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

Page 53

9 Maintenance (continued)

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 the Outdoor Knight XL Service Manual for other procedures to deal with low flame signal.

Review with owner

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

2.Emphasize the need to perform the maintenance schedule specified in the Outdoor 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 9B - Heat Exchanger Cleaning Kits.

1.Shut down boiler:

•Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 7 - Startup.

•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 ambient 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 in the Service 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.

Outdoor Knight XL Installation & Operation Manual

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

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 7 - Startup on pages 35 and 37 of this manual.

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

Table 9B Heat 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 9-5Rope 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. 9-5). 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 Outdoor Knight XL Models 400 Contents Please read before proceeding When servicing boilerStainless steel heat exchanger Outdoor Knight XL How it worksModel Models 601 Outdoor Knight XL Boiler Ahri Rating RatingsBefore locating the boiler, check Installation must comply withDetermine boiler location Outdoor vent / air intake location Provide clearancesFlooring and foundation Prevent combustion air contaminationRemove boiler from wood pallet Install flue pipe assembly Models 400Prepare boiler Models 701 3Install flue pipe assembly Models 701Gas conversions Model 4Installing Propane Orifice ModelLeveling the boiler Models 601Hydronic piping TEE with 1 Fitting on TOP Nipple Close Nipple Near boiler piping components Flow switch adjustmentVariable speed pump option Near boiler piping connectionsCirculator sizing 20F 25F 30F 35F Model Head FeetPressure 7Single Boiler Multiple Temperatures 8Single Boiler Primary/Secondary Piping Manifold Pipe Sizes in Inches mm Number of Units10Multiple Boilers Primary/Secondary Piping Temperature Wires to Loop Sensors 120VAC to Gas connections Connecting gas supply pipingPropane Gas Natural gasInches Check inlet gas supplyGas pressure Gas valve replacementInstallation must comply with Field wiringLine voltage connections Low voltage connectionsHigh gas pressure switch Outdoor temperature sensorLow gas pressure switch ThermostatAlarm contacts Flow switchWiring of the cascade ModBus3Low Voltage Field Wiring Connections Condensate drain Condensate disposalStart-up Freeze protection when usedCheck/control water chemistry Fill and test water systemCheck thermostat circuits Check for gas leaksInspect/fill condensate system Inspect/check condensate lines and fittingsStart the boiler Final checks before starting the boilerIf boiler does not start correctly Check system and boilerFor Your Safety Read Before Operating Natural Gas Propane Set space heating operationConfiguration of the cascade Verify DHW modeSet domestic hot water DHW operation General Operating informationHow the boiler operates How the control module operatesProtection features Temperature controlBoiler temperature regulation Cascade Outdoor reset operation, if usedOperation Display Sequence of operationStandby, ready to start a new cycle Installer Access modesOutdoor Knight XL control module UserCall for Heat Information Dial Function Owner maintenance Maintenance Maintenance and annual startupService technician Maintenance Check water system Flue vent system and air pipingCheck expansion tank Check boiler relief valveCheck all boiler wiring Check ignition ground wiringCheck control settings Inspect ignition and flame sense electrodesCleaning boiler heat exchanger Check flame signalReview with owner Model Kit Part Component Number DescriptionHigh Voltage Diagrams2Ladder Diagram
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400-801 specifications

The Lochinvar 400-801 is a high-efficiency commercial boiler that embodies advanced engineering and cutting-edge technology. Designed for a variety of commercial applications, this boiler is known for its reliability, efficiency, and robust performance.

One of the standout features of the Lochinvar 400-801 is its high thermal efficiency, which can reach up to 99%. This efficiency not only reduces fuel consumption but also lowers operating costs, making it an economical choice for businesses seeking to minimize overhead. The boiler employs a stainless steel fire-tube heat exchanger that ensures optimal heat transfer and durability. This construction allows for enhanced resistance to corrosion, thereby extending the boiler's lifespan.

The Lochinvar 400-801 is equipped with advanced control technologies that enhance its performance. With its built-in SMART SYSTEM control, users can easily monitor and manage the boiler’s operations, optimizing performance while ensuring ease of use. This control system features a user-friendly interface that provides real-time data, including temperature settings, pressure readings, and operational status, allowing for quick diagnostics and efficient troubleshooting.

Safety is paramount in the design of the Lochinvar 400-801. The boiler includes a comprehensive safety system that incorporates multiple safety interlocks and a venting system that prevents backflow and ensures safe exhaust. Moreover, the unit is designed to operate with minimal noise, making it suitable for environments where noise reduction is crucial.

Installation and maintenance of the Lochinvar 400-801 are straightforward, thanks to its compact design and multiple venting options. The low-profile construction allows for flexibility in placement, making it an ideal fit for tight spaces. Maintenance tasks are simplified with accessible components, minimizing downtime and ensuring the system operates efficiently over its lifespan.

In conclusion, the Lochinvar 400-801 stands out in the commercial boiler market with its blend of efficiency, reliability, and innovation. With its advanced technologies and features, businesses can achieve significant energy savings while ensuring comfortable and consistent heat for various applications. The Lochinvar 400-801 is an investment in quality and performance, backed by a well-established brand in the heating industry. Whether for a new installation or a replacement, this boiler offers a comprehensive solution for commercial heating needs.
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