BOILER 29 SOLUTION Installation amp Service Manual ILC Lochinvar 4 Water connections
16. knob is set to 0 or 1 the delay will be 10 seconds if set to 2 or above the delay will be 120 seconds Boiler Application Standard boiler units are equipped with one inlet water temperature sensor A system sensor is also provided for use as a remote system sensor Boilers with the outdoor air reset option also have an outside air temperature sensor Temperature Control Sensors This is a two stage temperature control that controls the burner ignition and pump 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 System Sensor 3 Outside Air Temperature Sensor Inlet Water Temperature Sensor This sensor measures the inlet water temperature coming into the unit The inlet water temperature sensor is placed into the inlet bulbwell on the boiler This sensor is installed by the factory in new units System Sensor Depending upon how your unit is set up this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications Connect this sensor to the two blue wires in the upper left hand corner of the control panel 5 Outdoor Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems The outside air sensor is optional This sensor allows you to tie boiler operation to the outdoor air temperature As outside temperature
17. lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the appliance until a new relief valve has been installed 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 45 7 Maintenance Check All Wiring 1 Inspect all wiring making sure wires are in good condition and securely attached Check Control Settings 1 Adjust settings if necessary See Section 5 Electrical Connections for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform Start up and Checks 1 Start appliance and perform checks and tests specified in Section 6 Start up 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check Burner Flame Visually check main burner flames at each start up after long shutdown periods or at least every six months A burner viewport is located on the burner mounting flange A WARNING Lhe area around the burner viewport is hot and direct contact could result in burns A WARNING The area around the burners is ho
18. must not be used to vent flue gases from this appliance An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall or flexible or rigid metallic liners are recommended Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney Sidewall Venting Negative Draft This appliance is NOT approved for sidewall venting with the negative draft venting system as shipped from the factory An induced draft fan MUST be used if the installation requires that the flue gases be vented out a sidewall unless a power venter is used see Fan Assisted Venting A properly sized and installed induced draft fan may also be used to vent the flue gases vertically if required by jobsite restrictions The induced draft fan must be listed by a nationally recognized test agency be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements Use care to ensure that the mechanically supplied draft does not exceed the range of a negative 0 02 to 0 05 inches water column to ensure proper operation If draft exceeds the specified range the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft An induced draft fan MUST be interlocked into the appliance s control circuit to sta
19. of gas Run pipe or tubing to the gas valve or manifold inlet If tubing is used obtain a tube to pipe coupling to connect the tubing to the gas valve or manifold inlet DO NOT OVER TIGHTEN Over tightening may result in damage to the gas valves Valve distortion or malfunction may result if the pipe is inserted too deeply into the gas valve Apply a moderate amount of good quality pipe compound DO NOT use Teflon tape to pipe only leaving two end threads bare Remove seal over gas valve or manifold inlet Connect pipe to gas valve or manifold inlet Use wrench to square ends of the gas valve FIG 3 2 19 3 Gas connections IS USED ZA 7 i Za BZ j WHEN FLANGE WHEN FLANGE IS NOT USED APPLY WRENCH TO FLANGE ONLY APPLY WRENCH FROM TOP OR BOTTOM OF GAS CONTROL TO EITHER SHADED AREA Figure 3 2 Wrench 8 For L P gas consult your L P gas supplier for expert installation Upon completion of any piping connections to the gas system leak test all gas connections with a soap solution while system is under pressure Immediately repair any leaks found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Gas Manifold Pressure Adjustment Procedure PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TAP OUTLET PRESSURE TAP FF PILOT PILOT OUTLET GAS CONTROL KNOB RED
20. system If a pressure regulator is also installed in the line the minimum recommended flow it should be adjusted to the same pressure because conditions unique to the installation system pressure operation of multiple zone valves glycol variations in flow etc may result in overheating of the boiler water causing noise or nuisance operation of safety limit controls Typical heating boiler applications will operate with a 20 F to B Repeat this procedure for each circuit 30 F temperature rise across the boiler 4 Close all valves Purge one circuit at a time as follows A Open one circuit drain valve and let the water drain for at least five minutes Ensure that there are no air bubbles visible in the water stream before closing the drain valve 5 Open all valves after all circuits have been purged Make sure there are no system leaks Do not use petroleum based stop leak products All system leaks must be repaired The constant addition of make up water can cause damage to the boiler heat exchanger due to scale accumulation Scale reduces flow and heat transfer causing overheating of the heat exchanger 6 Run the system circulating pump for a minimum of 30 minutes with the boiler turned off 7 Open all strainers in the system and check for debris 8 Recheck all air vents as described in step 4 General Plumbing Rules 24 4 Water connections continued 9 10 LE 12 1D 14 I5
21. system in cold climates 42 m SOLUTION Installation amp Service Manual 6 Shut down and Draining If for any reason the appliance is to be shut off the following precautionary measures must be taken a Shut off gas supply b Shut off water supply c Shut off electrical supply d Drain the unit completely Remove one threaded plug or bulbwell from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger Blow all water out of the heat exchanger e Drain pump and piping Freeze Protection for a Heating Boiler System if required 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 A CAUTION DO NOT use undiluted or automotive type antifreeze 2 A solution of 50 propylene glycol will provide maximum protection of approximately 30 F 3 Follow the instructions from the glycol antifreeze manufacturer The quantity of glycol antifreeze required is based on total system volume including expansion tank volume 4 Glycol is more dense than water and changes the viscosity of the system The addition of glycol will decrease heat transfer and increase frictional loss in the heating boiler and related piping A larger pump with more capacity may be required to maintain desired flow rates in a glycol system 5
22. to be performed 45 000 135 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position Do not force 180 000 260 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the OFF position Do not force Should overheating occur or the gas fail to A WARNING shut off turn off the external manual gas valve to the appliance Safety Shutoff Test for Spark Ignition Pilot System p 10 11 Turn OFF gas supply to the appliance Turn thermostat to highest setting Turn electric power ON Pump relay pulls in to start pump The ignition will begin sparking at the pilot The ignition module will lock out after the 90 second trial for ignition period Immediately call a qualified serviceman or installer to repair an ignition system that fails to lock out and properly shut down burner operation the After successful completion of the test readjust thermostat to normal setting Turn ON gas supply Turn power OFF then ON to reset ignition module If ignition system fails to operate properly repair work must be performed by a qualified serviceman or installer 41 6 Start up Intermittent Pilot Spark Ignition System The ignition module is not repairable Any modification or repairs will invalidate the warranty and may create hazardous
23. which automatically lights the pilot DO NOT try to light the pilot by hand 45 000 135 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position 180 000 260 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the OFF position Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Follow the steps in the What To Do If You Smell Gas section in the safety information on page 40 If you do not smell gas go on to the next step 45 000 135 000 Btu hr models rotate the gas control knob on the gas valve counterclockwise to the ON position 180 000 260 000 Btu hr models rotate the gas control knob on the gas valve counterclockwise to the line on the collar around the knob Allow the knob to pop up and continue rotation to the ON position Turn on all electric power to the appliance Set the thermostat to the desired setting Re install the control panel door If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier SOLUTION J 3b Installation amp Service Manual To Turn Off Gas to Appliance Set the thermostat to the OFF position Turn off all electric power to the appliance if service is
