KBX-I-O Rev G
Installation & Operation Manual
Models: 399 - 800
This manual must only be used by a
ƽ WARNING
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight XL Service Manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
Installation & Operation Manual
Please read before proceeding
Installer
–
Read all instructions,
When servicing boiler –
ƽ WARNING
including this manual and the Knight XL
Service Manual, before installing.
Perform steps in the order given.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
User – This manual is for use only by a
qualified
heating
installer/service
technician.
Refer to the User’s
Information Manual for your reference.
Boiler operation –
Have this boiler serviced/inspected by a
qualified service technician, at least
annually.
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the boiler –
Please have the boiler model and serial
number from the boiler rating plate.
• 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.
NOTICE
Consider piping and installation when
determining boiler location.
Boiler water –
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
• 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
page can result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
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.
ƽ WARNING
• 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 in system
components. Leaks in boiler or piping must be repaired
at once to prevent makeup water.
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.
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.
• 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.
3
Installation & Operation Manual
The Knight XL - How it works...
1. Stainless steel heat exchanger
16. SMART Control Module
Allows system water to flow through specially designed
coils for maximum heat transfer, while providing
protection against flue gas corrosion. The coils are
encased in a jacket that contains the combustion process.
The SMART Control responds to internal and external signals
and controls the blower, gas valve, and pumps to meet the
heating demand.
17. Automatic air vent
Designed to remove trapped air from the heat exchanger
coils.
2. Heat exchanger access cover
Allows access to the combustion side of the heat
exchanger coils.
18. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the boiler.
3. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the
burner, where they burn inside the combustion chamber.
19. High voltage junction box
The junction box contains the connection points for the line
voltage power and all pumps.
4. Gas valve
The gas valve senses the negative pressure created by the
blower, allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
20. Boiler drain port
Location from which the heat exchanger can be drained.
21. Low voltage connection board
The connection board is used to connect external low voltage
devices.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor
22. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if the flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
23. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
7. Boiler outlet temperature sensor
This sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control
module adjusts boiler firing rate so the outlet temperature is
correct.
24. Access cover - front
Provides access to the gas train and the heat exchanger.
25. Ignition electrode
Provides direct spark for igniting the burner.
8. Boiler inlet temperature sensor
26. Flame inspection window
The quartz glass window provides a view of the burner
surface and flame.
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the boiler firing rate so the inlet temperature is
correct.
27. Gas shutoff valve
Manual valve used to isolate the gas valve from the gas supply.
9. Temperature and pressure gauge (field installed, not
shown)
28. High limit
Monitors the outlet temperature of the boiler as well as the
system water pressure.
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, it will break the control circuit,
shutting the boiler down.
10. Electronic display
The electronic display consists of 7 buttons and a dual line 32-
character liquid crystal display.
29. Relief valve
Protects the heat exchanger from an over pressure condition.
The relief valve will be set at 50 PSI.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
boiler.
30. Flame sensor
Used by the control module to detect the presence of burner
flame.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
31. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
32. Top panel
13. Water outlet (system supply)
Removable panel to gain access to the internal components.
A 1-1/2" or 2" NPT (depending on the model) water
connection that supplies hot water to the system.
33. Power switch
Turns 120 VAC ON/OFF to the boiler.
14. Water inlet (system return)
34. Leveling legs
A 1-1/2" or 2" NPT (depending on the model) water
connection that returns water from the system to the heat
exchanger.
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
15. Gas connection pipe
35. Air shroud (Model 500 only)
Threaded pipe connection, either 1" or 1-1/2", depending on
the model. This pipe should be connected to the incoming gas
supply for the purpose of delivering gas to the boiler.
The air shroud controls air and gas flow into the burner.
4
Installation & Operation Manual
The Knight XL - How it works...
(continued)
37. Pump relay board
36. Air pressure switch
The pump relay board is used to connect the boiler, system and
The air pressure switch detects blocked flue/inlet conditions.
DHW pumps.
Model 399
32
31
10
18
22
33
15
11
24
6
Front View - Model 399
Rear View - Model 399
19
21
27
36
7
37
16
4
5
8
1
3
25
14
2
29
13
26
28
20
34
30
23
17
Left Side (inside unit) - Model 399
Right Side (inside unit) - Model 399
5
Installation & Operation Manual
The Knight XL - How it works...
Model 500
35
18
15
27
4
Rear View - Model 500
Left Side (inside unit) - Model 500
Models 600 - 800
5
18
4
15
27
Rear View - Models 600 - 800
Left Side (inside unit) - Models 600 - 800
6
Installation & Operation Manual
Ratings
Knight XL Boiler
I=B=R Rating
Other Specifications
Net
Input
I=B=R
Gross
Output
MBH
Boiler
Water
Model Number
Vent
Air
MBH
Ratings
Water,
MBH
Water
Gas
Content Connections Connections
Gallons
Size
Note: Change “N” to
“L” for L.P. gas models.
Size
(Note 4)
(Note 2)
(Note 1)
373
(Note 3)
4"
Min
80
Max
399
KBN399
KBN500
KBN600
KBN700
KBN800
324
3.4
4.2
4.2
5.0
5.7
1-1/2"
1-1/2"
2"
1"
1"
1"
1"
1"
4"
4"
4"
4"
4"
100
120
140
160
500
600
700
800
467
567
660
752
406
493
574
654
4"
4"
6"
6"
2"
2"
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. Net I=B=R ratings are based on net installed radiation of
sufficient quantity for the requirements of the building and
nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3. Knight XL boilers require special gas venting. Use only the
vent materials and methods specified in the Knight XL
Installation and Operation Manual.
3,000 FT. TO 12,000 FT.
4. Standard Knight XL boilers are equipped to operate from
sea level to 4,500 feet only with no adjustments. The boiler
will de-rate by 4% for each 1,000 feet above sea level up to
4,500 feet.
5. High altitude Knight XL boilers are equipped to operate
from 3,000 to 12,000 feet only with no field adjustments.
The boiler will de-rate by 2% for each 1,000 feet above
3,000 feet. High altitude models are manufactured with a
different control module for altitude operation, but the
operation given in this manual remains the same as the
standard boilers. A high altitude label (as shown in FIG. A)
is also affixed to the unit.
Figure A High Altitude Label Location
6. Ratings have been confirmed by the Hydronics Institute,
Section of AHRI.
7
Installation & Operation Manual
1 Determine boiler location
This appliance is certified as an indoor
appliance. Do not install the appliance
outdoors or locate where the appliance will
be exposed to freezing temperatures or to
temperatures that exceed 100°F (37.8°C).
Installation must comply with:
ƽ WARNING
•
Local, state, provincial, and national codes, laws,
regulations, and ordinances.
•
•
National Fuel Gas Code, ANSI Z223.1 – latest edition.
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1, when
required.
Failure to install the appliance indoors could
result in severe personal injury, death, or
substantial property damage.
•
•
National Electrical Code.
