Lochinvar CH1261 Installation Manual
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400,000 – 2,070,000 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 our 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 water heaters and boilers.
Sincerely,
Lochinvar Corporation
Lochinvar Corporation • 615-889-8900 • Fax: 615-547-1000
Lochinvar DESIGNER’S GUIDE COPPER- FIN II BOILER 615-889-8900 1
Air Removal . . . . . . . . . . . . . . . . . . . . . .23
Boiler Operating Temperature Control . . . .24
Circulator Pump Operation . . . . . . . . . . .18
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Combustion & Ventilation Air . . . . . . . . . . .6
Contaminants . . . . . . . . . . . . . . . . . . . . . .7
Determining Total “Free Area” . . . . . . . . . .7
Electrical Requirements . . . . . . . . . . . . . . .24
Gas Supply . . . . . . . . . . . . . . . . . . . . . .17
General Venting . . . . . . . . . . . . . . . . . . . .7
Location of Unit . . . . . . . . . . . . . . . . . . . . .2
Low System Water Volume . . . . . . . . . . . .23
Low Water Temperature System . . . . . . . .21
Outdoor Use . . . . . . . . . . . . . . . . . . . . . . .4
Outdoor Installation . . . . . . . . . . . . . . . . .16
Primary/Secondary Piping . . . . . . . . . . . .19
Relief Valve . . . . . . . . . . . . . . . . . . . . . . .20
Remote Temperature Control . . . . . . . . . . .24
Special Design Applications . . . . . . . . . . .22
Variable Speed Pumping . . . . . . . . . . . . .19
Venting Options . . . . . . . . . . . . . . . . . . . .9
Water Flow Requirements . . . . . . . . . . . .18
Water Velocity Control . . . . . . . . . . . . . . .18
Figures & Tables Index
FIG. 1 Models CH 991-2071
Requirements For Installation
Over Combustible Floor . . . . . . .3
FIG. 2 Models CH 401- 751 Special
Combustible Floor Base . . . . . . .4
FIG. 3 Boiler Equipment &
Control Orientation . . . . . . . . . . .5
FIG. 4-7 Combustion & Ventilation Air . .6,7
FIG. 8 Barometric Damper Installation . .9
FIG. 9 Multiple Unit Barometric
Damper Installation . . . . . . . . . .10
FIG. 10 Powered Sidewall Venting . . . . .10
FIG. 11 Power DirectAire Horizontal . . .11
FIG. 12 Vertical Vent and Air Inlet . . . . .13
FIG. 13 Vertical Vent and
Sidewall Air Inlet . . . . . . . . . . .13
FIG. 14 Aire-Lock Direct Vent . . . . . . . . .14
FIG. 15 Sidewall Vent . . . . . . . . . . . . . .16
FIG. 16 Outdoor Venting . . . . . . . . . . . .16
FIG. 17 Heat Exchanger Head Loss
Models CH 401-751 . . . . . . . .19
FIG. 18 Heat Exchanger Head Loss
Models CH 991-2071 . . . . . . .19
FIG. 19 Primary/Secondary
System Piping . . . . . . . . . . . . . .20
FIG. 20 High Flow System Piping . . . . . .20
FIG. 21 Low Temperature Bypass
System Piping . . . . . . . . . . . . . .21
FIG. 22 Low Temp Bypass Piping
On/Off . . . . . . . . . . . . . . . . . .22
FIG. 23 Low Temp Bypass Piping
Proportional Stage Firing . . . . . .22
FIG. 24 Heating/Chilled
Water System . . . . . . . . . . . . . .22
FIG. 25 Buffer Tank Piping . . . . . . . . . . .23
TABLE A. Combustible Floor Kits . . . . . . . .3
TABLE B. Clearances From
Combustibles . . . . . . . . . . . . . .4
TABLE C. Flue Sizes and
Inlet Air Pipe Sizes . . . . . . . . . . .9
TABLE D. Powered Sidewall Vent Kits . . .11
TABLE E. Powered DirectAire Horizontal
Vent Kits . . . . . . . . . . . . . . . . .12
TABLE F. DirectAire Vertical Sidewall and
Rooftop Air Inlet Kits . . . . . . . .14
TABLE G. Direct Vent Kits . . . . . . . . . . . . .15
TABLE H. Sidewall Vent Kits . . . . . . . . . . .15
TABLE I. Outdoor Kits . . . . . . . . . . . . . .16
TABLE J. Gas Supply Pipe Sizing . . . . . .17
TABLE K. Inlet Gas Pressure . . . . . . . . . . .18
TABLE L. Water Flow Requirements . . . . .18
TABLE M. Minimum and Maximum
Boiler Flow Rates . . . . . . . . . . .19
TABLE N. Amp Draw Data . . . . . . . . . . . .24
Boiler Piping Diagrams
Primary/Secondary . . . . . . . . . . . . . . . .A1
Multiple Unit Primary/Secondary . . . . . . .A2
Low Temperature Boiler Bypass . . . . . . . .A3
Low Temperature Boiler Bypass w/
3-Way valve . . . . . . . . . . . . . . . . . . . . . .A4
Table of Contents
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.
1.
2 Lochinvar DESIGNER’ S GUIDE COPPER- FIN II BOILER 615-889-8900
Lochinvar
•
Water Velocity
(See Page 19 for minimum
and maximum boiler flow rates.)
