Instruction/ maintenance manual of the product COPPER-FIN II 402 - 2072 Lochinvar
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Installation & Operation Manual Models: 402 - 2072 This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual and the Copper-fin II Service Manual be reviewed completely before proceeding with an installation.
Contents 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.
Installation & Operation Manual 3 3 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 be performed by a qualified service installer, service agency or the gas supplier.
4 Installation & Operation Manual Please read before proceeding Codes – The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases.
Installation & Operation Manual 5 The Copper-fin II - How it works... 1. Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process.
Installation & Operation Manual 6 The Copper-fin II - How it works... 18 18 13 13 27 27 18 18 Models 402 - 752 Front View Models 402 - 752 Left Side (inside unit) Models 402 - 752 Right Side (insi.
Installation & Operation Manual 7 The Copper-fin II - How it works... (continued) Models 992 - 2072 Left Side (inside unit) Models 992 - 2072 Right Side (inside unit) Models 992 - 2072 Rear View M.
Installation & Operation Manual 8 Ratings Notes: 1. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup.
Installation & Operation Manual 9 1 Determine unit location NOTICE Clearances from combustible construction are noted on the appliance rating plate. Location of unit This unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI standards for gas-fired units, ANSI Z21.
Installation & Operation Manual 10 1 Determine unit location 2. Outside Combustion Air, Using Ducts You can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room (see FIG. 1-5). Each of the two openings must have a minimum free area of one square inch per 2000 Btu input (11cm 2 per kW).
Installation & Operation Manual 1 Determine unit location (continued) 11 Figure 1-5_ Outside Combustion Air Through Ducts 4. Outside Combustion Air - Using Direct Venting With this option, you can connect combustion air vent piping directly to the unit.
Installation & Operation Manual 12 1 Determine unit location Exhaust fans Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and/or cause a down draft in the venting system.
Installation & Operation Manual 13 2 Venting BEFORE YOU BEGIN Identify your appliance’s vent system: This manual covers venting requirements for CAT I models and CAT IV vent materials. Be sure to correctly identify the type of vent system your appliance requires before proceeding.
Vent system options: (Note: Installations shown below are representative, actual installations may vary from those shown.) A This option uses a vertical rooftop flue termination with air supplied from the equipment room - see page 16.
Installation & Operation Manual 2 Venting (continued) 15 TABLE - 2A FLUE AND AIR INLET PIPE SIZES MODEL FLUE SIZE AIR INLET SIZE MODEL FLUE SIZE AIR INLET SIZE* 402 6" 6" 992 10" 10.
A Conventional negative draft venting - see page 14. NOTICE Before installing a venting system, follow requirements found in the General Venting section. This option uses Type-B double-wall flue outlet piping. The blower brings in combustion air. The buoyancy of the heated flue products cause them to rise up through the flue pipe.
Installation & Operation Manual 2 Venting (continued) 4. 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.
Figure 2-1_ Vent Termination from Peaked Roof - 10 ft. or Less From Ridge NOTICE Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer. Figure 2-2_ Vent Termination from Peaked Roof - 10 ft.
Installation & Operation Manual 2 Venting (continued) 19 The sidewall or vertical rooftop DirectAire™ combustion air supply system has specific material and installation requirements. The air inlet pipe connects directly to the unit to supply combustion air.
Installation & Operation Manual 20 2 Venting To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable cleara nce requirements in the latest edition of the National Fuel Gas Code and/or CAN/CGA-B149 Installation Code and instructions in the Installation and Operation Manual.
Installation & Operation Manual 2 Venting (continued) 21 TABLE - 2B DIRECTAIRE KITS MODEL HORIZONTAL KIT* VERTICAL KIT* 402 SVK3047 VDK3026 502 SVK3047 VDK3026 652 SVK3048 VDK3027 752 SVK3048 VDK3.
Installation & Operation Manual 2 Venting 22 Sidewall venting - see page 14. NOTICE Before installing a venting system, follow all requirements found in the General Venting section. C This option uses a powered vent assembly which pulls the flue products out of the stack.
Installation & Operation Manual 23 2 Venting (continued) Sidewall venting without fan For Models 402 - 752 which are approved for sidewall venting without an external power vent fan, you must install specific vent kits and venting materials (reference Table 2C on page 24 for kit numbers).
