Lochinvar 801, 400 operation manual Contents

Page 2

Contents

HAZARD DEFINITIONS

2

PLEASE READ BEFORE PROCEEDING

3

THE KNIGHT XL -- HOW IT WORKS

4-6

RATINGS

7

1. DETERMINE BOILER LOCATION

 

Provide Air Openings to Room

10

Flooring and Foundation

10

Residential Garage Installation

10

Vent and Air Piping

10

Prevent Combustion Air Contamination

10

Corrosive Contaminants and Sources

11

Using an Existing Vent System to Install a New Boiler

... 11

Removing a Boiler from Existing Common Vent

12

2. PREPARE BOILER

 

Remove Boiler from Wood Pallet

13

Gas Conversions

13

Model 400

13

Model 501

14

Models 601 - 801

14

Leveling the Boiler

14

3. GENERAL VENTING

 

Direct Venting Options

15-16

Install Vent and Combustion Air Piping

17

PVC/CPVC Vent Piping Materials

17

Requirements for Installation in Canada

17

Installing Vent or Air Piping

17-18

PVC/CPVC Air Intake/Vent Connections

18

Air Inlet Pipe Materials

19

Stainless Steel Air Intake/Vent Connections

20

Min./Max. Combustion Air & Vent Piping Lengths

21

Vent and Air Piping

21

Optional Room Air

21-22

4. SIDEWALL DIRECT VENTING

 

Vent/Air Termination - Sidewall

23-26

Determine Location

23-25

Prepare Wall Penetrations

25-26

Termination and Fittings

26

Multiple Vent/Air Terminations

26

Sidewall Termination - Optional Concentric Vent

27-29

5. VERTICAL DIRECT VENTING

 

Vent/Air Termination - Vertical

30-31

Determine Location

30

Prepare Roof Penetrations

31

Termination and Fittings

31

Multiple Vent/Air Terminations

31

Vertical Termination - Optional Concentric Vent ... 32-33

Alternate Vertical Concentric Venting

34-35

6. HYDRONIC PIPING

 

System Water Piping Methods

36

Low Water Cutoff Device

36

Chilled Water System

36

Freeze Protection

36

General Piping Information

36

Flow Switch and Relief Valve Installation

37

Flow Switch Adjustment

38

Near Boiler Piping Components

38-39

Circulator Sizing

39

Near Boiler Piping Connections

39

7. GAS CONNECTIONS

 

Connecting Gas Supply Piping

46

Natural Gas

47

Pipe Sizing for Natural Gas

47

Natural Gas Supply Pressure Requirements

............. 47

Propane Gas

47

Pipe Sizing for Propane Gas

47

Propane Supply Pressure Requirements

47

Check Inlet Gas Supply

48

Gas Pressure

49

Gas Valve Replacement

49

8. FIELD WIRING

 

Line Voltage Connections

50

Low Voltage Connections

50

Wiring of the Cascade

52

9. CONDENSATE DISPOSAL

 

Condensate Drain

54

10. STARTUP

55-60

11. OPERATING INFORMATION

 

General

61

Cascade

64

Sequence of Operation

65-66

Knight XL Control Module

67-68

Status Display Screens

69-71

12. MAINTENANCE

 

Maintenance and Annual Startup

72-76

13. DIAGRAMS

 

