Lochinvar CW 745, CW 645 User Manual

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Page 1

DESIGNER’S GUIDE COPPER-FIN®WATER HEAT ER

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 water heater 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 water heaters and boilers.

Sincerely,

Lochinvar Corporation

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

Page 3

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

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

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

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

Determining Total “Free Area” . . . . . . . .5

Electrical Requirements . . . . . . . . . . . .14

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

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

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

Low Water Temperature Delivery . . . . .12

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

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

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

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

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

Water Connections . . . . . . . . . . . . . . .11

Water Treatment . . . . . . . . . . . . . . . . .13

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

Figures & Tables Index

FIG. 1 Models CW 495-2066

Requirements For Installation

Over Combustible Floor . . . . .3

FIG. 2 Water Heater 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

TABLE A. Clearances From

Combustible . . . . . . . . . . . . .3

TABLE B. Flue Sizes . . . . . . . . . . . . . . . .8

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

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

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

TABLE F. Required Temperature Rise . . .12 TABLE G. Required Pump Performance .13 TABLE H. Common Water

Manifold Sizes . . . . . . . . . . .14

TABLE I. Amp Draw . . . . . . . . . . . . . .14

Appendix A -

Water Heater Piping Diagrams

Single Heater – Single Tank . . . . . . . . .A1

Single Heater – Two Tanks . . . . . . . . .A2

Two Temperature Installation

Single Heater – Single Tank . . . . . . . . .A3

Two Heaters – Single Tank . . . . . . . . .A4

Two Heaters – Two Tanks . . . . . . . . . .A5

Multi-Stack Frame

Two Heaters – Single Tank . . . . . . . . .A6

Table of Contents

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 WATER HEATER 615-889-8900

Lochinvar

Water Velocity

(See page 12 for Required Degree

Rise chart.)

Factory Supplied Pump

Capacity

(See page 12 for Pump Operation.)

Manifold Pipe Size

When using more than one heater

(See page 14 for Common Water

Manifold Size for Multiple Water

Heater Installation Table.)

Storage Tank Circulating

Tappings

(See page 14 for Manifold Pipe

Size.)

Placement of Cold Water

Inlet and Building Return

(See Appendix A for Water Heater

Piping Diagrams.)

Water Hardness

(

See page 13 for Water Treatment

Information.)

In designing

a water heater 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” 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.

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 WATER HEATER 615-889-8900 3

(FIG. 1) 495-2066 REQUIREMENTS FOR

INSTALLATION OVER COMBUSTIBLE FLOOR

(TABLE A) – CLEARANCES FROM

COMBUSTIBLE CONSTRUCTION

CLEARANCES CW495-2066 Right Side 3" Rear 3" Left Side 3"

(24" for Service)

Front ALCOVE*

(30" for Service) Top 3" Flue 1"

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

material manufacturer.

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

Lochinvar

(FIG. 2) WATER HEATER 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

OPERATOR ON/OFF SWITCH

OPERATOR

TERMINAL STRIP

ON/OFF SWITCH

LEFT SIDE

DRAIN

RELIEF VALVE

TAPPING

INLET GAS

CONNECTION

CW495-745

CW986-2066

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Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 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 input (5.5 cm

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

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 (11 cm

per kW).

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

specified above should have a net free area of one square inch for each 1000

(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

(WATER HEATER

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”.

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

Btu (22 cm2per 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 input (7 cm

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

Copper-Fin II Water Heaters 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

water heater.

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 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

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 7

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8 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 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 Copper-Fin 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

(FIG. 7) BAROMETRIC DAMPER INSTALLATION

(TABLE B)

FLUE SIZES AND COMBUSTION AIR PIPE SIZES

MODEL FLUE SIZE

NUMBER

CW 495 6"

CW 645 8"

CW 745 8"

CW 986 10"

CW 1256 12"

CW 1436 12"

CW 1796 14"

CW 2066 14"

NOTE:

A vent system should

never be sized based

only on the vent

connection diameter of

the appliance. For proper

vent design and sizing,

please consult the

National Fuel Gas Code

(ANSI Z223.1).