For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
This appliance requires a special venting
system. The vent connection to the
appliance must be made with the starter
CPVC/stainless steel pipe section provided
with the appliance. The field provided PVC
vent fittings must be cemented to the CPVC
pipe section. Use only the vent materials,
primer and cement specified in this manual
to make the vent connections. Failure to
follow this warning could result in fire,
personal injury, or death.
ƽ WARNING
The Knight XL gas manifold and controls
NOTICE
met safe lighting and other performance
criteria when the boiler underwent tests
specified in ANSI Z21.13 – latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
Closet and alcove installations
• Electrical power
A closet is any room the boiler is installed in which is less than
171 cubic feet for KBN399 models, 193 cubic feet for KBN500
models, 223 cubic feet for KBN600 models, 247 cubic feet for
KBN700 models and 278 cubic feet for KBN800 models.
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the
appliance. The pan must not restrict combustion air
flow. Under no circumstances is the manufacturer to be
held responsible for water damage in connection with
this appliance, or any of its components.
An alcove is any room which meets the criteria for a closet with
the exception that it does not have a door.
Example: Room dimensions = 5 feet long, 4 feet wide, and
8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would be
considered a closet for a Knight XL Boiler.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
For closet and alcove installations as shown
ƽ WARNING
in FIG.’s 1-1 and 1-2, CPVC or stainless steel
Failure to keep boiler area clear and free of
combustible materials, gasoline, and other
ƽ WARNING
vent material must be used inside the
structure. The ventilating air openings
shown in FIG.’s 1-1 and 1-2 are required for
this arrangement. Failure to follow this
warning could result in fire, personal injury,
or death.
flammable liquids and vapors can result in
severe personal injury, death, or
substantial property damage.
4. The Knight XL must be installed so that gas control
system components are protected from dripping or
spraying water or rain during operation or service.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1" (25 mm) from combustible
materials.
2. Vent pipe – at least 1" (25 mm) from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance
minimums.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system
and boiler to freeze and leak.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 9 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
boiler without removing it from the space.
8
Installation & Operation Manual
1 Determine boiler location
(continued)
Figure 1-1 Closet Installation - Minimum Required Clearances
CLOSET INSTALLATION
For closet installations, CPVC or
ƽ WARNING
1" (25 MM) MINIMUM CLEARANCE
AROUND HOT WATER
stainless steel material MUST BE
used in a closet structure due to
elevated temperatures. Failure to
follow this warning could result in
fire, personal injury, or death.
PIPES AND VENT PIPE
13" (330 MM)
TOP
VENTILATING*
AIR OPENING
CLOSED DOOR
VENTILATING*
AIR OPENING
12" (305 MM)
LEFT
6" (152 MM)
14" (356 MM)
REAR
RECOMMENDED SERVICE CLEARANCES:
0"
RIGHT
Front
Top
-
-
30" (762 mm)
24" (610 mm)
6" (152 MM)
F RONT
Left Side - 24" (610 mm)
*AREA OF EACH OPENING:
1 SQ. INCH PER 1000 BTU PER HOUR INPUT
WITH A MINIMUM OF 100 SQ. INCHES
Rear -
24" (610 mm)
Figure 1-2 Alcove Installation - Minimum Required Clearances
For alcove installations, CPVC or
ALCOVE INSTALLATION
1" (25 MM) MINIMUM CLEARANCE
AROUND HOT WATER
PIPES AND VENT PIPE
ƽ WARNING
stainless steel material MUST BE
used in an alcove structure due to
elevated temperatures. Failure to
follow this warning could result in
fire, personal injury, or death.
13" (330 MM)
TOP
OPEN
FRONT
12"
(305 MM)
LEFT
14" (356 MM)
REAR
RECOMMENDED SERVICE CLEARANCES:
0"
RIGHT
Front
Top
-
-
30" (762 mm)
24" (610 mm)
18" (457 MM)
FRONT
Left Side - 24" (610 mm)
Rear -
24" (610 mm)
9
Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
Residential garage installation
Precautions
Knight XL alone in boiler room
Take the following precautions when installing the appliance
in a residential garage. If the appliance is located in a
residential garage, it should be installed in compliance with
the latest edition of the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CGA-B149 Installation Code.
1. No air ventilation openings into the boiler room are
needed when clearances around the Knight XL are at least
equal to the SERVICE clearances shown in FIG.’s 1-1 and
1-2. For spaces that do NOT supply this clearance,
provide two openings as shown in FIG. 1-1. Each
opening must provide one square inch free area per 1,000
Btu/hr of boiler input.
• Appliances located in residential garages and in
adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
all burners and burner ignition devices are located not
less than 18 inches (46 cm) above the floor.
Knight XL in same space with other gas or oil-fired
appliances
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
Vent and air piping
The Knight XL requires a special vent system, designed for
pressurized venting.
The space must be provided with
ƽ WARNING
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the Knight XL.
The boiler is to be used for either direct vent installation or
for installation using indoor combustion air. When room air
is considered, see the General Venting Section. Note
prevention of combustion air contamination below when
considering vent/air termination.
Do not install the boiler in an attic.
Failure to comply with the above warnings
could result in severe personal injury,
death, or substantial property damage.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. You may use any of the vent/air piping
methods covered in this manual. Do not attempt to install the
Knight XL using any other means.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed
for the Knight XL because it takes its combustion air from
outside (direct vent installation).
Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits given in this
manual.
Flooring and foundation
Flooring
The Knight XL is approved for installation on combustible
flooring, but must never be installed on carpeting.
Prevent combustion air contamination
Install air inlet piping for the Knight XL as described in this
manual. Do not terminate vent/air in locations that can allow
contamination of combustion air. Refer to Table 1A, page 11
for products and areas which may cause contaminated
combustion air.
Do not install the boiler on carpeting even
ƽ WARNING
if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
You must pipe combustion air to the
ƽ WARNING
boiler air intake. Ensure that the
combustion air will not contain any of the
contaminants in Table 1A, page 11.
Contaminated combustion air will
damage the boiler, resulting in possible
severe personal injury, death or substantial
property damage. Do not pipe
combustion air near a swimming pool, for
example. Also, avoid areas subject to
exhaust fumes from laundry facilities.
These areas will always contain
contaminants.
10
Installation & Operation Manual
1 Determine boiler location
(continued)
Table 1A Corrosive Contaminants and Sources
When using an existing vent system to
install a new boiler:
Products to avoid:
Spray cans containing chloro/fluorocarbons
Failure to follow all instructions can result
ƽ WARNING
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
Permanent wave solutions
Chlorinated waxes/cleaners
Check the following venting components before installing:
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
• Material - For materials listed for use with this appliance,
see Section 3 - General Venting, Table 3A. For stainless
steel venting, an adapter of the same manufacturer
(Table 3B) must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3D.
Check to see that this size is used throughout the vent
system.
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
• Manufacturer - For a stainless steel application, you
must use only the listed manufacturers and their type
product listed in Table 3A for CAT IV positive pressure
venting with flue producing condensate.
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
• Terminations - Carefully review Sections 3 through 5 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section. For
stainless steel vent, only use terminations listed in Table
3B for the manufacturer of the installed vent.
