Instruction/ maintenance manual of the product 000 Lochinvar
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INST ALLA TION AND SER VICE MANUAL Intelli-Fin ® Hot W ater Heating Boilers Domestic Hot W ater Supply Boilers 1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models IFB/IFW -i&s-05 FIG. 1 Front V iew FIG. 2 Rear V iew Installation and service must be per formed by a qual i fied service in stall er , service agency or the gas supplier .
T ABLE OF CONTENTS W arranty .......................................................................... 1 Safety W arnings .............................................................. 3 Codes .........................................................
Upon receiving equipment, check for signs of ship ping damage. Pay par tic u lar attention to parts ac com pa ny ing the boiler, which may show signs of being hit or otherwise being mishandled. V erify total number of pieces shown on packing slip with those actually re ceived.
4 1. Locate the appliance so that if water connections should leak, water damage will not occur . When such lo ca tions cannot be avoided, it is recommended that a suitable drain pan, ad e quate ly drained, be installed under the unit. The pan must not restrict combustion airflow .
5 NOTE Clearances from combustible construction are noted on the appliance rating plate. Maintain minimum specified clearances for adequate operation. All in stal la tions must allow sufficient space .
6 T ABLE - B Minimum Recommended Combustion AIR SUPPL Y T O MECHANICAL ROOM Btu/hr Input 1,500,000 375 in 2 (2419 cm 2 ) 425 in 2 (2742 cm 2 ) 500 in 2 (3226 cm 2 ) 500 in 2 (3226 cm 2 ) 567 in 2 (365.
7 All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a com bus tion air opening a minimum of ap prox i mate ly 25%.
8 The construction air filter MUST be removed from the appliance’ s air inlet before the appliance is placed in normal operation. Once the construction air filter is removed, ensure that either the .
9 Category IV V enting A CA TEGOR Y IV POSITIVE PRESSURE VENTING SYSTEM FIG. 10 Basic Category IV V enting - V ertical FIG. 1 1 Basic Category IV V enting - Horizontal A Category IV venting system for the flue products is required on all models of this appliance.
10 Any vent materials specified must be listed by a nationally recognized test agency for use as a Category IV vent material. The venting system must be planned so as to avoid possible contact with con cealed plumbing or electrical wiring inside walls, floors or ceilings.
11 the tee. The drain tubing must have a trap provided by a 4" (10.2 cm)-diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent. Secure the trap loop in position with nylon wire ties.
12 CHIMNEY 3' MIN 2' MIN 10' OR LESS CHIMNEY 2' MIN WALL OR P ARAPET FIG. 15 V ent T ermination from Flat Roof - 10 Feet or Less from Parapet W all 3' MIN 10' OR MORE CHIMNEY WALL OR P ARAPET NOTE: NO HEIGHT ABOVE P ARAPET REQUIRED WHEN DIST ANCE FOR WALLS OR P ARAPETS IS MORE THAN 10'> FIG.
13 The installed sidewall vent cap assembly may be paint ed to match the exterior color . The opening through the wall for instal la tion of the sidewall vent cap must provide an air space clearance of 2 inches (5.1 cm) around the flue pipe. The diameter of the opening for installation of the sidewall cap will be 4 inches (10.
14 In cold climates, the use of type “B” double wall vent pipe or an insulated single wall pipe for combustion air is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.
15 sealant to ensure a proper seal at the appliance con nec tion and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and sup plied in proper volume.
16 VERTICAL COMBUSTION AIR INLET FIG. 21 Air Inlet Cap for Rooftop T ermination The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally . The air inlet cap consist of two 90° elbows installed at the point of termination for the air inlet pipe.
17 The Direct V ent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the spec i fied materials. The maximum installed length of the air inlet pipe fr om the appliance to the air inlet cap is 100 equivalent feet (30.
18 The sidewall combustion air inlet cap MUST NOT be installed above the sidewall flue outlet if it is located within a 10 foot (3.05 m ) radius of the flue outlet. The sidewall combustion air inlet cap must not be installed closer than 10 feet (3.05 m) from an inside corner of an L-shaped structure.
