Instruction/ maintenance manual of the product 500 Lochinvar
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Inst allation & Service Manual Models: 90,000 - 500,000 Btu/hr This manual supplies information for the installation, operation, and serv icing of the appliance. It is strongly reco mmended that this manual be reviewed complet ely before proceeding with an installation.
2 Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention to the pr esence of hazards of var ious risk level s or to important information concerning the life of the product.
3 Installation & Service Manual Please r ead bef or e pr oceeding NOTICE This is a gas appliance and should be installed by a lice nsed elect rician and/or certified gas supplier . Serv ice must be performed by a qualified serv ice installer , serv ice agency or the gas supplier .
4 Installation & Service Manual Please r ead bef or e pr oceeding W ARNING T o minimize the possibility of serious personal injur y , fir e, or damage to y our appliance, never violate the following safety rules: 1. Boilers and water heaters ar e heat producing appliances.
5 Ra tings Maximum allo wed working pressur e is located on the rating plate. NOTICE Installation & Service Manual Copper-fin I=B=R Rating Model Number Note: Change “N” to “L” for L.
6 Ra tings Installation & Service Manual Notes: 1. Copper -fins require special gas v enting. U se only the vent materials and methods specified in the Installation and Serv ice Man ual. 2. The Copper -fin is orificed for operation up to 2000 feet altitude.
7 Installation & Service Manual T he Copper-fin - How it w or ks... 1. Control panel cov er The control panel c over pr ovides access to the thermostat, ignition module, and transformer . 2. Drain por t (not shown) Location from which the heat ex changer can be drained.
Installation & Service Manual 8 Models CWN270 Front View Model CWN399 (inside unit) Model CWN399 Front View Model CWN270 (inside unit) T he Copper-fin - How it w or ks.
9 Installation & Service Manual T he Copper-fin - How it w or ks... (continued) Model CBN500 (inside unit) Model CBN500 Front View Models CBN399 (inside unit) Model CBN399 Front View 3 1 20 10 16 .
10 Installation & Service Manual 1 Deter mine unit location NOTICE Clearances from c ombustible construction are noted on the applianc e rating plate. Location of unit 1. Locate the applianc e so that if water connections should leak, water damage will not occur .
11 Installation & Service Manual 1 Deter mine boiler location Figure 1-3_ Combustion Air Direct from Outside Combustion and v entilation air requir ements for con v entionall y v ented a ppliances Pr ovisions for combustion and ventilation air must be in acco rdance with the latest edition of the N ational Fuel Gas Code, ANSI Z223.
12 1 Deter mine boiler location Installation & Service Manual 4. If a sing le combustion air opening is pr ovided to bring combustion air in dir ectly from the outdoors, the opening must be sized based on a minimum fr ee area of one square inch per 3000 Btu/hr (7 cm 2 per kW).
1 Deter mine boiler location (continued) 13 Installation & Service Manual T ABLE - 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPL Y TO EQUIPMENT R OOM Input Btu/hr *Outside Air from 2 Openings Direct.
14 Installation & Service Manual 2 V enting The distance of the vent terminal from adjac ent build ings, w indows that open and building open ings MUST comply with the latest edition of the National F uel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 In stal la tion Code for Gas Burn ing Applianc es and Equipment.
2 V enting (continued) 15 Installation & Service Manual Locate appliance as close as possible t o a chimney or gas vent. A void long horizontal runs of the vent pipe, 90° el bows, reductions and restrictions. Horizontal por tions of the venting syst em shall be suppor ted to prev ent sagging .
16 2 V enting Installation & Service Manual V er tical V ent T er mina tion Clear ances Figure 2-2_ V ent T ermination from Peaked Roof 10' or Less from Ridge Figure 2-4_ V ent T ermination f.
2 V enting (continued) 17 Installation & Service Manual Masonr y Chimney Installa tion A masonr y chimney must be properly siz ed for the installation of a gas fired appliance. V enting of an appliance into a cold or o versized masonry chimney can result in op er a tion al and safety problems.
18 2 V enting Installation & Service Manual Automa tic V ent Damper This heating boiler is design certified for use w ith the automatic vent damper (FIG. 2-7) part number printed on the boiler’ s rating plate. A vent damper is optional on heating boilers abo ve 360,000 Btu/hr .
