Lochinvar 81 286 User Manual

KBII-USER Rev D  
User’s Information Manual  
Models: 81 - 286  
ƽ WARNING  
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.  
Save this manual for future reference.  
User’s Information Manual  
Please read before proceeding  
The Knight Boiler Installation and  
Operation Manual along with the Knight  
Boiler service and maintenance –  
NOTICE  
• To avoid electric shock, disconnect electrical supply  
before performing maintenance.  
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).  
• 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.  
When calling or writing about the boiler  
NOTICE  
– Please have the boiler model and serial  
• 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.  
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.  
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.  
Factory warranty (shipped with unit) does  
not apply to units improperly installed or  
improperly operated.  
• 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.  
Failure to adhere to the guidelines on this  
ƽ WARNING  
page can result in severe personal injury,  
death, or 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.  
3
User’s Information Manual  
1 Prevent combustion air contamination  
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.  
ƽ WARNING  
Table 1 Corrosive Contaminants and Sources  
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  
If the boiler combustion air inlet is located  
in a laundry room or pool facility, for  
example, these areas will always contain  
hazardous contaminants.  
ƽ WARNING  
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.  
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  
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.  
Adhesives used to fasten building products and other similar  
products  
Areas likely to have contaminants  
Dry cleaning/laundry areas and establishments  
Swimming pools  
To prevent the potential of severe personal  
ƽ WARNING  
injury or death, check for areas and  
products listed in Table 1 before installing  
the boiler or air inlet piping.  
Metal fabrication plants  
Beauty shops  
If contaminants are found, you MUST:  
• Remove contaminants permanently.  
—OR—  
Refrigeration repair shops  
Photo processing plants  
• Relocate air inlet and vent  
terminations to other areas.  
Auto body shops  
Plastic manufacturing plants  
Furniture refinishing areas and establishments  
New building construction  
Remodeling areas  
Garages with workshops  
4
User’s Information Manual  
2 Maintenance schedule  
Owner maintenance  
Service technician  
(see pages 6 - 8 for detailed instructions)  
(see the Knight Boiler Service Manual)  
• Check boiler area  
General:  
• Check pressure/temperature  
• Reported problems  
gauge  
• Inspect interior; clean and vacuum if  
necessary  
Daily  
• Clean condensate trap and fill with fresh  
water  
• Check for leaks (water, gas, flue,  
condensate)  
• Check vent piping  
• Check air piping  
• Verify flue and air lines in good condition  
and sealed tight  
• Check system water pressure/system  
piping/expansion tank  
Monthly  
• Check air and vent termination  
screens  
• Check control settings  
• Check relief valve  
• Check condensate drain system  
• Check air vents  
• 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.  
• Test low water cutoff (if used)  
Periodically  
• Reset button (low water cutoff)  
• Flame inspection (stable, uniform)  
• Flame signal (at least 4 mA)  
• Check boiler piping (gas and  
water) for leaks  
• Clean the heat exchanger if flue  
temperature is more than 54°F above  
return water temperature.  
Every  
6 months  
• Operate relief valve  
If combustion or performance  
indicate need:  
• Clean heat exchanger  
End  
of season  
months  
•Shut boiler down (unless boiler  
used for domestic hot water)  
• Remove and clean burner using  
compressed air only  
• Clean the blower wheel  
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.  
ƽ WARNING  
5
User’s Information Manual  
2 Maintenance schedule  
Maintenance procedures  
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.  
Boiler must be serviced and maintained  
The boiler must be inspected and started  
ƽ WARNING  
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.  
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  
The following information provides  
NOTICE  
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.  
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.  
Failure to inspect the vent system as noted  
ƽ WARNING  
above and have it repaired by a qualified  
service technician can result in vent system  
failure, causing severe personal injury or  
death.  
Check boiler area  
Check air piping  
To prevent potential of severe personal  
ƽ WARNING  
injury, death, or substantial property  
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.  
damage, eliminate all materials discussed  
below from the boiler vicinity and the  
vicinity of the boiler combustion air inlet.  
If contaminants are found:  
2. Call your qualified service technician if you notice any  
problems.  
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.  
Check relief valve  
1. Inspect the boiler relief valve and the relief valve  
discharge pipe for signs of weeping or leakage.  
If products cannot be removed,  
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.  
immediately call  
a
qualified service  
technician to re-pipe vent and air piping  
and locate vent termination/air intake  
away from contaminated areas.  
Check condensate drain system  
1. Combustible/flammable materials -- Do not store  
combustible materials, gasoline or any other flammable  
vapors or liquids near the boiler. Remove immediately if  
found.  
1. Inspect the condensate drain line, condensate PVC  
fittings and condensate trap.  
Fill condensate trap with water  
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.  
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).  
6
User’s Information Manual  
2 Maintenance schedule  
(continued)  
3. Fill with fresh water until the water begins to pour out of  
the drain.  
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.  
NOTICE  
4. Replace the cap. Press the cap onto the trap until the cap  
makes contact with the drain.  
5. Replace the retaining screw.  
The condensate trap (FIG. 1) must be  
filled with water during all times of boiler  
ƽ WARNING  
operation to avoid flue gas emission from  
the condensate drain line. Failure to fill  
the trap could result in severe personal  
injury or death.  
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.  
NOTICE  
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.  
Figure 1 Condensate Trap  
RETAINING  
SCREW  
2” PVC CAP WITH  
BLOCKED DRAIN SWITCH  
PVC TEE ASSEMBLY  
(FACTORY SUPPLIED)  
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.  
CONDENSATE FROM  
HEAT EXCHANGER  
TO FLOOR  
DRAIN  
Condensate disposal  
Figure 2 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.  
1/2" PVC TEE ASSEMBLY  
(FACTORY SUPPLIED)  
A
Neutralizer Kit is available from the factory  
1/2" PVC UNION  
(FACTORY SUPPLIED)  
(Kit #3087). Call your qualified service technician to  
install.  
NEUTRALIZER KIT  
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.  
FLOOR DRAIN OR  
DRAIN PAN  
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).  
7
User’s Information Manual  
2 Maintenance schedule  
Check air vents  
Have leaks fixed at once by a qualified  
service technician. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
ƽ WARNING  
1. Reference FIG. 3 below.  
2. Visually inspect vent to make sure that no leaks are  
present.  
3. Replace the front access door.  
3. If there is leaking, tighten the pin valve.  
4. If the leak continues, replace the air vent.  
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.  
Figure 3 Manual Air Vent  
MANUAL  
AIR VENT VALVE  
To avoid water damage or scalding due  
ƽ WARNING  
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.  
Test low water cutoff (if installed)  
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.  
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.  
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.  
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)  
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.  
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.  
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.  
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User’s Information Manual  
3 Operating instructions  
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