Lochinvar 399 manual

INST ALLA TION AND SER VICE MANU AL Sav e this manual f or futur e reference.  WARNING : If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or loss of life. – Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other a[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 2 Table of Contents General Product Information . . . . . . . . . . . . . . . . . . . . . . . . .3 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Codes . . . . . . . . . . . [...]

Installa tion and Ser vice Manual 3 GENERAL PRODUCT INFORMATION Special Instr uctions This manual supplies information for the installation, operation and servicing of the appliance. Read and understand this manual completely before installing unit. Installation and service must be performed by a qualified service installer , service agency , or th[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 4 SAFETY INFORMATION The information contained in this manual is intended for use by qualified professional installers, service technicians or gas suppliers. Consult your local expert for proper installation or service procedures. 1. This unit is only for use with the type of gas indicated[...]

Installa tion and Ser vice Manual 5 PRODUCT IDENTIFICATION FIG . 1 Front and Rear V iew Rear V iew Front V iew[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 6 INST ALLA TION This unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9 and ANSI Z21.10.3/CSA 4.3. L OCA TING UNIT 1. Maintain all clearances from combustible co[...]

Installa tion and Ser vice Manual 7 Base for Combustible Floors There are no manufactured combustible floor base kits available for 990,000 - 2,070,000 Btu models. See T able-A below for floor base kits that are available. Y ou must construct a base for combustible floor installation. Install unit over a base of hollow clay tiles or concrete blocks[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 8 INSTALLATION Continued Shut-Down and Draining If for any reason, the unit is to be shut off, the following precautionary measures must be taken: 1. Shut off gas supply . 2. Shut off water supply . 3. Shut off electrical supply . 4. Drain the unit completely . Remove one threaded plug or [...]

Installa tion and Ser vice Manual 9 FIG . 4 Metal Panel Covering Side Combustion Air Inlet FIG . 5 Moving Air Filter/Bracket Assembly from Rear of Unit to Side Combustion Air Options This unit has four combustion air options. 1. Outside Combustion Air , No Ducts Y ou can direct outside combustion air to this unit using either one or two permanent o[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 10 INSTALLATION Continued FIG . 7 Outside Combustion Air - T wo Openings 2. Outside Combustion Air , Using Ducts Y ou can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room. Each of the two openings must have a minimum free area of one squa[...]

Installa tion and Ser vice Manual 11 Exhaust F ans Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and/or cause a down draft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 12 INSTALLATION Continued FIG . 1 1 V ent T ermination fr om Peaked Roof More Than 10’ From Ridge FIG . 12 V ent T ermination from Flat Roof 10’ or Less from Parapet W all FIG . 13 V ent T ermination from Flat Roof Mor e Than 10’ from Parapet W all Sidewall V ent T er mination Cleara[...]

Installa tion and Ser vice Manual 13 Input Flue Air Inlet Btu/hr Size Size* 399,999 6" 6" 500,000 6" 6" 650,000 8" 8" 750,000 8" 8" 990,000 10" 10" 1,260,000 12" 12" 1,440,000 12" 12" 1,800,000 14" 12" 2,070,000 14" 12" * Minimum diameter for air inlet pipe. I[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 14 INSTALLATION Continued FIG . 15 Air Inlet Cap for Sidewall T ermination T o 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/or CAN/CGA-B14[...]

Installa tion and Ser vice Manual 15 If the air inlet cap is within a 10-foot (3.05m) radius of the flue outlet, the point of termination for the combustion air inlet cap must be at least 3 feet (0.91m) below the point of flue gas termination (vent cap). Do not install the combustion air inlet cap closer than 10 feet (3.05m) from an inside corner o[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 16 INSTALLATION Continued 1. Con v entional Ne gativ e Dr aft V enting FIG . 17 Conventional Negative Draft V ertical V enting with Combustion Air Louvers This option uses T ype-B double-wall flue outlet piping. The blower brings in combustion air . The buoyancy of the heated flue products[...]

