1. Manuals
  2. Brands
  3. Lochinvar Manuals
  4. Boiler
  5. Knight 399
  6. Installation and service manual

Lochinvar 399 Installation And Service Manual

Hydronic heating boilers and domestic water heaters 399,999 - 2,070,000 btu/hr models
Hide thumbs Also See for 399:
Table of Contents

Advertisement

Quick Links

See also: Operation & Installation Manual
INSTALLATION AND SERVICE MANUAL
WARNING: Do not use
this appliance if any part
has been under water. The
possible
damage
flooded appliance can be
extensive
and
numerous safety hazards.
Any appliance that has
been under water must be
replaced.
HYDRONIC HEATING BOILERS and

DOMESTIC WATER HEATERS

399,999 - 2,070,000 Btu/hr MODELS
WARNING: Improper
installation,
alteration,
maintenance can cause
property damage, personal
injury,
hazardous
loss of life. Refer to this
manual. Installation and
service must be performed
by a qualified installer,
to
a
service agency or the gas
supplier. This unit contains
present
materials that have been
identified as carcinogenic,
or possibly carcinogenic,
to humans.
Save this manual for future reference.
adjustment,
service
or
exposure
to
materials
or
CF-CH(E)-i&s-08
WARNING:
information in this manual
is not followed exactly, a
fire
or
explosion
result causing property
damage, personal injury or
loss of life.
– Do not store or use
gasoline
or
flammable
vapors
liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL
GAS
• Do not try to light any
appliance.
• Do
not
touch
electric switch; do not
use any phone in your
building.
• Immediately call your
gas supplier from a
neighbors
Follow
the
supplier's instructions.
• If you cannot reach your
gas supplier, call the fire
department.
– Installation and service
must be performed by a
qualified installer, service
agency or the gas supplier.
If
the
may
other
and
any
phone.
gas

Advertisement

Table of Contents
loading

Related Manuals for Lochinvar 399

Summary of Contents for Lochinvar 399

  • Page 1: Domestic Water Heaters

    INSTALLATION AND SERVICE MANUAL HYDRONIC HEATING BOILERS and 399,999 - 2,070,000 Btu/hr MODELS WARNING: Do not use this appliance if any part has been under water. The possible damage flooded appliance can be extensive present numerous safety hazards. Any appliance that has been under water must be replaced.

  • Page 2: Table Of Contents

    Sequence of Operation ......59 Troubleshooting Guide 399,999 - 750,000 Btu/hr Models Troubleshooting Guide 990,000 - 2,070,000 Btu/hr Models Wiring Diagram .

  • Page 3: General Product Information

    GENERAL PRODUCT INFORMATION Special Instructions 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 the gas supplier. Unpacking Upon receiving equipment, check for signs of shipping damage.

  • Page 4: Safety Information

    Hydronic Heating Boilers and Domestic Water Heaters 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. IMPORTANT: Read this owner’s manual carefully and completely before trying to install, operate, or service this unit.

  • Page 5: Product Identification

    Installation and Service Manual PRODUCT IDENTIFICATION Front View Rear View FIG. 1 Front and Rear View...

  • Page 6: Installation

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION 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. LOCATING UNIT 1.

  • Page 7: Base For Combustible Floors

    This base must meet all local fire and safety codes. TABLE - A COMBUSTIBLE FLOOR KITS Input Btu/hr 399,999 500,000 650,000 750,000 FREEZE PROTECTION Although these units are CSA International design certified for outdoor installations, such installations are not recommended in areas where the danger of freezing exists.

  • Page 8: Shutdown And Draining

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION 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.

  • Page 9: Combustion Air Options

    FIG. 4 Metal Panel Covering Side Combustion Air Inlet FIG. 5 Moving Air Filter/Bracket Assembly from Rear of Unit to Side Installation and Service Manual Combustion Air Options CAUTION: Under no circumstances should the mechanical room ever be under a negative pressure.
  • Page 10 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION FIG. 7 Outside Combustion Air - Two Openings 2. Outside Combustion Air, Using Ducts You 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 square inch per 2000 Btu input (11cm FIG.

  • Page 11: Exhaust Fans

    Exhaust Fans 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.

  • Page 12: Sidewall Vent Termination Clearances And Location

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION MORE THAN 10' RIDGE 2' MIN. CHIMNEY FIG. 11 Vent Termination from Peaked Roof More Than 10’ From Ridge 10' OR LESS 2' MIN. 2' MIN. CHIMNEY WALL OR PARAPET FIG. 12 Vent Termination from Flat Roof 10’ or Less from Parapet Wall 10' OR LESS NOTE: NO HEIGHT...