19 Combined Air Inlet Points The air inlet pipes from multiple ap pli anc es installed with an Intelli-V ent system can be combined to a single common connection based on the cross sectional area of the common pipe as defined in the Direct V ent basic in for ma tion section.
20 Location of a Sidewall Air Inlet Cap Installation, location and clearance requirements for the sidewall air inlet cap in an Intelli-V ent application are the same as the installation, location and clearance requirements for the sidewall air inlet cap in the Hor i zon tal Direct V ent section of the venting instructions.
21 VERTICAL COMBUSTION AIR INLET FIG. 30 Air Inlet Cap for Rooftop T ermination The air inlet cap for the vertical roof top air inlet is assembled from com po nents purchased locally . The air inlet cap consist of two 90° elbows installed at the point of termination for the air inlet pipe.
22 CAUTION Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance. The flue and air inlet duct sizes for a Horizontal Intelli-V ent Installation with Sidewall Combustion Air Inlet are listed by unit size.
23 GAS SUPPL Y V erify that the appliance is supplied with the type gas specified on the rating plate. Consult factory for installations at altitude. INLET PRESSURE: Measur ed at the inlet pressur e tap on the appliance gas man i fold.
24 T ABLE - M Recommended Gas Pipe Size Single Appliance Installations Distance from Meter Btu/hr 1,500,000 2" 2 1/2" 2 1/2" 2 1/2" 2 1/2" 3" 3" 3" 3" 3" 3 1/2" 3 1/2" 3 1/2" 4" 1,700,000 2,000,000 0 - 50 ft.
25 GAS PIPING TRAP GAS INLET FIG. 34 Gas Line Connection to Unit with Sediment T rap and Manual Main Gas Shut-off V alve All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and nat u ral gas. All piping must comply with local codes and ordinances.
26 1. T urn the main power switch to “OFF” position. 2. Shut off gas supply at the manual gas cock in the as piping to the ap pli ance. If fuel supply is LP gas, shut off gas supply at the tank. 3. Remove the 1/8" hex plug from the gas pressure test port located on the inlet gas supply connection at the rear of the appliance.
27 supply pressure and adjust to ensure a supply pressure between 4.0 and 10.5 inches water col umn natural gas (13.0" w .c. for propane) while the appliance is firing at 100% of rated input. 7. This is a reference pressure only and is not field adjustable.
28 Inlet and Outlet Connections For ease of service, install unions on inlet and outlet of the appliance. The connection to the appliance marked “Inlet” on the header should be used for return from the system. The con nec tion on the header marked “Outlet” is to be connected to the supply side of the system.
29 INTEGRAL BYP ASS HOT WA T E R OUTLET SECONDARY HEA T EXCHANGER COLD WA T E R INLET PRIMARY HEA T EXCHANGER PUMP BYP ASS V AL VE FIG. 40 Bypass Piping with V alve Actuator and Pump temperature conformal coating to prevent any corrosive damage to the copper tubes or cast iron head ers from the low pH condensate.
30 BYP ASS PIPING ASSEMBL Y The primary and secondary heat ex chang ers are interconnected with a bypass and pump mounted in 2 1/2 inch (63.5 mm) diameter copper pipe. All access to the piping is from the rear of the appliance. On initial start up, all air must be removed from the bypass piping to ensure proper water flow through the appliance.
31 T ABLE - P T emperature Rise At Full Rate Fire Bypass Manually Fully Closed Btu/hr Input T emperature Rise 1,500,000 _______________________ 1,700,000 _______________________ 2,000,000 31.5°F (17.5°C) _______________________ 35.7°F (19.8°C) _______________________ 42.
32 T ABLE - Q Minimum Inlet W ater T emperatures Input Minimum Return Minimum Btu/hr T emperature Setpoint 1,500,000 ___________ 1,700,000 ___________ 2,000,000 105 ° F (40.
33 RELIEF V AL VE This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure V essel Code, Sec tion IV (“Heating Boilers”). The re lief valve(s) is installed in the ver ti cal position and mounted in the hot water outlet.