19 Installation & Service Manual 3 Gas connections Gas Supply V er ify that the appliance is supplied with the ty pe gas spec i fied on the rating plate. This applianc e is or ificed for operation up to 2000 feet altitude. The ap pli ance w ill be derated 4% per 1000 feet abov e 2000 feet el e va tion.
20 3 Gas connections Installation & Service Manual T ABLE - 3E MUL TIPLE APPLIANCE INST ALLA TIONS GAS PIPING SIZE CHAR T N ominal Iron Pipe Size Inches Length of Pipe in Str aight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 13.
3 Gas connections (continued) 21 Installation & Service Manual APPL Y WRENCH TO FLANGE ONL Y WHEN FLANGE IS USED APPL Y WRENCH FROM BOTTOM OF GAS CONTROL TO EITHER SHADED AREA WHEN FLANGE IS NOT USED Figure 3-2_ Wrench 8. For L.P . gas, consult y our L.
22 Installation & Service Manual Checking Gas Supply Pressur e GAS VALVE MANO MET ER GAS SUPPLY PR ESSURE UNION Figure 3-4_ Gas Supply Pressure 1. T urn the power “OFF” at the main dis con nect switch. 2. T urn gas valve c ontrol knob(s) to the “OFF” position.
3 Gas connections (continued) 23 Installation & Service Manual Combination Gas V alves W IRING T ERMINALS PRESSURE REGU LATOR A DJUSTMEN T (UNDER CAP SCRE W ) INLET PRESSURE TAP GAS CONTROL KNOB P.
24 4 Hy dr onic piping Installation & Service Manual RELIEF V AL VE Figure 4-1_ Relief V alve - CBN315-500 This appliance is supplied with a relief valv e(s) sized in acco rdance with ASME Boiler and Pr essure V es sel Code, Section IV (“Heating Boilers ”).
4 Hy dr onic piping (continued) 25 Installation & Service Manual A water flo w sw itch meets most code r e quire ments for a low-water cut off dev ice on boil ers requir ing forced cir cu la tion for operation.
26 4 Hy dr onic piping Installation & Service Manual 9. Inspect the liquid level in the e xpansion tank. The system must be full and under normal operating pressure t o ensure proper water lev el in the expansion tank. Ensure that diaphragm t y pe ex pan sion tanks are properly charged and not wat er logged.
4 Hy dr onic piping (continued) 27 Installation & Service Manual Hot wat er pip ing must be suppor ted by suitable hangers or floor stands, NOT by the boiler .
28 4 Hy dr onic piping Installation & Service Manual PUMP INST ALLA TION AND MAIN TE N ANCE: The boiler circulating pump must be pur chased lo cal ly . F or installation and maintenance information on the circulat or pump, refer to the pump man u fac tur ers in st ruc tion package included with the pump.
4 Hy dr onic piping (continued) 29 Installation & Service Manual Low T emperature Bypass Requirements This piping is like a primary/secondar y boiler installation with a bypass in the secondary boil er piping .
30 4 Hy dr onic piping Installation & Service Manual Primar y / Secondar y Piping EXPANSION TA NK AIR SE PARAT OR PRESSURE REDUCING VALVE BACK FLOW PREV ENTER BALL VALVE (TYPICAL) UNION (TYPICA L).
4 Hy dr onic piping (continued) 31 Installation & Service Manual Figure 4-5_ Single Boiler - Primary / Secondary with Low T emperature Bypass EXPANSION T ANK AIR SE PARAT OR PRES SURE REDU CING VA.
32 4 Hy dr onic piping Installation & Service Manual Primar y / Secondar y Piping Figure 4-8_ Multiple Boilers Zoned with Circulators EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW.
5 Electrical connections 33 Installation & Service Manual This appliance is wired for 120 V AC service. The applianc e, when installed, must be electr ically ground ed in accor dance with the requ.
34 5 Electrical connections Installation & Service Manual Pump W iring for a Hea ting Boiler The heating boiler circulating pump must be pur chased locally . The max i mum load for the pump sw itched b y the internal pump rela y must not exc eed 1 HP .
