Lochinvar 399 operation manual Hazard definitions, Danger, Caution Caution Notice, Contents

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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