24. with correct volume of combustion air Check Flue Gas Passageways Any sign of soot around the outer jacket at the burners or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted appliances seldom need flue cleaning NOTICE All gaskets on disassembled components must be replaced with new gaskets on reassembly Gasket kits are available from your distributor Heat Exchanger Burner Access A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline Silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines 7 Maintenance continued D D D DO Avoid b
25. PASS PUMP wor ii BK AALALALALALALI W TRANSFORMER Y MANUAL RESET E HIGH LIMIT n md m d row 1 SWITCH C Oo Ino BK 24VAC RELAY VENTER REL 5 y2 E L Jd 315 amp 360 ONLY OPTIONAL ITEMS BOX DEPICTS PUMP S L CIRCULATION L cml LJ BK R SYSTEM SENSOR Y INLET SENSOR PK Y CN1 2 2 OUVER RELAY 24VDC RELAY C OR ARMING RELAY pi ARMING RELAY RED WHITE YELLOW W y T R T TAN Lee r P L X O Co MaA ROLLOUT SWITCH R THERMOSTAT W OW WATER 2 1 i or OPERATOR R R CN8 p m E uj P Bk I Pk Bk rk CN1 1 m F ORANGE PINK PURPLE 24VDC RELAY GRAY 24VAC RELAY OFF RELAY OFF RELAY Y GY OR PK PR 120 GROUND LINE VENT DAMPER 13 Kr BK io BL E E d PR 4 CN1 4 OPERATOR CN1 3 315 amp 360 ONLY AUTO RESET HIGH LIMIT IGNITION MODULE OPERATOR G BL s l LOW WATER W CUTOFF 3 PR CONTACTS ON ANY FAILURE BK BLACK BL BLUE G GREEN lt BN BROWN LBL2723 A m Notes 51 Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision A ECO C03746 initial release SBR I S RevA 5 10
26. Primary Secondary Piping Figure 4 5 Single Boiler Primary Secondary with Low Temperature Bypass PRESSURE REDUCING VALVE CA PRESSURE BACKFLOW XC GAUGE PREVENTER Md A TUNSIN T T MAKE UP WATER SYSTEM SUPPLY AIR SENSOR SEPARATOR SYSTEM CIRCULATOR FROM ae T d a Dd SYSTEM TS SYSTEM f NOT TO EXCEED 12 APART BALL VALVE CN TYPICAL a EXPANSION TANK LOW TEMPERATURE BYPASS BOILER CIRCULATOR DRAIN POINT TYPICAL Y STRAINER RECOMMENDED UNION TYPICAL Oz O TEMPERATURE PRESSURE GAUGE DRAIN PRESSURE RELIEF VALVE OLUTION BOILER S 30 SOLUTION 4 Water connections continued Primary Secondary Piping Installation amp Service Manual Figure 4 6 Multiple Boilers Zoned with Circulators PRESSURE PRESSURE REDUCING VALVE GAUGE BACKFLOW PREVENTER EA LX EI gt ff NIN i MAKE UP WATER SYSTEM SUPPLY SENSOR WHEN USED AIR SEPARATOR Q NOT TO EXCEED 12 APART gt BALL VALVE TYPICAL EXPANSION TANK DRAIN POINT TYPICAL FLOW CHECK BOILER VALVE CIRCULATOR Y STRAINER RECOMMENDED i UNION TYPICAL TEMPERATURE PRESSURE GAUGE PRESSURE BOILER 2 BOILER 1 RELIEF VALVE LEADER 1 LEADER RELIEF VALVE HOT i WATER OUT ANTI SCALD MIXING VALVE RECIRCULATION LOOP AQUASTAT INDIRECT DHW TANK 31 SOLUTION Installation amp Service Manual I 4 Lo
27. RESET BUTTON MANOMETER Figure 3 3_Manifold Pressure Adjustment 20 SOLUTION Installation amp Service Manual 1 Turn the power OFF at the main disconnect switch Turn gas valve control knob to OFF position 3 Remove the 1 8 hex plug located on the outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge See FIG 3 3 Minimum range of scale should be up to 5 w c for Natural gas models and 10 w c for L P gas models 4 Remove the pressure regulator adjustment cap screw on the gas valve See FIG 3 3 for location Turn the power ON at the main disconnect switch 5 6 Turn gas valve control knob to ON position 7 Set the thermostat s to call for heat 8 Observe gas regulator pressure when all burners are firing See Table 3B Manifold Pressure page 18 for proper regulator pressure settings 9 If adjustment is necessary turn regulator adjustment screw clockwise to raise regulator gas pressure counterclockwise to lower gas pressure to proper setting NOTE Adjustment fitting is plastic and may require slightly greater turning force than a metal fitting 10 Turn the power OFF at the main disconnect switch NOTICE Do not increase regulator pressure beyond specified pressure setting 11 Turn gas valve control knob to OFF position 12 Remove fitting from the gas valve and replace the 1 8 hex plug th
28. Review with owner 1 Review the User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well 3 Remind the owner of the need to call a licensed contractor should the appliance or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season SOLUTION Installation amp Service Manual SSS Lochinvar 8 Troubleshooting Troubleshooting Guide M9 Solution Boilers Step 1 Is the spark Check continuity on the spark Check for an open ignitor sparking cable Check for 24 VAC on sensor If no open l the 24v terminal gray wire sensor make sure on the ignition module there s a call for heat If call for heat is present replace temperature control Check the pilot Sten 2 Is the pilot tube for gas tep 2 Check draft Em TET Replace ignition module Is there 24 VAC purple wire on the 4 pin connector plug on the temperature controller Is there 24 VAC tan wire on the 4 pin Step 3 Is the gas valve Replace the connector plug on getting 24 VAC ignition the temperature to the MV module controller terminal Check gas pressure and make sure gas valve knob 1s on Check 24 VAC at R and W on the terminal strip Check each of the following for an open X and B on the termina
29. SBR I S RevA SOLUTION Lochinvar Installation amp Service Manual Models 45 000 260 000 Btu hr Es TA 7 d A WARNING 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 Failure to comply could result in severe personal injury death or substantial property damage CERTIFIED High Efficiency Water Heaters Boilers and Pool Heaters E j 7 i Save this manual for future reference HAZARD DEFINITIONS 2 PLEASE READ BEFORE PROCEEDING 3 4 RATINGS 2 0 0 0 cee 5 THE SOLUTION HOW IT WORKS 6 8 1 DETERMINE BOILER LOCATION Location of Unit 0 0 0 0 eee ee 9 Clearances Er PT 9 Combustion and Ventilation Air 10 12 2 VENTING A Conventional Negative Draft Venting System 13 14 Vertical Vent Termination Clearances 15 Masonry Chimney Installation 16 Inspection of a Masonry Chimney 16 Automatic Vent Damper 2 00000 eee 17 3 GAS CONNECTIONS Gas Supply ze nuns mex a ER RR ERR de A REDE 18 Gas Pressure Test 0 00 cece eee ees 18 Gas Connection 0 0 00 ccc eee 18 Cas Piping vusvea ERES eae eeudeseacoduretae RE 19 Gas Manifold Press
30. SWITCH LOWER FRONT JACKET PANEL HEX FILLER BRACKET Figure 7 2_Outer Air Deflector and HEX Filler Bracket Water Circulating Pump Inspect pump every 6 months and oil if required Use SAE 30 non detergent oil or lubricant specified by pump manufacturer Clear Area 1 Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 Check frequently to be sure the flow of combustion and ventilation air to the boiler is not obstructed 48 SOLUTION Installation amp Service Manual Inspection of Heat Exchanger Waterways Appliances operated in hard water areas should have periodic inspections of the tubes to be sure that no sediment or scale accumulates on the heat transfer surfaces Inspection plugs are located at both ends of the heat exchanger Inspection plugs should be removed and tubes inspected at the end of the first 45 days of operation and again at the end of 90 days of operation If no scale accumulation is observed inspections can be made at the end of each six months of operation IMPORTANT Upon completion of any testing on the gas system leak test all gas connections with a soap solution while main burners are operating Immediately repair any leak found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Gas Train and Controls o GAS FLOW Figure 7 3 Gas Train
31. acement control replacement etc Bu RIGHT 4 Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the i s ig living space of a dwelling unit must be installed so that all ERON 7 LEFT burners and burner ignition devices have a minimum Figure 1 1 Alcove Installation Models 45 000 clearance of not less than 18 46cm above the floor The 180 000 Btu hr appliance must be located or protected so that it is not subject to physical damage by a moving vehicle Recommended Gruter Left 24 5 DO NOT install this appliance in any location where Front 24 gasoline or flammable vapors are likely to be present 6 All units have been approved for alcove installation an ALCOVE is a closet enclosure without a front door 7 The appliance must not be installed on carpet 8 All units have been approved for use on combustible C surfaces 29 TOP 9 Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the appliance NOTICE Clearances from combustible construction are noted on the appliance rating plate RIGHT 18 18 FRONT a LEFT Figure 1 2_Alcove Installation Models 215 000 260 000 Btu hr SOLUTION Installation amp Service Manual 1 Determine boiler location Combustion and ventilation air requirements for conventionally vented appliances Provisio
32. ake sure that it does not cause drafts which could lead to nuisance operational problems with the appliance 11 SOLUTION Installation amp Service Manual M Lochimar 1 Determine boiler location TABLE 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Outside Air from Outside Air from 2 Ducts Delivered from 1 Opening Directly Outdoors from Outdoors in Top Opening in Inside Air from 2 Ducts Delivered from Interior Space Top Opening in Outside Air from 2 Openings Directly from Input Outdoors Btu hr Top Bottom Opening in Opening in Bottom Opening in Bottom Opening in 45 000 12 12 15 23 23 100 100 78 cm 78 cm 97 cm 149 cm 149 cm 646 cm 646 cm 75 000 19 19 25 38 38 100 100 i 123cm 123 cm 162 cm 246 cm 246 cm 646 cm 646 cm 90 000 29 23 30 45 45 100 100 gt 148 cm 148 cm 194 cm 291 cm 291 cm 646 cm 646 cm 135 000 34 34 45 68 68 155 135 i 220 cm 220 cm 291 cm 439 cm 439 cm 871 cm 871 cm 180 000 45 45 60 90 90 180 180 291 cm 291 cm 388 cm 581 cm 581 cm 1 162 cm 1 162 cm 215 000 54 54 72 108 108 215 215 i 349 cm 349 cm 465 cm 697 cm 697 cm 1 388 cm 1 388 cm 260 000 65 65 87 130 130 260 260 gt 420 cm 420 cm 562 cm 839 cm 839 cm 1 678 cm 1 678 cm Outside air openings shall directly communicate with the outdoor
