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Lochinvar Knight 151 Installation & Operation Manual

Manual is about: Condensing water heater

Summary of Knight 151

  • Page 1

    Okb-i-o rev c outdoor knight boiler installation & operation manual models: 151 - 286 this manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the outdoor knight boiler service manual, before installing. Perform steps in th...

  • 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 outdoor knight boiler installation & operation manual please read before proceeding installer – read all instructions, including this manual and the outdoor knight boiler service manual, before installing. Perform steps in the order given. User – this manual is for use only by a qualified heating ...

  • Page 4

    The outdoor 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. Comb...

  • Page 5

    5 img00365 30 10 24 23 31 img00365 front view - models 151 - 211 10 25 28 33 15 8 14 27 13 32 22 39 1 img00367 19 left side (inside unit) - models 151 - 211 right side (inside unit) - models 151 - 211 the outdoor knight boiler - how it works... (continued) 21 29 11 6 img00366 38 rear view - models 1...

  • Page 6

    6 the outdoor knight boiler - how it works... Img00380 15 37 21 29 38 6 11 39 model 286 left side (inside unit) - model 286 right side (inside unit) - model 286 front view - model 286 rear view - model 286 img00379 24 23 10 31 30 img00381 4 33 25 28 5 36 2 22 32 19 13 27 14 8 15 18 20 10 img00382 34...

  • Page 7: Ratings

    7 ratings a s m e h notes: 1. As an energy star partner, lochinvar has determined that outdoor 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 ahri ratings are based on ne...

  • Page 8: Determine Boiler Location

    8 1 determine boiler location the outdoor knight gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ansi z21.13 – latest edition. Installation must comply with: • local, state, provincial, and national codes, laws, regulations, and...

  • Page 9: Determine Boiler Location

    9 1 determine boiler location (continued) table 1a corrosive contaminants and sources provide clearances: clearances from combustible materials 1. Hot water pipes—at least 1/4" (6 mm) from combustible materials. 2. Vent pipes—minimum of 14" (356mm) from the rear and 0" on the right side from combust...

  • Page 10: Prepare Boiler

    10 remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the installation kit. 2. Remove the front access covers to access the lag bolts in front of the unit (fig. 2-1). 3. To remove the boiler from the pallet (after removing the front access covers): a. ...

  • Page 11: Prepare Boiler

    5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the lp caution label (in the conversion kit bag) to the left side of the unit in the lower left corner. 6. Replace the top and front access covers. 11 2 prepare ...

  • Page 12: Hydronic Piping

    12 3 hydronic piping system water piping methods the outdoor boiler 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 boiler outlet. It is impor...

  • Page 13: Hydronic Piping

    13 *see the piping illustrations included in this section, fig.’s 3-4 thru 3-10 for suggested guidelines in piping the outdoor boiler with either zone valves or circulator pumps. *please note that these illustrations are meant to show system piping concept only, the installer is responsible for all ...

  • Page 14: Hydronic Piping

    14 3 hydronic piping 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. Typically the sensor will be located far enough downstream to sense system dilu...

  • Page 15: Hydronic Piping

    15 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 25 151 211 286 flow rate (gpm) pressure drop vs. Flow (includes secondary piping) pressure drop (feet of head) figure 3-3 pressure drop vs. Flow 20°f temperature rise applications model gpm ft/hd minimum pipe size pump gru...

  • Page 16: Hydronic Piping

    16 it is required that near boiler piping systems utilize the primary/secondary configuration shown in fig. 3-10 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system perform...

  • Page 17: Hydronic Piping

    17 3 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 zone #1 zone #2 zone #3 zone #4 ball valve (typical) union...

  • Page 18: Hydronic Piping

    18 3 hydronic piping indirect dhw tank backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve air separator expansion tank zone #1 zone #2 zone #3 zone #4 ball valve (typical) drain point (typical) make up water zone circulators (typical) flow check valve (typical) not to ...

  • Page 19: Hydronic Piping

    19 3 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. Indoor tank shown for illustration purposes. Notice boiler indirect dhw tank domestic hot water ci...

  • Page 20: Hydronic Piping

    20 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 (typical) flow check valve system suppl...

  • Page 21: Hydronic Piping

    21 3 hydronic piping (continued) 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 (typical)...

  • Page 22: Hydronic Piping

    22 3 hydronic piping indirect dhw tank backflow preventer pressure reducing valve pressure gauge anti-scald mixing valve temperature / pressure gauge air separator expansion tank zone #1 zone #2 ball valve (typical) drain point (typical) make up water zone valves (typical) boiler circulator boiler 2...

  • Page 23: Hydronic Piping

    23 3 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 (typical) union (typical) drain poin...

