Lochinvar - API of NH

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Designer’s Guide / Knight XL BoilerChapter 4 – WaterLOCHINVAR CORPORATION300 MADDOX SIMPSON PKWYLEBANON, TN 37090www.lochinvar.comWe are no longer designing the gigantic, lumbering, gravity-feed boiler systems of ourgrandfathers. Buildings are bigger and more complex. Energy efficiency and “green” buildingdemands have requirements for precise flow, for targeted temperatures, for low water volume andmore. They also demand a water piping system that will not only meet the demands of thebuilding but also not damage the boiler.IMPORTANT BULLET POINTS FOR WATER PIPING1. Water ConnectionsKnight 400-501 models have 1 ½” NPT and Knight 601-801 models have 2” NPTthreaded pipe inlet and outlet connections. Installed piping to the boiler must match the1 ½” or 2” diameter, minimum.2. Working PressureThe boiler should not be operated at less than 12 PSIG.3. Minimum & Maximum Water TemperaturesThe minimum inlet water temperature entering the boiler is 0°F (-18°C) with untreadedwater, less with a glycol mix.The maximum outlet water temperature leaving the boiler is 195°F (91°C).4. Flow RateThe boiler works best with a constant flow rate through the heat exchanger. However,recent changes to the SMART SYSTEM control allow the use of variable flow pumps.5. Unions and Ball ValvesThe water piping to the boiler should have unions and ball valves at the inlet and outletof the boiler to isolate the boiler for service. Use only full port ball valves.There are three major concepts to consider whendesigning the near boiler piping system. They are…WATER FLOWWATER TEMPERATUREWATER VOLUMEWaterBasically, a boiler or bank of boilers has a given range of operation under these three concepts.A boiler has a water flow rate range. A boiler has a water temperature range. A boiler has awater volume range. If you design a system that lets the boiler operate within its comfort zone, itlives a long and prosperous life. If the system forces the boiler to operate outside any one of thethree comfort zones; the boiler suffers.WATER FLOWThere are an infinite variety of system piping which will vary based on the system’s componentsand operational design. Our focus and the focus of this guide is to provide the Knight XL boilerwith the flow rate that will allow it to operate at maximum efficiency without damage. To that end,Lochinvar requires Primary / Secondary piping.Typically, system flow rates and boiler flow rates need to be controlled separately, that’s why aPrimary / Secondary piping loop is best. The Primary Loop, hereafter referred to as the “SystemLoop” flows water around the building. The Secondary Loop, hereafter referred to as the “BoilerLoop” branches off the system loop to flow water into and out of the boiler.17
Designer’s Guide / Knight XL BoilerLOCHINVAR CORPORATION300 MADDOX SIMPSON PKWYLEBANON, TN 37090www.lochinvar.comThe purpose of System / Boiler Loop piping is to separate or “decouple” the system flow rate fromthe 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 circulatethroughout the building. The Boiler Loop will have its own dedicated “Boiler Circulator”. Thiscirculator will pull from the system to flow into and out of the boiler. The Boiler circulator is fieldsupplied and must be sized for the head loss of the boiler and related pipe and fittings in theBoiler Loop only.BOILER CIRCULATOR REQUIREMENTSAgain, there will be a minimum of two pumps in a System / Boiler Loop. Both pumps areprovided by the installer. The boiler pump must be sized to provide adequate flow through theboiler and the Boiler Loop piping. A Boiler Temperature Rise Chart is provided to assist in properpump selection. This table provides GPM and boiler head-loss at various temperature rises foreach model based on Btu/hr input. Pipe diameter and length are critical to ensure proper flowthrough the boiler. The values listed on the table are based on 20 feet of piping, 4 – 90° elbowsand 2 – full port ball valves.CIRCULATOR PUMP SPECIFICATIONS1. Maximum operating pressure for the pump must exceed system operating pressure.2. Maximum water temperature should not exceed the nameplate rating.3. Cast iron circulators may be used in closed loop systems.18
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