33. at was previously removed and tighten 13 Turn the gas valve control knob to ON position 14 Turn the power ON at the main disconnect switch The appliance is now ready to operate If manifold pressure can not be properly adjusted use the procedure on page 21 to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control 3 Gas connections continued Checking Gas Supply Pressure GAS SUPPLY PRESSURE MANOMETER GAS VALVE Figure 3 4_Gas Supply Pressure l Turn the power OFF at the main disconnect switch Turn gas valve control knob to the OFF position Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P gas shut off gas supply at the tank Remove the 1 8 hex plug located on the inlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge Range of scale should be 14 w c or greater to check inlet pressure See FIG s 3 3 and 3 4 for location Turn on gas supply at the manual valve turn on L P gas at tank if required Turn the power ON at the main disconnect switch Follow the Lighting Instructions in Section 6 Startup to light the pilot Turn gas valve control knob to the ON position SOLUTION 10 11 12 13 14 15 16 17 18 19 IMPORTANT Installation amp Ser
34. ately repair any leak found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Check burner performance by cycling the system while you observe burner response Burners should ignite promptly Flame pattern should be stable see the Maintenance Section Normal Flame Pattern Turn system off and allow burners to cool then cycle burners again to ensure proper ignition and flame characteristics 21 SOLUTION Installation amp Service Manual 3 Gas connections Combination Gas Valves PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW WIRING TERMINALS i 4 s i U D t OUTLET PRESSURE TAP mi INLET PRESSURE TAP PILOT OUTLET S ONTROL KNOB Figure 3 5_M9 Gas Valve Each unit has a combination gas valve to control the gas supply to the burners The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves The valve has a gas control knob that must remain in the open position at all times when the appliance is in service Each gas valve has pressure taps located on the inlet and outlet sides Manifold pressure is adjusted using the regulator located on the valve The manifold pressure is preset at the factory and adjustment is not usually required If the manifold pressure is to be adjusted follow
35. ater boiler installed above radiation level must be General Plumbing Rules provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed An 1 Check all local codes electronic low water cutoff 1s available as a kit on all units Low water cutoffs should be inspected every six months including flushing of float types 3 2 For serviceability of the boiler always install unions Always pipe pressure relief valves to an open drain TABLE 4A 4 Locate system air vents at the highest point of the system MINIMUM REQUIRED FLOW FOR HEATING BOILER 5 Expansion tank must be installed near the boiler and on the suction side of the pump Input Btu hr GPM Flow 13 009 Placing the Boiler in Operation Filling the System All air must be purged from the system for 135 000 proper operation An air scoop and air vent must be located 180 000 close to the boiler outlet and there should be a minimum 215 000 B o distance between the cold water feed and the system purge valve 260 000 1 Close all drain cocks and air vents NOTICE Minimum flow is based on a 40 F 2 Open the makeup water valve and slowly fill the system temperature rise across the boiler 3 Ifa makeup water pump is employed adjust the pressure to Minimum flow may not prove a flow switch installed in the boiler piping Use provide a minimum of 12 psi at the highest point in the care when operating a boiler at or near
36. be performed by a qualified service installer service agency or the gas supplier If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors What to do if you smell gas Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Warranty Installation and service must be performed by a qualified service installer service agency or the gas supplier Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems l Excessive water hardness causing a lime scale build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty see Water Treatment and Water Chemistry
37. c damper must be installed to control draft 4 m SOLUTION Installation amp Service Manual TABLE 2A VENT PIPE SIZES B 9 EN NENNEN RN On a conventionally vented negative draft appliance the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type 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 double wall vent to properly size all vent connectors and stacks The Type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturer s listing The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes Any vent materials used must be listed by a nationally Figure 2 1 Conventional Negative Draft Vertical Venting recognized test agency for use as vent material 13 2 Venting Locate appliance as close as possible to a chimney or gas vent Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions Horizontal portions of the venting system shall be supported to prevent sagging Horizontal runs must slope upwards not less than 1 4 inch p
38. cause the tubes to accumulate a lime scale build up This will cause a NON WARRANTABLE FAILURE Water Connections Heating Boilers with inputs of 45 000 260 000 Btu hr have 1 2 NPT inlet and outlet connections A CAUTION Field installed reducing bushings may decrease flow resulting in boiler noise or flashing to steam m SOLUTION Installation amp Service Manual Circulator Pump Requirements This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation The boiler circulating pump must be field supplied The boiler circulator pump must operate continuously while the boiler is firing Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system design water temperature rise A heat exchanger pressure drop chart Table 4C is provided to assist in proper pump selection Also provided is a System Temperature Rise Chart Table 4B on page 25 This table provides GPM and boiler head loss at various temperature rises for each boiler based on Btu hr input Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing Example The boiler inlet temperature is 160 F and the boiler outlet temperature is 180 F this means that there is a 20 F temperature rise across the boiler TABLE 4C HEAT EXCHANGER PRESSURE DROP CHART FT HD 0 5 10 15 20 25 30 35 Gallon
39. chinvar 4 Water connections Full System Flow Figure 4 7_Single Boiler Full System Flow PRESSURE REDUCING VALVE PRESSURE EA BACKFLOW PA GAUGE PREVENTER pal Kj LI AN LI LI MAKE UP WATER SYSTEM SUPPLY AIR SENSOR SEPARATOR SYSTEM CIRCULATOR i EROR IS T k B Ici SYSTEM SYSTEM m 7 yt L L an T T BALL VALVE TYPICAL M EXPANSION TANK Y STRAINER RECOMMENDED i UNION TYPICAL i TEMPERATURE PRESSURE GAUGE DRAIN PRESSURE RELIEF VALVE i PH SOLUTION BOILER 32 SOLUTION Installation amp Service Manual 4 Water connections continued Full System Flow Figure 4 8 Single Boiler Full System Flow with Low Temperature Bypass PRESSURE REDUCING VALVE am PRESSURE BACKFLOW m GAUGE PREVENTER SS il NN MAKE UP WATER SYSTEM SUPPLY AIR SENSOR SEPARATOR SYSTEM CIRCULATOR T TO iIi W B mm am SYSTEM Na L7 d oh L ou BALL VALVE TYPICAL a Y 3 WAY VALVE W BYPASS PIPE e EXPANSION TANK BOILER CIRCULATOR Y STRAINER RECOMMENDED UNION TYPICAL TEMPERATURE PRESSURE GAUGE DRAIN PRESSURE RELIEF VALVE SOLUTION BOILER FROM SYSTEM 33 5 Electrical connections This appliance is wired for 120 VAC service The appliance 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 El
40. d to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year A CAUTION Avoid contact with hot discharge water Water Flow Switch if equipped FLOW SWITCH Figure 4 2 Water Flow Switch Top Connections A water flow switch is available as a factory supplied option on all heating boilers see FIG 4 2 The flow switch should be wired between terminals X and B Remove the jumper between the X and B terminals on the terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition A flow switch installed with the factory supplied minimum adjustment setting requires a specific minimum flow to make the switch and start burner operation The flow rate required is a function of the diameter of pipe and tee used for installation Ensure that the pump installed on the boiler will supply adequate flow to make the flow switch contacts and operate the boiler A water flow switch meets most code requirements for a low water cut off device on boilers requiring forced circulation for operation EN gt gt EH SOLUTION Installation amp Service Manual 4 water connections Low Water Cutoff if equipped Typical Heating Boiler Installations A hot w
41. doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any other appliances not connected to the common venting system Turn 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 Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 14 7a SOLUTION Installation amp Service Manual e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use g Any improper operation of the common venting system should be corrected so that the installation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 In Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment When resizing any por tion of the common venting system the common venting system should be resized to a