  • Page 13: Combustion Air Inlet Piping

    TABLE - B Flue and Air Inlet Pipe Sizes Input Flue Air Inlet Btu/hr Size 399,999 6" 500,000 6" 650,000 8" 750,000 8" 990,000 10" 1,260,000 12" 1,440,000 12" 1,800,000 14" 2,070,000 14" * Minimum diameter for air inlet pipe. Installer may increase diameter one pipe size for ease of installation, if needed.
  • Page 14 (3.05m) of the flue outlet from the powered vent cap. Make sure to properly install the air inlet cap assembly on the air inlet pipe. Minimum Recommended Combustion Air Supply To Boiler Room Boiler Input Outside Air*/2 Openings 399,999 100 in 500,000 125 in 650,000 163 in...

  • Page 15: Combined Air Inlet Points

    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 of an L-shaped structure.

  • Page 16: Conventional Negative Draft Venting

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION 1. Conventional Negative Draft Venting IMPORTANT: Before installing a venting system, follow all venting clearances and requirements found in the Venting, General Information section, page 11. FIG. 17 Conventional Negative Draft Vertical Venting with Combustion Air Louvers This option uses Type-B double-wall flue outlet piping.

  • Page 17: 2. Vertical Directaire™ Venting

    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. Turn on clothes dryers and any other appliances not connected to the common venting system.
  • Page 18 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION The Vertical 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 from the appliance manufacturer.

  • Page 19: Sidewall Venting

    See the installation instructions provided with the vent kit. Sidewall Venting Without Fan For 399,999 - 750,000 Btu/hr models approved for sidewall venting without an external power vent fan, you must install specific vent kits and venting materials.
  • Page 20 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION The following is a detailed explanation of Flue Outlet Piping Venting Guidelines If using this venting option, a sealed AL29-4C venting system for flue products is required on all models of this appliance. This venting system operates with a positive pressure in the vent.

  • Page 21: Horizontal Directaire ™ Venting

    You must connect the air inlet pipe to a combustion air inlet cap as specified in this section. Vent Max. Vent Termination Only Length (399,999 - 750,000 Btu/hr) SVK3043 50 ft. SVK3043 50 ft. SVK3044 50 ft.

  • Page 22: Direct Venting

    For proper operation, a barometric damper is provided for Horizontal DirectAire installations. The damper will help to ensure a draft between negative 0.04 to 0.08 inches w.c. TABLE–E Continued Horizontal DirectAire™ Kits Input Btu/hr 399,999 500,000 650,000 750,000 990,000 1,260,000 1,440,000 1,800,000 2,070,000 *These kits include a sidewall venter assembly, vent termination, DV box , page 8).
  • Page 23 Drain Tee 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 manufacturer’s instructions, shall be provided as a drain line from the tee.
  • Page 24 Horizontal Vent Termination Clearances and Location Follow all sidewall venting termination information for clearances and location under , page 12. TABLE-G Direct Vent Kits Input Horizontal Btu/hr Kit* 399,999 DVK3004 500,000 DVK3004 650,000 DVK3005 750,000 DVK3005 990,000 DVK3000 1,260,000 DVK3001...
  • Page 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 opening using the pre-drilled screw holes.

  • Page 26: Outdoor Installation Venting

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION WARNING: Locate and install the combustion air inlet termination correctly. Failure to do so can allow the discharge of flue products to be drawn into the combustion process. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products.
  • Page 27 Do not install in locations where rain from building runoff drains will spill onto the unit. Outdoor Vent Cap Kits Installation and Service Manual TABLE-H Outdoor Vent Cap Kits Kit* Input without Btu/hr Pump Cover 399,999 ODK3748 500,000 ODK3748 650,000 ODK3749 750,000 ODK3749 990,000 ODK3036 1,260,000 ODK3064...

  • Page 28: Connecting To Gas Supply

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION CONNECTING TO GAS SUPPLY 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.

  • Page 29: Gas Train And Controls

    Suggested Gas Pipe Size for Single Unit Installations Btu/hr Distance From Meter (in feet) Input 0-50 51-100 101-200 201-300 " " " 1 1/4 1 1/4 1 1/2 399,999 " " " 500,000 1 1/4 1 1/2 " " " 1 1/2 650,000 "...

  • Page 30: Combination Gas Valves

    Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Water heater models do not have downstream test valves, but the rest of the gas train is represented by Figure 29. Combination Gas Valves These units fire in multiple stages of burner input. Each stage of burner operation has a combination gas valve(s) to cycle the gas supply on and off and regulate gas to the burners.

  • Page 31: Gas Manifold Pressure Adjustment

    Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly. Flame pattern should be stable, see Turn system off and allow burners to cool, then cycle burners again to ensure proper ignition and flame characteristics. FIG.

