Lochinvar CB1256 Installation Manual

DESIGNER’S GUIDE COPPER-FIN®BOILER

495,000 – 2,065,000 Btu/hr

Dear Specifier/Project Manager,

At Lochinvar, we have long recognized the importance of innovation to any product or service. Those who enter into business must also accept the challenge of meeting constantly changing needs.

The designer’s guide you are now holding has been designed to make it more convenient for you to select the perfect Lochinvar boiler for your projects and provide correct specifications for your teams.

All information has been organized and presented in a succinct, easy-to-use manner, so you can use and share information confidently and with minimal effort.

However, it is important to remember that this guide is not intended to replace our installation manual. Installers should still refer to our installation manual for specific installation instructions.

We hope this manual will make your work easier and more productive. As always, we greatly appreciate your input on additional improvements for the future.

Thanks once again for specifying the Lochinvar family of quality standard and custom-built boilers and boilers.

Sincerely,

Lochinvar Corporation

Nashville, TN • 615-889-8900 • Fax: 615-547-1000

Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 1

Table of Contents

Air Removal . . . . . . . . . . . . . . . . . . . . . .16

Boiler Operating Temperature Control . . . .16

Circulator Pump Operation . . . . . . . . . . .12

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Combustion & Ventilation Air . . . . . . . . . . .5

Contaminants . . . . . . . . . . . . . . . . . . . . . .6

Determining Total “Free Area” . . . . . . . . . .7

Electrical Requirements . . . . . . . . . . . . . . .17

Gas Supply . . . . . . . . . . . . . . . . . . . . . .10

General Venting . . . . . . . . . . . . . . . . . . . .6

Location of Unit . . . . . . . . . . . . . . . . . . . . .2

Low System Water Volume . . . . . . . . . . . .16

Low Water Temperature System . . . . . . . .14

Outdoor Use . . . . . . . . . . . . . . . . . . . . . . .3

Outdoor Installation . . . . . . . . . . . . . . . . . .9

Primary/Secondary Piping . . . . . . . . . . . .13

Relief Valve . . . . . . . . . . . . . . . . . . . . . . .14

Remote Temperature Control . . . . . . . . . . .17

Special Design Applications . . . . . . . . . . .15

Variable Speed Pumping . . . . . . . . . . . . .16

Venting Options . . . . . . . . . . . . . . . . . . . .8

Water Flow Requirements . . . . . . . . . . . .12

Water Velocity Control . . . . . . . . . . . . . . .12

Figures & Tables Index

FIG. 1 Models CB 495-2066

Requirements For Installation

Over Combustible Floor . . . . . . .3

FIG. 2 Boiler Equipment &

Control Orientation . . . . . . . . . . .4

FIG. 3-6 Combustion & Ventilation Air . .5, 6 FIG. 7 Barometric Damper Installation . .8

FIG. 8 Multiple Unit Barometric

Damper Installation . . . . . . . . . . .9

FIG. 9 Outdoor Venting . . . . . . . . . . . . .9

FIG. 10 Heat Exchanger Head Loss

Models CB 495-745 . . . . . . . . .9

FIG. 11 Heat Exchanger Head Loss

Models CB 986-2066 . . . . . . . .9

FIG. 12 Primary/Secondary

System Piping . . . . . . . . . . . . . .13

FIG. 13 High Flow System Piping . . . . . .14

FIG. 14 Low Temperature Bypass

System Piping . . . . . . . . . . . . . .15

FIG. 15 Low Temperature Bypass Piping

On/Off . . . . . . . . . . . . . . . . . .15

FIG. 16 Low Temperature Bypass Piping

Stage Firing . . . . . . . . . . . . . . .15

FIG. 17 Heating/Chilled

Water System . . . . . . . . . . . . . .16

FIG. 18 Buffer Tank Piping . . . . . . . . . . .17

TABLE A. Clearances From

Combustibles . . . . . . . . . . . . . .3

TABLE B. Flue Sizes and

Combustion Air Pipe Sizes . . . . .8

TABLE C. Outdoor Kits . . . . . . . . . . . . . .10

TABLE D. Gas Supply Pipe Sizing . . . . . .11

TABLE E. Inlet Gas Pressure . . . . . . . . . .11

TABLE F. Water Flow Requirements . . . . .12

TABLE G. Minimum and Maximum

Boiler Flow Rates . . . . . . . . . . .12

TABLE H. Amp Draw Data . . . . . . . . . . . .17

Boiler Piping Diagrams

Primary/Secondary Boiler Piping . . . . . . .A1

Multiple Unit Primary/Secondary Piping . .A2 Low Temperature Boiler Bypass Piping . . .A3 Low Temperature Boiler Bypass Piping