42. e appliance it may be necessary to have a larger gas line reduced at the appliance Please reference the National Fuel Gas Code charts for more details Gas valve The gas valve allows the proper amount of gas to pass into the burner for combustion Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer The glass lined headers and copper finned tubing are encased in a jacket that contains the combustion process High limit sensor Device that monitors the outlet water temperature to ensure safe operation If the temperature exceeds its setting it will break the control circuit shutting the appliance down Ignition module The ignition module responds to a call for heat signal to provide burner operation Junction box The junction box contains the connection points for the line voltage power and all pumps Performance loop A pumped bypass provides constant flow through the heat exchanger when the building system flow is reduced Performance Loop Pump The pump ensures adequate flow to operate the unit Pilot not shown The pilot is a spark ignition device used to light a pilot flame which in turn is used to light the main burners Pump relay The pump relay energizes the pump on a call for heat Relief valve The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded SOLUTION 16 17 18 19 20
43. ectrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CSA C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 All the appliance and field installed devices shall be made with type T wire 63 F 35 C rise wiring between 2 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 Thepump must run continuously when the appliance is being fired 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Serious damage may result 5 Provide the unit with proper overload protection 6 Install a wall thermostat on the inside wall DO NOT install the thermostat in an area affected by drafts sunlight light fixtures hot or cold water pipes or near a fireplace See Room Thermostat or Remote Thermostat Connection to Terminal Strip this page for proper wiring connection Boiler Operating Temperature Control The operating temperature control is located in the control panel behind the control panel front access door The sensing element for the operator is placed in a bulbwell installed in the heat exchanger Carefully observe the inlet water temperature on the initial boiler on cycles The exact temperature set point is based on your system s requirements Turn the control set point dial to the desired operating water temperature Observe the boiler discharge temperature after
44. ed under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190 F Anytime the OJ2 jumper is cut with or without OJ1 a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200 F Set Point The Set Point knob specifies the target inlet 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 brings the unit back on again 36 A SOLUTION Installation amp Service Manual High Fire Offset The temperature control operates a two stage firing system The two stages are High Fire and Low Fire High Fire operates all burners at full rate while Low Fire operates the burners at approximately one half rate The High Fire Offset knob specifies the number of degrees below set point that the High Fire stage shuts down At that point the unit will continue to operate at the Low Fire stage until the set point is reached The High Fire Offset knob has settings between 0 F and 20 F If set at O E the High Fire Offset is disabled and the unit will operate the High Fire stage until the set point is reached and the temperature control shuts the unit off If the High Fire Offset
45. edicated pump to supply flow to the boiler only This pump is sized based on desired boiler flow rate boiler head loss and head loss in the secondary system piping only The secondary pump in stalled in the boiler piping ensures a constant water flow rate to the boiler for proper operation Boiler installation with a primary secondary piping system can prevent noise problems caused by low system water flows A primary secondary piping system is recommended on any boiler where low water flow conditions may present an operational problem 27 4 Water connections SOLUTION Installation amp Service Manual Primary Secondary Boiler Piping continued A primary secondary piping system is ideal for systems filled with a propylene glycol and water mixture A glycol and water mixture is more dense than water only and may result in a lower boiler flow rate A lower boiler flow may cause noisy operation or short cycling of the burners A larger secondary pump may be used on a primary secondary system to provide an increased boiler flow rate A glycol and water system may require from 10 to 20 more flow to compensate for the increased density of the glycol and its effect on the heat transfer process in the boiler The exact increase in flow that may be required is based on the type and percentage of glycol added to the boiler system Consult the manufacturer of the glycol for additional recommendations when using a glycol and water fill for you
46. ee FIG 1 4 Figure 1 5 Combustion Air from Interior Space 3 If air is taken from another interior space that is adequately ventilated each of the two openings specified above should have a net free area of one square inch for each 1000 Btu hr 22cm per kW of input but not less than 100 square inches 645cm see FIG 1 5 SOLUTION Installation amp Service Manual 4 Determine boiler location continued Figure 1 6 Combustion Air from Outside Single Opening 4 If a single combustion air opening is provided to bring combustion air in directly from the outdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7 cm per kW This opening must be located within 12 30 cm of the top of the enclosure see FIG 1 6 Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada refer to National Standard CAN B149 1 Check all local code requirements for combustion air 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 2596 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the room where the appliance is installed Each opening must have a net free area as specif
47. emperature rises above 50 F the pump relay will turn OFF 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 reason the appliance is shut off the following precautionary measures must be taken Shut off gas supply Shut off water supply Shut off electrical supply Drain the heat exchanger completely Remove one 3 8 NPT plug or bulbwell from the inlet side and one from the outlet side of the front header of the P a heat exchanger 5 Drain the pump Remove the 3 4 plug in the performance loop Pre start Checklist OPERATING A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas s
48. eps a thru e in Heat Exchanger Burner Access m Loosen mounting screws and remove front control panel n Loosen screws on the upper front jacket panel and remove toward front of the appliance Use caution to prevent damage to refractory on the doors inner surface o Check V baffles on top of the heat exchanger Remove and clean if necessary p Remove soot from the heat exchanger with a stiff bristle brush Soot may also be removed 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 installing Use a vacuum to remove loose soot from surfaces and inner chamber q Remove the heat exchanger HEX filler bracket FIG 7 2 r The heat exchanger can be removed by sliding towards the front of the appliance Once the heat exchanger is removed from the appliance a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces 47 Maintenance s Ensure that all burner ports are cleaned to remove any soot See Inspection and Cleaning Procedure page 47 t Carefully re install the heat exchanger V baffles jacket panels and wires u Reassemble all gas and water piping Test for gas leaks v Cycle the appliance and check for proper operation OUTER AIR DEFLECTOR UPPER FRONT JACKET PANEL FLAME ROLL OUT SWITCH DETAIL A INTERLOCK
49. er foot 21 mm m from the appliance to the vent terminal Follow manufacturer s instructions Do not use an existing chimney as a raceway for a flue pipe if another appliance or fireplace 1s vented through the chimney The weight of the venting system must not rest on the appliance Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured with rustproof sheet metal screws Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure Connection to a positive pressure chimney may cause flue products to be discharged into the living space causing serious health injury Common venting systems may be too large when an existing appliance 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 are not in Operation a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all
50. es below 140 F 60 C can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue Condensation can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the vent system and related components The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140 F 60 C This should prevent the products of combustion from condensing in most installations The bypass should be fully sized with a balancing valve to allow for proper adjustment A valve must also be provided on the boiler discharge after the bypass Closing this discharge valve forces water through the bypass Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open A small amount of the higher temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature Boiler Flow Rates A CAUTION The maximum flow rate through the boiler with a copper heat exchanger must not exceed 30 GPM The heat exchanger is generally capable of operating within the flow rates of a residential heating system Should the flow rate exceed the maximum allowable flow rate through the boiler 30 GPM an external bypass must be installed The bypass should be fully sized with a balancing valve to allow for proper adjustment of
