DACC & NMDA
Central Steam Disconnect Study
NMSU Facilities and Services Department
P.O. Box 30001
Las Cruces, NM 88003-8001
June 14, 2016
Final submittal
1065 S. Main St., Bldg. D, Ste. A
Las Cruces, New Mexico 88005
(575) 647-1554
PO #P0159187
DACC & NMDA Central Steam Disconnect Study Table of Contents PDF Page #
I. Introduction 3
II. System Requirements 4 III. Options Considered and Recommendations 7
IV. Estimated Implementation Costs – Opinion of Probable Costs 9
V. Plans and Schematics – Included as a separate package and Document file.
VI. Photos of Existing Systems 13
VII. Proposed Equipment Information 40
I. Introduction
This study is presented by RBM Engineering, Inc. of Las Cruces, NM under contract with NMSU Office of Facilities and Services by Professional Services Agreement/Purchase Order PO # 0159187. The project began with an initial discussion meeting on December 4, 2015 followed by development of proposals and contract execution on January 15, 2016. A formal kick off meeting was held on February 4th with representatives of NMDA, DACC and OFS. Receipt of requested existing plans and floor plan files was also in February and field work commenced in March for the NMDA building and continued in April for the DACC buildings.
This study is presented at the request of NMSU to provide an analysis of the heating systems currently serving the Dona Ana Community College buildings (Main Building DAMA 341, Trades/Shops, Learning Resource Center (LRC), Classroom building and Health Sciences building) and the New Mexico Department of Agriculture facility across the street. From this analysis, the study is to develop recommendations for the installation of standalone boiler systems or plants to replace the existing steam distribution and condensate return supplying these buildings from the NMSU central plant. With the installation of the standalone heating plants, the existing steam and condensate return system can be decommissioned for the southwest portion of the campus. The distribution mains can be capped off in the vicinity of the animal enclosures to the north of the Community College and Department of Agriculture buildings.
New Mexico State University (NMSU) provides steam supply through their central plant facility to buildings throughout the campus. The high pressure steam (+/-100 psig) provides the main heating source for building heating and domestic hot water systems. This thermal system is distributed throughout the campus in the utility tunnel system (mainly the central portion of the campus) with direct buried piping and vaults at valves and distribution junctions at the south end of the campus. This direct buried section serves the New Mexico Department of Agriculture facility (NMDA) and the Dona Ana Community College (DACC) facility at the corners of Gregg and Espina Streets.
Over the last several years, the steam and condensate return piping in this area has begun to fail and is a constant maintenance issue for NMSU facilities staff. Numerous leaks have developed and require immediate repair when they occur. It has now reached a point where new leaks appear almost as fast as the old ones are repaired. The failures are the result of the age of the piping and the breakdown of the corrosion protection and insulation systems.
The heating systems for the NMDA facility originate in the main building central mechanical room located in the basement. The building originally had a boiler and heating water distribution system which was converted to the central plant steam source at some point. Heat Exchangers use the central steam for heating water and domestic hot water. The adjacent annex building to the west was constructed in 2013 and has heating water sourced from the existing main mechanical room in the original building.
DACC campus consists of five buildings; Building 341 DAMA is the main building and extends in an “L” shape along Espina and Gregg Streets, Trades/Shops classroom building on the northwest side, Learning Resource Center (LRC), Classroom building and the Health Sciences Building. The LRC, Classroom and Health Sciences are located in the center portion of the campus behind or west of the main 341 building.
Within the DACC campus, there are now three (3) main heating source locations. Building 341 contains the center basement mechanical room with a steam source and heating and domestic
water heat exchangers and the south mechanical room with a steam source and heat exchangers for heating water to the south and east additions done later for the 341 building and also the heating water source for the Health Sciences building. The third steam source comes into the LRC building and heating water is provided to the LRC and the adjacent classroom building.
When the Trades/Shop building was originally constructed it contained a steam heating system. In the 2008 renovation the steam supply and condensate return system was removed and the building is now on natural gas rooftop units, unit heaters and water heaters. No steam is utilized in this building. The steam and condensate mains are completely removed from the mechanical room and the renovation plans do not define where the steam and condensate piping was capped or terminated.
