Lochinvar 502 manual

Installation & Operation Manual Models: 502 - 2072 This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual and the Copper-fin 2 Pool Heater Service Manual be reviewed completely before proceeding with an installation. Perform steps in the order given. Failure [...]

Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk level s 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[...]

3 3 Please read before proceeding NOTICE This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier.  WARNING If the information in these instructions is not followed exactly, a fire or explosion may result[...]

4 Please read before proceeding  Owner warning – The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers. NOTICE Consult and follow all local Building and Fire Regulations and other Safety Codes that apply to this installation. Consult local gas utility company to[...]

5 The Copper-fin 2 - How it works... 1. Heat exchanger The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper fined tubing are encased in a jacket that contains the combustion process. 2. Heat exchanger access cover The heat exchanger access cover is a galvanized[...]

6 The Copper-fin 2 - How it works... 16 11 16 16 16 24 Models 502 - 752 Front View Models 502 - 752 Left Side (inside unit) Models 502 - 752 Right Side (inside unit) Models 502 - 752 Rear View 13 20 23 2 22 4 3 15 21 14 8 12 19 5 6 1 18 17 7 Installation & Operation Manual[...]

7 The Copper-fin 2 - How it works... (continued) Models 992 - 2072 Left Side (inside unit) Models 992 - 2072 Right Side (inside unit) Models 992 - 2072 Rear View Models 992 - 2072 Front View 16 16 16 11 16 24 13 20 23 15 3 4 2 22 8 21 14 12 6 19 5 1 18 17 7 Installation & Operation Manual[...]

8 Ratings Notes: 1. Copper-fin 2 pool heaters require special gas venting. Use only the vent materials and methods specified in the Copper-Fin 2 Pool Heater Installation and Operation Manual. 2. The Copper-fin 2 is orificed for operation up to 2000 feet altitude, and including up to 4,500 feet, with no field adjustments. The appliance will de-rate [...]

9 1 Determine unit location 3" MIN REAR 3" MIN TOP 30" MIN FRONT 6" MIN LEFT SIDE 3" MIN RIGHT SIDE Installation & Operation Manual NOTICE Clearances from combustible construction are noted on the appliance rating plate. Location of unit This unit meets the safe lighting performance criteria with the gas manifold and co[...]

10 1 Determine unit location Installation & Operation Manual 2. Outside Combustion Air, Using Ducts You can direct outside combustion air to this unit using two air ducts to deliver the air to the mechanical room (see FIG. 1-5). Each of the two openings must have a minimum free area of one square inch per 2000 Btu input (11cm 2 per kW). 3. Comb[...]

1 Determine unit location (continued) 11 Installation & Operation Manual Figure 1-5_ Outside Combustion Air Through Ducts 4. Outside Combustion Air - Using Direct Venting With this option, you can connect combustion air vent piping directly to the unit. See the information under Direct Venting starting on page 26 for specific information regard[...]

12 1 Determine unit location Installation & Operation Manual Exhaust fans Any fan or equipment which exhausts air from the mechanical room may deplete the combustion air supply and/or cause a down draft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition tha[...]

13 2 Venting BEFORE YOU BEGIN Identify your appliance’s vent system: This manual covers venting requirements for CAT I models and CAT IV vent materials. Be sure to correctly identify the type of vent system your appliance requires before proceeding. CP (N,L) 0502 CP (N,L) 0652 CP (N,L) 0752 CP (N,L) 0992 CP (N,L) 1262 CP (N,L) 1442 CP (N,L) 1802 [...]

Vent system options: (Note: Installations shown below are representative, actual installations may vary from those shown.) Installation & Operation Manual 14 2 Venting A This option uses a vertical rooftop flue termination with air supplied from the equipment room - see page 16. This option uses a powered vent assembly to exhaust the flue produ[...]

2 Venting (continued) 15 Installation & Operation Manual TABLE - 2A FLUE AND AIR INLET PIPE SIZES MODEL FLUE SIZE AIR INLET SIZE MODEL FLUE SIZE AIR INLET SIZE* 502 6" 6" 1262 12" 12" 652 8" 8" 1442 12" 12" 752 8" 8" 1802 14" 12" 992 10" 10" 2072 14" 12" *Minimum di[...]

