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Lochinvar 81 - 286 Installation And Operation Manual
KBII-I-O Rev D
Installation & Operation Manual
Models: 81 - 286
This manual must only be used by
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.
WARNING
Save this manual for future reference.
Summary of 81 - 286
Page 1
Kbii-i-o rev d installation & operation manual models: 81 - 286 this manual must only be used by 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 comp...
Page 2: Hazard Definitions
2 hazard definitions the following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Danger warning caution caution notice danger indicates an imminently hazardous situati...
Page 3
3 installation & operation manual please read before proceeding installer – read all instructions, including this manual and the knight boiler service manual, before installing. Perform steps in the order given. User – this manual is for use only by a qualified heating installer/ service technician....
Page 4
The knight boiler - how it works... 1. Stainless steel heat exchanger allows system water to flow 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. Combustion c...
Page 5
5 installation & operation manual 10 30 24 front view - models 81 - 211 33 18 15 8 14 27 13 20 32 23 10 25 12 28 left side (inside unit) - models 81 - 211 right side (inside unit) - models 81 - 211 the knight boiler - how it works... (continued) 29 31 11 22 6 rear view - models 81 - 211 models 81 - ...
Page 6
6 installation & operation manual the knight boiler - how it works... 18 15 37 model 286 left side (inside unit) - model 286 right side (inside unit) - model 286 front view - model 286 rear view - model 286 10 24 33 4 34.
Page 7: Ratings
7 ratings 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. 3. Net i=b=r ratings are based on net installe...
Page 8: Determine Boiler Location
8 installation & operation manual the knight boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ansi z21.13 – latest edition. Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable...
Page 9: Determine Boiler Location
9 installation & operation manual 1 determine boiler location (continued) alcove installation open front 1/4" (6 mm) minimum clearance around hot water pipes 1” (25 mm) minimum clearance around vent pipe 0” right 18” front 14” rear 12” left 13” top recommended service clearances: front - 24” top - 2...
Page 10: Determine Boiler Location
10 installation & operation manual 1 determine boiler location provide air openings to room: knight boiler alone in boiler room 1. No air ventilation openings into the boiler room are needed when clearances around the knight boiler are at least equal to the service clearances shown in fig.’s 1-1 and...
Page 11: Determine Boiler Location
11 installation & operation manual products to avoid: spray cans containing chloro/fluorocarbons permanent wave solutions chlorinated waxes/cleaners chlorine-based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish re...
Page 12: Determine Boiler Location
Installation & operation manual 12 when removing a boiler from existing common vent system: do not install the knight boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial pr...
Page 13: Prepare Boiler
13 installation & operation manual figure 2-2 installing propane orifice remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. Remove the front door to access the lag bolts in front of the unit (fig. 2-1). 3. To remove the boiler from th...
Page 14: General
14 installation & operation manual 3 general venting figure 3-1 pvc/cpvc two-pipe sidewall termination - see page 21 for more details figure 3-3 pvc/cpvc concentric sidewall termination - see page 25 for more details direct venting options - sidewall vent figure 3-2 stainless steel two-pipe - see pa...
Page 15: General
15 installation & operation manual figure 3-5 stainless steel two- pipe vertical termination - see page 28 for more details figure 3-6 pvc/cpvc concentric vertical termination - see page 30 for more details figure 3-8 stainless steel vertical vent, sidewall air - see page 20 for more details figure ...
Page 16: General
16 installation & operation manual 3 general venting pvc/cpvc vent piping materials use only the materials listed in table 3a for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage. Installation must comply with local requirements...
Page 17: General
Installation & operation manual table 3a vent pipe, and fittings all vent pipe materials and fittings must comply with the following: item material standards for installation in: united states canada vent pipe and fittings pvc plastic pipe, schedules 40, 80, & 120 ansi/astm d1785 cpvc and pvc ventin...
Page 18: General
18 3 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 s...
Page 19: General
19 installation & operation manual 3" s.S. Adapter 3" s.S. Intermediate (for saf-t vent only) figure 3-11 near boiler stainless steel venting model 286 stainless steel air intake/vent connections 1. Combustion air intake connector (fig. 3-11) - used to provide combustion air directly to the unit fro...
