Page 1
DESIGNER’S GUIDE COPPER-FIN®BOILER
495,000 – 2,065,000 Btu/hr
Page 2
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
Page 3
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
Page 4
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
1.
Lochinvar
o
Water Velocity
(See page 12 for Minimum
and Maximum Flow Rates.)
o
Piping Requirements
and Specialities
(See page 12 for
Water Flow Requirements
and system piping.)
o
Low Water Temperature
System
(See page 14 & 15 for
piping and design
recommendations.)
o
System and Boiler Control
(See page 16 for Control
Connections and
Operator Settings.)
o
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.
Page 5
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.
2.
4.
3.
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 3
(FIG. 1) CB 495-2066 REQUIREMENTS FOR
INSTALLATION OVER COMBUSTIBLE FLOOR
5.
(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.
Page 6
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
Page 7
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
2
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
2
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
2
per kW).
If air is taken from another interior
space, each of the two openings
specified above should have a net free
1.
2.
3.
(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”.
Page 8
6 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900
area of one square inch for each 1000
Btu/hr (22 cm
2
per kW) of input, but not
less than 100 square inches (645 cm
2
).
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
2
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
4.
(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.
Page 9
Category I double wall vent (or equivalent)
connectors and sized according to vent
sizing tables (FAN column) in the latest
edition of the National Fuel Gas Code.
The Category I vent and accessories, such as
firestop spacers, thimbles, caps, etc., must
be installed in accordance with the vent
manufacturer’s listing. The vent connector and
firestop must provide correct spacing to
combustible surfaces and seal to the vent
connector on the upper and lower sides of
each floor or ceiling through which the vent
connector passes.
Any improper operation of the common
venting system in an existing building should
be corrected when new equipment is
installed, so the installation conforms to the
latest edition of the National Fuel Gas Code,
ANSI Z223.1.
When resizing any portion of the common
venting system, it should be resized to
approach the minimum size as determined
using the appropriate tables in the National
Fuel Gas Code.
The weight of the venting system must not
rest on the boiler. The venting system must
be adequately supported in compliance with
local codes and other applicable codes.
Vent Terminations
The vent terminal should be vertical and
exhaust outside the building at least 2 feet
(0.6 m) above the highest point of the roof
when within a 10 foot (3.05 m) radius.
Additionally, vertical terminations must be a
minimum of 3 feet (0.9 m) above the roof
line, and when less than 10 feet (3.05 m)
from a parapet wall must be a minimum of
2 feet (0.61 m) higher than the parapet wall.
Vent caps should have a minimum clearance
of 4 feet (1.2 m) horizontally from, and in no
case above or below [unless a 4 feet (1.2 m)
horizontal distance is maintained], electric
meters, gas meters, regulators and relief
equipment.
Maintain a distance of at least 3 feet
(0.9 m) above any forced air inlet within
10 feet (3.05 m) and a distance of at
least 4 feet (1.2 m) below, 4 feet (1.2 m)
horizontally from, or 1 foot (30 cm) above
any door, window or gravity air inlet.
Do not terminate the vent in a window well,
stairwell, alcove, courtyard or other recessed
area. The vent can not terminate
below grade. The bottom of the vent
terminal shall be located at least 12 inches
(30 cm) above grade and clear of snow,
ice, leaves or other debris.
The distance of the vent terminal from
adjacent public walkways, adjacent
buildings, windows, and building openings
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 7
Page 10
8 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900
must be consistent with the National Fuel
Gas Code Z223.1 or in Canada, the latest
edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment.
VENTING OPTIONS
Conventional Venting
A conventional venting system utilizes
the natural buoyancy of the heated flue
products to generate a negative draft. This
draft forces flue products to rise vertically
through a rooftop flue termination. The vent
connection is made directly to the top of the
unit and combustion air supplied from the
mechanical room. Properly sizing vent
material and the use of a barometric
damper (when required) will lead to proper
vent operation.
The minimum flue pipe diameters for all
models, utilizing negative draft venting
are as follows:
Size vent material using the “FAN” category
of vent sizing tables in the latest edition of
the National Fuel Gas Code. “FAN” applies
to fan-assisted combustion appliances in
Category I.