51. iciency requirements A vent damper is factory supplied with residential heating boilers with inputs of 45 000 thru 260 000 Btu hr The vent damper is a useful tool for saving energy when installed inside the living space where air can circulate freely around the appliance The vent damper will not save as much if any energy if it is installed in locations such as Unheated garage Attic Crawlspace Mechanical room that is vented outdoors For installation and maintenance on the vent damper refer to the instructions supplied with the vent damper Residential heating boilers with inputs of less than 300 000 Btu hr must have the vent damper properly installed and the vent damper wire harness plugged into the terminal block on the side of the control panel to allow the boiler to function Larger input heating boilers will have a jumper plug installed in the terminal block to allow operation without a damper Remove the jumper plug from the terminal block to connect an optional vent damper wire harness The jumper plug MUST be in place if an optional vent damper is not used on larger input heating boilers A CAUTION Install the vent damper to service only the single appliance for which it is intended If improperly installed a hazardous condition such as an explosion or carbon monoxide poisoning could result Do not install the vent damper within 6 152 mm of combustible materials The damper position indicator must be i
52. ied in Table 1B on page 12 Single openings shall be located within 12 30 cm of the ceiling Under no circumstances should the room where the appliance is installed ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the appliance A CAUTION The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as freon tricholorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure The result is improper combustion and a non warrantable premature appliance failure EXHAUST FANS Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and or cause a downdraft in the venting system Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected If a fan is used to supply combustion air to the equipment room the installer must m
53. igure 5 7 Blocked Vent Switch Location the main burner gas supply wait for the boiler to cool then press the red reset to return the boiler to operation Operation of a blocked vent and or flame roll out interlock switch usually indicates a problem with the venting system obstruction of the heat exchanger flue gas passageway and or a combustion air supply problem The cause for operation of the blocked vent and or flame roll out interlock switch must be determined and corrected If the boiler cannot be restored to normal operation contact a qualified service installer service agency or the gas supplier DRAFT HOOD 39 SOLUTION Installation amp Service Manual 6 Start up Initial Start up Follow the Lighting Instructions on the label applied to the 7 Check carefully for gas leaks appliance l EM l 8 Read the appliance s safety warnings lighting instructions A On boilers with the system pump delay option the and check out procedure carefully before firing the system operating temperature control will energize the i u pump relay which energizes the pump on a call for Lighting Instructions for Spark Ignition heat The operating temperature control will de Pilot Models energize the pump relay approximately 30 seconds after the call for heat ends If either the inlet sensor FOR YOUR SAFETY READ BEFORE or the optional multi purpose temperature sensor reads below 40 F the pump relay will turn ON When the t
54. ir Shutdown feature allows the unit to operate regardless of the outdoor air temperature This is needed for indirect domestic hot water systems for example Additional Temperature Controls High Water Temperature Limit Control The appliance is supplied with a fixed setting auto reset high water temperature limit control The setting of this control limits maximum discharge water temperature If water temperature exceeds the setting the limit will break the control circuit and shut down the appliance The limit control will only be reset after the water temperature has cooled well below the setting of the limit The auto reset high water temperature limit control is mounted in the outlet side of the front header SOLUTION Installation amp Service Manual 5 Electrical connections continued Blocked Vent and Flame Roll Out Flame Interlock Switch OUTER AIR DEFLECTOR UPPER FRONT JACKET PANEL FLAME ROLL OUT SWITCH DETAIL A INTERLOCK SWITCH LOWER FRONT JACKET PANEL HEX FILLER BRACKET BLOCKED VENT SWITCH INVERTED TO SHOW RESET UNDERNEATH Figure 5 8 Flame Roll Out Flame Interlock Switch Location All units are equipped with manual reset blocked vent and flame roll out flame interlock switches These temperature switches are located in the controls compartment and in the relief opening of the boiler s built in draft hood Each switch has a red reset button In the event the system has actuated to shut off F
55. izontally from or 1 foot 30cm above any door window or gravity air inlet into any building 10 OR LESS ___ 10 OR LESS 4 CHIMMEY WALL OR PARAPET CHIMMEY Figure 2 4 Vent Termination from Flat Roof 10 or Less from Parapet Wall iad 10 OR MORE g Y C UE Dunt are Be Ger UEU mme mw EIE be Su EDS ee NOTE NO HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FROM WALLS OR PARAPETS IS MORE THAN 10 WALL OR PARAPET CHIMNEY Figure 2 5 Vent Termination from Flat Roof More Than 10 from Parapet Wall Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent can not terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30cm above grade To 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 surfaces or on the vent cap Frozen condensate on the vent cap can result in a blocked vent condition Flue gas condensate can cause discoloration of exterior building surfaces Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate NOTICE Examine the venting system at least once a year Check all joints and vent pipe connections for tightness Also
56. l strip purple and gray wires on the vent damper Check each of the plug following for an open V and P on the white and purple wire on terminal strip the LWCO plug auto reset high limit rollout switch manual reset high limit spill switch If any of these devices are open press the reset button Check voltage to and from the transformer Check incoming 120 VAC 49 Manual ICe M9 Un ion amp Serv 45 000 260 000 Btu hr Models iagram Installat iring W SOLUTI N iagram M9 Uni 000 Btu hr Models Schematic D 260 9 Diagrams 45 000 A3 vCAC 181 XINO 09 SI ros E 39nvo ANY asnivsadWa MOTISA A 3dHnd Hd N33H9 95 H3H9IH HO YVnO3 JO JAIM SWALI 1VNOILdO 31IHM M XNid Md NMOMS N8 S19Id3d XO NVI l 39NVNHO HO Jnia 18 ISN SNIHIM SNIOV Td3H N3HM l AVHO AS MOv18 N8 lollid AlddNsS YIMOd DL O9fYld ASOLND Muvds JYNTIY4 ANY YaLVM MOI NO LOYLNO9 NOLLWINOUIO JINAON NOLLINSI LIWITHOIH T Lasse OLN Oo Sato TI VILLNaH3HUIG ae da0 o QNO 3Nung HOLIMS yd A RM LNOTION GND e T NYZ oz 09EG LE wLa glo iis diNid SSvdA8 Ov M 44OLNO H31VM MOT Ad rods vo L SS am l AJAN o c M viua AN LI 0 H sum j 09 0S Q E 3j NAOG LInHS h n A NMOGLNHS VO NET 04 ov HOSNIS q18vN3 S9 Sy q L3 TINI ONIOIAMH3S 380438 YAMOd LOANNOOSIG PR SWITCH 4 AY P _ cy SPILL PROVING R VENTER U V W W BY
57. n Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes 12 The distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equip ment Vent connection is made directly to the top of the appliance This appliance is designed with a built in draft diverter No additional external draft hood is required The connection from the appliance vent to the common vent or chimney must be made as direct as possible 2 Venting A Conventional Venting System Negative Draft The negative draft in a conventional vent installation must be within the range of a negative 0 02 to 0 05 inches water column to ensure proper operation All draft readings are made while the appliance is in stable operation approximately 2 to 5 minutes Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have draft within the proper range If the draft measured above the appliance s built in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances a barometri
58. n a visible location with access for service following installation The damper must be in an open position when appliance main burners are operating The part number for the automatic vent damper required on this heating boiler is printed on the rating plate Vent damper regulations are design certified per the latest edition of ANSI 721 66 SOLUTION Installation amp Service Manual VENT DAMPER x Mt Figure 2 7 Vent Damper and Vent Damper Terminal Block A CAUTION The vent damper must be installed directly on the flue outlet located on the top of the draft hood see FIG 2 7 Do not alter the wire harness supplied with the vent damper Follow the instructions supplied with the vent damper An appliance which is shut down or will not operate may experience freezing due to convective air flow down the flue pipe connected to the unit Proper freeze protection must be provided see Freeze Protection mW q7 3 Gas connections Gas Supply Verify that the appliance is supplied with the type gas specified on the rating plate This appliance is orificed for operation up to 2000 feet altitude The appliance will be derated 4 per 1000 feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation Field conversions for operation at high altitude must be performed by certified personnel only The appliance will be marked to indicate suitability for high altitude operation GAS SUPPLY