5 Electrical connections (continued) 35 Installation & Service Manual Locating T emper ature Control Re move the contr ol panel door on the front of the unit in order to locat e and access the temperature c ontrol.
36 5 Electrical connections Installation & Service Manual T emperature Control Sensors This is a two-stage temperatur e control (M9/F9) that contr ols the burner ignition and pump functions. This temperatur e controller can measur e up to three different sensor inputs, depending upon how the unit is set up .
5 Electrical connections (continued) 37 Installation & Service Manual Inst allation of a Remote Sensor (Boiler Application) 1. T urn OFF the main electrical power and the main manual gas shutoff to the appliance. 2. Remov e the side access panel from the applianc e to gain access t o the thermostat.
38 5 Electrical connections Installation & Service Manual Shut down The Shutdo w n knob specifies the outdoor air lock out temperature at which the c ontrol would prevent the unit fr om operating. Out door Air Max (O.A. Max) The O .A. Max knob allo ws a reset up to the maximum outdoor air te mper ature specified b y this knob setting .
5 Electrical connections (continued) 39 Installation & Service Manual Manual Reset High W ater T emperature Limit Control (St andard Fixed Settings on Boilers and Water Heaters with Optional Adjustable Settings) W ater heaters are supplied with a fix ed setting, manual r eset high water temperature limit c ontrol.
40 6 Star t-up Installation & Service Manual Initial Star t-up Follo w the Lighting Instructions on the label applied to the appliance. A. On wat er heaters and boilers with the system pump delay option, the operating temperature co ntrol w ill energize the pump relay which energizes the pump on a call for heat.
6 Star t-up (continued) 41 Installation & Service Manual Lighting Instr uctions 1. ST OP! Read the safety information (page 40). 2. Re move the contr ol panel door . 3. Set the thermostat to the low est setting (OFF). 4. T urn off all electrical power to the applianc e.
42 6 Star t-up Installation & Service Manual 10. U se the loop end of the wire lighting wand, shipped with the instruction pack age, to hold the match and reac h the pi lot. An acc ess slot is provided in the lower fr ont jacket panel, beside the burner , t o inser t the lighting wand and match t o the pilot.
6 Star t-up (continued) 43 Installation & Service Manual Lighting Instr uctions for Spar k Ignition Pilot Models (F9/M9) Models 90,000 through 500,000 Btu/hr Input FOR Y OUR SAFETY READ BEFORE OPE.
44 6 Star t-up Installation & Service Manual T o T ur n Of f Gas to A ppliance 1. Set the thermostat to the OFF position. 2. T urn off all elect ric power t o the appliance if ser vice is to be performed.
6 Star t-up (continued) 45 Installation & Service Manual 6. Shut-do w n and Draining - If for an y rea son, the appliance is to be sh ut off, the following precautionary measures must be tak en: (a) Shut off gas supply . (b) Shut off water supply .
46 7 Domestic wa ter hea ter s Installation & Service Manual Domestic Wa ter Heaters 90,000 - 500,000 Btu/hr Models This section applies only to those units used to sup ply direct fired domestic hot water and installed with a storage tank(s).
7 Domestic wa ter hea ter s (continued) 47 Installation & Service Manual Wa ter Chemistr y The required t emperature rise and the standard pump sizing are based on the heating of potable water with chemistr y within the specified limits. Caution should be used when heating water softened t o less than 5 gr ains per gallon.
48 Installation & Service Manual 7 Domestic wa ter hea ter s Figure 7-1_ Single water heater_single tank FLOW CHECK VALVE (TYPICAL) EX PANSION TANK TH ERMOMET ER COLD W ATER SUPPL Y HOT W ATER SUP.
49 Installation & Service Manual 7 Domestic wa ter hea ter s (continued) Figure 7-2_ Single water heater_multiple tank FLOW CHECK VALVE (TYPICAL) BALL VALVE (TYPICAL) EXPANSION TANK THER MOMET ER .
50 7 Domestic wa ter hea ter s Installation & Service Manual Figure 7-3_ Multiple water heater_single tank THER MOMETER HOT WATER SUPPLY DRAIN TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) FLO.
7 Domestic wa ter hea ter s (continued) 51 Installation & Service Manual Minimum Pump P erfor mance Based on heating potable water with a hardness of 8 to 25 grains per gallon and total dissolved solids not e xceeding 350 ppm. See “W ater Chemist r y” , page 47.
