Lochinvar TNR-I, Turbo Charger Service Manual
INSTALLATION & SERVICE MANUAL
TNR-I&S-02
HIGH EFFICIENCY COMMERCIAL GAS WATER HEATER
WARNING
If the information in these instructions is not followed exactly, a
fire or explosion may result causing property damage, personal
injury or death.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
telephone in your building.
• Immediately call your gas supplier from a neighbor’s
telephone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
TABLE OF CONTENTS
GENERAL INFORMATION ...................................................... 1
INSTALLATION .................................................................. 2
Locating The Water Heater ........................................... 2
Minimum Clearances ..................................................... 2
Venting ........................................................................ 6
Combustion Air Supply ................................................. 19
Water Connections ....................................................... 4
Gas Connections .......................................................... 14
GENERAL OPERATION........................................................... 15
MAINTENANCE ..................................................................... 17
TROUBLESHOOTING GUIDE .................................................. 20
GENERAL INFORMATION
This gas-fired water heater is design certified by CSA International under
the American National Standard, Z21.10.3 (as indicated on the rating
plate) and CAN/CGA 4.3-M (as indicated on the rating plate) available
from CSA Standards Association, 178 Rexdale Blvd., Etobicoke, Ontario,
Canada M9W 1R3.
This water heater must be installed in accordance with local codes. In the
absence of local codes, it must be installed in compliance with the National
Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1
Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane
Installation Code (Latest Edition).
DANGER
DO NOT store or use gasoline or other flammable, combustible, or corrosive
vapors and/or liquids in the vicinity of this or any other appliance.
DO NOT install any damaged venting system components. If damage is
evident then please contact the supplier where the water heater was
purchased or the manufacturer listed on the rating plate for replacement
parts.
TEMPERATURE & PRESSURE RELIEF VALVE
DANGER
Use only vent terminals provided or factory authorized terminals for
venting this water heater.
This water heater is equipped with an adjustable thermostat to control
water temperature. Hot water temperatures required for automatic
dishwasher and laundry use can cause scald burns resulting in serious
personal injury and/or death. The temperature at which injury occurs
varies with the person’s age and the time of exposure. The slower
response time of disabled persons increases the hazards to them. NEVER
allow small children to use a hot water tap, or to draw their own bath water.
NEVER leave a child or disabled person unattended in a bathtub or shower.
Failure to properly install the vent and air intake (if applicable) system
could result in property damage, personal injury, or death.
WARNING
Keep clear of the combination temperature and pressure relief
valve discharge line outlet. The discharge may be hot enough to
cause scald injury. The water is under pressure and may splash.
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local codes,
but not less than a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that maintains periodic
inspection of production of listed equipment or materials as meeting the
requirements of the Standard for Relief Valves and Automatic Gas Shutoff
Devices for Hot Water Supply Systems, ANSI Z21.22 and the Standard
CAN1-4.4 Temperature, Pressure, Temperature and Pressure Relief Valves
and Vacuum Relief Valves. The combination temperature and pressure
relief valve must be marked with a maximum set pressure not to exceed
the maximum working pressure of the water heater. The combination
temperature and pressure relief valve rating must not be less than the
hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the
opening provided and marked for this purpose on the water heater.
Note: Some models may already be equipped or supplied with an installed
combination temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve complies with local
codes. If the combination temperature and pressure relief valve does not
comply with local codes, replace it with one that does.
Install a discharge line so that water discharged from the combination
temperature and pressure relief valve will exit within six (6) inches (15.2
cm) above, or any distance below the structural floor and cannot contact
any live electrical part. The discharge line is to be installed to allow for
complete drainage of both the combination temperature and pressure
relief valve and the discharge line. The discharge opening must not be
subjected to blockage or freezing. DO NOT thread, plug or cap the discharge
line. It is recommended that a minimum clearance of four (4) inches (10.2
cm) be provided on the side of the water heater for servicing and
maintenance of the combination temperature and pressure relief valve.
Do not place a valve between the combination temperature and pressure
relief valve and the tank!