59. ns for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting d umm mmm emer Figure 1 3 Combustion Air Direct from Outside l If air is taken directly from outside the building with no duct provide two permanent openings see FIG 1 3 a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the floor b Ventilation air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the ceiling 10 Figure 1 4 Combustion Air Through Ducts Zs If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11cm per kW s
60. nstallation regulations in force in the local area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Where required by the authority having jurisdiction the installation must comply with the Canadian Association Code CAN CGA B149 1 and or B149 2 and or local codes This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas fired appliances ANSI Z21 13 and ANSI Z21 10 3 Installation amp Service Manual SOLUTION Installation amp Service Manual SSS Lochimar Ratings Solution Boiler Other Specifications I B R Rating Net Model Number Gross IFB R Output Ratings Boiler Water Note Change N to MBH Water Content L for L P gas models MBH Gallons Note 1 5 Note 1 5 CBN135 135 112 Water Connections 180 149 178 NOTICE Maximum allowed working p
61. of connection for Power Venting Systems see FIG 5 1 inset A A field supplied powered venter or powered louver damper may be connected to the Solution boiler via a terminal strip located on the left side of the unit see FIG 5 1 inset B A 24 VAC relay can be powered from this location when a call for heat has been established A device proving switch can be interlocked back to the appliance to ensure its operation before the appliance is allowed to fire Reference the wiring diagram on page 50 of this manual SOLUTION Installation amp Service Manual R Lochinvar 5 Electrical connections continued Pump Wiring for a Heating Boiler The heating boiler circulating pump must be purchased locally The maximum load for the pump switched by the internal pump relay must not exceed 1 HP The current draw for a field installed 120 VAC pump MUST be added to the boiler s current draw to determine the minimum wire size for 120 volt service TABLE 5B AMP DRAW DATA 45 000 thru 260 000 Btu hr Models MAXIMUM FIRING CONTROLS TOTAL AMPS 120 VAC M9 with Performance Loop Pump 1 25 IGNITION MODULE TEMPERATURE CONTROL MANUAL RESET HIGH LIMIT IF EQUIPPED PUMP RELAY TRANSFORMER Figure 5 2 Intermittent Pilot System M9 Control Panel Temperature Adjustment Operating Temperature Control The temperature controller is pre set at the NOTICE l factory with test settings You may need to adjust the
62. oint temperature Note that the set point knob will now indicate the minimum boiler temperature Target temperature is determined by the ratio and outdoor air temperature below the O A Max setting Ratio The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset The allowable ratios are as low as 0 5 1 or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature Selecting the 1 5 1 ratio will increase the set point 1 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature 38 u SOLUTION Installation amp Service Manual If the outdoor design and boiler design temperatures are known the Ratio setting can be calculated using the following formula Ratio boiler design temperature operator set point O A Max setting outdoor design temperature Note that the reset set point cannot exceed the maximum set point of the boiler thermostat These settings are illustrated graphically in FIG 5 6 RESET SET POINT A lt MAX SET POINT RATIO 1 5 1 0 RATIO 0 5 OPERATOR SET POINT lt O A TEMP 0 A MAX Figure 5 6 Outdoor Air Control Example Chart Outdoor Air Shutdown Enable Disable Switch The Outdoor Air Shutdown Enable Disable switch turns the outdoor air shutdown feature On and Off Disabling the Outdoor A
63. or expansion tank and other components required for proper installation must be purchased locally An air separation device must be supplied in the installation piping to eliminate trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type expansion tank is used The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation This boiler system should not be operated at A CAUTION less than 12 PSIG TABLE 4B SYSTEM TEMPERATURE RISE CHART Based on Boiler Output in Btu hr Btu hr 10 F AT 20 F AT 30 F AT 40 F AT Buh Cem f sa f a e a a a a a a mas f mom f a f e Duro a f oe E mee wem 9 ome p 3mm 2s 25 4 Water connections Hot water piping must be supported by suitable hangers or floor stands NOT by the boiler Copper pipe systems will be subject to considerable expansion and contraction Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system Padding is recommended on rigid hangers installed with a copper system The boiler pressure relief valve must be piped to a suitable floor drain See the relief valve section on page 23 of this manual A CAUTION leak in a boiler system will cause the system to intake fresh water constantly which will
64. pproach the min imum size as determined using the appropriate tables in Part 11 in the latest edition of the National Fuel Gas Code ANSI Z223 1 In Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment 2 Venti NG continued SOLUTION Installation amp Service Manual Vertical Vent Termination Clearances 10 OR LESS pee CHIMNEY 2 MIN 3 MIN 7v MESS 2 X Figure 2 2 Vent Termination from Peaked Roof 10 or Less from Ridge MORE THAN 10 t eT V V Figure 2 3 Vent Termination 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 highest point of the roof within a 10 foot 3 05m radius of the termination The vertical termination must be a minimum of 3 feet 0 91m above the point of exit A vertical terminal less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The venting system shall terminate at least 3 feet 0 9m above any forced air inlet within 10 feet 3 05m The venting system shall terminate at least 4 feet 1 2m below 4 feet 1 2m hor
65. r boiler system The installer must ensure that the boiler has adequate flow without excessive temperature rise The temperature rise on a multiple zone system should be made when only the zone with the longest length and or highest head loss is open 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 System noise may also indicate an oversized boiler A CAUTION t no time should the system pressure be less than 12 PSIG A boiler operated with an inlet temperature of less than 140 F 60 C must have a bypass to prevent problems with condensation A bypass as shown in FIG 4 8 see page 33 must be piped into the system at the time of installation Full Flow Application It is acceptable for the Solution boiler to be installed in a full flow application as long as the following requirements are met 1 The performance loop is in place and functional 2 The system flow is not lower than the minimum boiler flow 3 The boiler setpoint is 140 F or higher 4 If water temperature is below 140 F you must install a low temperature bypass VAL30000 and follow the piping diagram shown in FIG 4 7 Varying the flow through a Solution boiler can cause harmonic noises and high limit trips if the flow is below the minimum boiler flow rate found in Table 4A 28 Low Temperature Bypass Requirements Inlet water temperatur
66. r welding equipment 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 is recommended on all cable runs of more than 25 feet in length SOLUTION Installation amp Service Manual Electrical connections continea NOTICE Ground the cable shield at the connection to the boiler temperature control only Do not ground the shielded cable at the sensor end To maintain temperature accuracy sensor wires should be 18 AWG two conductor 18 2 Use shielded wire if required Installation of Remote Sensors l Turn OFF the main electrical power and the main manual gas shutoff to the appliance Remove the side access panel from the appliance to gain access to the thermostat Locate the sensor in the kit Determine the location of the remote sensor and measure the amount of wire needed to connect the sensor to the thermostat See Wiring of the Remote Sensors for guidelines Use twisted pair wire minimum 18 gauge or larger See Table 5A page 34 regarding distance versus wire gauge Ensure all wire insulation is trimmed to reveal at least 3 8 of exposed wire Connect the measured wire to the sensor wire using wire caps see FIG 5
67. reathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the jobsite conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove combustion chamber lining from the appliance and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air Turn OFF main power to the appliance b Turn OFF external manual gas shutoff valve to appliance c Remove the control panel door d Remove the outer air deflector FIG 7 2 e Disconnect gas valve wiring and remove gas manifold assembly f Remove ignition wire leading to the pilot assembly from the ignition module g Disconnect the wiring from the flame rollout interlock switch see FIG 5 8 page 39 h Remove the lower front jacket panel i Remove the control panel mounting screws When removing the control panel lay the cont
