Manuals / Lochinvar / Household Appliance / Water Heater

Lochinvar 999 - 750, CF-CH(E)-i&s-08, 399 service manual CF-CHE-i&s-08 1/09

Models: 399 CF-CH(E)-i&s-08 999 - 750

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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. 54 (page 53) and edits made to the scald warnings.

CF-CH(E)-i&s-08

1/09

Page 72

Image 72

Lochinvar 999 - 750, CF-CH(E)-i&s-08, 399 service manual CF-CHE-i&s-08 1/09

Contents

INSTALLATION AND SERVICE MANUAL Save this manual for future referenceWHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Immediately call your gas supplier from aTable of Contents Hydronic Heating Boilers and Domestic Water HeatersTable of Contents Programming Temperature Control Quick Programming OverviewWarranty GENERAL PRODUCT INFORMATIONSpecial Instructions CodesSAFETY INFORMATION DANGER Carbon Monoxide poisoning may lead to deathHydronic Heating Boilers and Domestic Water Heaters PRODUCT IDENTIFICATION Front View Rear View FIG. 1 Front and Rear ViewInstallation and Service Manual INSTALLATION LOCATING UNITClearances from Combustible Construction Right SideOutdoor Boiler Installation LocationFREEZE PROTECTION Pump OperationINSTALLATION Continued Shut-Down and DrainingFreeze Protection for a Heating Boiler System if required COMBUSTION AND VENTILATION AIRFIG. 5 Moving Air Filter/Bracket Assembly from Rear of Unit to Side Combustion Air Options1. Outside Combustion Air, No Ducts FIG. 4 Metal Panel Covering Side Combustion Air Inlet2. Outside Combustion Air, Using Ducts 3. Outside Combustion Air - Using Direct VentingFIG. 7 Outside Combustion Air - Two Openings 4. Combustion Air from Interior SpaceVENTING Exhaust FansGeneral Information Vertical Vent Termination Clearances and LocationSidewall Vent Termination Clearances and Location FIG. 11 Vent Termination from Peaked Roof More Than 10’ From RidgeFIG. 12 Vent Termination from Flat Roof 10’ or Less from Parapet Wall INSTALLATION ContinuedCombustion Air Inlet Piping Length of Air Inlet PipeSidewall Air Inlet FIG. 14 Sidewall Combustion Air InletContinued Vertical Rooftop Air InletFIG. 15 Air Inlet Cap for Sidewall Termination FIG. 16 Roof Top Combustion Air InletVent System Options Combined Air Inlet PointsBarometric Damper Location 1. Conventional Negative Draft Venting Negative DraftFlue Outlet Piping INSTALLATION Continued2. Vertical DirectAire Venting Vertical Vent Termination Clearances and LocationInstallation and Service Manual INSTALLATION Continued Vent Kits Venting of Flue ProductsFIG. 19 Air Inlet Cap for Sidewall Termination Hydronic Heating Boilers and Domestic Water Heaters3. Sidewall Venting Sidewall FanSidewall Venting Termination Sidewall Venting Without FanDrain Tee Installation Venting GuidelinesFIG. 22 Sidewall Vent INSTALLATION ContinuedMasonry Chimney Installation 4. Horizontal DirectAire VentingInstallation and Service Manual Sidewall Vent Termination Clearances and LocationVent Kits 5. Direct VentingINSTALLATION Continued Hydronic Heating Boilers and Domestic Water HeatersVertical DV Venting Termination Installation and Service ManualDrain Tee Installation Masonry Chimney InstallationConnecting the Air Inlet Pipe to the Unit Horizontal DV Venting TerminationHorizontal Vent Termination Clearances and Location Flue Pipe MaterialsFIG. 25 Moving Air Filter Assembly and DV Box Adapter Air Inlet Piping MaterialsSealing Type-B Double-Wall Vent Pipe or Galvanized Vent Pipe Sealing PVC, CPVC, ABS, Dryer Vent, and Flex Duct Vent Pipe6. Outdoor Installation Venting Multiple Sidewall Direct Vent Installations6 MAXIMUM Vertical Combustion Air Inlet ClearancesFIG. 27 Outdoor Vent Cap Installed on Rear of Unit Outdoor Vent/Air Inlet LocationThe Outdoor Vent Cap Kit Installation and Service ManualCONNECTING TO GAS SUPPLY Connecting Gas Piping to UnitGas Piping Gas Pressure TestGas Train and Controls FIG. 28 Gas Line ConnectionFIG. 29 Typical Boiler Gas Train Drawing TABLE-JCombination Gas Valves Checking Gas Supply PressureVenting of Combination Gas Valves INSTALLATION ContinuedGas Manifold Pressure Adjustment TABLE - L Multiple Unit Installations Gas Supply Pipe SizingFIG. 