The NMSU Central Plant steam distribution system approaches the area from the north and is direct buried. Junction vaults occur at various points for valve access and where branches to buildings occur. The steam and condensate return mains pass the NMDA building to its west and branch lines provide steam and condensate to the NMDA main mechanical room. From there it continues south and crosses Gregg St. into the lawn area on the north side of the DACC 341 building. Once in the lawn area it tees and goes west towards the Trades building and the west end of 341 then between the Trades and 341. A branch goes under 341 in a utility tunnel below the water utilities labs into the area behind 341 and to the LRC building. The other main branch of the tee continues east in the lawn area and goes around the east side of 341 and turns south along Espina St. all the way to the south mechanical room of Main building 341.
II. System Requirements:
Based on our review of existing plans and site investigation there are three source sites for heating water on the DACC campus and one for the NMDA facility. The approach to replace the existing steam and condensate systems (heat exchangers, regulating stations, condensate control, capture and return equipment and all related controls) is to disconnect the steam and condensate mains and replace the steam heating source equipment with heating boilers, variable speed primary pumps and related specialties and controls. Where steam also provided domestic hot water needs, new water heaters shall be provided in those specific locations. How those boiler systems shall be arranged allow for various options to be discussed in the Recommendation section of this report.
Estimations of the required system capacities for each source location were developed. The following summaries indicate these estimated heating requirements.
DAMA 341 South Mechanical Room 183 2,121,300 btu/hr.
DAMA 341 Central Boiler Room 1,446,000 btu/hr.
LRC Mechanical Room 1,200,000 btu/hr.
NMDA Main Mechanical Room 1,895,000 btu/hr.
III. Options Considered and Recommendations:
Considering the options available to disconnect the existing steam/condensate distribution system for these buildings a few approaches present themselves. The NMDA building must stand alone and independent from the DACC facilities. The DACC buildings present opportunities for either small independent heating water boiler systems or a larger more central heating boiler plant to serve multiple mechanical rooms. Utilization of modern high efficiency modular boiler systems allows small footprint equipment and multiple “modules” of boilers to provide backup capacity and system redundancy. Since the boilers are sealed combustion this will aid in avoiding significant combustion air openings for the boiler areas.
NMDA:
A new modular boiler plant consisting of two modular boilers, individual primary pumps and related controls shall be applied in the existing mechanical room in the basement. It shall be located in the vicinity of the existing steam equipment and specialties and where the original boiler was located. We shall take advantage of the existing boiler flue and path for the flue discharge.
Refer to plan sheets for additional information.
DACC:
Option 1 – Individual Boiler Systems
Provide three individual boiler systems located at the three source locations for heating the campus. One in the DAMA 341 central basement mechanical room, one in the DAMA 341 south mechanical room and one at the LRC mechanical room. Each would consist of a new modular boiler plant consisting of two modular boilers, individual primary pumps and related controls shall be applied in the existing mechanical rooms or in adjacent locations. It shall be located in the vicinity of the existing steam equipment and specialties.
Refer to plan sheets for additional information.
The main advantage of these individual systems is increased redundancy and decentralization of equipment. Any equipment item failure or shut down for maintenance will affect a smaller portion of the facility. These will also allow for phased installation so a system can be installed and started while the remainder of the facility remains on existing systems. In this scheme, construction would start at the south end mechanical room and work further north will follow. The result is the steam mains running along Espina St. can be shut down and capped at one of the existing vaults mitigating current leaks.
Option 2 – Centralize Boiler Plant to serve the DAMA 341 central mechanical room and LRC mechanical room.
The south mechanical room (DAMA 341) shall still have its own individual plant. The central plant would consist of a new modular boiler plant consisting of at least three modular boilers, individual primary pumps and related controls installed in a separate boiler plant in a new enclosure. It shall be located in the vicinity of the existing LRC mechanical room or condensing unit electrical yard between the two buildings. A new primary loop shall deliver heating water from the boiler plant to each existing mechanical room (341 basement and LRC) where the
existing heating pumps shall supply the buildings. A prefabricated boiler plant enclosure might be a consideration for this location.
Refer to plan sheets for additional information.
The main advantage of this central plant is a reduction in the number of individual plants and equipment to maintain and monitor. Construction phasing opportunities are similar to the individual plants since the south mechanical room would still be an independent system.
Disadvantage is that the location of this plant will have to be carefully considered due to the area proposed is congested and a number of utilities cross the area.
Recommendation for DACC is to utilize individual smaller systems at the three locations outlined.