with 3-way Valve . . . . . . . . . . . . . . . .A4

CODES

The equipment shall be installed in accordance with those installation regulations in effect 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 made.

In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1. Where required by the authority having jurisdiction, the installation must conform to

American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-1.

Where required by the authority having jurisdiction, the installation must comply with the Canadian Association Code, CAN/CGA- B149.1 and/or B149.2 and/or local codes.

LOCATION OF UNIT

Locate the unit so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the unit. The pan must not restrict combustion air flow.

2 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900

Lochinvar

Water Velocity

(See page 12 for Minimum

and Maximum Flow Rates.)

Piping Requirements

and Specialities

(See page 12 for

Water Flow Requirements

and system piping.)

Low Water Temperature

System

(See page 14 & 15 for

piping and design

recommendations.)

System and Boiler Control

(See page 16 for Control

Connections and

Operator Settings.)

Air Elimination and

Expansion Tank Placement

(See page 16 for Air

Removal Information.)

In designing a boiler system,

pay special attention to:

Under no circumstances is the manufacturer to be held responsible for water damage in connection with this unit or any of its components.

The indoor units must be installed so that the ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.).

The appliance must be installed on a level, non-combustible floor. Concrete over wood is not considered a non-combustible floor. Maintain required clearances from combustible surfaces.

For installation on a combustible floor only when installed on special base: Units installed over a

combustible floor must use the Special Combustible Floor Base. The unit must be centered on the base as shown in FIG. 1.

• Provide a base of hollow clay tile or concrete blocks from 8 to 12 inches thick and extending 24 inches beyond the sides.

• The blocks must be placed in line so that the holes line up horizontally to provide a clear passage through the blocks.

• This procedure should also be

followed if electrical conduit or radiant heat distribution piping runs through the floor and beneath the appliance.

• Ensure that combustible floor base meets local fire code requirements.

Outdoor models require the installation of an optional vent cap. Instructions for placement of the vent cap are included in the venting section.

Outdoor models must not be installed directly on the ground. The outdoor unit must be installed on a concrete brick, block or other non-combustible pad.

SPECIAL LOCATION: OUTDOOR USE

Outdoor models have additional location and clearance requirements. These requirements must be adhered to carefully, since wind, rain, snow and cold cannot be controlled in outdoor applications. See

Outdoor Installation on page 9.

Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 3

(FIG. 1) CB 495-2066 REQUIREMENTS FOR INSTALLATION OVER COMBUSTIBLE FLOOR

(TABLE A) – CLEARANCES FROM

COMBUSTIBLE CONSTRUCTION

CLEARANCES CB 495-2066 Right Side 3" Rear 3" Left Side 3"

(30" for Service)

Front ALCOVE*

(24" for Service) Top 3" Flue 1"+

* Alcove is a closet without a door. + Consult local codes and/or vent material manufacturer.

4 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900

Lochinvar

(FIG. 2) BOILER EQUIPMENT AND CONTROL ORIENTATION.

RIGHT SIDE

FLUE PRODUCTS VENT

TERMINAL

STRIP

HOT WATER

OUTLET

COLD WATER

INLET

BURNER INSPECTION PORT

FRONT

GAS

CONNECTION

HOT WATER

OUTLET

COLD WATER

INLET

BURNER

INSPECTION PORT

FRONT

AIR

INLET

FRESH AIR

INLET

RIGHT SIDE

FLUE PRODUCTS VENT

BACK

DRAIN

LEFT SIDE

BACK

120V ELECTRICAL

CONNECTION

ON/OFF SWITCH

OPERATOR

TERMINAL STRIP

ON/OFF SWITCH

LEFT SIDE

DRAIN

RELIEF VALVE

TAPPING

INLET GAS

CONNECTION

CB 495-745

CB 986-2066

Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 5

COMBUSTION & VENTILATION AIR

Provisions for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada, the latest edition of CGA Standard B149 Installation

Code for Gas Burning Appliances and Equipment; or applicable provisions of the

local building codes.