  • Page 32: Connecting To Water Supply

    The connection on the header marked “Outlet” is to be connected to the supply side of the system. , page 57 for TABLE-M Net Manifold Pressure 399,999 - 750,000 1.8" w.c. 4.6" w.c. 990,000 - 2,070,000 1.2" w.c. 4.6" w.c.

  • Page 33: Relief Valve

    2-1/2" NPT WATER OUTLET 2-1/2" NPT WATER INLET INSPECTION PLUGS FIG. 32 Water Connections Relief Valve This unit is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet.

  • Page 34: Boiler System Piping

    IMPORTANT: Do not block access to the electrical cover plate when installing electrical conduit. TABLE-N AMP Draw Data Btu/Hr Input Controls Fans 399,999 500,000 650,000 750,000 990,000 1,260,000 1,440,000 1,800,000 2,070,000 BOILER SYSTEM PIPING The drawings in this section show typical boiler piping installations.

  • Page 35: Primary/Secondary Boiler Piping

    180°F (82°C), this means that there is a 20°F (11°C) temperature rise across the boiler. Heat Exchanger Pressure Drop Chart FIG. 34 Pressure Drop Chart 399,999 - 750,000 Pressure Drop Chart 990,000 - 2,070,000 Btu/hr Models FLOW IN GALLONS PER MINUTE FIG.

  • Page 36: Low Temperature Return Water Systems

    Any non-condensing boiler and venting system will develop operational problems when exposed to inlet water temperatures below 140°F. Lochinvar offers a low temperature protection valve (LTV) that is factory preset to maintain 140°F inlet water to the boiler regardless of the system return water temperature.

  • Page 37: Radiant Floor And Snow Melt Heating Systems

    1,759,500 *Requires Cupro-Nickel heat exchanger. CAUTION: The maximum flow rate for models 399,999 - 750,000 Btu/hr is 55 GPM and 90 GPM on models 990,000 - 2,070,000 Btu/hr. Do not exceed the maximum flow rate of the heating boiler. If higher flow rates are required through the boiler, an optional Cupro-Nickel heat exchanger is available.

  • Page 38: Boiler Flow Rate

    MUST NOT exceed the following: Input - Btu/hr Maximum Flow Rate 399,999 - 750,000 990,000 - 2,070,000 If higher flow rates are required through the boiler, an optional Cupro-Nickel heat exchanger is available. Consult the factory for specific application requirements.

  • Page 39: Installation With A Chilled Water System

    For best performance, do not relocate the inlet or outlet sensors. Install an optional system sensor. If the unit is ordered as a water heater, the tank sensor is included with the unit. Do not relocate the inlet or outlet sensors from their bulbwells.

  • Page 40: Water Treatment

    FIG. 42-B shows connections to the terminal strip for Remote ON/OFF control of the boiler or water heater (Modes 1 or 2). The 1C-1NO jumper must be removed when making these wiring connections. This remote ON/OFF control will provide...

  • Page 41: Operation

    HeatDem1 HeatDem2 STAGE 1 STAGE 2 STAGE 3 CONTINUOUS INTERMITTENT Figure 42D 2 STAGE (High/Low Fire) BOILER OR WATER HEATER Remove Factory Jumper if Jumper Wire is Added. STAGE 4 STAGE 4 OPERATION STAGE 4 FOR YOUR SAFETY READ BEFORE OPERATING A.

  • Page 42: Lighting Instructions

    Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbors phone.

  • Page 43: To Turn Off Gas To Appliance

    CONTROL Note: The temperature controller is pre-programmed at the factory with test settings. Stages per model may vary. These pre-programmed values are as follows: Standard Btu/hr Models 399,999 - 500,000 2-Stage (Capable) 650,000 - 990,000 3-Stage (Capable) 1,260,000 - 2,070,000...

  • Page 44: Adjust Menu Setting Descriptions

    DIFF (1, 2, 3, or 4) Temperature differential for stages 1, 2, 3, or 4. STG DLY Stage delays can be set as follows: Btu/hr Input 399,999 - 500,000 650,000 - 750,000 990,000 1,260,000 - 2,070,000 ΔT MIN Set temperature at which purging stops.
  • Page 45 1, 2, 3, and 4, or 3, 4, 1, and 2. This allows greater programming flexibility to meet your individual needs. Note: One ignition system controls 1 - 3 stages on the 399,999 - 750,000 Btu/hr models. Operating Modes...

  • Page 46: Access Levels

    Hydronic Heating Boilers and Domestic Water Heaters 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 “View”...

  • Page 47: Staging Logic

    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 what mode the control is running under.
  • Page 48 Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued To program settings for Mode 1 operation, press in and hold the three programming buttons for 3 seconds. The screen will change from the View Menu to the Adjust Menu. “Adjust” will appear in the upper right corner of the screen.

