Lochinvar Water Heater Hot Water Generator User Manual

HOT WATER  
GENERATOR  
INSTALLATION and OPERATION  
MANUAL  
Unit shown with optional control package.  
The information contained in this  
ƽ
WARNING  
manual is intended for use by  
qualified professional installers, or  
service technicians. Consult your  
local expert for proper installation  
or service procedures.  
Save this manual for future reference.  
 
Hot Water Generator Installation Instructions  
1 General information  
• Before using product, read and The high quality enamel paint, applied to the jacket of the  
ƽ
WARNING  
understand instructions.  
unit, will provide years of protection against corrosion. If it is  
necessary to clean the outside of the unit, a mild cleaning  
agent should be used that will not damage the paint.  
• Save these instructions for future  
reference.  
For all piping connections, the use and/or type of joint  
compound or sealer on the joints should be determined by  
referring to local codes, accepted standards, and/or the  
requirements of the installing contractor.  
• All work must be performed by  
qualified personnel trained in the  
proper application, installation, and  
maintenance of steam systems and/or  
boiler water systems in accordance with Lochinvar’s Hot Water Generator Systems are ideal when  
all applicable codes and ordinances.  
boiler capacity is sufficiently sized to cover potable hot water  
demand and provide source water for hydronic heating  
systems. Hot Water Generator Systems use steam or boiler  
water as an energy source and can provide high recovery rates,  
making them an economical water heating system for end  
users.  
To prevent serious burns, wear heat  
resistant gloves when opening and  
closing steam valves, or handling hot  
equipment.  
To prevent serious burns, the internal  
pressure of the trap must be 0 psi  
(0 bar) before servicing.  
Availability  
Hot Water Generator Systems are pre-engineering and pre-  
assembled complete with all piping to meet your specific  
application. And like every Lochinvar product, we thoroughly  
test them to ensure proper performance from the moment  
they are installed.  
To prevent serious personal injury from  
steam pipe blow down, connect a  
temporary pipe between the steam pipe  
opening and a drain, or stand at least  
100 ft. (30 m) from the front of the pipe  
opening.  
Hot Water Generator Systems are available in horizontal or  
vertical configurations (see FIG.’s 1 and 2) in a wide array of  
gallon capacities. Standard packages are available in tank sizes  
from 200 - 1000 gallons with single wall copper tube bundle  
heating units. Custom configurations, smaller and larger tank  
and tube bundles, and optional control packages are also  
available. Consult the factory for specifications.  
To prevent property damage, personal  
injury, or death, cap off the gate valves  
if they are not connected to a drain and  
when they are not in use for test or  
pressure relief.  
Failure to follow this warning could cause  
property damage, personal injury, or  
death.  
Tank Construction -- Lochinvar tanks are available with glass  
or cement lining.  
ASME -- All Lochinvar tanks are constructed in accordance  
with ASME standards and certified for 125 psi working  
pressure (standard) or 150 psi working pressure (optional).  
This manual is intended to cover installation, operation, and  
maintenance procedures for Lochinvar’s Hot Water Generator  
Systems. Since each unit is built to meet customer  
specifications, instructions may not be specific to every  
system.  
Cathodic Protection -- All glass lined tanks are equipped  
with magnesium anodes to provide protection against  
corrosion.  
If questions are not answered by this manual, or if specific  
installation, operation, and/or maintenance procedures are  
not clearly understood, contact Lochinvar for clarification  
before proceeding.  
Manway - A manway is provided as an option on glass lined  
tanks and is standard on cement lined tanks.  
*Horizontal tanks with tube bundles 48" and longer require a  
manway.  
These Hot Water Generator Systems are designed for indoor  
use only, unless otherwise required by design specifications.  
Each unit requires at least two feet of clearance around and  
above the unit. It should be located on a level surface (no  
more than one-half degree of slope), capable of supporting  
the total weight of the unit when filled to capacity.  
Tank Circulator Package -- All standard Hot Water Generator  
Systems are equipped with a circulator package to maximize  
the amount of hot water provided.  
Five-Year Limited Tank Warranty -- Provides warranty  
protection against tank failure (see warranty for details).  
The unit should be mounted to the floor following applicable  
architectural and local code requirements for the specific  
installation site. Note: Tanks do not come standard with floor  
tie downs.  
One-Year Limited Warranty -- Tube Bundle, parts,  
accessories and controls (see warranty for details).  
3
 
Hot Water Generator Installation and Operation Manual  
1 General information  
Figure 1_Vertical Tanks  
Figure 2_Horizontal Tanks  
Optional control packages(see page 5)  
Steam to Water -- Control packages include an isolation valve, 2-way  
self-operated temperature regulator, inlet and outlet wye strainers, a  
float and thermostatic steam trap and all necessary piping.  
Water to Water -- Control packages include isolation valves, 2-way  
self-operated temperature regulator, inlet wye strainer and all  
necessary piping.  
Options:  
• Manual Reset High Limit  
• Solenoid Valve  
• Manway (see notes on manway) • 150 psi Tank Working Pressure  
Temperature & Pressure Gauge Vacuum Breaker  
4
 