Barometric Dampers
A barometric damper is required when draft
exceeds 0.08 inches of negative water
column. When installed and adjusted
properly, a barometric damper will maintain
draft between 0.02 and 0.08 inches of
negative water column ensuring proper
operation.
Multiple unit installations with combined
venting also require barometric dampers to
regulate draft at each unit. Again, the
negative draft must be within the range of
0.02 to 0.08 inches of negative water
column to ensure proper operation.
Lochinvar
NOTE:
Flue gases will form a
white plume in winter.
Plume could obstruct
window view. Flue gas
condensate can freeze
on exterior surfaces or
on the vent cap. Flue
gas condensate can
cause discoloration of
exterior building
surfaces. Adjacent brick
or masonry surfaces
should be protected with
a rust resistant sheet
metal plate.
(FIG. 7) BAROMETRIC DAMPER INSTALLATION
(TABLE B)
FLUE SIZES AND COMBUSTION AIR PIPE SIZES
MODEL FLUE SIZE
NUMBER
CB495 6"
CB645 8"
CB745 8"
CB986 10"
CB1256 12"
CB1436 12"
CB1796 14"
CB2066 14"
Page 11
For this type of installation, it is best to use a
draft control for each boiler located on the
riser between the vent outlet and the
breeching - Location “A”. When this riser is
too short to permit the installation of a draft
control, locate a separate control for each
boiler on the main breeching as illustrated in
Location “B”. If, because of general
crowding or other reasons, neither of these
locations are possible, use a single large
control in the breeching between the boiler
nearest the chimney and the chimney, as
shown in Location “C”.
All draft readings are made while unit is in
stable operation (approximately 5 minutes
running time).
Masonry Chimney
A masonry chimney must be properly sized
for the installation of a high efficiency gas
fired appliance. Exterior masonry chimneys,
with one or more sides exposed to cold
outdoor temperatures, are more likely to
have venting problems. The temperature of
the flue products from a high efficiency
appliance may not be able to sufficiently
heat the masonry structure of the chimney to
generate proper draft. This will result in
condensing of flue products, damage of the
masonry flue/tile, insufficient draft and
possible spillage of flue products into an
occupied living space.
Carefully inspect all chimney systems during
the project design phase. If there is any doubt
about the sizing or condition of a masonry
chimney, it is prudent to reline the chimney
with a properly sized and approved chimney
liner system. Metallic liner systems (Type “B”
doublewall or flexible or rigid metallic liners)
are recommended. Consult with local code
officials to determine code requirements or the
advisability of using or relining a masonry
chimney.
OUTDOOR INSTALLATION
Units are self venting and can be used
outdoors when installed with the optional
Outdoor Cap. This cap mounts directly to
the top of the boiler and covers the flue
outlet and combustion air inlet openings on
the jacket. No additional vent piping is
required. Maintain a minimum clearance of
3 inches (76 mm) to combustible surfaces
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 9
NOTE:
Common venting
systems may be too
large when an existing
unit is removed. Be
careful to resize any
common venting system
when new appliances
are installed or existing
appliances are replaced.
(FIG. 8) MULTIPLE UNIT BAROMETRIC
DAMPER INSTALLATION
(FIG. 9) OUTDOOR VENTING
NOTE:
Venting of a high
efficiency appliance into
a cold or oversized
masonry chimney can
result in operational and
safety problems.
Page 12
10 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900
and a minimum of 3 inches (76 mm)
clearance to the air inlet.
An outdoor unit should not be located so
that high winds can deflect off of adjacent
walls, buildings or shrubbery causing
recirculation. Recirculation of flue products
may cause operational problems, bad
combustion or damage to controls. The unit
should be located at least 3 feet (0.91m)
from any wall or vertical surface to prevent
adverse wind conditions from affecting
performance.
Multiple unit outdoor installations require 48
inches (1.22 m) clearance between each
vent cap. The outdoor cap must be located
4 feet (1.22 m) below and 4 feet (1.22 m)
horizontally from any window, door,
walkway or gravity air intake.
