DESIGNER’S GUIDE COPPER-FIN® WATER HEATER
4 9 5 , 0 0 0 – 2 , 0 6 5 , 0 0 0 B t u / h r
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Table of Contents
Codes . . . . . . . . . . . . . . . . . . . . . . . . .2
TABLE A. Clearances From
Combustible . . . . . . . . . . . . .3
Combustion & Ventilation Air . . . . . . . . .5
Contaminants . . . . . . . . . . . . . . . . . . . .6
Determining Total “Free Area” . . . . . . . .5
Electrical Requirements . . . . . . . . . . . .14
Gas Supply . . . . . . . . . . . . . . . . . . . .10
General Venting . . . . . . . . . . . . . . . . . .6
Location of Unit . . . . . . . . . . . . . . . . . .2
Low Water Temperature Delivery . . . . .12
Outdoor Use . . . . . . . . . . . . . . . . . . . .3
Outdoor Installation . . . . . . . . . . . . . . .9
Pump Operation . . . . . . . . . . . . . . . . .12
Relief Valve . . . . . . . . . . . . . . . . . . . .14
Venting Options . . . . . . . . . . . . . . . . . .8
Water Connections . . . . . . . . . . . . . . .11
Water Treatment . . . . . . . . . . . . . . . . .13
Water Velocity Control . . . . . . . . . . . .12
TABLE B. Flue Sizes . . . . . . . . . . . . . . . .8
TABLE C. Outdoor Kits . . . . . . . . . . . .10
TABLE D. Gas Supply Pipe Sizing . . . .11
TABLE E. Inlet Gas Pressure . . . . . . . . .11
TABLE F. Required Temperature Rise . . .12
TABLE G. Required Pump Performance .13
TABLE H. Common Water
Manifold Sizes . . . . . . . . . . .14
TABLE I. Amp Draw . . . . . . . . . . . . . .14
Appendix A -
Water Heater Piping Diagrams
Single Heater – Single Tank . . . . . . . . .A1
Single Heater – Two Tanks . . . . . . . . .A2
Two Temperature Installation
Figures & Tables Index
Single Heater – Single Tank . . . . . . . . .A3
Two Heaters – Single Tank . . . . . . . . .A4
Two Heaters – Two Tanks . . . . . . . . . .A5
Multi-Stack Frame
FIG. 1
Models CW 495-2066
Requirements For Installation
Over Combustible Floor . . . . .3
FIG. 2
Water Heater Equipment
& Control Orientation . . . . . . .4
Two Heaters – Single Tank . . . . . . . . .A6
FIG. 3-6 Combustion &
Ventilation Air . . . . . . . . . . .5,6
FIG. 7
Barometric Damper
Installation . . . . . . . . . . . . . . .8
FIG. 8
Multiple Unit Barometric
Damper Installation . . . . . . . .9
FIG. 9 Outdoor Venting . . . . . . . . . . .9
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CODES
In designing
The equipment shall be installed in
accordance with those installation
regulations in effect 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
installations are made.
a water heater system,
pay special attention to:
o Water Velocity
(See page 12 for Required Degree
Rise chart.)
In the absence of such requirements, the
installation shall conform to the latest edition of
the National Fuel Gas Code, ANSI Z223.1.
Where required by the authority having
jurisdiction, the installation must conform to
American Society of Mechanical Engineers
Safety Code for Controls and Safety Devices
for Automatically Fired Boilers, ASME CSD-1.
Where required by the authority having
jurisdiction, the installation must comply with
the Canadian Association Code, CAN/CGA-
B149.1 and/or B149.2 and/or local codes.
o Factory Supplied Pump
Capacity
(See page 12 for Pump Operation.)
o Manifold Pipe Size
When using more than one heater
(See page 14 for Common Water
Manifold Size for Multiple Water
Heater Installation Table.)
o Storage Tank Circulating
Tappings
(See page 14 for Manifold Pipe
LOCATION OF UNIT
Size.)
Locate the unit so that if water connections
should leak, water damage will not occur.
When such locations cannot be avoided, it
is recommended that a suitable drain pan,
adequately drained, be installed under the
unit. The pan must not restrict combustion
air flow.
1.
o Placement of Cold Water
Inlet and Building Return
(See Appendix A for Water Heater
Piping Diagrams.)
Under no circumstances is the
manufacturer to be held responsible
for water damage in connection
with this unit or any of its
components.
o Water Hardness
See page 13 for Water Treatment
(
Information.)
2
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2.