•
Piping Requirements
and Specialties
(See Page 19 for water flow
requirements and system piping.)
•
Low Water
Temperature System
(See Page 21 for piping and
design recommendations.)
•
System and Boiler
Control
(See Page 24 for boiler operating
and temperature control.)
•
Air Elimination and
Expansion Tank Placement
(See Page 23 for air removal
information.)
In designing
a hot water heating
system, pay special
attention to:
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” thick
and extending 24” 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.
• The correct kit number for the required base
is noted on the rating plate of each unit
and listed in Table A.
Lochinvar DESIGNER’S GUIDE COPPER- FIN II BOILER 615-889-8900 3
(TABLE A)
COMBUSTIBLE FLOOR KITS
MODEL NUMBER KIT NUMBER
CH401 CFK3301
CH501 CFK3302
CH651 CFK3303
CH751 CFK3304
2.
3.
4.
(FIG. 1) CH 991-2071 REQUIREMENTS FOR
INSTALLATION OVER COMBUSTIBLE FLOOR
Under no circumstances is the
manufacturer to be held responsible
for water damage in connection
with this unit or any of its
components.
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.
Outdoor models have additional special
location and clearance requirements.
(See Outdoor Installation Pg. 16)
SPECIAL LOCATION:
OUTDOOR USE
Copper-Fin II Models are approved for
outdoor installations. 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,
in the venting section on page 16.
5.
(FIG. 2) MODELS CH 401-751 INSTALLED WITH
OPTIONAL COMBUSTIBLE FLOOR BASE
4 Lochinvar DESIGNER’ S GUIDE COPPER- FIN II BOILER 615-889-8900
Lochinvar
(TABLE B) – CLEARANCES FROM COMBUSTIBLES
CLEARANCES CH401-751 CH991-2071
Right Side 1” 3”
Rear 1” 3”
Left Side 6” 3”
(24” for Service) (24” for Service)
Front ALCOVE* ALCOVE*
(24” for Service) (30” for Service)
Top 1” 3”
Flue 1”+1”+
Hot Water Pipes 1” 1”
* Alcove is a closet without a door.
+ Consult local codes and/or vent manufacturer.
Lochinvar DESIGNER’S GUIDE COPPER- FIN II BOILER 615-889-8900 5
(FIG. 3) BOILER EQUIPMENT AND CONTROL ORIENTATION.
FLUE PRODUCTS VENT
GAS CONNECTION
TERMINAL STRIP
DRAIN
BURNER INSPECTION PORT
OPERATOR INTERFACE PANEL
LEFT SIDE
FRONT
GAS
CONNECTION
DRAIN
LEFT SIDE
OPERATOR INTERFACE PANEL
BURNER INSPECTION PORT
FRONT
AIR INLET
SYSTEM SUPPLY
SYSTEM
RETURN
FLUE PRODUCTS VENT
BACK
BACK
SYSTEM RETURN
120V ELECTRICAL
CONNECTION
TERMINAL
STRIP
SYSTEM SUPPLY
AIR INLET
CH 401-751
CH 991-2071
6 Lochinvar DESIGNER’ S GUIDE COPPER- FIN II BOILER 615-889-8900
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EXAMPLE OF SIZING
FOR COMBUSTION
& VENTILATION AIR
OPENINGS (BOILER
WITH 2,070,000
Btu/hr
When combustion and
ventilated air is taken
from directly outside the
building (FIG. 4), divide
the total BTU’s by 4,000.
This yields 517.5 sq.in.
of “Free Area” without
restriction.
(2,070,000 ÷ 4000 =
517.5 sq.in.)
Since the air opening is
50% closed due to
screens and louvers, the
total opening MUST be
multiplied by 2.
(517.5 sq. in. x 2 =
1,035 sq.in.)
This project requires one
Ventilation Air Opening
with a net area of 1,035
square inches with louver
dimensions of 30” x 35”
and one Combustion Air
Opening with a net area
of 1,050 square inches
with louver dimensions
of 30” x 35”.
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 input (5.5 cm
2
per kW).
This opening must be located within 12”
(30 cm) of the bottom of the enclosure.
B. Ventilation air opening with a minimum
free area of one square inch per 4000
Btu input (5.5 cm
2
per kW). This opening
must be located within 12” (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 input (11cm
2
per kW).
If air is taken from another interior
space, each of the two openings
specified above should have a net free
2.
3.
(FIG. 4) COMBUSTION AIR DIRECT FROM OUTSIDE
(FIG. 5) COMBUSTION AIR THROUGH DUCTWORK
(FIG. 6) 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.
Lochinvar DESIGNER’S GUIDE COPPER- FIN II BOILER 615-889-8900 7
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
be sized to
make sure that
it does not
cause drafts
which could
lead to nuisance
operational
problems with
the boiler.
area of one square inch for each 1000
Btu (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 input (7 cm
2
per kW). This
opening must be located within 12”
(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 water heater.
Burning chemical fumes results in the
formation of corrosive acids which attack the
water heater, cause improper combustion
and premature failure of the water heater
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
4.
(FIG. 7) COMBUSTION AIR FROM OUTSIDE,
SINGLE OPENING
8 Lochinvar DESIGNER’ S GUIDE COPPER- FIN II BOILER 615-889-8900
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.
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 water heater. 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
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