Instruction/ maintenance manual of the product 800 Lochinvar
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Inst allation & Operation Manual Models: 399 - 800 T h i s ma n u a l m u s t o n l y b e u s ed b y a qualified heating installer / serv ice technician. Read all instructions, including this manual and the Knight XL Serv ice M anual, befor e installing.
2 Contents Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention t o the presence of hazards of various r isk level s or to important information concerning the life of the product.
Installation & Operation Manual Please r ead bef or e proceeding Installer – R ead all instructions, including this manual and the Knight XL Serv ice M anual, befor e installing. P erform steps in the order give n. Us e r – This manual is for use only by a qualified heating installer/serv ice technician.
Installation & Operation Manual 4 T he Knight XL - How it w or ks... 1. Stainless steel heat exc hanger Allows system wat er to flow through specially designed coils for maximum heat transfer , while pro viding protection against flue gas c orrosion.
Installation & Operation Manual Front View - Model 399 4 5 25 30 23 20 28 13 29 14 8 7 27 36 Left Side (inside unit) - Model 399 19 21 16 1 3 34 17 26 2 37 Right Side (inside unit) - Model 399 T he Knight XL - How it w or ks... (continued) Rear View - Model 399 5 Model 399 10 24 32 18 11 6 15 33 22 31 36.
Installation & Operation Manual 6 T he Knight XL - How it w or ks... 18 15 27 Rear View - Model 500 27 15 18 Rear View - Models 600 - 800 Left Side (inside unit) - Models 600 - 800 Left Side (insi.
Installation & Operation Manual Ra tings Notes: 1. The ratings are based on standard test pr ocedures prescribed by the U nited States Depart ment of Energ y . 2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup.
8 Installation & Operation Manual The Knight XL gas manifold and contr ols met safe lighting and other performance criteria when the boiler under went tests specified in ANSI Z21.
9 Installation & Operation Manual 1 Deter mine boiler location (continued) 12" (305 MM) LEFT 13" (330 MM) TOP 1" (25 MM) MINIMUM CLEARANCE AROUND HOT W A TER PIPES AND VENT PIPE 14&.
10 Installation & Operation Manual 1 Deter mine boiler location Provide air openings to room: Knight XL alone in boiler room 1. No air v entilation openings into the boiler room are needed when clearances around the K night XL are at least equal to the SER VICE clear ances sho w n in FIG.
11 Installation & Operation Manual Product s to avoid: Spray cans containing c hloro/fluorocarbons P ermanent wave solutions Chlorinated waxes/cleaners Chlorine-based sw imming pool chemicals Calc.
Installation & Operation Manual 1 Deter mine boiler location 12 W hen removing a boiler from e xisting common v ent system: Do not install the Knight XL into a common v ent w ith an y other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury , death, or substantial property damage.
Installation & Operation Manual 2 Prepar e boiler 13 R emov e boiler fr om wood pallet 1. After remo ving the outer shipping car ton fr om the boiler , remo ve the parts box. 2. Remo ve the front door t o access the lag bolts in front of the unit (FIG.
Installation & Operation Manual 2 Prepar e boiler 14 SCREWDRIVER SLOT LOWER RAISE Figure 2-5 Leveling Legs on the Boiler Le veling the boiler 1. Set the boiler in place and check level. a) Adjust legs if necessary to level boiler , see FIG. 2-5 below .
Installation & Operation Manual 15 PVC/CPVC T wo Pipe See Figure 4-1A Models 399 - 600 Only PVC/CPVC Alternate T wo Pipe See Figure 4-2A Stainless S teel Alternate T wo Pipe See Figure 4-2B Stainl.
Installation & Operation Manual 16 Direct venting options - V er tical V ent, Sidewall Air 3 Gener al venting Direct venting options - V er tical V ent PVC/CPVC T wo Pipe See Figure 5-1A Stainless.
Installation & Operation Manual 17 3 Gener al venting (continued) PV C/CPV C vent piping ma terials U se only the materials listed in T able 3A (pg. 18) for v ent pipe, and fittings. Failure to comply c ould result in sever e personal injur y , death, or substantial pr oper ty damage.
Installation & Operation Manual 18 3 Gener al venting 6. Priming and Cementing: a. Handle fittings and pipes carefully t o prevent contamination of surfaces. b. A pply a liberal e ven c oat of primer to the fitting socket. c. Apply a liberal even coat of pr imer to the pipe end to appro ximately 1/2" beyond the sock et depth.