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 12.
Plastic manufacturing plants
Furniture refinishing areas and establishments
With stainless steel vent, seal and connect all pipe and
components as specified by the vent manufacturer used; with
PVC/CPVC vent, see the Installing Vent or Air Piping Section
on page 17.
New building construction
Remodeling areas
Garages with workshops
If any of these conditions are not met, the
ƽ WARNING
existing system must be updated or
replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
11
Installation & Operation Manual
1 Determine boiler location
When removing a boiler from existing
common vent system:
Do not install the Knight XL into a
g. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code. When resizing any
portion of the common venting system, the common
venting system should be resized to approach the
minimum size as determined using the appropriate
tables in Part 11 of the National Fuel Gas Code, ANSI
Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas
and Propane Installation Code.
ƽ DANGER
common vent with any other appliance.
This will cause flue gas spillage or
appliance malfunction, resulting in
possible severe personal injury, death, or
substantial property damage.
At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining connected to
the common venting system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies,
which could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other spaces of
the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined herein, return
doors, windows, exhaust fans, fireplace dampers, and any
other gas-burning appliance to their previous conditions
of use.
12
Installation & Operation Manual
2 Prepare boiler
Remove boiler from wood pallet
Model 399
1. After removing the outer shipping carton from the boiler,
1. Remove the top and front access covers from the unit (no
tools required for removal).
remove the parts box.
2. Remove the three screws securing the venturi to the blower.
Note: When separating the venturi from the blower, take
care not to damage the O-ring inside the blower (FIG. 2-2).
2. Remove the front door to access the lag bolts in front of
the unit (FIG. 2-1).
3. To remove the boiler from the pallet (after removing the
front door):
3. Remove the four star-drive screws securing the gas valve to
the venturi (FIG. 2-2).
a. Remove the two lag bolts from the wood pallet
inside the boiler (FIG. 2-1).
b. Detach the boiler from the lag bolts in the rear of the
unit, see FIG. 2-1.
4. Locate the propane orifice disk from the conversion kit bag.
Verify that the stamping on the orifice disk matches the
boiler size (Model 399 - 8.0 LP orifice stamping).
5. Remove the existing orifice from the O-ring in the side of the
gas valve and replace it with the orifice from the kit. Position
and secure the orifice in the valve as shown in FIG. 2-2.
Do not drop the boiler or bump the jacket
NOTICE
on the floor or pallet. Damage to the
boiler can result.
6. Reposition the gas valve against the venturi and replace the
star-drive screws (FIG. 2-2) securing the valve to the venturi.
Figure 2-1 Boiler Mounted on Shipping Pallet
7. Inspect the O-ring inside the blower. Handle the O-ring
with care, do not damage. Reposition the venturi against the
blower and replace the screws securing the venturi to the
blower (FIG. 2-2).
8. After installation is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit bag)
to the left side of the unit in the lower left corner.
9. Replace the top and front access covers.
After converting to LP, check combustion per
ƽ WARNING
the Start-up procedure in Section 10 of this
manual.
Failure to check and verify
Gas conversions
combustion could result in severe personal
injury, death, or substantial property
damage.
For a boiler already installed, you must
ƽ WARNING
turn off gas supply, turn off power and
allow boiler to cool before proceeding. You
must also completely test the boiler after
conversion to verify performance as
described under Start-up, Section 10 of
this manual. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
Model 399: Inspect the O-ring when the
blower is disassembled. The O-ring must be
in good condition and must be installed.
Failure to comply will cause a gas leak,
resulting in severe personal injury or death.
ƽ DANGER
Figure 2-2 Installing Propane Orifice - Model 399
For the 399 Model you must install a
propane orifice to operate the Knight XL
on propane gas. Verify when installing that
the orifice size marking matches boiler size
(Model 399 - 8.0 LP orifice stamping).
BLOWER
O-RING
VENTURI
SCREWS
Models 500 - 800 do not require an orifice
installation for propane operation, but
they will require a valve adjustment.
QTY. 3
SCREWS
QTY. 4
O-RING
BRASS ORIFICE
GAS VALVE
13
Installation & Operation Manual
2 Prepare boiler
After converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe
personal injury, death, or substantial
property damage.
Model 500
ƽ WARNING
1. Remove the top access cover from the unit (no tools
required for removal).
2. Turn the adjustment screw on the gas valve clockwise until
it stops. Then turn the adjustment screw counterclockwise
four and three quarter (4 3/4) turns (see FIG. 2-3).
3. Use a combustion analyzer to verify CO2 is within the range
Figure 2-4 Gas Valve Adjustment - Models 600 - 800
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
COVER
(FIG. 2-3).
4. After adjustment is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit bag)
to the left side of the unit in the lower left corner.
ALLEN WRENCH
ADJUSTMENT SCREW
5. Replace the top access cover.
After converting to LP, check combustion
ƽ WARNING
per the Start-up procedure in Section 10 of
this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property
damage.
Figure 2-3 Gas Valve Adjustment - Model 500
ALLEN WRENCH
Leveling the boiler
1. Set the boiler in place and check level.
a) Adjust legs if necessary to level boiler, see FIG. 2-5
below.
Figure 2-5 Leveling Legs on the Boiler
ADJUSTMENT SCREW
SCREWDRIVER
SLOT
Models 600 - 800
1. Remove the top access cover from the unit (no tools
required for removal).
2. Remove the cover on top of the gas valve (FIG. 2-4).
3. Turn the adjustment screw on top of the gas valve clockwise
one and three quarter (1 3/4) turns on the 600 Model, one
and a half (1 1/2) turns on the 700 Model, and one turn on
the 800 Model (see FIG. 2-4).
4. Use a combustion analyzer to verify CO2 is within the range
LOWER
RAISE
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-4).
5. After adjustment is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit bag)
to the left side of the unit in the lower left corner.
6. Replace the gas valve cover along with the top access cover.
14
Installation & Operation Manual
3 General venting
Direct venting options - Sidewall Vent
PVC/CPVC Two Pipe
See Figure 4-1A
Models 399 - 600 Only
Stainless Steel
Two Pipe
See Figure 4-1C
Models 399 - 600 Only
PVC/CPVC Alternate
Two Pipe
See Figure 4-2A
PVC/CPVC Concentric
See Figure 4-7
Models 399 - 600 Only
Stainless Steel
Alternate Two Pipe
See Figure 4-2B
15
Installation & Operation Manual
3 General venting
Direct venting options - Vertical Vent
PVC/CPVC
Two Pipe
See Figure 5-1A
Stainless Steel
Two Pipe
See Figure 5-1B
PVC/CPVC
Concentric
See Figure 5-5
Direct venting options - Vertical Vent, Sidewall Air
PVC/CPVC
Vertical Vent, Sidewall Air
Stainless Steel
Vertical Vent, Sidewall Air
Stainless steel vent/air design and terminations will vary slightly by manufacturer.