Hot Water Generator Installation and Operation Manual  
1 General information  
(continued)  
Areas of potential danger:  
ƽ
WARNING  
Figure 3_Steam to Water Optional Control Package  
1. All steam/boiler water lines, joints,  
valves, and pressure regulators.  
2. All hot water outlet lines, joints,  
valves, and pressure regulators.  
3. All power connections and cables.  
Before attempting any installation,  
operation, or maintenance procedures  
pertaining to this unit:  
1. Assure that the incoming steam  
(or boiler water) has been turned off  
at the manual shutoff valve.  
2. If the unit has been in operation,  
allow the water in the heater and all  
components and surfaces (incoming  
steam line, hot water outlet line,  
etc.,) to cool before starting the  
procedure.  
3. Assure that all power has been  
shut off  
attempting any procedures.  
/
disconnected before  
Figure 4_Water to Water Optional Control Package  
4. Assure that all incoming and  
outgoing water lines have been  
turned off at the manual shutoff  
valves.  
Steam or boiler water present situations  
that can be very dangerous due to the fact  
they are under pressure and at very high  
temperatures. To avoid possible injury or  
death, use common sense and follow all  
accepted and recommended procedures  
when performing installation, operation,  
and maintenance procedures.  
ƽ WARNING  
The combination of electricity and water  
can pose a very dangerous situation.  
Assure that all power has been shut off /  
disconnected before attempting any  
installation or maintenance procedures.  
ƽ
WARNING  
As with any piece of equipment that utilizes  
ƽ WARNING  
steam or boiler water under pressure, as well as  
electricity, the potential exists for severe  
personal injury if proper installation,  
operation, and maintenance procedures are  
not followed. Listed in this section are specific  
warnings pertaining to Lochinvar Hot Water  
Generators. In addition, throughout this  
manual, warnings are restated when  
procedures are described pertaining to areas of  
potential danger. All warnings should be  
carefully read and understood. All precautions  
contained in the warnings should be carefully  
followed to reduce the chance of injury.  
5
 
Hot Water Generator Installation and Operation Manual  
2 Installation  
Transporting and unpacking the unit  
Each Lochinvar Hot Water Generator is crated as necessary at the factory. The crating is designed to provide protection for the  
unit during transportation, and to provide a safe means by which to lift and move the unit with a fork lift or hand truck.  
In order to prevent damage during shipment the controls package is disassembled at the factory after leak testing. Reassembly  
will require re-attaching the unions (or bolting flange) to the appropriate locations and insertion of the control valve bulb into  
the provided bulbwell and the system is ready for operation (see FIG.’s 5 and 6 below).  
All hardware for the reassembly is included with the system. Drawings of the specific controls package are included with each  
product illustrating the finished assembly. For water to water systems the bypass piping union may remain attached for  
shipment. See FIG.’s 5 and 6 below for a detailed explanation of the break points.  
Figure 5_Steam to Water Storage Heater  
Figure 6_Water to Water Storage Heater  
6
 
Hot Water Generator Installation and Operation Manual  
2 Installation  
(continued)  
Examining the unit  
Connecting the cold water source  
and the hot water outlet  
After the unit has been set in place and uncrated, it  
should be carefully examined to assure that neither the  
main unit nor components have been damaged during  
shipping. If any evidence of damage is detected that  
could affect the safe operation of the unit, contact  
Lochinvar Corporation, or your authorized sales  
representative, to report the damage and to receive  
instructions on how to proceed.  
Before making any connections of water  
NOTICE  
inlet or outlet to the unit, assure that all  
piping is clean and free of foreign material  
or scale. This can usually be accomplished  
by “blowing out” the pipe. Any foreign  
material or scale entering the unit can  
adversely  
affect  
operation  
and  
After the unit and all components have been inspected for  
damage, it is suggested that all pressure and temperature  
control components be checked to assure that they meet  
or exceed design specifications. If any discrepancy is  
found, contact Lochinvar Corporation, or your  
authorized representative, before proceeding with the  
installation.  
performance.  
Cold water source  
The first step in the installation process is to connect the cold  
water source to the water inlet port. The exact location of this  
port for the specific unit, as well as inlet pipe diameter and  
thread size, can be determined from the CAD drawing  
supplied with the unit.  
Mounting the unit  
A manual shutoff valve should be installed upstream on the  
cold water source as an isolation device. The shutoff valve  
should be in the closed position and remain so until the  
installation is complete.  
The unit should be mounted to the floor, following  
applicable architectural / local code requirements, or  
accepted standards for the specific installation site. The  
unit should be installed in a location with sufficient  
clearance to remove the tube bundle for repair or  
replacement.  
For all piping connections, the use and / or  
NOTICE  
type of joint compound or sealer on the  
joint should be determined by referring to  
local codes, accepted practices, or the  
requirements of the installing contractor.  
Unit and components  
Lochinvar Hot Water Generators are designed to make  
installation a relatively simple procedure. Because the  
unit is “Packaged, after placing and mounting the unit,  
installation involves the following:  
If the cold water source is equipped with an in-line check valve  
or backflow preventer, a suitable expansion tank must be  
installed in the hot water outlet side of the system. See the  
supplied CAD drawing(s) or contact Lochinvar Corporation  
for expansion tank specifications.  
• Connecting the cold water source to the water inlet.  
• Connecting the hot water outlet to the hot water feed  
line.  
Hot water outlet  
• Installing the control valve bulb into the tank bulbwell.  
The next step in the installation process is to connect the hot  
water system piping to the hot water outlet port. The exact  
location of this port for the specific unit, as well as outlet pipe  
diameter and thread size, can be determined from the CAD  
drawing(s) supplied with the unit.  
• Connecting the condensate / water return line and  
piping it to the recycling system.  
• Piping the pressure relief valve to an acceptable drain.  
• Connecting the energy source (steam or boiler water)  
to the unit.  
A manual shutoff valve should be installed downstream on the  
hot water outlet line as an isolation device in case the unit  
must be disconnected from the system. The shutoff valve  
should be in the closed position and remain so until the  
installation is complete.  
• Wiring the applicable source of electricity (if the unit is  
packaged with a circulating pump or electrically  
activated pressure or temperature controls).  
Each unit is supplied with CAD drawings that indicate  
the location and specifications for each connection that  
must be made. In addition, the drawing will enable the  
installer(s) to determine the flow direction of both the  
water and energy source.  
7
 
