Lochinvar Knight 81 Guide

User’s Information Manual

Models: 81 - 286

If the information in this manual is not followed exactly, a fire or

explosion may result causing property damage, personal injury or

loss of life.

This appliance MUST NOT be installed in any location where

gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your

building.

• Immediately call your gas supplier from a near by phone.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified

installer, service agency, or the gas supplier.

WARNING

Save this manual for future reference.

KBII-USER Rev D

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 situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not

related to personal injury or property damage.

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

1. PREVENT COMBUSTION AIR CONTAMINATION..... 4

2. MAINTENANCE SCHEDULE....................................... 5

Maintenance Procedures................................................... 6

Boiler Must Be Serviced and Maintained .................... 6

Check Boiler Area......................................................... 6

Check Pressure Temperature Gauge........................... 6

Check Vent Piping........................................................ 6

Check Air Piping........................................................... 6

Check Relief Valve....................................................... 6

Check Condensate Drain System ............................. 6-7

Check Air Vents............................................................ 8

Test Low Water Cutoff (if installed).............................. 8

Reset Button (low water cutoff).................................... 8

Check Boiler Piping (gas and water)............................ 8

Operate Relief Valve .................................................... 8

Shut Boiler Down.......................................................... 8

3. OPERATING INSTRUCTIONS..................................... 9

4. SMART SYSTEM CONTROL MODULE

SMART SYSTEM Control Module................................... 10

Access Modes ............................................................ 10

Saving Parameters..................................................... 10

Adjusting Parameters ............................................ 10-11

Status Display Screens ......................................... 12-14

Notes................................................................................. 15

Revision Notes.................................................. Back Cover

User’s Information Manual

Please read before proceeding

The Knight Boiler Installation and

Operation Manual along with the Knight

Boiler Service Manual are for use only

by a qualified heating installer/service

technician. Refer only to this User’s

Information Manual for your reference.

Improper installation, adjustment,

alteration, service or maintenance can

cause property damage, personal injury

(exposure to hazardous materials) or loss

of life. Installation and service must be

performed by a qualified installer, service

agency or the gas supplier (who must

read and follow the supplied instruction

before installing, servicing, or removing

this boiler. This boiler contains materials

that have been identified as carcinogenic,

or possibly carcinogenic, to humans).

Failure to adhere to the guidelines on this

page can result in severe personal injury,

death, or substantial property damage.

Boiler service and maintenance –

• To avoid electric shock, disconnect electrical supply

before performing maintenance.

• To avoid severe burns, allow boiler to cool before

performing maintenance.

Boiler operation –

• Do not block flow of combustion or ventilation air to

the boiler. This boiler is equipped with a control which

will automatically shut down the boiler should air or

vent be blocked. If vent or air blockage is easily

accessible and removable, remove it. The boiler should

attempt to restart. If blockage is not obvious or cannot

be removed, have the boiler and system checked by a

qualified service technician.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to the

circulator. 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.

Boiler water –

• Thoroughly flush the system (without boiler

connected) to remove sediment. The high-efficiency

heat exchanger can be damaged by build-up or

corrosion due to sediment.

• Do not use petroleum-based cleaning or sealing

compounds in the boiler system. Gaskets and seals in

the system may be damaged. This can result in

substantial property damage.

• Do not use “homemade cures” or “boiler patent

medicines”. Serious damage to the boiler, personnel,

and/or property may result.

• Continual fresh make-up water will reduce boiler life.

Mineral buildup in the heat exchanger reduces heat

transfer, overheats the stainless steel heat exchanger,

and causes failure. Addition of oxygen carried in by

makeup water can cause internal corrosion. Leaks in

boiler or piping must be repaired at once to prevent

makeup water.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited

propylene glycol solutions, which are specifically

formulated for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used in hydronic

systems.

When calling or writing about the boiler

– Please have the boiler model and serial

number from the boiler rating plate.

Consider piping and installation when

determining boiler location.

Any claims for damage or shortage in

shipment must be filed immediately

against the transportation company by

the consignee.

Factory warranty (shipped with unit) does

not apply to units improperly installed or

improperly operated.

NOTICE

WARNING

NOTICE

User’s Information Manual

1 Prevent combustion air contamination

If the boiler combustion air inlet is located

in a laundry room or pool facility, for

example, these areas will always contain

hazardous contaminants.