Installa tion and Ser vice Manual 17 3. If possible, close all building doors and windows. Close all doors between the space in which the appliances remaining connected to the common venting system are located and other building spaces. 4. T urn on clothes dryers and any other appliances not connected to the common venting system. T urn on any exha[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 18 INSTALLATION Continued The V ertical DirectAire™ vent system requires you to install two vent pipes directly to the unit; one vertical pipe with a rooftop termination for the flue products and one pipe for combustion air . For this venting option, you must purchase the DV box adapter [...]

Installa tion and Ser vice Manual 19 * The SVK kits include a DV box adapter and sidewall air inlet cap. The VDK kits include a DV box adapter and a rooftop air inlet cap. 3. Sidewall V enting This option uses a powered vent assembly which pulls the flue products out of the stack. This fan generates a negative draft at the unit. Combustion air is d[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 20 INSTALLATION Continued The following is a detailed explanation of Sidewall V enting W ithout an External Power V ent Fan installation requirements. Flue Outlet Piping V enting Guidelines If using this venting option, a sealed AL29-4C venting system for flue products is required on all m[...]

Installa tion and Ser vice Manual 21 Masonry Chimney Installation A masonry chimney must be properly sized for the installation of a high efficiency gas-fired appliance. V enting 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 ex[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 22 INSTALLATION Continued FIG . 23A Horizontal DirectAir e Installation (Illustration with Sidewall V enter and Sidewall Combustion Air) Combustion air supplied from outdoors must be free of contaminants (see Combustion and V entilation Air , page 8). V ent Kits Y ou must order the Horizon[...]

Installa tion and Ser vice Manual 23 Drain T ee Installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee must be installed as the first fitting after the horizontal ell on the top of the unit (see FIG . 23B). Plastic drain tubing, sized per the vent manufac[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 24 INSTALLATION Continued Horizont al DV V enting T ermination Horizontal venting uses the unit’ s internal combustion air blowers to force the flue products out of the horizontally- terminated flue. Y ou must purchase a horizontal direct vent kit from the appliance manufacturer to ensur[...]

Installa tion and Ser vice Manual 25 For venting versatility , you can move the air filter assembly and DV box adapter to the right side of the unit. Remove the metal panel on the unit’ s right side (see FIG . 25). Remove the filter/bracket assembly from the rear of the unit. Attach the filter/bracket assembly and DV box adapter to the right side[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 26 INSTALLATION Continued Y ou must locate the combustion air cap and the flue gas outlet on the same roof top surface (vertical direct vent system) or sidewall surface (horizontal direct vent system) and in the same pressure zone as the vent termination. Follow all clearance requirements [...]

Installa tion and Ser vice Manual 27 Combustion air supply must be free of contaminants (see Combustion and V entilation Air , page 8). T o prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section. Out door V ent/Air Inlet Location Keep venting areas free of obstructions. Keep area clean and [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 28 INSTALLATION Continued CONNECTING T O GAS SUPPL Y Only supply gas type specified on the unit’ s rating plate. This unit is orificed for operation up to 2000 feet altitude. If installing above 2000 feet elevation, consult the appliance manufacturer . INLET PRESSURE: Measure inlet press[...]

Installa tion and Ser vice Manual 29 FIG . 28 Gas Line Connection 2. Use new , properly threaded black iron pipe free from chips. If you use tubing, make sure the ends are cut square, deburred and clean. Make all tubing bends smooth and without deformation. A void flexible gas connections. Internal diameter of flexible lines may not provide unit wi[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 30 INSTALLATION Continued W ater heater models do not have downstream test valves, but the rest of the gas train is represented by Figure 29. Combination Gas V alv es These units fire in multiple stages of burner input. Each stage of burner operation has a combination gas valve(s) to cycle[...]

Installa tion and Ser vice Manual 31 Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly . Flame pattern should be stable, see Burner Flames , page 56. T urn system off and allow burners to cool, then cycle burners again to ensure proper ignition and flame characteristics. FIG . 30 Measur[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 32 INSTALLATION Continued 4. Locate the reference hose on the second gas valve which goes from the vent fitting on the gas valve to a barbed fitting on the deck of the unit (see FIG . 31). 5. Remove the flexible cap from the barbed fitting on the “tee” located in this line and hook one[...]

