Lochinvar Knight 55 - User Manual

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Overview

Function Description
Important Technical Specifications (as inferred from the manual)
Usage Features
Maintenance Features

The provided document is the User's Information Manual for the Lochinvar KNIGHT Fire Tube Boiler, specifically covering models 55 - 285. This manual outlines the operation, maintenance, and safety guidelines for the high-efficiency boiler and water heater system.

Function Description:

The Lochinvar KNIGHT Fire Tube Boiler is a high-efficiency appliance designed for space heating and domestic hot water (DHW) production. It utilizes a fire tube heat exchanger design, which contributes to its high efficiency. The boiler is controlled by a "SMART SYSTEM" control module that allows users and qualified installers to monitor and adjust various operating parameters, set temperatures, and manage system functions. The system can operate in different modes for space heating and DHW, including normal and zone modes for DHW, and offers features like night setback and cascade operation (though cascade details are less prominent in this user manual). The boiler is designed to produce condensate due to its high-efficiency operation, and proper condensate drainage is crucial.

Important Technical Specifications (as inferred from the manual):

Models Covered: 55 - 285 (likely referring to BTU/hr input or output, though not explicitly stated as such).
Heat Exchanger Type: Fire Tube.
Control System: SMART SYSTEM control module with a display, USB memory drive, and PC connection for advanced diagnostics and programming.
Operating Pressure: The manual advises ensuring the pressure reading on the boiler pressure/temperature gauge does not exceed 24 psi.
Condensate pH: Condensate from the boiler is slightly acidic, typically with a pH from 3 to 5, necessitating a neutralizing filter if required by local codes.
DHW Set Point: Factory set to 180°F, but adjustable.
Pump Delays: Factory set to 30 seconds for boiler and system pumps after a heating call ends.
Flame Signal: A minimum flame signal of 4 mA is mentioned for service technicians.
Flue Temperature: Heat exchanger cleaning is recommended if flue temperature is more than 54°F above return water temperature.
Connectivity: Includes USB Memory Drive and PC Connection for the SMART SYSTEM control module.

Usage Features:

SMART SYSTEM Control Module: The central interface for managing the boiler. It features a display, two SELECT keys (left and right), and a NAVIGATION dial.
- User Access: Allows users to adjust space heating and tank target temperatures, as well as date, time, and temperature units. This is done by pressing the NAVIGATION dial when "↓SETPOINTS" is flashing.
- Installer Access: Most parameters are accessible only by installers with a password, as detailed in the Knight Fire Tube Boiler Service Manual.
- Status Display Screens: Provide real-time information on boiler status (e.g., STANDBY, START, IGNITION, % fired, SHUTDOWN, SETPOINT MET, BLOCKED), heat demands (Room Thermostat 1, 2, 3, DHW tank, BMS signal, Cascade Mode), and operational information (SYSTEM TEMP, TANK TEMP, OUTDOOR TEMP, INLET TEMP, OUTLET TEMP, DHW RECIRC TEMP, DELTA T, FLUE TEMP, FLAME CURRENT, FAN SPEED, LOOP TEMPs, GAS PRESS SW, FLOW SW, LOUVER RELAY, LOUVER SW, BLOCKED DRAIN, GAS VALVE).
- History Screen: Logs total run times for space heat and DHW, demand cycles, power time, successful ignitions, and ignition attempts.
- Faults Screen: Displays the last 10 faults with fault number, description, date, and time.
Operating Instructions (Startup):
1. Set thermostat to lowest setting.
2. Turn off all electric power to the appliance.
3. Remove front door.
4. Move the gas control switch to "OFF."
5. Wait five minutes to clear any gas.
6. Move the gas control switch to "ON."
7. Install front door.
8. Turn on all electric power.
9. Set thermostat to desired setting.
Operating Instructions (Shutdown):
1. Set thermostat to lowest setting.
2. Turn off all electric power if service is to be performed.
3. Remove front door.
4. Move the gas control switch to "OFF."
5. Install front door.
DHW Operation: Supports "Normal Mode" and "Zone Mode" for indirect DHW tanks, with adjustable DHW boiler target temperature and maximum DHW fan speed.
Clock Setting: The SMART SYSTEM control has a built-in clock for night setback and event logging, which needs to be set upon installation or after power outages exceeding 4 hours. It does not adjust for Daylight Savings Time automatically.

Maintenance Features:

The manual provides a detailed maintenance schedule, distinguishing between "Owner maintenance" (daily, monthly, periodically, every 6 months, end of season) and "Service technician" tasks (annual start-up, and as needed if combustion or performance indicate).

Daily Owner Maintenance:
- Check boiler area for obstructions or contaminants.
- Check pressure/temperature gauge (ensure not exceeding 24 psi).
Monthly Owner Maintenance:
- Check vent piping for blockage, leakage, or deterioration.
- Check air piping for obstructions or damage.
- Check air and vent termination screens.
- Check relief valve for weeping or leakage.
- Check condensate drain system (lines, fittings, trap).
Periodically Owner Maintenance:
- Test low water cutoff (if installed) and reset button.
Every 6 Months Owner Maintenance:
- Check boiler piping (gas and water) for leaks.
- Operate relief valve to ensure proper function.
End of Season Months Owner Maintenance:
- Shut boiler down (unless used for domestic hot water).
Annual Start-Up (Service Technician):
- Inspect interior, clean, and vacuum.
- Clean condensate trap and fill with fresh water.
- Check for leaks (water, gas, flue, condensate).
- Verify flue and air lines are in good condition and sealed.
- Check system water pressure/system piping/expansion tank.
- Check control settings.
- Inspect and clean ignition and flame sense electrodes.
- Check wiring and connections.
- Perform start-up checkout and performance verification.
- Flame inspection (stable, uniform) and flame signal check (at least 4 mA).
- Clean heat exchanger if flue temperature is more than 54°F above return water temperature.
As Needed (Service Technician):
- Clean heat exchanger.
- Remove and clean burner using compressed air only.
- Clean blower wheel.
Corrosive Contaminant Prevention: Emphasizes avoiding installation in areas with corrosive contaminants (e.g., laundry rooms, swimming pools, areas with specific chemicals) to prevent damage and ensure safety. A table of products and areas to avoid is provided.
Boiler Water Quality: Advises against petroleum-based compounds, "homemade cures," and continuous fresh make-up water to prevent damage and corrosion. Recommends repairing leaks immediately.
Freeze Protection: Specifies using only inhibited propylene glycol solutions formulated for hydronic systems, explicitly prohibiting automotive antifreeze.