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INSTALLATION INSTRUCTIONS
WARNING
This water heater must be located in an area where leakage of the
tank, water line connections, or the combination temperature and
pressure relief valve will not result in damage to the area adjacent to
the water heater or to lower floors of the structure. When such locations
cannot be avoided, a suitable drain pan must be installed under the
water heater. The drain pan depth must be suitable for draining and
collecting water, and have a minimum length and width of at least four
(4) inches (10.0 cm) measured from the jacket of the water heater.
The drain pan, as described above, can be purchased from your
plumbing professional. The drain pan must be piped to an adequate
drain. The piping must be at least ¾ inch (2.0 cm) in diameter and
pitched for proper drainage.
Locating The Water Heater
1. LOCATE so that venting connections will be short and direct.
2. THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE
FLOOR. DO NOT install this water heater on carpeting.
3. FOR BASEMENT INSTALLATION, provide a solid level elevated base
such as concrete.
4. Minimum clearance to combustible material is 0" for the Top, Sides
and Rear of this water heater. However, it is recommended that at
least 18" from the Top, 24" from the Front, and 4" for the
Sides and Rear of the water heater be provided for servicing.
Clearance for servicing may be reduced down to minimum clearance
to combustible material, but service time and effort may be greatly
increased.
LOCATION
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND
LIQUIDS.
This water heater must be located in an area where the general public does
not have access to set temperatures.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
• Liquefied petroleum gases/propane gas and natural gas have
an odorant added by the gas supplier that aids in detection of
the gas.
• Most people recognize this odor as a “sulfur” or “rotten egg”
smell.
• Other conditions, such as “odorant fade” can cause the odorant
to diminish in intensity, or “fade”, and not be as readily
detectable.
• If you have a diminished sense of smell, or are in any way
unsure of the presence of gas, immediately contact your gas
supplier from a telephone in another building.
• Gas detectors are available. Contact your gas supplier or
plumbing professional for more information.
Liquefied petroleum gases/propane gas is heavier than air and will
remain at floor level if there is a leak. Basements, crawl spaces,
closets and areas below ground level will serve as pockets for
accumulation of leaking gas. Before lighting, smell all around the
appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any telephone in
your building.
• Immediately call your gas supplier from a telephone in another
building. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS
CORRECTED!
Figure 1 Minimum Clearance To Combustible
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AIR REQUIREMENTS
1. Do not obstruct the flow of combustion and ventilating air.
2. For safe operation, adequate air is needed for combustion and
ventilation. Sooting may result in serious damage to the water heater
and risk of fire or explosion. It can also create a risk of asphyxiation.
Such a condition often will result in a yellow, luminous burner flame,
causing carboning or sooting of the combustion chamber, burner and
flue tubes.
MECHANICAL EXHAUSTING OF ROOM AIR
1. Where an exhaust fan is installed in the same room with this water
heater and combustion air is drawn from inside the room, sufficient
openings for air must be provided in the walls.UNDERSIZED
OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH
THE WATER HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION
THAT MAY BE HAZARDOUS TO LIFE. SOOTING MAY RESULT IN SERIOUS
DAMAGE TO THE WATER HEATER AND RISK OF FIRE OR EXPLOSION
WHICH CAN ALSO CREATE A RISK OF ASPHYXIATION. Refer to local
codes and /or National Fuel Gas Code for proper air opening sizing.
UNCONFINED SPACE
1. In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion and
ventilation.
2. If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping, heavy
insulation, caulking, vapor barrier, etc.), air for combustion and
ventilation must be obtained from outdoors. This may be
accomplished by piping air directly to the water heater from outside
or providing opening or ducts in the wall. The installation instructions
for confined spaces in tightly constructed buildings must be followed
to ensure adequate air supply.
• If horizontal ducts are used, each opening shall have a free area
of not less than one square inch per 2000 Btu/hr of the total input
of all appliances in the enclosure.
3. If the water heater is installed as a direct vent (outside air piped
directly to the water heater), then additional opening, other than
the opening for the air intake, are not required. However, adequate
ventilation air must be provided in all cases to prevent increased
room temperature.
CHEMICAL VAPOR CORROSION
Corrosion of the flue ways and vent system will occur if air for combustion
contains certain chemical vapors. Such corrosion may result in poor
combustion and create a risk of asphyxiation. Spray can propellants,
cleaning solvents, refrigerator and air conditioning refrigerants, swimming
pool chemicals, calcium and sodium chloride, waxes and process chemicals
are corrosive. Products of this sort should not be stored near the water
heater or outside by the air intake (if applicable).
