Lochinvar EFFICIENCY PLUS Designer's Manual

Brand: Lochinvar

Model: EFFICIENCY PLUS

Type: Designer's Manual

DESIGNER’S GUIDE EFFICIENCY+

BOILER

150,000 – 300,000 BTU/HR

Dear Specifier/Project Manager,

At Lochinvar, we have long recognized the importance of innovation to any

product or service. Those who enter into business must also accept the challenge

of meeting constantly changing needs.

The designer’s guide you are now holding has been designed to make it more

convenient for you to select the perfect Lochinvar boiler for your projects and

provide correct specifications for your teams.

All information has been organized and presented in a succinct, easy-to-use

manner, so you can use and share information confidently and with minimal

effort.

However, it is important to remember that this guide is not intended to replace our

installation manual. Installers should still refer to our installation manual for

specific installation instructions.

We hope our manual will make your work easier and more productive.

As always, we greatly appreciate your input on additional improvements

for the future.

Thanks once again for specifying the Lochinvar family of quality standard

and custom-built water heaters and boilers.

Sincerely,

Lochinvar Corporation

Lochinvar Corporation • 615-889-8900 / Fax: 615-547-1000

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 1

Air Removal . . . . . . . . . . . . . . . . . . . . . .18

Boiler Operating Temperature Control . . . .19

Clearances . . . . . . . . . . . . . . . . . . . . . . . .3

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Combustion & Ventilation Air . . . . . . . . . . .3

Connection To Terminal Strip . . . . . . . . . .19

Contaminants . . . . . . . . . . . . . . . . . . . . . .5

Electrical Requirements (North America) . . 19

Gas Supply . . . . . . . . . . . . . . . . . . . . . .14

Location of Unit . . . . . . . . . . . . . . . . . . . . .2

Low Water Temperature Systems . . . . . . . .17

Outdoor Installation . . . . . . . . . . . . . . . . .13

Outdoor Use . . . . . . . . . . . . . . . . . . . . . . .3

Primary/Secondary Piping . . . . . . . . . . . .15

Relief Valve Piping . . . . . . . . . . . . . . . . . .16

Remote Temperature Control . . . . . . . . . . .19

Special Design Applications . . . . . . . . . . .18

Three-Way Valves . . . . . . . . . . . . . . . . . .16

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Venting Options . . . . . . . . . . . . . . . . . . . .7

Water Flow Requirements . . . . . . . . . . . .15

Water Velocity Control . . . . . . . . . . . . . . .15

Figures & Tables Index

FIG. 1 Boiler Equipment & Control

Orientation . . . . . . . . . . . . . . . .3

FIG. 2-5 Combustion & Ventilation Air . . .4

FIG. 6 Barometric Damper

Installation . . . . . . . . . . . . . . . . .8

FIG. 7 Multiple Unit Barometric

Damper Installation . . . . . . . . . .8

FIG. 8 E+ Vent With

Sidewall Air Inlet . . . . . . . . . . . .9

FIG. 9 E+ Vent With

Vertical Air Inlet . . . . . . . . . . . .10

FIG. 10 Horizontal Direct Vent . . . . . . .11

FIG. 11 Horizontal Direct Vent Cap . . . .11

FIG. 12 Multiple Sidewall Vent Caps . . .12

FIG. 13 Vertical Direct Vent . . . . . . . . . .12

FIG. 14 Outdoor Venting . . . . . . . . . . .13

FIG. 15 Primary/Secondary

System Piping . . . . . . . . . . . . .16

FIG. 16 Low Temperature Bypass

System Piping . . . . . . . . . . . . .17

FIG. 17 Heating/Chilled

Water System . . . . . . . . . . . . .18

TABLE A. Clearances From

Combustible Construction . . . . . .3

TABLE B. Conventional Venting,

Vent Flue Size . . . . . . . . . . . . . .7

TABLE C. E+ Vent Sidewall

Air Kit Part Numbers . . . . . . . . .9

TABLE D. E+ Vent Horizontal

Air Kit Part Numbers . . . . . . . .11

TABLE E. Vertical Direct Vent Flue &

Air Inlet Sizes . . . . . . . . . . . . .13

TABLE F. Outdoor Vent Kit . . . . . . . . . . .13

TABLE G. Gas Supply Pipe Sizing . . . . . .14

TABLE H. Inlet Gas Pressure . . . . . . . . . .14

TABLE I. Minimum & Maximum

Boiler Flow Rates . . . . . . . . . . .15

TABLE J. Water Flow Requirements . . . . .15

TABLE K. Heat Exchanger Head-loss . . . .16

TABLE L. Amp Draw . . . . . . . . . . . . . . .19

Appendix A: Boiler Piping Diagrams

Primary/Secondary Boiler . . . . . . . . . . . .A1

Multiple Unit - Primary/Secondary . . . . . .A2

Low Temperature Bypass Piping . . . . . . . .A3

Table of Contents

CODES

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 must be

carefully followed in all cases. Authorities

having jurisdiction must be consulted before

installations are made. In the absence of such

requirements, the installation must 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, No.(CSD-1). All boilers conform

to the latest edition of the ASME Boiler and

Pressure Vessel Code, Section IV. Where

required by the authority having jurisdiction,

the installation must comply with the

Canadian Gas Association Code,

CAN/CGA-B149.1 and/or B149.2

and/or local codes.