Installation & Operation Manual 24 WARNING Do not combine the flue from this unit with the vent from any other appliance. Do not combine flues from multiple appliances into a common vent. The flue from this unit must be a dedicated stack. Connect the flue vent directly to the flue outlet opening on the top of the unit.
Installation & Operation Manual 2 Venting (continued) 25 Horizontal DirectAire™ venting (Powered Venting) - see page 14. The Horizontal DirectAire™ vent system is the same as the Sidewall Venting system, except it pulls combustion air from the outdoors through a sidewall air inlet.
Installation & Operation Manual 26 2 Venting E This option uses sealed AL29-4C vent materials for the flue outlet piping and separate combustion air inlet piping. This system terminates both the flue and combustion air inlet in the same pressure zone.
Installation & Operation Manual 2 Venting (continued) 27 Masonry chimney installation Do not use a standard masonry chimney to directly vent the combustion products from this unit. To use a masonry chimney, the chimney must use a sealed, corrosion-resistant liner system.
Installation & Operation Manual 2 Venting Length of air inlet pipe The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet (15.2m). Subtract 5 feet (1.5m) of equivalent length for each 90° elbow.
Installation & Operation Manual 2 Venting (continued) 29 2. For PVC, CPVC, ABS, dryer vent, or flex duct air inlet piping, use a silicone sealant to ensure a proper seal at the unit inlet and the air inlet cap. 3. For Dryer vent or flex duct, also use a screw-type clamp to attach the inlet vent material to the unit inlet and the air inlet cap.
Installation & Operation Manual 30 2 Venting Outdoor installation - see page 14. NOTICE Before installing a venting system, follow all requirements found in the General Venting section. Units are self-venting and can be used outdoors when installed with the optional outdoor cap.
Installation & Operation Manual 31 3 Gas connections Connecting to gas supply Verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 4,500 feet altitude. Consult factory for installations above 4,500 feet elevation.
Installation & Operation Manual 32 3 Gas connections 2. Use new, properly threaded black iron pipe free from chips. If you use tubing, make sure the ends are cut square, deburred and clean. Make all tubing bends smooth and without deformation. Avoid flexible gas connections.
Installation & Operation Manual 33 3 Gas connections (continued) Figure 3-3_ Measuring Gas Supply Pressure at Combination Gas Valve 13. Remove the manometer and related fitting from the “inlet” side of the gas valve, replace 1/8" hex plug in gas valve and tighten.
34 Installation & Service Manual 4 Water connections Figure 4-1_ Water Connections - Models 402 - 752 Heat exchanger This appliance uses a finned copper tube heat exchanger to maximize the heat transfer process. The heat exchanger is mounted in the inner jacket of the appliance.
Installation & Operation Manual 35 Relief valve This unit 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 installed in the vertical position and mounted in the hot water outlet.
36 Installation & Service Manual 4 Water connections CAUTION At no time should the system pressure be less than 12 PSIG. Pump Maintenance: Inspect the pump every six (6) months and oil as necessary. Use SAE 30 non-detergent oil or lubricant specified by the pump manufacturer.
Installation & Operation Manual 37 CAUTION A boiler allowed to operate at set point temperatures below the specified minimum settings may experience operational problems with the operating controls and safety switches, obstruction of the flue gas passages on the heat exchanger, incomplete combustion and possible flue gas spillage.
38 Installation & Service Manual 4 Water connections The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded.
Installation & Operation Manual 39 Figure 4-3_ Primary/Secondary Piping of a Single Boiler w/DHW 4 Water connections (continued) COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Number of Units GPM Diameter (in.) 15 5 2 COMMON MANIFOLD SIZE (Min.
40 Installation & Service Manual 4 Water connections Figure 4-4_ Primary/Secondary Piping of Multiple Boilers COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Number of Units GPM Diameter (in.) 2 110 3 3 165 3 1/2 4 220 4 5 275 5 6 330 5 7 385 6 8 440 6 COMMON MANIFOLD SIZE (Min.
Installation & Operation Manual 41 Figure 4-5_ Boiler with Low Temperature Bypass Piping - Using a Low Temperature Valve Required for Systems Operating at less than 140°F (60°C) Return Water Temperatures from the Heating Return Loop 4 Water connections (continued) COMMON MANIFOLD SIZE (Min.