The equipment room must be provided with properly sized openings to assure adequate combustion air and proper ventilation when the unit is installed with conventional venting or sidewall venting.

If air is taken directly from outside the building with no duct, provide two

permanent openings:

A. Combustion air opening with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm

per kW). This

opening must be located within 12 inches (30 cm) of the bottom of the enclosure.

B. Ventilation air opening with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm

per kW). This

opening must be located within 12 inches (30 cm) of the top of the enclosure.

If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two

openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr input (11 cm

per kW).

If air is taken from another interior space, each of the two openings

specified above should have a net free

(FIG. 3) COMBUSTION AIR DIRECT FROM OUTSIDE

(FIG. 4) COMBUSTION AIR THROUGH DUCTWORK

(FIG. 5) COMBUSTION AIR FROM AN

INTERIOR SPACE

CAUTION: Under no circumstances should the equipment room be under a negative pressure when atmospheric combustion equipment is installed in the room.

EXAMPLE OF

SIZING FOR

COMBUSTION

& VENTILATION

AIR OPENINGS

(BOILER WITH

2,065,000 Btu/hr

INPUT):

When combustion and

ventilated air is taken

from directly outside the

building (FIG. 4), divide

the total BTU’s by 4,000.

This yields 516.25 sq.in.

of “Free Area” without

restriction.

(2,065,000 ÷ 4000 =

516.25 sq.in.)

Since the air opening is

50% closed due to

screens and louvers, the

total opening must be

multiplied by 2.

(516.25 sq. in. x 2 =

1,032 sq.in.)

This project requires one

Ventilation Air Opening

with net “Area” of

1,032 square inches with

louver dimensions of 30”

x 35” and one

Combustion Air Opening

with net “Area” of

1,032 square inches with

louver dimensions

of 30” x 35”.

6 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900

area of one square inch for each 1000 Btu/hr (22 cm

per kW) of input, but not

less than 100 square inches (645 cm

If a single combustion air opening is provided to bring combustion air in directly from the outdoors,

the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr input (7 cm

per kW).

This opening must be located within 12 inches (30 cm) of the top of the enclosure.

CONTAMINANTS

Combustion air drawn from an interior or exterior space must be free of any chemical fumes which could be corrosive to the boiler. Burning chemical fumes results in the formation of corrosive acids which attack the boiler, cause improper combustion and premature failure of the boiler and vent. These fumes are often present in areas where refrigerants, salts, and solvents are used. Therefore, be aware of swimming pool equipment, water softening, and cooling system placement.

VENTING

General

These boilers are classified as Category I appliances when tested to the latest ANSI Standard. This classification requires all conventionally vented combustion products to be vented using Category I listed vent pipe.

Additionally, it is recommended that this vent material be double wall construction or insulated in the field. A Category I appliance operates with a non-positive static vent pressure and with flue loss greater than 17 percent.

Vent installations for connection to gas vents or chimneys must be in accordance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of the local building codes.

The connection from the appliance vent to the stack must be as direct as possible and sized correctly. The horizontal breeching of a vent must have at least 1/4” rise per linear foot. The horizontal portions should also be supported for the design and weight of the material employed to maintain clearances, prevent physical damage and separation of joints.

The connection from the appliance vent to the stack or vent termination outside the building must be made with listed

Lochinvar

(FIG. 6) COMBUSTION AIR FROM OUTSIDE,

SINGLE OPENING

CAUTION!

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a down draft in the venting system. If a fan is used to supply combustion air to the equipment room, it must by sized such to make sure that it does not cause drafts which could lead to nuisance operational problems with the boiler.

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