  • Page 24: Gas Connections

    24 4 gas connections connecting gas supply piping 1. Remove the top access cover and refer to fig. 4-1 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 boiler jacket when required by local codes ...

  • Page 25: Gas Connections

    25 4 gas connections (continued) use two wrenches when tightening gas piping at boiler (fig. 4-2), 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 line components. Img00384 use back...

  • Page 26: Gas Connections

    26 4 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 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 7...

  • Page 27: Gas Connections

    27 4 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 personal injury, death, or substan...

  • Page 28: Field Wiring

    5 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. If original wiring as supplied with ...

  • Page 29: Field Wiring

    29 5 field wiring (continued) thermostat 1. Connect the room thermostats or end switches (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in fig. 5-3. 2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, ...

  • Page 30: Field Wiring

    30 5 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 boiler firing rate to maintain t...

  • Page 31: Field Wiring

    31 5 field wiring (continued) flow sw itch t a nk ther m o st at r oom therm o stat 3 sy stem suppl y sensor bu ildin g ma n a g e m e n t sy st em com no low w a t e r c u toff outd oor sensor tank sens o r shield sh ield to ne x t boiler a b a b fr om previous boiler r oom therm o stat 1 r oom the...

  • Page 32: Condensate Disposal

    6 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. 6-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neut...

  • Page 33: Start-Up

    33 7 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. Consult local water treatment companies...

  • Page 34: Start-Up

    34 7 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 cover and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indicati...

  • Page 35: Start-Up

    35 7 start-up (continued) final checks before starting the boiler read the outdoor knight boiler service manual to familiarize yourself with smart system control module operation. Read this manual, page 36 for proper steps to start boiler. Verify the boiler and system are full of water and all syste...

  • Page 36: Start-Up

    36 7 start-up figure 7-2 operating instructions outdoor knight boiler installation & operation manual.

  • Page 37: Start-Up

    37 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 programmed at the factory to control the...

  • Page 38: Start-Up

    7 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 temperature to the dhw boiler set poi...

  • Page 39: Operating Information

    39 8 operating information general how the boiler operates the outdoor 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 through the heat exchanger and flue p...

  • Page 40: Operating Information

    40 8 operating information temperature control modulation the outdoor boiler is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the call for heat (i.E., space heating or domestic hot water), the heating load, ramp delay (if enabled), a...

  • Page 41: Operating Information

    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. H...

  • Page 42: Operating Information

    42 8 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 all others would be designated as...

  • Page 43: Operating Information

    43 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 air press...

  • Page 44: Operating Information

    44 8 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 w...

  • Page 45: Operating Information

    45 outdoor knight boiler control module figure 8-1 control panel use the control panel (fig. 8-1) to set temperatures, operating conditions, and monitor boiler operation. 8 operating information (continued) the information on the bottom of the display shows the functions of the two select keys (on e...

  • Page 46: Operating Information

    46 8 operating information 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 begun a burn cycle and is checking all safety c...

  • Page 47: Operating Information

    47 8 operating information (continued) 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 temperature read by the o...

  • Page 48: Operating Information

    48 8 operating information status display screens (cont’d) section display description d (left select key function) menu press and hold the left select key for 5 seconds to enter the menu screen. Exit press the left select key to exit the current screen or setting. Yes press the left select key to c...

  • Page 49: Maintenance

    9 maintenance maintenance and annual startup table 9a 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 fill with fresh water • check for ...

  • Page 50: Maintenance

    9 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 directions in this manual and component l...

  • Page 51: Maintenance

    9 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. 2. Verify that boiler vent discharge and air intake are clean and free of obstructions...

  • Page 52: Maintenance

    9 maintenance 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 electrodes cannot be cleaned satisfactorily, repla...

  • Page 53: Maintenance

    Review with owner 1. Review the outdoor knight boiler user’s information manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the outdoor knight boiler user’s information manual (and in this manual as well). 3. Remind the owner of the need to call a licensed ...

  • Page 54: Diagrams

    10 diagrams box depicts optional items ladder diagram lbl20148 rev d 120 vac 24 vac 120vac terminal strip 120v supply "l" on / off switch x1-6 f2 neutral cn5-6 cn5-12 cn5-11 x4-2 x4-10 x4-11 integrated control louver relay coil 24vac louver proving switch cn5-4 x4-4 x2-1 gas valve gas valve relay x5...

  • Page 55: Diagrams

    55 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 alarm contacts run-time contact...

  • Page 56

    Revision notes: revision a (eco c11234) initial release. Revision b (eco #c11235) reflects updates made to the freezing conditions warnings. Revision c (eco #c11736) reflects changes made to the ratings page (page 7). Okb-i-o rev c 11/12.