68. ressure is located on the rating plate Notes l The ratings are based on standard test procedures prescribed by the United States Department of Energy 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 allowance of 1 15 UNIT EQUIPPED FOR HIGH ALTITUDE UP TO 2000 FT S Use only the vent materials and methods specified in the Installation and Service Manual The Solution is orificed for operation up to 2000 feet altitude The appliance will be derated 496 per 1000 feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation Figure A High Altitude Label Location p Ratings have been confirmed by the Hydronics Institute Section of AHRI The Solution How it works L 10 11 12 13 14 15 Control panel cover The control panel cover provides access to the thermostat ignition module and transformer Burner not shown The burner is a cylindrical stainless steel tube used to regulate burner flame Drain port Location from which the heat exchanger can be drained Flue outlet The flue outlet allows the connection of the vent pipe to the unit Gas connection The gas pipe connection on this appliance is 1 2 or 3 4 NPT To deliver the correct amount of gas volume to th
69. rol panel to the side with the wiring intact being careful not to damage any of the wiring Remove the combustion chamber door Use caution to prevent damage to burners refractory pilot or wiring SOLUTION Installation amp Service Manual Inspection and Cleaning j Check the heat exchanger surface for sooting The external surfaces of the copper tubes should be free of any soot deposits A slight black smudge is normal with some types of gases If abnormal soot deposits are present the heat exchanger must be cleaned and the cause of the soot problem corrected Proceed as follows k Remove soot from burners and bottom of the finned tubes with a stiff bristle brush Dirt may also be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installing Damaged burners must be replaced An appliance installed in a dust or dirt contaminated atmosphere will require cleaning of the burners on a 3 to 6 month schedule or more often based on severity of contamination Contaminants can be drawn in with the combustion air Non combustible particulate matter such as dust dirt concrete dust or dry wall dust can block burner ports and cause non warrantable failure Use extreme care when operating an appliance for temporary heat during new construction The burners will probably require a thorough cleaning before the appliance is placed in service l Remove gas manifold as described in st
70. rs can cause improper and dangerous operation Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect appliance area 1 Verify that appliance area is free of any combustible materials gasoline and other flammable vapors and liquids Inspect appliance interior 1 Remove the outer access panels and inspect the interior of the appliance 2 Vacuum any sediment from inside the appliance and components Remove any obstructions Check all piping for leaks Listed below are items that must be checked to ensure safe reliable operation Verify proper operation after servicing Eliminate all system or appliance leaks Continual fresh makeup water will reduce appliance life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 3 Gas Connections Flue vent system and air supply l Examine the venting system at least once a year Check more often in the first year to determine inspection interval Check all joints and pipe connections for tightness corrosion or deterioration Clean louvers and or screens in the combustion air intake system as required Have
71. rt when the appliance calls for heat 16 m SOLUTION Installation amp Service Manual The induced draft fan MUST also be equipped with a proving switch properly interlocked into the appliance s control circuit to prove fan operation before the main burners are allowed to fire A vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommendations of the fan manufacturer and provide proper clearances from any combustion or ventilation openings windows doors or other Openings into the building All induced draft fan installations must comply with local code requirements Fan Assisted Venting A Power Venter Kit is available on Models 45 000 135 000 Btu hr only see Table 2B TABLE 2B VENT MATERIALS Input Btu hr 45 000 PVC Rated CPVC Optional 75 000 PVC Rated CPVC Optional KIT3103 90 000 CPVC Rated 135 000 CPVC Rated Minimum Vent Length 12 Equivalent Feet ALL UNITS Maximum Vent Length 25 Equivalent Feet ALL UNITS Equivalent Feet 90 Elbow 5 Feet 45 Elbow 3 Feet KIT3104 Figure 2 6 Unit with Fan Assisted Venting 2 Venti NG continued Automatic Vent Damper 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 eff
72. s 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 Openings The above requirements are for the boiler only additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances Combined interior space must be 50 cubic feet per 1 000 Btu hr input Buildings MUST NOT be of Tight Construction For buildings of Tight Construction provide air openings into the building from outside No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btu hr of all installed gas fired appliances Buildings MUST NOT be of Tight Construction Tight Construction is defined as a building with less than 0 40 ACH air changes per hour Vent installations for connection to gas vents or chimneys must be in accordance with Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Adequate combustion and ventilation air must be supplied to the room where the appliance is installed in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 i
73. s drop the control will increase the temperature setting of the boiler As outdoor temperatures rise the control will decrease the temperature to the selected set point of the boiler You can set the control to shut the boiler off when a desired outdoor air temperature level is reached You must purchase the sensor from the appliance manufacturer The sensor comes with a housing that helps protect the sensor from the elements Mount the air sensor housing outdoors under the eve of the roof Make sure the housing is out of direct sunlight This will ensure that the sensor will accurately read the true outdoor temperature Connect the outdoor air temperature sensor to the terminal block on the outdoor air reset board For more information on wiring the sensor see Wiring of Remote Sensors this page Wiring of Remote Sensors To wire 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 sensor Turn wires at least three or four turns per linear foot of wiring This provides protection against some types of electrical interferences 1 Do not route temperature sensor wiring with building power wiring 2 Do not locate temperature sensor wiring next to control contactors 3 Do not locate temperature sensor wiring near electric motors 4 Do not locate temperature sensor wiring nea
74. s per Minute 26 CB 315 CB 360 CB 399 CB 500 4 Water connections continued PUMP INSTALLATION AND MAINTENANCE The boiler circulating pump must be purchased locally For installation and maintenance information on the circulator pump refer to the pump manufacturers instruction package included with the pump Circulator Pump Specifications 1l Maximum operating pressure for the pump must exceed system operating pressure 2 Maximum water temperature should not exceed nameplate rating 3 Cast iron circulators may be used for closed loop systems 4 A properly sized expansion tank must be installed near the boiler and located on the suction side of the pump Circulator Pump Operation Boilers are equipped with a relay for controlling the circulation pump for the hot water loop The relay turns ON and OFF in response to the W input from the wall thermostat or zone control The field installed boiler pump MUST NOT exceed 1 h p For continuous pump operation wire the system pump to the 120V supply The pump should be connected at the junction box as shown in FIG 4 3 120V SUPPLY CIRCULATION V PUMP TO PERFORMANCE LOOP PUMP OPT Figure 4 3 Boiler Wiring Circulation Pump to Junction Box zm SOLUTION Installation amp Service Manual PERFORMANCE LOOP These units are equipped with an integral performance loop which is designed to provide efficiency optimization b
75. settings to meet your specific needs A WARNING Return wari temperatures must not be less than 140 F If lower return water temperatures are required follow the instructions for Low Temperature Bypass Requirements see page 28 Locating Temperature Control Remove the control panel door on the front of the unit in order to locate and access the temperature control Temperature Control Settings Remove the control panel door on the front of the unit in 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 are explained under Outdoor Air Reset Option page 38 The three setting knobs on the temperature control are for Set point Differential and High Fire Offset see FIG 5 3 Ce TT s us ore 240 DIFFERENTIAL OFF SETPOINT TST2314 Figure 5 3 Temperature Control 35 5 Maximum Set Point Determination Electrical connections The maximum set point for the control is factory set Boilers can be set to 240 F max These maximum set points are established by 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 Table 5C TABLE 5C MAXIMUM SET POINT DETERMINATION t t MAX SET POINT Connected 240 F NOTICE Anytime that OJ is the only jumper cut a new overlay is requir
