Lochinvar Hot Water Generator User Manual
HOT WATER
GENERATOR
INSTALLATION and OPERATION
MANUAL
The information contained in this
manual is intended for use by
qualified professional installers, or
service technicians. Consult your
local expert for proper installation
or service procedures.
WARNING
Save this manual for future reference.
Unit shown with optional control package.
2
Hot Water Generator Installation and Operation Manual
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Optional control packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Startup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shutdown procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storage tank maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Component(s) replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Notes page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important
but not related to personal injury or property damage.
Hot Water Generator Installation Instructions
3
1
General information
This manual is intended to cover installation, operation, and
maintenance procedures for Lochinvar’s Hot Water Generator
Systems. Since each unit is built to meet customer
specifications, instructions may not be specific to every
system.
If questions are not answered by this manual, or if specific
installation, operation, and/or maintenance procedures are
not clearly understood, contact Lochinvar for clarification
before proceeding.
These Hot Water Generator Systems are designed for indoor
use only, unless otherwise required by design specifications.
Each unit requires at least two feet of clearance around and
above the unit. It should be located on a level surface (no
more than one-half degree of slope), capable of supporting
the total weight of the unit when filled to capacity.
The unit should be mounted to the floor following applicable
architectural and local code requirements for the specific
installation site. Note: Tanks do not come standard with floor
tie downs.
The high quality enamel paint, applied to the jacket of the
unit, will provide years of protection against corrosion. If it is
necessary to clean the outside of the unit, a mild cleaning
agent should be used that will not damage the paint.
For all piping connections, the use and/or type of joint
compound or sealer on the joints should be determined by
referring to local codes, accepted standards, and/or the
requirements of the installing contractor.
Lochinvar’s Hot Water Generator Systems are ideal when
boiler capacity is sufficiently sized to cover potable hot water
demand and provide source water for hydronic heating
systems. Hot Water Generator Systems use steam or boiler
water as an energy source and can provide high recovery rates,
making them an economical water heating system for end
users.
Availability
Hot Water Generator Systems are pre-engineering and preassembled complete with all piping to meet your specific
application. And like every Lochinvar product,we thoroughly
test them to ensure proper performance from the moment
they are installed.
Hot Water Generator Systems are available in horizontal or
vertical configurations (see FIG.’s 1 and 2) in a wide array of
gallon capacities. Standard packages are available in tank sizes
from 200 - 1000 gallons with single wall copper tube bundle
heating units. Custom configurations, smaller and larger tank
and tube bundles, and optional control packages are also
available. Consult the factory for specifications.
Tank Construction -- Lochinvar tanks are available with glass
or cement lining.
ASME -- All Lochinvar tanks are constructed in accordance
with ASME standards and certified for 125 psi working
pressure (standard) or 150 psi working pressure (optional).
Cathodic Protection -- All glass lined tanks are equipped
with magnesium anodes to provide protection against
corrosion.
Manway - A manway is provided as an option on glass lined
tanks and is standard on cement lined tanks.
*Horizontal tanks with tube bundles 48" and longer require a
manway.
Tank Circulator Package -- All standard Hot Water Generator
Systems are equipped with a circulator package to maximize
the amount of hot water provided.
Five-Year Limited Tank Warranty -- Provides warranty
protection against tank failure (see warranty for details).
One-Year Limited Warranty -- Tube Bundle, parts,
accessories and controls (see warranty for details).
WARNING
• Before using product, read and
understand instructions.
• Save these instructions for future
reference.
• All work must be performed by
qualified personnel trained in the
proper application, installation, and
maintenance of steam systems and/or
boiler water systems in accordance with
all applicable codes and ordinances.
• To prevent serious burns, wear heat
resistant gloves when opening and
closing steam valves, or handling hot
equipment.
• To prevent serious burns, the internal
pressure of the trap must be 0 psi
(0 bar) before servicing.
• To prevent serious personal injury from
steam pipe blow down, connect a
temporary pipe between the steam pipe
opening and a drain, or stand at least
100 ft. (30 m) from the front of the pipe
opening.
• To prevent property damage, personal
injury, or death, cap off the gate valves
if they are not connected to a drain and
when they are not in use for test or
pressure relief.
Failure to follow this warning could cause
property damage, personal injury, or
death.
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Hot Water Generator Installation and Operation Manual
1
General information
Optional control packages (see page 5)
Steam to Water -- Control packages include an isolation valve, 2-way
self-operated temperature regulator, inlet and outlet wye strainers, a
float and thermostatic steam trap and all necessary piping.
Water to Wate r -- Control packages include isolation valves, 2-way
self-operated temperature regulator, inlet wye strainer and all
necessary piping.
