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Lochinvar COPPER-FIN 497 - 2067 User Manual

Lochinvar COPPER-FIN 497 - 2067
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Installation & Service Manual
Models: 497 - 2067
Save this manual for future reference.
CBX-CWX-I-S Rev A
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual be reviewed completely before proceeding
with an installation. Perform steps in the order
given. Failure to comply could result in severe
personal injury, death, or substantial property
damage.
WARNING:
-- This water heater MUST NOT be installed
in any location where gasoline or flammable
vapors are likely to be present.
-- WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not
use any phone in your building.
Immediately call your gas supplier from a
near by phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed
by a qualified installer, service agency, or
the gas supplier.
WARNING: If the information in
this manual is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or loss of life.

Table of Contents

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Lochinvar COPPER-FIN 497 - 2067 Specifications

General IconGeneral
BrandLochinvar
ModelCOPPER-FIN 497 - 2067
CategoryWater Heater
LanguageEnglish

Summary

Please Read Before Proceeding

Special Instructions

Important notices and warnings before starting installation or operation.

Checking Equipment

Procedures for inspecting the unit upon delivery for damage or shortages.

Warranty Information

Explains warranty limitations related to installation and operation.

Safety Information

Owner Warnings

Critical safety alerts and precautions for the user.

Applicable Codes

Lists installation standards and local code requirements.

The Copper-Fin - How It Works

Ratings

1. Determine Unit Location

Locating the Unit

Guidance on selecting an appropriate installation site for the unit.

Indoor Clearances

Specifies minimum space requirements around the unit for operation and service.

Freeze Protection

Methods to prevent freezing damage to the unit and system.

Outdoor Boiler Installation

Specific requirements for installing units outdoors.

Shut-down and Draining

Procedures for safely winterizing the unit.

Combustion and Ventilation Air

Requirements for air supply to ensure proper combustion and venting.

Combustion Air Filter

Maintenance and function of the combustion air filter.

Combustion Air Options

Various methods for supplying combustion air to the unit.

2. Venting

General Venting Information

General rules and safety precautions for venting systems.

Venting Support

Guidelines for properly supporting vent pipes to prevent sagging.

Vertical Vent Termination Clearances

Specifies required distances for vertical vent outlets from structures.

Barometric Damper Location

Preferred placement for optimal performance of the barometric damper.

Conventional Negative Draft Venting

Details on this specific venting method using rooftop termination.

Masonry Chimney Installation

Procedures and considerations for using masonry chimneys.

Inspection of a Masonry Chimney

How to check chimney suitability for appliance venting.

Outdoor Installation Venting

Details on venting requirements for outdoor unit installations.

3. Gas Connections

Connecting to Gas Supply

How to safely connect the unit to the gas source.

Gas Piping

Requirements for gas pipe sizing and installation according to codes.

Gas Train and Controls

Explanation of the gas delivery system and its control components.

Combination Gas Valves

Description and function of the unit's combination gas valves.

Checking Gas Supply Pressure

Procedure to verify gas supply pressure meets specifications.

Gas Manifold Pressure Adjustment

How to adjust manifold pressure for proper burner operation.

4. Water Connections

Inlet and Outlet Connections

How to connect water lines to the unit's inlet and outlet.

Relief Valve

Installation and purpose of the pressure relief valve.

Water Flow Switch

Function and requirements of the water flow switch.

Low Water Cutoff

Description of the low water cutoff safety feature.

Piping of the Boiler System

General plumbing guidelines for boiler system installations.

Circulator Pump Specifications

Requirements for selecting an appropriate circulating pump.

Circulator Pump Operation

How the pump operates during heating cycles.

Pump Delay Operation

Details on the pump's delay feature for residual heat removal.

Minimum Boiler Water Temperatures

Importance of maintaining minimum water temperatures to prevent condensation.

Low System Water Volume

Impact of low system water volume on boiler efficiency and component life.

Low Temperature Return Water Systems

Managing low return water temperatures to prevent condensation.

Radiant Floor and Snow Melt Heating Systems

Specific considerations for these types of heating systems.

Installation with a Chilled Water System

Considerations for applying the unit in chilled water systems.

Typical Heating Boiler Installations

General plumbing practices and rules for boiler system installations.