The indoor units must be installed so that
the ignition system components are
protected from water (dripping, spraying,
rain, etc.) during appliance operation and
service (circulator replacement, control
replacement, etc.).
• This procedure should also be
followed if electrical conduit or
radiant heat distribution piping
runs through the floor and
beneath the appliance.
• Ensure that combustible floor base
meets local fire code requirements.
3.
4.
The appliance must be installed
on a level, non-combustible floor.
Concrete over wood is not considered a
non-combustible floor. Maintain required
clearances from combustible surfaces.
5.
Outdoor models require the installation of
an optional vent cap. Instructions for
placement of the vent cap are included in
the venting section.
For installation on a combustible
floor only when installed on
special base: Units installed over a
combustible floor must use the Special
Combustible Floor Base. The unit must be
centered on the base as shown in FIG. 1.
Outdoor models must not be installed
directly on the ground. The outdoor unit
must be installed on a concrete brick,
block or other non-combustible pad.
(TABLE A) – CLEARANCES FROM
COMBUSTIBLE CONSTRUCTION
CLEARANCES
Right Side
Rear
CW495-2066
• Provide a base of hollow clay tile or
concrete blocks from 8” to 12” thick
and extending 24” beyond the sides.
3"
3"
Left Side
3"
(24" for Service)
ALCOVE*
(30" for Service)
3"
Front
Top
Flue
• The blocks must be placed in line so that
the holes line up horizontally to provide a
clear passage through the blocks.
1"**
* Alcove is a closet without a door.
** Consult local codes and/or vent
material manufacturer.
SPECIAL LOCATION: OUTDOOR USE
Outdoor models have additional location
and clearance requirements. These
requirements must be adhered to carefully,
since wind, rain, snow and cold cannot be
controlled in outdoor applications. See
Outdoor Installation, on page 9.
(FIG. 1) 495-2066 REQUIREMENTS FOR
INSTALLATION OVER COMBUSTIBLE FLOOR
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RIGHT SIDE
INLET GAS
FLUE PRODUCTS VENT
CONNECTION
OPERATOR
FRESH AIR
ON/OFF SWITCH
INLET
TERMINAL
STRIP
HOT WATER
OUTLET
120V ELECTRICAL
CONNECTION
RELIEF VALVE
TAPPING
BACK
COLD WATER
INLET
FRONT
DRAIN
CW495-745
BURNER INSPECTION PORT
LEFT SIDE
FLUE PRODUCTS VENT
RIGHT SIDE
OPERATOR
GAS
ON/OFF SWITCH
AIR
CONNECTION
INLET
TERMINAL STRIP
HOT WATER
OUTLET
FRONT
BACK
COLD WATER
LEFT SIDE
INLET
BURNER
DRAIN
CW986-2066
INSPECTION PORT
(FIG. 2) WATER HEATER EQUIPMENT AND CONTROL ORIENTATION.
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This opening must be located within 12”
(30 cm) of the bottom of the enclosure.
EXAMPLE OF
COMBUSTION & VENTILATION AIR
Provisions for combustion and ventilation air
must be in accordance with Section 5.3,
Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas
Code, ANSI Z223.1; in Canada, the latest
edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment; or applicable provisions of the
local building codes.
SIZING FOR
COMBUSTION
& VENTILATION
AIR OPENINGS
(WATER HEATER
WITH 2,065,000
Btu/hr INPUT):
B. Ventilation air opening with a minimum
free area of one square inch per 4000
2
Btu input (5.5 cm per kW). This opening
must be located within 12” (30 cm) of the
top of the enclosure.
When combustion and
ventilated air is taken
from directly outside the
building (FIG. 4), divide
the total BTU’s by 4,000.
This yields 516.25 sq.in.
of “Free Area” without
restriction.
The equipment room must be provided with
properly sized openings to assure adequate
combustion air and proper ventilation when
the unit is installed with conventional venting
or sidewall venting.
(2,065,000 ÷ 4000 =
516.25 sq.in.)
(FIG. 4) COMBUSTION AIR THROUGH DUCTWORK
Since the air opening is
50% closed due to
screens and louvers, the
total opening must be
multiplied by 2.
2.
If combustion and ventilation air is
taken from the outdoors using a
duct to deliver the air to the
CAUTION: Under no circumstances should
the equipment room be under a negative
pressure when atmospheric combustion
equipment is installed in the room.
mechanical room, each of the two
openings should be sized based on a
minimum free area of one square inch
(516.25 sq. in. x 2 =
1,032 sq.in.)
