Table of Contents
Advertisement
KBII-I-O Rev D
Installation & Operation Manual
Models: 81 - 286
This manual must only be used by
WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight Boiler Service Manual,
before installing. Perform steps in
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.
Advertisement
Table of Contents
Related Manuals for Lochinvar 81 - 286
Summary of Contents for Lochinvar 81 - 286
- Page 1 KBII-I-O Rev D Installation & Operation Manual Models: 81 - 286 This manual must only be used by WARNING a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Boiler Service Manual, before installing. Perform steps in the order given.
-
Page 2: Table Of Contents
Vent and Air Piping ... 10 Prevent Combustion Air Contamination ... 10 Corrosive Contaminants and Sources ... 11 Using an Existing Vent System to Install a New Boiler ... 11 Removing a Boiler from Existing Common Vent ... 12 2. PREPARE BOILER Remove Boiler from Wood Pallet ... -
Page 3: Please Read Before Proceeding
Instead, shut off the gas supply at a location external to the appliance. • Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced. -
Page 4: The Knight Boiler - How It Works
The venturi controls air and gas flow into the burner. Flue gas sensor (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating. - Page 5 The Knight Boiler - How it works... Models 81 - 211 Front View - Models 81 - 211 Left Side (inside unit) - Models 81 - 211 Installation & Operation Manual (continued) Rear View - Models 81 - 211 Right Side (inside unit) - Models 81 - 211...
-
Page 6: The Knight Boiler -- How It Works
The Knight Boiler - How it works... Model 286 Front View - Model 286 Left Side (inside unit) - Model 286 Installation & Operation Manual Rear View - Model 286 Right Side (inside unit) - Model 286... -
Page 7: Ratings
Maximum allowed working pressure is located on the rating plate. NOTICE Notes: 1. As an Energy Star Partner, Lochinvar has determined that Knight boilers meet the Energy Star guidelines for energy efficiency. 2. The ratings are based on standard test procedures prescribed by the United States Department of Energy. -
Page 8: Determine Boiler Location
Closet and alcove installations A closet is any room the boiler is installed in which is less than 67 cubic feet for KBN081 and KBN106 models, 86 cubic feet for KBN151 models, 107 cubic feet for KBN211 models, and 120 cubic feet for KBN286 models. - Page 9 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances CLOSET INSTALLATION 1" MINIMUM CLEARANCE AROUND HOT WATER PIPES AND VENT PIPE 12" LEFT 14" REAR RECOMMENDED SERVICE CLEARANCES: FRONT - 24” - 24” LEFT SIDE - 24” REAR - 24”...
-
Page 10: Provide Air Openings To Room
Do not attempt to install the Knight boiler using any other means. Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual. -
Page 11: Corrosive Contaminants And Sources
• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 12. With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used;... -
Page 12: Removing A Boiler From Existing Common Vent
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. -
Page 13: Prepare Boiler
Remove the two lag bolts from the wood pallet inside the boiler (FIG. 2-1). b. Detach the boiler from the lag bolts in the rear of the unit, see FIG. 2-1. Do not drop the boiler or bump the jacket NOTICE on the floor or pallet. -
Page 14: General Venting
General venting Direct venting options - Sidewall Vent Figure PVC/CPVC Two-Pipe Termination - See page 21 for more details Figure Termination - See page 25 for more details Sidewall Figure 3-2 Stainless Steel Two-Pipe - See page 22 for more details PVC/CPVC Concentric Installation &... -
Page 15: Direct Venting Options
General venting Direct venting options - Vertical Vent Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 28 for more details Direct venting options - Vertical Vent, Sidewall Air Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air - See page 20 for more details Stainless steel vent/air design and terminations will vary slightly by manufacturer. -
Page 16: Install Vent And Combustion Air Piping
The 3" Concentric Vent Kit available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Knight boiler. -
Page 17: Pvc/Cpvc Air Intake/Vent Connections
ANSI/ASTM F439 UL1738 Approved Stainless Steel Vent Manufacturers Make Figure 3-10 Near Boiler PVC/CPVC Venting Model 286 4” CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS. -
Page 18: Air Inlet Pipe Materials
General venting 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 Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. -
Page 19: Stainless Steel Air Intake/Vent Connections
FSRC4(R.C.) 303888 * = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-11, unless approved vent other than standard diameter is used. Consult a Heat Fab representative for questions. -
Page 20: Vent And Air Piping
Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion). You may use any of the vent/air piping methods covered in this manual. -
Page 21: Sidewall Direct Venting Vent/Air Termination - Sidewall
This arrangement avoids Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown. 12" OVER- HANG... - Page 22 Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate PVC/CPVC Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION BIRD SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT (IF SPACE PERMITS)
-
Page 23: Prepare Wall Penetrations
Sidewall direct venting Figure 4-3A Clearance to Forced Air Inlets IF LESS THAN 10’ VENT / AIR TERMINATION 7' MIN. ABOVE ANY PUBLIC WALKWAY Figure 4-3B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings 7’ MIN. ABOVE ANY PUBLIC WALKWAY Prepare wall penetrations Use the factory supplied wall plate as a template to locate... -
Page 24: Termination And Fittings
Canadian installations, provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of a Knight boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents. -
Page 25: Sidewall Termination - Optional Concentric Vent
Sidewall direct venting Sidewall termination – optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3" diameter - Models 81 - 211 and #CVK3007 for 4" diameter - Model 286). - Page 26 Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-9 Concentric Vent Dimensional Drawing - Models 81 - 211 Instead of cementing the smaller pipe NOTICE to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG.