Boiler Bypass Requirements

When and how to install a boiler bypass for flow control.

Temperature / Pressure Gauge

Description of the gauge and its function for monitoring system status.

Filling the System

Step-by-step process for filling the system with water and purging air.

Water Treatment

Importance of water treatment, especially in hard water areas.

5. Electrical Connections

Connecting to Electrical Supply

How to safely connect the unit to the electrical power supply.

Terminal Strip Connection Options

Various ways to connect external controls and safety devices.

Temperature Adjustment

How to set and adjust the unit's temperature controls.

Temperature Control Settings

Details on setting specific temperature parameters like setpoint and differential.

Outdoor Reset Option

How to use the outdoor reset control for efficient operation.

Temperature Control Sensors

Types and functions of temperature sensors used in the unit.

Remote Sensor for Pump Delay

Connecting a remote sensor for accurate pump delay operation.

Placement of Sensors

How to install sensors for accurate readings and reliable operation.

Hot Surface Ignition System

Igniter and Ignition Control Module

Components and function of the hot surface ignition system.

Diagnostic Status Indication

Understanding the status LED codes on the ignition module.

Ignition and Control Timings

Nominal timings for ignition sequences and control operations.

Operation and Diagnostic Lights

Interpreting the unit's operational lights and diagnostic codes.

6. Startup

Operating Instructions

Step-by-step instructions for safely starting the appliance.

To Turn Off Gas To Appliance

Procedure for safely shutting off the gas supply to the unit.

Check Water Chemistry

Verifying water quality and freeze protection fluid status.

Fill and Test Water System

Procedure for filling the system with water and testing for leaks.

Purge Air from Water System

Removing air from the water system for proper operation.

Check for Gas Leaks

Procedure to detect and address potential gas leaks before operation.

Check Vent and Air Piping

Inspecting the integrity of vent and air piping for safety.

Placing the Boiler in Operation

Performing operational checks before initial use of the boiler.

7. Domestic Water Heaters

Required Temperature Rise

Determining the necessary temperature increase for domestic hot water.

Water Velocity Control

Managing water speed for optimal heat exchanger performance and longevity.

Initial Set-up of Maximum Water Flow

Setting initial water flow rates during setup.

Pipe Size Requirements

Minimum pipe sizes for common manifold piping to ensure adequate flow.

Circulating Pump

Requirements and installation of the circulating pump for water heaters.

Heat Exchanger

Description and function of the unit's sophisticated heat exchanger.

Potable Hot Water Temperature Control Settings

Adjusting water heater temperature for optimal performance and safety.

Location of Cold Water Supply Piping Connections

Proper connection of cold water supply to prevent condensation issues.

High Water Temperature Limit Control

Setting and function of the high limit control for safety.

Optional Relief Valve

Information on optional pressure relief valves and their installation.

Thermal Expansion

Managing thermal expansion in closed hot water systems.

Cathodic Protection

Preventing issues related to hydrogen gas buildup in unused systems.

8. Maintenance

Appliance Area

Keeping the area around the unit clear of obstructions and flammables.

Water Circulating Pump

Maintenance schedule and procedure for the circulating pump.

Burner Flames

How to check and interpret burner flame patterns for proper operation.

Flue Gas Passageways Cleaning Procedure

Steps for cleaning flue passages to maintain efficiency and safety.

Heat Exchanger Cleaning

Procedures for cleaning the heat exchanger to remove soot and debris.

Combustion and Ventilation Air

Ensuring proper air supply for combustion and ventilation.

Ignition System Checkout

Steps to verify the ignition system is functioning correctly.

Sequence of Operation

Step-by-step process detailing the unit's operational sequence.

9. Glossary

Power Supply

Electrical power requirements and connection details for the unit.

Ignition Module

The control unit responsible for managing ignition sequences.

Electronic Temperature Controller

The main control unit that maintains desired temperature set points.

Post-Purge

The process of clearing the combustion chamber of by-products after operation.

Pump Delay

The function that keeps the pump running after burner shutdown to remove residual heat.

10. Diagrams

Ladder Diagram

Schematic showing electrical connections and operational logic flow.

Connection Diagram

Visual representation of component wiring and connections for troubleshooting.

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