NOTICE
16
Installation & Operation Manual
3 General venting
(continued)
Install vent and combustion air piping
The Knight XL must be vented and
Requirements for installation in
Canada
ƽ DANGER
supplied with combustion and ventilation
air as described in this section. Ensure the
vent and air piping and the combustion air
supply comply with these instructions
regarding vent system, air system, and
combustion air quality. See also Section 1
of this manual.
1. Installations must be made with a vent pipe system
certified to ULC-S636.
IPEX is an approved vent manufacturer in Canada
supplying vent material listed to ULC-S636.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings. For concentric vent installations, the inner
vent tube must be replaced with field supplied certifiedvent
material to comply with this requirement.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
PVC/CPVC vent piping materials
Use only the materials listed in Table 3A
ƽ WARNING
Improper installation of PVC or CPVC
ƽ CAUTION
(pg. 18) for vent pipe, and fittings. Failure
systems may result in injury or death.
to comply could result in severe personal
injury, death, or substantial property
damage.
Installing vent or air piping
Use only cleaners, primers, and solvents that
NOTICE
Installation must comply with local
NOTICE
are approved for the materials which are
requirements and with the National Fuel
joined together.
Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
1. Work from the boiler to vent or air termination. Do not
exceed the lengths given in this manual for the air or vent
piping.
For closet and alcove installations, CPVC
ƽ WARNING
material MUST BE used in a closet/alcove
structure. Failure to follow this warning
could result in fire, personal injury, or
death.
2. Cut pipe to the required lengths and deburr the inside and
outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
All PVC vent pipes must be glued, properly
NOTICE
supported, and the exhaust must be pitched
a minimum of a 1/4 inch per foot back to
the boiler (to allow drainage of
condensate).
4. Clean all pipe ends and fittings using a clean dry rag.
(Moisture will retard curing and dirt or grease will prevent
adhesion.)
This appliance requires a special venting
ƽ WARNING
5. Dry fit vent or air piping to ensure proper fit up before
assembling any joint. The pipe should go a third to
two-thirds into the fitting to ensure proper sealing after
cement is applied.
system. The vent connection to the
appliance must be made with the starter
CPVC pipe section provided with the
appliance if PVC/CPVC vent is to be used.
For stainless steel venting use an adapter
from Table 3B (pg. 20) that corresponds
with the intended vent manufacturer to be
used and discard the CPVC starter piece.
The field provided vent fittings must be
cemented to the CPVC pipe section using
an “All Purpose Cement” suitable for PVC
and CPVC pipe. Use only the vent
materials, primer, and cement specified in
this manual to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
17
Installation & Operation Manual
3 General venting
6. Priming and Cementing:
f. While primer is still wet, apply an even coat of
approved cement to the fitting socket.
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
g. Apply a second coat of cement to the pipe.
h. While the cement is still wet, insert the pipe into the
fitting, if possible twist the pipe a 1/4 turn as you insert
it. NOTE: If voids are present, sufficient cement was
not applied and joint could be defective.
b. Apply a liberal even coat of primer to the fitting
socket.
c. Apply a liberal even coat of primer to the pipe end to
approximately 1/2" beyond the socket depth.
d. Apply a second primer coat to the fitting socket.
e. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the fitting socket.
j. Wipe excess cement from the joint removing ring or
beads as it will needlessly soften the pipe.
Table 3A Vent Pipe, and Fittings
All vent pipe materials and fittings must comply with the following:
Standards for installation in:
Item
Material
United States
ANSI/ASTM D1785
ANSI/ASTM D2665
Canada
CPVC and PVC venting must be ULC-
S636 Certified. IPEX is an approved
manufacturer in Canada supplying vent
material listed to ULC-S636.
PVC schedule 40
PVC-DWV
Vent pipe and fittings
Pipe cement/primer
CPVC schedule 40
AL29-4C
PVC
ANSI/ASTM F441
UL1738
ULC-S636
ANSI/ASTM D2564
ANSI/ASTM F493
IPEX System 636
Cements & Primers
CPVC
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
Approved Stainless Steel Vent Manufacturers
Make
Model
FasNSeal Vent
Z-Vent
ProTech Systems (Simpson Dura-Vent Co.)
Z-Flex (Nova Flex Group)
Heat Fab (Selkirk Corporation)
Saf-T Vent
PVC/CPVC air intake/vent connections
1. Combustion Air Intake Connector (FIG.’s 3-9 and 3-10) - Used to provide combustion air directly to the unit from
outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines
listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.
2. Vent Connector (FIG.’s 3-9 and 3-10) - Used to provide a passageway for conveying combustion gases to the outside.
Transition fittings are provided with the unit for final connection. Vent piping must be supported per the National Building
Code, Section 305, Table 305.4 or as local codes dictate.
Figure 3-10 Near Boiler PVC/CPVC Venting
-
Figure 3-9 Near Boiler PVC/CPVC Venting - Models 399 - 600
Models 700 - 800
AIR
VENT
AIR
VENT
6” COUPLING
(FIELD SUPPLIED)
*
6” CPVC
STARTER
* 4” CPVC STREET ELBOW
MAY BE SUBSTITUTED
4" CPVC PIPE SUPPLIED WITH
BOILER MUST BE USED FOR VENT CONNECTION
PIECE
(FACTORY SUPPLIED)
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN
CLOSET AND ALCOVE INSTALLATIONS.
THE 6” STAINLESS STEEL ADAPTER SUPPLIED
WITH THE BOILER MUST BE USED FOR VENT
CONNECTION TO PVC/CPVC. THE 6” CPVC
STARTER PIECE MUST BE USED FOR PVC ONLY.
18
Installation & Operation Manual
3 General venting
(continued)
When a sidewall or vertical rooftop combustion air supply
system is disconnected for any reason, the air inlet pipe must
be resealed to ensure that combustion air will be free of
contaminants and supplied in proper volume.
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
PVC, CPVC or ABS
Dryer Vent or Sealed Flexible Duct (not recommended for
rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as
specified in this section.
Type “B” double-wall vent with joints and seams sealed as
specified in this section.
Failure to properly seal all joints and
ƽ DANGER
seams as required in the air inlet piping
may result in flue gas recirculation,
spillage of flue products and carbon
monoxide emissions causing severe
personal injury or death.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
Stainless steel vent
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3A.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
Use only the materials, vent systems, and
ƽ WARNING
terminations listed in Table 3B. DO NOT
mix vent systems of different types or
manufacturers, unless listed in this
manual. Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Using vent or air intake materials other
ƽ WARNING
than those specified, failure to properly seal
all seams and joints or failure to follow vent
pipe manufacturer’s instructions can result
in personal injury, death or property
damage. Mixing of venting materials will
void the warranty and certification of the
appliance.
Installations must comply with applicable
NOTICE
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
The use of double-wall vent or insulated
NOTICE
material for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.
Installation of a stainless steel vent system
NOTICE
should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
Sealing of Type “B” double-wall vent material or galvanized
vent pipe material used for air inlet piping on a sidewall or
vertical rooftop Combustion Air Supply System:
The installer must use a specific vent
a. Seal all joints and seams of the air inlet pipe using either
Aluminum Foil Duct Tape meeting UL Standard 723 or
181A-P or a high quality UL Listed silicone sealant such as
those manufactured by Dow Corning or General Electric.
