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
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.
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.
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
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”.
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.
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