Installation & Operation Manual 19 3 Gener al v enting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe mat er ials from the .
Installation & Operation Manual 20 3 Gener al venting Figure 3-12 Near Boiler S tainless S teel V enting Models 700 - 800 4" S.S. ADAPTER VENT 4" S.
Installation & Operation Manual 21 Model Kit Number Equivalent V ent Length 399 CVK3007 5 Feet (1.5 m) 500 CVK3007 30 Feet (9 m) 600 CVK3007 30 Feet (9 m) 3 Gener al venting (continued) V ent, air piping and termination: The Knight XL vent and air piping can be installed thr ough the roof or through a sidewall.
Installation & Operation Manual 22 3 Gener al v enting If the boiler combustion air inlet is located in a laundry room or pool facility , for example, these areas w ill alwa ys contain hazardous contaminants.
Installation & Operation Manual 23 4 Sidewall direct v enting V ent/air ter mination – sidew all Follo w instructions below when determining vent location t o av oid possibility of severe personal injury , death, or substantial property damage.
Installation & Operation Manual 12" (305 MM) MIN 15" (381 MM) M AX 12" (305 MM) MI N FROM BOILER VENT PIPE CONNECTION TO BOILER INT AKE AIR CONNECTION BIRD SCREEN Figure 4-1C Altern.
Installation & Operation Manual 25 12” (305 MM) MIN BIRD SCREEN (TYPICAL) 12” (305 MM) MIN 12” (305 MM) MIN Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings 36” (914 MM) MIN 7’ (2.
Installation & Operation Manual 26 4 Sidewall direct v enting SIDEWALL TERMINA TION PLA TE VENT PIPING GAL V ANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES) ELBOW ELBOW AIR PIPING BIRD SCREEN BIRD SCREEN Figure 4-5B A T ypical Sidewall T ermination Assembly - Models 399 - 800 PVC/CPVC or S tainless S teel T er mination and fittings 1.
Installation & Operation Manual 27 4 Sidewall direct v enting (continued) 4" (102 MM) DIA. 6" (152 MM) DIA. RAIN CAP "Y" CONCENT RIC FITTING "FLEXIBLE" PIPE COUPLING 6" (152 MM) DIA.
Installation & Operation Manual 28 4 Sidewall direct v enting Sidewall ter mination – optional concentric v ent: Models 399 - 600 Only Figure 4-9 Concentric V ent Dimensional Drawing - Models 39.
Installation & Operation Manual 29 4 Sidewall direct v enting (continued) Sidewall ter mination – optional concentric v ent: Models 399 - 600 Only Multiventing sidewall terminations W hen two (2) or more direct v ent appliances are v ented near each other , eac h appliance must be individually vent ed (see FIG.
Installation & Operation Manual 30 5 V er tical dir ect v enting V ent/air ter mination – v er tical Follo w instructions below when determining vent location t o av oid possibility of severe personal injury , death or substantial property damage.
Installation & Operation Manual 31 5 V er tical dir ect v enting (continued) V ent/air ter mination – v er tical Prepar e roof penetr ations 1. Air pipe penetr ation: a. Cu t a hole for the air pipe. Siz e the air pipe hole as close as desired to the air pipe outside diamet er .
Installation & Operation Manual 32 5 V er tical dir ect v enting V er tical ter mina tion – optional concentric vent: Models 399 - 600 Only Description and usage Lochin var offers an optional concentric combustion air and vent pipe t ermination kit.
Installation & Operation Manual 33 5 V er tical dir ect v enting (continued) V er tical ter mina tion – optional concentric vent: Models 399 - 600 Only ELBOW (FIELD SUPPLIED) SUPPORT (FIELD SUPP.
Installation & Operation Manual 34 6 Hy dr onic piping System wa ter piping methods The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kP a). A temperature and pr essure gauge is included to monitor system pressur e and outlet temperature and should be located on the boiler outlet.
Installation & Operation Manual 35 RELIEF V AL VE TEE WITH 3/4” FITTING ON TOP CLOSE NIPPLE (FIELD PROVIDED) CLOSE NIPPLE TEE WITH FITTING ON TOP (FIELD PROVIDED) TEMPERA TURE AND PRESSURE GAUGE.
Installation & Operation Manual 36 6 Hy dr onic piping Near boiler piping connections Y-STRAINER (RECOMMENDED) BOILER PUMP INDIRECT DOMESTIC HOT WATER TANK SYSTEM PUMP TO FLOOR DRAIN TO FROM FROM .