Options:
• Manual Reset High Limit • Solenoid Valve
• Manway (see notes on manway) • 150 psi Tank Working Pressure
• Temperature & Pressure Gauge • Vacuum Breaker
Figure 1_Vertical Tanks
Figure 2_Horizontal Tanks
Hot Water Generator Installation and Operation Manual
5
1
General information
(continued)
Figure 3_Steam to Water Optional Control Package
Figure 4_Water to Water Optional Control Package
WARNING
As with any piece of equipment that utilizes
steam or boiler water under pressure, as well as
electricity, the potential exists for severe
personal injury if proper installation,
operation, and maintenance procedures are
not followed. Listed in this section are specific
warnings pertaining to Lochinvar Hot Water
Generators. In addition, throughout this
manual, warnings are restated when
procedures are described pertaining to areas of
potential danger. All warnings should be
carefully read and understood. All precautions
contained in the warnings should be carefully
followed to reduce the chance of injury.
WARNING
Areas of potential danger:
1. All steam/boiler water lines, joints,
valves, and pressure regulators.
2. All hot water outlet lines, joints,
valves, and pressure regulators.
3. All power connections and cables.
Before attempting any installation,
operation, or maintenance procedures
pertaining to this unit:
1. Assure that the incoming steam
(or boiler water) has been turned off
at the manual shutoff valve.
2. If the unit has been in operation,
allow the water in the heater and all
components and surfaces (incoming
steam line, hot water outlet line,
etc.,) to cool before starting the
procedure.
3. Assure that all power has been
shut off / disconnected before
attempting any procedures.
4. Assure that all incoming and
outgoing water lines have been
turned off at the manual shutoff
valves.
WARNING
Steam or boiler water present situations
that can be very dangerous due to the fact
they are under pressure and at very high
temperatures. To avoid possible injury or
death, use common sense and follow all
accepted and recommended procedures
when performing installation, operation,
and maintenance procedures.
WARNING
The combination of electricity and water
can pose a very dangerous situation.
Assure that all power has been shut off /
disconnected before attempting any
installation or maintenance procedures.
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Installation
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Hot Water Generator Installation and Operation Manual
Transporting and unpacking the unit
Each Lochinvar Hot Water Generator is crated as necessary at the factory. The crating is designed to provide protection for the
unit during transportation, and to provide a safe means by which to lift and move the unit with a fork lift or hand truck.
In order to prevent damage during shipment the controls package is disassembled at the factory after leak testing. Reassembly
will require re-attaching the unions (or bolting flange) to the appropriate locations and insertion of the control valve bulb into
the provided bulbwell and the system is ready for operation (see FIG.’s 5 and 6 below).
All hardware for the reassembly is included with the system. Drawings of the specific controls package are included with each
product illustrating the finished assembly. For water to water systems the bypass piping union may remain attached for
shipment. See FIG.’s 5 and 6 below for a detailed explanation of the break points.
Figure 5_Steam to Water Storage Heater
Figure 6_Water to Water Storage Heater
2
Installation
(continued)
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Hot Water Generator Installation and Operation Manual
Examining the unit
After the unit has been set in place and uncrated, it
should be carefully examined to assure that neither the
main unit nor components have been damaged during
shipping. If any evidence of damage is detected that
could affect the safe operation of the unit, contact
Lochinvar Corporation, or your authorized sales
representative, to report the damage and to receive
instructions on how to proceed.
After the unit and all components have been inspected for
damage, it is suggested that all pressure and temperature
control components be checked to assure that they meet
or exceed design specifications. If any discrepancy is
found, contact Lochinvar Corporation, or your
authorized representative, before proceeding with the
installation.
Mounting the unit
The unit should be mounted to the floor, following
applicable architectural / local code requirements, or
accepted standards for the specific installation site. The
unit should be installed in a location with sufficient
clearance to remove the tube bundle for repair or
replacement.
Unit and components
Lochinvar Hot Water Generators are designed to make
installation a relatively simple procedure. Because the
unit is “Packaged”, after placing and mounting the unit,
installation involves the following:
• Connecting the cold water source to the water inlet.
• Connecting the hot water outlet to the hot water feed
line.
• Installing the control valve bulb into the tank bulbwell.
• Connecting the condensate / water return line and
piping it to the recycling system.
• Piping the pressure relief valve to an acceptable drain.
• Connecting the energy source (steam or boiler water)
to the unit.
• Wiring the applicable source of electricity (if the unit is
packaged with a circulating pump or electrically
activated pressure or temperature controls).
Each unit is supplied with CAD drawings that indicate
the location and specifications for each connection that
must be made. In addition, the drawing will enable the
installer(s) to determine the flow direction of both the
water and energy source.
Connecting the cold water source
and the hot water outlet
Before making any connections of water
inlet or outlet to the unit, assure that all
piping is clean and free of foreign material
or scale. This can usually be accomplished
by “blowing out” the pipe. Any foreign
material or scale entering the unit can
adversely affect operation and
performance.
