Lochinvar LBF121 Installation, Commissioning & Maintenance Instructions Download

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The LBF range

High Efficiency Gas Fired Water Heaters

Installation, Commissioning & Maintenance
Instructions

Models:

LBF81

LBF121

LBF151

LBF171

LBF221

LBF301

LBF401

INS0044 Issue No 2 | July 2013

Summary of Contents for LBF121

Page 1: ...The LBF range High Efficiency Gas Fired Water Heaters Installation Commissioning Maintenance Instructions Models LBF81 LBF121 LBF151 LBF171 LBF221 LBF301 LBF401 INS0044 Issue No 2 July 2013 ...

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Page 3: ...1 9 9 FLUE TERMINAL GUARDING 31 10 0 AIR SUPPLY 31 10 1 COMBUSTION VENTILATION 31 10 2 COOLING VENTILATION 31 11 0 WATER CONNECTIONS 32 11 1 GENERAL 32 11 1 1 SYSTEM DE STRATIFICATION 32 11 2 OPEN VENTED SYSTEM ARRANGEMENT 32 11 3 UNVENTED SYSTEM ARRANGEMENT 32 11 3 1 EXPANSION VESSEL SIZING 35 12 0 ELECTRICAL SUPPLY 35 12 1 ELECTRICAL CONNECTION 35 12 2 EXTERNAL CONTROLS 36 12 3 ARC WELDING PRECA...

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Page 5: ...gulations Health Safety requirements must also be taken into account when installing any equipment Failure to comply with the above may lead to prosecution If the equipment is to be connected to an unvented pressurised system care must be taken to ensure all extra safety requirements are satisfied should a high or low pressure condition occur in the system The equipment is designed for direct conn...

Page 6: ... Storage vessel 3 Flue hood 4 Upper casing 5 Flue baffle 6 Hot outlet tube 7 Front casing 8 Gas inlet pipe 9 Control panel 10 Gas valve 11 Power connection PCB 12 Ignition sequence controller 13 Burner assembly 14 Lower casing 15 Side casing TABLE 2 1 LBF81 121 PRINCIPAL PARTS ...

Page 7: ...ol panel 15 Burner door 5 Ignition electrode cable white 16 Gas pipe 6 Upper cover 17 Gas pipe gaskets 7 Flame sense electrode red 18 Burner assembly 8 Ignition sequence controller 19 Combustion chamber casing 9 Ignition sequence controller cable 20 Storage vessel 10 Power supply cable 21 Flue baffle 11 Lower cover 22 Flue hood TABLE 2 2 LBF151 171 PRINCIPAL PARTS ...

Page 8: ...er 5 Ignition electrode cable white 17 Lower cover 6 Burner door gasket 18 Power supply cable 7 Burner door 19 Upper cover 8 Electrode grommets 20 Control panel 9 Gas pipe 21 Flue Baffles 10 Gas pipe gaskets 22 Fan Assembly 11 Flame sense electrode cable red 23 Flue Hood 12 Burner assembly TABLE 2 3 LBF221 401 PRINCIPAL PARTS A replacement parts list is available to download from Lochinvar s websi...

Page 9: ...50 D Depth 460 460 E Centre Line Of Flue Outlet 895 1255 F Diameter Of Outer Flue 100 100 G Diameter Of Inner Flue 60 60 H Service Clearance From Front 500 500 I Service Clearance From Above 200 200 J Service Clearance From Sides 50 50 K Service Clearance From Below 200 200 TABLE 2 4 DIMENSIONS LBF81 121 C J J B A I F G E K H TOP VIEW FRONT VIEW LBF81 121 D ...

Page 10: ...et 1625 1825 1285 1640 1985 H Gas Supply 432 432 475 475 475 I Inspection Flange 460 465 570 570 570 J HWS Return 720 720 960 960 1135 K Relief Valve Tapping 1470 1670 1485 1835 1835 L Drain Valve N A N A 405 405 403 TABLE 2 5 DIMENSIONS LBF151 171 221 301 401 A B F J K B 300 D H I A L F J K G E 500 50 50 200 500 200 50 300 E I D 300 G C C H SIDE VIEW RIGHT FRONT VIEW TOP VIEW TOP VIEW FRONT VIEW ...

