Lochinvar COPPER-FIN 497 - 2067 User Manual

Installation & Service ManualModels: 497 - 2067Save this manual for future reference.CBX-CWX-I-S Rev AThis manual supplies information for the

101 Determine unit locationLocating the unit1. Maintain all clearances from combustible construction when locating unit. See Clearances from Combu

1 Determine unit location (continued)11TABLE 1ACOMBUSTIBLE FLOOR KITSModel Kit Number497 CFK3302647 CFK3303747 CFK3304 CAUTIONAlthough these units

121 Determine unit location TABLE 1BMINIMUM RECOMMENDED COMBUSTIONAIR SUPPLY TO EQUIPMENT ROOMModelNumber*Outside Air from 2 Openings Directly from

13Combustion air filterThis unit has a standard air filter located at the combustion air inlet. This filter helps ensure clean air is used for the com

141 Determine unit locationThis unit has four combustion air options. 1. Outside Combustion Air, No DuctsYou can direct outside combustion air to thi

1 Determine unit location (continued)153. Combustion Air from an Interior SpaceYou can direct combustion air to this unit using air from an adjoinin

General informationYou must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal fr

172 Venting (continued)Barometric damper locationAny venting system option that requires a barometric damper must adhere to the following directions

2 Venting 181. Conventional negative draft ventingNOTICEBefore installing a venting system, follow all venting clearances and requirements found in

192 Venting (continued)Common venting systems may be too large when an existing unit is removed. At the time of removal of an existing appliance, the

ContentsHazard definitionsThe following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk le

2 Venting 202. Outdoor installation ventingUnits are self-venting and can be used outdoors when installed with the optional outdoor caps. These caps

212 Venting (continued)The optional outdoor vent kit is available from the appliance manufacturer. The outdoor kit part numbers are listed by unit si

3 Gas connections 22Connecting to gas supplyVerify that the appliance is supplied with the type of gas specified on the rating plate. This appliance

233 Gas connections (continued)Gas connectionAll gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum

3 Gas connections24Combination gas valvesThese units fire in multiple stages of burner input. Each stage of burner operation has a combination gas v

NOTICEThe gas valves are referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressu

3 Gas connections2612. If adjustment is necessary, remove the regulator cover screw on the gas valve. Note: If the gas valve under adjustment is loc

274 Water connectionsInlet and outlet connectionsFor ease of service, install unions on the water inlet and water outlet of the unit. The connection

4 Water connections28Boiler circulator requirementsThis is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, effi

294 Water connections (continued)A buffer tank is an effective way to enhance a small system load and increase heating system efficiency (see FIG. 4-

Installation & Service Manual 33Please read before proceeding NOTICEThis is a gas appliance and should be installed by a lic

4 Water connections30Low temperature return water systemsAny non-condensing boiler and venting system will develop operational problems when exposed

TOFLOORDRAINHEATINGSUPPLYLOOPTO EXPANSIONTANK AND MAKEUPWATER SYSTEM HEATINGRETURNLOOP12"MAX314 Water connections (continued)Figure 4-5_Primary/

324 Water connections Installation & Service Manual Figure 4-6_Primary/secondary piping of multiple boilersSECONDARYBOILERPUM

33HEAEATITINGSUPPLYLYLOOPTOFLOORDRDRAINMIXINGVALVETO EXPANSIONTANK ANDND MAKEAKEUPWATER SYSTEMHEATITINGRETURURNLOOOOP12”12”MAXFigure 4-7_Boiler with l

341" TEMPERATUREAND PRESSUREGAUGEAUTOMATIC AIRELIMINATOR/VENTSYSTEMOUTLETSYSTEMSENSORLOCATIONSYSTEMINLETBUFFERTANKDRAINPUMPCOMMOM MANIFOLDMUST BE

354 Water connections (continued) Installation with a chilled water systemPipe refrigeration systems in parallel. Install duct coil downstream at co

364 Water connections The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended

375 Electrical connections Connecting to electrical supplyThis unit is wired for 120 VAC service. The unit, when installed, must be electrically grou

385 Electrical connectionsExternal EMS connection to terminal strip for stage firing control of burnersThis unit is equipped with a factory installed

395 Electrical connections (continued)Temperature adjustmentNote: The temperature controller is preset at the factory with test settings. You may nee

4Please read before proceedingCodes –The equipment shall be installed in accordance with those installation regulations in force in the local area whe

405 Electrical connectionsSetpointThe Set Point knob specifies the target water temperature in degrees, Fahrenheit. After the water temperature reach