  • Page 49: Hot Surface Ignition System

    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 where condensation can occur.
  • Page 50 Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued Diagnostic Status 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.

  • Page 51: Operation And Diagnostic Lights

    Time Delay Between Stages 1&2 and 3&4*: 15 Seconds 399,999 - 750,000 TIME DELAY stages 1 and 2 ONLY. Note: Delay starts from the beginning of the ignition process. In order to achieve a 15 second delay, a 60 second delay would have to be programmed.

  • Page 52: Domestic Water Heaters

    4. Be sure the installed circulation pipes between the water heater and storage tank are not less than 2" in diameter on 399,999 - 750,000 Btu/hr models and 2 1/2" in diameter on 990,000 - 2,070,000 Btu/hr models. 5. Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tappings to ensure proper flow.

  • Page 53: Pipe Size Requirements

    FIG. 54 Typical Water Heater Piping with Storage Tank Pipe Size Requirements The pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow. Number of Units 399,999 - 750,000 Btu/hr Models Number of Units 990,000 - 2,070,000 Btu/hr Models EXPANSION TANK (IF REQUIRED)

  • Page 54: Minimum Pump Performance

    120°F (49°C) or lower temperature hot water to reduce risk of scald injury. Operate this high efficiency hot water heater at a temperature setting high enough to prevent condensing of the products of combustion on the unit’s heat exchanger or in the attached venting system.

  • Page 55: Location Of Cold Water Supply Piping Connections

    5. Stage firing is achieved by setting the differentials 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 only be used to replace system standby heat loss.

  • Page 56: Cleaning And Maintenance

    Hydronic Heating Boilers and Domestic Water Heaters CLEANING AND MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

  • Page 57: Combustion And Ventilation Air

    Heat Exchanger 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 3.

  • Page 58: Adjusting Differential Air Pressure

    The following is a recommended method for setting the differential air pressure (ΔP) for each fan. AIR SHUTTER FIG. 56 Adjusting Air Shutter 399,999 - 750,000 Btu/hr Models FIG. 57 Loosening Fan Transition Box Screws FIG. 58 Adjusting Air Shutter 990,000 - 2,070,000 Btu/hr...

  • Page 59: Servicing Hot Surface Igniter And Ignition Module

    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.
  • Page 60 Hydronic Heating Boilers and Domestic Water Heaters SEQUENCE OF OPERATION Continued MANUAL RESET HIGH-LIMIT THERMOSTAT 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.
  • Page 61 Installation and Service Manual 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 24VAC to the gas valves on one or the other of the primary stages .

  • Page 62: Troubleshooting Guide

    Hydronic Heating Boilers and Domestic Water Heaters TROUBLESHOOTING GUIDE 399,999 - 750,000 Btu/hr Models...

  • Page 63: Troubleshooting Guide

    Installation and Service Manual TROUBLESHOOTING GUIDE 990,000 - 2,070,000 Btu/hr Models...

  • Page 64: Wiring Diagram

    Hydronic Heating Boilers and Domestic Water Heaters WIRING BOX CONNECTIONS - WIRING DIAGRAM A 399,999 - 750,000 BTU/HR MODELS LIMITS R/BK PR/BK R/BK BR/W BL/BK...
  • Page 65 Installation and Service Manual LADDER DIAGRAM 399,999 - 750,000 BTU/HR MODELS...
  • Page 66 Hydronic Heating Boilers and Domestic Water Heaters WIRING BOX CONNECTIONS - WIRING DIAGRAM B 399,999 - 750,000 BTU/HR MODELS...
  • Page 67 Installation and Service Manual WIRING BOX CONNECTIONS - WIRING DIAGRAM B (CONTINUED) 399,999 - 750,000 BTU/HR MODELS...
  • Page 68 Hydronic Heating Boilers and Domestic Water Heaters LADDER DIAGRAM 990,000 - 2,070,000 BTU/HR MODELS...
  • Page 69 WIRING DIAGRAM A 990,000 - 2,070,000 BTU/HR MODELS O/BK R/BK R/BK BR/W O/BK Installation and Service Manual O.C. G ND BOARD RELAY ADDED ALARM UNLESS CONNECTED...
  • Page 70 Hydronic Heating Boilers and Domestic Water Heaters WIRING BOX CONNECTIONS - WIRING DIAGRAM B CONNECTIONS 990,000 - 2,070,000 BTU/HR MODELS...
  • Page 71 Installation and Service Manual DIAGRAM B CONNECTIONS 990,000 - 2,070,000 BTU/HR MODELS (CONTINUED)
  • Page 72 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.

This manual is also suitable for:

999 - 750Cf-ch(e)-i&s-08500,000750,000990,0001,260,000 ... Show all

Table of Contents