Page 20: General
20 installation & operation manual 3 general venting air contamination pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, c...
Page 21: Sidewall Direct
Installation & operation manual 4 sidewall direct venting vent/air termination – sidewall follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not terminate ...
Page 22: Sidewall Direct Venting
Installation & operation manual vent/air termination – sidewall 4 sidewall direct venting alternate venting arrangement (if space permits) bird screen 12” min 12” min 15” max coupling to boiler intake air connection from boiler vent pipe connection bird screen grade or snow line figure 4-1c alternat...
Page 23: Sidewall Direct Venting
23 installation & operation manual forced air inlet vent / air termination 7' min. Above any public walkway if less than 10’ 36" min. Figure 4-3a clearance to forced air inlets 4 sidewall direct venting (continued) prepare wall penetrations (alternate - field supplied option) 1. Air pipe penetration...
Page 24: Sidewall Direct Venting
24 installation & operation manual 12" min. Between edge of air inlet and adjacent vent outlet vent / air termination vent air figure 4-5a multiple vent terminations (must also comply with figure 4-1a) all vent pipes and air inlets must terminate at the same height to avoid possibility of severe per...
Page 25: Sidewall Direct Venting
25 installation & operation manual 4 sidewall direct venting (continued) 4" dia. Sdr-26 pipe 2 1/2" dia. Sdr-26 pipe rain cap "y" concentric fitting figure 4-7 kit contents_cvk3003 sidewall termination installation 1. Determine the best location for the termination kit (see fig. 4-6). 2. The total l...
Page 26: Sidewall Direct Venting
26 installation & operation manual 4 sidewall direct venting sidewall termination – optional concentric vent figure 4-9 concentric vent dimensional drawing - models 81 - 211 instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2...
Page 27: Sidewall Direct Venting
27 installation & operation manual 4 sidewall direct venting (continued) sidewall termination – optional concentric vent multiventing sidewall terminations when two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see fig. 4-13). Never common...
Page 28: Vertical Direct Venting
28 installation & operation manual 5 vertical direct venting vent/air termination – vertical follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Installation must comply with local requirements and with the na...
Page 29: Vertical Direct Venting
29 installation & operation manual 5 vertical direct venting (continued) vent/air termination – vertical prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a ...
Page 30: Vertical Direct Venting
30 installation & operation manual 5 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 terminat...
Page 31: Vertical Direct Venting
31 installation & operation manual 5 vertical direct venting (continued) vertical termination – optional concentric vent figure 5-6 concentric vent roof installation ensure termination height is above the roof surface or anticipated snow level (12 inches in u.S.A. Or 18 inches in canada) as shown in...
Page 32: Vertical Direct Venting
Installation & operation manual 5 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 ve...
Page 33: Vertical Direct Venting
Installation & operation manual 33 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 flue exhaust flue outlet e...
Page 34: Hydronic Piping
34 installation & operation manual 6 hydronic piping system water piping methods the knight is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the bo...
Page 35: Hydronic Piping
35 installation & operation manual relief valve and temperature and pressure gauge installation basic steps are listed below to guide you through the installation of the relief valve and the temperature and pressure (t & p) gauge provided with the unit. 1. Install the tee with the 3/4 inch fitting p...
Page 36: Hydronic Piping
36 installation & operation manual 6 hydronic piping 13. Indirect water heaters: the knight boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. As depicted on pages 39 through 45 there are two options when utilizing an indirect water heater...
Page 37: Hydronic Piping
37 installation & operation manual 0 5 10 15 20 25 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 81 106 151 211 286 flow rate (gpm) pressure drop vs. Flow (includes secondary piping) pressure drop (feet of head) figure 6-3 pressure drop vs. Flow 20°f temperature rise applications mod...
Page 38: Hydronic Piping
Installation & operation manual 38 it is required that near boiler piping systems utilize the primary/secondary configuration shown in fig. 6-10 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit s...
Page 39: Hydronic Piping
Installation & operation manual 39 6 hydronic piping (continued) boiler indirect dhw tank domestic hot water circulator backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve cold water in temperature / pressure gauge air separator expansion tank ball valve (typical) union...