Existing Steam Distribution and Condensate Return System:
Two considerations apply to the existing steam and condensate return system. Upon the disconnection of the steam and condensate systems to what extent is it capped and abandoned or completely dug up and removed. In either scenario, NMSU will have to determine where the main system disconnection is made and at that vault location an end of main condensate trap will have to be installed. For purposes of this report, the disconnection point is indicated to be slightly north of the NMDA building where a vault occurs at the branch junction. This disconnection could be considerably further north in the vicinity of the animal holding pens if no other branch mains tie in. This is a consideration for NMSU. The extent and final location of the disconnection shown in this study can be updated and revised.
Whether the piping is completely removed or abandoned in the areas of direct burial is really a cost and disruption discussion. Removal means working across Gregg St., digging up the landscaping around the exterior (north and east) perimeter of DAMA 341 building and related sidewalk removal and repair.
Recommendation for the steam system disconnect is to decommission the steam and condensate return piping, demolish existing piping and specialties in the mechanical rooms and vaults and abandon all direct buried sections. This is due to the high cost of this demolition work which would disrupt landscaped areas and required street removal and patching (Gregg St.) and sidewalk repairs. Future projects, street repair or resurfacing or landscaping can allow the complete demolition of this piping in the future.
Review of this report by NMSU Facilities staff indicates that the preference is to demolish the existing steam and condensate mains completely and not abandon any piping or components for future demolition. Further, the extent of the termination of the steam and condensate mains will be further North beyond Stewart St. near Frenger St. The exact termination point will be confirmed once NMSU staff verifies what buildings or facilities still have steam demand.
IV. Estimated Implementation Costs Refer to the following cost summaries for specific information.
17-May-16
RE: DACC/NMDA Steam Disconnect Study
OPINION OF PROBABLE COSTS
Below is a summary Opinion of Probable cost for the above referenced project.
New Individual Boiler System Set Up Cost Cost
Demolition of Steam Equip & Piping $15,000.00
New Boiler System(s) $134,000.00
Sub-Total Cost for Individual Boiler Room $149,000.00
Sub-Total Cost for the 4 boiler systems (LRC, 341 south, 341 central, $596,000.00
nmda)
Central Boiler Room Bldg (DAMA341 & LRC)
Demolition of Steam Equip & Piping $30,000.00
Boilers, Pumps, Controls, Elect, Construction $281,000.00
Sub-Total Cost for Central Boiler Room $311,000.00
Sub-Total Cost for Individual 341 south Boiler Room $298,000.00
and NMDA
Sub-Totals $609,000.00 $596,000.00
General Contractors Mark ups 20% 0.2 $121,800.00 $119,200.00
Sub-Total $730,800.00 $715,200.00
NMGRT 7.53% 0.0753 $55,029.24 $53,854.56
Grand Total Central Blr Rm (341 Central & LRC) $785,829.24
note 3
Grand Total (Individual Boiler Systems) $769,054.56
Cost with Contingency (10%) $864,412.16 $845,960.02
note 1 note 2
Steam Disconnects and Demolition
Sub-Total Cost for St. Disconnect/Demo $90,500.00
General Contractors Mark ups 20% 0.2 $18,100.00
Sub-Total $108,600.00
NMGRT 7.53% 0.0753 $8,177.58
Grand Total Steam Disconnect/Demo $116,777.58
Project(s) Grand Total Costs $981,189.74 $962,737.60
Notes:
Note 1 - add $20,000 to cost for ultra-high efficiency boilers
Note 2 - add $30,000 to cost for ultra-high efficiency boilers.
Note 3 - includes individual boiler rooms for NMDA and 341 south mechanical room.
17-May-16
RE: DACC/NMDA Steam Disconnect Study
OPINION OF PROBABLE COSTS
Below is a breakdown of the general construction, mechanical and electrical cost for the above referenced project.
Please review and comment as necessary.
All costs and calculations were comprised using the Means booklet or from
venders or manufacturer's representatives.
