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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 designers 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
Table of Contents
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 FIG. 15 FIG. 16 FIG. 17 TABLE A. TABLE B. TABLE C. TABLE D. TABLE E. TABLE TABLE TABLE TABLE F. G. H. I. Outdoor Venting . . . . . . . . . . .13 Primary/Secondary System Piping . . . . . . . . . . . . .16 Low Temperature Bypass System Piping . . . . . . . . . . . . .17 Heating/Chilled Water System . . . . . . . . . . . . .18 Clearances From Combustible Construction . . . . . .3 Conventional Venting, Vent Flue Size . . . . . . . . . . . . . .7 E+ Vent Sidewall Air Kit Part Numbers . . . . . . . . .9 E+ Vent Horizontal Air Kit Part Numbers . . . . . . . .11 Vertical Direct Vent Flue & Air Inlet Sizes . . . . . . . . . . . . .13 Outdoor Vent Kit . . . . . . . . . . .13 Gas Supply Pipe Sizing . . . . . .14 Inlet Gas Pressure . . . . . . . . . .14 Minimum & Maximum Boiler Flow Rates . . . . . . . . . . .15 Water Flow Requirements . . . . .15 Heat Exchanger Head-loss . . . .16 Amp Draw . . . . . . . . . . . . . . .19
Appendix A: Boiler Piping Diagrams Primary/Secondary Boiler . . . . . . . . . . . .A1 Multiple Unit - Primary/Secondary . . . . . .A2 Low Temperature Bypass Piping . . . . . . . .A3
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In designing a hot water heating system, pay special attention to:
Water Velocity (See Page 15 for minimum and
maximum flow rates.)
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
1. 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.
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the ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.)
3. Units located in a residential garage
*Allow sufficient space for servicing pipe connections, pump and other auxiliary equipment, as well as the appliance.
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.
4. 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.
5. The appliance must not be installed on
GAS CONNECTION SYSTEM RETURN FRONT LEFT SIDE BACK SYSTEM SUPPLY (FIG. 1) BOILER EQUIPMENT & CONTROL ORIENTATION BURNER INSPECTION PORT
EB150-300
DRAIN
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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 BTUs 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.
(FIG. 2) COMBUSTION AIR DIRECT FROM OUTSIDE (FIG. 4) COMBUSTION AIR FROM INTERIOR SPACE
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.
CAUTION: Under no circumstances should the equipment room be under a negative pressure when atmospheric combustion equipment is installed in the room.
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.
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.
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 cm2).
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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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.
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 manufacturers 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.
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.
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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.
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.
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.
NOTE: The weight of the venting system MUST NOT rest on the boiler. It should be properly supported.
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.
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.
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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.
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)
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.
CONVENTIONAL VENTING, VENT CONNECTION SIZE MODEL EB150 EB200 EB250 EB300 CONVENTIONAL VENT FLUE SIZE 5 5 6 6
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NOTE: An unlined masonry chimney should not be used to vent flue products from this high efficiency appliance.
When each unit is installed with an individual vent, and the negative draft is higher than the specified range (0.02 to 0.05 inches of water column), a barometric damper will be necessary.
All draft readings are made while the unit is in stable operation (approximately 2 to 5 minutes). For this type of installation, it is best to use a draft control for each boiler located on the riser between the vent outlet and the breeching - Location A. (Figure 7) When this riser is too short to permit the installation of a control, locate a separate control for each boiler on the main breeching as illustrated in Location B. (Figure 7) If, because of general crowding or other reasons, neither of these locations are possible, use a single large control in the breeching between the boiler nearest the chimney and the chimney, as shown in Location C. (Figure 7) Conventional Venting with Direct Combustion Air Intake (E+Vent) This vent system uses two pipes, one vertical pipe with a roof top termination for the flue products and one pipe for combustion air. The combustion air pipe may terminate horizontally with a sidewall air inlet or vertically with a roof top air inlet. All instructions for Conventional Venting Negative Draft apply to Conventional Venting with Direct Combustion Air. The flue may be combined with the vent from any other negative draft, Category I appliances. Utilize Category I type B vent material for venting flue products.
Multiple unit installations with combined venting require barometric dampers to regulate draft at each unit. The negative draft must be within the range of 0.02 to 0.05 inches of water column to ensure proper operation.