Page 11

For this type of installation, it is best to use a draft control for each water heater 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 water heater 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 water heater 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 water heater 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” (76 mm) to combustible surfaces and a minimum of 3” (76 mm) clearance to the air inlet.

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 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.

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. 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 WATER HEATER 615-889-8900

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” (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 water heater 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 water heater.

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

The gas pressure regulator supplied is for low pressure service. If upstream pressure exceeds 6 oz. (10.5" water column), an intermediate gas pressure regulator, of the lock up type, must be installed.

The gas line should be a separate line direct from meter, unless the existing gas line is of sufficient capacity. Verify pipe size with your gas supplier.

A trap (drip leg) should be provided in the inlet gas connection to the water heater.

Lochinvar

(TABLE C) - OUTDOOR VENT KIT PART NUMBERS

MODEL

NUMBER PART NUMBER

CW 495 ODK3023

CW 645 ODK3024

CW 745 ODK3024

CW 986 ODK3046

CW 1256 ODK3047

CW 1436 ODK3047

CW 1796 ODK3048

CW 2066 ODK3048

Page 13

A manual main gas shutoff valve is provided outside the jacket, upstream of the main gas valve.

In Canada, derated10% from 2,000 4,500 ft., over 4,500 ft. derate must be in accordance with local authorities. Consult factory for installations at higher elevations.

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 water heater.

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 Water Heater Piping Diagrams).

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 11

(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

11/2

31/2

(TABLE E) – INLET GAS PRESSURE

MODELS NAT. GAS

LP GAS

CW 495-745

Minimum Allowable 4” 8”

Maximum Allowable 10.5” 13”

CW 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

LOW WATER TEMPERATURE DELIVERY

A number of water heating applications may require delivered water temperature in a system below 140°F. Systems such as nursing homes and hospitals would be examples of this type of system.

A water heating system that will be operated at less than 140°F must use a mixing valve on the outlet side of the storage tank in order to ensure that the products of combustion do not condense inside the combustion chamber of the water heater.

The mixing valve allows the water heater to operate above 140°F to protect from condensation, while still allowing a delivery of colder water to the system fixtures. Also inherent in this design is the protection of occupants from water containing bacteria such as Legionella. Legionella can be significantly reduced in the water storage vessel by heating the water to a minimum of 140°F. (See Appendix A for piping details.)

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 water heater.

PUMP OPERATION

The water heater MUST be connected with a properly sized and installed, intermittent operating, all bronze pump that circulates water between heater and storage tank.

The pump is sized to heater input and water hardness. Should water hardness exceed 25 grains/350 TDS, consult factory for pump sizing.

The pump chart (TABLE H) is based on the following fittings:

6-90° elbows 2 ball valves 2 unions 1 cold water supply tee

Lochinvar

12 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900

(TABLE F) - REQUIRED TEMPERATURE RISE

MODEL NUMBER TEMPERATURE RISE °F

CW 495 15

CW 645 19

CW 745 22

CW 986 19

CW 1256 24

CW 1436 27

CW 1796 34

CW 2066 39

Page 15

Due to pump capacity the following specifications cannot be exceeded when using the standard pump:

• Not more than 45 feet of straight pipe.

• For every elbow and tee in excess of those shown above, DEDUCT 5 FEET from maximum allowable straight pipe in heater-to-tank circulating loop.

WATER TREATMENT

In hard water areas, water treatment should be used to reduce introduction of minerals into the system. Minerals in the water can collect in the heat exchanger tubes causing noise and inefficient operation. Excessive build-up of materials in the heat exchanger can cause a non-warrantable failure.