Boiler Room Demolition:
Line Item Quantity Unit Unit Cost Total
Steam Equipment 1 ls $7,500.00 $7,500.00
Piping 1 ls $2,500.00 $2,500.00
Electrical 1 ls $5,000.00 $5,000.00
Sub-Total $15,000.00
New Work (Individual Blr Rm)
Line Item Quantity Unit Unit Cost Total Ultra Hi-eff Boiler
Boilers, flues, piping 2 ea 45,000.00$ 90,000.00$ $110,000.00
Pumps & Specialties 2 ea 12,000.00$ 24,000.00$
Controls 1 ls 10,000.00$ 10,000.00$
Electrical 1 ls 10,000.00$ 10,000.00$
Sub-Total 134,000.00$ $154,000.00
New Work (Central Blr Rm - DAMA 341 Central MR & LRC)
Line Item Quantity Unit Unit Cost Total
Boilers 3 ea $45,000.00 135,000.00$ $165,000.00
Pumps 3 ea $12,000.00 36,000.00$
Controls 1 ls $10,000.00 $10,000.00
Electrical 1 ls $25,000.00 $25,000.00
Mech Building Constr. 500 sq. ft. $150.00 $75,000.00
Sub-Total 281,000.00$ $311,000.00
New Work (Steam & Cond Ret Distr Piping Demolition)
Line Item Quantity Unit Unit Cost Total
New End of Main Trap 1 ls 9,000.00$ 9,000.00$
Piping Demolition 3000 lf 20.00$ 60,000.00$
Street Repair 1 ls 1,500.00$ 1,500.00$
Landscaping 2000 lf 10.00$ 20,000.00$
Sub-Total 90,500.00$
V. Plans and Schematics Plan sheets provided under a separate pdf file.
VI. Photos of Existing Systems:
DAMA 341 Basement Mechanical Room
Photo - 1 Steam main and condensate return to basement mechanical room.
Photo - 2 Steam and CR lines in mechanical room.
Photo - 3 Steam and CR in mechanical room.
Photo - 4 Steam and CR lines in mechanical room.
Photo - 5 Steam and CR lines in mechanical room.
Photo - 6 Steam and CR lines in mechanical room.
Photo - 7 Steam and CR lines in mechanical room.
Photo - 8 Steam and CR lines in mechanical room.
Photo - 9 Steam and CR lines in mechanical room.
Photo - 10 Steam regulator Station and heat exchanger stands.
Photo - 11 Steam PRV Station and Ht. Exch.'s
Photo - 12 Condensate Return (CR) specialties.
Photo - 13 Heating water pumps and specialties.
Photo - 14 Heating water installation, opposite end of photo 13
Photo - 15 heating Water Pump
Photo - 16 Heating water pump, nameplate
Photo - 17 Heating Water Pump, nameplate
Photo - 18 Heat Pump Chiller pumps
DAMA 341 AHU Mechanical Room (Typical of 2)
Photo - 19 AHU-Q in room
Photo - 20 AHU-Q
Photo - 21 Coil Piping to AHU
DAMA 341 South Mechanical Room
Photo - 22 CR specialties and piping.
Photo - 23 Steam regulator station and specialties
Photo - 24 Incoming steam main and CR main up through floor
Photo - 25 Steam regulator station and piping
Photo - 26 Heat Exchangers, one serves 341 addition(s) and one serves Health Sciences
building.
Photo - 27 HE control valves
Photo - 28 HE stands and 341 heating pumps
Photo - 29 Health Sciences heating pump
Photo - 30 Overall of Steam stations and HE's
Photo - 31 Chilled and heating distribution piping entering/leaving room
Photo - 32 Coil piping to AHU in south mechainical room.
Photo - 33 Outdoor area adjacent to cooling tower
Photo - 34 Exterior steam/utility vault at corner of Espina and Wells
Photo - 35 Existing steam leak on east side of 341 along Espina St.
LRC Mechanical Room
Photo - 36 Condensate receiver and pump station, steam regulator station above
Photo - 37 Incoming main steam line up through floor
Photo - 38 CR main down through floor
Photo - 39 Heat Exchanger
Photo - 40 Overall photo of steam specialties and heating water pumps
Photo - 41 Heating pump nameplate
LRC – Classroom Building Mechanical Room
Photo - 42 AHU in Classroom building
Photo - 43 AHU piping to LRC building
Photo - 44 AHU piping leaving mechanical room to LRC building
Outdoor Yard Areas
Photo - 45 Outdoor area adjacent to 341 basement mechanical room. Exterior condensing
units for heat pump chillers.
Photo - 46 Exterior area just north of condensing unit and electrical yard.
Photo - 47 Exterior area north of condenser and electrical yard
Photo - 48 LRC exterior area, door to right of column is mechanical room door.
VII. Proposed Equipment Information
Models 504A thru 2004ACategory I with vertical vent
Models 503A thru 2003AModels 2503 thru 4003Category IV Venting
Up to 88.4% thermal efficiency!