The combustion air inlet of the outdoor cap
must be located at least one foot (0.30 m)
above grade and above normal snow
levels. The boiler must be at least 10 feet
(3.05 m) away from any forced air inlet
and at least 3 feet (0.91 m) outside any
overhang.
Do not install in locations where rain from
building runoff drains will spill onto the boiler.
Lochinvar must furnish an outdoor vent kit
in accordance with CSA international
requirements. Each kit includes the flue
outlet/combustion air inlet, assembly,
gasket and pump cover.
Freeze ProtectionOutdoor Installation
A snow screen should be installed to prevent
snow and ice accumulation around the
appliance or its venting system.
If for any reason the unit is to be shut off:
(a.) Shut off water supply.
(b.) Drain unit completely.
(c.) Drain pump and piping.
If freeze protection is not provided for the
system, a low ambient temperature alarm or
automatic drain system is recommended.
GAS SUPPLY
Safe operation of unit requires properly
sized gas supply piping (See TABLE D).
Gas pipe size may be larger than the
heater connection.
A gas pressure regulator is suggested to
help assure proper inlet gas pressure. If
upstream pressure exceeds 6 oz. (10.5
inches of water column), an intermediate
gas pressure regulator, of the lockup type,
must be installed.
Installation of a union is suggested for
ease of service.
Lochinvar
(TABLE C) - OUTDOOR VENT KIT PART NUMBERS
MODEL
NUMBER PART NUMBER
CB495 ODK3023
CB645 ODK3024
CB745 ODK3024
CB986 ODK3046
CB1256 ODK3047
CB1436 ODK3047
CB1796 ODK3048
CB2066 ODK3048
1.
2.
3.
4.
Page 13
Install a manual main gas shut-off valve
with test plug, outside of the appliance
gas connection and before the gas valve,
when local codes require.
A trap (drip leg) should be provided in
the inlet of the gas connection to the unit.
High Altitude Applications
Atmospheric pressure decreases as the
height above sea level increases. At any
altitude above sea level, a cubic foot will
contain less gas than a cubic foot at sea
level. Thus, the heating value of a cubic foot
of fuel gas will decrease as height above
sea level increases.
Specific gravity of a gas with respect to sea
level also decreases with altitude. These
changes in heating value and specific
gravity tend to offset each other.
However, as elevation above sea level is
increased, there is less oxygen per cubic foot
of air. Therefore, heat input rate should be
reduced in an appliance above 2000 feet.
Ratings should be reduced at the rate of 4
percent for each 1000 feet above sea level.
WATER CONNECTIONS
Inlet and Outlet Water Connections
For ease of service, install unions on inlet and
outlet of the boiler.
The connection on the unit marked “Inlet”
should be used for return water from the
storage tank. The connection on the header
marked “Outlet” should be connected to the
inlet of the storage tank. (See Appendix A for
Boiler Piping Diagrams).
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 11
5.
6.
(TABLE D) – GAS SUPPLY PIPE SIZING
Length of Pipe In Straight Feet
Nominal Iron
Pipe Size, Inches 10 20 30 40 50 60 70 80 90 100 125 150 175 200
369 256 205 174 155 141 128 121 113 106 95 86 79 74
697 477 384 328 292 267 256 246 210 200 179 164 149 138
1,400 974 789 677 595 543 502 472 441 410 369 333 308 287
2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441
4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820
6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300
11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340
23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720
Maximum capacity of pipe in thousands of BTU’s per hour for gas pressures of 14” Inches Water Column (0.5 PSIG) or less and a total
system pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025 BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity).
11/
4
3
/
4
11/2
1
2
1
/
2
31/2
3
2
(TABLE E) – INLET GAS PRESSURE
MODELS NAT. GAS
LPG GAS
CB 495-645
Minimum Allowable 5” 11”
Maximum Allowable 10.5” 13”
CB 745
Minimum Allowable 5.5” 11”
Maximum Allowable 10.5” 13”
CB 986-2066
Minimum Allowable 4.5” 8”
Maximum Allowable 10.5” 13”
EXAMPLE OF
HIGH ALTITUDE
APPLICATIONS
For example, if a unit’s
input is 100,000 Btu/hr
at sea level, the rated
input at 4000 feet of
elevation can be calculated
by derating input 4% per
1000 feet above sea
level.