415 Electrical connections (continued)Temperature control sensorsThis is a two-stage temperature control that controls the burner ignition, pump, and

425 Electrical connectionsRemote mounting of a sensorYou must mount the outside air temperature sensor outside the building. To mount remote sensors,

435 Electrical connections (continued)Diagnostic Status IndicationThe ignition module has an LED which indicates the status of the safety circuits. A

445 Electrical connectionsOperation and diagnostic lightsThe diagnostic control panel has up to 6 indicating and diagnostic lights to show all major

456 StartupFigure 6-1_Operating instructions Installation & Service Manual FOR YOUR SAFETY READ BEFORE OPERATINGA. This applia

466 StartupCheck/control water chemistryDo not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and

6 Startup (continued) Installation & Service Manual Check thermostat circuit(s)1. Disconnect the two external wires connected

487 Domestic water heaters This section applies only to those units used to supply potable hot water for domestic use. The water heater must be insta

497 Domestic water heaters (continued)OUTLETCOLDWATERSUPPLYBUILDINGHOT WATERSUPPLYRELIEFVALVELOCK-TEMPSTORAGETANKDRAINBUILDINGRETURNINLETRELIEFVALVEM

5The Copper-fin - How it works... 1. Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum hea

50OUTLETCOLDWATERSUPPLYBUILDINGHOT WATERSUPPLYRELIEFVALVELOCK-TEMPSTORAGETANKDRAINBUILDINGRETURNINLETMIXINGVALVEFigure 7-2_Single water heater piping

Installation & Service Manual 517 Domestic water heaters (continued)RELIEFVALVEBUILDINGHOTWATERSUPPLYCOLDWATERSUPPLYBUILDINGR

RELIEFVALVEBUILDINGHOTWATERSUPPLYCOLDWATERSUPPLYBUILDINGRETURNMIXINGVALVEDRAINMIN 4"COMMONMANIFOLDSIZELOCK-TEMPSTORAGETANKFigure 7-4_Multiple wat

7 Domestic water heaters (continued)TABLE 7CPipe Sizing Chart497 - 747 987 - 2067Number of UnitsCommon Pipe Size (Min.)Number of UnitsCommon Pipe Si

54Minimum pump performanceThis is based on heating potable water with a hardness of 5 to 25 grains per gallon and/or total dissolved solids not exceed

7 Domestic water heaters (continued)Storing the water at a higher temperature and thermostatically mixing the water increases the available quantity

567 Domestic water heatersHigh water temperature limit controlThe unit is equipped with an adjustable setting, auto-reset high water temperature limi

578 MaintenanceListed below are items that must be checked to ensure safe, reliable operations. Verify proper installation after servicing.Label all

588 MaintenanceHeat exchanger cleaning1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must

598 Maintenance (continued)AIR PRESSURE SWITCHFigure 8-2_Air pressure switchAdjustment procedure Models 497 - 1257:1. Remove the upper front jacket

6The Copper-fin - How it works... 2626171717171212Models 497 - 747 Front View Models 497 - 747 Left Side (inside unit) Models 497 - 747 Right Side (in

608 MaintenanceTRANSITION BOX SCREWSFigure 8-5_Loosening the transition box screws, Models 1437, 1797 and 2067 onlyINCREASE AIRPRESSUREDECREASEAIR PR

8 Maintenance (continued) 9. 24VAC is supplied to the intermittent alarm field safety contacts, B1 and B2.10. 24VAC is supplied to the water flow

629 Glossary Power Supply(AC120VAC/60Hz)120VAC/60Hz/1PH power connects to black (line) and white (neutral) wires located within an electrical wiring

639 Glossary (continued)Once the ignition module sees a 24VAC input from the pressure switch, it runs the blower for approximately 15 seconds in orde

6410 Diagrams Ladder diagram Installation & Service Manual

6510 Diagrams (continued)Ladder diagram (continued)0987-20670497-747 Installation & Service Manual

6610 Diagrams Connection diagram Installation & Service Manual

6710 Diagrams (continued)Connection diagram (continued) Installation & Service Manual

Revision Notes: Revision A (ECO #C07390) initial release.CBX-CWX-I-S Rev A3/11

7 Installation & Service ManualThe Copper-fin - How it works... (continued) Models 987 - 2067 Left Side (inside unit) Models 987 - 2067 Right

8Ratings Maximum allowed working pressure is located on the rating plate. NOTICECopper-finI=B=R RatingModel NumberNote: Change “N” to “L” for L.P. ga

9Ratings (continued) Notes:1. Copper-fins require special gas venting. Use only the vent materials and methods specified in the Installation and Ser