Hot Water Generator Installation and Operation Manual  
2 Installation  
Do not attempt to lift condensate with a  
Connecting the energy source  
ƽ
WARNING  
float and thermostatic trap. Pipe the  
condensate outlet from the main steam  
trap to a gravity drain or to a condensate  
pump.  
(Steam or boiler water)  
Steam or boiler water present situations  
ƽ
WARNING  
that can be very dangerous because of the  
high temperatures and pressures. Use  
common sense and follow all accepted and  
Lifting condensate without the assistance  
of a condensate pump can cause erratic  
temperature control, failure of the tube  
bundle, damage to the control valve, or  
damage to the condensate trap. Any failure  
caused due to lifting of condensate without  
a condensate pump is not covered by the  
warranty.  
recommended  
procedures  
when  
performing installation, operation, and  
maintenance procedures to avoid possible  
injury or death.  
Assure that a manual shutoff valve is installed upstream in the  
steam or boiler water line (energy source), and that it is  
functioning properly. If any doubt exists concerning the  
integrity of the shutoff valve, replace the valve before  
attempting installation. All energy source valves should be  
closed and remain closed throughout the installation process.  
Boiler water and high temperature water  
return line  
After the boiler water has passed through the tube bundle, and  
the heat has been extracted and transferred to the domestic  
water system, the water must return to the system. The water  
return line serves this purpose.  
Connect the energy source to the line(s) leading to the  
temperature control valve. The exact location of the  
temperature control valve for the specific unit, as well as  
energy source pipe diameter and thread size, can be  
determined from the CAD drawing(s) supplied with the unit.  
The water return line should be connected to the unit at the  
return port. Unlike the steam condensate return line, the  
return lines for boiler water do not have in-line condensate  
traps. The exact location of this port for the specific unit, as  
well as the water return pipe diameter and thread size, can be  
determined from the CAD drawing supplied with the unit.  
For all energy source piping connections,  
NOTICE  
A manual shutoff valve should be installed downstream in the  
water return line to allow the unit to be isolated from the  
system. The water return shutoff valve will present backflow  
of boiler water if the line is disconnected.  
the use and / or type of joint compound or  
sealer on the joint should be determined by  
referring to local codes, accepted practices,  
or the requirements of the installing  
contractor.  
Piping the relief valves to drain  
Connecting the steam condensate  
line or the boiler water return lines  
Steam condensate return line  
As the heat is extracted from the steam and transferred to the  
water heating system, condensate will form. This condensate  
must have a means by which it can drain from the unit and  
return to the steam system. The condensate return line serves  
this purpose.  
All Lochinvar Hot Water Generators are equipped with a  
pressure relief valve for the tank. The valve should be piped to  
a vent line leading to a suitable drain. Piping the pressure  
relief valves to suitable drains will prevent both water and heat  
damage to the unit, as well as reduce the risk of injury from  
released steam or water. The pipe must be of adequate size to  
properly handle the capacity of the relief valve and vent line.  
Check local codes to assure compliance.  
If a check valve has been installed on the inlet water line,  
thermal expansion may take place causing build up of  
excessive pressure when the water is being heated. This  
expansion will cause the relief valve to open, releasing hot  
water to the vent line.  
The condensate return line should be connected to the unit at  
the condensate return port. The condensate port is normally  
located downstream from the main and auxiliary traps. The  
exact location of this port for the specific unit, as well as the  
condensate return pipe diameter and thread size, can be  
determined from the CAD drawing(s) supplied with the unit.  
The condensate line should be piped back into the site’s steam  
system for recycling.  
A manual shutoff valve should be installed downstream in the  
condensate return line to allow the unit to be isolated from the  
system. The condensate shutoff valve will prevent backflow of  
steam if the line is disconnected.  
8
 
Hot Water Generator Installation and Operation Manual  
2 Installation  
(continued)  
Do not install a valve between the  
water heater relief valve and the vent.  
Doing so could cause serious injury or  
death if the pressure relief valve  
released and the manual valve was  
closed. This would cause excessive  
buildup of pressure in the water  
heater which could result in an  
explosion.  
Completing installation  
ƽ
WARNING  
Installation of the Lochinvar Hot Water Generator is now  
complete. All documentation supplied with the unit should  
be passed along to maintenance personnel for future  
reference.  
Connecting  
the  
circulation  
pump and electrically activated  
controls  
Lochinvar Hot Water Generators are equipped with a  
circulation pump. If the unit being installed is so  
equipped, the correct power source(s) must be  
connected. The circulation pump must run all the time.  
Wire this pump to a correctly sized disconnect switch per  
local codes.  
The combination of electricity and  
ƽ WARNING  
water can pose a very dangerous  
situation. Assure that all electric  
power has been turned off before  
attempting any installation or  
maintenance procedures.  
Reference the wiring CAD drawing included with the  
unit, or the installation instructions contained in the  
Installation Manual for the component, for specific  
wiring instructions.  
All power connections should be  
NOTICE  
performed by trained, certified  
electricians.  
9
 