This project requires one
Ventilation Air Opening
with net “Area” of
1,032 square inches with
louver dimensions of 30”
x 35” and one
2
per 2000 Btu input (11 cm per kW).
Combustion Air Opening
with net “Area” of
1,032 square inches with
louver dimensions
(FIG. 3) COMBUSTION AIR DIRECT FROM OUTSIDE
1.
If air is taken directly from outside
the building with no duct, provide two
permanent openings:
(FIG. 5) COMBUSTION AIR FROM AN
INTERIOR SPACE
of 30” x 35”.
3.
If air is taken from another interior
space, each of the two openings
specified above should have a net free
area of one square inch for each 1000
A. Combustion air opening with a
minimum free area of one square inch per
2
4000 Btu input (5.5 cm per kW).
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2
Btu (22 cm per kW) of input, but not less
than 100 square inches (645 cm ).
VENTING
General
2
Copper-Fin II Water Heaters are classified as
Category I appliances when tested to the
latest ANSI Standard. This classification
requires all conventionally vented
combustion products to be vented using
Category I listed vent pipe.
(FIG. 6) COMBUSTION AIR FROM OUTSIDE,
SINGLE OPENING
Additionally, it is recommended that this vent
material be double wall construction or
insulated in the field. A Category I
appliance operates with a non-positive static
vent pressure and with flue loss greater than
17 percent.
4. If a single combustion air opening
is provided to bring combustion
air in directly from the outdoors,
the opening must be sized based on a
minimum free area of one square inch
2
per 3000 Btu input (7 cm per kW). This
Vent installations for connection to gas vents
or chimneys must be in accordance with
Part 7, “Venting of Equipment,” of the latest
edition of the National Fuel Gas Code, ANSI
Z223.1, or applicable provisions of the local
building codes.
opening must be located within 12”
(30 cm) of the top of the enclosure.
CAUTION!
EXHAUST FANS:
Any fan or equipment
which exhausts air
from the equipment
room may deplete the
combustion air supply
and/or cause a down
draft in the venting
system. If a fan is used
to supply combustion
air to the equipment
room, it must by sized
such to make sure that
it does not cause drafts
which could lead to
nuisance operational
problems with the
CONTAMINANTS
Combustion air drawn from an interior
or exterior space must be free of any
chemical fumes which could be corrosive to
the water heater.
The connection from the appliance vent
to the stack must be as direct as possible
and sized correctly. The horizontal breeching
of a vent must have at least 1/4” rise per
linear foot. The horizontal portions should
also be supported for the design and weight
of the material employed to maintain
clearances, prevent physical damage and
separation of joints.
Burning chemical fumes results in the
formation of corrosive acids which attack the
water heater, cause improper combustion
and premature failure of the water heater
and vent.
These fumes are often present in areas
where refrigerants, salts, and solvents are
used. Therefore, be aware of swimming
pool equipment, water softening, and
cooling system placement.
The connection from the appliance vent
to the stack or vent termination outside the
building must be made with listed
water heater.
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Category I double wall vent (or equivalent)
connectors and sized according to vent
sizing tables (FAN column) in the latest
edition of the National Fuel Gas Code.
Vent Terminations
The vent terminal should be vertical and
exhaust outside the building at least 2 feet
(0.6 m) above the highest point of the roof
when within a 10 foot (3.05 m) radius.
The Category I vent and accessories, such as
firestop spacers, thimbles, caps, etc., must
be installed in accordance with the vent
manufacturer’s listing. The vent connector and
firestop must provide correct spacing to
combustible surfaces and seal to the vent
connector on the upper and lower sides of
each floor or ceiling through which the vent
connector passes.
Additionally, vertical terminations must be a
minimum of 3 feet (0.9 m) above the roof
line, and when less than 10 feet (3.05 m)
from a parapet wall must be a minimum of
2 feet (0.61 m) higher than the parapet wall.
Vent caps should have a minimum clearance
of 4 feet (1.2 m) horizontally from, and in no
case above or below [unless a 4 feet (1.2 m)
horizontal distance is maintained], electric
meters, gas meters, regulators and relief
equipment.
Any improper operation of the common
venting system in an existing building should
be corrected when new equipment is
installed, so the installation conforms to the
latest edition of the National Fuel Gas Code,
ANSI Z223.1.