30 Measuring Gas Supply Pressure at Combination Gas Valve Installation and Service ManualCONNECTING TO WATER SUPPLY Inlet and Outlet ConnectionsRetain this cap for future use FIG. 31 Measuring Manifold Gas PressureCONNECTING TO ELECTRICAL SUPPLY Water Flow SwitchRelief Valve Low Water CutoffBOILER SYSTEM PIPING TABLE-N AMP Draw DataGeneral Plumbing Rules Water Connections Heating Boilers OnlyHeat Exchanger Pressure Drop Chart Circulator Pump SpecificationsPump Installation and Maintenance FIG. 34 Pressure Drop Chart 399,999 - 750,000Low Temperature Return Water Systems Table - O LTV Valve KitsInput LTV Valve Kit Btu/hr 399,999 - 750,000VAL3048 990,000 - 2,070,000 VAL3047TABLE-P System Temperature Rise Chart Based on Btu/hr Input Radiant Floor and Snow Melt Heating Systems10ºF 20ºFTemperature/Pressure Gauge Boiler Flow RatePlacing the Boiler in Operation Boiler Bypass RequirementsInstallation with a Chilled Water System Boiler Operating Temperature ControlFIG. 41 Installation with a Chilled Water System Installation and Service ManualWATER TREATMENT Terminal Strip Connection OptionsINSTALLATION Continued Hydronic Heating Boilers and Domestic Water HeatersFOR YOUR SAFETY READ BEFORE OPERATING OPERATIONFigure 42C Figure 42BFIG. 43 Control Panel Cover FIG. 44 ON/OFF Switch OPERATION ContinuedLIGHTING INSTRUCTIONS WHAT TO DO IF YOU SMELL GAS Do not try to light any appliancePower Up PROGRAMMING TEMPERATURE CONTROLQuick Programming Overview To Turn Off Gas To ApplianceAdjust Menu Setting Descriptions TABLE-Q Adjust Menu Settings for Operating ModesTABLE-R View Menu Information Menu DescriptionAdjust Menu FIG. 48 Adjust MenuIgnition Systems and Stages Operating ModesAccess Levels Temperature ControlPlacement of Sensors FIG. 49 User Access Level Dip Switch LocationGraphic Symbols SettingsFIG. 50 Graphic Symbols Staging LogicProgramming For Mode 2, Water Heating Operation Programming For Mode 3, Sequenced OperationRemote Mounting of Sensors TABLE-S Programming WorksheetError and Warning Messages TABLE-T Remote Wire ConnectionHOT SURFACE IGNITION SYSTEM Hot Surface Igniter and Ignition Control ModuleDiagnostic Status Indication Access to Internal Control PanelIgnition Control Diagnostic Codes Removing the Control PanelOPERATION AND DIAGNOSTIC LIGHTS Time Delay Between Stages 1&2 and 3&4Pump Delay Timing Status LED Diagnostic CodesRequired Temperature Rise Temperature Rise ChartDOMESTIC WATER HEATERS Water Velocity ControlPipe Size Requirements Circulating PumpTABLE-X FIG. 54 Typical Water Heater Piping with Storage TankPotable Hot Water Temperature Control Settings Domestic Water TemperaturesDOMESTIC WATER HEATERS ContinuedHigh Water Temperature Limit Control Optional Relief ValveThermal Expansion Location of Cold Water Supply Piping ConnectionsCLEANING AND MAINTENANCE Flue Gas Passageways Cleaning ProceduresBurner Removal and Cleaning Appliance AreaHeat Exchanger Cleaning Fan CleaningCombustion Air Fan Adjustment ElectricalCLEANING AND MAINTENANCE Continued Adjusting Differential Air PressureFIG. 56 Adjusting Air Shutter 399,999 - 750,000 Btu/hr Models FIG. 58 Adjusting Air Shutter 990,000 - 2,070,000 Btu/hr ModelsPOWER SUPPLY ON/OFF ROCKER SWITCHSEQUENCE OF OPERATION Servicing Hot Surface Igniter and Ignition ModuleMANUAL RESET HIGH-LIMIT THERMOSTAT SAFETY DEVICE TERMINALSELECTRONIC TEMPERATURE CONTROLLER PRESSURE SWITCHIGNITION HEAT TRANSFER PROCESSPOST-PURGE IDLETROUBLESHOOTING GUIDE 399,999 - 750,000 Btu/hr Models Hydronic Heating Boilers and Domestic Water HeatersStep StepTROUBLESHOOTING GUIDE 990,000 - 2,070,000 Btu/hr Models Installation and Service ManualStep StepWIRING BOX CONNECTIONS - WIRING DIAGRAM ADomestic Water Heaters Hydronic Heating BoilersLADDER DIAGRAM 399,999 - 750,000 BTU/HR MODELS LBL20008 REV AInstallation and Service Manual SCHEMATIC DIAGRAMHydronic Heating Boilers and Domestic Water Heaters Installation and Service Manual LADDER DIAGRAM 990,000 - 2,070,000 BTU/HR MODELS LBL20012 REV AHydronic Heating Boilers and Domestic Water Heaters 120 VAC 15AMPSWIRING DIAGRAM MODELSCONNECTOR CONNECTION DIAGRAM AHydronic Heating Boilers and Domestic Water Heaters DIAGRAM B CONNECTIONS 990,000 - 2,070,000 BTU/HR MODELS CONTINUEDCF-CHE-i&s-08 1/09