Hot Water Generator Installation and Operation Manual  
3 Operation  
After all installation procedures have been completed, and all  
water, energy source joints, and power connections have been  
double checked, the unit is ready for operation. As a  
precaution, it is strongly suggested that the following Startup  
and Shutdown procedures be followed.  
Steam or boiler water present situations  
ƽ
WARNING  
that can be very dangerous because of the  
high temperatures and pressures. Use  
common sense and follow all accepted and  
recommended  
procedures  
when  
performing installation, operation, and  
maintenance procedures to avoid possible  
injury or death.  
Startup procedure  
1. Assure that all manual shutoff valves on the water and  
energy source lines are closed.  
9. Turn on power to the rest of the electrically controlled  
components of the unit (if equipped).  
2. Slowly open the manual shutoff valve on the cold water  
inlet line, checking to assure that there are no leaks at the  
valve or any joints. Allow the tank to fill with water. As  
the tank is filling, hold the pressure relief valve open to  
allow air to bleed out of the tank. This will speed the  
filling process.  
10. As the unit is initially heating the water, carefully  
re-inspect cold water inlet, hot water outlet, steam inlet  
(or boiler water inlet), and condensate return (or boiler  
water return line) joints for signs of leakage.  
11. As the unit approaches the desired operating  
temperature, adjust the temperature control valve.  
3. Adjust the operating temperature control to the desired  
operating temperature.  
12. After the unit has reached operating temperature, re-  
inspect all joints for signs of leakage. In addition, check  
all gauges and controls to verify that the water  
temperature and pressure, as well as energy source  
pressure, are within design specifications.  
4. Set the high temperature limit thermostat at 10 to 15  
degrees Fahrenheit (10°F to 15°F) above the desired  
operating temperature.  
5. If the unit is so equipped, turn on the internal circulating  
pump. The circulating pump will operate constantly as  
long as power is supplied to the pump.  
Shutoff valves are located on the inlet and/or outlet side  
of the circulating pump line. These valves should be  
opened before the pump is turned on. After the power to  
the pump is turned on verify that the pump is working.  
If the pump is an oil lubricated unit, verify proper oiling.  
13. The unit is now ready for normal operation.  
Shutdown procedure  
1. Turn off all power to the circulating pump and/or electric  
controls, if equipped.  
2. Close all valves in the steam inlet line (or boiler water  
line).  
6. Open the valve on the condensate drain line, or boiler  
water return line.  
3. Relieve the pressure from the energy source line (steam or  
boiler water), where possible.  
7. For steam to water controls, slowly open the manual  
shutoff valve on the steam inlet. Create a load/demand  
situation of approximately 10 to 25% of the system  
design conditions. As the valves are being opened,  
check for leaks at the valves and all pipe joints.  
4. Close all remaining valves in the system in this order:  
• the hot water outlet line;  
• the cold water inlet line; and  
• the condensate return line (or boiler water return line)  
8. For water to water controls, slowly open the manual  
shutoff valves on the boiler water inlet and outlet lines.  
Create a load/demand situation of approximately 10 to  
25% of the system design conditions. As the valves are  
being opened, check for leaks at the valves and all pipe  
joints. Open the bypass loop ball valve approximately  
half way. Allow the system to push air out of the tube  
bundle and the piping slowly.  
5. After the system has cooled, drain the unit by opening  
the tank drain valve and holding the pressure relief valve  
in the open position. This will prevent the formation of  
a vacuum and increase the drainage flow.  
6. Proceed with the required maintenance or repairs.  
7. After performing the required maintenance or repairs,  
return the unit to operation by following the Startup  
Procedure.  
Note: It should be noted that when the control valve is closed  
the boiler water will flow through the bypass loop. When the  
valve is open, less water will “bypass. Adjustment of the  
bypass loop ball valve will be necessary to balance your  
system. For initial installation the bypass valve should be  
closed.  
10  
 
Hot Water Generator Installation and Operation Manual  
4 Inspection  
The following table summarizes the recommended time intervals for inspections of the water heater, components, inlet and  
outlet water, energy source lines (steam or boiler water), and power connections.  
RECOMMENDED INSPECTIONS  
Time Interval  
Per  
Manufacturer  
Specs  
Semi-  
Quarterly  
To Be Inspected  
Weekly  
Monthly  
Quarterly  
Annually  
Circulating Pump  
Control Valves -  
Temperature & Pressure  
Gauges - Pressure &  
Temperature  
Lines - Inlet, Outlet, &  
Return  
Power Connections  
Pressure Relief Valve  
Shutoff Valves - Manual  
Single Solenoid Safety  
System  
Strainers  
Temperatures - Water &  
Operating  
Thermometer  
Traps - Main & Auxiliary  
Magnesium Anode Rods  
11  
 
Hot Water Generator Installation and Operation Manual  
5 Troubleshooting  
SYMPTOM  
PROBABLE CAUSE  
CORRECTIVE ACTION  
• The thermometer is not correctly  
sensing the water temperature.  
• Check the water temperature with  
a
Water heater does not  
maintain the required  
temperature at the rated  
capacity.  
temperature gauge that is known to be  
correct. Replace the thermometer if it  
is found to be incorrectly sensing the  
water temperature.  
• Check the primary energy source  
pressure/temperature. If the reading is  
low, adjust the inlet pressure/temperature to  
meet the design requirements. If there is a  
restriction in the primary energy source  
line, the pressure reading will drop  
excessively when the generator calls  
for full energy on steam systems, even  
though the pressure seems to be  
normal during light demand. If the  
primary pressure is correct, the system  
should reach design pressure for  
energy source in the tube bundle as the  
temperature of the water in the tank  
heater approaches shutoff.  
• Inlet energy source pressure is too  
low or boiler water temperature is too  
low.  
• Reconfigure the condensate  
/
water  
return piping and check valve to allow  
for proper drainage. Check to assure  
that there is no restriction in the  
condensate / water drain line. Replace  
the check valve if it is leaking or has  
failed. Also, check to assure that there  
is no restriction in the condensate /  
water drain line.  
• The condensate / water return piping  
has not been installed properly,  
allowing the condensate  
drain freely (by gravity);  
condensate water drain line is  
/
water to  
the  
/
restricted; or the condensate / water  
check valve is leaking or has failed.  
• Adjust bypass valve approximately half  
closed. Readjust as necessary.  
• Water bypass valve has not been  
adjusted (boiler water).  
• Notify factory for replacement.  
• Control valve bulb not installed or not  
properly installed in tank bulbwell.  
• Verify actuator is not working. Notify factory  
for replacement.  
• Control valve actuator defective.  
• Check the water temperature with  
a
• The thermometer is not correctly  
sensing the water temperature.  
Outlet temperature is too  
high.  
temperature gauge that is known to be  
correct. Replace the thermometer if it  
is found to be incorrectly sensing the  
water temperature.  
• The condensate / water return piping  
has not been installed properly,  
• Reconfigure the condensate  
/
water  
return piping and check valve to allow  
for proper drainage. Check to assure  
that there is no restriction in the  
condensate / water drain line. Replace  
the check valve if it is leaking or has  
failed. Also, check to assure that there  
is no restriction in the condensate /  
water drain line.  
allowing the condensate  
drain freely (by gravity);  
condensate water drain line is  
/
water to  
the  
/
restricted; or the condensate / water  
check valve is leaking or has failed.  
• Verify bulb is installed in bulbwell.  
• Control valve bulb not installed or not  
properly installed in tank bulbwell.  
• Verify actuator is not working. Notify factory  
for replacement.  
• Control valve actuator defective.  
12  
 
