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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Lochinvar 800 operation manual Contents

800 specifications

Lochinvar 800 is a groundbreaking boiler system designed to meet the heating needs of modern residential and commercial buildings. Renowned for its reliability and advanced technology, the Lochinvar 800 promises efficiency and performance that set it apart from conventional heating systems.

One of the standout features of the Lochinvar 800 is its high-efficiency heat exchanger, which enables significantly lower energy consumption compared to traditional units. This efficiency translates to substantial energy savings, making it not only an environmentally friendly choice but also a cost-effective one. The system boasts an impressive thermal efficiency rating, often exceeding 95%, which ensures that a large portion of the energy consumed is converted into usable heat.

Incorporating cutting-edge control technologies, the Lochinvar 800 utilizes smart controls that enable precise temperature regulation. These controls provide users with the ability to program and adjust settings according to specific heating needs, enhancing comfort while minimizing energy waste. The integration of modulating gas burners further optimizes energy usage, continuously adjusting the output based on the current demand, thereby preventing energy loss.

Another key characteristic of the Lochinvar 800 is its compact and sleek design, allowing for easy installation in various spaces, from utility rooms to commercial settings. The boiler's lightweight construction means that it can be mounted in tight areas, providing flexibility that adapts to the needs of the installation site.

Safety features are a top priority for the Lochinvar 800, equipped with advanced diagnostics and monitoring systems that ensure trouble-free operation. These systems continually assess performance and identify potential issues before they can evolve into serious problems, promoting longevity and reliability.

The Lochinvar 800 is also compatible with various heating distribution systems, including radiant floor heating and traditional radiators, making it a versatile choice for a wide range of applications. Coupled with its low emissions profile, the Lochinvar 800 stands out as a sustainable option in today’s market.

In summary, the Lochinvar 800 represents a new era in boiler design, merging efficiency, innovative technology, and adaptability to meet the challenges of contemporary heating needs. Its advanced features ensure optimal performance while maintaining a commitment to environmental responsibility, making it an ideal solution for energy-conscious consumers.