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Lochinvar 402 - 2072 - page 1
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. Perform steps in the order given. Failure to comply c ...
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Lochinvar 402 - 2072 - page 2
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. DANGER WARNING CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which, if not avoided, will ...
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Lochinvar 402 - 2072 - page 3
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. WARNING If the information in these instructions is not followed exa ...
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Lochinvar 402 - 2072 - page 4
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. Authorities having jurisdiction shall be consulted before installations are ...
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Lochinvar 402 - 2072 - page 5
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. 2. Heat exchanger access cover The heat e ...
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Lochinvar 402 - 2072 - page 6
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 (inside unit) Models 402 - 752 Rear View 15 15 23 23 26 26 4 25 25 24 24 16 16 14 14 3 17 17 10 10 19 19 21 21 2 7 12 12 8 6 22 22 11 11 20 20 1 9 ...
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Lochinvar 402 - 2072 - page 7
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 Models 992 - 2072 Front View 18 18 13 13 27 27 18 18 15 15 26 26 23 23 8 3 4 2 21 21 19 19 10 10 24 24 16 16 25 25 17 17 14 14 6 22 22 7 9 1 20 20 12 1 ...
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Lochinvar 402 - 2072 - page 8
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. Ratings are base ...
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Lochinvar 402 - 2072 - page 9
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 Z21.13/CSA ...
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Lochinvar 402 - 2072 - page 10
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). 3. Combusti ...
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Lochinvar 402 - 2072 - page 11
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. See the information under Direct Venting starting on page 26 for specific information regard ...
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Lochinvar 402 - 2072 - page 12
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. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that mu ...
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Lochinvar 402 - 2072 - page 13
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. C(F,H) (N,L)0402 C(F,H) (N,L)0502 C(F,H) (N,L)0652 C(F,H) (N,L ...
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Lochinvar 402 - 2072 - page 14
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. This option uses a powered vent assembly to exhaust the flue products out a sidewall with air supplied by a pipe fr ...
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Lochinvar 402 - 2072 - page 15
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" 502 6" 6" 1262 12" 12" 652 8" 8" 1442 12" 12" 752 8" 8" 1802 14" 12" -- -- -- 2072 ...
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Lochinvar 402 - 2072 - page 16
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. The flue outlet t ...
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Lochinvar 402 - 2072 - page 17
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. Do not operate a summer exhaust fan. 5. Close fireplace dampers. 6. Place in operation th ...
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Lochinvar 402 - 2072 - page 18
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. or More From Ridge Figure 2-4_ Vent Termination from ...
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Lochinvar 402 - 2072 - page 19
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. In most installations, the combustion air inlet pipe will be a dedicated system with ...
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Lochinvar 402 - 2072 - page 20
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. Clearan ...
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Lochinvar 402 - 2072 - page 21
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 VDK3027 992 SVK3040 VDK3023 1262 SVK3041 VDK3024 1442 SVK3041 VDK3024 1802 SVK3041 VDK3024 2072 SVK3041 VDK3024 *The SVK kits include a DV box adapter and ...
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Lochinvar 402 - 2072 - page 22
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. This fan generates a negative draft at the unit. Combustion air is drawn ...
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Lochinvar 402 - 2072 - page 23
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). The following is a detailed explanation of Sidewall Vent ...
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Lochinvar 402 - 2072 - page 24
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. Make the connections ...
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Lochinvar 402 - 2072 - page 25
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. Follow all requirements in Sidewall Venting section on page ...
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Lochinvar 402 - 2072 - page 26
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. The flue outlet and combustion air intake may terminate at either a sidewall or the rooftop. T ...
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Lochinvar 402 - 2072 - page 27
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. Sealed, corrosion-resistant liner systems (single-wall, double-wall, flexi ...
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Lochinvar 402 - 2072 - page 28
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. Subtract 2.5 feet (0.7m) of equivalent length for each 45° elbow. Do not exceed the lim ...
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Lochinvar 402 - 2072 - page 29
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. ...
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Lochinvar 402 - 2072 - page 30
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. This cap mounts directly to the t op of the unit and covers the fl ...
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Lochinvar 402 - 2072 - page 31
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. Inlet gas pressure: Measured at the inlet pres ...