- Page 27 Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-12 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. DO NOT use field-supplied couplings CAUTION to extend pipes. will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly.
-
Page 28: Vertical Direct Venting Vent/Air Termination - Vertical
Vertical direct venting Vent/air termination – vertical Follow instructions WARNING determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to the WARNING vent pipe or multiple boilers to a common vent pipe. -
Page 29: Prepare Roof Penetrations
FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of a Knight boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents. -
Page 30: Vertical Termination - Optional Concentric Vent
Vertical direct venting Vertical termination – optional concentric vent 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. The termination kit must terminate outside the structure and must be installed as shown in FIG. -
Page 31: Vertical Termination - Optional Concentric Vent
Vertical direct venting Vertical termination – optional concentric vent Do not operate the appliance with WARNING the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. -
Page 32: Alternate Vertical Concentric Venting
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. - Page 33 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase AIR INLET FLUE EXHAUST SEAL...
-
Page 34: Hydronic Piping
Chilled water system If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. -
Page 35: Relief Valve / T & P Installation
12. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. -
Page 36: Near Boiler Piping Connections
DHW and space heating. Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger. - Page 37 FT/HD 11.0 15.0 Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude NOTICE models. Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude NOTICE models.
-
Page 38: Variable Speed Pump Option
The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 6B to the boiler high voltage terminal strip.) - Page 39 Hydronic piping Figure 6-4 Single Boiler - Single Temperature Zoned with Circulators PRESSURE PRESSURE GAUGE REDUCING VALVE BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR (WHEN USED) AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) TEMPERATURE / Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 40 Y-STRAINER (RECOMMENDED) (TYPICAL) TEMPERATURE / PRESSURE GAUGE BOILER 2 (MEMBER 1) Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. Model 1-1/4" 1-1/2"...
- Page 41 Hydronic piping Figure 6-6 Single Boiler - Multiple Temperatures PRESSURE REDUCING VALVE BACKFLOW PREVENTER MAKE WATER AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 42 Y-STRAINER (RECOMMENDED) TEMPERATURE / PRESSURE GAUGE BOILER Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 43 Hydronic piping Figure 6-8 Single Boiler - Multiple Temperatures with DHW Piped as a Zone PRESSURE REDUCING VALVE BACKFLOW PREVENTER PRESSURE MAKE WATER AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) (TYPICAL) TEMPERATURE / Mixing valves are required for the protection of low temperature loops.
- Page 44 Y-STRAINER (RECOMMENDED) (TYPICAL) TEMPERATURE / PRESSURE GAUGE BOILER 2 (MEMBER 1) Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. Model 1-1/4" 1-1/2"...
- Page 45 SYSTEM BALL VALVE (TYPICAL) TEMPERATURE / PRESSURE GAUGE BOILER 4 (MEMBER 3) Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. (continued) Model 1-1/4"...
-
Page 46: Gas Connections Connecting Gas Supply Piping
VALVE Figure 7-2 Gas Supply Piping - Model 286 SEDIMENT TRAP / DRIP LEG Installation & Operation Manual 3. Support piping with hangers, not by the boiler or its accessories. The gas valve and blower will not support WARNING the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. -
Page 47: Natural Gas
Pipe sizing for natural gas Failure to 1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas... -
Page 48: Check Inlet Gas Supply
WARNING fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 13). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage. -
Page 49: Gas Pressure
LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Knight boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. -
Page 50: Field Wiring
2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code (see FIG. 8-1). 3. The boiler pump is shipped loose. Wire the boiler pump as shown in FIG. 8-1. 4. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. -
Page 51: Outdoor Temperature Sensor
SMART SYSTEM control to anticipate changes in the building heat load. By connecting this 0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or cascade) can modulate up and down as the primary flow increases and decreases. -
Page 52: Wiring Of The Cascade
Boiler management system 1. An external control may be connected to control either the firing rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the Room Thermostat 1 terminals. - Page 53 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections...