BAROMETRIC DAMPER ON SINGLE UNIT INSTALLATION
Lined Chimney
WATER HEATER/BOILER
WATER HEATER/BOILER
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The sidewall or vertical roof top E+Vent combustion air supply system has specific vent material and installation requirements. The air inlet pipe connects directly to the boiler to supply combustion air. In most installations, the combustion air inlet pipe will be a dedicated system with one air inlet pipe per boiler. Multiple air inlets may be combined if the guidelines in Combined Air Inlet Points are followed. The air inlet pipe will be connected to a combustion air inlet cap as specified in this section. Combustion air supplied from outdoors should be free of contaminants. The air inlet pipe(s) must be sealed. Select air inlet pipe material from the following specified materials: PVC, CPVC or ABS (4, 5 or 6 I.D.). Dryer vent (not recommended for roof top air inlet) Galvanized steel vent pipe with joints and seams sealed. Type B double wall vent with joints and seams sealed. The total equivalent length of the sidewall or vertical roof top E+Vent combustion air inlet pipe shall not exceed a maximum of 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.5m) for each elbow in the air intake system.
(TABLE C) E+ VENT SIDEWALL AIR KIT PART NUMBERS MODE NUMBER EB150 EB200 EB250 EB300 CONVENTIONAL VENT AIR SIDEWALL FLUE SIZE* INLET PIPE** E+ VENT KIT 5 5 6 6 4 4 5 5 SVK 3020 SVK 3020 SVK 3021 SVK 3021
NOTE: The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the accumulation of condensation on the pipe exterior.
*Vent size with 1 increaser installed for conventional negative draft venting.
Sidewall Air Inlet The sidewall air inlet cap is supplied in the E+ Sidewall Vent Kit. Each kit includes a sidewall combustion air inlet cap to supply air to a single boiler and instructions for proper installation. The part number for each kit is listed by unit size. Locate units as close as possible to the sidewall where the combustion air supply system will be installed. To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance requirements in the latest edition of the National Fuel Gas Code and instructions in this guide. The combustion air inlet cap must be placed at least one foot (0.3m) above ground level and above normal snow levels.
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Vertical Air Inlet The air inlet cap for the vertical roof top air inlet is assembled from components purchased locally. The air inlet cap consist of two 90 ells installed at the point of termination for the air inlet pipe. The point of termination for the combustion air inlet cap must be at least 2 feet (0.6m) below the point of flue gas termination (vent cap) if it is located within 10 ft. (3.0m) of the flue outlet. The termination ell on the air inlet must be located a minimum of 12 (0.3m) above the roof or above normal levels of snow accumulation. It must not be placed closer than 10 feet (3.0m) from an inside corner of an L-shaped structure. Incorrect location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process of the boiler. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. Combined Air Inlet Points The air inlet pipes from multiple boilers can be combined into a single common connection, if the common air inlet pipe has a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe. The air inlet point for multiple boiler air inlets shall be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet. This exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 50 equivalent feet(15.2m). Deduct the restriction in area provided by any screens, grills or louvers installed in the common air inlet point. Screens, grills, or louvers installed in the common air inlet can reduce the free area of the opening from 25% to 75% based on the materials used. The air inlet cap for the combined air supply from multiple boilers can be purchased or fabricated in the field. Direct Venting A direct vent boiler uses a two pipe system, one pipe for the flue products and one pipe for the combustion air supply. The flue cannot be combined with any other appliance vent or common vent from multiple boilers. The vent on a direct vent system will have a positive pressure in the flue, which requires all vent joints and seams to be sealed gas-tight. The flue from a direct vent system shall have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system. Direct vent systems require Category IV vent material with AL29-4C approved stainless steel. The air inlet pipe connects directly to the boiler to supply combustion air. The air inlet pipe must be sealed. Choose acceptable
EXAMPLE OF COMBINED AIR INLET SIZING Two 5 air inlet pipes (19.6 in2 area each) have a total area of 39.2 in2 requiring an 8 (50.3 in2 area) common air inlet pipe.
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combustion air pipe materials from those specified in this section. Approved material for air inlet pipes include: PVC, CPVC or ABS (3, 4, 5 or 6 I.D.), dryer vent, and galvanized steel vent pipe with joints and seams sealed. The total equivalent length of the direct vent flue pipe or the air inlet pipe should not exceed a maximum of 50 equivalent feet (15.2m) in length for each pipe. Subtract 5 feet (1.5m) for each elbow in the vent pipe or air intake system.