LOCATION OF UNIT

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.

Under no circumstances is the

manufacturer to be held responsible for

water damage in connection with this

unit or any of its components.

2 Lochinvar

DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

Lochinvar

Water Velocity

(

See Page 15 for minimum and

maximum flow rates.)

Piping Requirements and

Specialties

(

See Page 15 for piping

application requirements.)

System Water Temperature

(

See Page 17 for piping and

design recommendations.)

System and Boiler Control

(See Page 19 for boiler

operating and temperature

control.)

Air Elimination and

Expansion Tank Placement

(

See Page 18 for air removal

information.)

In designing

a hot water heating system,

pay special attention to:

The indoor unit 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.)

Units located in a residential garage

must be installed so that all burners and

burner ignition devices have a minimum

clearance of 18” (46cm) above the floor.

The unit must be located or protected so

that it is not subject to physical damage

by a moving vehicle.

The appliance must be installed on a

level floor. A combustible wood floor may

be used without additional bases or

special floor buildup. Maintain required

clearances from combustible surfaces.

The appliance must not be installed on

carpet or other combustible material other

than wood flooring.

SPECIAL LOCATION:

OUTDOOR USE

Efficiency+ Models are approved for

outdoor installations. 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,

in the venting section on page 13.

COMBUSTION AND VENTILATION

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, or in Canada, the

latest edition of CGA Standard B149

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 3

(TABLE A)

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

RIGHT SIDE 1”

REAR 1”

LEFT SIDE 6” (24” suggested for service)

FRONT 3” (24” suggested for service)

Suitable for closet installation

TOP 3”

*Allow sufficient space for servicing pipe connections, pump

and other auxiliary equipment, as well as the appliance.

FLUE PRODUCTS

VENT

GAS

CONNECTION

SYSTEM

RETURN

BURNER

INSPECTION

PORT

SYSTEM

SUPPLY

BACK

AIR INLET

TERMINAL

STRIP

(INSIDE)

120V

ELECTRICAL

CONNECTION

DRAIN

LEFT SIDE

FRONT

EB150-300

(FIG. 1) BOILER EQUIPMENT &

CONTROL ORIENTATION

4 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

Installation Code for Gas Burning Appliances

and Equipment, or applicable provisions of

the local building codes.

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.

If air is taken directly from outside

the building with no duct, provide

two permanent openings:

A. Combustion air opening with a

minimum free area of one square inch per

4000 Btu/hr input. This opening must be

located within 12” (30 cm) of the bottom of

the enclosure.

B. Ventilation air opening with a minimum

free area of one square inch per 4000

Btu/hr input. This opening must be

located within 12” (30 cm) of the top of

the enclosure.

If combustion and ventilation air is

taken from the outdoors using a

duct to deliver the air to the

mechanical room, each of the two

openings should be sized based on a

minimum free area of one square inch per

2000 Btu/hr.

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

Btu/hr of input, but not less than 100

square inches (645 cm

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 per 3000 Btu/hr.

This opening must be located within 12”

(30 cm) of the top of the enclosure.

Lochinvar

(FIG. 4) COMBUSTION AIR FROM INTERIOR SPACE

(FIG. 3) COMBUSTION AIR THROUGH DUCTWORK

(FIG. 5) COMBUSTION AIR FROM

OUTSIDE SINGLE OPENING

(FIG. 2) COMBUSTION AIR DIRECT FROM OUTSIDE

EXAMPLE OF

SIZING FOR

COMBUSTION

& VENTILATION

AIR OPENINGS

(BOILER WITH

300,000 BTU/HR

INPUT):

When combustion and

ventilated air is taken from

directly outside the building

(FIG. 2), divide the total BTU’s

by 4,000. This yields 75 sq.in.

of “Free Area” without

restriction.

300,000 ÷ 4,000 =

75 sq.in.

Since the air opening is 50%

closed due to screens and

louvers, the total opening

MUST be multiplied by 2.

75 sq.in. x 2 =

150 sq.in.

This project requires one

Ventilation Air Opening with

net “Area” of 75 square

inches with louver dimensions of

12” x 15”= 168 sq.in.

and one Combustion Air

Opening with net “Area”

of 75 square inches with

louver dimensions of

12” x 15”= 168 sq in.

CAUTION: Under no circumstances should

the equipment room be under a negative

pressure when atmospheric combustion

equipment is installed in the room.

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 5

CONTAMINANTS

Combustion air drawn from an interior or

exterior space must be free of any chemical

fumes which could be corrosive to the boiler.

Burning chemical fumes results in the

formation of corrosive acids which attack

the boiler and cause improper combustion

and premature failure of the boiler 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.

VENTING

General

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.

The connection from the appliance vent to the

stack must be as direct as possible and

sized correctly, using the proper vent table.

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.

The connection from the appliance vent to the

stack or vent termination outside the building

must be made with listed Type “B” double

wall vent (or equivalent) for conventional vent

applications.

