Lochinvar 400-801 operation manual Contents

Page 2

Contents

HAZARD DEFINITIONS

2

Pipe Sizing for Natural Gas

25

PLEASE READ BEFORE PROCEEDING

3

Natural Gas Supply Pressure Requirements

............. 25

THE OUTDOOR KNIGHT XL -- HOW IT WORKS

4-6

Propane Gas

25

RATINGS

7

Pipe Sizing for Propane Gas

25

1. DETERMINE BOILER LOCATION

 

Propane Supply Pressure Requirements

25

Flooring and Foundation

9

Check Inlet Gas Supply

26

Prevent Combustion Air Contamination

9

Gas Pressure

27

Corrosive Contaminants and Sources

9

Gas Valve Replacement

27

2. PREPARE BOILER

 

5. FIELD WIRING

 

Remove Boiler from Wood Pallet

10

Line Voltage Connections

28

Install Flue Pipe Assembly

10-11

Low Voltage Connections

28-29

Gas Conversions

12

Wiring of the Cascade

30

Model 400

12

6. CONDENSATE DISPOSAL

 

Model 501

13

Condensate Drain

32

Models 601 - 801

13

7. STARTUP

33-38

Leveling the Boiler

13

8. OPERATING INFORMATION

 

3. HYDRONIC PIPING

 

General

39

System Water Piping Methods

14

Cascade

42

Low Water Cutoff Device

14

Sequence of Operation

43-44

Chilled Water System

14

Outdoor Knight XL Control Module

45

Freeze Protection

14

Status Display Screens

46-48

General Piping Information

14

9. MAINTENANCE

 

Flow Switch and Relief Valve Installation

15

Maintenance and Annual Startup

49-53

Flow Switch Adjustment

16

10. DIAGRAMS

 

Circulator Sizing

17

Wiring Diagram

54

4. GAS CONNECTIONS

 

Ladder Diagram

55

Connecting Gas Supply Piping

24

Revision Notes

Back Cover

Natural Gas

25

 

 

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 Outdoor Knight XL Models 400 Contents When servicing boiler Please read before proceedingOutdoor Knight XL How it works Stainless steel heat exchangerModel Models 601 Ratings Outdoor Knight XL Boiler Ahri RatingBefore locating the boiler, check Installation must comply withDetermine boiler location Flooring and foundation Provide clearancesOutdoor vent / air intake location Prevent combustion air contaminationRemove boiler from wood pallet Install flue pipe assembly Models 400Prepare boiler 3Install flue pipe assembly Models 701 Models 7014Installing Propane Orifice Model Gas conversions ModelModels 601 Leveling the boilerHydronic piping TEE with 1 Fitting on TOP Nipple Close Nipple 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 Temperature Wires to Loop Sensors 120VAC to 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 connectionsLow gas pressure switch Outdoor temperature sensorHigh gas pressure switch ThermostatWiring of the cascade Flow switchAlarm contacts ModBus3Low 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 Verify DHW modeSet domestic hot water DHW operation How the boiler operates Operating informationGeneral How the control module operatesTemperature control Protection featuresBoiler temperature regulation Outdoor reset operation, if used CascadeSequence of operation Operation DisplayStandby, ready to start a new cycle Outdoor Knight XL control module Access modesInstaller UserCall for Heat Information Dial Function Owner maintenance Maintenance Maintenance and annual startupService technician Maintenance Check 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
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400-801 specifications

The Lochinvar 400-801 is a high-efficiency commercial boiler that embodies advanced engineering and cutting-edge technology. Designed for a variety of commercial applications, this boiler is known for its reliability, efficiency, and robust performance.

One of the standout features of the Lochinvar 400-801 is its high thermal efficiency, which can reach up to 99%. This efficiency not only reduces fuel consumption but also lowers operating costs, making it an economical choice for businesses seeking to minimize overhead. The boiler employs a stainless steel fire-tube heat exchanger that ensures optimal heat transfer and durability. This construction allows for enhanced resistance to corrosion, thereby extending the boiler's lifespan.

The Lochinvar 400-801 is equipped with advanced control technologies that enhance its performance. With its built-in SMART SYSTEM control, users can easily monitor and manage the boiler’s operations, optimizing performance while ensuring ease of use. This control system features a user-friendly interface that provides real-time data, including temperature settings, pressure readings, and operational status, allowing for quick diagnostics and efficient troubleshooting.

Safety is paramount in the design of the Lochinvar 400-801. The boiler includes a comprehensive safety system that incorporates multiple safety interlocks and a venting system that prevents backflow and ensures safe exhaust. Moreover, the unit is designed to operate with minimal noise, making it suitable for environments where noise reduction is crucial.

Installation and maintenance of the Lochinvar 400-801 are straightforward, thanks to its compact design and multiple venting options. The low-profile construction allows for flexibility in placement, making it an ideal fit for tight spaces. Maintenance tasks are simplified with accessible components, minimizing downtime and ensuring the system operates efficiently over its lifespan.

In conclusion, the Lochinvar 400-801 stands out in the commercial boiler market with its blend of efficiency, reliability, and innovation. With its advanced technologies and features, businesses can achieve significant energy savings while ensuring comfortable and consistent heat for various applications. The Lochinvar 400-801 is an investment in quality and performance, backed by a well-established brand in the heating industry. Whether for a new installation or a replacement, this boiler offers a comprehensive solution for commercial heating needs.