Lochinvar 400-801 Start-up, Check/control water chemistry, Freeze protection when used

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7 Start-up

Check/control water chemistry

￿CAUTION Do not use petroleum-based cleaning or sealing compounds in the boiler system.

Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

Hardness less than 7 grains

1.Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1.Do not fill boiler or operate with water containing chlorine in excess of 200 ppm.

2.Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3.Do not use the boiler to directly heat swimming pool or spa water.

Test/replace freeze protection fluid

1.For systems using freeze protection fluids, follow fluid manufacturer’s instructions.

2.Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.

Freeze protection (when used)

1.Determine freeze protection fluid quantity using system water content, following fluid manufacturer’s instructions. Boiler water content is listed on page 7. Remember to include expansion tank water content.

2.Local codes may require a backflow preventer or actual disconnect from city water supply.

3.When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

4.The freeze protection set points may be lowered when freeze protection fluid is used (see the Outdoor Knight XL Service Manual).

Fill and test water system

1.Fill system only after ensuring the water meets the requirements of this manual.

2.Close manual and automatic air vents and boiler drain valve.

Outdoor Knight XL Installation & Operation Manual

3.Fill to correct system pressure. Correct pressure will vary with each application.

a.The minimum cold water fill pressure for a commercial system is 12 psi (82.7 kPa).

b.Pressure will rise when boiler is turned on and system water temperature increases.

4.At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

￿WARNING Eliminate all system leaks. Continual fresh makeup water will reduce boiler life.

Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Purge air from water system

1.Purge air from system:

a.Connect a hose to the purge valve (see purge/drain valves, in piping diagrams on page 22). Route the hose to an area where water can drain and be seen.

b.Close the boiler or system isolation valve between the purge valve and fill connection to the system.

c.Close zone isolation valves.

d.Open quick-fill valve on cold water makeup line.

e.Open purge valve.

f.One zone at a time, open the isolation valves. Allow water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g.Close the quick-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h.After the system has operated for a while, eliminate any residual air by using the manual air vents located throughout the system.

i.If purge valves are not installed in the system, open the manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.

2.Open automatic air vent (diaphragm-type or bladder- type expansion tank systems only) one turn.

3.Open other vents:

a.Starting on the lowest floor, open air vents one at a time until water squirts out.

b.Repeat with remaining vents.

4.Refill to correct pressure.

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Contents Outdoor Knight XL Models 400 Contents Please read before proceeding When servicing boilerStainless steel heat exchanger Outdoor Knight XL How it worksModel Models 601 Outdoor Knight XL Boiler Ahri Rating RatingsInstallation must comply with Determine boiler locationBefore locating the boiler, check Outdoor vent / air intake location Provide clearancesFlooring and foundation Prevent combustion air contaminationInstall flue pipe assembly Models 400 Prepare boilerRemove boiler from wood pallet Models 701 3Install flue pipe assembly Models 701Gas conversions Model 4Installing Propane Orifice ModelLeveling the boiler Models 601Hydronic piping TEE with 1 Fitting on TOP Nipple Close Nipple Near boiler piping components Flow switch adjustmentNear boiler piping connections Circulator sizingVariable speed pump option Head Feet Pressure20F 25F 30F 35F Model 7Single Boiler Multiple Temperatures 8Single Boiler Primary/Secondary Piping Manifold Pipe Sizes in Inches mm Number of Units10Multiple Boilers Primary/Secondary Piping Temperature Wires to Loop Sensors 120VAC to Gas connections Connecting gas supply pipingPropane Gas Natural gasInches Check inlet gas supplyGas pressure Gas valve replacementInstallation must comply with Field wiringLine voltage connections Low voltage connectionsHigh gas pressure switch Outdoor temperature sensorLow gas pressure switch ThermostatAlarm contacts Flow switchWiring of the cascade ModBus3Low Voltage Field Wiring Connections Condensate drain Condensate disposalStart-up Freeze protection when usedCheck/control water chemistry Fill and test water systemCheck thermostat circuits Check for gas leaksInspect/fill condensate system Inspect/check condensate lines and fittingsStart the boiler Final checks before starting the boilerIf boiler does not start correctly Check system and boilerFor Your Safety Read Before Operating Natural Gas Propane Set space heating operationVerify DHW mode Set domestic hot water DHW operationConfiguration of the cascade General Operating informationHow the boiler operates How the control module operatesProtection features Temperature controlBoiler temperature regulation Cascade Outdoor reset operation, if usedOperation Display Sequence of operationStandby, ready to start a new cycle Installer Access modesOutdoor Knight XL control module UserCall for Heat Information Dial Function Maintenance Maintenance and annual startup Service technicianOwner maintenance Maintenance Check water system Flue vent system and air pipingCheck expansion tank Check boiler relief valveCheck all boiler wiring Check ignition ground wiringCheck control settings Inspect ignition and flame sense electrodesCleaning boiler heat exchanger Check flame signalReview with owner Model Kit Part Component Number DescriptionHigh Voltage Diagrams2Ladder Diagram
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Manual 48 pages 50.5 Kb

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.
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