The part number for each kit is listed by unit size. Each kit includes a sidewall vent cap for flue products, a firestop, a combustion air inlet cap, and instructions for proper installation. It is important to be careful in the placement of the horizontal direct vent caps. Combustion air supplied from outdoors should be free of contaminants. To prevent recirculation of flue products into the combustion air inlet:
1. The combustion air inlet cap must not be
NOTE: The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the accumulation of condensation on the pipe exterior.
Horizontal Direct Vent Horizontal direct vent applications require a vent kit which will be supplied by Lochinvar to assure proper operation.
clearance between the combustion air inlet cap and the flue outlet cap. Additional space may be required between caps where high winds may occur.
3. The combustion air inlet cap and vent cap
for flue outlet must be located on the same sidewall and in the same pressure zone.
4. Do not place the combustion air inlet cap
(FIG. 11) HORIZONTAL DIRECT VENT CAP
(TABLE D)
HORIZONTAL DIRECT VENT KIT PART NUMBERS MODEL NUMBER FLUE PIPE SIZE AIR INLET PIPE PART NUMBER
one foot (0.3m) above ground level and above normal snow levels.
4 4 5 5
4 4 5 5
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CAUTION!
Boilers which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit. Proper freeze protection MUST be provided.
(FIG. 12) MULTIPLE SIDEWALL VENT CAPS AIR INLETS FLUE OUTLETS 3 feet MIN. 3 feet MIN. AIR INLETS
Vertical Direct Vent Vertical direct vent applications do not require a vent kit to be supplied by Lochinvar. The vent cap and air inlet cap for vertical direct vent applications are fabricated or purchased in the field. A vertical vent cap, as specified by the vent material manufacturer, is used to vent the flue products to the outdoors. The air inlet cap consists of two 90 ells installed at the point of termination for the air inlet pipe. The termination ell on the air inlet must be located a minimum of 12 (15.2cm) above the roof or above normal levels of snow accumulation. The point of termination for the air inlet shall be 24 (0.6m) lower than the point of flue gas termination, if it is located within 10 ft. (3.0m) of the flue outlet. Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the boiler. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products.
Multiple Unit Applications (Horizontal Direct Vent) The combustion air inlet caps for multiple unit installations must maintain the minimum 3 foot (0.9m) radius clearance below or horizontally from the closest flue outlet. Multiple flue outlet caps may be installed side by side, and multiple air inlet caps may be installed side by side, but the 3 foot (0.9m) radius minimum clearance between air inlet and flue outlet must be maintained. All clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple unit installations.
CAUTION!
Maintain a minimum 3 foot (0.9m) radius clearance between the combustion air inlet cap and the flue outlet cap.
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Multiple Unit Applications (Vertical Direct Vent) The combustion air inlet caps for multiple unit installations must maintain the minimum 2 foot (0.6m) clearance below the closest vertical flue outlet if within 10 feet (3.0m). Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side, but the air inlet must always be at least 2 feet (0.6m) below the closest flue outlet if the outlet is within 10 feet (3.0m).
(FIG. 14) OUTDOOR VENTING
OUTDOOR INSTALLATION
Units are self venting and can be used outdoors when installed with the optional Outdoor Vent Kit. This kit includes a one piece top cover which replaces the standard two piece cover, air inlet cap, exhaust cap, gas valve cover and junction box cover. The 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" (76mm) to combustible surfaces and a minimum of 3" (76 mm) clearance to the air inlet. 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.
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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, gas valve cover, junction box cover and one piece unit top.
(TABLE F) OUTDOOR VENT KITS
MODEL NUMBER EB150 EB200 EB250 EB300 OUTDOOR VENT KIT ODK3069 ODK3070 ODK3071 ODK3072
Freeze Protection- Outdoor 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.
EFFICIENCY
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EXAMPLE OF HIGH ALTITUDE APPLICATIONS For example, if a units input is 200,000 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 x 0.04)] = Btu/hr Input at specified elevation. [200,000][1.00 (4000/1000 x 0.04)] = Btu/hr Input 4000 elevation. [200,000][0.84] = 168,000 Btu/hr Input at 4000 elevation.
1 1-1/4 1-1/2 2 2-1/2 3 4 Nominal Iron Pipe Size, Inches 3/4 10 369 697 1,400 2,150 4,100 6,460 11,200 20 256 477 974 1,500 2,820 4,460 7,900 30 205 384 789 40 174 328 677 50 155 292 595 923 1,720 2,720 4,870
Maximum capacity of pipe in thousands of BTUs 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 BTUs per Cubic Foot of Gas and 0.60 Specific Gravity).
GAS SUPPLY
1. Safe operation of unit requires properly
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.
