Lochinvar EFFICIENCY PLUS Designer's Manual

DESIGNER’S GUIDE EFFICIENCY+

®

BOILER

150,000 – 300,000 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: [phone]

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 1

Air Removal . . . . . . . . . . . . . . . . . . . . . .18

Boiler Operating Temperature Control . . . .19

Clearances . . . . . . . . . . . . . . . . . . . . . . . .3

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

Combustion & Ventilation Air . . . . . . . . . . .3

Connection To Terminal Strip . . . . . . . . . .19

Contaminants . . . . . . . . . . . . . . . . . . . . . .5

Electrical Requirements (North America) . . 19

Gas Supply . . . . . . . . . . . . . . . . . . . . . .14

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

Low Water Temperature Systems . . . . . . . .17

Outdoor Installation . . . . . . . . . . . . . . . . .13

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

Primary/Secondary Piping . . . . . . . . . . . .15

Relief Valve Piping . . . . . . . . . . . . . . . . . .16

Remote Temperature Control . . . . . . . . . . .19

Special Design Applications . . . . . . . . . . .18

Three-Way Valves . . . . . . . . . . . . . . . . . .16

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Venting Options . . . . . . . . . . . . . . . . . . . .7

Water Flow Requirements . . . . . . . . . . . .15

Water Velocity Control . . . . . . . . . . . . . . .15

Figures & Tables Index

FIG. 1 Boiler Equipment & Control

Orientation . . . . . . . . . . . . . . . .3

FIG. 2-5 Combustion & Ventilation Air . . .4
FIG. 6 Barometric Damper

Installation . . . . . . . . . . . . . . . . .8

FIG. 7 Multiple Unit Barometric

Damper Installation . . . . . . . . . .8

FIG. 8 E+ Vent With

Sidewall Air Inlet . . . . . . . . . . . .9

FIG. 9 E+ Vent With

Vertical Air Inlet . . . . . . . . . . . .10

FIG. 10 Horizontal Direct Vent . . . . . . .11

FIG. 11 Horizontal Direct Vent Cap . . . .11

FIG. 12 Multiple Sidewall Vent Caps . . .12

FIG. 13 Vertical Direct Vent . . . . . . . . . .12

FIG. 14 Outdoor Venting . . . . . . . . . . .13

FIG. 15 Primary/Secondary

System Piping . . . . . . . . . . . . .16

FIG. 16 Low Temperature Bypass

System Piping . . . . . . . . . . . . .17

FIG. 17 Heating/Chilled

Water System . . . . . . . . . . . . .18

TABLE A. Clearances From

Combustible Construction . . . . . .3

TABLE B. Conventional Venting,

Vent Flue Size . . . . . . . . . . . . . .7

TABLE C. E+ Vent Sidewall

Air Kit Part Numbers . . . . . . . . .9

TABLE D. E+ Vent Horizontal

Air Kit Part Numbers . . . . . . . .11

TABLE E. Vertical Direct Vent Flue &

Air Inlet Sizes . . . . . . . . . . . . .13

TABLE F. Outdoor Vent Kit . . . . . . . . . . .13

TABLE G. Gas Supply Pipe Sizing . . . . . .14

TABLE H. Inlet Gas Pressure . . . . . . . . . .14

TABLE I. Minimum & Maximum

Boiler Flow Rates . . . . . . . . . . .15

TABLE J. Water Flow Requirements . . . . .15

TABLE K. Heat Exchanger Head-loss . . . .16

TABLE L. Amp Draw . . . . . . . . . . . . . . .19

Appendix A: Boiler Piping Diagrams

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

Multiple Unit - Primary/Secondary . . . . . .A2

Low Temperature Bypass Piping . . . . . . . .A3

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 must be
carefully followed in all cases. Authorities
having jurisdiction must be consulted before
installations are made. In the absence of such
requirements, the installation must 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, No.(CSD-1). All boilers conform
to the latest edition of the ASME Boiler and
Pressure Vessel Code, Section IV. Where

required by the authority having jurisdiction,
the installation must comply with the

Canadian Gas 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.

Under no circumstances is the

manufacturer to be held responsible for

water damage in connection with this

unit or any of its components.

2 Lochinvar

DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

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Water Velocity

(

See Page 15 for minimum and

maximum flow rates.)

Piping Requirements and

Specialties

(

See Page 15 for piping

application requirements.)