76. t and direct contact could result in burns NORMAL YELLOW TIP D FLAME LIFT YELLOW FLAME Figure 7 1 Flame Pattern Illustration Normal Flame A normal flame is blue with slight yellow tips with a well defined inner cone and no flame lifting Yellow Tip Yellow tip can be caused by blockage or partial obstruction of air flow to the burner s Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner s or excessive gas input This condition MUST be corrected immediately Lifting Flames Lifting flames can be caused by over firing the burner s or excessive primary air If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 46 SOLUTION Installation amp Service Manual Combustion Air This appliance uses an atmospheric combustion process Combustion air is provided to the burners by the gas injection pressure into the venturi of the burners The burners do not have an adjustable air shutter Adequate combustion air must be supplied to the room where the appliance is installed to ensure proper burner operation Check frequently to be sure the flow of combustion and ventilation air to the unit is not obstructed When the main burners light observe the burner flame Flames should be light blue in color with slight yellow tips flames should be settled on burner head with no lifting when supplied
77. the Gas Manifold Pressure Adjustment Procedure page 20 for proper adjustment 22 Venting of Combination Gas Valves The combination gas valve regulator used on all models is equipped with an integral vent limiting orifice The vent limiter ensures that the volume of gas emitted from the valve does not exceed the maximum safe leakage rate allowed by agency requirements Combination gas valve regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors A dust cap is provided at the vent termination point on the valve to prevent blockage of the vent limiter by foreign material The combination gas valve regulator with an integral vent limiter complies with the safety code requirements of CSD 1 CF 190 a as shipped from the manufacturer without the installation of additional vent lines Two Stage Burner Control System The 45 000 thru 260 000 Btu hr boilers M9 are equipped with a two stage burner control system 4 Water connections ding Baiba SOLUTION Installation amp Service Manual Relief Valve RELIEF VALVE Figure 4 1_Relief Valve This appliance is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve s is mounted directly into the heat exchanger inside the header see FIG 4 1 To prevent water damage the discharge from the relief valve shall be pipe
78. the entire system including the venting system periodically inspected by a qualified service agency Check for gastight seal at every connection seam of air piping and vent piping periodically inspected by a qualified service agency A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check water system l Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 PSI Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents 7 Maintenance continued Check Expansion Tank l Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed diaphragm or bladder type See Section 4 Water Connections for suggested best location of expansion tanks and air eliminators Check Relief Valve l A WARNING Inspect the relief valve and lift the lever to verify flow Before opera
79. ting any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 4 Water Connections before proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage SOLUTION A WARNING Installation amp Service Manual Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating
80. tions and other Safety Codes that apply to this installation Consult your local gas utility company to authorize and inspect all gas and flue connections Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance SOLUTION Please read before proceeding A WARNING To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules 1 Boilers are heat producing appliances To 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 2 Never cover your appliance lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to your appliance 3 UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance vent air intake system or any location from which fumes could reach the appliance or vent air intake system Codes The equipment shall be installed in accordance with those i
81. upplier call the fire department Use only your hand to turn the gas control knob 1 Inspect the burners to be sure they are properly aligned Never use tools If the knob will not turn by hand 2 Inspect the pilot gas line thermocouple leads ignition don t try to repair it call a qualified Dee technician leads and wire connections to the gas valve to be sure PDC attempted repair may result in a fire or l explosion none were damaged during shipment 3 Check to ensure that gas connections have been made AO O dE as aPpAair ed any p ne i uae DAMEN line j dora water Immediately call a qualified service technician A c A LE to inspect the appliance The possible damage to a 4 Check to ensure that water connections are tight and the flooded appliance can be extensive and present appliance and piping system have been properly filled numerous safety hazards Any appliance that has been under water must be replaced 5 Ensure that discharge from the relief valve has been piped to a floor drain 6 Verify that properly sized combustion and ventilation air openings are provided and not obstructed in any way 40 6 Start u D continued Operating Instructions l 2 6a 6b 8a 8b 10 Ll IPA STOP Read the safety information first Remove the control panel door Set the thermostat to the lowest setting OFF Turn off all electrical power to the appliance This appliance is equipped with an ignition device
82. ure Adjustment Procedure 20 Checking Gas Supply Pressure 21 Combination Gas Valves llus 22 4 WATER CONNECTIONS Relief Valve 2 0 ee ees 23 Water Flow Switch if equipped 23 Low Water Cutoff if equipped 24 Typical Heating Boiler Installations 24 25 Piping of the Boiler System llus 25 Performance Loop sossasek RR ERES ERE 27 Primary Secondary Boiler Piping 27 28 Low Temperature Bypass Requirements 28 Boiler Flow Rates ellen 28 Primary Secondary Piping lesus 29 31 Full System Flow 0 00 eee eee 32 33 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 A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury 5 ELECTRICAL CONNECTIONS Boiler Operating Temperature Control 34 Room Thermostat or Remote Thermostat Connection 34 Auxiliary Device Connection to Terminal Strip 34 Pump Wiring for a Heating Boiler 35 Temperature Adjustment llus 35 Temperature Control Settings 35 Maximum Set Point Determination
83. vice Manual Set the thermostat s to call for heat Observe the gas supply pressure with all burners firing Ensure inlet pressure is within specified range Check gas supply pressure with all other gas fired appliances in operation to ensure proper gas volume during periods of peak gas usage If gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control If the gas supply pressure is within the specified range proceed with the following steps to return the appliance to service Turn the power OFF at the main disconnect switch Turn gas valve control knob to OFF position Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P Gas shut off gas supply at the tank Remove the manometer and related fittings from the inlet side of the gas valve replace 1 8 hex plug in gas valve Turn on gas supply at the manual valve turn on L P Gas at tank if required Turn the power ON at the main disconnect switch Turn the gas valve control knob to the ON position Spark ignition models will automatically light the pilot on a call for heat Set the thermostat to call for heat The appliance is now ready to operate Upon completion of any testing on the gas system leak test all gas connections with a soap solution while main burners are operating Immedi
84. y maintaining a constant flow through the unit s heat exchanger loop when building system flow is reduced The performance loop assembly is standard equipment and is NOT to be used as a system or boiler pump The performance loop is dedicated to the unit and does not affect the building s system or primary secondary flow characteristics and will not circulate the building It is acceptable to remove the performance loop as long as the following requirements are met 1 The boiler is piped to the system in primary secondary fashion The system setpoint is 140 F or higher The boiler circulating pump is sized for the appropriate flow through the boiler 4 The system sensor is installed in an acceptable location for sensing the system supply temperature 5 If water temperature is below 140 F a low temperature bypass must be installed VAL30000 1 1 2 LTV Valve Kit and follow the piping diagram in FIG 4 4 NOTICE A WARNING oe If removal of the performance loop is necessary consult the manufacturer for a Solution Without a Performance Loop KIT30068 Failure to install the system sensor can cause operation problems such as nuisance high limit trips Primary Secondary Boiler Piping A primary secondary piping system may also be installed to ensure proper boiler flow rates Primary secondary piping is also ideal for systems using a mixture of propylene glycol and water A primary secondary piping system uses a d

Lochinvar 000 - 260 Boiler User Manual

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