When utilizing direct vent capabilities

connections must be made with AL29-4C

stainless steel (or equivalent) vent material.

Material should be sized according

to vent sizing tables (FAN column) in

the latest edition of the National Fuel

Gas Code.

The vent materials and accessories, such as

firestop spacers, thimbles, caps, etc., must

be installed in accordance with the

manufacturer’s listing.

The vent connector and firestop shall 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.

Any improper operation of the common

venting system in the existing building must

be corrected when new equipment is

installed, so the installation conforms to the

latest edition of the National Fuel Gas Code,

ANSI Z223.1.

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 be sized to make

sure that it does not

cause drafts which could

lead to nuisance

operational problems

with the boiler.

6 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

The efficiency of this appliance allows its

products of combustion to be vented through

a smaller vent pipe when compared to units

of the same Btu/hr capacity. For this reason,

resizing common venting systems is

recommended for proper operation.

When resizing any portion of the common

venting system, it should be resized to

approach the minimum size as determined

using the appropriate tables (FAN column) in

the National Fuel Gas Code.

Failure to resize a common venting system

could lead to the formation of condensate

and premature deterioration of the vent

material.

Flue gas condensate can freeze on exterior

walls or on the vent cap. Frozen condensate

on the vent cap can result in a blocked flue

condition. Some discoloration to exterior

building surfaces can be expected. Adjacent

brick or masonry surfaces should be

protected with a rust resistant sheet metal

plate.

Vent connectors serving appliances vented by

natural draft must not be connected to

any portion of a mechanical draft system

operating under positive pressure.

Connection to a positive pressure stack may

cause flue products to be discharged into the

living space causing serious health injury.

Locate units as close as possible to a chimney

or gas vent.

Vent Terminations

When locating the vent cap, consider the effects

of snow, leaf dropping, etc., to ensure that no

blockage occurs.

The distance of the vent terminal from adjacent

public walkways, adjacent buildings, windows

that open and building openings must comply

with the latest edition of the National Fuel Gas

Code, ANSI Z223.1.

The vent terminal must be vertical and

exhaust outside the building at least 2 feet

(0.6m) above the highest point of the roof

within a 10 foot (3.0m) radius of the

termination.

The vertical termination must be a minimum

of 3 feet (0.9m) above the point of exit in the

rooftop.

A vertical termination less than 10 feet (3.0m)

from a parapet wall shall be a minimum of 2

feet (0.6m) higher than the parapet wall.

The vent cap shall terminate at least 3 feet

(0.9m) above any forced air inlet within 10

feet (3.05m). The vent shall terminate at least

4 feet (1.2m) below, 4 feet (1.2m)

horizontally from or 1 foot (0.30m) above

any door, window, or gravity air inlet to the

building.

Do not terminate the vent in a

window well, stairwell, alcove,

courtyard, or other recessed area.

The vent cannot terminate below

grade.

Lochinvar

IMPORTANT!

The vent cap should

have a minimum

clearance of 4 feet

horizontally from electric

meters, gas meters,

regulators, air inlets and

air relief equipment.

Additionally, the vent

cap should never be

located above or below

these items, unless a 4

foot horizontal distance

is maintained.

NOTE:

The weight of the

venting system MUST

NOT rest on the boiler.

It should be properly

supported.

WARNING

Vent connectors serving

gas appliances, which

operate under a

negative vent pressure,

shall not be connected

into any portion of

mechanical draft

systems operating under

positive vent pressure.

Masonry Chimney

A masonry chimney must be properly sized

for the installation of a high efficiency gas fired

appliance. Venting of a high efficiency

appliance into a cold or oversized masonry

chimney can result in operational and safety

problems.

Exterior masonry chimneys, with one or more

sides exposed to cold outdoor temperatures, are

more likely to have venting problems. For this

reason, exterior masonry chimneys are not

generally recommended to vent high efficiency

gas appliances.

An interior masonry chimney, which is not

exposed to the outdoors below the roofline, may

be used to vent high efficiency gas appliances

based on the results of careful inspection,

proper sizing and local code approval. If there

is any doubt about the sizing or condition of a

masonry chimney, it should be relined with a

properly sized and approved chimney liner

system.

An interior masonry chimney should be carefully

inspected to determine its suitability for the

venting of flue products.

A clay tile lined chimney must be structurally

sound, straight and free of misaligned tile, gaps

between liner sections, missing sections of liner

or any signs of condensate drainage at the

breeching or clean out.

If there is any doubt about the condition of a

masonry chimney, it should be relined.

Metallic liner systems (Type “B” double-wall,

flexible, or rigid metallic liners) are

recommended to line or reline an existing

masonry chimney. Consult with local code

officials to determine code requirements or the

advisability of using a lined masonry chimney

or relining of a masonry chimney.

VENTING OPTIONS

Conventional Venting - Negative Draft

Size vent material according to the “FAN”

column of vent sizing tables in the latest edition

of the National Fuel Gas Code. “FAN” applies

to Category I fan assisted combustion

appliances with natural draft. Utilize Category

I type “B” vent material for all conventional

venting applications.