Hot Water Generator Installation and Operation Manual  
5 Troubleshooting  
(continued)  
SYMPTOM  
PROBABLE CAUSE  
CORRECTIVE ACTION  
• Inlet energy source pressure is too  
low or boiler water temperature is too low.  
• For steam systems check the primary  
energy source pressure/temperature. If the  
reading is low, adjust the inlet  
pressure/temperature to meet the design  
requirements. If there is a restriction in the  
primary energy source line, the pressure  
reading will drop excessively when the  
generator calls for full energy on steam  
systems, even though the pressure seems  
to be normal during light demand. If the  
primary pressure is correct, the system  
should reach design pressure for energy  
source in the tube bundle as the  
Outlet  
temperature  
fluctuates widely.  
temperature of the water in the tank  
heater approaches shutoff.  
• Reconfigure the condensate  
/
water  
• The condensate / water return piping  
has not been installed properly,  
return piping and check valve to allow  
for proper drainage. Check to assure  
that there is no restriction in the  
condensate / water drain line. Replace  
the check valve if it is leaking or has  
failed. Also, check to assure that there  
is no restriction in the condensate /  
water drain line.  
allowing the condensate  
drain freely (by gravity);  
condensate water drain line is  
/
water to  
the  
/
restricted; or the condensate / water  
check valve is leaking or has failed.  
• Verify control valve bulb was installed in  
the bulbwell.  
• The primary / inlet temperature control  
valve is not closing properly.  
• Adjust bypass valve approximately half  
closed. Readjust as necessary.  
• Bypass valve not adjusted (boiler  
water).  
• Verify control valve actuator is working  
properly , if not replace.  
• The primary / inlet temperature control  
valve is not opening properly.  
• The condensate / water return piping • Reconfigure the condensate  
/
water  
Excess or insufficient  
condensate (boiler water)  
being returned from the  
unit.  
has not been installed properly,  
allowing the condensate water to  
drain freely (by gravity); the  
condensate water drain line is  
return piping and check valve to allow  
for proper drainage. Check to assure  
that there is no restriction in the  
condensate / water drain line. Replace  
the check valve if it is leaking or has  
failed. Also, check to assure that there  
is no restriction in the condensate /  
water drain line.  
/
/
restricted; or the condensate / water  
check valve is leaking or has failed.  
• Adjust bypass valve approximately half  
closed. Readjust as necesssary.  
• Bypass loop valve not adjusted (boiler  
water).  
Steam being discharged  
• The tube bundle is heavily scaled or • Call Lochinvar Corporation, or an  
into  
the  
condensate  
damaged.  
authorized sales agent for instructions  
on repair or replacement.  
drain.  
13  
 