System Water Temperature

(

See Page 17 for piping and

design recommendations.)

System and Boiler Control

(See Page 19 for boiler

operating and temperature

control.)

Air Elimination and

Expansion Tank Placement

(

See Page 18 for air removal

information.)

In designing

a hot water heating system,

pay special attention to:

1.

The indoor unit 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.)

Units located in a residential garage
must be installed so that all burners and
burner ignition devices have a minimum
clearance of 18” (46cm) above the floor.
The unit must be located or protected so
that it is not subject to physical damage
by a moving vehicle.

The appliance must be installed on a
level floor. A combustible wood floor may
be used without additional bases or
special floor buildup. Maintain required
clearances from combustible surfaces.

The appliance must not be installed on
carpet or other combustible material other
than wood flooring.

SPECIAL LOCATION:
OUTDOOR USE

Efficiency+ 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 13.

COMBUSTION AND VENTILATION

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, or in Canada, the
latest edition of CGA Standard B149

2.

3.

4.

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 3

5.

(TABLE A)

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

RIGHT SIDE 1”

REAR 1”

LEFT SIDE 6” (24” suggested for service)

FRONT 3” (24” suggested for service)

Suitable for closet installation

TOP 3”

*Allow sufficient space for servicing pipe connections, pump

and other auxiliary equipment, as well as the appliance.

FLUE PRODUCTS

VENT

GAS

CONNECTION

SYSTEM
RETURN

BURNER

INSPECTION

PORT

SYSTEM
SUPPLY

BACK

AIR INLET

TERMINAL

STRIP

(INSIDE)

120V

ELECTRICAL

CONNECTION

DRAIN

LEFT SIDE

FRONT

EB150-300

(FIG. 1) BOILER EQUIPMENT &

CONTROL ORIENTATION

4 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

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. 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/hr input. 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/hr.

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
Btu/hr 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.
This opening must be located within 12”
(30 cm) of the top of the enclosure.

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(FIG. 4) COMBUSTION AIR FROM INTERIOR SPACE

(FIG. 3) COMBUSTION AIR THROUGH DUCTWORK

2.

3.

4.

(FIG. 5) COMBUSTION AIR FROM

OUTSIDE SINGLE OPENING

(FIG. 2) COMBUSTION AIR DIRECT FROM OUTSIDE

1.

EXAMPLE OF

SIZING FOR

COMBUSTION

& VENTILATION

AIR OPENINGS

(BOILER WITH

300,000 BTU/HR

INPUT):

When combustion and
ventilated air is taken from
directly outside the building
(FIG. 2), divide the total BTU’s
by 4,000. This yields 75 sq.in.
of “Free Area” without
restriction.
300,000 ÷ 4,000 =
75 sq.in.
Since the air opening is 50%
closed due to screens and
louvers, the total opening
MUST be multiplied by 2.
75 sq.in. x 2 =
150 sq.in.
This project requires one
Ventilation Air Opening with
net “Area” of 75 square
inches with louver dimensions of
12” x 15”= 168 sq.in.
and one Combustion Air
Opening with net “Area”
of 75 square inches with
louver dimensions of
12” x 15”= 168 sq in.

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 EFFICIENCY+ BOILER 615-889-8900 5

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 and 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

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, using the proper vent table.

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 Type “B” double
wall vent (or equivalent) for conventional vent
applications.

When utilizing direct vent capabilities
connections must be made with AL29-4C
stainless steel (or equivalent) vent material.

Material should be sized according
to vent sizing tables (FAN column) in
the latest edition of the National Fuel

Gas Code.

The vent materials and accessories, such as
firestop spacers, thimbles, caps, etc., must
be installed in accordance with the
manufacturer’s listing.

The vent connector and firestop shall 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 the existing building must
be corrected when new equipment is
installed, so the installation conforms to the
latest edition of the National Fuel Gas Code,

ANSI Z223.1.

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.

6 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

The efficiency of this appliance allows its
products of combustion to be vented through
a smaller vent pipe when compared to units
of the same Btu/hr capacity. For this reason,
resizing common venting systems is
recommended for proper operation.

When resizing any portion of the common
venting system, it should be resized to
approach the minimum size as determined
using the appropriate tables (FAN column) in
the National Fuel Gas Code.

Failure to resize a common venting system
could lead to the formation of condensate
and premature deterioration of the vent
material.