A bell increaser is provided and installed

directly on the boiler vent outlet. The bell

increases the boiler vent size by 1 inch

(25.4mm) in diameter. The vent connection

is made directly to the bell increaser on the

top of the unit. No additional draft diverter

or barometric damper is required.

(TABLE B)

CONVENTIONAL VENTING, VENT CONNECTION SIZE

CONVENTIONAL

MODEL VENT FLUE SIZE

EB150 5

”

EB200 5

”

EB250 6”

EB300 6”

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 7

8 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

When each unit is installed with an individual

vent, and the negative draft is higher than the

specified range (0.02 to 0.05 inches of water

column), a barometric damper will be necessary.

Multiple unit installations with combined

venting require barometric dampers to

regulate draft at each unit. The negative

draft must be within the range of 0.02 to

0.05 inches of water column to ensure

proper operation.

All draft readings are made while the unit is

in stable operation (approximately 2 to 5

minutes).

For this type of installation, it is best to use a

draft control for each boiler located on the

riser between the vent outlet and the

breeching - Location “A”. (Figure 7)

When this riser is too short to permit the

installation of a control, locate a separate

control for each boiler on the main breeching

as illustrated in Location “B”. (Figure 7)

If, because of general crowding or other

reasons, neither of these locations are

possible, use a single large control in the

breeching between the boiler nearest the

chimney and the chimney, as shown in

Location “C”. (Figure 7)

Conventional Venting with Direct

Combustion Air Intake (E+Vent)

This vent system uses two pipes, one vertical

pipe with a roof top termination for the flue

products and one pipe for combustion air. The

combustion air pipe may terminate

horizontally with a sidewall air inlet or

vertically with a roof top air inlet. All

instructions for “Conventional Venting -

Negative Draft” apply to “Conventional

Venting with Direct Combustion Air”. The flue

may be combined with the vent from any

other negative draft, Category I appliances.

Utilize Category I type “B” vent material for

venting flue products.

Lochinvar

WATER HEATER/BOILER

BAROMETRIC DAMPER ON SINGLE UNIT INSTALLATION

Lined

Chimney

WATER HEATER/BOILER

BAROMETRIC DAMPER ON SINGLE UNIT INSTALLATION

(FIG. 6) BAROMETRIC DAMPER INSTALLATION

(FIG. 7) MULTIPLE UNIT BAROMETRIC

DAMPER INSTALLATION

NOTE:

An unlined masonry

chimney should not be

used to vent flue

products from this high

efficiency appliance.

The sidewall or vertical roof top E+Vent

combustion air supply system has specific vent

material and installation requirements.

The air inlet pipe connects directly to the boiler

to supply combustion air. In most installations,

the combustion air inlet pipe will be a

dedicated system with one air inlet pipe per

boiler. Multiple air inlets may be combined if

the guidelines in “Combined Air Inlet Points”

are followed. The air inlet pipe will be

connected to a combustion air inlet cap as

specified in this section. Combustion air

supplied from outdoors should be free of

contaminants. The air inlet pipe(s) must be

sealed. Select air inlet pipe material from the

following specified materials:

• PVC, CPVC or ABS (4”, 5” or 6” I.D.).

• Dryer vent (not recommended for roof

top air inlet)

• Galvanized steel vent pipe with joints

and seams sealed.

• Type “B” double wall vent with joints

and seams sealed.

The total equivalent length of the sidewall or

vertical roof top E+Vent combustion air inlet pipe

shall not exceed a maximum of 50 equivalent

feet (15.2m) in length. Subtract 5 feet (1.5m) for

each elbow in the air intake system.

Sidewall Air Inlet

The sidewall air inlet cap is supplied in the E+

Sidewall Vent Kit. Each kit includes a sidewall

combustion air inlet cap to supply air to a single

boiler and instructions for proper installation. The

part number for each kit is listed by unit size.

Locate units as close as possible to the sidewall

where the combustion air supply system will be

installed.

To prevent recirculation of flue products from an

adjacent vent cap into the combustion air inlet,

follow all applicable clearance requirements in

the latest edition of the National Fuel Gas Code

and instructions in this guide.

The combustion air inlet cap must be placed at

least one foot (0.3m) above ground level and

above normal snow levels.

NOTE:

The use of double wall

vent material for the

combustion air inlet pipe

is recommended in cold

climates to prevent the

accumulation of

condensation on the

pipe exterior.

(FIG. 8) E+ VENT WITH SIDEWALL AIR INLET

(TABLE C)

E+ VENT SIDEWALL AIR KIT PART NUMBERS

MODE CONVENTIONAL VENT AIR SIDEWALL

NUMBER FLUE SIZE* INLET PIPE** E+ VENT KIT

EB150 5

”

SVK 3020

EB200 5

”

SVK 3020

EB250 6

”

SVK 3021

EB300 6

”

SVK 3021

*Vent size with 1” increaser installed for conventional negative

draft venting.

Lochinvar

DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 9

(FIG. 9) E+ VENT WITH VERTICAL AIR INLET

10 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

Vertical Air Inlet

The air inlet cap for the vertical roof top

air inlet is assembled from components

purchased locally. The air inlet cap consist

of two 90° ells installed at the point of

termination for the air inlet pipe.

