Lochinvar KNIGHT 399 User Manual

Installation & Operation ManualModels: 399 - 800This manual must only be used by aqualified heating installer / servicetechnician. Read all instr

10Installation & Operation Manual1 Determine boiler locationProvide air openings to room:Knight XL alone in boiler room1. No air ventilation open

11Installation & Operation ManualProducts to avoid:Spray cans containing chloro/fluorocarbonsPermanent wave solutionsChlorinated waxes/cleanersChl

Installation & Operation Manual1 Determine boiler location12When removing a boiler from existingcommon vent system:Do not install the Knight XL i

Installation & Operation Manual2 Prepare boiler13Remove boiler from wood pallet1. After removing the outer shipping carton from the boiler,remove

Installation & Operation Manual2 Prepare boiler14SCREWDRIVERSLOTLOWERRAISEFigure 2-5 Leveling Legs on the BoilerLeveling the boiler1. Set the boi

Installation & Operation Manual15PVC/CPVC Two PipeSee Figure 4-1AModels 399 - 600 OnlyPVC/CPVC AlternateTwo PipeSee Figure 4-2AStainless Steel Alt

Installation & Operation Manual16Direct venting options - Vertical Vent, Sidewall Air3 General venting Direct venting options - Vertical VentPVC/

Installation & Operation Manual173 General venting (continued)PVC/CPVC vent piping materialsUse only the materials listed in Table 3A(pg. 18) for

Installation & Operation Manual183 General venting 6. Priming and Cementing:a. Handle fittings and pipes carefully to prevent contamination of su

Installation & Operation Manual193 General venting (continued)Air inlet pipe materials:The air inlet pipe(s) must be sealed. Choose acceptableco

2ContentsHazard definitionsThe following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk l

Installation & Operation Manual203 General venting Figure 3-12 Near Boiler Stainless Steel Venting Models700 - 8004" S.S. ADAPTERVENT4"

Installation & Operation Manual21Model Kit NumberEquivalentVent Length 399 CVK3007 5 Feet (1.5 m)500 CVK3007 30 Feet (9 m)600 CVK3007 30 Feet (9

Installation & Operation Manual223 General ventingIf the boiler combustion air inlet islocated in a laundry room or poolfacility, for example, th

Installation & Operation Manual234 Sidewall direct ventingVent/air termination – sidewallFollow instructions below whendetermining vent location

Installation & Operation Manual12" (305 MM) MIN15" (381 MM) MAX12" (305 MM) MINFROM BOILERVENT PIPECONNECTIONTO BOILERINTAKE AIRCON

Installation & Operation Manual2512” (305 MM)MINBIRDSCREEN(TYPICAL)12” (305 MM)MIN12” (305 MM)MINFigure 4-3B Alternate Clearance to Gravity AirInl

Installation & Operation Manual264 Sidewall direct venting SIDEWALLTERMINATION PLATEVENTPIPINGGALVANIZEDTHIMBLE (WHEN REQUIRED BY LOCAL CODES)EL

Installation & Operation Manual274 Sidewall direct venting (continued)4" (102 MM) DIA.6" (152 MM) DIA.RAIN CAP"Y" CONCENTRICF

Installation & Operation Manual284 Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 OnlyFigure 4-9 Con

Installation & Operation Manual294 Sidewall direct venting (continued)Sidewall termination – optional concentric vent: Models 399 - 600 OnlyMulti

Installation & Operation ManualPlease read before proceedingInstaller – Read all instructions,including this manual and the Knight XLService Manua

Installation & Operation Manual305 Vertical direct ventingVent/air termination – verticalFollow instructions below whendetermining vent location

Installation & Operation Manual315 Vertical direct venting (continued)Vent/air termination – vertical Prepare roof penetrations1. Air pipe penetr

Installation & Operation Manual325 Vertical direct venting Vertical termination – optional concentric vent: Models 399 - 600 Only Description an

Installation & Operation Manual335 Vertical direct venting (continued)Vertical termination – optional concentric vent: Models 399 - 600 Only ELBO

Installation & Operation Manual346 Hydronic pipingSystem water piping methodsThe Knight XL is designed to function in a closed looppressurized sy

Installation & Operation Manual35RELIEF VALVETEE WITH 3/4” FITTING ON TOPCLOSE NIPPLE (FIELD PROVIDED)CLOSE NIPPLETEE WITH FITTING ON TOP(FIELD PR

Installation & Operation Manual366 Hydronic piping Near boiler piping connectionsY-STRAINER(RECOMMENDED)BOILER PUMP INDIRECT DOMESTICHOT WATE

Installation & Operation Manual376 Hydronic piping (continued)Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500Table 6B Sizing Information

Installation & Operation Manual386 Hydronic piping It is required that near boiler pipingsystems utilize Primary/Secondaryconfigurations as sho

Installation & Operation Manual396 Hydronic piping (continued)EXPANSION TANKAIR SEPARATORPRESSURE REDUCING VALVEBACK FLOWPREVENTERBAL

Installation & Operation Manual4The Knight XL - How it works...1. Stainless steel heat exchangerAllows system water to flow through specially desi

Installation & Operation Manual40EXPANSIONTANKAIR SEPARATORPRESSURE REDUCING VALVEBACK FLOWPREVENTERBALL VALVE(TYPICAL)UNION (TYPICAL)

Installation & Operation Manual417 Gas connectionsConnecting gas supply piping1. Remove the top access panel and refer to FIG.’s 7-1 thru7-3 to p

Installation & Operation Manual427 Gas connections Failure to apply pipe sealing compoundas detailed in this manual can result insevere persona

Installation & Operation Manual43NominalIron PipeSize(inches)Natural Gas Pipe Capacity ChartLength of Pipe in Straight FeetMaximumCapacity of Pipe

Installation & Operation Manual44 WARNINGWhen re-tightening the set screw, be sureto tighten securely to prevent gas leaks.Do not check for gas l

Installation & Operation Manual458 Field wiring ELECTRICAL SHOCK HAZARD – Foryour safety, turn off electrical powersupply before making any elect

Installation & Operation Manual46Low voltage connections 1. Route all low voltage wires through the knockouts in therear of the boiler, as shown

Installation & Operation Manual478 Field wiring (continued)System supply sensor1. By installing the system supply sensor into the supply of thepr

Installation & Operation Manual488 Field wiring AUX. DEVICEPILOT SUPPLY24VACGNDAUX. DEVICEPROVINGGAS PRESSURESWITCHFLOWSWITCHALARMCONTACTSRUNTIM

Installation & Operation Manual499 Condensate disposalCondensate drain1. This boiler is a high efficiency appliance that producescondensate.2. Th

Installation & Operation ManualFront View - Model 399452530232028132914872736Left Side (inside unit) - Model 39919211613341726237Right Side (insid

Installation & Operation Manual5010 Start-upCheck/control water chemistryDo not use petroleum-based cleaning orsealing compounds in the boiler sy

Installation & Operation Manual5110 Start-up (continued)Check for gas leaksBefore starting the boiler, and duringinitial operation, smell near th

Installation & Operation Manual5210 Start-up Final checks before starting the boiler Read the Knight XL Service Manual to familiarizeyourself w

Installation & Operation Manual53 FOR YOUR SAFETY READ BEFORE OPERATINGWARNING: If you do not follow these instructions exactly,

Installation & Operation Manual5410 Start-up Check flame and combustion (continued)4. Place the boiler into the active position by pressing theS

Installation & Operation Manual55Set domestic hot water (DHW) operationVerify DHW circulator modeThe DHW Mode is programmed to heat an indirect do

Installation & Operation Manual56GeneralHow the boiler operatesThe Knight XL uses an advanced stainless steel heat exchangerand electronic control

Installation & Operation Manual5711 Operating information (continued)Ramp delayFor systems with lower flow, the SMART SYSTEM can limitthe firing

Installation & Operation Manual5811 Operating information High limit operationsWhen outlet temperature exceeds 200°F (93.3°C), high limitaction

Installation & Operation Manual5911 Operating information (continued)Cascade (continued)If the water temperature at the system supply sensor is l

Installation & Operation Manual6The Knight XL - How it works...181527Rear View - Model 500271518Rear View - Models 600 - 800 Left Side (inside uni

Installation & Operation Manual6011 Operating information Sequence of operationOPERATION DISPLAY1. Upon a call for heat, the control turns on th

Installation & Operation Manual6111 Operating information (continued)Knight XL control module• Hold 5 seconds to enter code Input Mode (Menu Mod

Installation & Operation Manual62Access modesUserThe user can adjust space heating target temperature by using the UP andDOWN buttons (FIG. 11-1)

Installation & Operation Manual6311 Operating information (continued)Status Display ScreensBy using the Previous/Next (, ) arrow keys on the SM

Installation & Operation Manual64Status Display Screens (cont’d)By using the Previous/Next (, ) arrow keys on the SMART SYSTEM display panel, yo

Installation & Operation Manual6511 Operating information (continued)Status Display Screens (cont’d)By using the Previous/Next (, ) arrow keys

Installation & Operation Manual66Status Display Screens (cont’d)Operation of the cascadeThe boiler designated as the Leader will have two addition

Installation & Operation Manual67Maintenance and annual startupTable 12A Service and Maintenance SchedulesService technician(see the following pag

Installation & Operation Manual6812 MaintenanceFollow the Service and maintenance procedures given throughout this manual and in component litera

Installation & Operation Manual6912 Maintenance (continued)Flue vent system and air piping1. Visually inspect the entire flue gas venting system

Installation & Operation ManualRatingsNotes:1. The ratings are based on standard test proceduresprescribed by the United States Department of Ener

Installation & Operation Manual7012 MaintenanceInspect ignition and flame senseelectrodes1. Remove the ignition and flame sense electrodes from t

Installation & Operation Manual7112 Maintenance (continued)Check flame signal1. At high fire the flame signal shown on the display shouldbe at le

Installation & Operation Manual72Figure 13-1 Wiring Diagram13 Diagrams DISPLAYX1-8X5-5X5-13X5-6X5-12INTEGRATED CONTROLBLOWERX1-1X2-2X2-1X1-7GASV

Installation & Operation Manual73Figure 13-2 Ladder DiagramBOX DEPICTSOPTIONAL ITEMSLADDER DIAGRAMLBL2356 REV C120 VAC24 VAC120VACTERMINAL STRIP12

Notes74

Notes75

Revision Notes: Revision B (ECO #C02407) reflects gas valveadjustment, room air, new sidewall vent termination, piping diagrams,flow switch, relief va

8Installation & Operation ManualThe Knight XL gas manifold and controlsmet safe lighting and other performancecriteria when the boiler underwent t

9Installation & Operation Manual1 Determine boiler location (continued)12" (305 MM)LEFT13" (330 MM)TOP1" (25 MM) MINIMUM CLEARANCE