Page 11: ...ximum gas inlet pressure mbar 45 Minimum gas inlet pressure mbar 30 Burner pressure mbar 28 0 28 0 28 0 28 0 28 0 28 0 28 0 Injector Size mm 1 15 1 15 0 70 0 70 0 65 0 72 0 75 Gas flow rate m3 hr 0 39 0 39 0 75 0 79 1 05 1 21 1 21 Gas Inlet connection size BSP 3 8 3 8 1 2 1 2 1 2 1 2 1 2 WATER DATA Storage capacity litres 75 115 145 160 220 300 390 Water connections BSP 1 1 1 System return connect...

Page 12: ...tisfactory installation BS 5440 1 2008 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Part 1 Specification for installation and maintenance of flues BS 5440 2 2009 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 2nd and 3rd family gases Part 2 ...

Page 13: ...talled in a room that complies with the appropriate ventilation requirements The Lochinvar LBF range can be used as a type C12 C32 C52 appliance Due to its room sealed design ventilation allowances for combustion air are not necessary If the appliance is to be installed in a compartment or a hot environment ventilation for cooling purposes must be fitted For further guidance please refer to Sectio...

Page 14: ...PLY PIPES Supply pipes must be fitted in accordance with IGE UP 2 Pipework from the meter to the equipment must be of adequate size The complete installation must be purged and tested as described in IGE UP 1 Refer to Section 13 LPG FUEL for information on LPG pipework installation guidance 7 4 BOOSTED SUPPLIES Where it is necessary to employ a gas pressure booster the controls must include a low ...

Page 15: ...er in a separate box that contains A Flue hood casing in black painted aluminium B fan assembly C Ø 60 100 Transition piece with flue sampling point Plastic bag with fixing screws 8 2 FLUE HOOD INSTALLATION Place the fan assembly on the top of the water heater pointing the Ø 60 flue outlet in the desired direction ...

Page 16: ...16 Fix the fan in position with the screws contained in the box Fix the bracket with the hole for cables vertically ...

Page 17: ...17 Feed the air pressure switch hoses through the bracket Connect the motor supply cable pos 2 and 3 Connect the earth cable pos 1 ...

Page 18: ...18 Connect the two tubes to the pressure points IMPORTANT Pink tube pressure point 1 the metal one Clear tube pressure point 2 the plastic one Place the black flue hood casing on the heater ...

Page 19: ...19 Centre the Flue hood casing by means of the 4 spacers on the top of the heater Connect the Transition piece with sampling point ...

Page 20: ...20 Fix the black flue hood casing to the heater using the screws supplied in the box ...

Page 21: ...ce facing the terminal 600 K From a terminal facing the terminal 1200 L From an opening in the car port e g door window into the dwelling 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wall 300 P From a vertical structure on the roof 300 Q Above intersection with the roof 300 TABLE 8 1 FLUE TERMINAL MINIMUM DISTANCES 9 1 FLUE SYSTEM GENERAL REQUI...

Page 22: ...equired length of the flue pipe item 3 in Figure 8 2 and cut as necessary NOTE When determining the required length the extension pipe must protrude by a minimum of 150mm NOTE Once cut remove all burrs and sharp edges 4 Insert the flue pipe into the drilled hole The terminal section should be installed with a slight fall to outside Max 10mm per metre to prevent the ingress of water 5 Position the ...

Page 23: ...o the roofing material Extra care should be taken to ensure that the hole is drilled vertically 3 Install the roof flashing and secure as appropriate 4 Carefully insert the roof terminal through the roof flashing and hole in the roof NOTE When inserting the roof terminal do not support or turn the terminal using the cap 5 Ensure the terminal is vertical using a spirit level 6 Fit the support brack...

Page 24: ...length of the flue pipe item 3 in Figure 8 4 and cut as necessary NOTE When determining the required length the extension pipe must protrude by a minimum of 150mm NOTE Ensure that the terminal end item 5 in Figure 8 4 is correctly positioned so as the row of air inlet openings are clearly visible NOTE Once cut remove all burrs and sharp edges 4 Insert the flue pipe into the drilled hole The termin...

Page 25: ...ge is done to the roofing material Extra care should be taken to ensure that the hole is drilled vertically 3 Install the roof flashing and secure as appropriate 4 Carefully insert the roof terminal through the roof flashing and hole in the roof NOTE When inserting the roof terminal do not support or turn the terminal using the cap 5 Ensure the terminal is vertical using a spirit level 6 Fit the s...

Page 26: ...ength of the extension pipes items 7 3 in Figure 8 6 and cut as necessary NOTE When determining the required lengths the outlet extension pipe must protrude by a minimum of 150mm and the air inlet a minimum of 10mm NOTE Once cut remove all burrs and sharp edges 4 Insert the extension pipes into the drilled holes The terminal sections should be installed level or with a fall to outside Max 10mm per...