Installa tion and Ser vice Manual 33 FIG . 32 W ater Connections R elief V alv e This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure V essel Code, Section IV (“Heating Boilers”). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. Place no other valve between [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 34 INSTALLATION Continued 1. Use only T ype-T wire [63°F (35°C) rise] on all wiring between the unit and field-installed devices. 2. Enclose line voltage wire exterior to the unit in approved conduit or approved metal-clad cable. 3. The pump must run continuously when unit is being fired[...]

Installa tion and Ser vice Manual 35 Example : The boiler inlet temperature is 160°F (71°C) and the boiler outlet temperature is 180°F (82°C), this means that there is a 20°F (1 1°C) temperature rise across the boiler . Heat Ex changer Pressure Dr op Char t FIG . 34 Pressur e Drop Chart 399,999 - 750,000 FIG . 35 Pressur e Drop Chart 990,000 [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 36 INSTALLATION Continued FIG . 36 Primary/Secondary Piping of a Single Boiler FIG . 37 Primary/Secondary Piping of Multiple Boilers Low T emper ature Retur n Wa ter Systems Any non-condensing boiler and venting system will develop operational problems when exposed to inlet water temperatu[...]

Installa tion and Ser vice Manual 37 Radiant Floor and Snow Melt Heating Systems This type of heating boiler application operates in a low temperature range which requires a boiler bypass as described under Low T emperatur e Return W ater Systems . A non-metallic rubber or plastic tubing installed in a radiant (in floor) system must have an oxygen [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 38 INSTALLATION Continued Boiler Flow Ra te If higher flow rates are required through the boiler , an optional Cupro-Nickel heat exchanger is available. Consult the factory for specific application requirements. The heat exchanger is generally capable of operating within the design flow ra[...]

Installa tion and Ser vice Manual 39 9. Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged and not water logged. 10. Start the boiler according to the operating instructions in [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 40 INSTALLATION Continued Set the control set point(s) to the desired operating water temperature. Observe the boiler discharge temperature after each set point adjustment to ensure proper operation. See Pr ogramming T emperatur e Contr ol , page 43 for complete programming information. WA[...]

Installa tion and Ser vice Manual 41 OPERA TION FOR Y OUR SAFETY READ BEFORE OPERA TING A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner . Do not try to light the burner by hand. B. BEFORE OPERA TING , smell around the appliance area for gas. Be sure to smell next to the floor bec[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 42 OPERATION Continued C. Use only your hand to turn the gas control lever . Never use tools. If the lever will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this boiler if any par[...]

Installa tion and Ser vice Manual 43 T o T ur n Of f Gas T o A ppliance 1. Open the front access panel to access control panel. 2. T urn power switch to “OFF” position. 3. Turn the manual gas cock clockwise to the “OFF” position. FIG . 45 Combination Gas V alve PROGRAMMING TEMPERA TURE CONTROL Note : The temperature controller is pre-progra[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 44 OPERATION Continued Note: * indicates the setting is only available in the advanced access level ** units listed in KBtu Adjust Menu Setting Descriptions BOIL MAX Maximum boiler target supply temperature [either 200°F (93°C) or 250°F (121°C)]. SEn Select whether staging is based on [...]

Installa tion and Ser vice Manual 45 STG MODE Used to distinguish between single and dual ignition module appliances. Applies ONL Y on 650,000, 750,000, and 990,000 Btu/hr models. OUTDR DSGN Design outdoor air temperature used in the heat loss calculations. BOIL ST ART Starting temperature of the boiler heating curve at outdoor starting temperature[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 46 OPERATION Continued Scroll through the different settings by pressing the “Select” button. Change settings by pressing either the “+” button or the “–” button. If no buttons are pushed after a few seconds, the control will time-out and return to the “V iew” menu. T ABL[...]