The point of termination for the combustion

air inlet cap must be at least 2 feet (0.6m)

below the point of flue gas termination

(vent cap) if it is located within 10 ft. (3.0m)

of the flue outlet.

The termination ell on the air inlet must be

located a minimum of 12” (0.3m) above the

roof or above normal levels of snow

accumulation. It must not be placed closer

than 10 feet (3.0m) from an inside corner of

an L-shaped structure.

Incorrect location of the air inlet cap can

allow the discharge of flue products to be

drawn into the combustion process of the

boiler. This can result in incomplete

combustion and potentially hazardous levels

of carbon monoxide in the flue products.

Combined Air Inlet Points

The air inlet pipes from multiple boilers can

be combined into a single common

connection, if the common air inlet pipe has a

cross sectional area equal to or larger than

the total area of all air inlet pipes connected

to the common air inlet pipe.

The air inlet point for multiple boiler air inlets

shall be provided with an exterior opening

which has a free area equal to or greater

than the total area of all air inlet pipes

connected to the common air inlet. This

exterior opening for combustion air must

connect directly to the outdoors.

The total length of the combined air inlet pipe

must not exceed a maximum of 50

equivalent feet(15.2m). Deduct the restriction

in area provided by any screens, grills or

louvers installed in the common air inlet point.

Screens, grills, or louvers installed in the

common air inlet can reduce the free area

of the opening from 25% to 75% based on

the materials used. The air inlet cap for the

combined air supply from multiple boilers can

be purchased or fabricated in the field.

Direct Venting

A direct vent boiler uses a two pipe system,

one pipe for the flue products and one pipe

for the combustion air supply.

The flue cannot be combined with any other

appliance vent or common vent from multiple

boilers. The vent on a direct vent system will

have a positive pressure in the flue, which

requires all vent joints and seams to be

sealed gas-tight. The flue from a direct vent

system shall have a condensate drain with

provisions to properly collect and dispose of

any condensate that may occur in the venting

system. Direct vent systems require Category

IV vent material with AL29-4C approved

stainless steel.

The air inlet pipe connects directly to the

boiler to supply combustion air. The air inlet

pipe must be sealed. Choose acceptable

Lochinvar

EXAMPLE OF

COMBINED

AIR INLET

SIZING

Two 5” air inlet pipes

(19.6 in

area each) have

a total area of 39.2 in

requiring an 8” (50.3 in

area) common air inlet

pipe.

combustion air pipe materials from those

specified in this section. Approved material

for air inlet pipes include: PVC, CPVC or ABS

(3”, 4”, 5” or 6” I.D.), dryer vent, and

galvanized steel vent pipe with joints and

seams sealed.

The total equivalent length of the direct vent

flue pipe or the air inlet pipe should not

exceed a maximum of 50 equivalent feet

(15.2m) in length for each pipe. Subtract

5 feet (1.5m) for each elbow in the vent

pipe or air intake system.

Horizontal Direct Vent

Horizontal direct vent applications require a

vent kit which will be supplied by Lochinvar

to assure proper operation.

The part number for each kit is listed by unit

size. Each kit includes a sidewall vent cap for

flue products, a firestop, a combustion air

inlet cap, and instructions for proper

installation.

It is important to be careful in the placement

of the horizontal direct vent caps. Combustion

air supplied from outdoors should be free of

contaminants.

To prevent recirculation of flue products into

the combustion air inlet:

The combustion air inlet cap must not be

installed above the flue outlet cap.

Maintain a minimum 3 foot (0.9m) radius

clearance between the combustion air inlet

cap and the flue outlet cap. Additional

space may be required between caps

where high winds may occur.

The combustion air inlet cap and vent cap

for flue outlet must be located on the

same sidewall and in the same pressure

zone.

Do not place the combustion air inlet cap

closer than 10 feet (3.0m) from an inside

corner of an L-shaped structure.

Place the combustion air inlet cap at least

one foot (0.3m) above ground level and

above normal snow levels.

(FIG. 10) HORIZONTAL DIRECT VENT

(FIG. 11) HORIZONTAL DIRECT VENT CAP

(TABLE D)

HORIZONTAL DIRECT VENT KIT PART NUMBERS

MODEL FLUE AIR PART

NUMBER PIPE SIZE INLET PIPE NUMBER

EB150 4” 4” HDK 3013

EB200 4” 4” HDK 3013

EB250 5” 5” HDK 3014

EB300 5” 5” HDK 3014

NOTE:

The use of double wall

vent material for the

combustion air inlet

pipe is recommended in

cold climates to prevent

the accumulation of

condensation on the

pipe exterior.

Lochinvar

DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 11

Multiple Unit Applications

(Horizontal Direct Vent)

The combustion air inlet caps for multiple unit

installations must maintain the minimum 3

foot (0.9m) radius clearance below or

horizontally from the closest flue outlet.

Multiple flue outlet caps may be installed side

by side, and multiple air inlet caps may be

installed side by side, but the 3 foot (0.9m)

radius minimum clearance between air inlet

and flue outlet must be maintained.