-
Page 54: Condensate Disposal Condensate Drain
1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. -
Page 55: Startup
200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the boiler to directly heat swimming pool or spa water. Test/replace freeze protection fluid 1. -
Page 56: Check For Gas Leaks
Check for gas leaks Before starting the boiler, and during WARNING initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. -
Page 57: Start The Boiler
Check flame and combustion 1. Turn the main power off to the boiler by placing the “On/ Off” switch in the OFF position. 2. Remove the flue temperature sensor from the flue pipe connection. - Page 58 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions...
-
Page 59: Set Space Heating Operation
(if connected), and the boiler (secondary) pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect DHW (Domestic Hot Water) tank, and the set point is not met, it also turns on the boiler pump. -
Page 60: Startup
This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 4 hours. Use the following procedure to set the clock: Press and hold the LEFT SELECT [MENU] key for at least 5 seconds. -
Page 61: Operating Information
The control module regulates blower speed to control the boiler firing rate. The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow. How the control module operates The SMART SYSTEM control module receives inputs from boiler sensors and external devices. -
Page 62: Protection Features
55°F and the minimum off time has expired. Freeze protection DO NOT install the boiler in a room likely to freeze. The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system. -
Page 63: Boiler Temperature Regulation
210°F. When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 190°F, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at 210°F. -
Page 64: Cascade
M1-M2-M3-M4-M5-M6-M7-L Day 1 + 2 hours M2-M3-M4-M5-M6-M7-L-M1 If a boiler is used to heat an indirect DHW tank, or locks out, it will automatically be given the lowest priority for the rest of that 24 hour period. DHW, Night Setback, and Ramp Delay operation... -
Page 65: Sequence Of Operation
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). The flow switch and/or LWCO must close. - Page 66 DHW boiler set point. 9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisfied.
-
Page 67: Knight Boiler Control Module
Operating information Knight boiler control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the... -
Page 68: Access Modes
Remember to press the RIGHT SELECT [HOME] key when finished programming in order to save the changes made. See the Knight Boiler Service Manual for a detailed description of parameters and access modes. Installation & Operation Manual... -
Page 69: Status Display Screens
(BOILER STATUS) (OPERATIONAL INFORMATION) (LEFT SELECT KEY) Section STANDBY START PREPURGE IGNITION (Boiler Status Bar) POSTPURGE SHUTDOWN BLOCKED (Call for Heat Indicators) (continued) (NAVIGATION DIAL) Status Display Screens Display 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. - Page 70 The status of the DHW pump output. The voltage received from a BMS system. The speed signal sent to a variable speed boiler pump in percent. The speed signal received from a variable speed system pump control. A 0 - 10V signal indicating the firing rate of the boiler.
-
Page 71: Status Display Screens
Turning the NAVIGATION dial will increase or decrease the current setting. Press the RIGHT SELECT key to turn the boiler OFF. Press the RIGHT SELECT key to turn the boiler ON. Press the RIGHT SELECT key to cancel the shutdown operation. -
Page 72: Maintenance Maintenance And Annual Startup
• Check condensate drain system • Check air vents • Test low water cutoff (if used) • Reset button (low water cutoff) • Check boiler piping (gas and water) for leaks • Operate relief valve • Shut boiler down (unless boiler... -
Page 73: Check Expansion Tank
2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi). 3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high. -
Page 74: Address Reported Problems
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance WARNING and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure. -
Page 75: Check Burner Flame
4. Replace ground wires if ground continuity is not satisfactory. Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. -
Page 76: Review With Owner
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. -
Page 77: Diagrams
SYSTEM X1-1 PUMP "L" PUMP "N" X1-2 3.15A SYSTEM PUMP BOILER BOILER SYSTEM PUMP PUMP "L" PUMP "N" X1-4 RELAY BOILER PUMP BOILER RELAY PUMP PUMP "L" PUMP "N" X1-3 DHW PUMP RELAY TERMINAL TERMINAL STRIP STRIP 24V DC PUMP... -
Page 78: Wiring Diagram
X1-2 X1-3 Installation & Operation Manual BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING BOX DEPICTS JUNCTION OPTIONAL ITEMS X1-3 PUMP X1-4 BOILER PUMP X1-2 SYSTEM PUMP KB ONLY ON/OFF SWITCH 120V X1-6 SUPPLY X1-5 X1-8 X1-1 TRANSFORMER... - Page 79 Installation & Operation Manual Notes...
-
Page 80: Revision Notes
Revision Notes: Revision A (ECO C05747) initial release. Reflects the new model numbers for the Knight upgrade. Revision B (ECO #C06188) reflects updates made to the ladder and wiring diagrams (ECO #C06158). Revision C (ECO #C06234) reflects changes made to the Service Reminder feature.