42 Installation & Operation Manual 4 Water connections Figure 4-6_ Primary/Secondary Piping with Buffer Tank 1" TEMPERATUR E AND PRESSU RE GAUGE AUTOMATIC AIR ELIMINATOR /VENT SYSTEM OUTLET S.
Installation & Operation Manual 43 5 Electrical connections Boiler operating control module The operating control for the appliance is the SMART SYSTEM control module. It is located on the inside of the control panel, behind the front access door.
44 Installation & Operation Manual 5 Electrical connections Line voltage connections 1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 5-1. 2. Provide and install a fused disconnect or service switch (15 AMP recommended) as required by the code (see FIG.
Installation & Operation Manual 5 Electrical connections (continued) 45 Louver relay When the heater is to control combustion air louvers, a field provided 24VAC louver relay must be installed. Connect the Louver Relay Coil terminals to the louver relay coil.
Installation & Operation Manual 46 5 Electrical connections ALARM S T A G I N G C A S C A D E M O D B U S CN3 CN2 RUN-TIME CONTACTS OPEN CLOSE COM S1 S2 S2 S3 S3 S4 S4 LOUVER RELAY COIL LOUVER PRO.
47 Installation & Operation Manual 6 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.
Installation & Operation Manual 48 6 Start-up Check thermostat circuit(s) 1. Disconnect the two external wires connected to the enable terminals on the connection board.
49 Installation & Operation Manual 6 Start-up (continued) FOR YOUR SAFETY READ BEFORE OPERATI NG A. This appliance is equipped with an ignition device which automa tically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERA T ING smell all around the appliance area for gas.
Installation & Operation Manual 50 6 Start-up Set DHW operation Verify DHW circulator mode (boiler only) The DHW Mode is programmed to heat an indirect domestic hot water tank. When the tank thermostat or tank sensor calls for heat, the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump (if running).
Installation & Operation Manual 51 7 Operating information (continued) General How the appliance operates The Copper-fin II uses a copper finned tube heat exchanger to transfer heat from the flue products to the water. An electronic control module monitors various inputs to initiate a call for heat.
52 Installation & Operation Manual 7 Operating information Temperature control Firing rate Depending upon the model, the Copper-fin II is capable of staging its firing rate from a minimum of 25% to a maximum of 100%. The firing rate is dictated by the call for heat (i.
Installation & Operation Manual 53 7 Operating information (continued) Run-time and alarm outputs The appliance provides dry contacts for indicating when the appliance is running, and when it is unable to operate. Run-time and cycle counting The control uses two timers to monitor the total hours of burner operation.
54 Installation & Operation Manual 7 Operating information The appliance will fire at its ignition speed and will then stage its firing rate to maintain the set point. If the first appliance reaches 100% of its firing rate, the Leader will calculate at what point the second appliance could fire at its minimum firing rate.
Installation & Operation Manual 55 7 Operating information (continued) OPERATION DISPLAY 1. The manual reset high limit must be closed before any action will take place. HTR: Standby OUT: 123.8F(129) 2. Upon a call for heat the control turns on the appropriate pumps (system and boiler pumps for space heating; DHW pump for DHW call).
Installation & Operation Manual Copper-fin II control module MENU/E X I T DISPLAY SCREEN E NTER/ RESET T X E N S U O I V E R P N W O D P U • Press to turn heater off or back on • Press to sele.
57 Installation & Operation Manual 7 Operating information (continued) Access modes User The user can adjust the space heating target temperature and the tank target temperature (if a tank sensor is used) by using the UP and DOWN buttons (FIG. 7-1) at any time during normal operation.
Installation & Operation Manual 58 7 Operating information Status Display Screens By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items.
59 Installation & Operation Manual 7 Operating information (continued) Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items.
Installation & Operation Manual 60 7 Operating information Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items.
61 Installation & Operation Manual 7 Operating information (continued) Status Display Screens (cont’d) Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade.
Installation & Operation Manual 62 8 Domestic water heaters This section applies only to those appliances used to supply domestic hot water, installed with a storage tank(s). A circulating pump MUST be installed in the piping assembly to the storage tank and valves used to control water velocity through the appliance.
Installation & Operation Manual 63 8 Domestic water heaters (continued) If the temperature rise is too low, the water velocity is too high, adjust as follows: 1.