To prevent the potential of severe personal

injury or death, check for areas and

products listed in Table 1 before installing

the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently.

—OR—

• Relocate air inlet and vent

terminations to other areas.

WARNING

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 removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other similar

products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1 Corrosive Contaminants and Sources

WARNING If the boiler combustion air inlet is located

in any area likely to cause contamination,

or if products which would contaminate

the air cannot be removed, you must have

the combustion air and vent re-piped

and terminated to another location.

Contaminated combustion air will damage

the boiler, resulting in possible severe

personal injury, death, or substantial

property damage.

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, causing serious damage and presenting a possible

threat of flue gas spillage or boiler water leakage into the

building.

Please read the information listed in Table 1. If contaminating

chemicals will be present near the location of the boiler

combustion air inlet, have your installer pipe the boiler

combustion air and vent to another location, per the Knight

Boiler Installation and Operation Manual.

User’s Information Manual

2 Maintenance schedule

Service technician

(see the Knight Boiler Service Manual)

General:

• Reported problems

• Inspect interior; clean and vacuum if

necessary

• Clean condensate trap and fill with fresh

water

•Check for leaks (water, gas, flue,

condensate)

• Verify flue and air lines in good condition

and sealed tight

•Check system water pressure/system

piping/expansion tank

• Check control settings

•Ignition and flame sense electrodes

(sand off any deposits; clean and

reposition)

• Wiring and connections

•Perform start-up checkout and

performance verification per Section 10

in the Knight Installation and Operation

Manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 4 mA)

•Clean the heat exchanger if flue

temperature is more than 54°F above

return water temperature.

If combustion or performance

indicate need:

• Clean heat exchanger

•Remove and clean burner using

compressed air only

• Clean the blower wheel

Owner maintenance

(see pages 6 - 8 for detailed instructions)

Daily

• Check boiler area

•Check pressure/temperature

gauge

Monthly

• Check vent piping

• Check air piping

• Check air and vent termination

screens

• Check relief valve

• Check condensate drain system

•Check air vents

Periodically • Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

•Check boiler piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

•Shut boiler down (unless boiler

used for domestic hot water)

WARNING Follow the maintenance procedures given throughout this manual. Failure to perform the service and

maintenance or follow the directions in this manual could result in damage to the boiler or system,

resulting in severe personal injury, death, or substantial property damage.

ANNUAL START-UP

User’s Information Manual

2 Maintenance schedule

Maintenance procedures

Boiler must be serviced and maintained

WARNING The boiler must be inspected and started

annually at the beginning of the heating

season by a qualified service technician.

In addition, the maintenance and care

of the boiler designated on page 5 of this

manual and explained on pages 6 through

8 must be performed to assure maximum

boiler efficiency and reliability. Failure to

service and maintain the boiler and system

could result in equipment failure, causing

possible severe personal injury, death, or

substantial property damage.

NOTICE The following information provides

detailed instructions for completing

the maintenance items listed in the

maintenance schedule on page 5. In

addition to this maintenance, the boiler

must be serviced and started up at the

beginning of each heating season by a

qualified service technician.

Check boiler area

WARNING To prevent potential of severe personal

injury, death, or substantial property

damage, eliminate all materials discussed

below from the boiler vicinity and the

vicinity of the boiler combustion air inlet.

If contaminants are found:

Remove products immediately from the

area. If they have been there for an

extended period, call a qualified service

technician to inspect the boiler for possible

damage from acid corrosion.

If products cannot be removed,

immediately call a qualified service

technician to re-pipe vent and air piping

and locate vent termination/air intake

away from contaminated areas.

1. Combustible/flammable materials -- Do not store

combustible materials, gasoline or any other flammable

vapors or liquids near the boiler. Remove immediately if

found.

2. Air contaminants -- Products containing chlorine or

fluorine, if allowed to contaminate the boiler intake air,

will cause acidic condensate in the boiler. This will cause

significant damage to the boiler if allowed to continue.

Read the list of potential materials listed in Table 1 on

page 4 of this manual. If any of these products are in the

room from which the boiler takes its combustion air, they

must be removed immediately or the boiler combustion

air (and vent termination) must be relocated to another

area.

Check pressure/temperature gauge

1. Make sure the pressure reading on the boiler pressure/

temperature gauge does not exceed 24 psi. Higher

pressure may indicate a problem with the expansion

tank.

