Lochinvar 801, 400 Hydronic piping, System water piping methods General piping information

	Installation & Operation Manual
6 Hydronic piping
System water piping methods	General piping information

The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

It is important to note that the boiler has a minimal amount of pressure drop which must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation or basic service of circulator replacement, valves, and others.

Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

￿WARNING Use only inhibited propylene glycol solutions, which are specifically formulated

for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

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Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-7 through 6-11), which will guide you through the installation of the Knight XL (reference FIG.’s 6-4A and 6-4B).

1.Connect the system return marked “Inlet”.

2.Connect the system supply marked “Outlet”.

3.Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4.Install a backflow preventer on the cold feed make-up water line.

5.Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).

6.Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7.Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8.Install an air elimination device on the system supply.

9.Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi (103 kPa).

10.This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

￿ WARNING The relief valve, tee and any other necessary fittings are shipped in the install kit with the

boiler and are to be field installed (FIG.’s 6-1 and 6-2).

11.On any pre-existing system, it is good practice to install a field supplied strainer to prevent damage to the heat exchanger.

See the piping illustrations included in this section, FIG.’s 6-7 and 6-11 for suggested guidelines in piping the Knight XL.

NOTICE	Please note that these illustrations are
	meant to show system piping concept only,
	the installer is responsible for all equipment
	and detailing required by local codes.