Instruction/ maintenance manual of the product 801 Lochinvar
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Installation & Operation Manual Models: 400 - 801 This manual must only be used by a qualifi ed heating installer / service technician. Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given.
2 Contents Hazard de fi nitions The following defi ned 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.
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician.
4 The Knight XL - How it works... 1. Stainless steel heat exchanger Allows system water to fl ow through specially designed coils for maximum heat transfer, while providing protection against fl ue gas corrosion. The coils are encased in a jacket that contains the combustion process.
Front View - Model 400 27 35 8 7 20 13 28 23 14 29 25 4 5 37 38 Left Side (inside unit) - Model 400 19 21 36 16 1 3 17 33 26 2 Right Side (inside unit) - Model 400 The Knight XL - How it works.
6 The Knight XL - How it works... 18 15 27 39 Rear View - Model 501 27 15 18 39 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801 Left Side (inside unit) - Model 501 Model 501 Mo.
Ratings Notes: 1. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 2. Net I=B=R ratings are based on net installed radiation of suffi cient quantity for the requirements of the building and nothing need be added for normal piping and pickup.
8 The Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specifi ed in ANSI Z21.13 – latest edition.
9 1 Determine boiler location (continued) ALCOVE INST ALLA TION OPEN FRONT 1/4" (6 MM) MIN IMU M C LEARA NCE AROUND HO T WA T ER PIPES 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE 18" (45.
10 1 Determine boiler location Provide air openings to room: Knight XL alone in boiler room 1. No air ventilation openings into the boiler room are needed when clearances around the Knight XL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2.
11 Products to avoid: Spray cans containing chloro/fl uorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium c.
1 Determine boiler location 12 When removing a boiler from existing common vent system: Do not install the Knight XL into a common vent with any other appliance. This will cause fl ue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
2 Prepare boiler 13 Remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1). 3. To remove the boiler from the pallet (after removing the front door): a.
2 Prepare boiler 14 SCREWDRIVER SLOT LOWER RAISE Figure 2-5 Leveling Legs on the Boiler Leveling the boiler 1. Set the boiler in place and check level. a) Adjust legs if necessary to level boiler, see FIG. 2-5 below. ALLEN WRENCH ADJUSTMENT SCREW Figure 2-3 Gas Valve Adjustment - Model 501 Model 501 1.
15 PVC/CPVC Two Pipe See Figure 4-1A PVC/CPVC Alternate Two Pipe See Figure 4-2A Stainless Steel Alternate Two Pipe See Figure 4-2B Stainless Steel Two Pipe See Figure 4-1C PVC/CPVC Concentric See Fig.
16 Direct venting options - Vertical Vent, Sidewall Air 3 General venting Direct venting options - Vertical Vent PVC/CPVC Two Pipe See Figure 5-1A Stainless Steel Two Pipe See Figure 5-1B PVC/CPVC Con.
17 3 General venting (continued) PVC/CPVC vent piping materials Use only the materials listed in Table 3A (pg. 18) for vent pipe, and fi ttings. Failure to comply could result in severe personal injury, death, or substantial property damage. Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.
18 3 General venting 6. Priming and Cementing: a. Handle fi ttings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fi tting socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth.
19 3 General venting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: PVC, CPVC or ABS Dryer V.
20 3 General venting Figure 3-12 Near Boiler Stainless Steel Venting Models 701 - 801 4" S.S. ADAPTER VENT 4" S.S. INTERMEDIATE (FOR SAF-T VENT ONLY ) Figure 3-11 Near Boiler Stainless Steel.
21 Model Kit Number Equivalent Vent Length 400 CVK3007 5 Feet (1.5 m) 501 CVK3007 30 Feet (9 m) 601 CVK3007 30 Feet (9 m) 3 General venting (continued) Vent, air piping and termination: The Knight XL vent and air piping can be installed through the roof or through a sidewall.
22 3 General venting If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants. To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 11 before installing the boiler or air inlet piping.
23 4 Sidewall direct venting Vent/air termination – sidewall Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.
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 GRADE OR SNOW LINE Figure 4-1C Alternate Stainless Ste.
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.