Hot Water Generator Installation and Operation Manual  
5 Troubleshooting  
SYMPTOM  
PROBABLE CAUSE  
CORRECTIVE ACTION  
• The primary / inlet temperature control  
valve is not closing properly.  
• Verify control valve bulb was installed in  
tank bulbwell.  
Pressure relief  
“pops”.  
valve  
• Verify  
control  
valve  
actuator  
is  
• The secondary / outlet energy source  
pressure  
control  
system  
is  
not  
operating properly.  
operating properly.  
• The over-temperature limit system is  
out of adjustment, or some component  
of the system has failed.  
• Check the individual components of the  
system and repair or replace the failed  
component(s) as necessary.  
• The over-temperature limit system is • Check the individual components of the  
Water shuts down at or  
too close to (above or  
below) the design outlet  
temperature.  
out of adjustment, or some component  
of the system has failed.  
system and repair or replace the failed  
component(s) as necessary.  
A loud banging in the  
water heater, primary  
piping, or condensate /  
water return piping (not  
to be confused with a  
normal clicking noise  
made during operation).  
• The condensate / water return piping • Reconfigure the condensate  
/
water  
has not been installed properly,  
allowing the condensate water to  
drain freely (by gravity); the  
condensate water drain line is  
return piping and check valve to allow  
for proper drainage. Check to assure  
that there is no restriction in the  
condensate / water drain line. Replace  
the check valve if it is leaking or has  
failed. Also, check to assure that there  
is no restriction in the condensate /  
water drain line.  
/
/
restricted; or the condensate / water  
check valve is leaking or has failed.  
• Primary  
/
inlet steam line is not • The steam supply should be clean dry  
properly trapped (steam as energy  
source only).  
steam.  
Do not slug controls system  
This  
with boiler startup condensate.  
can damage controls as well as tube  
bundle.  
14  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
9. Turn on electric power to the circulating pump and other  
electrical components if necessary.  
Storage tank maintenance  
A new tank installation should have a regular inspection  
program set up. The first inspection should be within the first  
three months of operation. Once the tendency to accumulate  
sediment has been established, the inspection program can be  
modified to suit the water conditions. Typical inspection  
programs flush the tank at six-month intervals and clean the  
tank in yearly intervals.  
10. Observe tank and piping to ensure all components are  
functioning properly.  
Cleaning the storage tank  
The mineral accumulation in an un-fired tank will be in a soft  
sediment form that can be removed by a regular cleaning of  
the lower portion of the tank. Many tanks will have a hand  
hole or a larger manway to allow access to the interior of the  
tank for complete removal of accumulated sediment. An  
access opening to remove the manway or hand hole is  
provided in the exterior jacket. The sheetmetal jacket  
components are removed with hand tools. The opening will  
be in the bottom portion of a vertical tank and on the end of  
a horizontal tank (see FIG’s 1 and 2 on page 4 of this manual).  
Deliming solvents or acid type flush agents are not  
recommended for use in lined storage tanks. These chemical  
cleaners are usually designed for use in non-potable systems  
such as heating boilers. These chemicals may be aggressive  
and cause damage to the tank lining and deteriorate the  
magnesium anodes supplied in glass-lined storage tanks.  
Hot water will be released under pressure.  
ƽ WARNING  
Avoid contact with the hot discharge water  
To clean the tank, follow these steps (reference FIG.’s 7 and 8):  
to prevent the risk of severe scald injury.  
1. Close valves from boiler water or steam supply and  
return or condensate pipes.  
Flushing the storage tank  
2. Turn off electrical power to the circulating pump and  
other electrical components if necessary.  
Since the mineral accumulation is occurring in an un-fired  
tank it will be in a soft sediment form. This soft sediment can  
be removed by a regular flushing of the lower portion of the  
tank.  
3. Close the valve on the hot water outlet on the top of the  
storage tank and the cold water supply to the system.  
To flush the tank, follow these steps:  
4. Ensure that the drain located on the bottom of the tank  
is routed to a floor drain with adequate capacity to allow  
the tank to be drained.  
1. Turn off electrical power to the circulating pump and any  
other tank accessories.  
5. Open the drain valve and open a vent to allow the air to  
enter the tank (manually opening the relief valve will  
usually accomplish this). Use extreme caution, as the  
water exiting the tank drain may be very hot. Avoid  
contact with the hot discharge water to prevent the risk  
of severe scald injury.  
2. Close the valve on the hot water outlet on the top of the  
storage tank.  
3. Ensure that the drain located on the bottom of the tank  
is routed to a floor drain with adequate capacity to allow  
the tank to be flushed.  
4. Open the drain valve and allow the incoming cold water  
to flush the soft sediment out the bottom of the storage  
tank. Use extreme caution, as the water exiting the tank  
drain may be very hot. Avoid contact with the hot  
discharge water to prevent the risk of severe scald injury.  
6. Allow the tank to drain completely.  
7. Remove the jacket cover over the manway or hand hole.  
Remove the bolt(s) securing the tank access opening.  
Use a flashlight to observe the sediment collected in the  
tank.  
5. Observe the color of the water initially discharged from  
the tank drain. This water will generally be milky or  
slightly discolored by the sediment discharge. Allow the  
drain to run until the water runs clear.  
8. Use hand tools to remove all sediment from the interior  
of the tank. Use care not to damage the interior lining of  
the storage tank.  
9. Use a water hose to flush the remaining sediment from  
the interior surfaces of the tank and ensure that all debris  
is removed. Scale or sediment allowed to reach the  
potable system can foul valves, pumps, strainers, and  
other water fixtures. Ensure that the tank interior is clean  
before refilling the vessel.  
6. Close the drain valve on the tank.  
7. Open the hot water outlet valve on the top of the tank.  
8. Open an adjacent hot water tap to purge any air that may  
have entered the storage tank during the draining  
process. Close the hot water tap if no air discharge is  
observed.  
15  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
10. Install a new gasket on the manway or hand hole to  
prevent any possible leaks. Tighten the gasket properly to  
prevent leaks. Caution: Over tightening can result in  
cutting the gasket and allowing a water leak to occur.  
Magnesium anode rod inspection  
Glass lined storage tanks have a magnesium anode(s) to  
provide cathodical protection of the lining and minimize  
corrosion. Aggressive water conditions in some areas of the  
country may accelerate the deterioration of the anode(s). The  
anode(s) should be periodically removed and inspected to  
determine if replacement is necessary.  
11. Replace the jacket cover over the manway or hand hole.  
12. Close the drain and open the cold water supply and hot  
water outlet. If the relief valve was used for a vent ensure  
that it is now closed. Open the closest hot water valve to  
allow the air in the tank to vent as water enters the vessel.  
Close the valve opened for a vent when water flows from  
the valve.  
The tank must be valved off from the system and fully drained  
to remove an anode for inspection. Anodes are supplied in  
threaded fittings on the top head of small vertical storage  
tanks. Top mounted anodes may be accessed by removing the  
jacket top. Large vertical storage tanks and horizontal storage  
tanks have multiple anodes installed in threaded tappings  
along the length of the tank. These anodes may be accessed by  
removing a jacket panel and/or corner post corresponding to  
the mounting point of the anodes. Adequate service clearance  
is required to allow removal of an anode. The anode(s)  
should be replaced when more than six inches of the core wire  
is exposed at either end of the rod. Medium sized tanks with  
round jackets provide an opening for individual anode rod  
access.  
13. Check the manway or hand hole and all related piping for  
any water leaks.  
14. Turn on electric power to the circulating pump and other  
electric components if necessary.  
15. Open valves for boiler water or steam supply. Also open  
the boiler water return, or condensate line.  
16. Observe tank and piping to ensure all components are  
functioning properly.  
Figure 7_Horizontal Storage Tank w/Anodes  
Figure 8_Vertical Storage Tank w/Anodes  
16  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
(continued)  
The combination of electricity and water  
Component(s) replacement  
ƽ
WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
Circulating pump - inspection and  
replacement  
Lochinvar Hot Water Generators can be equipped with a  
circulating pump to assist in the even heating of the water. If  
the unit is equipped with a circulating pump, the following  
procedure should be followed to replace the pump.  
2. After assuring that the power has been turned off,  
disconnect the electric leads to the circulating pump  
(FIG. 9).  
3. Break the joints between the pump and the inlet and  
outlet piping. Remove the pump.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
service the circulating pump.  
4. Remove the shutoff valves.  
5. Install the new valves. Follow recommendations  
contained in the manufacturer’s documentation, local  
codes, or accepted contractor practices as to the use and /  
or type of joint compound or sealer at the connections.  
The combination of electricity and water  
ƽ
WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
6. Reconnect the pump to the inlet and outlet piping.  
Follow  
recommendations  
contained  
in  
the  
2. Refer to the manufacturer’s documentation supplied  
with the unit pertaining to testing the pump. If found to  
be defective or questionable, replace the pump by  
continuing with the steps that follow.  
manufacturer’s documentation, local codes, or accepted  
contractor practices as to the use and / or type of joint  
compound or sealer at the connections.  
7. Open the manual shutoff valves located on the inlet and  
outlet sides of the pump.  
3. After assuring that the power has been turned off,  
disconnect the electric leads to the circulating pump  
(FIG. 9).  
8. Reconnect the electric leads to the pump (reference  
FIG. 9 to assure proper wiring).  
4. Close the manual shutoff valves located near the inlet and  
outlet ports of the pump.  
9. Follow the startup procedures (page 10) to put the unit  
back on-line. Carefully check all joints for any sign of  
leakage.  
5. Break the joints between the pump and the inlet and  
outlet piping. Remove the pump.  
6. Reconnect the pump to the inlet and outlet piping.  
Figure 9_Pump Wiring Diagram  
Follow  
recommendations  
contained  
in  
the  
manufacturer’s documentation, local codes, or accepted  
contractor practices as to the use and / or type of joint  
compound or sealer at the connections.  
7. Open the manual shutoff valves located on the inlet and  
outlet sides of the pump and check for any leakage at the  