CSA Certified Lead ContentLess Than .25% Lead
Proudly Assembled in the U.S.A
Versa IC ®
ControlPlatform
Models Dimensions (inches)
MVBCat. I*
MVBCat. IV W* X*
- 2503 58.22 67.12
- 3003 63.22 72.12
- 3503 68.22 77.12
- 4003 73.22 82.12
PHYSICAL DATA
*Category I with vertical vent, category III with horizontal venting and no extractor.†NPT shown is for Natural Gas. For Propane, NPT= 1” for 503/4 thru 2003/4 and 2-1/2” for 2503 thru 4003 all water heater/boiler sizes.‡Current draw is for heater only. (Supply breaker must have a delayed trip.)
4
503A thru 2003A504A thru 2004A
Models Dimensions (inches)OperatingWeight(lbs.)
Amps‡MVBCat. I*
MVBCat. IV
BHt.
D E F G†
NPTH K-Ø
Cat. I*K-ØCat. IV
MCat I*
MCat IV
NCA Ø
P R V
504A 503A 43 32 35 23-3/4 1 2 NPT 8 6 14-1/8 14-1/2 6 35 6 2 600 12754A 753A 49 38 41 29-3/4 1 2 NPT 10 6 16 14-1/2 6 41 6 2 660 121104A 1003A 55 44 47 35-3/4 1-1/4 2-1/2 NPT 10 6 16 14-1/2 6 48-1/2 6 2 720 121504A 1253A 61 50 53 41-3/4 1-1/4 2-1/2 NPT 12 8 18-1/8 17-3/4 8 53 6 2 780 12- 1503A 67 56 59 47-3/4 1-1/4 2-1/2 NPT - 8 - 17-3/4 8 59 6 2 840 12
2004A 1753A 75 62 65 53-3/4 2 2-1/2 NPT 14 8 20-1/8 17-3/4 8 68 9 5 940 18- 2003A 81 68 71 59-3/4 2 2-1/2 NPT - 8 - 17-3/4 8 74 9 5 1000 18- 2503 68-1/4 62 64-7/8 7-5/16 2-1/2 4” groove - 10 - 26-3/4 10 N/A N/A 4-13/16 1150 12- 3003 73-1/4 67 69-7/8 7-5/16 2-1/2 4” groove - 10 - 29-1/4 10 N/A N/A 4-13/16 1250 15- 3503 78-1/4 71 74-7/8 7-5/16 2-1/2 4” groove - 12 - 31-3/4 12 N/A N/A 4-13/16 1375 17- 4003 83-1/4 76 79-7/8 7-5/16 2-1/2 4” groove - 12 - 34-1/4 12 N/A N/A 4-13/16 1450 20
PHYSICAL DATA
*Only one port is to be used. All three ports are shown for pictorial purposes.
Note: Current draw (Amps) is for pump only Water hardness grains per gallon*Pump selections based on 75ft equivalent length of tubing Soft = 3-4 • Medium = 5-15 • Hard = 16-25** At 230 VAC
HeaterSide
From CombustibleSurfaces (min.)
For Service503/4A thru 2003/4A
For Service2503 thru 4003
Floor* 0” 0” 0”
Rear 12” 24” 36”
Right Side 1” 1” 24”**
Left Side 1” 1” 24”**
Top IndoorOutdoor
0”Unobstructed
10”Unobstructed
12”Unobstructed
Front Open 24” 30”
Vent Stack Indoor 1” 1” 1”
Vent Cap Outdoor 12” 12” 12”
CLEARANCES
MVBModel
Water HardnessSoft Medium Hard
HP Amps HP Amps HP Amps503A/504A 1/4 6 1/4 6 3/4 11
753A/754A 1/4 6 1/2 7 3/4 11
1003A/1104A 1/4 6 1/2 7 1 14
1253A 1/2 7 1 14 1 14
1503A/1504A 3/4 11 1 14 1 14
1753A 1 14 1-1/2 15 1-1/2 15
2003A/2004A 1-1/2 15 1-1/2 15 1-1/2 15
2503 1-1/2 8.2 1-1/2 8.2 3 16
3003 1-1/2 8.2 3 16 3 16
3503 1-1/2 8.2 3 16 3 16
4003 3 16 5 23 5 23
*Do not install on carpetingNote: Local codes may require increased clearances
PUMP
5
All components are contained inside the cabinet (except PRV), no external fans orvalves to deal with.