Installation & Operation Manual 16 2 Venting A Conventional negative draft venting - see page 14. NOTICE Before installing a venting system, follow requirements found in the General Venting section. This option uses Type-B double-wall flue outlet piping. The blower brings in combustion air. The buoyancy of the heated flue products cause them to[...]

Installation & Operation Manual 17 2 Venting (continued) 4. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. 5. Close fireplace dampers. 6. Place in operation[...]

Installation & Operation Manual 18 2 Venting Figure 2-1_ Vent Termination from Peaked Roof - 10 ft. or Less From Ridge NOTICE Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer. Figure 2-2_ Vent Termination from Peaked Roof - 10 ft. or [...]

2 Venting (continued) 19 Installation & Operation Manual The sidewall or vertical rooftop DirectAire™ combustion air supply system has specific material and installation requirements. The air inlet pipe connects directly to the unit to supply combustion air. In most installations, the combustion air inlet pipe will be a dedicated system with [...]

20 2 Venting Installation & Operation Manual To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable cleara nce requirements in the latest edition of the National Fuel Gas Code and/or CAN/CGA-B149 Installation Code and instructions in the Installation and Operation Manual. Clearan[...]

2 Venting (continued) 21 Installation & Operation Manual TABLE - 2B DIRECTAIRE KITS MODEL HORIZONTAL KIT* VERTICAL KIT* 502 SVK3047 VDK3026 652 SVK3048 VDK3027 752 SVK3048 VDK3027 992 SVK3040 VDK3023 1262 SVK3041 VDK3024 1442 SVK3041 VDK3024 1802 SVK3041 VDK3024 2072 SVK3041 VDK3024 *The SVK kits include a DV box adapter and sidewall air inlet [...]

2 Venting 22 Installation & Operation Manual Sidewall venting - see page 14. NOTICE Before installing a venting system, follow all requirements found in the General Venting section. C This option uses a powered vent assembly which pulls the flue products out of the stack. This fan generates a negative draft at the unit. Combustion air is drawn [...]

23 2 Venting (continued) Installation & Operation Manual Sidewall venting without fan For Models 502 - 752 which are approved for sidewall venting without an external power vent fan, you must install specific vent kits and venting materials (reference Table 2C on page 24 for kit numbers). The following is a detailed explanation of Sidewall Vent[...]

24 2 Venting Installation & Operation Manual  WARNING Do not combine the flue from this unit with the vent from any other appliance. Do not combine flues from multiple appliances into a common vent. The flue from this unit must be a dedicated stack. Connect the flue vent directly to the flue outlet opening on the top of the unit. Make the co[...]

2 Venting (continued) 25 Installation & Operation Manual Horizontal DirectAire™ venting (Powered Venting) - see page 14. The Horizontal DirectAire™ vent system is the same as the Sidewall Venting system, except it pulls combustion air from the outdoors through a sidewall air inlet. Follow all requirements in Sidewall Venting section on page[...]

26 2 Venting Installation & Operation Manual E This option uses sealed AL29-4C vent materials for the flue outlet piping and separate combustion air inlet piping. This system terminates both the flue and combustion air inlet in the same pressure zone. The flue outlet and combustion air intake may terminate at either a sidewall or the rooftop. T[...]

2 Venting (continued) 27 Installation & Operation Manual Masonry chimney installation Do not use a standard masonry chimney to directly vent the combustion products from this unit. To use a masonry chimney, the chimney must use a sealed, corrosion-resistant liner system. Sealed, corrosion-resistant liner systems (single-wall, double-wall, flexi[...]

28 2 Venting Installation & Operation Manual Length of air inlet pipe The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet (15.2 m). Subtract 5 feet (1.5 m) of equivalent length for each 90° elbow. Subtract 2.5 feet (0.7 m) of equivalent length for each 45° elbow. Do not exceed t[...]