Maintain a distance of at least 3 feet
(0.9 m) above any forced air inlet within
10 feet (3.05 m) and a distance of at
least 4 feet (1.2 m) below, 4 feet (1.2 m)
horizontally from, or 1 foot (30 cm) above
any door, window or gravity air inlet.
When resizing any portion of the common
venting system, it should be resized to
approach the minimum size as determined
using the appropriate tables in the National
Fuel Gas Code.
Do not terminate the vent in a window well,
stairwell, alcove, courtyard or other recessed
area. The vent can not terminate
below grade. The bottom of the vent
terminal shall be located at least 12 inches
(30 cm) above grade and clear of snow,
ice, leaves or other debris.
The weight of the venting system must not
rest on the water heater. The venting system
must be adequately supported in
compliance with local codes and other
applicable codes.
The distance of the vent terminal from
adjacent public walkways, adjacent
buildings, windows, and building openings
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must be consistent with the National Fuel
The minimum flue pipe diameters for
Copper-Fin models, utilizing negative draft
venting are as follows:
NOTE:
Gas Code Z223.1 or in Canada, the latest
edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment.
A vent system should
never be sized based
only on the vent
(TABLE B)
FLUE SIZES AND COMBUSTION AIR PIPE SIZES
connection diameter of
the appliance. For proper
vent design and sizing,
please consult the
MODEL
FLUE SIZE
NUMBER
CW 495
CW 645
CW 745
CW 986
CW 1256
CW 1436
CW 1796
CW 2066
6"
8"
VENTING OPTIONS
Conventional Venting
8"
A conventional venting system utilizes
the natural buoyancy of the heated flue
products to generate a negative draft. This
draft forces flue products to rise vertically
through a rooftop flue termination. The vent
connection is made directly to the top of the
unit and combustion air supplied from the
mechanical room. Properly sizing vent
material and the use of a barometric
damper (when required) will lead to proper
vent operation.
National Fuel Gas Code
(ANSI Z223.1).
10"
12"
12"
14"
14"
Size vent material using the “FAN” category
of vent sizing tables in the latest edition of
the National Fuel Gas Code. “FAN” applies
to fan-assisted combustion appliances in
Category I.
Barometric Dampers
A barometric damper is required when draft
exceeds 0.08 inches of negative water
column. When installed and adjusted
properly, a barometric damper will maintain
draft between 0.02 and 0.08 inches of
negative water column ensuring proper
operation.
Multiple unit installations with combined
venting also require barometric dampers to
regulate draft at each unit. Again, the
negative draft must be within the range of
0.02 to 0.08 inches of negative water
column to ensure proper operation.
(FIG. 7) BAROMETRIC DAMPER INSTALLATION
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condensing of flue products, damage of the
masonry flue/tile, insufficient draft and
possible spillage of flue products into an
occupied living space.
NOTE:
Common venting
systems may be too
large when an existing
unit is removed. Be
careful to resize any
common venting system
when new appliances
are installed or existing
appliances are replaced.
Carefully inspect all chimney systems during
the project design phase. If there is any doubt
about the sizing or condition of a masonry
chimney, it is prudent to reline the chimney
with a properly sized and approved chimney
liner system. Metallic liner systems (Type “B”
doublewall or flexible or rigid metallic liners)
are recommended. Consult with local code
(FIG. 8) MULTIPLE UNIT BAROMETRIC
DAMPER INSTALLATION
For this type of installation, it is best to use a
draft control for each water heater located
on the riser between the vent outlet and the
breeching - Location “A”. When this riser is
too short to permit the installation of a draft
control, locate a separate control for each
water heater on the main breeching as
illustrated in Location “B”. If, because of
general crowding or other reasons, neither
of these locations are possible, use a single
large control in the breeching between the
water heater nearest the chimney and the
chimney, as shown in Location “C”.
NOTE:
Flue gases will form a
officials to determine code requirements or the white plume in winter.
Plume could obstruct
window view. Flue gas
condensate can freeze
on exterior surfaces or
on the vent cap. Flue
gas condensate can
cause discoloration of
exterior building
advisability of using or relining a masonry
chimney.
OUTDOOR INSTALLATION
surfaces. Adjacent brick
or masonry surfaces
should be protected with
a rust resistant sheet
metal plate.
All draft readings are made while unit is in
stable operation (approximately 5 minutes
running time).
(FIG. 9) OUTDOOR VENTING
Masonry Chimney
Units are self venting and can be used
outdoors when installed with the optional
Outdoor Cap. This cap mounts directly to
the top of the water heater and covers the
flue outlet and combustion air inlet openings
on the jacket. No additional vent piping is
required. Maintain a minimum clearance of
3” (76mm) to combustible surfaces and a
minimum of 3” (76 mm) clearance to the air
inlet.