Wiring Diagram

77

Ladder Diagram

78

Revision Notes

Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

￿DANGER

￿WARNING

￿CAUTION CAUTION NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

2

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Contents Models 400 Contents When servicing boiler Please read before proceedingKnight XL How it works Stainless steel heat exchangerModel Models 601 Ratings Knight XL Boiler =B=R RatingDetermine boiler location Installation must comply withCloset and alcove installations Before locating the boiler, checkAlcove Installation Vent and air piping Residential garage installationProvide air openings to room Flooring and foundationAreas likely to have contaminants When using an existing vent system to install a new boilerProducts to avoid When removing a boiler from existing common vent system Gas conversions Model Prepare boilerRemove boiler from wood pallet Models 601 Leveling the boilerGeneral venting Direct venting options Vertical Vent Installing vent or air piping Install vent and combustion air pipingRequirements for installation in Canada General ventingPVC/CPVC air intake/vent connections Vent Pipe, and FittingsAir inlet pipe materials Stainless steel ventFasNSeal Saf-T Vent Stainless Steel Air Intake/vent ConnectionsOptional room air Removing from existing ventModel Description Kit Number Air contaminationVent/air termination sidewall If using the alternate sidewall terminationSidewall direct venting Determine location3AClearance to Gravity Air Inlets Prepare wall penetrations Bird Screen TypicalTermination and fittings Prepare wall penetrations Alternate Field Supplied OptionMultiple vent/air terminations Sidewall termination installation Description and usage9Concentric Vent Dimensional Drawing Models 400 11Concentric Vent Sidewall Attachment Multiventing sidewall terminationsVertical direct venting Vent/air termination verticalPrepare roof penetrations Multiple vent/air terminationsVertical termination installation 4Concentric Vertical TerminationMultiventing vertical terminations Mm see -9,Alternate vertical concentric venting Concentric Venting ArrangementExisting vent as a chase 10Existing Vent as a ChaseLow water cutoff device Hydronic pipingSystem water piping methods General piping information Chilled water systemHydronic piping Flow switch adjustment Near boiler piping componentsVariable speed pump option Near boiler piping connectionsCirculator sizing 20F 25F 30F 35F Model Head FeetPressure 7Single Boiler Multiple Temperatures 8Single Boiler Primary/Secondary Piping Number of Units Manifold Pipe Sizes in Inches mm10Multiple Boilers Primary/Secondary Piping Loop Connecting gas supply piping Gas connectionsNatural gas Propane GasCheck inlet gas supply InchesGas valve replacement Gas PressureLine voltage connections Field wiringInstallation must comply with Low voltage connectionsHigh gas pressure switch Outdoor temperature sensorLouver proving switch Low gas pressure switchWiring of the cascade Flow switchAlarm contacts ModbusManual Condensate disposal Condensate drainCheck/control water chemistry Freeze protection when usedStart-up Fill and test water systemInspect/fill condensate system Check for gas leaksCheck thermostat circuits Inspect/check condensate lines and fittingsIf boiler does not start correctly Final checks before starting the boilerStart the boiler Check system and boilerFor Your Safety Read Before Operating Set space heating operation Natural Gas PropaneConfiguration of the cascade Verify DHW modeSet domestic hot water DHW operation Operating information GeneralProtection features Boiler temperature regulation Outdoor reset operation, if used CascadeSequence of operation Operation DisplayStandby, ready to start a new cycle Knight XL control module Navigation DialUser Access modesInstaller Call for Heat Information Dial Function Instructions Maintenance Maintenance and annual startupService technician Clean condensate trap Check all piping for leaks MaintenanceAddress reported problems Inspect boiler areaCheck expansion tank Flue vent system and air pipingCheck water system Check boiler relief valveCheck control settings Check ignition ground wiringCheck all boiler wiring Inspect ignition and flame sense electrodesReview with owner Check flame signalCleaning boiler heat exchanger Model Kit Part Component Number DescriptionDiagrams LOW Voltage 120 VAC High Voltage2Ladder Diagram Page KBXII-I-O Rev D
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400, 801 specifications

The Lochinvar 801,400 is a cutting-edge solution in the realm of high-efficiency commercial water heating. This model represents a significant advancement in the design and functionality of water heaters, catering primarily to the demands of large-scale facilities like hotels, hospitals, and large industrial operations.

One of the standout features of the Lochinvar 801,400 is its impressive heating capacity, which can produce up to 801,400 BTUs, making it suitable for high-demand applications. This output is crucial for establishments that require a consistent supply of hot water, such as commercial kitchens and laundry facilities. The robust design ensures that it can handle peak demand periods without compromising performance.

Another significant aspect is the innovative use of advanced technology in its operation. The Lochinvar 801,400 integrates smart controls that enhance its efficiency and ease of operation. These controls allow for precise monitoring and adjustment of water temperatures, ensuring that the system operates within optimal parameters while maximizing energy savings. The intelligent monitoring system can provide real-time updates, making it easier for facility managers to keep track of performance and address maintenance needs proactively.

The construction of the Lochinvar 801,400 incorporates durable materials that not only enhance the longevity of the unit but also offer resistance to corrosion and wear. This durability translates into lower maintenance costs and an extended lifespan for the unit, making it a worthwhile investment for businesses.

Moreover, the Lochinvar 801,400 is designed with energy efficiency in mind. It boasts a high thermal efficiency rating, which reduces operational costs and minimizes the carbon footprint of heating operations. This efficiency is critical in today’s environmentally conscious market, where businesses are seeking to reduce their energy consumption and comply with strict regulations.

The design of the Lochinvar 801,400 also prioritizes safety, featuring innovative safety controls and fail-safes that protect both the unit and the users.

In summary, the Lochinvar 801,400 offers a combination of high capacity, advanced technology, durability, and energy efficiency, making it an excellent choice for commercial water heating solutions. As industries continue to evolve, the demand for reliable and efficient water heating solutions like the Lochinvar 801,400 will only increase.