[Btu/hr Input]
[1.00 - (Elevation/ 1000
ft. x 0.04)] = Btu/hr
Input at specified
elevation.
[100,000][1.00 - (4000
ft. /1000 ft. x 0.04)]
= Btu/hr Input 4000’
elevation.
[100,000][0.84] =
84,000 Btu/hr Input at
4000 ft. elevation.
Page 14
WATER VELOCITY CONTROL
IMPORTANT
To ensure proper velocity through the heat
exchanger, it is necessary to regulate the
temperature rise across the heat exchanger
from inlet to outlet. (This must be done on
initial installation and periodically rechecked).
With the correct temperature rise across the
heat exchanger (See TABLE F), you may be
assured of the proper velocity in the tubes
and long life and economical operation from
the boiler.
CIRCULATOR PUMP OPERATION
A pump control relay is optional on
CB 495-2066 heating boilers. When
designing a system to utilize primary/
secondary operation, specify a pump control
relay for intermittent pump operation.
WATER FLOW REQUIREMENTS
and SYSTEM PIPING
Lochinvar boilers are generally capable of
operating within the design flow rates for the
building heating system. To ensure the most
efficient operation, a boiler needs adequate
water flow. Pump sizing, pipe sizing, and
piping layout must be taken into
consideration for proper system flow.
(TABLE F) provides Gallons Per Minute and
boiler head-loss at various temperature rises
for each boiler based on Btu/hr input.
(TABLE G) provides maximum and minimum
flow data for each model. These two charts
will provide assistance in system flow design.
Variable Speed System Pump
High efficiency boilers require minimum flow
rates through the heat exchangers to operate
safely and efficiently. A variable speed
pump that reduces the flow rate, in the main
system piping loop, below the minimum
requirements of the total boiler system must
not be installed.
Lochinvar
12 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900
(TABLE F) – WATER FLOW REQUIREMENTS
TEMPERATURE RISE 15ºF ΔΔT 20ºF ΔΔT 25ºF ΔΔT 30ºF ΔΔT 35ºF ΔΔT 40ºF ΔΔT
INPUT OUTPUT GPM FT.HD GPM FT.HD GPM FT.HD GPM FT.HD GPM FT.HD GPM FT.HD
495,000 400,950 53.5 5.3 41.0 4.1 32.1 1.9 27.0 1.6 22.9 0.8 20.0 0.7
645,000 522,450 69.7 6.7 53.0 5.1 41.8 3.6 35.0 3.0 29.9 1.8 27.0 1.6
745,000 603,450 70.0* 8.9 61.0* 6.1 48.3 4.8 41.0 4.1 34.5 2.6 31.0 2.3
985,000 797,850 — — 81.0 5.2 63.9 3.0 54.0 2.5 45.6 1.7 41.0 1.5
1,255,000 1,016,550 — — 103.0* 7.3 81.4 5.1 69.0 4.3 58.1 3.0 52.0 2.7
1,435,000 1,162,350 — — — — 103.0* 6.7 79.0 6.3 66.4 4.2 59.0 3.7
1,795,000 1,453,950 — — — — — — 97.0* 7.9 83.1 7.3 74.0 6.5
2,065,000 1,672,650 — — — — — — — — 105.2* 9.2 85.0 8.8
(TABLE G) – MINIMUM & MAXIMUM
BOILER FLOW RATES
MODEL MINIMUM MAXIMUM
NUMBER FLOW (GPM) FLOW (GPM)
CB495 20.5 75
CB645 21.0 75
CB745 25.0 75
CB986 32.0 90
CB1256 41.0 90
CB1436 47.0 90
CB1796 59.0 90
CB2066 68.0 90
NOTE: In Table F * indicates flows in excess of maximum
flow rating for copper tube HEX. Cupronickel tube HEX
are recommended for these flow rates.
IMPORTANT!