RATING PLATE
2503 thru 4003
** One side 24” other 1” clearance.
6
Control Faults• Low 24VAC• Control Setup• ID Card Fail• Device Lost• Device Error• PIM Error
Ignition Control Faults• Ignition Lockout• False Flame• Ignition Failure• Low HSI Current• Blower Speed
Safety Faults• Sensor Failure - 6• Vent Block• Manual Limit• Auto Limit• Water Flow• Delta T Fault• Low Water• Low Gas• High Gas• Extra 1• Options
Diagnostic Information
Versa IC Boiler Control and On-BoardDiagnostic CenterVersa IC merges safety, ignition and temperature control, outdoor reset andfreeze protection, plus system monitoring, alarm and diagnostics, and BMStransmission all in one Integrated Control Platform. Easy front access toread, set up and trouble shoot on a 3.5” LCD screen. The entire package isCSA certified, and listed for each individual function.
Inlet and outlet sensors factory installed in boiler. Remote sensor for system included. BMS all point diagnostics transmission port. 0-10V DCset point input standard. Also can drive and monitor external motorized auxiliaries such as extractors and louvers. Additional connections forauxiliary functions, indirect DHW, and dry contact remote alarm relay are provided.
Outdoor ProvenRaypak is no stranger to the outdoor environment. Our touchpad is 100% waterproof and has been proven and perfected on our pool prod-ucts. No guesswork here, just one tough boiler ready to take on jobs that others have to walk away from.
ITEM MENU
RESET
ModelVentingCategory
†
Boilers Water HeatersInputMin.Input Output Efficiency Input Output Efficiency
503A IV 500 431 86.2% 500 435 87% 71753A IV 750 647 86.2% 750 653 87% 1081003A IV 999 861 86.2% 999 869 87% 1431253A IV 1250 1078 86.2% 1250 1088 87% 1791503A IV 1500 1293 86.2% 1500 1305 87% 2141753A IV 1750 1508 86.2% 1750 1523 87% 2502003A IV 1999 1723 86.2% 1999 1739 87% 2862503 IV 2501 2126 85% 2501 2126 85% 3503003 IV 3000 2550 85% 3000 2550 85% 4203503 IV 3500 2975 85% 3500 2975 85% 4904003 IV 3999 3399 85% 4000 3400 85% 560504A I* 500 420 84% 500 420 84% 300754A I* 750 630 84% 750 630 84% 4501104A I* 1100 924 84% 1045 888 85% 6601504A I* 1500 1260 84% 1425 1211 85% 9002004A I* 1999 1679 84% 1900 1615 85% 1199
*Category I with vertical vent, category III with horizontal venting and no extractor.†Category IV requires sealed vent with condensate drain. Category I uses conventional B vent.Note: Ratings are for natural or propane gas and for elevations up to 5,000 ft. above sea level. For higher elevations, consult the factory.
MBTUH
Models1005A, 1505A, 2005A
2505, 3005, 3505, 4005
Up to 99% thermal efficiency!
Proudly assembled in the U.S.A.
VERSA IC ®
ControlPlatform
TOP VIEW
FRONT VIEW REAR VIEW
*For propane gas, all models are 1-1/4 NPT. †Separate wiring connection required for pumps. **At 240VAC.
4
CLEA
RANCE
S
Floor* 0 N/ARear 12 36Right Side 1 24Left Side 1 1Front 24 24Top Indoor 0 10
Outdoor Unobstructed UnobstructedVent Stack Indoor 1 N/AVent Cap Outdoor 12 12
From CombustibleSurfaces (min.)
For Service(recommended)
*Do not install on carpetingNote: Local codes may require increased clearances
HeaterSide
Water hardness grains per gallon Soft = 3-4 • Medium = 5-15 • Hard = 16-25
**At 240VAC.
Model MBTUHInput
Boiler
Output Efficiency
Water Heaters
Output EfficiencyMBTUHInput
MinimumInput
MBT
UH
1005A 999 959 96% 999 969 97% 1401505A 1500 1440 96% 1500 1455 97% 2102005A 1999 1919 96% 1999 1939 97% 2802505 2501 2378 95.1% 2501 2381 95.2% 2003005 3000 2853 95.1% 3000 2856 95.2% 2403505 3500 3329 95.1% 3500 3332 95.2% 2804005 4000 3804 95.1% 4000 3800 95.2% 560
ModelDimensions (inches)
BHt.