26 4 Sidewall direct venting SIDEWALL TERMINA TION PLATE VENT PIPING GAL VANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES) ELBOW ELBOW AIR PIPING BIRD SCREEN BIRD SCREEN Figure 4-5B A Typical Sidewall Termination Assembly - Models 400 - 801 PVC/CPVC or Stainless Steel Termination and fi ttings 1.
27 4 Sidewall direct venting (continued) 4" (102 MM) DIA. 6" (152 MM) DIA. RAIN CAP "Y" CONCENT RIC FITTING "FLEXIBLE" PIPE COUPLING 6" (152 MM) DIA. 6" (152 MM) DIA. 6" (152 MM) TO 4" (102 MM) R E DUCER Figure 4-8 Kit Contents_CVK3007 - Models 400 - 601 Sidewall termination installation 1.
28 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 400 - 601 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 601 Instead of cementing the smaller.
29 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 400 - 601 Only Multiventing sidewall terminations When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG.
30 5 Vertical direct venting Vent/air termination – vertical Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.
31 5 Vertical direct venting (continued) Vent/air termination – vertical Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a.
32 5 Vertical direct venting Vertical termination – optional concentric vent: Models 400 - 601 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit.
33 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 400 - 601 Only ELBOW (FIELD SUPPLIED) SUPPORT (FIELD SUPPLIED) ROOF BOOT / FLASHING (FIELD SUPPLIED) VENT COMBUSTI ON AIR VENT 12" (305 MM) ( 18" (457 MM) F OR CAN ADA ) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIP A TED SNOW LEVEL.
34 5 Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.
35 5 Vertical direct venting (continued) Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths.
36 6 Hydronic piping System water piping methods The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.
37 RELIEF V ALVE FLOW SWITCH P ADDLE TEMPERA TURE AND PRESSURE GAUGE TEE WITH FITTING ON TOP (FIELD PROVIDED) CLOSE NIPPLE (FIELD PROVIDED) TEE WITH 1” FITTING ON TOP CLOSE NIPPLE TEE WITH 3/4” FI.
6 Hydronic piping Figure 6-3 Flow Switch Adjustment Flow switch adjustment Refer to Table 6A for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a Phillips driver until it stops (FIG.
39 6 Hydronic piping (continued) Near boiler piping connections Y -ST RAINER (RECOMMENDED) BOILER PUMP INDIRECT DOMESTIC HOT WA TER T ANK SYSTEM PUMP TO FLOOR DRAIN T O F R O M F R O M S Y S T E M T O.
40 Figure 6-5 Pressure Drop vs. Flow - Models 400 and 501 Table 6B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F Figure 6-6 Pressure Drop vs.
41 6 Hydronic piping (continued) EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE C.
42 6 Hydronic piping EXP ANSION T ANK AIR SEP ARA TOR PRESSURE RE DUCI NG V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VA LV E FLOW CHECK V AL VE (T YPICAL) INDIR.
43 6 Hydronic piping (continued) EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (T YPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE .
44 6 Hydronic piping EX PAN SIO N TANK AIR SEPARATOR PRESSURE REDU CING V ALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRECT D HW T.
45 6 Hydronic piping (continued) EX PANSION TANK AIR SEPARATOR PRESSURE REDUCIN G VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE.
46 7 Gas connections Connecting gas supply piping 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the boiler. a . Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements.
47 7 Gas connections (continued) Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Use two wrenches when tightening gas piping at boiler (FIG. 7-4), using one wrench to prevent the boiler gas line connection from turning.
48 Nominal Iron Pipe Size (inches) Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on NAT GAS, 1025 Btu/ hr per Cubic Foot of Gas and 0.
49 WARNING When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open fl ame -- 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.
50 8 Field wiring ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.
51 8 Field wiring (continued) Thermostat 1. Connect the room thermostats or end switches (isolated contact only) to room thermostat 1, 2, or 3, as shown in FIG. 8-3. 2. Install the thermostat on the inside wall away from infl uences of drafts, hot or cold water pipes, lighting fi xtures, television, sunlight, or fi replaces.
52 8 Field wiring Modbus When the optional ModBus interface module is installed, the RS-485 ModBus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module.