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Lochinvar 402 - 2072 - page 32
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. Internal diameter of flexible lines may not provide unit with proper v ...
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Lochinvar 402 - 2072 - page 33
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. 14. Turn on gas supply at the manual valve, turn on L.P. gas at the tank ...
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Lochinvar 402 - 2072 - page 34
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. A series of “V” shaped baffles are installed between the indiv ...
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Lochinvar 402 - 2072 - page 35
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. No valve is to be placed between the relief valve and the u ...
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Lochinvar 402 - 2072 - page 36
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. The boiler is recommended for installation in a primary/ secondar ...
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Lochinvar 402 - 2072 - page 37
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. Operation ...
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Lochinvar 402 - 2072 - page 38
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. The bypass will help to ensure that the boiler can be supp ...
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Lochinvar 402 - 2072 - page 39
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.) Models: 992, 1262, 1442, 1802 & 2072 Number of Units GPM Diameter (in.) 1 90 2 1/2 ...
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Lochinvar 402 - 2072 - page 40
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.) Models: 992, 1262, 1442, 1802 & 2072 Number of U ...
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Lochinvar 402 - 2072 - page 41
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.) Models: 402, 502, 652, & 752 Number of Units GP ...
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Lochinvar 402 - 2072 - page 42
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 SYSTEM SENSOR LOCATION SYSTEM INLET BUFFER TANK DRAIN PUM P COMMOM MANIF OLD MUST BE SIZ ED TO ACCOM ODATE COMBIN ED FLOW RATE FOR ALL BOILERS NOTICE T ...
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Lochinvar 402 - 2072 - page 43
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. Access to adjust the temperature set point and other user adjustable points is made through the Op ...
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Lochinvar 402 - 2072 - page 44
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. 5-1). 3. To activate a system pump, ...
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Lochinvar 402 - 2072 - page 45
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. Louver proving switch The operation of a louver proving switch needs to be verified be ...
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Lochinvar 402 - 2072 - page 46
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 PROVING S W CONTACTS S1 AQUAS TAT TAN K TAN K SENSOR SHIELD A B SHIELD + 0-10V - BMS IN + 0-10V - RATE OUT SHIELD A B SHIELD 35 34 33 32 31 30 29 28 27 2 ...
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Lochinvar 402 - 2072 - page 47
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. Hardness less than 7 grains 1. Consult local water treatment companies for hard wate ...
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Lochinvar 402 - 2072 - page 48
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. 2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading acros ...
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Lochinvar 402 - 2072 - page 49
49 Installation & Operation Manual 6 Start-up (continued) FOR YOUR SAFETY READ BEFORE OPERAT ING 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. Be sure to smell next to the floor because some ...
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Lochinvar 402 - 2072 - page 50
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). If the system pump ...
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Lochinvar 402 - 2072 - page 51
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. The blower provides both primary and secondar ...
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Lochinvar 402 - 2072 - page 52
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.e., space heating or domestic hot water), the heating load, ramp delay (if en ...
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Lochinvar 402 - 2072 - page 53
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. One timer monitors the time ...
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Lochinvar 402 - 2072 - page 54
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. At this point, the Lea ...
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Lochinvar 402 - 2072 - page 55
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). The flow sw ...
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Lochinvar 402 - 2072 - page 56
Installation & Operation Manual Copper-fin II control module MENU/E XIT DISPLAY SCREEN ENT ER/RES ET 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 select a menu item • Press after parameter programming to store parameter data • Press to exit Service Mode • Hold 5 seconds to enter code Input Mode ...
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Lochinvar 402 - 2072 - page 57
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. By entering the USER code (0704), the user can also change t ...
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Lochinvar 402 - 2072 - page 58
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. The following is a description of the individual items and what the y can displ ...
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Lochinvar 402 - 2072 - page 59
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. The following is a description of the individual items a ...
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Lochinvar 402 - 2072 - page 60
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. The following is a description of the individual items and what the ...
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Lochinvar 402 - 2072 - page 61
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. Each screen will contain two viewable it ...
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Lochinvar 402 - 2072 - page 62
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. Proper water velocity is i ...