EXAMPLE
OF VARIABLE
SPEED PUMP
REQUIREMENTS:
4 - CBN2066
(Min. Flow = 68 GPM)
The combined "minimum"
flow for the boiler
system is
68 GPM x 4 = 272 GPM.
A variable speed pump
must not reduce the
system flow rate below
272 GPM.
Page 15
Primary/Secondary Piping
Using a primary/secondary piping arrangement
can solve system flow complications.
This piping arrangement uses a dedicated
pump to supply flow to the boiler. The pump
is sized based on the required boiler flow
rate, boiler head-loss and head-loss in the
secondary system piping. A separate pump
is used to provide the desired flow for the
system. Primary/Secondary piping allows
the system and the boiler(s) to operate at their
optimum flow rate. The system works best
when the boiler(s) are supplied with pump
control relays which are used to cycle the
secondary pump(s). When piped correctly,
the secondary pump helps to prevent flow
through the boiler(s) when they are not firing.
Use of a primary/secondary system will
eliminate the need for a System or Boiler
Bypass. (FIGURE 12) depicts one example
of primary/secondary piping.
Water Flow Switch
Due to the low water content (between 1 and
6 gallons) of the copper finned tube heat
exchanger, a flow switch is factory installed
as a low water cutoff device on all CB
models. The flow switch is installed in the
outlet piping of the boiler and wired into the
ignition system. Per ASME CSD1 and in most
localities, a flow switch is accepted as a low
water cutoff for boilers requiring forced
circulation. (See CSD1 CW-210, Part A) It is
prudent to verify preference with the local
code official.
A specially sealed flow switch and conduit
are furnished for outdoor installations.
Low Water Cutoff
If this boiler is installed above radiation level,
a low water cutoff device must be installed
at the time of boiler installation (option,
available from factory).
Relief Valve
This boiler is supplied with a pressure relief
valve(s) sized in accordance with ASME
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 13
(FIG. 12) PRIMARY/SECONDARY SYSTEM PIPING
HEATING SUPPLY
LOOP
*12” MAX
TO FLOOR
DRAIN
MAKE-UP WATER
LIT0476
HEATING RETURN LOOP
HEAT EXCHANGER HEAD LOSS CHART
Models 401-751
Pressure Drop in Feet Head
Pressure Drop in Feet Head
HEAT EXCHANGER HEAD LOSS CHART
Models 991-2071
(FIG. 10) BOILER HEAD LOSS CB 495-745
(FIG. 11) BOILER HEAD LOSS CB 986-2066
Page 16
14 Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900
Lochinvar
Low Flow Systems
When the system flow rate is less than the
minimum flow required for proper boiler
operation, the boiler should be installed
with a primary/secondary piping system.
This will allow the installation of a secondary
circulating pump sized specifically to provide
a higher flow rate through the boiler and the
secondary loop piping to ensure proper
operation. See “Primary/Secondary Piping”
for installation and piping requirements.
High Flow Systems
When the flow rate of the system exceeds the
maximum allowable flow rate through the
boiler (TABLE G), boiler bypass piping should
be installed. The bypass will divert the
required portion of the system flow to the
boiler and bypass excess system flow. This
will effectively reduce boiler flow to an
acceptable rate and increase system flow.
The bypass piping should be sized equal to
the system piping. (FIGURE 13) depicts the
proper piping arrangement for the boiler
bypass.
Low Water Temperature System
Any boiler system operating at a temperature
of less than 140°F is considered a “low water
temperature system” and must be piped with
a low temperature bypass. There are a
number of hydronic boiler applications that
call for system water temperatures in the
range of 60°F to 100°F. Typical applications
are: Radiant heating systems; Water source
heat pump systems; Greenhouse soil heating
and irrigation systems; Process and
manufacturing operations. These installations
often incur problems resulting from boiler
condensation, thermal stresses and poor
overall system efficiency.
Copper-tube boilers are particularly adaptable
to these applications for several reasons:
A copper-tube boiler is an instantaneous
boiler, requiring virtually no heat-up time,
and having no temperature “overshoot.”
Result - High system efficiency.
