Lochinvar 399 operation manual Contents

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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 399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Model 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Models 600 - 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 34

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 34

Flow Switch and Relief Valve Installation . . . . . . . . . . . . 35

Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . 36

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 36

Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 38

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 41

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 42

Natural Gas Supply Pressure Requirements . . . . . . . 42

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 42

Propane Supply Pressure Requirements . . . . . . . . . . 42

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 44

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 45

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 46

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9. CONDENSATE DISPOSAL

 

Condensate Drain

49

10. STARTUP

50-55

11. OPERATING INFORMATION

 

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-59

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Knight XL Control Module . . . . . . . . . . . . . . . . . . . . . . . . 61-62

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 63-66

12. MAINTENANCE

 

Maintenance and Annual Startup

67-71

13. DIAGRAMS

 

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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.

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Contents Models 399 Save this manual for future referenceContents When servicing boiler Please read before proceedingKnight XL How it works Air pressure switch Pump relay board ModelModels 600 Ratings Knight XL Boiler =B=R RatingDetermine boiler location Installation must comply withCloset and alcove installations Before locating the boiler, checkFor closet installations, Cpvc or TOPVent 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 Model Prepare boilerRemove boiler from wood pallet Gas conversionsLeveling the boiler Models 600General venting Direct venting options Vertical Vent Installing vent or air piping Install vent and combustion air pipingRequirements for installation in Canada General ventingMake PVC/CPVC air intake/vent connectionsApproved Stainless Steel Vent Manufacturers Air 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 399 11Concentric Vent Sidewall Attachment Multiventing sidewall terminationsVertical direct venting Vent/air termination verticalPrepare roof penetrations 2Vertical Terminations with Multiple BoilersVertical termination installation 4Concentric Vertical TerminationMultiventing vertical terminations Mm see -9,Hydronic piping Hydronic piping Circulator sizing Flow switch adjustmentNear boiler piping connections 20F 25F 30F 35F Head FeetPressure 399 500 600 700 800Near boiler piping components 7Single Boiler Primary/Secondary Piping Number of Units Model Manifold Pipe Sizes in Inches mm Connecting gas supply piping Gas connectionsNatural gas Propane GasIron Pipe Nominal Natural Gas Pipe Capacity ChartCheck inlet gas supply Length of Pipe in Straight FeetGas valve replacement Gas PressureLine voltage connections Field wiringInstallation must comply with High gas pressure switch Outdoor temperature sensorAuxiliary device proving switch Low gas pressure switchSystem supply sensor Alarm contactsWiring of the cascade Boiler management system3Low Voltage Field Wiring Connections 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 Set domestic hot water DHW operationOperating information GeneralProtection features Cascade Boiler temperature regulationOutdoor reset operation, if used DHW, Night Setback, and Ramp Delay operation with Cascade Sequence of the cascadeSequence of operation BLR IgnitionKnight XL control module ShutdownUser Access modesInstaller To save parameters and exit programmingSet Point Met ServiceStandby PrepurgeSYS ***.*F Control will display the actual fan motor RPMDelay 10V in **.VdcOperation of the cascade Owner maintenance 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 High Voltage2Ladder Diagram Page Page KBX-I-O Rev H
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Manual 72 pages 15.81 Kb

399 specifications

Lochinvar 999 - 750, CF-CH(E)-i&s-08,399 is a cutting-edge boiler designed for commercial heating applications. With its robust construction and high efficiency, this model stands out in the crowded market of heating solutions.

One of the main features of the Lochinvar 999 - 750 is its exceptional thermal efficiency rating. The unit incorporates advanced condensing technology that allows it to recover heat from flue gases, which helps in achieving efficiency levels of up to 99%. This efficiency not only reduces energy consumption but also lowers operational costs, making it an excellent investment for businesses looking to minimize their carbon footprint.

The boiler is designed to provide a powerful output of 750 kW, ensuring it meets the heating demands of larger buildings or commercial spaces. Its capacity makes it suitable for a range of applications including schools, hospitals, and industrial facilities. Moreover, the unit features a built-in cascading system that enables multiple boilers to be connected, enhancing system reliability and flexibility.

In terms of technology, the Lochinvar 999 - 750 is equipped with a user-friendly touchscreen interface. This innovative control system allows operators to monitor and adjust settings with ease, providing real-time performance data and alerts for maintenance needs. The intelligent controls optimize operation to match the heating load, further enhancing energy efficiency.

Safety is a top priority with this model. It is built with multiple safety features such as automatic shut-off valves, pressure relief valves, and flame monitoring systems, ensuring safe operation under various conditions. The unit also adheres to stringent industry standards and regulations, making it a reliable choice for commercial applications.

Furthermore, the Lochinvar 999 - 750 is designed with serviceability in mind. Its compact footprint and accessible components simplify maintenance, reducing downtime and associated costs. The unit also supports a variety of fuel sources, including natural gas, propane, and biodiesel, providing flexibility to meet different facility requirements.

In summary, the Lochinvar 999 - 750, CF-CH(E)-i&s-08,399 represents a blend of efficiency, reliability, and safety in commercial heating. Its advanced technologies and thoughtful design make it a powerful solution for various heating needs, making it an ideal choice for businesses aiming for excellence in energy management and operational efficiency.
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