NOTICE
starter adapter at the flue collar
connection, supplied by the vent
manufacturer to adapt to its vent system.
See Table 3B for approved vent adapters.
Discard CPVC starter piece.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe
should use a silicone sealant to ensure a proper seal at the
appliance connection and the air inlet cap connection. Dryer
vent or flex duct should use a screw type clamp to seal the vent
to the appliance air inlet and the air inlet cap. Proper sealing
of the air inlet pipe ensures that combustion air will be free of
contaminants and supplied in proper volume.
19
Installation & Operation Manual
3 General venting
Table 3B Approved Stainless Steel Terminations and Adapters
ProTech
FasNSeal
Heat Fab
Saf-T Vent
Z Flex
Z-Vent
Model
Intake
Air
Termination
Intake
Boiler
Flue
Boiler Intermediate
Adapter Adapter
Flue
Termination
Boiler
Flue
Intake Air
Air
Adapter Termination
Adapter Termination Termination
Termination
FSBS4
F303759
FSAIH04
9492
5400CI
2SVSTP04
2SVSRCX04
KB285600 9454BUREZ-1*
9414TERM 2SVSLA04
2SVSTEX0490
399-600
700-800
FSRC4(R.C)
303888
F303759
FSAIH04
303888
(Intake
Only)
FSBS6
* = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-11, unless approved vent
other than standard diameter is used. Consult a Heat Fab representative for questions.
Figure 3-11 Near Boiler Stainless Steel Venting Models
399 - 600
Table 3C Stainless Steel Vent Termination Kit(s)
Model
Kit Number
700 - 800
KIT3137
VENT
Stainless
connections
steel
air
intake/vent
1. Combustion Air Intake Connector (FIG.’s 3-11 and
3-12) - Used to provide combustion air directly to the
unit from outdoors. A fitting is provided on the unit
for final connection. Combustion air piping must be
supported per guidelines listed in the National
Mechanical Code, Section 305, Table 305.4 or as local
codes dictate.
2. Vent Connector (FIG.’s 3-11 and 3-12) - Used to
provide
a
passageway for conveying combustion
4" S.S. ADAPTER
gases to the outside. A transition fitting is provided
on the unit for final connection. Vent piping must
be supported per the National Building Code,
Section 305, Table 305.4 or as local codes dictate.
4" S.S. INTERMEDIATE
(FOR SAF-T VENT ONLY)
Figure 3-12 Near Boiler Stainless Steel Venting Models
700 - 800
20
Installation & Operation Manual
3 General venting
(continued)
The Knight XL uses model specific combustion air intake and
vent piping sizes as detailed in Table 3D below.
Vent and air piping
Vent and air system:
Table 3D Air Intake/Vent Piping Sizes
Installation must comply with local
NOTICE
requirements and with the National Fuel Gas
Code, ANSI Z223.1 for U.S. installations or
CSA B149.1 for Canadian installations.
Model
399 - 600
700 - 800
Air Intake
Vent
4 inches (102 mm)
4 inches (102 mm)
4 inches (102 mm)
6 inches (152 mm)
You must also install air piping from outside to the boiler air
intake adapter. The resultant installation is direct vent (sealed
combustion).
Increasing or decreasing combustion air
or vent piping is not authorized.
NOTICE
You may use any of the vent/air piping methods covered in this
manual. Do not attempt to install the Knight XL using any
other means.
Minimum
/
Maximum
allowable
combustion air and vent piping lengths
are as follows:
DO NOT mix components from different
ƽ WARNING
systems. The vent system could fail, causing
Combustion Air = 12 equivalent feet (3.7 m) minimum / 100
leakage of flue products into the living
space. Use only approved stainless steel,
PVC or CPVC pipe and fittings. For
PVC/CPVC use with primer and cement
specifically designed for the material used.
equivalent feet (30.5 m) maximum
Vent = 12 equivalent feet (3.7 m) minimum / 100 equivalent
feet (30.5 m) maximum
When determining equivalent combustion air and vent
length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m)
for each 45° elbow.
Vent, air piping and termination:
The Knight XL vent and air piping can be installed through the
roof or through a sidewall. Follow the procedures in this
manual for the method chosen. Refer to the information in this
manual to determine acceptable vent and air piping length.
EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows + (3)
45° elbows + (1) concentric vent kit (CVK3007) = 49
equivalent feet (15 m) of piping.
The appliance output rating will reduce by
up to 1.5% for each 25 feet (68 m) of vent
length.
Optional room air
NOTICE
Optional room air is intended for
NOTICE
commercial applications. Combustion air
piping to the outside is recommended for
residential applications.
Table 3E Concentric Vent Kit Equivalent Vent Lengths
Equivalent
Commercial applications utilizing the Knight XL boiler may be
installed with a single pipe carrying the flue products to the
outside while using combustion air from the equipment room.
In order to use the room air venting option the following
conditions and considerations must be followed.
Model
Kit Number
Vent Length
5 Feet (1.5 m)
30 Feet (9 m)
30 Feet (9 m)
399
500
600
CVK3007
CVK3007
CVK3007
•
The unit MUST be installed with the appropriate
room air kit (Table 3F).
Removing from existing vent
•
The equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
Follow the instructions in Section 1, page 12 of this manual
when removing a boiler from an existing vent system.
•
•
There will be a noticeable increase in the noise level
during normal operation from the inlet air opening.
Using the room air kit makes the unit vulnerable to
combustion air contamination from within the
building.
Please review Section 1, Prevent
Combustion Air Contamination, to ensure proper
installation.
•
Vent system and terminations must comply with the
standard venting instructions set forth in this manual.
21
Installation & Operation Manual
3 General venting
If the boiler combustion air inlet is
located in a laundry room or pool
facility, for example, these areas will
When utilizing the single pipe method,
ƽ WARNING
ƽ WARNING
provisions for combustion and ventilation
air must be in accordance with Air for
Combustion and Ventilation, of the latest
edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition
of CGA Standard B149 Installation Code
for Gas Burning Appliances and
Equipment, or applicable provisions of the
local building codes.
always
contain
hazardous
contaminants.
To prevent the potential of severe
personal injury or death, check for
areas and products listed in Table 1A,
page 11 before installing the boiler or
air inlet piping.
ƽ WARNING
Table 3F Optional Room Air Kit
If contaminants are found, you
MUST:
Model
Description
Kit Number
KIT30022
KIT30053
• Remove products permanently.
—OR—
• Relocate air inlet and vent
terminations to other areas.
Filter Box Assembly
90° Elbow with Screen
399 - 800
Air contamination
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 given in Table 1A, page 11, listing
contaminants and areas likely to contain them.
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 this
manual.
22
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination – sidewall
Figure 4-1A PVC/CPVC Sidewall Termination of Air and
Vent
Follow instructions below when
ƽ WARNING
determining vent location to avoid
possibility of severe personal injury, death,
or substantial property damage.