NOTE:
A masonry chimney must be properly sized
for the installation of a high efficiency gas
fired appliance. Exterior masonry chimneys,
with one or more sides exposed to cold
outdoor temperatures, are more likely to
have venting problems. The temperature of
the flue products from a high efficiency
appliance may not be able to sufficiently
heat the masonry structure of the chimney to
generate proper draft. This will result in
Venting of a high
efficiency appliance into
a cold or oversized
masonry chimney can
result in operational and
safety problems.
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An outdoor unit should not be located so
(TABLE C) - OUTDOOR VENT KIT PART NUMBERS
that high winds can deflect off of adjacent
walls, buildings or shrubbery causing
recirculation. Recirculation of flue products
may cause operational problems, bad
combustion or damage to controls. The unit
should be located at least 3 feet (0.91m)
from any wall or vertical surface to prevent
adverse wind conditions from affecting
performance.
MODEL
NUMBER
PART NUMBER
ODK3023
ODK3024
ODK3024
ODK3046
ODK3047
ODK3047
ODK3048
ODK3048
CW 495
CW 645
CW 745
CW 986
CW 1256
CW 1436
CW 1796
CW 2066
Freeze Protection-
Outdoor Installation
Multiple unit outdoor installations require
48” (1.22 m) clearance between each vent
cap. The outdoor cap must be located 4
feet (1.22 m) below and 4 feet (1.22 m)
horizontally from any window, door,
walkway or gravity air intake.
A snow screen should be installed to prevent
snow and ice accumulation around the
appliance or its venting system.
If for any reason the unit is to be shut off:
(a.) Shut off water supply.
(b.) Drain unit completely.
(c.) Drain pump and piping.
The combustion air inlet of the outdoor cap
must be located at least one foot (0.30 m)
above grade and above normal snow
levels. The water heater must be at least 10
feet (3.05 m) away from any forced air inlet
and at least 3 feet (0.91 m) outside any
overhang.
If freeze protection is not provided for the
system, a low ambient temperature alarm or
automatic drain system is recommended.
GAS SUPPLY
The gas pressure regulator supplied is for
low pressure service. If upstream pressure
exceeds 6 oz. (10.5" water column), an
intermediate gas pressure regulator, of the
lock up type, must be installed.
1.
Do not install in locations where rain from
building runoff drains will spill onto the
water heater.
The gas line should be a separate line
direct from meter, unless the existing
gas line is of sufficient capacity. Verify
pipe size with your gas supplier.
2.
3.
Lochinvar must furnish an outdoor vent kit
in accordance with CSA international
requirements. Each kit includes the flue
outlet/combustion air inlet, assembly, gasket
and pump cover.
A trap (drip leg) should be provided in the
inlet gas connection to the water heater.
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4.
5.
A manual main gas shutoff valve is
provided outside the jacket, upstream
of the main gas valve.
of air. Therefore, heat input rate should be
reduced in an appliance above 2000 feet.
Ratings should be reduced at the rate of 4
percent for each 1000 feet above sea level.
EXAMPLE OF
HIGH ALTITUDE
APPLICATIONS
For example, if a unit’s
input is 100,000 Btu/hr
at sea level, the rated
input at 4000 feet of
elevation can be calculated
by derating input 4% per
1000 feet above sea
level.
In Canada, derated10% from 2,000 -
4,500 ft., over 4,500 ft. derate must be
in accordance with local authorities.
Consult factory for installations at
higher elevations.
(TABLE E) – INLET GAS PRESSURE
LP GAS
MODELS
NAT. GAS
CW 495-745
Minimum Allowable
Maximum Allowable
4”
8”
10.5”
13”
High Altitude Applications
CW 986-2066
Atmospheric pressure decreases as the
height above sea level increases. At any
altitude above sea level, a cubic foot will
contain less gas than a cubic foot at sea
level. Thus, the heating value of a cubic foot
of fuel gas will decrease as height above
sea level increases.
[Btu/hr Input]
Minimum Allowable
Maximum Allowable
4.5”
8”
[1.00 - (Elevation/ 1000
ft. x 0.04)] = Btu/hr
Input at specified
10.5”
13”
WATER CONNECTIONS
Inlet and Outlet Water Connections
For ease of service, install unions on inlet and
outlet of the water heater.
elevation.