Acceptable Water Quality Levels Maximum Water Hardness = 25 Grains Minimum Water Hardness = 5 Grains Maximum Total Dissolved Solids = 350 PPM Range of Acceptable pH = 7.2 to 7.8

Standard production Lochinvar water heaters are designed to operate free of impurity build-up in the heat exchanger when properly installed and operated under the specified water quality conditions.

For installation in areas outside these parameters, please consult the factory.

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 models CW495 thru CW2066. The flow switch is installed in the outlet piping from the water heater and wired in series with the ignition system safety controls.

In most localities, a flow switch is acceptable as a low water cutoff device on water heaters requiring forced circulation. It is prudent to verify acceptance with the local code official.

If the local water quality levels are slightly higher than recommended, it may be possible to use a copper-nickel heat exchanger. With copper-nickel being a harder alloy, flow rates can be safely increased to keep the greater water hardness and TDS in suspension. The flow rate can be increased up to 25% faster than the flow rates listed above.

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 13

NOTE:

Care should be taken to

measure temperature

rise and maintain proper

water velocity in the

heat exchanger.

NOTE:

A larger pump must be

utilized in situations

when the distance

between the water

and tank exceed

those specified.

NOTE:

If a pressure reducing

valve or check valve is

in the system a properly

sized expansion tank

may be required.

(TABLE G) – REQUIRED PUMP

PERFORMANCE FOR WATER HARDNESS

OF 5 TO 25 GRAINS

MODEL GPM FT. HD AMP DRAW HORSE VOLTAGE/

POWER PHASE

CW 495-745 60 10 5.8 1/4 120/1

CW 986-2066 90 15 7.4 1/2 120/1

Page 16

14 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900

Relief Valve

This water heater is supplied with temperature and pressure relief valve(s) sized in accordance with ASME Boiler and

Pressure Vessel Code, Section IV “Heating Boilers.”

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 be wired to run continuously when unit is firing.

It is recommended that the water heater and pump be wired on separate circuits with properly sized breakers.

Lochinvar

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.

NOTE:

Incorrect piping

of the cold water

supply to the

system will result

in condensate formation

on the heat exchanger

and operational

problems. Higher water

temperatures reduce

condensate formation.

Refer to drawings in

Appendix A.

(TABLE H) – COMMON WATER MANIFOLD

SIZE FOR MULTIPLE WATER HEATER

INSTALLATION

Pipe sizing chart provides minimum pipe size for

common manifold piping to ensure adequate flow.

NUMBER OF COMMON MANIFOLD SIZE

UNITS (Min.)

CW 495 thru 745

12”

23”

/2”

44”

55”

65”

CW 986 thru 2066

/2”

24”

34”

45”

56”

66”