TYPICAL INSTALLATION ILLUSTRATION
CAUTION
If building cold water supply has a back-flow preventer, check valve
or water meter with check valve provisions for thermal expansion of
water in the hot water system must be provided.
Figure 2
Typical Front Inlet Connection
CONFINED SPACE
1. When drawing combustion air from inside a conventionally
constructed building to a confined space, such a space shall be
provided with two permanent openings.
• The top opening is to be located within twelve (12) inches of the
enclosure top and the bottom opening within twelve (12) inches
of the enclosure bottom.
• Each opening shall have a free area of at least one square inch
per 1000 Btu/hr of the total input of all appliances in the enclosure,
but not less than 100 square inches.
2. If the confined space is within a building of tight construction, air for
combustion and ventilation must be obtained from outdoors. This
may be accomplished by piping air directly to the water heater from
outside or providing opening or ducts in the wall. When directly
communicating with the outdoors through vertical ducts, two
permanent openings, located in the above manner, shall be provided.
• Each opening shall have a free area of not less than one square
inch per 4000 Btu/hr of the total input of all appliances in the
enclosure.
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Figure 3
Typical Front Inlet Connect with Storage Tank
Figure 4
Typical Two Water Heater Connection
Figure 6 Typical Four Water Heater Connection
WATER CONNECTIONS
WARNING
Failure to install and maintain a new, listed temperature and pressure
relief valve will release the manufacturer from any claim, which might
result from excessive temperature and pressures.
Hydrogen gas can be produced in an operating water heater that has
not had water drawn from the tank for a long period of time (generally
two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE. To
prevent the possibility of injury under these conditions, we recommend
the hot water faucet to be open for several minutes at the kitchen sink
before you use any electrical appliance, which is connected to the hot
water system. If hydrogen is present, there will be an unusual sound
such as air escaping through the pipes as hot water begins to flow. Do
not smoke or have open flame near the faucet at the time it is open.
Figure 5
Typical Three Water Heater Connection
Keep clear of the combination temperature and pressure relief valve
discharge line outlet. The discharge may be hot enough to cause scald
injury. The water is under pressure and may splash.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples in
front or side of the water heater. Sweat the tubing to the adapter
before fitting the adapter to the water connections. It is imperative
that heat is not applied to the nipples containing a plastic liner.
INSTRUCTIONS FOR CONNECTIONS
1. BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN
WATER SUPPLY VALVE. After shutting off the main water supply,
open a faucet to relieve the water line pressure to prevent any
water from leaking out of the pipes while making the water
connections to the water heater. The COLD water inlet and HOT
water outlet are identified on the water heater. Make the proper
plumbing connections between the water heater and the plumbing
system to the house. Install a shut-off valve in the cold water
supply line.
2. If this water heater is installed in a closed water supply system, such
as the one having a back-flow preventer in the cold water supply,
provisions must be made to control thermal expansion. DO NOT
operate this water heater in a closed system without provisions for
controlling thermal expansion. Warranties do not cover damages
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from thermal expansion such as pressure bulges and/or deformities.Your
water supplier or local plumbing inspector should be contacted on how
to control this situation.
3. After installation of the water lines, open the main water supply valve
and fill the water heater. While the water heater is filling, open
several hot water faucets to allow air to escape from the water system.
When a steady stream of water flows through the faucets, close them
and check all water connections for possible leaks.
4. Never operate the water heater without first being certain it is filled
with water.
SCALDING
This water heater can deliver scalding temperature water at any faucet in
the system. Be careful whenever using hot water to avoid scalding injury.
Certain appliances such as dishwashers and automatic clothes washers
may require increased temperature water. By setting the thermostat on
this water heater to obtain the increased temperature water required by
these appliances, you may create the potential for scald injury. To protect
against injury, you should install ASSE approved mixing valve in the water
system. This valve will reduce point of discharge temperature by mixing
cold and hot water in branch supply lines. Such valves are available from
the local plumbing supplier.