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
12"
A gas vent extending through an exterior
ƽ WARNING
wall shall not terminate adjacent to a wall
MIN
or below building extensions such as
eaves, parapets, balconies, or decks.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
POSSIBLE ORIENTATIONS
TO
OVER-
HANG
VENT / AIR
TERMINATION
Do not connect any other appliance to the
ƽ WARNING
12"
MIN
vent pipe or multiple boilers to a common
vent pipe. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
GRADE OR
SNOW LINE
Installation must comply with local
NOTICE
Table 4A Sidewall Vent Kits
requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
Model Kit Number
Vent Size
4 inch vent
399 - 600
KIT30046
700 - 800
KIT30048
6 inch vent
Determine location
If using the alternate sidewall termination:
3. The air piping must terminate in a down-turned elbow as
shown in FIG. 4-1B. This arrangement avoids recirculation
of flue products into the combustion air stream.
Locate the vent/air terminations using the following
guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 21
of this manual.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
2. You must consider the surroundings when terminating
the vent and air:
Do not exceed the maximum lengths of the
ƽ WARNING
a. Position the vent termination where vapors will
not damage nearby shrubs, plants or air
conditioning equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of
condensate and water/ice buildup where flue
products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
outside vent piping shown in FIG. 4-1B.
Excessive length exposed to the outside could
cause freezing of condensate in the vent pipe,
resulting in potential boiler shutdown.
Figure 4-1B Alternate PVC/CPVC Sidewall Termination
of Air and Vent w/Field Supplied Fittings
e. Do not locate the terminations where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells,
alcoves, courtyards, or other recessed areas.
Sidewall vent and air inlet terminations
must terminate in the same pressure
zone.
ƽ WARNING
f. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
23
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination – sidewall
Figure 4-2B Alternate Stainless Steel Sidewall
Termination Models 700 - 800 w/Field Supplied Fittings
Figure 4-1C Alternate Stainless Steel Vent Termination
- Typical Stainless Steel Sidewall Termination of Air and
Vent Models 399 - 600 w/Field Supplied Fittings,
Utilizing FasNSeal’s Hood Intake. Available Through
FasNSeal Only
TO BOILER INTAKE
AIR CONNECTION
BIRD SCREEN
TO BOILER
INTAKE AIR
CONNECTION
12" (305 MM) MIN
15" (381 MM) MAX
12" (305 MM) MIN
15" (381 MM) MAX
FROM BOILER VENT
PIPE CONNECTION
12" (305 MM) MIN
FROM BOILER
VENT PIPE
CONNECTION
NOTICE
PVC/CPVC or ABS is acceptable air inlet pipe material.
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4B,
pages 23 thru 25. Also maintain the following:
a. Vent must terminate:
12" (305 MM) MIN
• At least 6 feet (1.8 m) from adjacent walls.
• No closer than 12 inches (305 mm) below roof
overhang.
• At least 7 feet (2.1 m) above any public walkway.
• At least 3 feet (.9 m) above any forced air intake
within 10 feet (3 m).
• No closer than 12 inches (305 mm) below or
horizontally from any door or window or any other
gravity air inlet.
Figure 4-1D Alternate PVC/CPVC/SS Vent Termination
- Typical Stainless Steel Sidewall Termination of Air and
Vent Models 399 - 600 w/Field Supplied Fittings,
Utilizing 90° Elbow Intake
b. Air inlet must terminate at least 12 inches (305 mm)
above grade or snow line; at least 12 inches (305 mm)
below the vent termination (FIG. 4-1B); and the vent
pipe must not extend more than 24 inches (610 mm)
vertically outside the building.
c. Do not terminate closer than 4 feet (1.2 m)
horizontally from any electric meter, gas meter,
regulator, relief valve, or other equipment. Never
terminate above or below any of these within 4 feet
(1.2 m) horizontally.
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
12" MIN
15" MAX
12" MIN
6. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
BIRD SCREEN
Figure 4-2A Alternate PVC/CPVC Sidewall Termination
Models 399 - 800 w/Field Supplied Fittings
Figure 4-3A Clearance to Gravity Air Inlets
BIRD SCREEN
TO BOILER
INTAKE AIR
CONNECTION
12" (305 MM) MIN
15" (381 MM) MAX
FROM BOILER
VENT PIPE
CONNECTION
12"
MIN.
BIRD SCREEN
VENT / AIR
TERMINATION
12"
MIN.
12" (305 MM) MIN
12"
MIN.
24
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Vent/air termination – sidewall
Prepare wall penetrations
1. Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
Figure 4-3B Alternate Clearance to Gravity Air
Inlets w/Field Supplied Fittings
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole
with at least a 1/2 inch clearance around the vent pipe
outer diameter:
12” (305 MM)
MIN
• 5½ inch hole (140 mm) hole for 4 inch (102 mm)
vent pipe
BIRD
SCREEN
(TYPICAL)
• 7½ inch hole (191 mm) hole for 6 inch (152 mm)
vent pipe
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
12” (305 MM)
MIN
2. Install the vent and air intake piping through the wall into
the vent plate openings. Seal all gaps between the pipes and
wall. Use RTV silicone sealant to seal the air pipe. Use the
cement/primer listed in Table 3A on page 18 to seal the vent
pipe.
12” (305 MM)
MIN
Figure 4-4A Clearance to Forced Air Inlets
IF LESS
THAN 10’
3. Mount and secure the vent plate to the wall using stainless
steel screws. Seal around the plate to the wall assuring no
air gaps.
VENT / AIR
TERMINATION
36"
MIN.
4. Assemble the vent cap to the vent plate (see FIG. 4-4A).
Insert the stainless steel screws into the vent cap screw hole
openings and securely attach the vent cap to the vent plate.
FORCED AIR
INLET
5. Seal all wall cavities.
Figure 4-5A Sidewall Termination Assembly
7' MIN. ABOVE ANY
PUBLIC WALKWAY
AIR PIPING
VENT PIPING
Figure 4-4B Alternate Clearance to Forced Air Inlets
w/Field Supplied Fittings
VENT PLATE
WALL PLATE
VENT CAP
IF LESS
THAN 10’ (3 M)
GALVANIZED
THIMBLE
36” (914 MM)
MIN
FORCED AIR
INLET
BIRD
SCREEN
(TYPICAL)
7’ (2.1 M) MIN ABOVE ANY
PUBLIC WALKWAY
25
Installation & Operation Manual
4 Sidewall direct venting
Prepare wall penetrations (Alternate - Field Multiple vent/air terminations
Supplied Option)
1. When terminating multiple Knight XL’s terminate each
1. Air pipe penetration:
vent/air connection as described in this manual
(FIG. 4-6A).
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
All vent pipes and air inlets must
2. Vent pipe penetration:
ƽ WARNING
terminate at the same height to avoid
possibility of severe personal injury,
death, or substantial property damage.
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the vent
pipe outer diameter:
2. Place wall penetrations to obtain minimum clearance of
12 inches (305 mm) between vent pipe and adjacent air
inlet elbow, as shown in FIG. 4-6A for U.S. installations.