Page 27: ...nd outlet pipes NOTE The holes should be drilled from the outside to ensure that no damage is done to the roofing material Extra care should be taken to ensure that the hole is drilled vertically 3 Install the roof flashing and secure as appropriate 4 Carefully insert the roof terminals items 3 7 in Figure 8 7 through the roof flashings Fit the terminal end caps secure using appropriate fixings it...

Page 28: ...nsion pipe into the drilled hole The terminal sections should be installed with a slight fall to outside Max 10mm per metre to prevent the ingress of water 5 Fill the void between the extension pipe and wall with water resistant sealant 6 Repeat the above procedure for the air supply noting the minimum protrusion is reduced to 10mm 7 Fit the relevant air intake and flue outlet terminal end fitting...

Page 29: ...he outside to ensure that no damage is done to the roofing material Extra care should be taken to ensure that the hole is drilled vertically 3 Install the roof flashing and secure as appropriate 4 Carefully insert the roof terminal through the roof flashing NOTE When inserting the roof terminal do not support or turn the terminal using the cap 5 Ensure the terminal is vertical using a spirit level...

Page 30: ...ch 90 bend 1 0 metre should be deducted from the total length NOTE This is the maximum length for each pipe and not an aggregate for the two for example a 3 metre inlet cannot be combined with a 9 metre exhaust 9 6 1 AIR RESTRICTION PLATE The following restriction plate should be inserted if required LBF151 171 No Restriction Plate required LBF221 Ø 52mm Restriction Plate required LBF301 Ø 52mm Re...

Page 31: ...hed from a window door or balcony a terminal guard must be fitted The guard should be installed centrally around the terminal ensuring a gap of at least 50mm between the guard and terminal is maintained 10 0 AIR SUPPLY The following information is based on single water heater installations only If more than one water heater is being used BS5440 2 should be consulted to calculate the necessary requ...

Page 32: ...nt temperature throughout By achieving a uniformed stored water temperature of at least 60 C the risk of any bacterial contamination is virtually eliminated Systems that have a building loop incorporated onto the vessel may not require a de stratification kit as the circulation around the building from the top of the vessel back to the bottom should provide sufficient mixing Lochinvar has develope...

Page 33: ...RT VALVE TO ATMOSPHERE DV DRAIN VALVE BRP BUILDING RETURN PUMP COLD SUPPLY TO BUILDING VENT PIPE BUILDING FLOW BUILDING FLOW PTRV TD IV ISOLATION VALVE NRV NON RETURN VALVE TD TUNDISH PTRV PRESSURE TEMPERATURE RELIEF VALVE OPTIONAL TPV THREE PORT VALVE TO ATMOSPHERE DV DRAIN VALVE BRP BUILDING RETURN PUMP COLD SUPPLY TO BUILDING VENT PIPE IV IV BRP BUILDING RETURN NRV NRV ...

Page 34: ...DRAIN VALVE BRP BUILDING RETURN PUMP OPTIONAL EXPANSION VESSEL IF SYSTEM VOLUME REQUIRES BUILDING FLOW BUILDING RETURN PTRV TD IV ISOLATION VALVE PRV PRESSURE REDUCING VALVE NRV NON RETURN VALVE EV EXPANSION VALVE TD TUNDISH LSV LOCKSHIELD VALVE EXV EXPANSION VESSEL PTRV PRESSURE TEMPERATURE RELIEF VALVE DV DRAIN VALVE BRP BUILDING RETURN PUMP OPTIONAL EXPANSION VESSEL IF SYSTEM VOLUME REQUIRES BU...

Page 35: ...REQUIREMENTS WARNING THIS APPLIANCE MUST BE EARTHED A suitably competent person MUST check wiring Normal supply required is 230 VAC single phase 50 Hz An isolator with a contact separation of at least 3mm in all poles should be sited close to the equipment and must only serve that equipment The double pole switch must be readily accessible under all conditions 12 1 ELECTRICAL CONNECTION Access to ...

Page 36: ...he outputs can be found on the power supply PCB and are marked as follows SV Burner on TS High temperature limit Where applicable SB Flame failure Relays to convert these outputs into volt free contacts are available as ancillary options the part number for the relay is RLY2716 and one relay will be required for each option 12 3 ARC WELDING PRECAUTIONS The appliance must be isolated from the mains...