Table 1
Approximate Time/Temperature Scald Chart
APPROXIMATE TIME/TEMPERATURE
RELATIONSHIPS IN SCALDS
120° F More than 5 minutes
125° F 1½ to 2 minutes
130° F About 30 seconds
135° F About 10 seconds
140° F Less than 5 seconds
145° F Less than 3 seconds
150° F About 1½ seconds
155° F About 1 second
ALTERNATE SPACE HEATING WATER CONNECTIONS
DANGER
Toxic chemical, such as those used for boiler treatment, shall not be
introduced into potable water used for space heating.
This water heater shall not be connected to an existing heating
system or component(s) previously used with a non-potable water
heating appliance.
All piping components connected to this water heater for space
heating applications must be suitable for use with potable water.
Figure 7 Scald Warning
When the system requires water for space heating at temperatures
WARNING
higher than required for other means, a tempering valve shall be
installed to temper the water for those uses in order to reduce the
scald hazard potential.
Failure to properly pipe this water heater may result in improper
operation and damage to the water heater or structure.
Oxygen contamination of this water heater will cause corrosion of iron
and steel components, and can lead to water heater failure.
Connect the system supply and return piping to the water heater.
Refer to Figure 8 and Figure 9 for installation examples. Maintain a
minimum ½” clearance from hot water piping to combustible materials.
Figure 8
Alternate Space Heating Connections
The following chart details the relationship of water temperature and time
with regard to scald injuy and may be used as a guide in determining the
safest water temperature for your applications.
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Figure 9 Typical Plumbing Schematic for Zoned Heating
TuboCharger Water Heater
VENTING
WARNING
The vent system must be properly installed. Failure to properly install
the vent system could result in property damage, personal injury, or
death.
DO NOT install damaged venting system components. If damage is
evident then please contact the supplier where the water heater was
purchased or the manufacturer listed on the rating plate for
replacement parts.
Use only the vent terminals provided or factory authorized terminals
for venting this water heater.
The water heater requires its own separate venting system. Do not
connect the exhaust vent into an existing vent pipe or chimney.
All of the exhaust venting connections must be leak checked with a
soap solution upon initial start up of the water heater. Any leaks must
be repaired before continuing operation of the water heater.
Do not terminate the venting where noise from the exhaust or intake
will be objectionable. This includes locations close to or across from
windows and doors. Avoid anchoring the vent and intake pipes directly
to framed walls, floors, or ceilings unless rubber isolation pipe hangers
are used. This prevents any vibrations from being transmitted into the
living spaces.
Do not exceed the venting distances or the number of elbows listed in
this manual. Exceeding the maximum venting distances may cause
the water heater to malfunction or cause an unsafe condition.
DO NOT operate this water heater until the venting installation is
complete and the piping completed. Failure to complete installation
before operation can result in property damage, personal injury, or
death.
CAUTION
The vent shall terminate a minimum of 12 inches above expected
snowfall level to prevent blockage of vent termination.
The horizontal centerline of the exhaust vent terminal (if applicable)
must not be located lower than the horizontal centerline of the air
intake terminal if vented through the same wall.
A service drain loop must be installed in the drain tubing to serve as
a condensate trap to prevent flue gases from escaping in the room.
DO NOT position air intake terminal above exhaust terminal.
NEVER locate air intake terminal when exhaust gases can be introduced.
NOTICE
Before beginning installation of any vent pipe, read the vent pipe
manufacturer’s installation instructions.
Water heater must be protected from freezing downdrafts during
shutdown periods.
Provide protection of the building materials from degradation by flue
gases from the exhaust vent terminal.
The venting instructions must be followed to avoid restricted combustion
or recirculation of flue gases. Such conditions cause sooting or risks of fire
and asphyxiation.
This water heater can be installed as either a direct vent system or power
vent (air from inside) system. If it is installed as a direct vent system,
then the air intake and the exhaust vent are piped to the outside. If a
power vented system is used, then air is drawn from inside and only the
exhaust is piped to the outside. Determine which system is best for your
application and install as described in the following sections.
DIRECT VENT INSTALLATION
Venting may be run horizontally through an outside wall or vertically
through a roof through using either 3 inch (7.6 cm) or 4 inch (10.2 cm)
diameter PVC or CPVC pipe. This water heater is supplied with a 3 inch PVC
screened intake and exhaust 90° elbow referred to as the exhaust vent
terminal and the air intake terminal.
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