Lochinvar COPPER-FIN CW 645 User manual

DESIGNER’S GUIDE COPPER-FIN®WAT ER HEAT ER
495,000 – 2,065,000 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 water heater 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 this 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
Nashville, TN • 615-889-8900 • Fax: [phone]

Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900 1
Codes . . . . . . . . . . . . . . . . . . . . . . . . .2
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
Figures & Tables Index
FIG. 1 Models CW 495-2066
Requirements For Installation
Over Combustible Floor . . . . .3
FIG. 2 Water Heater Equipment
& Control Orientation . . . . . . .4
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
TABLE A. Clearances From
Combustible . . . . . . . . . . . . .3
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
Single Heater – Single Tank . . . . . . . . .A3
Two Heaters – Single Tank . . . . . . . . .A4
Two Heaters – Two Tanks . . . . . . . . . .A5
Multi-Stack Frame
Two Heaters – Single Tank . . . . . . . . .A6
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 shall
be carefully followed in all cases. Authorities
having jurisdiction shall be consulted before
installations are made.
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.
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.
2Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900
1.
Lochinvar
oWater Velocity
(See page 12 for Required Degree
Rise chart.)
oFactory Supplied Pump
Capacity
(See page 12 for Pump Operation.)
oManifold Pipe Size
When using more than one heater
(See page 14 for Common Water
Manifold Size for Multiple Water
Heater Installation Table.)
oStorage Tank Circulating
Tappings
(See page 14 for Manifold Pipe
Size.)
oPlacement of Cold Water
Inlet and Building Return
(See Appendix A for Water Heater
Piping Diagrams.)
o Water Hardness
(See page 13 for Water Treatment
Information.)
In designing
a water heater system,
pay special attention to:
Under no circumstances is the
manufacturer to be held responsible
for water damage in connection
with this unit or any of its
components.

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.).
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.
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.
• Provide a base of hollow clay tile or
concrete blocks from 8”to 12”thick
and extending 24”beyond the sides.
• The blocks must be placed in line so that
the holes line up horizontally to provide a
clear passage through the blocks.
• 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.
Outdoor models require the installation of
an optional vent cap. Instructions for
placement of the vent cap are included in
the venting section.
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.
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.
2.
4.
3.
Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900 3
(FIG. 1) 495-2066 REQUIREMENTS FOR
INSTALLATION OVER COMBUSTIBLE FLOOR
5.
(TABLE A) – CLEARANCES FROM
COMBUSTIBLE CONSTRUCTION
CLEARANCES CW495-2066
Right Side 3"
Rear 3"
Left Side 3"
(24"for Service)
Front ALCOVE*
(30"for Service)
Top 3"
Flue 1"**
* Alcove is a closet without a door.
** Consult local codes and/or vent
material manufacturer.

4Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900
Lochinvar
(FIG. 2) WATER HEATER EQUIPMENT AND CONTROL ORIENTATION.
RIGHT SIDE
FLUE PRODUCTS VENT
TERMINAL
STRIP
HOT WATER
OUTLET
COLD WATER
INLET
BURNER INSPECTION PORT
FRONT
GAS
CONNECTION
HOT WATER
OUTLET
COLD WATER
INLET BURNER
INSPECTION PORT
FRONT
AIR
INLET
FRESH AIR
INLET
RIGHT SIDE FLUE PRODUCTS VENT
BACK
DRAIN LEFT SIDE
BACK
120V ELECTRICAL
CONNECTION
OPERATOR
ON/OFF SWITCH
OPERATOR
TERMINAL STRIP
ON/OFF SWITCH
LEFT SIDE
DRAIN
RELIEF VALVE
TAPPING
INLET GAS
CONNECTION
CW495-745
CW986-2066

Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900 5
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.
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 input (5.5 cm2per kW).
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 input (5.5 cm2per kW). 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 input (11 cm2per kW).
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
(FIG. 3) COMBUSTION AIR DIRECT FROM OUTSIDE
(FIG. 4) COMBUSTION AIR THROUGH DUCTWORK
(FIG. 5) COMBUSTION AIR FROM AN
INTERIOR SPACE
CAUTION: Under no circumstances should
the equipment room be under a negative
pressure when atmospheric combustion
equipment is installed in the room.
1.
2.
3.
EXAMPLE OF
SIZING FOR
COMBUSTION
& VENTILATION
AIR OPENINGS
(WATER HEATER
WITH 2,065,000
Btu/hr INPUT):
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.
(2,065,000 ÷ 4000 =
516.25 sq.in.)
Since the air opening is
50% closed due to
screens and louvers, the
total opening must be
multiplied by 2.
(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
Combustion Air Opening
with net “Area” of
1,032 square inches with
louver dimensions
of 30”x 35”.

6Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900
Btu (22 cm2per kW) of input, but not less
than 100 square inches (645 cm2).
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 input (7 cm2per kW). This
opening must be located within 12”
(30 cm) of the top of the enclosure.
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.
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.
VENTING
General
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.
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.
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. 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
Lochinvar
4.
(FIG. 6) COMBUSTION AIR FROM OUTSIDE,
SINGLE OPENING
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
water heater.

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.
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.
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.
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.
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.
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.
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.
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.
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 distance of the vent terminal from
adjacent public walkways, adjacent
buildings, windows, and building openings
Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900 7

8Lochinvar DESIGNER’S GUIDE COPPER-FIN WATER HEATER 615-889-8900
must be consistent with the National Fuel
Gas Code Z223.1 or in Canada, the latest
edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment.
VENTING OPTIONS
Conventional Venting
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.
The minimum flue pipe diameters for
Copper-Fin models, utilizing negative draft
venting are as follows:
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.
Lochinvar
(FIG. 7) BAROMETRIC DAMPER INSTALLATION
(TABLE B)
FLUE SIZES AND COMBUSTION AIR PIPE SIZES
MODEL FLUE SIZE
NUMBER
CW 495 6"
CW 645 8"
CW 745 8"
CW 986 10"
CW 1256 12"
CW 1436 12"
CW 1796 14"
CW 2066 14"
NOTE:
A vent system should
never be sized based
only on the vent
connection diameter of
the appliance. For proper
vent design and sizing,
please consult the
National Fuel Gas Code
(ANSI Z223.1).