PumpAmps†
PHYS
ICAL DAT
A
1005A 55-1/8 45 47-1/8 36-1/2 1-1/4 6 40-1/16 11-1/2 6 47-1/8 8-1/16 6-1/16 1065 12 101505A 67-1/8 57 59-1/16 38-1/2 1-1/4 8 52-1/16 12-5/8 8 59-1/8 8-3/16 6-1/16 1234 12 142005A 81-1/8 71 71-3/16 38-1/2 2 8 64-1/16 12-5/8 8 73-1/8 8-3/16 6-1/4 1461 18 172505 68-3/16 65 64-13/16 7-5/16 2-1/2 10 21-1/8 18-1/2 10 70 - - 2656 12** 15**3005 73-3/16 70 69-13/16 7-5/16 2-1/2 10 26-1/8 23-1/2 10 65 - - 2775 15** 16**3505 78-3/16 75 74-13/16 7-5/16 2-1/2 10 31-1/8 28-1/2 12 60 - - 2925 17** 16**4005 83-3/16 80 79-13/16 7-5/16 2-1/2 10 30-7/8 29-1/4 12 55 - - 3058 20** 24**
BoilerAmps
Weight(lbs.)
D E F G*
NPTK
Flue ØL M
NC/A Ø
P R Y
Xtreme Small Footprint
1005A 12 10 12 10 12 14 -1505A 12 10 12 14 12 17 -2005A 18 17 18 17 N/A N/A -2505** 12 8 12 8 12 8 73005** 15 8 15 16 15 16 83505** 17 8 17 16 17 16 84005** 20 16 20 16 20 16 8
Soft
Water Heater Power Requirements
HardMedium
Heater Pumps Heater PumpsHeater Pumps
XThermModel
ExternalInjectorPump
H-Models Hydronic
AHRI Certified Not AHRI Certified
Models 1005A thru 2005A 1005A thru 2005A Heating Boiler
94%Thermal Efficiency
Lo c h i n v a r.c o m
H I G H E F F I C I E N C Y CO M M E R C I A L CO N D E N S I N G B O I L E R S
OPERATING CONTROL FEATURING A BUILT-IN CASCADING SEQUENCER
5 MODELS: 399,000 – 800,000 BTU/HR
FIRING RATE MODULATION TO 5:1
LESS THAN 20 ppm NOx
DIRECT VENT FLEXIBILITY TO 100 FEET
> High Voltage Terminal Strip 120 VAC / 60 Hertz / 1 Phase Power Supply Three sets of Pump Contacts with Pump Relays> Low Voltage Terminal Strip 24 VAC Device Relay Proving Switch Contacts Flow Switch Contacts Alarm on Any Failure Contacts Runtime Contacts DHW Thermostat Contacts 3 Space Heat Thermostat Contacts System Sensor Contacts DHW Tank Sensor Contacts Outdoor Air Sensor Contacts Cascade Contacts 0-10 VDC BMS External Control Contact 0-10 VDC Boiler Rate Output Contacts 0-10 VDC Variable Speed System Pump Signal Input 0-10 VDC Signal to Control Variable Speed Boiler Pump Modbus Contacts> Time Clock> Data Logging Hours Running, Space Heating Hours Running, Domestic Hot Water Ignition Attempts Last 10 Lockouts> Other Features Low Water Flow Safety Control & Indication Password Security Inlet & Outlet Temperature Readout Customizable Freeze Protection Parameters Custom Maintenance Reminder with Contractor Info
*Exclusive feature, available only from Lochinvar
Standard Features> 94% Thermal Efficiency> Modulating Burner with 5:1 Turndown Direct-Spark Ignition Low NOx Operation Sealed Combustion Low Gas Pressure Operation> ASME Stainless Steel Heat Exchanger ASME Certified, ”H” Stamped Gasketless Heat Exchanger 160 psi Working Pressure 50 psi ASME Relief Valve Highly efficient, condensing design> Vertical & Horizontal Direct-Vent Category IV venting up to 100 feet PVC, CPVC, Polypropylene or AL29-4C Venting up to 100 Feet Factory Supplied Sidewall Vent Termination> Smart System Control> Other Features On/Off Switch Adjustable High Limit w/ Manual Reset Automatic Reset High Limit Flow Switch Flue Temperature Sensor Low Air Pressure Switch Temperature & Pressure Gauge Adjustable Leveling Legs Condensate Trap Zero Clearances to Combustible Material 10 Year Limited Warranty (See Warranty)
Smart System Features> SMART SYSTEM Digital Operating Control Multi-Color Graphic LCD Display w/ Navigation Dial > Three Reset Temperature Inputs with curves for three set point temperature inputs > Built in Cascading Sequencer for up to 8 Boilers Multiple Size Boiler Cascade Front end loading capability with Copper Fin II Lead Lag Efficiency Optimization > Outdoor Reset Control with Outdoor Air Sensor > Programmable System Efficiency Optimizers Night Setback DHW Night Setback Anti-Cycling Outdoor Air Reset Curve Ramp Delay Boost Temperature & Time > Three Pump Control System Pump With Parameter for Continuous Operation Boiler Pump With Variable Speed Pump Control* Domestic Hot Water Pump > Domestic Hot Water Prioritization DHW tank piped with priority in the boiler loop DHW tank piped as a zone in the system with the pumps controlled by the Smart System DHW Modulation Limiting Separately Adjustable SH/DHW Switching Times* > Building Management System Integration 0-10 VDC Input to Control Modulation or Set Point 0-10 VDC Input Signal from Variable Speed System Pump* 0-10 VDC Modulation Rate Output 0-10 VDC Input to Enable/Disable call for heat Access to BMS Settings through Display
KBX-06 (Reprint KBX-06 1/15) PDP-5M-8/15-Printed in U.S.A.