(TABLE H) INLET GAS PRESSURE REQUIREMENTS
NATURAL GAS
Max. Allowable (Inches-water column) Min. Allowable (Inches-water column) 10.5
heater connection.
3. An internal gas pressure regulator is required
if upstream pressure exceeds 6 oz. (10.5" water column), an intermediate gas pressure regulator, of the lockup type,
must be installed.
4. Installation of a union is suggested for
ease of service.
5. Install a manual main gas shutoff valve
LPG
13
NOTE: Care should be taken to measure temperature rise and maintain proper water velocity in the heat exchanger.
with test plug, outside of the appliance gas connection and before the gas valve, when local codes require.
6. A trap (drip leg) should be provided in the
4.7
WATER CONNECTIONS
Inlet and Outlet Water Connections For ease of service, install unions on inlet and outlet of the boiler. The connection on the unit marked Inlet should be used for return water from the system. The connection on the header marked Outlet should be connected to the system supply. (See Boiler Piping diagrams, Appendix A).
EFFICIENCY
inlet of the gas connection to the unit. 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
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layout must be taken into consideration for proper system flow. (Table I) provides maximum and minimum flow data for each model. (Table J) provides Gallons Per Minute and boiler head-loss at various temperature rises for each boiler based on Btu/hr input. These two charts will provide assistance in system flow design. Primary/Secondary Piping Using a primary/secondary piping arrangement can solve many system flow complications. This piping arrangement uses a dedicated pump to supply flow to the boiler. The pump is sized based on the required boiler flow rate, boiler head-loss and head-loss in the secondary system piping. A separate pump is used to provide the desired flow for the system.
Primary/Secondary piping allows the system and the boiler(s) to operate at their optimum flow rate. The system works best when the boiler(s) are supplied with pump control relays which are used to cycle the secondary pump(s). When piped correctly, the secondary pump helps to prevent flow through the boiler(s) when they are not firing. Use of primary/secondary system will eliminate the need for a system or boiler bypass. Figure 15 depicts one example of primary/secondary piping.
6 8 10 12
60 60 60 60
(TABLE J) WATER FLOW REQUIREMENTS TEMPERATURE RISE INPUT 150,000 200,000 250,000 300,000 OUTPUT 126,000 168,000 210,000 252,000 GPM 25.2 33.7 42.1 50.5 10F T FT. HD 0.9 1.4 1.7 2.6 GPM 16.8 22.4 28 33.6 15F T FT. HD 0.5 0.6 1.2 1.6 GPM 12.6 16.8 21 25.2 20F T FT. HD 0.4 0.5 0.7 1.1 GPM 10.1 13.4 16.8 20.2 25F T FT. HD 0.3 0.4 0.6 0.7 GPM 8.4 11.2 14 16.8 30F T FT. HD 0.2 0.3 0.5 0.6 40F T GPM 6.3 8.4 10.5 12.6 FT. HD 0.2 0.3 0.4 0.5
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IMPORTANT! Operation of this boiler on a low temperature system requires special piping to ensure correct operation. Consult Low Water Temperature System section for piping details.
*12 MAX HEATING RETURN LOOP HEATING SUPPLY LOOP TO FLOOR DRAIN MAKE-UP WATER LIT0476
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 available for use as a low water cutoff device on all models. The flow switch should be installed in the outlet piping of the boiler and wired into the ignition system. Per ASME CSD1 and in most localities, a flow switch is accepted as a low water cutoff for boilers requiring forced circulation. (See CSD1 CW-210, Part A) It is prudent to verify preference with the local code official.
A specially sealed flow switch and conduit are furnished for outdoor installations.
Low Water Cut-off If this boiler is installed above radiation level, a low water cut-off device must be installed at the time of boiler installation (option available from factory). Relief Valve Piping This boiler is supplied with a pressure relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV Heating Boilers. Low Flow Systems When the system flow rate is less than the minimum flow required for proper boiler operation, the Efficiency+ boiler should be installed with a primary/secondary piping system. This will allow the installation of a secondarycirculating pump sized specifically to provide a higher flow rate through the boiler and the secondary loop piping to ensure proper operation. See Primary/Secondary Piping for installation and piping requirements.
Three Way Valves The installation of a three-way valve in a hydronic heating application is not generally recommended, as most piping methods allow the three-way valve to vary flow through the boiler. This variable flow through the boiler is not recommended, as it alters heat transfer speed and places undue heat stresses on the heat exchanger surface. Additionally, low flow rates can result in overheating of the boiler water, which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. For these reasons, constant circulation is recommended to maintain proper operation while the boiler is firing.