[100,000][1.00 - (4000
ft. /1000 ft. x 0.04)]
= Btu/hr Input 4000’
elevation.
Specific gravity of a gas with respect to sea
level also decreases with altitude. These
changes in heating value and specific
gravity tend to offset each other.
[100,000][0.84] =
84,000 Btu/hr Input at
4000 ft. elevation.
The connection on the unit marked “Inlet”
should be used for return water from the
storage tank. The connection on the header
marked “Outlet” should be connected to the
inlet of the storage tank. (See Appendix A for
Water Heater Piping Diagrams).
However, as elevation above sea level is
increased, there is less oxygen per cubic foot
(TABLE D) – GAS SUPPLY PIPE SIZING
Length of Pipe In Straight Feet
Nominal Iron
Pipe Size, Inches
10
369
697
20
256
477
30
205
384
40
174
328
50
155
292
60
141
267
70
128
256
80
121
246
90
113
210
100
106
125
95
150 175 200
3/4
86
79
74
1
200
179
164
149
138
11/4
11/2
2
1,400
2,150
974
789
677
595
923
543
830
502
769
472
707
441
666
410
636
369
564
333
513
308
472
287
441
1,500 1,210 1,020
4,100
6,460
2,820 2,260 1,950 1,720 1,560
4,460 3,610 3,100 2,720 2,460
1,440 1,330
2,310 2,100
1,250
2,000
1,180
1,900
1,100
1,700
974
871
820
21/2
1,540 1,400 1,300
3
11,200
7,900 6,400 5,400 4,870 4,410
4,000 3,800
8,300 7,690
3,540
7,380
3,300
6,870
3,000
6,150
2,720 2,500 2,340
5,640 5,130 4,720
31/2
23,500 16,100 13,100 11,100 10,000 9,000
Maximum capacity of pipe in thousands of BTU’s per hour for gas pressures of 14” Inches Water Column (0.5 PSIG) or less and a total
system pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025 BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity).
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Lochinvar
assured of the proper velocity in the tubes
and long life and economical operation from
the water heater.
LOW WATER
TEMPERATURE DELIVERY
A number of water heating applications may
require delivered water temperature in a
system below 140°F. Systems such as nursing
homes and hospitals would be examples of
this type of system.
(TABLE F) - REQUIRED TEMPERATURE RISE
MODEL NUMBER
TEMPERATURE RISE °F
CW 495
15
19
22
19
24
27
34
39
CW 645
CW 745
A water heating system that will be operated
at less than 140°F must use a mixing valve
on the outlet side of the storage tank in order
to ensure that the products of combustion do
not condense inside the combustion chamber
of the water heater.
CW 986
CW 1256
CW 1436
CW 1796
CW 2066
PUMP OPERATION
The mixing valve allows the water heater to
operate above 140°F to protect from
1. The water heater MUST be connected
with a properly sized and installed,
intermittent operating, all bronze pump
that circulates water between heater
and storage tank.
condensation, while still allowing a delivery of
colder water to the system fixtures. Also
inherent in this design is the protection of
occupants from water containing bacteria
such as Legionella. Legionella can be
2.
The pump is sized to heater input and
water hardness. Should water hardness
exceed 25 grains/350 TDS, consult
factory for pump sizing.
significantly reduced in the water storage
vessel by heating the water to a minimum of
140°F. (See Appendix A for piping details.)
WATER VELOCITY CONTROL
IMPORTANT
The pump chart (TABLE H) is based on the
following fittings:
To ensure proper velocity through the heat
exchanger, it is necessary to regulate the
temperature rise across the heat exchanger
from inlet to outlet. (This must be done on
initial installation and periodically rechecked).
6-90° elbows 2 ball valves
2 unions
1 cold water supply tee
With the correct temperature rise across the
heat exchanger (See TABLE F), you may be
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Due to pump capacity the following
specifications cannot be exceeded
when using the standard pump:
Standard production Lochinvar water heaters
are designed to operate free of impurity
build-up in the heat exchanger when
properly installed and operated under the
specified water quality conditions.
NOTE:
A larger pump must be
utilized in situations
when the distance
between the water
and tank exceed
• Not more than 45 feet of straight pipe.
those specified.
• For every elbow and tee in excess of
those shown above, DEDUCT 5 FEET
from maximum allowable straight pipe
in heater-to-tank circulating loop.
For installation in areas outside these
parameters, please consult the factory.