Knight® XL Boiler Dimensions and Specifications
Model Number Guide
KB N 701 M13
Model
Firing Controls
Natural Gas
Btu/hr Input
Input Net Model Min Max Thermal Output AHRI RatingNumber MBH MBH Efficiency MBH MBHKBN400 80 399 94.0% 376 327KBN501 100 500 94.0% 470 409KBN601 120 600 94.0% 564 490KBN701 140 700 94.0% 658 572KBN801 160 800 94.0% 752 654
A B C D E F G H I J K Gas Water Air Vent Shipping Conn. Conn. Inlet Size Wt. (lbs.) 42-1/2” 15-1/2” 27-3/4” 3-3/4” 20-3/4” 21” 14” 34” 34” 2” 18-3/4” 1” 1-1/2” 4” 4” 280 42-1/2” 15-1/2” 31-1/2” 3-3/4” 25-1/2” 21” 14” 32-1/2” 36” 2” 18” 1” 1-1/2” 4” 4” 310 42-1/2” 15-1/2” 36-1/4” 3-3/4” 25” 21” 14” 36” 32-3/4” 5-1/2” 19-1/2” 1” 2” 4” 4” 340 42-1/2” 15-1/2” 40-1/4” 3-3/4” 29” 23” 17” 36” 32-3/4” 3-1/4” 23-1/2” 1” 2” 4” 6” 370 42-1/2” 15-1/2” 45-1/4” 3-3/4” 33-1/4” 23” 17” 36” 32-3/4” 3-1/4” 27-3/4” 1” 2” 4” 6” 405
Notes: Indoor installation only. All information subject to change. Change “N” to “L” for LP gas models.
Knight XL Boiler,
Natural Gas,
700,000 Btu/hr input,
M13 firing controls
LEFT SIDE
FRONTBACK
8"
39-1/2"
13-3/4"
18-3/4"
H
K
D
GF
EC
9"
A
1-1/4"1/4" - ADJUSTABLE
AIR INLET
FLUE
LOW VOLTAGEELECTRICALCONNECTIONS
GAS
INLET OUTLET
HEATEXCHANGERDRAIN3/4" NPT
CONDENSATEDRAIN
FLUE
B
I
J
HIGH VOLTAGEELECTRICALCONNECTIONS
38-3/4"
3-1/2"
Optional Equipment Alarm Bell Condensate Neutralization Kit Concentric Vent Kit (KB400-KB601) BMS Gateway to LON or BacNet High & Low Gas Pressure Switches w/ Manual Reset (KB501-KB801) Variable Speed Boiler Circulation Pump
MODBUS Communication Multi Temperature Loop Control Low Water Cutoff w/Manual Reset & Test Constant Speed Boiler Circulation Pump SMART SYSTEM PC Software Stainless Steel Vent Kits (KB701-KB801) Stack Frame
Firing Codes M9 Standard Construction M7 California Code M13 CSD1 / FM / GE Gap (KB501-KB801)
Knight XL Heating Boiler Dimensions and Specifications
Registered Under U.S. Patents
#7824178 and 7506617
Lochinvar, LLC 300 Maddox Simpson ParkwayLebanon, Tennessee 37090P: 615.889.8900 / F: 615.547.1000
Lochinvar.com