34 V enting of Gas V alves and Pressure Switches The diaphragm type gas valve and op tion al gas pressure switches are pro vid ed with threaded termination points to be vented to the atmosphere, outside the building. The gas pressure reg u la tion function is provided by the ratio gas valve which does not require in stal la tion of a vent line.
35 the inner jacket and secondary heat exchanger chamber are also stainless steel. The stainless steel screws are identified by a sealing washer mounted on each screw . DO NOT mix stainless steel and standard plated fasteners when disassembling and reassembling the inner jacket sheet metal components.
36 FIG. 48 T ransformer and Relay Locations V ARIABLE FREQUENCY DRIVE FIG. 49 Internal Control Panel Location FIG. 50 V ariable Frequency Drive A transformer and relay mounting panel is located above the front control panel, underneath the curved exterior front jacket panel.
37 blower from 25% up to 100% of capacity corresponding to the same variation in burner input. The output from the Excel 10 to the variable frequency drive ensures that combustion air and gas are always supplied in the proper ratio for clean combustion.
38 Excel 10 Boiler Interface Contr oller - The boiler interface control ler for this appliance is based on the Excel 10 controller platform with unique software customized for op er a tion of the Lochinvar Intelli-Fin . The Excel 10 is also compatible with LonW orks ® building management systems.
39 is unique to each Excel 10 and must be placed into the network of an energy management system so that the Excel 10 can be recognized by the system. NOTE: If the Excel 10 is ever replaced, a tear -off label on the new Excel 10 must be placed over this label on the back of the unit for easy ref er ence.
40 The Command Display provides a com mu ni ca tion interface with the Excel 10 via a series of display screens. The front view of the display screen shows the digital display with a cluster of arrow keys on the lower left side. These directional arrow keys move the cursor in the direction of the arrow .
41 NOTE: Allow 10 seconds for data shown in the display screens to update when viewing or making adjustments to any of the six adjustable points. POINTS FROM INFORMA TION VISIBLE FROM THE SCREEN OF THE COMMAND DISPLA Y 1.
42 FIG. 56a Command Display Data Screen FIG. 56b Command Display Data Screen FIG. 56c Command Display Data Screen FIG. 56d Command Display Data Screen FIG.
43 FIG. 56g Command Display Data Screen ST A TUS POINTS In the screen display for a specific boiler or water heater , there will be a Status indication. The status point details the operational mode of the appliance or in the event of a control sensed failure, a status point alarm.
44 Pressing the Back key will return you to the Heat Source display . The up and down arr ow keys can be used to scroll the cursor up and down to the various heat sources (boilers or water heaters) at this location. T o the right of each heat source displays the operational status of the in di vid u al appliance.
45 Setpoint T emp — This is the lowest boiler operating temperature that the boiler will maintain when the outside air temperature is at the O.A. Max.
46 INTERF ACING MUL TIPLE APPLIANCES P ARALLEL CONNECTION FIG. 59 E-Bus Connection to Controls Connection between multiple Intelli-Fin appliances is accomplished via an E-Bus connection. An E-Bus terminal is provid ed on the rear of each appliance. The minimum specification for the communication wire is for a Level IV , 22 A W G (0.
47 STRIP 1/2" FROM WIRE TO BE A TT ACHED. 1/2" (13MM) TWIST WIRES TOGETHER WITH PLIERS (MINIMUM OF THREE TURNS) INSERT TWISTED WIRES UNDER TERMINAL AND TIGHTEN. CHECK FOR A GOOD MECHANICAL CONNECTION. FIG. 60 W ire T ermination for E-Bus Connection 1 .
48 FIG. 61 T ypical Building Management System Diagram HIGH W A TER TEMPERA TURE LIMIT CONTROL FIG. 62 High W ater T emperature Contr ol A Manual Reset High Limit control is located on the left front side of the control panel, beside the Command Dis play .
49 HOT SURF ACE IGNITION SYSTEM IGNITION CONTROL MODULE DIAGNOSTIC ST A TUS CODES FIG. 63 Hot Surface Ignition Control Module FIG. 64 Hot Surface Igniter This appliance uses a proven hot sur face ignition control system.