All clearance and installation requirements in

this section and the applicable portions of the

general venting section must be maintained

on multiple unit installations.

Vertical Direct Vent

Vertical direct vent applications do not require

a vent kit to be supplied by Lochinvar. The

vent cap and air inlet cap for vertical direct

vent applications are fabricated or purchased

in the field.

A vertical vent cap, as specified by the vent

material manufacturer, is used to vent the flue

products to the outdoors. The air inlet cap

consists of two 90° ells installed at the point

of termination for the air inlet pipe. The

termination ell on the air inlet must be

located a minimum of 12” (15.2cm) above

the roof or above normal levels of snow

accumulation. The point of termination for the

air inlet shall be 24” (0.6m) lower than the

point of flue gas termination, if it is located

within 10 ft. (3.0m) of the flue outlet.

Incorrect installation and/or location of the

air inlet cap can allow the discharge of flue

products to be drawn into the combustion

process on the boiler. This can result in

incomplete combustion and potentially

hazardous levels of carbon monoxide in the

flue products.

Lochinvar

12 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

(FIG. 13) VERTICAL DIRECT VENT

CAUTION!

Boilers which are shut

down or will not

operate may

experience freezing

due to convective air

flow in the air inlet

pipe connected to the

unit. Proper freeze

protection MUST be

provided.

(FIG. 12) MULTIPLE SIDEWALL VENT CAPS

AIR INLETS

3 feet

MIN.

3 feet

MIN.

FLUE OUTLETS

CAUTION!

Maintain a minimum

3 foot (0.9m) radius

clearance between

the combustion air

inlet cap and the

flue outlet cap.

(TABLE E) – VERTICAL DIRECT VENT,

FLUE AND AIR INLET SIZES.

MODEL DIRECT VENT AIR INLET

NUMBER FLUE SIZE PIPE

EB150 4” 4”

EB200 4” 4”

EB250 5” 5”

EB300 5” 5”

Multiple Unit Applications

(Vertical Direct Vent)

The combustion air inlet caps for multiple unit

installations must maintain the minimum 2

foot (0.6m) clearance below the closest

vertical flue outlet if within 10 feet (3.0m).

Multiple flue outlet caps may be installed side by

side and multiple air inlet caps may be installed

side by side, but the air inlet must always be at

least 2 feet (0.6m) below the closest flue outlet if

the outlet is within 10 feet (3.0m).

OUTDOOR INSTALLATION

Units are self venting and can be used

outdoors when installed with the optional

Outdoor Vent Kit. This kit includes a one piece

top cover which replaces the standard two

piece cover, air inlet cap, exhaust cap, gas

valve cover and junction box cover. The 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.

An outdoor unit should not be located so 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. 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.

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. Do not install in

locations where rain from building runoff drains

will spill onto the water heater. Lochinvar must

furnish an outdoor vent kit in accordance with

CSA international requirements. Each kit includes

the flue outlet/combustion air inlet, gas valve

cover, junction box cover and one piece unit top.

Freeze Protection- Outdoor Installation

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.

If freeze protection is not provided for the

system, a low ambient temperature alarm or

automatic drain system is recommended.

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 13

(FIG. 14) OUTDOOR VENTING

(TABLE F)

–

OUTDOOR VENT KITS

MODEL OUTDOOR

NUMBER VENT KIT

EB150 ODK3069

EB200 ODK3070

EB250 ODK3071

EB300 ODK3072

14 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

GAS SUPPLY

Safe operation of unit requires properly

sized gas supply piping (See TABLE G).

Gas pipe size may be larger than the

heater connection.

An internal gas pressure regulator is required

if upstream pressure exceeds 6 oz. (10.5"

water column), an intermediate gas

pressure regulator, of the lockup type,

must be installed.

Installation of a union is suggested for

ease of service.

Install a manual main gas shutoff valve

with test plug, outside of the appliance

gas connection and before the gas valve,

when local codes require.

A trap (drip leg) should be provided in the

inlet of the gas connection to the unit.

High Altitude Applications

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.

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. However, as

elevation above sea level is increased, there

is less oxygen per cubic foot 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.

WATER CONNECTIONS

Inlet and Outlet Water Connections

For ease of service, install unions on inlet and

outlet of the boiler. The connection on the unit

marked “Inlet” should be used for return

water from the system. The connection on the

header marked “Outlet” should be connected

to the system supply. (See Boiler Piping

diagrams, Appendix A).

Lochinvar

NOTE:

Care should be

taken to measure

temperature rise

and maintain proper

water velocity in

the heat exchanger.

(TABLE H) – INLET GAS PRESSURE REQUIREMENTS

NATURAL GAS LPG

Max. Allowable 10.5” 13”

(Inches-water column)

Min. Allowable 4.7” 8”

(Inches-water column)

EXAMPLE OF

HIGH

ALTITUDE

APPLICATIONS

For example, if a unit’s

input is 200,000 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.

[Btu/hr Input]

[1.00 - (Elevation/ 1000’

x 0.04)] = Btu/hr Input

at specified elevation.

[200,000][1.00 -

(4000’/1000’ x 0.04)] =

Btu/hr Input 4000’

elevation.