Water Flow Switch
Due to the low water content (between 1
and 6 gallons) of the copper finned tube
heat exchanger, a flow switch is factory
installed as a low water cutoff device on
models CW495 thru CW2066.
The flow switch is installed in the outlet
piping from the water heater and wired in
series with the ignition system safety controls.
WATER TREATMENT
(TABLE G) – REQUIRED PUMP
PERFORMANCE FOR WATER HARDNESS
OF 5 TO 25 GRAINS
NOTE:
Care should be taken to
measure temperature
rise and maintain proper
water velocity in the
heat exchanger.
MODEL
GPM
FT. HD
AMP DRAW
HORSE
VOLTAGE/
PHASE
POWER
CW 495-745
60
90
10
15
5.8
7.4
1/4
1/2
120/1
120/1
CW 986-2066
In most localities, a flow switch is acceptable
as a low water cutoff device on water
heaters requiring forced circulation. It is
prudent to verify acceptance with the local
code official.
In hard water areas, water treatment
should be used to reduce introduction
of minerals into the system. Minerals
in the water can collect in the heat
exchanger tubes causing noise and
inefficient operation. Excessive build-up
of materials in the heat exchanger can
cause a non-warrantable failure.
NOTE:
If a pressure reducing
valve or check valve is
in the system a properly
sized expansion tank
may be required.
If the local water quality levels are slightly
higher than recommended, it may be
possible to use a copper-nickel heat
exchanger. With copper-nickel being a
harder alloy, flow rates can be safely
increased to keep the greater water
hardness and TDS in suspension. The flow
rate can be increased up to 25% faster than
the flow rates listed above.
Acceptable Water Quality Levels
Maximum Water Hardness = 25 Grains
Minimum Water Hardness = 5 Grains
Maximum Total Dissolved Solids = 350 PPM
Range of Acceptable pH = 7.2 to 7.8
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Lochinvar
Relief Valve
NOTE:
ELECTRICAL REQUIREMENTS
(North America)
The appliance is wired for 120 volts.
Incorrect piping
This water heater is supplied with
temperature and pressure relief valve(s)
sized in accordance with ASME Boiler and
Pressure Vessel Code, Section IV “Heating
Boilers.”
of the cold water
supply to the
system will result
in condensate formation
on the heat exchanger
and operational
1.
All wiring between the unit and field
installed devices shall be made of type
T wire [63°F (35°C) rise].
(TABLE H) – COMMON WATER MANIFOLD
SIZE FOR MULTIPLE WATER HEATER
INSTALLATION
problems. Higher water
temperatures reduce
condensate formation.
Refer to drawings in
Appendix A.
2.
3.
The pump must be wired to run
continuously when unit is firing.
Pipe sizing chart provides minimum pipe size for
common manifold piping to ensure adequate flow.
NUMBER OF
UNITS
COMMON MANIFOLD SIZE
(Min.)
It is recommended that the water heater
and pump be wired on separate circuits
with properly sized breakers.
CW 495 thru 745
1
2
3
4
5
6
2”
3”
1
3
/
/
”
”
2
2
4”
5”
5”
(TABLE I) – AMP DRAW DATA
CW 986 thru 2066
MODEL
FAN(S)
CONTROLS
PUMP
TOTAL AMPS
w/PUMP
1
1
2
3
4
5
6
2
NUMBER
4”
4”
5”
6”
6”
CW 495-745
3.4
3.4
3.8
4.6
4.6
4.6
5.8
7.4
7.4
13.8
15.4
15.8
CW 986-1256
CW 1436-2066
NOTE:
When the unit is
installed in Canada, it
must conform to the
CAE C22.1, Canadian
Electrical Code, Part 1,
and/or local Electrical
Codes.