Page 40: Hydronic Piping
40 installation & operation manual 6 hydronic piping indirect dhw tank backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve air separator expansion tank ball valve (typical) drain point (typical) make up water zone circulators (typical) flow check valve (typical) not to ...
Page 41: Hydronic Piping
41 installation & operation manual 6 hydronic piping (continued) please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Notice boiler indirect dhw tank domestic hot water circulator anti...
Page 42: Hydronic Piping
42 installation & operation manual domestic hot water circulator anti-scald mixing valve cold water in air separator ball valve (typical) drain point (typical) make up water hot water out boiler circulator backflow preventer pressure reducing valve pressure gauge expansion tank mixing valves (typica...
Page 43: Hydronic Piping
43 installation & operation manual 6 hydronic piping (continued) boiler indirect dhw tank domestic hot water circulator anti-scald mixing valve cold water in temperature / pressure gauge air separator ball valve (typical) union (typical) drain point (typical) make up water hot water out boiler circu...
Page 44: Hydronic Piping
44 installation & operation manual 6 hydronic piping indirect dhw tank backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve temperature / pressure gauge air separator expansion tank ball valve (typical) drain point (typical) make up water zone valves (typical) boiler cir...
Page 45: Hydronic Piping
45 installation & operation manual 6 hydronic piping (continued) boiler 1 (leader) indirect dhw tank domestic hot water circulator backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve cold water in temperature / pressure gauge air separator expansion tank ball valve (typ...
Page 46: Gas Connections
46 installation & operation manual 7 gas connections connecting gas supply piping 1. Remove the top access panel and refer to fig.’s 7-1 and 7-2 to pipe gas to the boiler. A. Install ground joint union for servicing, when required. B. Install a manual shutoff valve in the gas supply piping outside b...
Page 47: Gas Connections
47 installation & operation manual 7 gas connections (continued) use two wrenches when tightening gas piping at boiler (fig. 7-3), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas li...
Page 48: Gas Connections
48 installation & operation manual 7 gas connections nominal iron pipe size (inches) single unit natural gas pipe capacity chart length of pipe in straight feet for 1/2 psi 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 3/4 369 256 205 174 15...
Page 49: Gas Connections
49 installation & operation manual 7 gas connections (continued) warning when re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe pe...
Page 50: Field Wiring
50 installation & operation manual 8 field wiring electrical shock hazard – for your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be n.E.C. Class 1. I...
Page 51: Field Wiring
51 installation & operation manual 8 field wiring (continued) thermostat 1. Connect the room thermostats or end switches (isolated contact only) to room thermostat 1, 2, or 3, as shown in fig. 8-3. 2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, ...
Page 52: Field Wiring
52 installation & operation manual 8 field wiring system supply sensor 1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The smart system control automatically detects the presence of this sensor, and controls the ...
Page 53: Field Wiring
53 installation & operation manual 8 field wiring (continued) lo u v er r e la y flow s w itch ta n k t h e r m o s t a t ro o m t h e r m o s t a t 3 sy st em s u ppl y sen s o r b u il di ng ma n a g e me n t sy st em lou v er pr ovin g sw itc h co m no low w a t e r c u toff ou t d oo r sen so r ...
Page 54: Condensate Disposal
54 installation & operation manual 9 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 boi...
Page 55: Start-Up
55 installation & operation manual 10 start-up check/control water chemistry do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consul...
Page 56: Start-Up
56 installation & operation manual 10 start-up check for gas leaks before starting the boiler, and during 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. Do not proceed with...
Page 57: Start-Up
57 installation & operation manual 10 start-up (continued) final checks before starting the boiler read the knight boiler service manual to familiarize yourself with smart system control module operation. Read this manual, page 58 for proper steps to start boiler. Verify the boiler and system are fu...
Page 58: Start-Up
58 installation & operation manual 10 start-up figure 10-2 operating instructions.
Page 59: Start-Up
59 installation & operation manual check flame and combustion (continued) set space heating operation determine controlling sensor for space heating systems, the temperature control can be based on one of three sensors; the inlet, outlet, or system supply sensor. The smart system control is programm...