50 Diagnostic Status Indication The ignition module has an LED that indicates the status of the ignition safety circuits. The flashing op er a tion of this LED indicates the di ag nos tic status of the ignition control module. The following listing gives the flashing diagnostic status codes as signaled by the ignition module.
51 OPERA TION/DIAGNOSTIC LIGHTS, RESETS AND SWITCHES ADJ HI-LIMIT CIRCUIT BREAKER ALARM RESET SOUND ALARM POWER SILENCE AUTO RESET TEST MANUAL LOW W A TER CUT -OFF ALARM BURNER FIG.
52 This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the primary heat exchanger . There is a unique burner for each one of the three models. Burners may NOT be changed between different Btu/hr input models.
53 FIL TER ACCESS PLA TE FIG. 70 Cleaning the Internal Combustion Air Blower Inlet Filter CONDENSA TE MANAGEMENT SYSTEM (Optional) FIG. 71 Location and Connection of Neutralization Reservoir This high efficiency appliance may operate as a condensing appliance for extended periods of time based on return water temperatures.
54 Many codes will require the acidic condensate to be neu tral ized before it can be placed in a drain system. The optional condensate management system consists of a neutralizer kit to control the pH of the liquid discharged to a drain system.
55 WARNING Use a level to ensure that the condensate trap is level on its base. Failure to keep the condensate trap level can result in the spillage of flue products from the condensate trap. Failure to follow this warning could result in product damage or improper operation, personal injury , or death.
56 LIGHTING INSTRUCTIONS 1. STOP! Read the safety information. 2. Set the T emperature Set Point func tion of the Command Display to the lowest setting. 3. Turn Of f all electrical power to the appliance. 4. This appliance is equipped with an ignition device, which automatically lights the burner .
57 SEQUENCE OF OPERA TION 1. The power switch is placed in the “ON” position and the run/stop switch is in the “RUN” position. 2. 120 V AC Power is supplied to the con trol junction box and to the integral pump. 3. 120 V AC Power is supplied to the con trol T ransformer , Ignition Module and Excel 10.
58 32. Rate of flue product movement is controlled by “V” Baffles on the heat exchanger to maximize heat transfer . 33. Heated products of combustion then pass over the Secondary Heat Exchanger to absorb additional heat. 34. Flue products pass into the flue collector and are exhausted from the unit.
59 NOTE: All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/sealant on reassembly . Gasket and sealant kits are available from your distributor .
60 NOTE: When the combustion air blower is removed for any reason, the inlet to the burner must be covered to prevent foreign objects from falling into the burner . A foreign object such as a nut, bolt, wire or other metallic items will cause a rapid non-warrantable failure of the burner on operation.
61 NOTE: All gaskets/sealant on disassembled components or jacket panels must be replaced with new gaskets/ sealant on reassembly . Gasket and sealant kits are available from your distributor . F . PRIMARY HEA T EXCHANGER INSPECTION 1. T urn off all power to the appliance.
62 9. Carefully reinstall the heat ex chang er if removed from the appliance. 10. Reinstall inner rear jacket panels, bypass piping and condensate hoses. Use new gasket material to ensure a proper air seal. 1 1. Reassemble all water piping. T est for leaks.
63 FREEZE PROTECTION CAUTION Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids. 4. As the appliance comes on and fires, record the inches of water column of displacement on both sides of the manometer .
64 (d) Drain the unit completely . Remove the caps from the two drains located on the rear of the appliance. Open the relief valve and manually open the bypass valve to allow air into the system so the water will drain out. Open the union fitting on the inlet so water can be drained from the secondary heat exchanger .
65 PIPING LENGTHS The boiler ’ s integral circulator pro vides the water flow from the primary boiler piping, through the boiler and back to the primary system. Pipe di am e ter and length are critical to ensure proper flow through the boiler . A 3 inch (76.