Installa tion and Ser vice Manual 47 System Sensor: This is used for boiler applications. This sensor will control the water temperature within the building loop. Staging Logic There are two different types of staging logic used in the temperature control; Proportional (step) Staging Logic and PID Staging Logic. The staging logic used depends upon [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 48 OPERATION Continued T o program settings for Mode 1 operation, press in and hold the three programming buttons for 3 seconds. The screen will change from the V iew Menu to the Adjust Menu. “Adjust” will appear in the upper right corner of the screen. Just under the word “Adjust”[...]

Installa tion and Ser vice Manual 49 3. Do not locate temperature sensor wiring near electric motors. 4. Do not locate temperature sensor wiring near welding equipment. 5. Make sure good mechanical connections are made to the sensor , any interconnecting wiring and the controller . 6. Do not mount sensor with leadwire end pointing up in an area whe[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 50 OPERATION Continued Diagnostic St atus Indication The ignition module has an LED which indicates the status of the safety circuits. A remote Ignition Module Status indicating light(s) is wired from the ignition module Status LED and mounted on the front control panel. The flashing opera[...]

Installa tion and Ser vice Manual 51 Ignition and Control Timings Proven Pilot Hot Surface Ignition System M-9 on 990,000 through 2,070,000 Btu/hr models with two hot surface ignition modules. Hot Surface Ignition Module Timings (Nominal) Prepurge: 15 Seconds Hot Surface Igniter Heat-up Time: 25- 35 seconds Main Burner Flame Establishing Period: 4 [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 52 DOMESTIC WATER HEATERS This section applies only to those units used to supply potable hot water for domestic use. The hot water supply boiler must be installed with a storage tank. This section contains specific instructions for those units used to supply domestic hot water . All warni[...]

Installa tion and Ser vice Manual 53 potable water exceeding these specifications. Heating of high hardness and/or high total dissolved solids water will require a larger circulating pump, an optional cupro-nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated. W ater with a hardne[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 54 DOMESTIC WATER HEATERS Continued This pump is sized based on installation of a single storage tank and heater in close proximity . If the number of fittings and straight pipe exceeds the quantities shown in this section, a larger pump will be required. The standard pump selection is bas[...]

Installa tion and Ser vice Manual 55 4. The temperature set points for all stages should be set at the same temperature when supplying potable hot water for domestic use. 5. Stage firing is achieved by setting the dif ferentials at approximately 3°F , 5°F , 7°F and 9°F for stages 1, 2, 3, and 4. Stage firing of a potable water heater should onl[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 56 CLEANING AND MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations. V erify proper operation after servicing. Appliance Ar ea Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Wa ter Circu[...]

Installa tion and Ser vice Manual 57 Heat Ex changer Cleaning 1. While burners are removed, check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows. 2. Remove gas manifold(s)/orifice assemblies as described in steps 1 through 5 in Burner Removal and Cleaning , page 56. 3. Di[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 58 CLEANING AND MAINTENANCE Continued Adjusting Dif f er ential Air Pressur e The following is a recommended method for setting the differential air pressure ( Δ P) for each fan. FIG . 56 Adjusting Air Shutter 399,999 - 750,000 Btu/hr Models FIG . 57 Loosening Fan T ransition Box Screws F[...]

Installa tion and Ser vice Manual 59 6. Adjust the air shutter on the right fan until the differential pressure is nominally 1.1-1.3 inches water column. 7. Once the adjustment procedure is complete, reattach the caps to the tees in the hoses to the pressure switches and check all tubing and wire connections for snug fit. T est fire the unit. Insta[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s SEQUENCE OF OPERATION Continued MANU AL RESET HIGH-LIMIT THERMOST A T A manual reset high limit thermostat is provided as backup for the electronic adjustable temperature controller . An adjustable dial thermostat will trip and require resetting should water temperature exceed its settings[...]

Installa tion and Ser vice Manual 61 are energized. This does not interfere with the safety functionality of either pressure switch or the ignition modules. IGNITION (Ignition Module Function) Once the trial for ignition period has been completed, the ignition module sends 24V AC to the gas valves on one or the other of the primary stages . Gas val[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 62 Chec k th e flo w swit ch and Tek mar pi ns #15 and #1 6 for 2 4VAC. Step 1 Does the power switch provide power to the unit? Check the switch f or proper operation. Check the line voltage. NO YES Check 24VAC a t T H (orange wire) on the ig nition module. YES Check all saf ety limit devi[...]