NOTICE
Cold water source
The first step in the installation process is to connect the cold
water source to the water inlet port. The exact location of this
port for the specific unit, as well as inlet pipe diameter and
thread size, can be determined from the CAD drawing
supplied with the unit.
A manual shutoff valve should be installed upstream on the
cold water source as an isolation device. The shutoff valve
should be in the closed position and remain so until the
installation is complete.
NOTICE
For allpiping connections, the use and / or
type of joint compound or sealer on the
joint should be determined by referring to
local codes, accepted practices, or the
requirements of the installing contractor.
If the cold water source is equipped with an in-line check valve
or backflow preventer, a suitable expansion tank m
ust
be
installed in the hot water outlet side of the system. See the
supplied CAD drawing(s) or contact Lochinvar Corporation
for expansion tank specifications.
Hot water outlet
The next step in the installation process is to connect the hot
water system piping to the hot water outlet port. The exact
location of this port for the specific unit, as well as outlet pipe
diameter and thread size, can be determined from the CAD
drawing(s) supplied with the unit.
A manual shutoff valve should be installed downstream on the
hot water outlet line as an isolation device in case the unit
must be disconnected from the system. The shutoff valve
should be in the closed position and remain so until the
installation is complete.
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Installation
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Hot Water Generator Installation and Operation Manual
Connecting the energy source
(Steam or boiler water)
WARNING
Steam or boiler water present situations
that can be very dangerous because of the
high temperatures and pressures. Use
common sense and follow all accepted and
recommended procedures when
performing installation, operation, and
maintenance procedures to avoid possible
injury or death.
Assure that a manual shutoff valve is installed upstream in the
steam or boiler water line (energy source), and that it is
functioning properly. If any doubt exists concerning the
integrity of the shutoff valve, replace the valve before
attempting installation. All energy source valves should be
closed and remain closed throughout the installation process.
Connect the energy source to the line(s) leading to the
temperature control valve. The exact location of the
temperature control valve for the specific unit, as well as
energy source pipe diameter and thread size, can be
determined from the CAD drawing(s) supplied with the unit.
NOTICE
For all energy source piping connections,
the use and / or type of joint compound or
sealer on the joint should be determined by
referring to local codes, accepted practices,
or the requirements of the installing
contractor.
Connecting the steam condensate
line or the boiler water return lines
Steam condensate return line
As the heat is extracted from the steam and transferred to the
water heating system, condensate will form. This condensate
must have a means by which it can drain from the unit and
return to the steam system. The condensate return line serves
this purpose.
The condensate return line should be connected to the unit at
the condensate return port. The condensate port is normally
located downstream from the main and auxiliary traps. The
exact location of this port for the specific unit, as well as the
condensate return pipe diameter and thread size, can be
determined from the CAD drawing(s) supplied with the unit.
The condensate line should be piped back into the site’s steam
system for recycling.
A manual shutoff valve should be installed downstream in the
condensate return line to allow the unit to be isolated from the
system. The condensate shutoff valve will prevent backflow of
steam if the line is disconnected.
WARNING
Do not attempt to lift condensate with a
float and thermostatic trap. Pipe the
condensate outlet from the main steam
trap to a gravity drain or to a condensate
pump.
Lifting condensate without the assistance
of a condensate pump can cause erratic
temperature control, failure of the tube
bundle, damage to the control valve, or
damage to the condensate trap. Any failure
caused due to lifting of condensate without
a condensate pump is not covered by the
warranty.
Boiler water and high temperature water
return line
After the boiler water has passed through the tube bundle, and
the heat has been extracted and transferred to the domestic
water system, the water must return to the system. The water
return line serves this purpose.
The water return line should be connected to the unit at the
return port. Unlike the steam condensate return line, the
return lines for boiler water do not have in-line condensate
traps. The exact location of this port for the specific unit, as
well as the water return pipe diameter and thread size, can be
determined from the CAD drawing supplied with the unit.
A manual shutoff valve should be installed downstream in the
water return line to allow the unit to be isolated from the
system. The water return shutoff valve will present backflow
of boiler water if the line is disconnected.
Piping the relief valves to drain
All Lochinvar Hot Water Generators are equipped with a
pressure relief valve for the tank. The valve should be piped to
a vent line leading to a suitable drain. Piping the pressure
relief valves to suitable drains will prevent both water and heat
damage to the unit, as well as reduce the risk of injury from
released steam or water. The pipe must be of adequate size to
properly handle the capacity of the relief valve and vent line.
Check local codes to assure compliance.
If a check valve has been installed on the inlet water line,
thermal expansion may take place causing build up of
excessive pressure when the water is being heated. This
expansion will cause the relief valve to open, releasing hot
water to the vent line.
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