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Lochinvar 402 - 2072 - page 63
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. Temperature rise can be increased by slowly closing the field-installed ball valve in the outlet piping from the water heater to the storage tank to achieve the proper temperature rise ...
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Lochinvar 402 - 2072 - page 64
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.) Models: 992, 1262, 1442, 1802 & 2072 Number of Units GPM Diameter (in.) 1 90 2 1/2 OUTLET COL ...
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Lochinvar 402 - 2072 - page 65
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.) Models: 402, 502, 652, & 752 Number of Units GP ...
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Lochinvar 402 - 2072 - page 66
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.) Models: 402, 502, 652, & 752 Nu ...
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Lochinvar 402 - 2072 - page 67
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.) Models: 402, 502, 652 ...
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Lochinvar 402 - 2072 - page 68
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. 2. The pump is sized to the heater input and water chemistry specifications noted in the Water Chemistry section on page 6 ...
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Lochinvar 402 - 2072 - page 69
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. When pressing the UP or DOWN key to ...
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Lochinvar 402 - 2072 - page 70
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. The cold water supp ...
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Lochinvar 402 - 2072 - page 71
Installation & Operation Manual 71 Maintenance and annual startup Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water, gas, flue, condensate) • Examine venting system • Check system water pressure/system piping/ex ...
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Lochinvar 402 - 2072 - page 72
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. Failure to follow the directions in this manual and component literature could res ...
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Lochinvar 402 - 2072 - page 73
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. Read Section 4 - Water Connections of the Copper-fin II Installation and Operation Manual before procee ...
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Lochinvar 402 - 2072 - page 74
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. Start appliance and perform checks and tests specified in Section 7 - Start-up ...
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Lochinvar 402 - 2072 - page 75
Installation & Operation Manual 75 Inspect and clean the heat exchanger 1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. 2. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning, p ...
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Lochinvar 402 - 2072 - page 76
Installation & Operation Manual 10 Connection diagram + + + + + + + + OU T D OOR SEN SO R SYS R ET U R N SEN SOR SYS SU P PL Y SEN SO R 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 I ED W IRING + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + ALARM CO NTACTS OPEN CLO SE COM RUNTI ME CON TACTS 3- W AY VA L V ...
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Lochinvar 402 - 2072 - page 77
Installation & Operation Manual 10 Connection diagram (continued) NOT E: N UM BE R OF G A S VAL VES VARIE S BY MO DEL GR O U N D X11 X4 X9 X5 X6 X7 X8 X13 F2 F4 MAIN U NIT 1 18 2 3 5 6 20 19 17 16 12 7 15 14 Y T W GY BL Y/G BR /W BL BK /R R/ B K BL/ BK BR BK 1 R/ B K 4 8 O/R PR 1 12 2 3 4 5 6 10 11 13 14 12 7 15 16 BL Y R W/B K O/ B K T R GY O/ ...
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Lochinvar 402 - 2072 - page 78
Installation & Operation Manual 78 11 Ladder diagram BLOWER N ON/OFF SWITC H F2 3.15A BOX DEPI CTS OPTI ON AL I TE MS 120 VAC LOW VOL TAGE TERMINAL STRIP BLOW ER RELA Y HI/LO SPEED RELA Y HI/LO SPEED RELA Y HIG H SPEED LOW SPEED G L N UNIT PUM P RELA Y X1 -6 F4 5A BLOWER RELAY X1-8 X1-8 X1 -8 HI/LO SPEED RELAY X2-4 X1-2 UNIT PUMP RE LA Y X1-1 X ...
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Lochinvar 402 - 2072 - page 79
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 ECTI ON BOARD 1 X6-7 CN5-1 RUNTIM E CON TAC TS X6-16 CN5-7 X6-2 CN5-8 X13-1 CN5-9 X6-6 CN5-3 X6-15 CN5-10 X6-11 CN5-12 X6-14 CN5-4 X8-5 CN6-4 X6-10 X8-15 CN6-9 X7-8 CN6-5 X7-4 CN6-10 X8-7 CN6-7 X8-17 CN6-3 X8-6 CN ...
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Lochinvar 402 - 2072 - page 80
Revision Notes: Revision A (ECO #C08226) initial release. CFX-CHX-I-O Rev A 6/11 ...
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