[200,000][0.84] =

168,000 Btu/hr Input

at 4000’ elevation.

(TABLE G) – GAS SUPPLY PIPE SIZING

Length of Pipe In Straight Feet

Nominal Iron

Pipe Size, Inches 10 20 30 40 50 60 70 80 90 100 125 150 175 200

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).

3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74

1 697 477 384 328 292 267 246 256 210 200 179 164 149 138

1-1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287

1-1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441

2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820

2-1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300

3 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340

4 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720

WATER VELOCITY CONTROL

IMPORTANT

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).

With the correct temperature rise across the

heat exchanger (See TABLE J), you may be

assured of the proper velocity in the tubes

and long life and economical operation from

the boiler.

WATER FLOW REQUIREMENTS

AND SYSTEM PIPING

Lochinvar boilers are generally capable of

operating within the design flow rates for the

building heating system. To ensure the most

efficient operation, a boiler needs adequate

water flow. Pump sizing, pipe sizing, and piping

layout

must be taken into consideration for

proper system flow. (Table I) provides maximum

and minimum

flow data for each model. (Table J)

provides Gallons Per Minute and boiler head-loss

at various temperature rises for each boiler based

on Btu/hr input. These two charts will provide

assistance in system flow design.

Primary/Secondary Piping

Using a primary/secondary piping arrangement

can solve many system flow complications.

This piping arrangement uses a dedicated pump

to supply flow to the boiler. The pump is sized

based on the required boiler flow rate, boiler

head-loss and head-loss in the secondary system

piping. A separate pump is used to provide the

desired flow for the system.

Primary/Secondary piping allows the system and

the boiler(s) to operate at their optimum flow rate.

The system works best when the boiler(s) are

supplied with pump control relays which are used

to cycle the secondary pump(s). When piped

correctly, the secondary pump helps to prevent

flow through the boiler(s) when they are not firing.

Use of primary/secondary system

will eliminate the need for a system or boiler

bypass. Figure 15 depicts one example of

primary/secondary piping.

Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 15

GPM

25.2

33.7

42.1

50.5

FT. HD

0.9

1.4

1.7

2.6

GPM

16.8

22.4

33.6

FT. HD

0.5

0.6

1.2

1.6

GPM

12.6

16.8

25.2

FT. HD

0.4

0.5

0.7

1.1

GPM

10.1

13.4

16.8

20.2

FT. HD

0.3

0.4

0.6

0.7

GPM

8.4

11.2

16.8

FT. HD

0.2

0.3

0.5

0.6

GPM

6.3

8.4

10.5

12.6

FT. HD

0.2

0.3

0.4

0.5

INPUT

150,000

200,000

250,000

300,000

OUTPUT

126,000

168,000

210,000

252,000

TEMPERATURE RISE 10°F

∆∆

T 15°F

∆∆

T 20°F

∆∆

T 25°F

∆∆

T 30°F

∆∆

T 40°F

∆∆

(TABLE J) – WATER FLOW REQUIREMENTS

(TABLE I) – MINIMUM & MAXIMUM

BOILER FLOW RATES

MODEL MINIMUM FLOW MAXIMUM FLOW

NUMBER (GPM) (GPM)

EB 150 6 60

EB 200

EB 250 10 60

EB 300 12 60

*Min. flow based on 40°F temperature rise.

16 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

Lochinvar

Three Way Valves

The installation of a three-way valve in a

hydronic heating application is not generally

recommended, as most piping methods allow

the three-way valve to vary flow through the

boiler. This variable flow through the boiler is not

recommended, as it alters heat transfer speed

and places undue heat stresses on the heat

exchanger surface. Additionally, low flow rates

can result in overheating of the boiler water,

which can cause short burner on cycles, system

noise and in extreme cases, a knocking flash to

steam. For these reasons, constant circulation is

recommended to maintain proper operation

while the boiler is firing.

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 available for use as a

low water cutoff device on all models. The flow

switch should be installed in the outlet piping of

the boiler and wired into the ignition system. Per

ASME CSD1 and in most localities, a flow switch

is accepted as a low water cutoff for boilers

requiring forced circulation. (See CSD1 CW-210,

Part A) It is prudent to verify preference with the

local code official.

A specially sealed flow switch and conduit are

furnished for outdoor installations.

Low Water Cut-off

If this boiler is installed above radiation level, a

low water cut-off device must be installed at the

time of boiler installation (option available from

factory).

Relief Valve Piping

This boiler is supplied with a pressure relief

valve(s) sized in accordance with ASME Boiler

and Pressure Vessel Code, Section IV “Heating

Boilers”.

Low Flow Systems

When the system flow rate is less than the

minimum flow required for proper boiler

operation, the Efficiency+ boiler should be

installed with a primary/secondary piping

system.

This will allow the installation of a secondary-

circulating pump sized specifically to provide

a higher flow rate through the boiler and the

secondary loop piping to ensure proper

operation. See “Primary/Secondary Piping”

for installation and piping requirements.

IMPORTANT!

Operation of this boiler

on a low temperature

system requires special

piping to ensure correct

operation. Consult “Low

Water Temperature

System” section for

piping details.