Page 60: Start-Up
60 installation & operation manual 10 start-up set domestic hot water (dhw) operation verify dhw mode there are two (2) modes of operation for dhw. In normal mode, when a dhw demand begins, the control will start the dhw pump, turn off the boiler pump (if running), and modulate to bring the outlet t...
Page 61: Operating Information
61 installation & operation manual 11 operating information general how the boiler operates the knight boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler throu...
Page 62: Operating Information
62 installation & operation manual 11 operating information ramp delay for systems with lower flow, the smart system can limit the firing rate (when enabled) when a space heating call for heat starts, or when switching from a dhw call for heat to a space heating call for heat. There are six (6) limi...
Page 63: Operating Information
High limit operations the knight boiler is equipped with adjustable automatic reset and manual reset high limits. The automatic reset high limit has a maximum set point of 200°f and the manual reset high limit has a maximum set point of 210°f. When the outlet temperature exceeds 200°f, the automatic...
Page 64: Operating Information
64 installation & operation manual 11 operating information cascade when multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the leader control and ...
Page 65: Operating Information
65 operation display 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. 3. The control t...
Page 66: Operating Information
66 11 operating information sequence of operation (continued) operation display 8. If the space heating call for heat is active, and the tank thermostat or sensor starts a dhw call for heat, the boiler will switch to the dhw mode. If programmed for normal dhw operation (not as a zone), the dhw pump ...
Page 67: Operating Information
67 knight boiler control module navigation dial figure 11-1 control panel use the control panel (fig. 11-1) to set temperatures, operating conditions, and monitor boiler operation. 11 operating information (continued) the information on the bottom of the display shows the functions of the two select...
Page 68: Operating Information
68 installation & operation manual access modes user the user can adjust space heating and tank target temperatures by pressing the navigation dial when “ setpoints” is flashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 60). Installer mo...
Page 69: Operating Information
69 installation & operation manual 11 operating information (continued) status display screens section display description a (boiler status bar) standby 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. Start the unit has be...
Page 70: Operating Information
70 installation & operation manual 11 operating information status display screens (cont’d) section display description c (operational information) system: the temperature read by the system supply sensor (if connected). Tank: the temperature read by the tank sensor (if connected). Outdoor: the temp...
Page 71: Operating Information
71 11 operating information (continued) status display screens (cont’d) section display description e (navigation dial function) turning the navigation dial will select the next or previous status screen. Pressing the navigation dial will show the next fault, nsb (night setback) trigger, or ramp del...
Page 72: Maintenance
Installation & operation manual 12 maintenance maintenance and annual startup table 12a service and maintenance schedules service technician (see the following pages for instructions) general: • address reported problems • inspect interior; clean and vacuum if necessary; • clean condensate trap and ...
Page 73: Maintenance
Installation & operation manual 12 maintenance (continued) flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly ...
Page 74: Maintenance
Installation & operation manual 12 maintenance follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directio...
Page 75: Maintenance
Installation & operation manual 12 maintenance (continued) inspect ignition and flame sense electrodes 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the elect...
Page 76: Maintenance
Installation & operation manual review with owner 1. Review the knight boiler user’s information manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the knight boiler user’s information manual (and in this manual as well). 3. Remind the owner of the need to ...
Page 77: Diagrams
Installation & operation manual 13 diagrams box depicts optional items ladder diagram lbl20148 rev c 120 vac 24 vac 120vac terminal strip 120v supply "l" on / off switch x1-6 f2 neutral flow cn5-6 cn5-12 cn5-11 x4-2 x4-10 x4-11 integrated control low gas pressure switch high gas pressure switch louv...
Page 78: Diagrams
Installation & operation manual 78 x1-7 on/off switch 1 2 3 4 5 g r r w r t w bk y bl blower -t high limit sensor s1b operating sensor s1a inlet sensor s2 flue sensor s3a flue sensor s3b integrated control bk y gas valve @24vac spark rod transformer tr2 g high voltage spark lead caution flame sensor...
Page 79: Notes
Installation & operation manual 79 notes.
Page 80
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. Revision d (...