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manual abstract
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. The equipment should be operated and maintained only by personnel who have read this manual and who have a working knowledge and understanding of the equipment. V.__J NOTE These instructions are intended as a guide for the Installing Contractor and as a reference for the Operator, Owner and Serviceman. RETAIN THESE INSTRUCTIONS NEAR THE EQUIPMENT FOR READY REFERENCE The instructions contained in this manual are intended as a guide only and do not supplant any National, State or Local Codes. This unit must be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installation is made. LOCHINVAR has a commitment to product improvement and continually strives for the highest standards of product performance. In pursuing this policy of continuous development of products, the manufacturer reserves the right to vary any details in this manual without notice. TABLE OF CONTENTS CHAPTER 1: INTRODUCTION A. General Information B. Local Regulations • C. Recommendations 1. Preventive Maintenance 2. Water Treatment CHAPTER 2: STORAGE & HANDLING A. Receiving B. Storage C. Uncrating D. PlacemenT Figure 1.1 Minimum Clearance CHAPTER 3: INSTALLATION A. Piping Connections B. Electrical Connections 1. Power Feed Wiring 2. Grounding Conductors 3. Control Wiring C. Filling the System CHAPTER 4: PRE-STARTUP INSPECTION A. Minimum Equipment for Startup B. Mechanical System Checks 1. Plumbing Connections 2. Feedpump/ Circ Pumps 3. System Flush 4. Valves C. Electrical System Checks D. Heating Elements E. Inspection Power/ Voltage CHAPTER 5: STARTUP INSTRUCTIONS A. Control Settings 1. Controller 2. High Limit 3. Low Water Cutoffs 4. Low Limit Sensors B. Operating Instructions CHAPTER 6: SEQUENCE OF OPERATION A. Activation of Heating Element Circuits 1. Contactors 2. Fuses B. Sequencing Controls 1. Staged Control Circuit 2. Proportional Step Controls 3. Recycle Feature 4. Preheat Switch CHAPTER 7: OPERATIONAL TESTING A. Standard Controls 1. 135-ohm Controllers 2. Solid State Controls B. Outdoor Reset Controls 1. 135-ohm Controllers 2. Solid State Dual Input Controls CHAPTER 8: PREVENTIVE MAINTENANCE A. General B. Water Treatment Figure 8.1 Feedwater/ Boiler Water Properties C. Electrical System Maintenance D. Mechanical System Maintenance E. Element Replacement Procedure CHAPTER 9: WARRANTY & RETURNS A. Assistance - Figure 9.1 Data Plate B. Part Orders C. Repair Procedures D. Warranty Return Procedures E. Limited Warranty CHAPTER 10: ADDITIONAL INFORMATION A. Boiler Parts List and Schematics B. Vendor Literature C. Troubleshooting D. Factory Startup Checklist E. Recommended Spare Parts Chapter 1 INTRODUCTION 1.A. GENERAL INFORMATION This LOCHINVAR Electric Hot Water and Steam Boiler Operation and Maintenance Manual presents information that will help to properly operate and care for the equipment. Study the contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. The standard Limited Warranty does not apply to boilers not installed or operated in accordance with these procedures. LOCHINVAR boilers are designed and engineered to provide excellent service and to give long life on the job. Although the unit and its components afford a high degree of protection and safety, operation of the equipment is not to be considered free from hazards inherent in the handling of electricity and pressurized hot water or steam. Pay close attention to WARNINGS and CAUTIONS as these present situations of potential hazard, and remember no amount of written instruction can replace intelligent thinking and reasoning. 1.B. LOCAL REGULATIONS Consult local building and safety codes before proceeding with work. The operation of this equipment by the owner and his operating personnel must comply with all requirements or regulations of the authorities having jurisdiction. In the absence of such authorities, the installation must conform to the safety codes set forth by the American Society of Mechanical Engineers (ASME). 1.C. RECOMMENDATIONS 1.C.1. Preventive Maintenance A Preventive Maintenance Schedule is provided as a recommendation for periodic boiler inspections. Recording of daily, weekly, monthly and yearly maintenance activities, as well as the recording of any unusual operation, will serve as a valuable guide to any necessary investigation. The standard Limited Warranty does not cover any damage caused by lack of required maintenance. Chapter 1-1 Page 2 Chapter 1 INTRODUCTION 1.C.2. -WATER TREATMENT Feedwater and Boiler Water Properties should be maintained in accordance with the table provided in th...