(FIG. 15) PRIMARY/SECONDARY SYSTEM PIPING

HEATING SUPPLY

LOOP

*12” MAX

TO FLOOR

DRAIN

MAKE-UP WATER

LIT0476

HEATING RETURN LOOP

(TABLE K) – HEAT EXCHANGER

HEAD-LOSS CURVE

High Flow Systems

When the flow rate of the system exceeds the

maximum allowable flow rate through the boiler

(Table I), boiler bypass piping should be

installed.

The bypass will divert the required portion of the

system flow to the boiler and bypass excess

system flow. This will effectively reduce boiler

flow to an acceptable rate and increase system

flow. The bypass piping should be sized equal

to the system piping. Figure 16 depicts the

proper piping arrangement for the Boiler

Bypass.

Low Water Temperature System

Any boiler system operating at a temperature of

less than 140°F is considered a “low water

temperature system” and must be piped with a

low temperature bypass. There are a number of

hydronic boiler applications that call for system

water temperatures in the range of 60°F to

100°F. Typical applications are: Radiant

heating systems; Water source heat pump

systems; Greenhouse soil heating and irrigation

systems; Process and manufacturing operations.

These installations often incur problems resulting

from boiler condensation, thermal stresses and

poor overall system efficiency.

Copper tube boilers are particularly adaptable

to these applications for several reasons:

A copper tube boiler is an instantaneous

boiler, requiring virtually no heat-up time,

and having no temperature “overshoot”.

Result - High system efficiency.

The boiler’s unique construction prevents the

transfer of heat exchanger thermal stresses to

other boiler components, reducing wear and

tear while increasing equipment life.

Its compact, simple design and low

boiler mass permits a simple bypass

arrangement which will allow the system to

be operated at any temperature above

60°F (16°C).

A boiler operated with an inlet temperature of

less than 140°F (60°C) must have a bypass to

prevent problems with condensation.

A Low Temperature Bypass as shown in Figure

15 should be piped into the system at the time

of installation. This piping is like a primary/

secondary boiler installation with a bypass in

the secondary boiler piping. Inlet water

temperatures below 140°F (60°C) can

excessively cool the products of combustion

resulting in condensation on the heat exchanger

and in the flue. The bypass allows part of the

boiler discharge water to be mixed with the

cooler boiler return water to increase the boiler

inlet temperature to at least 140°F (60°C). This

will prevent the products of combustion from

condensing in most installations. Size low

temperature bypass piping equal to system

piping, and use fully ported control valves.

Lochinvar

DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900 17

(FIG. 16) LOW TEMPERATURE BYPASS SYSTEM PIPING

HEATING SUPPLY

LOOP

TO FLOOR

DRAIN

BYPASS

MAKE-UP WATER

HEATING RETURN LOOP

LIT0473

SPECIAL DESIGN

APPLICATIONS

Air Conditioning Re-Heat System

When used in connection with a refrigeration

system, the boiler must be installed so the

chilled medium is piped in parallel with the

boiler and with appropriate valves to prevent

the chilled medium from entering the boiler.

The piping system of the hot water boiler

(when connected to heating coils located in

air handling units where they may be

exposed to refrigerated air circulation)

must

be equipped with flow control valves or other

automatic means to prevent gravity circulation

of the boiler water during the cooling cycle.

The heating coil

must be vented at the high

point, and the hot water from the boiler

must

enter the coil at this point. Due to the fast

heating capacity of the boiler, it is not

necessary to provide a duct-stat to delay

circulator operation. Also, omit thermal flow

checks, as the boiler is cold when the heating

thermostat is satisfied. This provides greater

economy overall by maintaining standby

heat.

AIR REMOVAL

An air separation device should be placed in

the installation piping, on the suction side of

the system pump, to eliminate trapped air in

the system. Locate a system air vent at the

highest point in the system. Additionally, a

properly sized expansion tank may be

required. Air charged, diaphragm type

compression tanks are common. The

expansion tank must be installed close to the

boiler and on the suction side of the system

pump to ensure proper operation.

18 Lochinvar DESIGNER’S GUIDE EFFICIENCY+ BOILER 615-889-8900

Lochinvar

EXPANSION

TANK

LOW WATER

FLOW SWITCH

PUMP

OUT

WATER

SUPPLY

GAS

SUPPLY

DIAGRAM NOTES:

1. VALVES "D" AND "C" MAY BE MANUAL OR AUTOMATIC- TO SUIT.

2. PROVIDE DRAIN FOR RELIEF VALVE "R" TO SAFE PLACE.

3. CLOSE BOTH "A" AND "C" VALVES WHEN RUNNING CHILLER.

4. CLOSE BOTH "B" AND "D" VALVES WHEN RUNNING BOILER.

5. WATER SUPPLY VALVE REMAINS OPEN AT ALL TIMES.

HEATING &

COOLING

COIL

CHILLER

BOILER

(FIG. 17) HEATING/CHILLED WATER SYSTEM

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Lochinvar EFFICIENCY PLUS Designer's Manual

Lochinvar EFFICIENCY PLUS Designer's Manual

Lochinvar EFFICIENCY PLUS Designer's Manual

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