2. Contact a qualified service technician if problem persists.

Check vent piping

1. Visually inspect the flue gas vent piping for any signs of

blockage, leakage, or deterioration of the piping. Notify

your qualified service technician at once if you find any

problems.

WARNING Failure to inspect the vent system as noted

above and have it repaired by a qualified

service technician can result in vent system

failure, causing severe personal injury or

death.

Check air piping

1. Visually inspect the air inlet termination to be sure it is

unobstructed. Inspect the entire length of air piping to

ensure piping is intact and all joints are properly sealed.

2. Call your qualified service technician if you notice any

problems.

Check relief valve

1. Inspect the boiler relief valve and the relief valve

discharge pipe for signs of weeping or leakage.

2. If the relief valve often weeps, the expansion tank may

not be working properly. Immediately contact your

qualified service technician to inspect the boiler and

system.

Check condensate drain system

1. Inspect the condensate drain line, condensate PVC

fittings and condensate trap.

Fill condensate trap with water

1. Remove the PVC cap retaining screw from the PVC cap

(FIG. 1).

2. Remove the 2" PVC cap with the switch located at the top

of the trap (FIG. 1).

User’s Information Manual

2 Maintenance schedule (continued)

3. Fill with fresh water until the water begins to pour out of

the drain.

4. Replace the cap. Press the cap onto the trap until the cap

makes contact with the drain.

5. Replace the retaining screw.

WARNING The condensate trap (FIG. 1) must be

filled with water during all times of boiler

operation to avoid flue gas emission from

the condensate drain line. Failure to fill

the trap could result in severe personal

injury or death.

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

TO FLOOR

DRAIN

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

Figure 1 Condensate Trap

Condensate disposal

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. 2).

3. Slope condensate tubing down and away from the

boiler into a drain or condensate neutralizing filter.

Condensate from the Knight boiler will be slightly acidic

(typically with a pH from 3 to 5). Install a neutralizing

filter if required by local codes. Call your qualified service

technician to inspect the boiler and system.

A Neutralizer Kit is available from the factory

(Kit #3087). Call your qualified service technician to

install.

4. Install the 1/2 inch PVC tee assembly (shipped with the

unit) as shown in FIG. 2. Call your qualified service

technician to inspect the boiler and system.

5. Leave the top of the 1/2 inch tee OPEN. This is needed as

a vacuum break.

6. Do not expose condensate line to freezing temperatures.

7. Use only plastic tubing or piping as a condensate drain

line (FIG. 2).

Use materials approved by the authority

having jurisdiction. In the absence of

other authority, PVC and CPVC pipe

must comply with ASTM D1785 or D2845.

Cement and primer must comply with

ASME D2564 or F493. For Canada use

CSA or ULC certified PVC or CPVC pipe,

fittings, and cement.

8. A condensate removal pump is required if the boiler is

below the drain. When installing a condensate pump,

select one approved for use with condensing boilers

and furnaces. The pump should have an overflow

switch to prevent property damage from condensate

spillage. Call your qualified service technician to inspect

the boiler and system.

NOTICE

NOTICE To allow for proper drainage on large

horizontal runs, a second line vent may

be required and tubing size may need to

increase to 1 inch.

The condensate line must remain

unobstructed, allowing free flow of

condensate. If condensate is allowed to

freeze in the line or if the line is obstructed

in any other manner, condensate can exit

from the boiler tee, resulting in potential

water damage to property. Call your

qualified service technician to inspect

the boiler and system.

1/2" PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

1/2" PVC UNION

(FACTORY SUPPLIED)

FLOOR DRAIN OR

DRAIN PAN

NEUTRALIZER KIT

Figure 2 Condensate Disposal

User’s Information Manual

2 Maintenance schedule

WARNING Have leaks fixed at once by a qualified

service technician. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

Operate relief valve

1. Before proceeding, verify that the relief valve outlet has

been piped to a safe place of discharge, avoiding any

possibility of scalding from hot water.

WARNING To avoid water damage or scalding due

to valve operation, a metal discharge

line must be connected to the relief

valve outlet and run to a safe place of

disposal. This discharge line must be

installed by a qualified heating installer

or service technician in accordance with

the instructions in the Knight Boiler

Installation and Operation Manual. The

discharge line must be terminated so as

to eliminate possibility of severe burns

or property damage should the valve

discharge.