The boiler’s unique construction prevents
the transfer of heat exchanger thermal
stresses to other boiler components,
reducing wear and tear while increasing
equipment life.
Its compact, simple design and low
boiler mass permits a simple bypass
arrangement which will allow the system to
be operated at any temperature above 60°F.
A boiler operated with an inlet temperature of
less than 140°F (60°C) must have a bypass
to prevent problems with condensation.
IMPORTANT:
Operation of this boiler
on low temperature
systems requires
special piping to insure
correct operation.
Consult low temperature
system section for
piping details.
(FIG. 13) HIGH FLOW SYSTEM PIPING
HEATING SUPPLY
LOOP
TO FLOOR
DRAIN
MAKE-UP WATER
HEATING RETURN LOOP
LIT0471
2.
3.
1.
Page 17
A Low Temperature bypass as shown in
Figure 14 must be piped into all ON/OFF
boilers at the time of installation. This piping
is like a primary/secondary boiler
installation with a bypass in the secondary
boiler piping. Inlet water temperatures below
140°F (60°C) can excessively cool the
products of combustion resulting in
condensation on the heat exchanger and in
the flue. The bypass allows part of the
boiler discharge water to be mixed with the
cooler boiler return water to increase the
boiler inlet temperature to at least 140°F
(60°C). This will prevent the products of
combustion from condensing in most
installations. Size Low Temperature bypass
piping equal to system piping, and use fully
ported control valves.
To prevent system return water temperature
below 140° F from entering the inlet in a
proportional stage-fired boiler, a quick
acting, self contained, 3-way valve, set at
140°F, or an electric actuated 3-way valve
with a sensor located on the boiler inlet pipe
must be provided. To prevent manual reset
high limit problems, 3-way valve minimum
flow stops or a valve leak-through should be
evaluated. The installation of a 3-way valve
in the piping system as shown in Figure 15
should not restrict or vary the water flow
through the boiler. Constant water flow
through the boiler must be provided at all
times when the boiler is operating. The
boiler's operating temperature sensor can be
remote mounted in a bulb well installed in
the system water flow to control boiler
operation at a low temperature range.
SPECIAL DESIGN APPLICATIONS
Air Conditioning Re-Heat System
When used in connection with a refrigeration
system, the boiler must be installed so the
chilled medium is piped in parallel with the
boiler and with appropriate valves to prevent
the chilled medium from entering the boiler.
Lochinvar DESIGNER’S GUIDE COPPER- FIN BOILER 615-889-8900 15
(FIG. 14) LOW TEMPERATURE BYPASS
SYSTEM PIPING
HEATING SUPPLY
LOOP
TO FLOOR
DRAIN
MAKE-UP WATER
HEATING RETURN LOOP
LIT0473
CAUTION!
For proper
operation the
system should
not be operated
at less than
12 PSIG.
(FIG. 15) LOW TEMPERATURE BYPASS SYSTEM PIPING
ON/OFF FIRING ONLY
(FIG. 16) LOW TEMPERATURE BYPASS SYSTEM PIPING
PROPORTIONAL STAGED-FIRING
Page 18
The piping system of the hot water boiler
(when connected to heating coils located in
air handling units where they may be exposed
to refrigerated air circulation) must be
equipped with flow control valves or other
automatic means to prevent gravity circulation
of the boiler water during the cooling cycle.
The heating coil must be vented at the high
point, and the hot water from the boiler must
enter the coil at this point. Due to the fast
heating capacity of the boiler, it is not
necessary to provide a duct-stat to delay
circulator operation; also, omit thermal flow
checks, as the boiler is cold when the heating
thermostat is satisfied. This provides greater
economy overall by maintaining standby heat.
AIR REMOVAL
An air separation device should be placed in
the installation piping, on the suction side of
the system pump, to eliminate trapped air in
the system. Locate a system air vent at the
highest point in the system. Additionally, a
properly sized expansion tank is required. Air
charged, diaphragm-type compression tanks
are common. The expansion tank must be
installed close to the boiler and on the suction
side of the system pump to ensure proper
operation.