For Canadian installations, provide clearances required by
CSA B149.1 Installation Code.
•
5½ inch hole (140 mm) hole for 4 inch (102 mm)
vent pipe
•
7½ inch hole (191 mm) hole for 6 inch (152 mm)
vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-5B.
3. The air inlet of a Knight XL is part of a direct vent
connection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
Figure 4-6A Multiple Vent Terminations (must also
comply with Figure 4-1A)
5. Seal exterior openings thoroughly with exterior caulk.
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
Figure 4-5B A Typical Sidewall Termination Assembly
- Models 399 - 800 PVC/CPVC or Stainless Steel
GALVANIZED
VENT
SIDEWALL
TERMINATION PLATE
THIMBLE
(WHEN REQUIRED BY LOCAL CODES)
AIR
ELBOW
VENT
PIPING
AIR PIPING
BIRD SCREEN
VENT / AIR
TERMINATION
ELBOW
BIRD SCREEN
Figure 4-6B Alternate Multiple Vent Terminations
w/Field Supplied Fittings (must also comply with
Figure 4-1B)
Termination and fittings
1. Prepare the vent termination elbow and the air termination
elbow (FIG. 4-5B) by inserting bird screens. Bird screens
can be obtained locally.
VENT
2. When completed, the air termination coupling must be
oriented at least 12 inches (305 mm) below the vent
termination and at least 12 inches (305 mm) above grade or
snow line as shown in FIG. 4-1A, page 23.
12” (305 MM) MIN
15” (381 MM) MAX
3. Maintain the required dimensions of the finished
termination piping as shown in FIG. 4-1A, page 23.
4. Do not extend exposed vent pipe outside of building more
than shown in this document. Condensate could freeze and
block vent pipe.
12” (305 MM) MIN. BETWEEN EDGE
OF AIR PIPE AND ADJACENT VENT
PIPE
5. PVC/CPVC terminations are designed to accommodate any
wall thickness of standard constructions per the directions
found in this manual.
AIR
6. Stainless steel terminations are designed to penetrate walls
with a thickness up to 9.25 inches of standard construction.
26
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent: Models 399 - 600 Only
Description and usage
Lochinvar offers an optional concentric combustion air and 3. You must consider the surroundings when terminating the
vent pipe termination kit (#CVK3007 for 4" (102 mm)
diameter - Models 399 - 600). Both combustion air and vent
pipes must attach to the termination kit. The termination kit
must terminate outside the structure and must be installed as
shown below in FIG. 4-7.
vent and air:
a. Position the vent termination where vapors will not
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
Field supplied pipe and fittings are required to complete the
installation.
The required combustion vent pipe materials are listed in
Table 3A, on page 18 of this manual.
Figure 4-7 Concentric Sidewall Termination - Models
399 - 600
f. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
OVERHANG
OR ROOF
Figure 4-8 Kit Contents_CVK3007 - Models 399 - 600
RAIN CAP
12" (305 MM)
MIN
6" (152 MM) TO 4" (102 MM) REDUCER
6" (152 MM) DIA.
6" (152 MM) DIA.
12" (305 MM)
MIN
4" (102 MM) DIA.
"Y" CONCENTRIC
FITTING
GRADE / SNOW LINE
6" (152 MM) DIA.
Sidewall termination installation
1. Determine the best location for the termination kit (see
FIG. 4-7).
"FLEXIBLE" PIPE
COUPLING
2. The total length of piping for vent or air must not exceed
the limits given in the General Venting section on page 21
of this manual.
4. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007
installations into the structure to install the termination kit.
5. Partially assemble the concentric vent termination kit.
Clean and cement using the procedures found in these
instructions.
a. Cement the Y concentric fitting to the larger kit pipe
(FIG. 4-8).
b. Cement the rain cap to the smaller diameter kit pipe
(FIG. 4-8).
27
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent: Models 399 - 600 Only
Figure 4-9 Concentric Vent Dimensional Drawing - Models 399 - 600
"A"
"B" DIA.
"C" DIA.
"D"
3"
(76 MM)
"E"
"G"
"H" DIA.
"B" DIA. PVC
VENT / EXHAUST
"F"
A
B
C
D
E
F
G
H
60"
4"
6"
(152 MM)
21 1/8"
10"
7 5/8"
3"
(76 MM)
6 5/8"
(168 MM)
(537 MM) (254 MM) (194 MM)
(1524 MM) (102 MM)
Instead of cementing the smaller pipe to the
rain cap, a field-supplied stainless steel
screw may be used to secure the two (2)
6. Install the Y concentric fitting and pipe assembly through
the structure’s hole from an inside wall.
NOTICE
Do not allow insulation or other materials
to accumulate inside the pipe assembly
when installing through the hole.
components
disassembly is desired for cleaning (see
FIG. 4-10).
together
when
field
NOTICE
When using the alternate screw assembly
method, drill a clearance hole in the rain cap
and a pilot hole in the vent pipe for the
screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
7. Install the rain cap and small diameter pipe assembly into
the Y concentric fitting and large pipe assembly from an
outside wall. Ensure small diameter pipe is fastened
tightly into the rubber adapter for #CVK3007
installations.
ƽ WARNING
8. Secure the assembly to the structure as shown in
FIG. 4-11 using field-supplied metal strapping or
equivalent support material.
Ensure termination location clearance
NOTICE
Do not operate the appliance with the rain
cap removed or recirculation of combustion
products may occur. Water may also collect
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to
follow this warning could result in product
damage or improper operation, personal
injury, or death.
ƽ WARNING
dimensions are as shown in FIG. 4-7.
If assembly needs to be extended to allow
NOTICE
sidewall thickness requirement, the two
(2) pipes supplied in the kit may be
replaced by using the same diameter, field-
supplied standard schedule 40 PVC for
CVK3007. Do not extend dimension D*
more than 60 inches (1524 mm) (see
FIG. 4-9).
Figure 4-10 Rain Cap to Vent Pipe Alternate Assembly
STAINLESS STEEL SCREW
(FIELD SUPPLIED)
If assembly depth needs to be reduced,
dimension D can be as short as possible.
NOTICE
DRILL CLEARANCE HOLE IN
RAIN CAP & PILOT HOLE
IN VENT PIPE
28
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent: Models 399 - 600 Only
Figure 4-11 Concentric Vent Sidewall Attachment
STRAP
(FIELD SUPPLIED)
ELBOW
(FIELD SUPPLIED)
COMBUSTION AIR
COMBUSTION AIR
VENT
VENT
Multiventing sidewall terminations
DO NOT use field-supplied couplings to
extend pipes. Airflow restriction will
occur and may cause intermittent
operation.
CAUTION
When two (2) or more direct vent appliances are vented near
each other, each appliance must be individually vented (see
FIG. 4-12). NEVER common vent or breach vent this appliance.