52 Installation & Service Manual 7 Domestic wa ter hea ter s CAUTION Setting the temperature select or to high er settings provides hotter wate r , whic h in creas es the risk of scald injur y .
53 Installation & Service Manual 7 Domestic wa ter hea ter s (continued) Figure 7-8_ Relief V alve - Water heater Figure 7-9_ Water Flow Switch, W ater heater R elief V alv e RELIEF VA LV E FLOW S.
54 Installation & Service Manual 8 Maintenance and annual star tup Ser vice technician (see the following p ages for instructions) General: • Address reported problems • Inspect interior; clea.
8 Maintenance (continued) 55 Installation & Service Manual Follo w the ser vice and maintenance proc edures given thr oughout this manual and in component literature shipped with the appliance. F ailure to perform the serv ice and maintenanc e could result in damage to the appliance or system.
56 8 Maintenance Installation & Service Manual Check Expansion T ank 1. Expansion tanks pro vide space for water to mov e in and out as the heating system water e xpands due to temperature incr ease or contracts as the water cools. T anks may be open, closed, diaphragm or bladder t ype.
Installation & Service Manual 8 Maintenance (continued) 57 Check All Wiring 1. Inspect all wiring , making sure wires are in good condition and secur ely attached. Check Control Settings 1. Adjust settings if necessar y . See Section 5 - Electr ical Connections for adjustment procedur es.
58 8 Maintenance Installation & Service Manual A void breathing dust and c ontact w ith skin and eyes. • Use NIOSH c ert ified dust respirator (N95). This ty pe of respirator is based on the OSHA requir ements for cristobalite at the time this document was written.
8 Maintenance (continued) 59 Installation & Service Manual p. Check “V” baffles on top of the heat ex chang er . Re move and clean if necessar y . q. Remov e soot from the heat ex changer w ith a stiff bristle brush. Soot ma y also be re moved from the heat ex changer by washing thoroughly with detergent and water .
8 Maintenance 60 Installation & Service Manual IMPORT ANT U pon completion of any testing on the gas system, leak test all gas connections with a soap solution while main bur ners are operating. I m me di ate ly repair an y leak found in the gas train or re lat ed comp on ent s.
9 T r oubleshooting 61 Installation & Service Manual T r oubleshooting Guide: 315,000 - 500,000 Btu/hr Models - Boiler s 90,000 - 500,000 Btu/hr Wa ter Heaters F9/M9 Step 1: Step 2: Step3: Is t he sp ar k ignitor sparking? No Yes Check continuity on the spark cable.
9 T r oubleshooting 62 Installation & Service Manual Step 1: Step 2: Step 3: Is the pilot lit? Yes Is the gas valve getting 24VAC to the MV terminal? Yes Check gas pressure and make sure the gas valve knob is on No Check gas pressure. Check the pilot assembl y and thermocouple.
10 Diag r ams 63 Installation & Service Manual Schema tic Diag r am - F1 Unit 90,000 - 270,000 Btu/hr Models W iring Dia g ram - F1 Unit 90,000 - 270,000 Btu/hr Models.
10 Diag r ams 64 Installation & Service Manual Schema tic Diag r am - F9 Unit 315,000 - 399,999 Btu/hr Models W iring Dia g ram - F9 Unit 315,000 - 399,999 Btu/hr Models.
65 Installation & Service Manual 10 Diag r ams (continued) Schema tic Diag r am - M9 Unit 315,000 - 399,999 Btu/hr Models BO X D EPI C T S O PT I O N A L I TE M S 120V LINE 120 NEUTRAL GROUND 24VD.
66 Schema tic Diag r am - F9/M9 Unit 500,000 Btu/hr Models W iring Dia g ram - F9/M9 Unit 500,000 Btu/hr Models 10 Diag r ams Installation & Service Manual.
67 Notes.
Revision A (ECO #C06290) initial release. CF A-I-S Rev A 09/10.
An important point after buying a device Lochinvar 500 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lochinvar 500 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lochinvar 500 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar 500 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar 500 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar 500, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lochinvar 500.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar 500. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar 500 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