14
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WA T E R H E A T E R P I P I N G D I A G R A M S
A P P E N D I X A
PIPING DIAGRAM
SINGLE HEATER - SINGLE TANK
BUILDING HOT
WATER SUPPLY
COLD WATER SUPPLY
LOCHINVAR
WATER HEATER
RELIEF
VALVE
INLET
OUTLET
LOCK-TEMP
STORAGE
TANK
DRAIN
BUILDING RETURN
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
LIT0133
L E G E N D
FULL PORT
BALL VALVE
SYSTEM
PUMP
SYSTEM
TEE
ELBOW
UNION
EXPANSION
TANK
CHECK
VALVE
THERMOMETER
RELIEF VALVE
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PIPING DIAGRAM
SINGLE HEATER - TWO TANK
BUILDING HOT
WATER SUPPLY
COLD WATER
SUPPLY
RELIEF VALVE
LOCHINVAR WATER
HEATER
OUTLET
INLET
LOCK-TEMP
STORAGE TANK
DRAIN
BUILDING
RETURN
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
LIT0135
L E G E N D
FULL PORT
BALL VALVE
SYSTEM
PUMP
SYSTEM
TEE
ELBOW
UNION
EXPANSION
TANK
CHECK
VALVE
THERMOMETER
RELIEF VALVE
A2
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PIPING DIAGRAM
TWO TEMPERATURE INSTALLATION - SINGLE HEATER-SINGLE TANK
1800F HOT WATER
SUPPLY
1400F HOT WATER
SUPPLY
LOCK-TEMP
STORAGE TANK
LOCHINVAR
LOW TEMPERATURE
BUILDING RETURN
CHECK VALVE
WATER HEATER
RELIEF
VALVE
MIXING
VALVE
INLET
OUTLET
DRAIN
HIGH TEMPERATURE
BUILDING RETURN
COLD WATER
SUPPLY
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
LIT0136
L E G E N D
FULL PORT
BALL VALVE
SYSTEM
PUMP
SYSTEM
TEE
ELBOW
UNION
EXPANSION
TANK
CHECK
VALVE
THERMOMETER
RELIEF VALVE
Lochinvar D E S I G N E R’S G U I D E C O P P E R - F I N W A T E R H E AT E R 615-889-8900
A3
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PIPING DIAGRAM
TWO HEATERS-SINGLE TANK
LOCK-TEMP
STORAGE TANK
RELIEF
VALVE
BUILDING
HOT WATER
SUPPLY
COLD WATER
SUPPLY
DRAIN
OUTLET
OUTLET
BUILDING RETURN
INLET
INLET
LOCHINVAR
WATER HEATERS
Gray shaded area represents common manifold piping.
COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATION
Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.
NUMBER OF
UNITS
COMMON MANIFOLD SIZE
(Min.)
NUMBER OF
UNITS
COMMON MANIFOLD SIZE
(Min.)
CW 495-745
CW 986-2066
1
2
3
4
5
6
2”
3”
1
2
3
4
5
6
2-1/2”
4”
3-1/2”
4”
4”
5”
5”
6”
5”
6”
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
LIT0138
L E G E N D
SYSTEM
TEE
FULL PORT
BALL VALVE
SYSTEM
PUMP
ELBOW
UNION
EXPANSION
TANK
CHECK
VALVE
THERMOMETER
REDUCING
TEE
REDUCING
TEE
RELIEF VALVE
A4
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PIPING DIAGRAM
TWO HEATERS-TWO TANKS
COLD WATER
SUPPLY
LOCHINVAR
WATER HEATERS
OUTLET
RELIEF
VALVE
BUILDING
HOT WATER
SUPPLY
INLET
LOCK-TEMP
STORAGE
TANKS
OUTLET
DRAIN
BUILDING
RETURN
Gray shaded area represents common manifold piping.
COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATION
Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.
NUMBER OF
UNITS
COMMON MANIFOLD SIZE
(Min.)
NUMBER OF
UNITS
COMMON MANIFOLD SIZE
(Min.)
CW 495-745
CW 986-2066
1
2
3
4
5
6
2”
3”
1
2
3
4
5
6
2-1/2”
4”
3-1/2”
4”
4”
5”
5”
6”
5”
6”
This illustration is for concept only and should not be used for any actual installation without engineering
or technical advice from a licensed engineer. All necessary equipment may not be illustrated.
LIT0451
L E G E N D
FULL PORT
BALL VALVE
SYSTEM
PUMP
SYSTEM
TEE
ELBOW
UNION
EXPANSION
TANK
CHECK
VALVE
THERMOMETER
REDUCING
TEE
REDUCING
TEE
RELIEF VALVE
Lochinvar D E S I G N E R’S G U I D E C O P P E R - F I N W A T E R H E AT E R 615-889-8900
A5
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PIPING DIAGRAM
MULTI-STACK FRAME W/ WATER HEATERS AND STORAGE TANK
Heater
Model
Heater Inlet/
Outlet Size
Manifold
Pipe Size
CW495-745
2”
3”
4”
CW986-2066
2-1/2”
LIT0396
A6
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Lochinvar Corporation • Lebanon, TN • 615-889-8900 / Fax: 615-547-1000
CW-DG-05 (Revised CW-DG-05 1/07)
4/09-Printed in U.S.A.
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