66 PRIMAR Y/SECONDAR Y BOILER PIPING TO EXP ANSION T ANK AND MAKEUP W A TER SYSTEM TO SYSTEM 12” MAX. FROM SYSTEM FIG. 80 Primary/Secondary Piping of a Single Boiler CAUTION At no time should the system pressure be less than 12 PSIG.
67 The automatic bypass system allows part of the boiler discharge water to be mixed with the inlet water to the pri ma ry heat exchanger to increase the boiler inlet temperature above 130°F (55°C). This will prevent the products of combustion from condensing on the primary heat exchanger .
68 TEMPERA TURE/PRESSURE GAUGE This boiler is equipped with a dial type temperature/pressure gauge. This gauge is factory installed in the out let side of the boiler bypass piping. The gauge has one scale to read system pressure and a separate scale to read water temperature in °F .
69 Boiler Operation 28. T urn the run/stop switch to the “RUN” position to start boiler operation. 29. Push the resets for low water lev el, high water temperature and flame failure. 30. Observe the boiler synchronization process before start-up of the boiler begins.
70 DOMESTIC HOT W A TER SUPPL Y BOILER This section applies only to those appliance used to supply domestic hot water , installed with a storage tank(s). The integral circulating pump installed in the bypass piping assembly is used to control water ve loc i ty through the appliance.
71 T ABLE - EE Maximum Flow Rate Btu/hr Input Maximum Flow 1,500,000 - 2,000,000 90 GPM If higher flow rates are required through the water heater , an optional Cupro-Nickel heat exchanger is avail able. Consult the factory for specific application requirements.
72 5. Be sure the pipes between the water heater or hot water supply boiler and storage tank are not less than 3 inch (76.2 mm) diameter for up to 70 equivalent feet (21.
73 PIPING - MUL TIPLE UNIT INST ALLA TIONS MIXING V ALVE BUILDING HOT W A TER SUPPLY RELIEF V ALVE TO DRAIN LOCK-TEMP STORAGE T ANK DRAIN BUILDING RETURN COLD WA TER SUPPL Y FIG. 84 Single W ater Heater Piping with T wo Storage T anks MIXING V AL VE BUILDING HOT W A TER SUPPL Y RELIEF V AL VE TO DRAIN DRAIN BUILDING RETURN MIN.
74 T ABLE - GG Common W ater Manifold Size For Multiple W ater Heater Hot W ater Supply Boiler Installations Btu/hr Input T emperature Rise Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow .
75 THERMOST A T SETTINGS 1. The Excel 10 temperature con trol ler is adjusted to a low test setting when shipped from the factory . 2. Using the Command Display , adjust the temperature set point to the lowest settings which will satisfy hot water demands and pr event a risk of scald injury .
76 NOTE: (1) This water heater , when set at the lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes.
77 Ladder Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models J 3 5 4 6 1 2 3 O . C . J1 J 2 3 2 1 J 4 P RES E T R E SE T C HA S S I S G R O UN D G N D P U G PU BL Y 24 V A C LW C O PRO B E T ~ ~ .
78 Wiring Diagram 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models 888 8 P R O G V OL T S A MP S HE RT Z RUN F W D RE V VFD ENAB LE J3 E G ND GN D A1 - 3 O H M G ND G N D 2 2V D C O U T E - BUS D I - 4.
79 Wiring Diagram (continued) 1,500,000 - 1,300,000 - 2,000,000 Btu/hr Models 50 Hz L i mi t Res i s to r 1. 2 K Oh m Y TO V F D TE R M I NAL NU M B E R 15 T O V FD TE R M I NAL NUMB E R 14 O P TI O NAL 50 H z LI M I T R ESI S TO R P O P T I O NAL WARNING : To avoi d possi ble shock haza rd , disconn ect pow er before ser vicing .
80 1/09-Printed in U.S.A. Revision Notes: Rev . 4 (IFB/IFW -i&s-04) r eflects additional text on Page 39, changes made to Figur es 47 & 48, T able AA (Page 51), and LBLs on Pages 77-79.
An important point after buying a device Lochinvar 000 (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 000 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 000 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar 000 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar 000 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar 000, 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 000.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar 000. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar 000 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
