Lochinvar 801, 400 Check flame signal, Review with owner, Cleaning boiler heat exchanger

Page 32

2 Maintenance

Check flame signal

1.At high fire the flame signal shown on the display should be at least 10 microamps.

2.A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode.

3.See Section 3 - Troubleshooting in this manual for other procedures to deal with low flame signal.

Review with owner

1.Review the Knight XL User’s Information Manual with the owner.

2.Emphasize the need to perform the maintenance schedule specified in the Knight XL User’s Information Manual (and in this manual as well).

3.Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4.Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 2-2 - Heat Exchanger Cleaning Kits.

1.Shut down boiler:

•Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Installation and Operation Manual.

•Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2.Allow time for the boiler to cool to room temperature if it has been firing.

3.Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

4.Remove the heat exchanger access cover, burner, and gas/air arm assembly.

￿WARNING The boiler contains ceramic fiber materials. Use care when handling these

materials per instructions on page 3 of this manual. Failure to comply could result in severe personal injury.

5.Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4” diameter hose to a drain pan. Using field supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.

6.Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.

32

Service Manual

7.Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger.

8.Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low pressure water supply.

9.Allow the heat exchanger to thoroughly dry.

10.Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

11.Close isolation valves on piping to isolate boiler from system. Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler.

12.Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 - Startup of the Installation and Operation Manual.

13.Replace the access cover and restore boiler to operation.

Table 2-2Heat Exchanger Cleaning Kits

Model

Kit

Part

Component

Number

Number

Description

 

 

 

CTN20005

Rear Refractory Cover

400

KIT30063

MSC20083*

Nylon 4" Wheel Brush*

 

 

MSC20084

3mm Allen Wrench

 

 

 

 

 

 

 

 

MSC20086

1/4" x 24" Drill Extension

 

 

 

 

 

 

CTN20005

Rear Refractory Cover

501 - 801

KIT30064

MSC20083*

Nylon 4" Wheel Brush*

MSC20085

1/4" x 12" Drill Extension

 

 

 

 

 

 

 

 

MSC20086

1/4" x 24" Drill Extension

 

 

 

 

￿CAUTION * Do NOT use a metal brush. Only use the kit provided brush or an equivalent

replacement nylon brush.

Figure 2-5Rope Gasket - Heat Exchanger Door

ROPE GASKET

CAUTION: IF GASKET IS DAMAGED

DO NOT REUSE, THE HEAT EXCHANGER DOOR

MUST BE REPLACED.

Rope gasket is intended for sealing combustion NOTICE (FIG. 2-5). If damaged DO NOT reuse, the

heat exchanger door must be replaced. Consult factory for replacement heat exchanger door (kit WTR3080 and WTR3086).

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Contents Models 400 Contents Niosh stated First Aid Please read before proceedingHandling ceramic fiber materials When servicing boiler What is in this manual? ServiceMaintenance TroubleshootingService Near boiler pipingKnight XL display Navigation DialControl inputs LOW Voltage Connection BoardSmart Control Module Control outputsAccess modes General OperationHow the boiler operates How the control module operatesOperation Display From previous page Sequence of Operation Display panel menu access Button Screen Operation Display StatusDisplay panel parameter access Button Screen Status Operation DisplayMenu Description See User Access Installer Access Display ModifyParameter table DHW Settings Resetoutdoor See User Access Installer Access Display Modify DescriptionBMS Service Notification Temperature units C / F Viewable and changeable control parametersTime and Date Software VersionFunctions Temperature SettingsData Logging DHW Settings Outdoor Reset Anti-Cycling Ramp Settings Control modesControlling Sensor BMS Thermostat InputCascade Offset Minimum On/Off TimeCirculation pumps Service Notification Owner maintenance Maintenance Maintenance and annual startupService technician Maintenance Flue vent system and air piping Check water systemCheck expansion tank Check boiler relief valveCheck ignition ground wiring Check all boiler wiringCheck control settings Inspect ignition and flame sense electrodesCheck flame signal Cleaning boiler heat exchangerReview with owner Model Kit Part Component Number DescriptionTroubleshooting Before troubleshootingCheck control module fuses Check the followingNo Display No BurnerOperation Unit DoesChecking temperature sensors Temperature Resistance Temperature ResistanceWire Color R/BK and Y Wire Color G and Y Resistance TemperatureNoisy No PumpBoiler Pump System PumpTroubleshooting Temp Sw OpenAnti-cycling Flame Fail IgnCont’d Flame SequenceOutlet Arhl Outlet MrhlFan Low/High Fan Speed LowHigh GV/RelayFault Sensor ShortedLouver Proving Inlet SensorFlue Sensor Fault Fatal ErrorMemory Error Flue Temp DiffOutlet Temp Flue Temp HighDelta T High Service Blk Watch Dog ErrorNo Error Stored Rem Ctrl FltCombustion Analysis Procedure Models 601 Gas valve adjustment procedureModel
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400, 801 specifications

The Lochinvar 801,400 is a cutting-edge solution in the realm of high-efficiency commercial water heating. This model represents a significant advancement in the design and functionality of water heaters, catering primarily to the demands of large-scale facilities like hotels, hospitals, and large industrial operations.

One of the standout features of the Lochinvar 801,400 is its impressive heating capacity, which can produce up to 801,400 BTUs, making it suitable for high-demand applications. This output is crucial for establishments that require a consistent supply of hot water, such as commercial kitchens and laundry facilities. The robust design ensures that it can handle peak demand periods without compromising performance.

Another significant aspect is the innovative use of advanced technology in its operation. The Lochinvar 801,400 integrates smart controls that enhance its efficiency and ease of operation. These controls allow for precise monitoring and adjustment of water temperatures, ensuring that the system operates within optimal parameters while maximizing energy savings. The intelligent monitoring system can provide real-time updates, making it easier for facility managers to keep track of performance and address maintenance needs proactively.

The construction of the Lochinvar 801,400 incorporates durable materials that not only enhance the longevity of the unit but also offer resistance to corrosion and wear. This durability translates into lower maintenance costs and an extended lifespan for the unit, making it a worthwhile investment for businesses.

Moreover, the Lochinvar 801,400 is designed with energy efficiency in mind. It boasts a high thermal efficiency rating, which reduces operational costs and minimizes the carbon footprint of heating operations. This efficiency is critical in today’s environmentally conscious market, where businesses are seeking to reduce their energy consumption and comply with strict regulations.

The design of the Lochinvar 801,400 also prioritizes safety, featuring innovative safety controls and fail-safes that protect both the unit and the users.

In summary, the Lochinvar 801,400 offers a combination of high capacity, advanced technology, durability, and energy efficiency, making it an excellent choice for commercial water heating solutions. As industries continue to evolve, the demand for reliable and efficient water heating solutions like the Lochinvar 801,400 will only increase.
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