53 8 Field wiring (continued) LOUVER RE LA Y FLOW SW ITCH TA N K T H E R M O S TAT ROOM T HERMO STA T 3 SYSTEM SUPPL Y SENSOR BUIL DI NG MAN AG EME NT SYSTEM LOUVER PROVING SW ITCH COM NO LOW W A TER .
54 9 Condensate disposal Condensate drain 1. This boiler is a high effi ciency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) PVC union for connection of a 1/2 inch (12.7 mm) PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing fi lter.
55 10 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1.
56 10 Start-up Check for gas leaks Before starting the boiler, and during initial operation, smell near the fl oor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak.
57 10 Start-up (continued) Final checks before starting the boiler Read the Knight XL Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, page 58 for proper steps to start boiler. Verify the boiler and system are full of water and all system components are correctly set for operation.
58 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. It is equipped with an ignition device which automatically lights the burner .
59 10 Start-up (continued) Check fl ame and combustion (continued) 4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 67). 5. Locate the pinhole button below the RESET button on the display board (FIG.
60 Set domestic hot water (DHW) operation Verify DHW mode There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point.
General How the boiler operates The Knight XL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes fl ue products out of the boiler through the heat exchanger and fl ue piping.
62 11 Operating information Ramp delay For systems with lower fl ow, the SMART SYSTEM can limit the fi ring rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat to a space heating call for heat.
63 11 Operating information (continued) Monitor external limits Connections are provided on the connection board for external limits such as fl ow switch, low water cutoff, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open.
64 11 Operating information Outdoor reset operation, if used Target temperature with outdoor reset This feature improves the system’s effi ciency as the outdoor temperature warms up. See the Knight XL Service Manual to change the settings. Reset curve The reset curves look at outdoor air temperature and adjusts the set points.
65 11 Operating information (continued) Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW).
66 OPERATION DISPLAY 8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on fi rst, then the boiler pump will turn off 2 seconds later.
67 11 Operating information (continued) Knight XL control module NA VIGA TION DIAL Figure 11-1 Control Panel Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
68 Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “ SETPOINTS” is fl ashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 60).
69 11 Operating information (continued) Status Display Screens Section Display Description A (Boiler Status Bar) STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat. START The unit has begun a burn cycle and is checking all safety circuits.
70 11 Operating information Status Display Screens (cont’d) Section Display Description C (Operational Information) SYSTEM: The temperature read by the system supply sensor (if connected). TANK: The temperature read by the tank sensor (if connected).
71 11 Operating information (continued) Status Display Screens (cont’d) Section Display Description E (NAVIGATION Dial Function) Turning the NAVIGATION dial will select the next or previous Status Screen. Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.
72 Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior;.
73 12 Maintenance (continued) Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.
74 12 Maintenance Flue vent system and air piping 1. Visually inspect the entire fl ue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.
75 AIR ARM SCREW S (QTY . 5) GASKET BURNER Figure 12-4 Burner Assembly - Models 601 - 801 12 Maintenance (continued) Inspect ignition and fl ame sense electrodes 1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover.
76 12 Maintenance Check fl ame signal 1. At high fi re the fl ame signal shown on the display should be at least 10 microamps. 2. A lower fl ame signal may indicate a fouled or damaged fl ame sense electrode.
77 Figure 13-1 Wiring Diagram 13 Diagrams X1- 7 OR OR BR PR OR BR BR PR PR CN2-4 CN2- 1 CN1-5 CN1-6 CN1-3 CN1-4 CN1-1 CN1- 2 K1 K2 K3 RELAY BOARD ON/OF F SW ITCH JUNCTION BOX BK W 1 2 3 4 5 G R R W 3.
Figure 13-2 Ladder Diagram BOX DEPICTS OPTION AL ITEMS LADDER DIAGRAM LBL20141 REV C 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPLY "L" ON / OFF SWITCH X1-6 X1-2 F2 NEUTRAL TERMINA L S TRI.
Notes 79 Installation & Operation Manual.
Revision Notes: Revision A (ECO #C05747) initial release. Re fl ects the new model numbers for the Knight XL upgrade. Revision B (ECO #C0 6188) re fl ects changes made to FIG.
An important point after buying a device Lochinvar 801 (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 801 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 801 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar 801 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar 801 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar 801, 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 801.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar 801. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar 801 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