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High Flow Systems When the flow rate of the system exceeds the maximum allowable flow rate through the boiler (Table I), boiler bypass piping should be installed. The bypass will divert the required portion of the system flow to the boiler and bypass excess system flow. This will effectively reduce boiler flow to an acceptable rate and increase system flow. The bypass piping should be sized equal to the system piping. Figure 16 depicts the proper piping arrangement for the Boiler Bypass.
boiler mass permits a simple bypass arrangement which will allow the system to be operated at any temperature above 60F (16C). A boiler operated with an inlet temperature of less than 140F (60C) must have a bypass to prevent problems with condensation. A Low Temperature Bypass as shown in Figure 15 should be piped into the system at the time of installation. This piping is like a primary/ secondary boiler installation with a bypass in the secondary boiler piping. Inlet water temperatures below 140F (60C) can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue. The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature to at least 140F (60C). This will prevent the products of combustion from condensing in most installations. Size low temperature bypass piping equal to system piping, and use fully ported control valves.
MAKE-UP WATER
LIT0473
boiler, requiring virtually no heat-up time, and having no temperature overshoot. Result - High system efficiency.
2. The boilers unique construction prevents the
transfer of heat exchanger thermal stresses to other boiler components, reducing wear and tear while increasing equipment life.
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EXPANSION TANK
OUT
IN R GAS SUPPLY
WATER SUPPLY
CHILLER
BOILER
DIAGRAM NOTES: 1. VALVES "D" AND "C" MAY BE MANUAL OR AUTOMATIC- TO SUIT. 2. PROVIDE DRAIN FOR RELIEF VALVE "R" TO SAFE PLACE. 3. CLOSE BOTH "A" AND "C" VALVES WHEN RUNNING CHILLER. 4. CLOSE BOTH "B" AND "D" VALVES WHEN RUNNING BOILER. 5. WATER SUPPLY VALVE REMAINS OPEN AT ALL TIMES.
AIR REMOVAL
An air separation device should be placed in the installation piping, on the suction side of the system pump, to eliminate trapped air in the system. Locate a system air vent at the highest point in the system. Additionally, a properly sized expansion tank may be required. Air charged, diaphragm type compression tanks are common. The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation.
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CAUTION!
For proper operation the system should not be operated at less than 12 PSIG.
NOTE:
ELECTRICAL REQUIREMENTS
(North America)
1. The appliance is wired for 120 volts.
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.
All wiring between the unit and field installed devices shall be made of type T wire [63F (35C) rise].
2. The pump must be wired to run
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20 8900
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PIPING DIAGRAM
MAKE-UP WATER
TO FLOOR DRAIN
12 MAX* *AS CLOSE AS PRACTICAL 12 OR 4 PIPE DIAMETERS MAXIMUM DISTANCE BETWEEN MANIFOLD CONNECTIONS TO SYSTEM. HEATING RETURN LOOP
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.
LIT0476
L E G E N D
RELIEF VALVE
CHECK VALVE
TEE
ELBOW
EXPANSION TANK
TANK FITTING
SYSTEM PUMP
UNION
AIR SEPARATOR
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A1
PIPING DIAGRAM
MAKE-UP WATER
TO SYSTEM SUPPLY
*AS CLOSE AS PRACTICAL 12 OR 4 PIPE DIAMETERS MAXIMUM DISTANCE BETWEEN MANIFOLD CONNECTIONS TO SYSTEM.
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.
LIT0475
L E G E N D
RELIEF VALVE
CHECK VALVE
TEE
ELBOW
EXPANSION TANK
TANK FITTING
SYSTEM PUMP
UNION
AIR SEPARATOR
A2
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PIPING DIAGRAM
MAKE-UP WATER
PRIMARY - SECONDARY BOILER PIPING WITH BYPASS FOR LOW TEMPERATURE OPERATION *AS CLOSE AS PRACTICAL 12 OR 4 PIPE DIAMETERS MAXIMUM DISTANCE BETWEEN MANIFOLD CONNECTIONS TO SYSTEM.
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.
LIT0473
L E G E N D
RELIEF VALVE
CHECK VALVE
TEE
ELBOW
EXPANSION TANK
TANK FITTING
SYSTEM PUMP
UNION
AIR SEPARATOR
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A3
Notes
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EB-DG-03
4.5M-2/05-Printed in U.S.A.