Table Of Contents; Hazard Definitions - Lochinvar 400 Installation & Operation Manual

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 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Model 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Models 601 - 801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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
DANGER
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
WARNING
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
CAUTION
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
CAUTION
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
NOTICE
related to personal injury or property damage.
2
Contents
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 31
Vertical Termination - Optional Concentric Vent . . . . 32-33
Alternate Vertical Concentric Venting . . . . . . . . . . . . 34-35
6. HYDRONIC PIPING
System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 36
Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 36
Flow Switch and Relief Valve Installation . . . . . . . . . . . . 37
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . 38
Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 38-39
Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 39
7. GAS CONNECTIONS
Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 46
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 47
Natural Gas Supply Pressure Requirements . . . . . . . 47
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 47
Propane Supply Pressure Requirements . . . . . . . . . . 47
Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 49
8. FIELD WIRING
Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9. CONDENSATE DISPOSAL
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-60
11. OPERATING INFORMATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 65-66
Knight XL Control Module . . . . . . . . . . . . . . . . . . . . . . . . 67-68
Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 69-71
12. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 72-76
13. DIAGRAMS
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover