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Dear Design-Build Contractor / Project Manager / Design Engineer, At Lochinvar, we have long recognized the importance of innovation to any product or service. Those who share in this business also face the challenge of meeting constantly changing needs and energy efficiency demands. The designer’s guide you are now holding has been designed to make it more convenient for you to select the perfect Lochinvar boiler for your projects and provide correct specifications for your teams.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Table of Contents 1 Venting ……………………..…..……………………… Page 2 2 Combustion Air 3 Gas ….….…………….……………….………………… Page 15 4 Water …..……………………..……………………….. Page 17 5 Electricity & Controls ……………………………….. Page 23 6 Other Details ..……………………………………….. Page 28 7 Appendix A ….……..…………………………………. Page 31 8 Appendix B …………………………………………… Page 34 ….………………………………….. Page 12 .
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com At Lochinvar, we know that designing a boiler is hard work. Well, designing a boiler system is no picnic either. Demands for greater efficiency and elaborate system control have made systems more complex. This designers guide will break down the system requirements that match the Knight XL boiler to assure safe operation, highly efficient heating and long life.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Chapter 1 – Venting Venting is often the most difficult design element for the installation of a gas fired appliance, but not with the Knight XL. The designs are simple and deliver ideal operation. Still, with the venting of flue products there are important rules and regulations to follow and the installation bears a responsibility for human safety.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com AIR INTAKE MATERIAL With air intake material, you have a wider choice. PVC, CPVC and ABS are allowed. Steel pipe, galvanized or stainless with all joints and seams sealed gas tight. Type “B” double wall vent material with all joints and seams sealed gas tight. With horizontal applications only, you may even use Sealed Flex Duct. Again, you can choose whatever but we remind you of several points.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / SIDEWALL - CATEGORY IV VENTING PVC / CPVC WITH VENT/AIR TERMINATION PLATE. The exhaust piping terminates out the sidewall. The combustion air piping terminates out the sidewall. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / SIDEWALL - CATEGORY IV VENTING PVC / CPVC WITH CONCENTRIC VENT KITS (400-601 ONLY). The exhaust piping terminates out the sidewall. The combustion air piping terminates out the sidewall. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / SIDEWALL - CATEGORY IV VENTING PVC / CPVC WITH TWO PIPE TERMINATION. The exhaust piping terminates out the sidewall. The combustion air piping terminates out the sidewall. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / SIDEWALL - CATEGORY IV VENTING STAINLESS STEEL WITH TWO PIPE TERMINATION. The exhaust piping terminates out the sidewall. The combustion air piping terminates out the sidewall. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / VERTICAL - CATEGORY IV VENTING PVC / CPVC WITH CONCENTRIC VENT KIT (400-601 ONLY). The exhaust piping terminates through the rooftop. The combustion air piping terminates through the rooftop. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / VERTICAL - CATEGORY IV VENTING PVC / CPVC WITH TWO PIPE TERMINATION. The exhaust piping terminates through the rooftop. The combustion air piping terminates through the rooftop. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DIRECT VENT / VERTICAL - CATEGORY IV VENTING STAINLESS STEEL WITH TWO PIPE TERMINATION. The exhaust piping terminates on the rooftop. The combustion air piping terminates through the rooftop. BULLET POINTS This is Category IV venting, positive pressure, condensing stack. All joints and seams must be sealed gastight and may not be common vented.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com ROOFTOP VENT WITH ROOM AIR OR SIDEWALL AIR - CATEGORY IV PVC / CPVC OR STAINLESS STEEL VENT WITH AIR FROM THE EQUIPMENT ROOM OR FROM DIFFERENT PRESSURE ZONES. The exhaust piping terminates on the rooftop. The combustion air is drawn from the equipment room or from a sidewall termination.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Chapter 2 – Combustion and Ventilation Air Everybody’s gotta breathe. Even boilers need air. Air seems easy enough. You stand in the equipment room and you breathe comfortably. Open a door. Open a window. This is a big room. There’s lots of air in here for the boiler. Right? The average person inhales 400 to 500 cubic feet of air in a 24 hour period. A 500,000 Btu/hr boiler will draw 113.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com 1. COMBUSTION AIR FROM OUTSIDE If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room: (a) Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm² per kW). This opening must be located within 12" (30 cm) of the bottom of the enclosure.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com 4. DIRECT OUTSIDE AIR, SINGLE OPENING If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm² per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Chapter 3 – Gas Supply Lochinvar products are designed with the concept of flame control. We develop combustion systems that tightly control the flow of air and gas to deliver a clean and efficient flame. In Chapters 1 and 2, we showed the various methods to deliver an ample quantity of air to the appliance. In Chapter 3, we discuss delivering a steady and reliable supply of gas to the appliance.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com The Knight XL Boiler 400-801 has a 1” gas pipe connection. Logically, the gas pipe size from the meter to the boiler may be larger than the appliance connection. The table below lists the Minimum and Maximum Inlet Gas Pressures. Model Number Knight XL 400-801 INLET GAS PRESSURE NATURAL GAS Max. w.c. Min. w.c. 14” 4” L.P. GAS Max. w.c. Min. w.c. 14” 8” L.P.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Chapter 4 – Water We are no longer designing the gigantic, lumbering, gravity-feed boiler systems of our grandfathers. Buildings are bigger and more complex. Energy efficiency and “green” building demands have requirements for precise flow, for targeted temperatures, for low water volume and more.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com The purpose of System / Boiler Loop piping is to separate or “decouple” the system flow rate from the boiler flow rate. Reference Drawing A1 – Page 32. Reference Drawing A1 – Page ?? The System Loop will have its own dedicated “System Circulator”. This circulator will circulate throughout the building. The Boiler Loop will have its own dedicated “Boiler Circulator”.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Model Number KBN 400 KBN 501 KBN 601 KBN 701 KBN 801 BOILER TEMPERATURE RISE CHART Minimum 20°FΔT 25°FΔT 30°FΔT Pipe Size GPM Ft/hd GPM Ft/hd GPM Ft/hd 1 1/2" 37 21 30 14 26 11 1 1/2" 46 23 37 16 32 13 2" 55 31 44 22 38 18 2" 65 30 52 20 45 16 2" 74 33 60 23 51 18 35°FΔT GPM Ft/hd 21 8 26 10 32 13 37 11 42 12 WATER FLOW We have one item to check regarding water flow.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Recirculation System Flow < Boiler Flow Good Flow System Flow > Boiler Flow This dynamic is occurring more and more often as we see Variable Speed pumps and 3-way valves used in System Loop piping. The principle of the variable speed pump or 3-way valve is to increase or decrease flow rates through the System Loop as building demand changes.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Therefore, cooler inlet water means higher efficiency. See the chart on the following page. With low return water temperatures, the efficiency rating is high, up to 98%. As the return water temperature rises, the heat transfer from the flue products is reduced and efficiency drops. Do not exceed the maximum outlet water temperature of 195°F.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com On a very cold winter day, all three air handlers will call for heat and the two Knight XL will fire at 100% input rate to meet the demand. On a comparatively cool autumn day, only one 400,000 Btu/hr air handler might be calling for heat. The boilers, connected together with their Smart System controls will fire only one boiler at its reduced input and output rate.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Chapter 5 – Electrical & Controls The first idea for this chapter is supplying power to the boiler. A 120 VAC, 15 Amp, 1 ph, 60 Hz circuit is required for operation of the boiler.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com CASCADE The Cascade feature in the Smart System control will operate up to eight boilers. Connected with 2-wire “Daisy Chain” cable with ground, one boiler in the group is chosen as the Leader. The other boilers operate as Members. The Leader boiler makes the decision on which boiler is firing and at what rate to meet the demand. There are two types of Cascade operation.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com LOW VOLTAGE TERMINAL BOARD Every Knight XL is equipped with a Low Voltage Terminal Board for a variety of field connections and control features. Alarm on Any Failure Contacts Should the Smart System control detect a fault, it will send an alarm signal through these dry contacts to a remote control board or activate an alarm bell.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Run Time Contacts The Smart System control will “make” these dry contacts for the duration of the Main Burner. System Supply Sensor A sensor to be mounted in the supply line of the primary system loop. When the Smart System is programmed to operate off the outlet sensor (default setting), and the system supply sensor is connected, it will control the firing rate based on this sensor.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PC SOFTWARE All of these features are built into the Smart System control on every model as standard equipment. But to help you see them better, Lochinvar offers PC Software. The PC software program can be downloaded onto a laptop computer and with the connection cable provided in the PC Software kit. You can connect to the PC port on the front of every Knight XL control panel.
Designer’s Guide / Knight XL Boiler Chapter 6 – Other Details of Great Importance LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com STANDARD CODES, STANDARD CONSTRUCTION The Knight XL boiler is design certified to the latest edition of ANSI Z21.13. The third party certification was performed by CSA International and the boiler bears the American Blue Star emblem and the Canadian Blue Flame emblem.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com DETERMINE THE UNIT LOCATION 1. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the unit. The pan must not restrict combustion airflow.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com CONDENSATE TRAP The Knight XL is fitted with a condensate trap to be field mounted onto the appliance. The trap is a requirement of the ANSI standard for any Category IV vented appliance with condensation forming in the stack. If condensate neutralization is required, please order KIT3087 for KB400-501 and KIT3046 for KB601-801.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A1 PRIMARY/SECONDARY or SYSTEM/BOILER PIPING The illustration is for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer. All necessary system equipment may not be illustrated.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com PAGE A2 MULTIPLE UNIT – PRIMARY/SECONDARY or SYSTEM/BOILER PIPING The illustration is for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer. All necessary system equipment may not be illustrated.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Knight XL – the components, the design 1. Stainless steel heat exchanger System water flows through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Heat exchanger access cover The cover allows access to the combustion side of the heat exchanger coils. 3.
Designer’s Guide / Knight XL Boiler The Vent is designed to remove trapped air from the heat exchanger coils. LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com 18. Air intake adapter The adapter allows for the connection of the air intake pipe to the boiler. 19. High voltage junction box The junction box contains the connection points for the line voltage power and all pumps. 20. Boiler drain port The port is the location from which the heat exchanger can be drained. 21.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.
Designer’s Guide / Knight XL Boiler LOCHINVAR, LLC 300 MADDOX SIMPSON PKWY LEBANON, TN 37090 www.lochinvar.com Go to www.lochinvar.com for more information on all Lochinvar products. This is a screen shot of the Knight XL webpage. From the home page, click the “Products” button on the top tool bar. From the menu on the Products page, click “Boilers”, then on the “Boilers” page, click “Commercial Boilers”. Finally, click on “Knight XL”.
NOTES
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