Installation & Operation Manual 37 6 Hy dr onic piping (continued) Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500 T able 6B Sizing Information for T emperature Rise Applications_20°F , 25°F , 30°F and 35°F Figure 6-6 Pressure Drop vs.
Installation & Operation Manual 38 6 Hy dr onic piping It is requir ed that near boiler piping systems utilize Primary/Secondar y configurations as shown in FIG.
Installation & Operation Manual 39 6 Hy dr onic piping (continued) EXP ANSION T ANK AIR SEP ARA TOR PRESSURE REDUCING V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TY PICAL) PRESSURE R.
Installation & Operation Manual 40 EXP ANSION TA N K AIR SEP ARA TOR PRESSURE RE DUCING V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VA LV E FLOW CHECK V AL V.
Installation & Operation Manual 41 7 Gas connections Connecting gas supply piping 1. Re move the top ac cess panel and refer t o FIG. ’ s 7-1 thr u 7-3 to pipe gas to the boiler . a. Install ground joint union for serv icing, when requ ired . b.
Installation & Operation Manual 42 7 Gas connections Failure t o apply pipe sealing compound as detailed in this manual can result in severe personal injury , death, or substantial property damage. U se two wrenches when tightening gas piping at boiler (FIG.
Installation & Operation Manual 43 Nominal Iron Pipe Size (inches) Natural Gas Pipe Cap acity Chart Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 14 Inches Wa t e r C o l u m n (0.5 PSIG) or less and a pressure drop of 0.
Installation & Operation Manual 44 W ARNING When re-tightening the set scr ew , be sur e to tighten securely t o prevent gas leaks. Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury , death, or substantial property damage.
Installation & Operation Manual 45 8 Field wiring ELECTRICAL SHOCK HAZARD – For your safety , turn off electrical power supply before making an y electr ical connections t o avoid possible electric shock hazard. Failure to d o so can cause severe personal injury or death.
Installation & Operation Manual 46 Low v olta ge connections 1. Route all lo w voltage wires through the knock outs in the rear of the boiler , as sho wn in FIG. 8-2. 2. Connect lo w voltage wir ing to the lo w voltage connection board as sho w n in FIG.
Installation & Operation Manual 47 8 Field wiring (continued) System supply sensor 1. By installing the system supply sensor into the supply of the primar y loop, the temperature of the system supply can be contr olled.
Installation & Operation Manual 48 8 Field wiring AU X. D EVIC E PILOT SUPPL Y 24V A C GND AU X. D EVIC E PROVING GAS PRESSURE SWITCH FLOW SWITCH A LARM CONT A C TS RU NTIME CONT A C TS SYSTEM SEN.
Installation & Operation Manual 49 9 Condensa te disposal Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) PV C union for connection of a 1/2 inch (12.7 mm) PV C pipe (FIG.
Installation & Operation Manual 50 10 Star t-up Check/control wa ter chemistr y Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gask ets in the system could oc cur , resulting in substantial property damage.
Installation & Operation Manual 51 10 Star t-up (continued) Check f or gas leaks Before starting the boiler , and during initial operation, smell near the floor and around the boiler for gas odorant or an y unusual odor . R emov e the top access panel and smell the interior of the boiler enclosure.
Installation & Operation Manual 52 10 Star t-up Final chec ks before star ting the boiler Read the K night XL Ser vice Manual t o familiar ize yourself w ith SMAR T SYSTEM control module operation. R ead this manual, page 53 for proper steps to start boiler .
Installation & Operation Manual 53 FOR YOUR SAFETY READ BEFORE OPERA TING W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury , or loss of life. A. This appliance does not have a pilot.
Installation & Operation Manual 54 10 Star t-up Check flame and combustion (continued) 4. Place the boiler into the acti ve position by pr essing the SHUTDO WN button on the display board (FIG. 11-1, page 61) until BLR:Standby appears in the display window .
Installation & Operation Manual 55 Set domestic hot wa ter (DHW) oper ation V erify DHW circulator mode The DHW M ode is progr ammed to heat an indir ect domestic hot water tank. W hen the tank thermostat calls for heat, the SMAR T SYSTEM contr ol w ill turn on the DHW pump and turn off the boiler pump (if running).