2 Venting (continued) 29 Installation & Operation Manual 2. For PVC, CPVC, ABS, dryer vent, or flex duct air inlet piping, use a silicone sealant to ensure a proper seal at the unit inlet and the air inlet cap. 3. For Dryer vent or flex duct, also use a screw-type clamp to attach the inlet vent material to the unit inlet and the air inlet cap. [...]

2 Venting 30 TABLE - 2F OUTDOOR VENT CAP KITS MODEL OUTDOOR VENT KIT MODEL OUTDOOR VENT KIT 502 ODK3075 1262 ODK3078 652 ODK3076 1442 ODK3079 752 ODK3076 1802 ODK30005 992 ODK3077 2072 ODK30005 Installation & Operation Manual Outdoor installation - see page 14. NOTICE Before installing a venting system, follow all requirements found in the Gene[...]

31 3 Gas connections Connecting to gas supply Verify that the appliance is supplied with the type of gas specified on the rating plate. This appliance is configured for operation up to 4,500 feet altitude. Consult factory for installations above 4,500 feet elevation. Inlet gas pressure: Measured at the inlet pressure tap on the appliance gas manifo[...]

32 3 Gas connections Installation & Operation Manual 2. Use new, properly threaded black iron pipe free from chips. If you use tubing, make sure the ends are cut square, deburred and clean. Make all tubing bends smooth and without deformation. Avoid flexible gas connections. Internal diameter of flexible lines may not provide unit with proper v[...]

33 3 Gas connections (continued) SUPPLY INLET PRESSURE TAP INLET GAS VALVE CONTROL KNOB OUTLET Installation & Operation Manual Figure 3-3_ Measuring Gas Supply Pressure at Combination Gas Valve 13. Remove the manometer and related fitting from the “inlet” side of the gas valve, replace 1/8" hex plug in gas valve and tighten. 14. Turn o[...]

34 4 Water connections Figure 4-1_ Water Connections - Models 502 - 752 2" NPT WA TE R INLET 2" NPT WA TE R OUTLET INSPECTION PLUGS Figure 4-2_ Water Connections - Models 992 - 2072 2-1/2" NPT WA TE R INLET 2-1/2" NPT WA TE R OUTLET INSPECTION PLUGS Installation & Operation Manual Circulating pump 1. This pool heater is fact[...]

Heat exchanger This is a highly sophisticated heat exchanger, designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build-up of impurities. The straight-line, two pass design of the tubes sends water into the headers at a properly rated velocity. The configuration of the headers, in tu[...]

36 4 Water connections Figure 4-3_ Heater Within 15 feet of Pool Piping Installation & Operation Manual Figure 4-4_ Heater Beyond 15 feet of Pool Piping AUTOMATIC BYPASS VALVE PVC MIN (SEE TABLE) RECOMMENDED ISOLATION VALVE REQUIRED POOL RETURN SENSOR LOCATION POOL RE TURN SENS OR * SECONDARY LO CATIO N 20' MAX POOL RE TURN SENS OR PRIMARY[...]

37 4 Water connections (continued) Installation & Operation Manual Figure 4-5_ Cascaded heaters Within 15 feet of Perpendicular Pool Piping Figure 4-6_ Cascaded Heaters Beyond 15 feet of Pool Piping AUTOMATIC BYPASS VALVE RECOMMENDED ISOLATION VALVE * POOL RETURN SENSOR SECONDARY LOCATION POOL RE TURN SENS OR PRIMARY LOCATION 110 ° LIMIT 3&apo[...]

38 4 Water connections Figure 4-7_ Multi-stack frame - Cascaded heaters beyond 15 feet of pool piping Installation & Operation Manual AUTOMATIC BYPASS VALVE RECOMMENDE D ISOLATION VALVE PRIMARY LOCATION POOL SUPPLY SENSOR POOL RETURN SENSOR LOCATION COPPER OR PVC (SEE TAB LE) 110 ° LIMIT 3' MIN FROM POOL TO POOL 4" PVC 4" PVC FL[...]

39 4 Water connections (continued) Installation & Operation Manual INST ALLED VIEW END CAP (JKD6653) PLASTIC ACTUA TOR COVER V ALVE COVER (JKD6652) END CAP (JKD6654) EXPLODED VIEW * *NOTE: Refer to the numbers located next to the terminals when making wiring connections. R BK O BL FIELD CONNECTIONS TO TERMINAL #5 TO TERMINAL #6 TO TERMINAL #7 T[...]

40 4 Water connections Installation & Operation Manual Relief valve This pool heater is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV. The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. Place no other valve between the relief valve and the po[...]

41 5 Electrical connections Installation & Operation Manual 3-way automatic bypass valve wiring If the piping loop was disassembled for shipping or needs to be fitted with an outdoor enclosure, connection or disconnection of the 3-way automatic bypass valve will be required. Wiring connections should be made to the appropriately numbered termin[...]

42 5 Electrical connections Installation & Operation Manual Installation must comply with: 1. National Electrical Code and any other national, state, provincial, local codes, or regulations. 2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes. Pool heater operating control module The operating control for the appliance [...]

43 Installation & Operation Manual EMS or remote thermostat connection An EMS, remote thermostat or other remote temperature control may be connected to the pool heater (see FIG. 5-4). Follow the manufacturer’s instructions supplied with the remote temperature control for proper installation and adjustment. Connection of a set of dry switchin[...]

Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the heater is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the pool heater is down. Wiring of the cascade When wiring the heaters for Cascade operation, select one heater as the Leader. The rema[...]

45 6 Startup Installation & Operation Manual Check/control water chemistry Salt levels above 5000 ppm can cause corrosion damage to heat exchangers.  CAUTION The water chemistry of your pool changes daily due to natural evaporation of the water and the addition of chemicals. Chemicals are used to sanitize and control algae growth in the pool[...]

46 6 Startup Installation & Operation Manual If freeze protection is not provided for the system, a low ambient temperature alarm is recommended for the equipment room. Damage to the pool heater by freezing is non-warrantable. 1. Pump Operation - MOST IMPORTANT - This pool heater is designed for continuous operation of the filter system pump wh[...]

47 Installation & Operation Manual Figure 6-2_ Operating Instructions FOR YOUR SAFET Y READ BEFORE OPERAT ING A. This appliance is equipped with an ignition device which autom atically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERA TING smell all around the appliance area for gas. Be sure to smell next to the floor b[...]

48 Installation & Operation Manual 6 Startup Set clock The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the appliance is installed, and anytime the appliance has been powered off for more than one month. Use the following procedure to set the clock: 1. P[...]

7 Operating information 49 Installation & Operation Manual General How the appliance operates The Copper-fin 2 uses a copper finned tube heat exchanger to transfer heat from the flue products to the water. An electronic control module monitors various inputs to initiate a call for heat. The blower provides both primary and secondary air to the [...]

50 7 Operating information Installation & Operation Manual Freeze protection DO NOT install the appliance in a room likely to freeze. The following integral feature of the SMART SYSTEM control module provides some protection for the appliance only -- not for the system. • The SMART SYSTEM control module provides freeze-up protection as follow[...]

51 7 Operating information (continued) Installation & Operation Manual Cascade When multiple appliances are installed, they can be wired together in a cascade sequence. A maximum of eight appliances can be controlled from a single control. In this application one appliance would be designated as the Leader control and all others would be design[...]

52 7 Operating information Installation & Operation Manual Sequence of operation OPERATION DISPLAY 1. The high limit may require reset through the display before any action will take place. HTR: Standby OUT: 123.8F( 78) 2. Upon a call for heat the control turns on the unit pump. The flow switch and low water cutoff (if equipped) must close. HTR[...]

53 7 Operating information (continued) Installation & Operation Manual Copper-fin 2 control module MENU/E XIT DISPLAY SCREEN ENT ER/RE SET T X E N S U O I V E R P N W O D P U • Press to turn heater off or back on • Press to select a menu item • Press after parameter programming to store parameter data • Press to exit Service Mode • Ho[...]