Installation & Operation Manual 64 8 Domestic water heaters Figure 8-1_ Typical Water Heater Piping with Storage Tank COMMON MANIFOLD SIZE (Min.) Models: 402, 502, 652, & 752 Number of Units GPM Diameter (in.) 15 5 2 COMMON MANIFOLD SIZE (Min.
Installation & Operation Manual 65 8 Domestic water heaters (continued) Figure 8-2_ Single Water Heater Piping with Two Storage Tanks OUTLET COLD WA TE R SUPPLY BUILDI NG HOT W ATER SUPPLY RELIE F VALVE LOCK-TEMP STORAGE TANK DRAIN BUILDING RETURN INLET MIXING VALVE COMMON MANIFOLD SIZE (Min.
Installation & Operation Manual 66 8 Domestic water heaters Figure 8-3_ Multiple Water Heater Piping with a Single Storage Tank RELIE F VALVE BUILDI NG HOT WA TE R SUPPLY COLD WA TE R SUPPLY BUILDING RETURN MIXING VALVE DRAIN MIN 4" COMMON MANIFOL D SIZE LOCK-TEMP STORAGE TANK COMMON MANIFOLD SIZE (Min.
Installation & Operation Manual 67 8 Domestic water heaters (continued) Figure 8-4_ Multiple Water Heater Piping with Multiple Storage Tanks RELI EF VALVE BUIL DING HOT WA T ER SUPPLY COLD WA T ER SUPPLY BUIL DING RETURN MIXING VALVE DRAIN MIN 4" COMMON MANIFO LD SIZE LOCK-TEMP STORAGE TANK COMMON MANIFOLD SIZE (Min.
Installation & Operation Manual 68 8 Domestic water heaters Pump operation 1. The water heater must have a properly sized circulating pump. This pump is sized to circulate water between the heater and the storage tank only.
Installation & Operation Manual 69 8 Domestic water heaters (continued) Failure to press the ENTER key after changing the display value will result in the set point reverting back to its previous value after the current heat demand ends. The control may be adjusted any time regardless of call for heat status.
Installation & Operation Manual 70 8 Domestic water heaters Figure 8-5_ Danger Warning Location of Cold Water Supply Piping Connections Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems.
Installation & Operation Manual 71 Maintenance and annual startup Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean a.
Installation & Operation Manual 72 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.
Installation & Operation Manual 73 Check relief valve 1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential.
9 Maintenance Installation & Operation Manual 74 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. Perform start-up and checks 1.
Installation & Operation Manual 75 Inspect and clean the heat exchanger 1. While burners are removed, check the heat exchanger surface for sooting.
Installation & Operation Manual 10 Connection diagram + + + + + + + + OU T D OO R SEN SOR SYS R ET U R N SEN SOR SYS SU PPL Y SEN SOR 0-1 0V S YS -P U M P I N CN 2 1 2 3 4 5 6 7 8 FI E LD SU PP L .
Installation & Operation Manual 10 Connection diagram (continued) NOT E: N UM BER OF G A S V A L VE S VARIES B Y M O DEL GR OU N D X11 X4 X9 X5 X6 X7 X8 X13 F2 F4 MAIN U NIT 1 18 2 3 5 6 20 19 17 .
Installation & Operation Manual 78 11 Ladder diagram BLOWER N ON/OFF SWITC H F2 3.15A BOX DEPI CTS OPTI ONA L IT EMS 120 VAC LOW VOLT AGE TERMINAL STRIP BLOW ER RELA Y HI/LO SPEED RELA Y HI/LO SPE.
Installation & Operation Manual 11 Ladder diagram (continued) 79 CN5-11 X6-1 X6 -13 CN5-5 LOUVER RE LAY CN4- 5 X3-1 CN4- 6 X3-2 CONN ECTIO N BO ARD 1 X6-7 CN5 -1 RUNTIM E CON TAC TS X6-16 CN5-7 X6.
Revision Notes: Revision A (ECO #C08226) initial release. CFX-CHX-I-O Rev A 6/11.
An important point after buying a device Lochinvar COPPER-FIN II 402 - 2072 (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 COPPER-FIN II 402 - 2072 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 COPPER-FIN II 402 - 2072 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar COPPER-FIN II 402 - 2072 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar COPPER-FIN II 402 - 2072 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar COPPER-FIN II 402 - 2072, 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 COPPER-FIN II 402 - 2072.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar COPPER-FIN II 402 - 2072. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar COPPER-FIN II 402 - 2072 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