(TABLE I) – AMP DRAW DATA

MODEL FAN(S) CONTROLS PUMP TOTAL AMPS NUMBER w/PUMP

CW 495-745 3.4 4.6 5.8 13.8

CW 986-1256 3.4 4.6 7.4 15.4

CW 1436-2066 3.8 4.6 7.4 15.8

Page 17

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 A1

WATER HEATER PIPING DIAGRAMS

APPENDIX A

PIPING DIAGRAM SINGLE HEATER - SINGLE TANK

BUILDING HOT WATER SUPPLY

RELIEF VALVE

LOCK-TEMP

STORAGE

TAN K

DRAIN

FULL PORT

BALL VALVE

SYSTEM

PUMP

SYSTEM

RELIEF VALVE

TEE ELBOW UNION EXPANSION

TAN K

CHECK VALVE

THERMOMETER

COLD WATER SUPPLY

BUILDING RETURN

INLET

OUTLET

LOCHINVAR

WATER HEATER

LEGEND

LIT0133

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 18

A2 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900

PIPING DIAGRAM SINGLE HEATER - TWO TANK

FULL PORT

BALL VALVE

SYSTEM

PUMP

SYSTEM

RELIEF VALVE

TEE ELBOW UNION EXPANSION

TAN K

CHECK VALVE

THERMOMETER

LEGEND

BUILDING HOT

WATER SUPPLY

LOCHINVAR WATER

HEATER

COLD WATER

SUPPLY

BUILDING

RETURN

LOCK-TEMP

STORAGE TANK

RELIEF VALVE

DRAIN

OUTLET

INLET

LIT0135

Page 19

FULL PORT

BALL VALVE

SYSTEM

PUMP

SYSTEM

RELIEF VALVE

TEE ELBOW UNION EXPANSION

TAN K

CHECK VALVE

THERMOMETER

LEGEND

PIPING DIAGRAM TWO TEMPERATURE INSTALLATION - SINGLE HEATER-SINGLE TANK

HIGH TEMPERATURE

BUILDING RETURN

LOW TEMPERATURE

BUILDING RETURN

DRAIN

INLET

RELIEF VALVE

OUTLET

COLD WATER

SUPPLY

140

F HOT WATER

SUPPLY

180

F HOT WATER

SUPPLY

LOCK-TEMP

STORAGE TANK

LOCHINVAR

WATER HEATER

MIXING

VALVE

CHECK VALVE

LIT0136

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 A3

Page 20

A4 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900

PIPING DIAGRAM TWO HEATERS-SINGLE TANK

FULL PORT

BALL VALVE

SYSTEM

PUMP

SYSTEM

RELIEF VALVE

TEE

ELBOW UNION EXPANSION

TAN K

CHECK VALVE

THERMOMETER

REDUCING

TEE

REDUCING

TEE

LEGEND

LOCHINVAR

WATER HEATERS

INLET

OUTLET

RELIEF VALVE

OUTLET

BUILDING RETURN

DRAIN

LOCK-TEMP

STORAGE TANK

COLD WATER

SUPPLY

BUILDING

HOT WATER

SUPPLY

LIT0138

COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATION

Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.

NUMBER OF COMMON MANIFOLD SIZE NUMBER OF COMMON MANIFOLD SIZE

UNITS (Min.) UNITS (Min.)

CW 495-745 CW 986-2066

1 2” 1 2-1/2”

23”2 4”

3 3-1/2” 3 4”

44”4 5”

55”5 6”

65”6 6”

Gray shaded area represents common manifold piping.

Page 21

Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900 A5

FULL PORT

BALL VALVE

SYSTEM

PUMP

SYSTEM

RELIEF VALVE

TEE ELBOW UNION EXPANSION

TAN K

CHECK VALVE

REDUCING

TEE

REDUCING

TEE

LEGEND

PIPING DIAGRAM TWO HEATERS-TWO TANKS

BUILDING

RETURN

LOCHINVAR

WATER HEATERS

COLD WATER

SUPPLY

LOCK-TEMP

STORAGE

TAN KS

DRAIN

INLET

OUTLET

RELIEF VALVE

BUILDING

HOT WATER

SUPPLY

LIT0451

THERMOMETER

COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATION

Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.

NUMBER OF COMMON MANIFOLD SIZE NUMBER OF COMMON MANIFOLD SIZE

UNITS (Min.) UNITS (Min.)

CW 495-745 CW 986-2066

1 2” 1 2-1/2”

23”2 4”

3 3-1/2” 3 4”

44”4 5”

55”5 6”

65”6 6”

Gray shaded area represents common manifold piping.

Page 22

A6 Lochinvar DESIGNER’ S GUIDE COPPER- FIN WATER HEATER 615-889-8900

PIPING DIAGRAM MULTI-STACK FRAME W/ WATER HEATERS AND STORAGE TANK

LIT0396

Heater Heater Inlet/ Manifold Model Outlet Size Pipe Size

CW495-745 2” 3” CW986-2066 2-1/2” 4”

Page 23

Page 24

Lochinvar Corporation • Lebanon, TN • 615-889-8900 / Fax: 615-547-1000

www.Lochinvar.com

CW-DG-05 (Revised CW-DG-05 1/07) 4/09-Printed in U.S.A.