54 Installation & Operation Manual 7 Operating information Access modes User The user can adjust the space heating target temperature and the tank target temperature (if a tank sensor is used) by using the UP and DOWN buttons (FIG. 7-1) at any time during normal operation. By entering the USER code (0704), the user can also change temperature u[...]

55 Installation & Operation Manual 7 Operating information (continued) Status Display Screens By using the Previous/Next (  ,  ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what the[...]

56 Installation & Operation Manual 7 Operating information Status Display Screens (cont’d) By using the Previous/Next (  ,  ) arrow keys on the SMART SYSTEM display panel, you can navigate through the 11 display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what the [...]

57 8 Maintenance Installation & Operation Manual Maintenance and annual startup Table 8A_ Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water, gas, flue, condensate) • Examine venti[...]

Installation & Operation Manual 8 Maintenance 58 Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system. Failure to follow the directions in this manual and component litera[...]

Installation & Operation Manual 8 Maintenance (continued) 59 Check relief valve 1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 4 - Water Connections of the Copper-fin 2 Installation and Opera[...]

Installation & Operation Manual 8 Maintenance 60 Check burner flame Visually check main burner flames at each start-up after long shutdown periods or at least every six months. A burner viewport is located on the burner mounting flange. Perform start-up and checks Start appliance and perform checks and tests specified in Section 6 - Start-up of[...]

Installation & Operation Manual 8 Maintenance (continued) 61 Inspect and clean the heat exchanger 1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. 2. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burn[...]

62 Installation & Operation Manual 9 Connection diagram + + + + + + + + OU T D OOR SEN SO R SYS R ET U R N SEN SOR SYS SU P PL Y SEN SO R 0-1 0V S YS -P U M P I N CN 2 1 2 3 4 5 6 7 8 FIE LD SU PP L I ED W IRING + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + ALARM CO NTACTS OPEN CLO SE COM RUNTI ME CON TACTS 3- W AY VA L [...]

Installation & Operation Manual 63 NOT E: NUMBER O F G AS VALVE S VARIES B Y MO DEL GR O U N D X11 X4 X9 X5 X6 X7 X8 X13 N UNIT 1 18 2 3 5 6 20 19 17 16 12 7 15 14 Y T W GY BL Y/G BR /W BL BK /R R/ B K BL/ BK BR BK 1 R/ B K 4 8 O/R PR 1 12 2 3 4 5 6 10 11 13 14 12 7 15 16 BL Y R W/B K O/ B K T R GY O/R T/W R/O R/ W BR BR /W 1 6 2 3 4 5 BL R /O [...]

64 Installation & Operation Manual 10 Ladder diagram BLOWER N ON/OFF SWITC H F2 3.15A BOX DEPI CTS OPTI ON AL I T EMS 120 VAC LOW VOL TAGE TERMINAL STRIP BLOW ER RELA Y HI/LO SPEED RELA Y HI/LO SPEED RELA Y HIG H SPEED LOW SPEED G L N UNIT PUM P RELA Y X1 -6 F4 5A BLOWER RELAY X1-8 X1-8 X1 -8 HI/LO SPEED RELAY X2-4 X1-2 UNIT PUM P R ELA Y X1-1 [...]

65 Installation & Operation Manual 10 Ladder diagram (continued) CN5-11 X6-1 X6 -13 CN5-5 LOUVER RE LAY CN4- 5 X3-1 CN4- 6 X3-2 CONN ECTI ON BOA RD 1 X6-7 CN5-1 RUNTIM E CON TAC TS X6-16 CN5-7 X6-2 CN5-8 X13-1 CN5-9 X6-6 CN5-3 X6-15 CN5-10 X6-11 CN5-12 X6-14 CN5-4 X8-5 CN6-4 X6-10 X8-15 CN6-9 X7-8 CN6-5 X7-4 CN6-10 X8-7 CN6-7 X8-17 CN6-3 X8-6 C[...]

66 Notes[...]

67 Notes[...]

Revision Notes: Revision A (ECO #C08226) initial release. Revision B (ECO #C08423) reflects updates made to images and text as a result of questions/requests from the field. CPX-I-O Rev B 7/11[...]