TEMPERATURE/PRESSURE GAUGE
This boiler is equipped with a dial type
temperature/pressure gauge. This gauge is
factory installed in the outlet side of the heat
exchanger. The gauge has one scale for
reading system pressure and a separate scale
for water temperature in degrees Fahrenheit.
LOW SYSTEM WATER VOLUME
System run time is very important to overall
operating efficiency of the boiler. Short
cycling of the boiler creates problems with
condensation in the vent stack,
condensation on the heat exchanger,
system temperature spikes, and mechanical
component failures. To prevent short cycling
of the boiler, it is important to limit the boiler
cycles to six or fewer per hour.
A Buffer Tank is an effective way to
enhance a small system load and increase
heating system efficiency. Buffer tanks add
water volume to the system and act as a
flywheel to absorb the additional Btu's
provided by the boiler when only a single
zone of a large system is calling for heat.
To calculate the proper buffer tank size for
a multiple zone system:
(Run Cycle) (Output - Minimum System Load)
(Temp. Rise) (8.33)(60 Min.)
BOILER OPERATING
TEMPERATURE CONTROL
In the absence of a remote temperature
control, a digital operator controls the boiler
operating temperature. The sensing element for
the operator is placed in a bulb well, installed
in the inlet side of the heat exchanger front
header. Due to the location of the temperature
sensor, the operator will generally require a
16 Lochinvar
DESIGNE R’ S GUIDE COPPER- FIN BOILER 615-889-8900
Lochinvar
R.
.
(FIG. 17) HEATING/CHILLED WATER SYSTEM
EXAMPLE
OF BUFFER
TANK:
CBN1256 Boiler
Run cycle = 10 min.
Temp. rise = 10°F
Min. load =
100,000 Btu/hr
(10)(1,016,000 -
100,000) divided by
40 x 8.33 x 60
= 485 gallons
LOW WATER
FLOW SWITCH
IN
OUT
R
BOILER
GRAM NOTES:
ALVES "D" AND "C" MAY BE MANUAL OR AUTOMATIC- TO SUIT.
ROVIDE DRAIN FOR RELIEF VALVE "R" TO SAFE PLACE.
EXPANSION
TANK
HEATING &
COOLING
PUMP
COIL
SUPPLY
A
C
GAS
B
D
WATER
SUPPLY
E
3. CLOSE BOTH "A" AND "C" VALVES WHEN RUNNING CHILLE
4. CLOSE BOTH "B" AND "D" VALVES WHEN RUNNING BOILER
5. WATER SUPPLY VALVE REMAINS OPEN AT ALL TIMES.
CHILLER
Page 19
Lochinvar
DESIGNER’ S GUIDE COPPER- FIN BOILER 615-889-8900 17
lower temperature setpoint to achieve the
desired discharge water temperature from the
boiler. This sensing element location allows a
boiler operating with a low to moderate flow
rate to sustain longer burner “ON” cycles,
based on high discharge water temperatures.
For example, a boiler operating with a 180°F
discharge and a 20°F temperature rise would
require approximately a 160°F to 165°F set
point with the temperature sensor installed on
the inlet side of the heat exchanger. The exact
temperature set point is based on system
requirements.
REMOTE TEMPERATURE CONTROL,
CONNECTION TO TERMINAL STRIP
A remote temperature control may be
connected to the boiler. The boiler is
equipped with a terminal strip to allow
easy connection. Connection to the terminal
strip will allow the remote temperature control
to make and break the 24 VAC boiler control
circuit, turning the boiler on and off based on
building and system demands.
ELECTRICAL REQUIREMENTS
(North America)
The appliance is wired for 120 volts.
All wiring between the unit and field
installed devices shall be made of type
T wire [63°F (35°C) rise].
The pump must run continuously when
the unit is firing.
It is recommended that the boiler and
pump be wired on separate circuits with
properly sized circuit breakers.
(FIG. 18) BUFFER TANK PIPING
2.
3.
1.