Flue gas condensate can freeze on exterior
walls or on the vent cap. Frozen condensate
on the vent cap can result in a blocked flue
condition. Some discoloration to exterior
building surfaces can be expected. Adjacent
brick or masonry surfaces should be
protected with a rust resistant sheet metal
plate.

Vent connectors serving appliances vented by
natural draft must not be connected to
any portion of a mechanical draft system
operating under positive pressure.

Connection to a positive pressure stack may
cause flue products to be discharged into the
living space causing serious health injury.

Locate units as close as possible to a chimney
or gas vent.

Vent Terminations

When locating the vent cap, consider the effects
of snow, leaf dropping, etc., to ensure that no
blockage occurs.

The distance of the vent terminal from adjacent
public walkways, adjacent buildings, windows
that open and building openings must comply
with the latest edition of the National Fuel Gas

Code, ANSI Z223.1.

The vent terminal must be vertical and
exhaust outside the building at least 2 feet
(0.6m) above the highest point of the roof
within a 10 foot (3.0m) radius of the
termination.

The vertical termination must be a minimum
of 3 feet (0.9m) above the point of exit in the
rooftop.

A vertical termination less than 10 feet (3.0m)
from a parapet wall shall be a minimum of 2
feet (0.6m) higher than the parapet wall.

The vent cap shall terminate at least 3 feet
(0.9m) above any forced air inlet within 10
feet (3.05m). The vent shall terminate at least
4 feet (1.2m) below, 4 feet (1.2m)
horizontally from or 1 foot (0.30m) above
any door, window, or gravity air inlet to the
building.

Do not terminate the vent in a
window well, stairwell, alcove,
courtyard, or other recessed area.
The vent cannot terminate below
grade.

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IMPORTANT!

The vent cap should
have a minimum
clearance of 4 feet
horizontally from electric
meters, gas meters,
regulators, air inlets and
air relief equipment.
Additionally, the vent
cap should never be
located above or below
these items, unless a 4
foot horizontal distance
is maintained.

NOTE:

The weight of the

venting system MUST

NOT rest on the boiler.

It should be properly

supported.

WARNING

Vent connectors serving

gas appliances, which

operate under a

negative vent pressure,

shall not be connected

into any portion of

mechanical draft

systems operating under

positive vent pressure.

Masonry Chimney

A masonry chimney must be properly sized
for the installation of a high efficiency gas fired
appliance. Venting of a high efficiency
appliance into a cold or oversized masonry
chimney can result in operational and safety
problems.

Exterior masonry chimneys, with one or more
sides exposed to cold outdoor temperatures, are
more likely to have venting problems. For this
reason, exterior masonry chimneys are not
generally recommended to vent high efficiency
gas appliances.

An interior masonry chimney, which is not
exposed to the outdoors below the roofline, may
be used to vent high efficiency gas appliances
based on the results of careful inspection,
proper sizing and local code approval. If there
is any doubt about the sizing or condition of a
masonry chimney, it should be relined with a
properly sized and approved chimney liner
system.

An interior masonry chimney should be carefully
inspected to determine its suitability for the
venting of flue products.

A clay tile lined chimney must be structurally
sound, straight and free of misaligned tile, gaps
between liner sections, missing sections of liner
or any signs of condensate drainage at the
breeching or clean out.

If there is any doubt about the condition of a
masonry chimney, it should be relined.

Metallic liner systems (Type “B” double-wall,
flexible, or rigid metallic liners) are
recommended to line or reline an existing
masonry chimney. Consult with local code
officials to determine code requirements or the
advisability of using a lined masonry chimney
or relining of a masonry chimney.

VENTING OPTIONS

Conventional Venting - Negative Draft

Size vent material according to the “FAN”
column of vent sizing tables in the latest edition
of the National Fuel Gas Code. “FAN” applies
to Category I fan assisted combustion
appliances with natural draft. Utilize Category
I type “B” vent material for all conventional
venting applications.

A bell increaser is provided and installed
directly on the boiler vent outlet. The bell
increases the boiler vent size by 1 inch
(25.4mm) in diameter. The vent connection
is made directly to the bell increaser on the
top of the unit. No additional draft diverter
or barometric damper is required.

(TABLE B)

CONVENTIONAL VENTING, VENT CONNECTION SIZE

CONVENTIONAL

MODEL VENT FLUE SIZE

EB150 5

”

EB200 5

”

EB250 6”

EB300 6”

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 7