Installation & Operation Manual 56 General How the boiler operates The Knight XL uses an advanced stainless st eel heat exc hanger and electronic contr ol module that allows fully condensing operation. The blo wer pulls in air and pushes flue products out of the boiler through the heat ex changer and flue piping.
Installation & Operation Manual 57 11 Oper a ting infor mation (continued) Ramp delay For syst ems w ith low er flow , the SMAR T SYSTEM can limit the firing rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat t o a space heating call for heat.
Installation & Operation Manual 58 11 Oper a ting infor mation High limit operations W hen outlet temperature ex ceeds 200°F (93.3°C), hig h limit action occurs. The boiler shuts down until the outlet water cools down. Low water cutoff protection 1.
Installation & Operation Manual 59 11 Oper a ting infor mation (continued) Cascade (continued) If the water temperature at the system supply sensor is less than the set point + the turn-off offset.
Installation & Operation Manual 60 11 Oper a ting infor mation Sequence of oper a tion OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pump s (system and boiler pumps for sp ace heating call; DHW pump for DHW call).
Installation & Operation Manual 61 11 Oper a ting infor mation (continued) Knight XL control module • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level in Menu M.
Installation & Operation Manual 62 Access modes User The user can adjust space heating target temperatur e by using the UP and DO WN buttons (FIG. 11-1) at an y time during normal oper ation. By entering the USER code (0704), the user can also change temperature units, time and date, and nig ht setback settings.
Installation & Operation Manual 63 11 Oper a ting infor mation (continued) Status Display Screens By using the Pr ev ious/N ext ( , ) arrow k eys on the SMART SY STEM display panel, you can navigate thr ough the eig ht (8) display scr eens.
Installation & Operation Manual 64 Status Display Screens (cont ’ d) By using the Pr ev ious/N ext ( , ) arrow k eys on the SMART SY STEM display panel, you can navigate thr ough the eig ht (8) display scr eens. Each scr een w ill co ntain two (2) viewable items.
Installation & Operation Manual 65 11 Oper a ting infor mation (continued) Status Display Screens (cont ’ d) By using the Pr ev ious/N ext ( , ) arrow k eys on the SMART SY STEM display panel, you can navigate thr ough the eig ht (8) display scr eens.
Installation & Operation Manual 66 Status Display Screens (cont ’ d) Operation of the cascade The boiler designated as the Leader will have tw o additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade.
Installation & Operation Manual 67 Maintenance and annual star tup T able 12A Service and Maintenance Schedules Ser vice technician (see the following p ages for instructions) General: • Address.
Installation & Operation Manual 68 12 Maintenance Follo w the Ser vice and maintenance pr ocedures giv en throughout this manual and in component literatur e shipped with the boiler . Failure to perform the serv ice and maintenanc e could result in damage to the boiler or system.
Installation & Operation Manual 69 12 Maintenance (continued) Flue vent system and air piping 1. Visually inspect the entire flue gas v enting system and air piping for blockage, deterioration or leakage. R epair any joints that show signs of leakage.
Installation & Operation Manual 70 12 Maintenance Inspect ignition and flame sense electrodes 1. R emov e the ig nition and flame sense electrodes fr om the boiler heat ex changer access c over . 2. R emov e any deposits accumulat ed on the ignition/flame sense electrode using sandpaper .
Installation & Operation Manual 71 12 Maintenance (continued) Check flame signal 1. A t high fire the flame signal shown on the display should be at least 10 microamps. 2. A lo wer flame signal may indicate a fouled or damaged flame sense electrode.
Installation & Operation Manual 72 Figure 13-1 Wiring Diagram 13 Diag r ams DISPLA Y X1-8 X5-5 X5-13 X5-6 X5-12 INTEGRA TED CONTROL BLOW ER X1-1 X2-2 X2-1 X1-7 GAS VA LV E FLAME ROD SP ARK ROD W/ .
Installation & Operation Manual 73 Figure 13-2 Ladder Diagram BOX DEPICTS OPTIONAL ITEMS LADDER D IAGRAM LBL2356 REV C 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPL Y "L" ON / OFF SWIT.
Notes.
Notes.
Revision Notes: Revision B (ECO #C02407) reflects gas valve adjustment, room air , new sidewall vent termination, piping diagrams, flow switch, relief valve, T & P gauge, Maintenance Section, FIG .
An important point after buying a device Lochinvar 800 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lochinvar 800 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lochinvar 800 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar 800 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar 800 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar 800, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lochinvar 800.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar 800. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar 800 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