joints.  
8. Reconnect the electric leads to the pump (reference  
FIG. 9 to assure proper wiring).  
9. Follow the startup procedures (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
Circulating pump shutoff valves -  
replacement  
If the Lochinvar Hot Water Generator is equipped with a  
circulating pump to assist in the even heating of the water,  
manual shutoff valves will be located on both the inlet and  
outlet side piping. To replace the valves, follow the procedure  
detailed below.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
service the circulating pump shutoff valves.  
17  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
3. Carefully break the connections between the tube bundle  
head and the energy source inlet and outlet lines.  
Power connections - rewiring  
If any of the power connections must be rewired at the  
circulating pump or electrically activated controls, follow the  
steps listed below.  
It may be necessary to break the lines at a  
ƽ
WARNING  
second location, and for the lines to be  
rotated to allow clearance for the tube  
bundle to be removed from the tank. If it  
is necessary, care should be taken to ensure  
that in-line components are not damaged.  
The combination of electricity and water  
ƽ
WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
4. Break the bolts loose that secure the tube bundle head  
to the tank. After all bolts have been broken loose,  
remove them from the unit.  
1. Follow Steps 1 through 4 of the shutdown procedure  
(page 10) to take the unit off-line before attempting any  
electrical service.  
The tube bundle head is heavy and can  
cause serious injury if it falls on your foot,  
leg, etc., use caution.  
2. After assuring the power has been turned off, disconnect  
and rewire the electrical connections in question.  
ƽ
WARNING  
3. Turn the power on and check that the component that  
has been rewired is functioning properly.  
The tube bundle weight depends on the  
size installed. A hoist or some type of lift  
system should be made available to assist  
in removal or installation of the tube  
bundle.  
ƽ WARNING  
4. Slowly open the shutoff valves on the condensate (or  
boiler water return) line, cold water inlet line, and hot  
water outlet line.  
5. Slowly open the shutoff valves on the energy source inlet  
line.  
5. Remove the tube bundle from the tank, use care not to  
damage the soft copper tubes.  
6. Inspect for damage or excessive scale, etc.  
7. Remove old gaskets and clean gasket sealing surfaces.  
8. Reinstall the tube bundle.  
Tube  
bundle  
-
inspection  
and  
replacement  
The tube bundle is the heart of the Lochinvar Hot Water  
Generator. It should be removed and inspected every two (2)  
years.  
Inlet, outlet, and condensate / water  
return line and manual shutoff valves -  
replacement  
If any of the inlet, outlet, return lines, or shutoff valves are  
damaged and must be replaced, follow the steps outlined  
below.  
Steam or boiler water present situations  
ƽ WARNING  
that can be very dangerous because of the  
high temperature and pressures. To avoid  
possible injury or death, use common  
sense and follow all accepted and  
The combination of electricity and water  
recommended  
performing installation, operation, and  
maintenance procedures.  
procedures  
when  
ƽ
WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
The combination of electricity and water  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
ƽ WARNING  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
replace damaged lines or shutoff valves.  
While it might seem feasible to replace  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
remove and inspect the tube bundle.  
ƽ WARNING  
inlet, outlet, condensate / water return  
lines, and shutoff valves without shutting  
down the entire unit, it is not advised.  
Unless the unit is completely shutdown,  
and the water and the energy source are  
isolated from the system, failure of a  
manual shutoff valve during the  
replacement process could result in serious  
injury.  
2. Assure that the energy source, condensate / water return  
line, cold water inlet, and hot water inlet have been shut  
off; that the tank has been completely drained; that the  
pressure has been bled from both the water and energy  
source systems; and that the water, all components, and  
surfaces have cooled.  
18  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
(continued)  
2. Assure that the energy source, condensate / water return  
line, cold water inlet, and hot water outlet have been shut  
off; that the tank has been completely drained; that the  
pressure has been bled from both the water and energy  
source systems; and that all components and surfaces  
have cooled.  
Single solenoid safety system (optional)-  
inspection and replacement  
The single solenoid safety system closes the steam (or boiler  
water) control valve in an over-temperature condition. The  
system should be checked semi-annually. (See manufacturer’s  
documentation for the solenoid safety system provided with  
the unit for specific inspection intervals and test routine.) If  
the system is found to be malfunctioning and must be  
replaced, follow the procedure outlined below.  
3. Carefully break the joint between the unit and the line or  
valve to be replaced.  
4. Remove the section of line or valve to be replaced.  
5. Replace the damaged section of line or valve.  
The combination of electricity and water  
6. Reconnect the line or valve to the unit. Follow  
recommendations contained in the manufacturer’s  
documentation, local codes, or accepted contractor  
practices as to the use and / or type of joint compound or  
sealer at the connections.  
ƽ
WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
replace the single solenoid safety system.  
7. Follow the startup procedures (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
2. If the system is electrically activated, turn off the power  
and disconnect the electric leads from the safety system.  
Temperature/pressure gauge (tank)  
(optional) - replacement  
3. Remove the solenoid valve from the piping or high limit  
thermostat from mounting.  
If the temperature/pressure gauge for the water tank is not  
functioning correctly and must be replaced, follow the  
procedure outlined below.  
4. Mount the new safety system.  
5
Reference the manufacturer’s documentation for the  
safety system that was supplied with your unit for  
additional installation / setup instructions.  
The combination of electricity and water  
ƽ WARNING  
can pose a very dangerous situation. Turn  
6. Follow the startup procedures (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
off / disconnect all electric power before  
attempting any maintenance procedure.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
replace the water temperature/pressure gauge.  
2. Carefully unscrew the water temperature/pressure gauge  
from the port in the tank.  
3. Install the new gauge by screwing it into the port in the  
tank. Follow recommendations contained in the  
manufacturer’s documentation, local codes, or accepted  
contractor practices as to the use of joint compound or  
sealer at the connections.  
4. Follow the startup procedure (page 10) to put the unit  
back on-line. Carefully check all connections for any  
sign of leakage.  
19  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
7. Remove the temperature control valve from the system.  
Temperature control valve (optional) -  
inspection and replacement  
8. Follow the supplied manufacturer instructions for  
inspecting the valve. If found to be malfunctioning,  
replace the valve.  
The temperature control valve is installed adjacent to the tube  
bundle. The manufacturer’s documentation included with  
the unit gives specifics for operation and maintenance of the  
control valve. The CAD drawing included with the unit will  
give the exact location, as well as interlocks with other  
components. This information should be reviewed before  
removal / replacement of the temperature control valve.  
9. Carefully replace the temperature control valve into the  
system by reattaching it to the energy source inlet line and  
the tube bundle outlet line. Follow recommendations  
contained in the manufacturer’s documentation, local  
codes, or accepted contractor practices as to the use and /  
or type of joint compound or sealer at the connections.  
Steam or boiler water present situations  
ƽ
WARNING  
10. Align the valve as it was situated before removal and  
tighten the connections. If lines were broken at an  
additional location to allow for removal of the valve, be  
sure to also tighten those connections.  
that can be very dangerous because of the  
high temperatures and pressures. Use  
common sense and follow all accepted and  
recommended  
procedures  
when  
11. Reconnect the temperature control valve to the system  
interlocks and install the sensing probe into the tank.  
performing installation, operation, and  
maintenance procedures to avoid possible  
injury or death.  
If the unit is equipped with a circulating  
ƽ WARNING  
The combination of electricity and water  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
ƽ WARNING  
pump, the pump relay must be interlocked  
with the temperature control valve so that  
the energy source will shut off if the pump  
is not operational. Failure to do so could  
create a very dangerous situation if the  
pump were to fail.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
remove and inspect the temperature control valve.  
12. Follow the startup procedure (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
2. Assure that the energy source, condensate / water return  
line, cold water inlet, and hot water outlet have been shut  
off; that the tank has been completely drained; that the  
pressure has been bled from both the water and energy  
source systems; and that all components and surfaces  
have cooled.  
Strainers - inspection and replacement  
The strainers are installed upstream of the energy source  
shutoff valve for the main traps. These strainers must be  
blown down periodically (approximately every three (3) to six  
(6) months) to prevent the build up of any sediment.  
3. If the temperature control valve is electrically activated,  
turn off the power and disconnect the leads to the valve.  
4. Remove the control valve probe from the tank port.  
The combination of electricity and water  
ƽ WARNING  
5. Carefully break the joints between the temperature  
control valve and the unions on either side of the valve  
per FIG.’s 5 and 6 on page 6 of this manual.  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
6. Carefully break the connections between the energy  
source inlet line and the tube bundle.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
replace the energy source strainers.  
It may be necessary to break the lines at  
NOTICE  
a second location, and for the lines to be  
2. The location of the strainers can differ between packages.  
Reference FIG.’s 3 and 4 on page 5 of this manual to  
identify the location of the strainers on the unit.  
rotated to allow clearance for the  
temperature control valve to be  
removed from the system. If it is  
necessary, care should be taken to  
ensure that in-line components are not  
damaged.  
3. Carefully break the line connections on the inlet side of  
both strainers.  
4. Carefully break the line connection on the outlet side of  
the strainers.  
5. Remove and examine the strainers.  
20  
 
Hot Water Generator Installation and Operation Manual  
6 Maintenance  
(continued)  
6. Remove any sediment that is present in the strainers. If  
they cannot be satisfactorily cleaned, replace with new  
strainers.  
7. Place the strainers back on-line in the system.  
8. Reconnect the inlet and outlet lines to each strainer.  
Follow  
recommendations  
contained  
in  
the  
manufacturer’s documentation, local codes, or accepted  
contractor practices as to the use and / or type of joint  
compound or sealer at the connections.  
9. Follow the startup procedures (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
Traps - replacement (steam systems  
only)  
The main and auxiliary traps are installed upstream of the  
condensate shutoff valve on units that use steam as the energy  
source. The traps are designed to maintain the flow of  
condensate with the rise and fall of the float as changes in  
condensate level occur within the body of the trap. If the  
traps are not functioning properly and must be replaced,  
follow the procedure outlined below.  
The combination of electricity and water  
ƽ WARNING  
can pose a very dangerous situation. Turn  
off / disconnect all electric power before  
attempting any maintenance procedure.  
1. Follow Steps 1 through 5 of the shutdown procedure  
(page 10) to take the unit off-line before attempting to  
replace the main or auxiliary traps.  
2. The exact location of the traps can differ depending on  
the unit. Reference the CAD drawing supplied with the  
unit to identify the location of the traps on the unit.  
3. Carefully break the joint on the inlet side of the trap.  
4. Carefully break the joint on the outlet side of the trap.  
5. Remove and examine the trap.  
6. If the trap is not functioning properly, replace it  
with a new trap.  
7. Place the trap back on-line in the system.  
8. Reconnect the inlet and outlet lines to the trap. Follow  
recommendations contained in the manufacturer’s  
documentation, local codes, or accepted contractor  
practices as to the use and / or type of joint compound or  
sealer at the connections.  
9. Follow the startup procedure (page 10) to put the unit  
back on-line. Carefully check all connections for any sign  
of leakage.  
21  
 
Hot Water Generator Installation and Operation Manual  
7 Notes  
22  
 
Hot Water Generator Installation and Operation Manual  
7 Notes  
23  
 
HWG-i&o-01  
CP-2M-12/05  
 

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