Page 37: ...Limit thermostat SV Green burner on light V Fan GV Gas valve SB Lock out light PS Reset push button P Differential pressure switch ER Flame sense electrode EA Ignition electrode F1 Fuse 2 A 1 Flue hood 2 Power connection PCB 3 Instrument control panel 4 Ignition sequence controller wh white bl blue gy grey bn brown bk black rd red gn green ...

Page 38: ... electrode ER flame detection electrode F line trap FB fuse for printed circuit 2A I On Off switch P differential pressure switch PS reset push button SB lock out light SV green burner on light TR adjustable thermostat TS limit thermostat V fan VG double gas electro valve wh white bl blue gy grey bn brown bk black rd red gn green TABLE 11 2 WIRING DIAGRAM LEGEND ...

Page 39: ... ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages are clear and the termination complies with Table 8 1 2 Ensure that the flue run is within the maximum length specified within Table 3 1 3 Adequate ventilation exists in the plant room if necessary 4 The system is fully charged with water ready to receive heat A...

Page 40: ...ppliance should go to a flame failure condition within 10 seconds this will be indicated by a red lock out light on the control panel 5 If the above occurs correctly open the gas inlet appliance isolating valve and reset the unit by depressing the red lock out light on the control panel and a new ignition cycle will begin 6 The combustion fan will repeat the pre purge procedure and attempt to ligh...

Page 41: ...UEL 4 Switch off the appliance remove manometer and close pressure test point 5 Open the pressure test point on the outlet side of the gas valve and attach a manometer 6 Relight the appliance and check the burner pressure according to the model 7 If required the burner pressure can be corrected by removing the dust cap with a large slotted screwdriver and the adjusting screw turned clockwise to in...

Page 42: ...LY RECOMMENDED THAT ON LPG INSTALLATIONS GAS DETECTION EQUIPMENT IS FITTED THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE APPLIANCE AND AT LOW LEVEL IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE APPLIANCE IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL THIS APPLIANCE MUST NOT BE LOCATED BELOW GROUND E G IN A CELLAR 14 1 RELATED DOCUMENTS In addition to those documents listed in Section 4 1 RELATED ...

Page 43: ... Table 3 1 2 Close the gas inlet appliance isolating valve and isolate the electrical supply 3 Unscrew the injector holder Item C in Figure 13 1 with a suitable hexagonal spanner 4 Undo the injector Item D in Figure 13 1 and replace it with the one contained in the kit 5 Refit the injector holder and reconnect any pipework disturbed in the removal process 6 Unscrew the dust cap Item A in Figure 13...

Page 44: ...d 7 Remove the dust cap Item D in Figure 13 2 and turn the pressure governor screw clockwise until it stops 8 Replace the dust cap Item D in Figure 13 2 Once reinstalled the dust cap should be marked with an anti tamper indicator 9 Loosen the outlet test point screw see Figure 12 3 and attach a manometer Start up the water heater and adjust the inline governor to give a pressure at the burner of 2...

Page 45: ...t also reduces efficiency of the water heater and increases fuel consumption The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always remove all of the hardness scale For this reason it is recommended that a regular schedule of de scaling be maintained The depth of the build up should be measured after 3 months of operation to determin...

Page 46: ...n the quality of the water therefore it is essential that the anodes are inspected at least once a year NOTE Where a water softener is used the conditioned water may reduce the serviceable life of the tank The condition of the anodes must therefore be checked more frequently 15 5 1 ANODE REMOVAL LBF81 121 FIGURE 13 1 LBF81 121 ANODE LOCATION 1 Drain the water heater Refer to Section 14 3 DRAINING ...

Page 47: ...nsure excessive localised depletion has not occurred Where the anode is covered with particles it should be cleaned 5 Locate the cleanout opening and remove outer cover and then the internal plate 6 The lower anode Item B in Figure 14 2 is located on the rear of the internal plate inspect condition of the lower anode 7 The reassembly procedure is the reverse of removal ensuring a water tight joint...

Page 48: ...ct the wiring to the ignition and flame sense electrodes noting the correct locations for each 7 Remove the outer base cover from the appliance 8 Remove the inner base cover by removing the retaining nut 1 x screw and 2 x locating studs 9 Detach the gas pipe from the burner assembly 10 Unclip the burner assembly from the storage vessel body and remove from the appliance 11 With the burner assembly...

Page 49: ...ash red Remedial action should be taken as a matter of urgency if such a situation arises The Correx system passes and monitors an electrical current flow through the water If this current flow becomes too high or too low a fault is indicated Factors that may cause incorrect current flow include Short circuiting of the cables between the potentiostat and electrodes Poor conductivity between the el...

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