Lochinvar WH 55-399 operation manual Contents

Page 2
￿ DANGER
￿ WARNING
￿ CAUTION
CAUTION
NOTICE
2

Contents

HAZARD DEFINITIONS

. . . 2

PLEASE READ BEFORE PROCEEDING

. . . 3

THE KNIGHT WALL MOUNT BOILER-- HOW IT WORKS . 4-5

RATINGS

. . . 6

1. DETERMINE BOILER LOCATION

 

Provide Clearances

. . . 7

Provide Air Openings to Room

. . . 9

Wall Mounting Location

. . 9

Residential Garage Installation

. . . 9

Vent and Air Piping

. . . 9

Prevent Combustion Air Contamination

. . . 9

Corrosive Contaminants and Sources

. . 10

Using an Existing Vent System to Install a New Boiler

. . 10

Removing a Boiler from Existing Common Vent

. . 11

2. PREPARE BOILER

 

Remove Boiler from Wood Pallet

. . 12

Gas Conversions

. . 12

Mounting the Boiler

. . 13

3. GENERAL VENTING

 

Direct Venting Options

14

Install Vent and Combustion Air Piping

15

Requirements for Installation in Canada

16

Sizing

16

Materials

17

Optional Room Air

18

PVC/CPVC

19

Polypropylene

20

Stainless Steel Vent

21

4. SIDEWALL DIRECT VENTING

 

Vent/Air Termination - Sidewall

22-28

Determine Location

22-24

Prepare Wall Penetrations

24

Multiple Vent/Air Terminations

25

Sidewall Termination - Optional Concentric Vent

26-28

5. VERTICAL DIRECT VENTING

 

Vent/Air Termination - Vertical

29-30

Determine Location

29

Prepare Roof Penetrations

29

Multiple Vent/Air Terminations

30

Vertical Termination - Optional Concentric Vent ...

30-31

Alternate Vertical Concentric Venting

32

6. HYDRONIC PIPING

System Water Piping Methods. . . . . . . . . . . . . . . . . . . . . 33

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chilled Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Freeze Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 33

Near Boiler Piping Components. . . . . . . . . . . . . . . . . . . . 34

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . . 35

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Variable Speed Pump Option . . . . . . . . . . . . . . . . . . . . . 37

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 48

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 49

Natural Gas Supply Pressure Requirements . . . . . . . 49

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 49

Propane Supply Pressure Requirements . . . . . . . . . . 49

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 51

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-63

11. OPERATING INFORMATION

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 68-69

Knight Wall Mount Boiler Control Module . . . . . . . . . . . . 70

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . 71-73

12. MAINTENANCE

Maintenance and Annual Startup. . . . . . . . . . . . . . . . 74-77

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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 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 WH 55 Contents Boiler operation When servicing boilerPlease read before proceeding Boiler waterKnight Wall Mount Boiler How it works Stainless steel heat exchangerModels 55 Ratings Knight Wall Mount Boiler Ahri RatingDetermine boiler location Installation must comply withCloset and alcove installations Before locating the boiler, check1Closet Installation Minimum Required Clearances Wall mounting location PrecautionsVent and air piping Prevent combustion air contaminationAreas 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 Prepare boilerRemove boiler from wood pallet Mounting to a concrete wall Mounting the boilerMounting to a wood studded wall Mounting to a metal studded wallGeneral venting Direct venting options Sidewall VentInstall vent and combustion air piping Air intake/vent connectionsModel Kit Number Equivalent Vent Length Requirements for installation in CanadaSizing Model Max Vent AirMaterials Air inlet pipe materialsOptional room air Air contaminationVent pipe Approved PVC/CPVC Vent Pipe and FittingsMaterial Standard Vent fittingsCentrotherm InnoFlue SW Duravent Polypro ModelPolypropylene Stainless steel vent Vent/air termination sidewall If using the alternate sidewall terminationSidewall direct venting Determine location2AClearance to Gravity Air Inlets Model Air Vent Centerline Width Prepare wall penetrationsPrepare wall penetrations Alternate Field Supplied Option Multiple vent/air terminationsDescription and usage Sidewall termination installationSidewall termination optional concentric vent 92 and 3 Concentric Vent Dimensional Drawing reference D on Sidewall termination optional concentric vent models12Concentric Vent Sidewall Attachment Multiventing sidewall terminationsPrepare roof penetrations Vertical direct ventingVent/air termination vertical Vertical termination installation Vertical termination optional concentric ventMultiventing vertical terminations Minimum Combustion AIR TypicalConcentric Venting Arrangement Alternate vertical concentric ventingVent / Air Inlet Size Minimum Existing Vent / Chase Size Existing vent as a chaseLow water cutoff device Hydronic pipingSystem water piping methods General piping information Chilled water systemNear boiler piping components Near boiler piping connections Circulator sizing35F Temperature Rise Applications 20F Temperature Rise Applications25F Temperature Rise Applications Pump Size GrundfosVariable speed pump option Smart System / Multi-temperature loop control optionVariable speed pump setup 3Single Boiler Primary / Secondary Piping Make UP Water Indirect Number of Units Boiler Member 8Single Boiler Multiple Temperature DHW Priority Model Required Pipe Sizes Boiler Make UP Boiler Connecting gas supply piping Gas connectionsNatural gas Propane GasLength of Pipe in Straight Feet for 1/2 PSI Natural Gas Pipe Capacity ChartCheck inlet gas supply Gas valve replacement Gas PressureLine voltage connections Field wiringInstallation must comply with Low voltage connections Flow switch Outdoor temperature sensorLouver proving switch ThermostatSystem supply sensor Alarm contactsWiring of the cascade Boiler management systemInstallation FieldwiringCondensate disposal Condensate drainCheck/control water chemistry Freeze protection when usedStart-up Fill and test water systemCheck thermostat circuits Clean/Inspect Trap AssemblyCheck for gas leaks Inspect/fill condensate system Inspect/check condensate lines and fittingsIf boiler does not start correctly Final checks before starting the boilerStart the boiler Check system and boiler2Operating Instructions Models 55 Operating Instructions Model Set space heating operation Natural Gas PropaneSet domestic hot water DHW operation Verify DHW modeConfiguration of the cascade Operating information GeneralProtection features Boiler temperature regulation Outdoor reset operation, if used CascadeSequence of operation Operation DisplayUser Access modesInstaller Knight wall mount boiler control module 1Control PanelCall for Heat Information Dial Function Owner maintenance Maintenance Maintenance and annual startupService technician See the following pages for instructions GeneralMaintenance Check control settings Check ignition ground wiringCheck all boiler wiring Flue vent system and air pipingPerform start-up and checks Check flame signalCleaning boiler heat exchanger Check burner flameDiagrams PC Interface2Wiring Diagram
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