(TABLE I) – AMP DRAW DATA
MODEL FAN(S) CONTROLS APPROX. TOTAL AMPS
NUMBER @ 120 VAC
CB495 3.6 3.6 7.2
CB645 3.6 3.6 7.2
CB745 3.6 3.6 7.2
CB986 3.4 4.6 8.0
CB1256 3.4 4.6 8.0
CB1436 3.8 4.6 8.4
CB1796 3.8 4.6 8.4
CB2066 3.8 4.6 8.4
NOTE:
When the unit is
installed in Canada,
it MUST conform to
the CAE C22.1,
Canadian Electrical
Code, Part 1
and/or local Electrical
Codes.
Page 20
A1 Lochinvar DESIGNER’ S GUIDE COPPER- FIN BOILER 615-889-8900
PIPING DIAGRAM PRIMARY/SECONDARY BOILER PIPING
PRESSURE
REDUCING VALVE
FULL PORT
BALL VALVE
RELIEF VALVE CHECK VALVE TEE ELBOW
EXPANSION TANK TANK FITTING SYSTEM PUMP LOW WATER
CUTOFF
UNION AIR SEPARATOR
LEGEND
12” MAX*
HEATING RETURN LOOP
HEATING SUPPLY LOOP
*AS CLOSE AS
PRACTICAL –
12” OR 4 PIPE
DIAMETERS MAXIMUM
DISTANCE BETWEEN
MANIFOLD
CONNECTIONS TO
SYSTEM.
MAKE-UP WATER
TO FLOOR DRAIN
LIT0476
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
BOILER PIPING DIAGRAMS
Page 21
Lochinvar DESIGNER’ S GUIDE COPPER- FIN BOILER 615-889-8900 A2
PIPING DIAGRAM MULTIPLE UNIT PRIMARY/SECONDARY PIPING
PRESSURE
REDUCING VALVE
FULL PORT
BALL VALVE
RELIEF VALVE CHECK VALVE TEE ELBOW
EXPANSION TANK TANK FITTING SYSTEM PUMP LOW WATER
CUTOFF
UNION AIR SEPARATOR
LEGEND
12” MAX*
FROM SYSTEM
RETURN
*AS CLOSE AS
PRACTICAL –
12” OR 4 PIPE
DIAMETERS MAXIMUM
DISTANCE BETWEEN
MANIFOLD
CONNECTIONS TO
SYSTEM.
TO SYSTEM SUPPLY
MAKE-UP WATER
CAP EACH MANIFOLD
LIT0475
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
Page 22
A3 Lochinvar DESIGNER’ S GUIDE COPPER- FIN BOILER 615-889-8900
PIPING DIAGRAM LOW TEMPERATURE BOILER-BYPASS PIPING
PRESSURE
REDUCING VALVE
FULL PORT
BALL VALVE
RELIEF VALVE CHECK VALVE TEE ELBOW
EXPANSION TANK TANK FITTING SYSTEM PUMP LOW WATER
CUTOFF
UNION AIR SEPARATOR
LEGEND
MAKE-UP WATER
HEATING RETURN
LOOP
HEATING SUPPLY
LOOP
PRIMARY - SECONDARY BOILER
PIPING WITH BYPASS FOR LOW
TEMPERATURE OPERATION
*AS CLOSE AS PRACTICAL –
12
” OR 4 PIPE DIAMETERS MAXIMUM
DISTANCE BETWEEN MANIFOLD
CONNECTIONS
TO SYSTEM.
TO FLOOR
DRAIN
*12
” MAX
LIT0473
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
BYPASS
Page 23
Lochinvar
DESIGNER’ S GUIDE COPPER- FIN BOILER 615-889-8900 A4
PIPING DIAGRAM LOW TEMPERATURE BOILER-BYPASS PIPING W/ 3-WAY VALVE
PRESSURE
REDUCING VALVE
FULL PORT
BALL VALVE
RELIEF VALVE CHECK VALVE TEE ELBOW
EXPANSION TANK TANK FITTING SYSTEM PUMP LOW WATER
CUTOFF
UNION AIR SEPARATOR
LEGEND
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
Page 24
Lochinvar Corporation • Lebanon, TN • 615-889-8900 / Fax: 615-547-1000
www.Lochinvar.com
CB-DG-06 5M-1/06-Printed in U.S.A.
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