2. Read the boiler pressure/temperature gauge to make

sure the system is pressurized. Lift the relief valve

top lever slightly, allowing water to relieve through

the valve and discharge piping.

3. If water flows freely, release the lever and allow the valve

to seat. Watch the end of the relief valve discharge pipe

to ensure that the valve does not weep after the line has

had time to drain. If the valve weeps, lift the seat again to

attempt to clean the valve seat. If the valve continues to

weep afterwards, contact your qualified service

technician to inspect the valve and system.

4. If water does not flow from the valve when you lift the

lever completely, the valve or discharge line may be

blocked. Immediately shut down the boiler, following

the operating instructions on page 9 of this manual. Call

your qualified service technician to inspect the boiler and

system.

Shut boiler down (unless boiler is used

for Domestic Water)

1. Follow “To Turn Off Gas to Appliance” on page 9 of this

manual.

2. Do not drain the system unless exposure to freezing

temperatures will occur.

3. Do not drain the system if it is filled with an antifreeze

solution.

4. DO NOT shut down boilers used for domestic water

heating, they must operate year-round.

Check air vents

1. Reference FIG. 3 below.

2. Visually inspect vent to make sure that no leaks are

present.

3. If there is leaking, tighten the pin valve.

4. If the leak continues, replace the air vent.

3. Replace the front access door.

Test low water cutoff (if installed)

1. If the system is equipped with a low water cutoff, test the

low water cutoff periodically during the heating season,

following the low water cutoff manufacturer’s

instructions.

Reset button (low water cutoff)

1. Testing the low water cutoff shuts the unit off. Press the

RESET button on the low water cutoff to turn the unit

back on.

Check boiler piping (gas and water)

1. Remove the boiler front access door and perform a gas

leak inspection per steps 1 through 7 of the Operating

Instructions on page 9. If gas odor or leak is detected,

immediately shut down the boiler following the

procedures on page 9. Call a qualified service technician.

2. Visually inspect for leaks around water piping.

Also inspect the circulators, relief valve, and fittings.

Immediately call a qualified service technician to repair

any leaks.

Figure 3 Manual Air Vent

MANUAL

AIR VENT VALVE

User’s Information Manual

3 Operating instructions

NAVIGATION DIAL

Figure 4 Control Panel

Knight boiler control module

Use the control panel (FIG. 4) to set temperatures, operating conditions, and monitor boiler operation.

4 SMART SYSTEM control module

User’s Information Manual

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the

NAVIGATION dial (in the center): MENU = Left SELECT Key

SETPOINTS = NAVIGATION Dial - Pressing Down

SHDN = Right SELECT Key

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 user can adjust the date and time, temperature units,

and night setback override (if active) by pressing the

LEFT SELECT [MENU] key for 5 seconds. When the user

password “0000” appears, then press the RIGHT SELECT

[SAVE] key (do not change the password).

Installer

Most parameters are available only to the installer, accessible

only by entering the installer password, see the Knight

Boiler Service Manual.

Saving parameters

Press the RIGHT SELECT [SAVE] key one time to return to

the parameter listing. Press the RIGHT SELECT [HOME]

key again to store the new settings and return to the Status

Screen.

Please note that the brackets ([]) denote

screen status.

NOTICE

Adjusting parameters

CAUTION Before changing parameters, note the

settings so that the unit can be returned to

its original operating parameters.

The control uses an internal clock for the night setback feature

and for logging of events. For these features to work properly,

the clock must be set when the boiler is first installed or any

time the boiler has been powered off for more than four (4)

hours. This parameter must be accessed to set the clock.

NOTICE The internal clock does not adjust for

Daylight Savings Time and therefore,

will require a manual adjustment.

To set the clock, access the clock menu as described in the

User section. Rotate the NAVIGATION dial (if needed) until

the arrow (>) is pointing to “TIME & DATE”. Press the

NAVIGATION dial once. If the date and time are incorrect,

press the NAVIGATION dial again. The hours value will

begin flashing. Rotate the NAVIGATION dial until the hour

and AM/PM values are correct. Press the NAVIGATION

dial again. The minutes value will begin flashing. Rotate

the NAVIGATION dial to adjust the minutes. Repeat this

procedure to adjust the month, date and year. Save the

new settings as described in the Saving Parameters section

(this page).

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