Installa tion and Ser vice Manual 63 Step 1 Does the power switch provide power to the control panel? Check the switch and/or the line voltage. Step 1 Does the power switch provide power to the Check the switch and/or the line voltage. NO YES Combustion air blow ers come on. NO Is there 24VAC at B2 on the terminal strip. Check 24VAC at TH (orange w[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 64 WIRING BO X CONNECTIONS - WIRING DIA GRAM A 399,999 - 750,000 BTU/HR MODELS PR BR 12 3 56 4 24 VAC XFM R . ELECTRO NIC CONT ROLL ER DI SPLAY BOARD ALAR M ENABL E REL AY 24 V SENSO R CO NNECTOR CIRCUI T BREAKER 120V 24V OPTI ONA L FLAME FA IL ENAB LE RELAY 24 V BK W BL Y Y Y S2/F S F2 F1[...]

Installa tion and Ser vice Manual 65 LADDER DIA GRAM 399,999 - 750,000 BTU/HR MODELS NC N C NO ALARM I NPUTS 1, 2, & 3 JOIN HE RE S2 / FS - + F2 F1 NE U LIN E S 1 O R P RESS URE SWITCH R ESET PUR GE GY GY PUMP RE LA Y B K STA GE #2 STAGE #1 16 15 18 1 7 20 19 HEA T DEM # 1 EL EC TRONIC TE MP E RA TURE CONT R OL LE R O P TI ON A L RUN TIM E RE L[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 66 WIRING BO X CONNECTIONS - WIRING DIA GRAM B 399,999 - 750,000 BTU/HR MODELS[...]

Installa tion and Ser vice Manual 67 WIRING BOX CONNECTIONS - WIRING DIAGRAM B (CONTINUED) 399,999 - 750,000 BTU/HR MODELS[...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 68 LADDER DIAGRAM 990,000 - 2,070,000 BTU/HR MODELS 24 VAC CONT ROL J3 5 4 6 1 2 3 O.C . J1 J2 3 2 1 J4 P O N C BR / W ALARM INP UTS 1, 2, 3 & 4 JO IN HERE S2/F S F2 F 1 L I N E S 1 O/ W P RESSUR E SWIT CH # 2 R ESE T P U R G E Y P T /W S 2 / F S - + F2 F1 N EU L INE S 1 O G R PRESSURE[...]

Installa tion and Ser vice Manual 69 WIRING DIAGRAM A 990,000 - 2,070,000 BTU/HR MODELS J3 5 4 6 1 2 3 O.C . J1 J2 3 2 1 J4 P BK /W BR FF 12 3 5 6 4 4 5 6 1 2 3 24 VAC XFM R . ELECTRO NIC CO NTROLL ER DI SPLAY BOARD ALARM ENAB LE RELAY 24 V PRESSU RE SWITCH PROVI NG REL AY 2 4 V RUN TIME STG 1 SENSO R CO NNECTO R CIRCUI T BREAKER 120V 24V TES T OP [...]

Hy dr onic Hea ting Boiler s and Domestic W a ter Hea ter s 70 WIRING BOX CONNECTIONS - WIRING DIAGRAM B CONNECTIONS 990,000 - 2,070,000 BTU/HR MODELS[...]

Installa tion and Ser vice Manual 71 DIAGRAM B CONNECTIONS 990,000 - 2,070,000 BTU/HR MODELS (CONTINUED)[...]

Revision 6 (CF-CH(E)-i&s-06) reflects changes made to text on Page 33 and the LBLs on pages 64-65, 68-69. Revision 7 (ECO C02822) reflects moving FIG . 22A (page 20) to page 23 and adding Aire-Lock to the title. Revision 8 (ECO #C02870) reflects the addition of a mixing valve to FIG . 54 (page 53) and edits made to the scald warnings. CF-CH(E)-[...]