When two (2) or more direct vent appliances are vented near
each other, two (2) vent terminations may be installed as shown
in FIG. 4-12. The next two (2) terminations must be at least 36
inches (914 mm) away from the first two (2) terminations. It is
important that vent terminations be made as shown to avoid
recirculation of flue gases. Dimension A in FIG. 4-12 represents
the distance between pipes or rain shields, as touching or a
2 inch (51 mm) maximum separation.
9. Cement appliance combustion air and vent pipes to the
concentric vent termination assembly. See FIG. 4-11
for proper pipe attachment.
10. Operate the appliance one (1) heat cycle to ensure
combustion air and vent pipes are properly connected
to the concentric vent termination connections.
"A"
36"
(914 MM)
VENT
COMBUSTION
AIR
Figure 4-12 Concentric Vent and Combustion Air Termination Dimension A as
Touching or 2 inches (51 mm) Maximum Separation
29
Installation & Operation Manual
5 Vertical direct venting
Vent/air termination – vertical
Rooftop vent and air inlet terminations
must terminate in the same pressure zone,
unless vertical vent sidewall air is set up as
shown in the General Venting - Vertical
Vent, Sidewall Air Section.
ƽ WARNING
Follow instructions below when
ƽ WARNING
determining vent location to avoid
possibility of severe personal injury, death
or substantial property damage.
Do not connect any other appliance to the
ƽ WARNING
vent pipe or multiple boilers to a common
Figure 5-1A PVC/CPVC Vertical Termination of Air and
vent pipe. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24" (610 MM)
OF VENT PIPE
Installation must comply with local
NOTICE
requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
BIRD SCREEN
(TYPICAL)
VENT
Determine location
Locate the vent/air terminations using the following
guidelines:
COUPLING
(FIELD SUPPLIED)
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 21
of this manual.
VENT OUTLET
COMBUSTION
12" MINIMUM
AIR
ABOVE AIR INLET
2. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least
2 feet above any part of a building within 10 horizontal
feet.
Figure 5-1B Stainless Steel Vertical Termination of Air
and Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” (610 MM)
OF VENT PIPE
3. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet (.6 m) from the center
of the vent pipe. This placement avoids recirculation of
flue products into the combustion air stream.
BIRD SCREEN
(TYPICAL)
VENT
4. The vent piping must terminate in an up-turned coupling
as shown in FIG. 5-1A. The top of the coupling must be
at least 1 foot above the air intake. When the vent
termination uses a rain cap as illustrated in FIG. 5-1B
maintain at least 36" (914 mm) above the air inlet. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than
2 feet (.6 m) apart and with the vent termination at least
1 foot above the air intake.
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
COM,BUSTION
AIR
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
5. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
30
Installation & Operation Manual
5 Vertical direct venting
(continued)
Vent/air termination – vertical
Prepare roof penetrations
Multiple vent/air terminations
1. Air pipe penetration:
1. When terminating multiple Knight XL boilers, terminate
each vent/air connection as described in this manual
(FIG. 5-2).
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
Terminate all vent pipes at the same height
ƽ WARNING
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the
vent pipe outer diameter:
and all air pipes at the same height to
avoid recirculation of flue products and
the possibility of severe personal injury,
death, or substantial property damage.
•
5½ inch hole (140 mm) hole for 4 inch (102 mm)
2. Place roof penetrations to obtain minimum clearance of
12 inches (305 mm) between edge of air intake elbow and
adjacent vent pipe of another boiler for U.S. installations
(see FIG. 5-2). For Canadian installations, provide
clearances required by CSA B149.1 Installation Code.
vent pipe
•
7½ inch hole (191 mm) hole for 6 inch (152 mm)
vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole (when required by local codes).
3. The air inlet of a Knight XL boiler is part of a direct vent
connection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
3. Space the air and vent holes to provide the minimum
spacing shown in FIG.’s 5-1A and 5-1B, page 30.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
Figure 5-2 Vertical Terminations with Multiple Boilers
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
12" (305 MM) MINIMUM
VERTICALLY FROM VENT
OUTLET TO ANY AIR INLET
Termination and fittings
VENT
AIR
12" (305 MM) MINIMUM FROM EDGE
OF AIR INTAKE PIPE TO ADJACENT
VENT PIPE FROM ANOTHER BOILER
1. Prepare the vent termination coupling and the air
termination elbow (FIG.’s 5-1A and 5-1B) by inserting
bird screens. Bird screens should be obtained locally.
VENT
AIR
2. The air piping must terminate in a down-turned 180°
return bend as shown in FIG.’s 5-1A and 5-1B. Locate the
air inlet pipe no further than 2 feet (.6 m) from the center
of the vent pipe. This placement avoids recirculation of
flue products into the combustion air stream.
Figure 5-3 Alternate Vertical Terminations with Multiple
3. The vent piping must terminate in an up-turned
coupling as shown in FIG. 5-1A. The top of the coupling
must be at least 1 foot (.3 m) above the air intake. When
the vent termination uses a rain cap as illustrated in
FIG. 5-1B maintain at least 36" (914 mm) above the air
inlet. The air inlet pipe and vent pipe can be located in
any desired position on the roof, but must always be no
further than 2 feet (.6 m) apart and with the vent
termination at least 1 foot (.3 m) above the air intake.
Boilers
VENT
VENT
12" (305 MM) MINIMUM
VERTICALLY FROM VENT
OUTLET TO ANY AIR INLET
4. Maintain the required dimensions of the finished
termination piping as shown in FIG.’s 5-1A and 5-1B.
AIR
AIR
5. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
31
Installation & Operation Manual
5 Vertical direct venting
Vertical termination – optional concentric vent: Models 399 - 600 Only
Description and usage
2. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007
Lochinvar offers an optional concentric combustion air and
vent pipe termination kit. Both combustion air and vent
pipes must attach to the termination kit. The termination kit
must terminate outside the structure and must be installed as
shown in FIG. 5-4.
installations) into the structure to install the termination
kit.
3. Partially assemble the concentric vent termination kit.
Clean and cement following the cleaning procedures in
these instructions.
Field supplied pipe and fittings are required to complete the
installation.
a. Cement the Y concentric fitting to the larger
diameter kit pipe (see FIG. 4-8, page 27).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG. 4-8, page 27).
The required combustion vent pipe fittings are listed in
Table 3A, on page 18 of this manual.
Vertical termination installation
Instead of cementing the smaller pipe to the
rain cap, a field supplied stainless steel screw
may be used to secure the two (2)
NOTICE
1. See Section 5, Vertical Direct Venting - Determine
Location (where applicable).
components
together
when
field
disassembly is desired for cleaning (see
FIG. 4-10, page 28).
Figure 5-4 Concentric Vertical Termination
When using the alternate screw assembly
method, drill a clearance hole in the rain cap
and a pilot hole in the vent pipe for the
screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
ƽ WARNING
VENT
COMBUSTION
AIR
12" (305 MM) (18" (457 MM)
FOR CANADA) MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24" (610 MM) ABOVE ROOF.
Figure 5-5 Do Not Install U-Bent to Rain Cap
32
Installation & Operation Manual
5 Vertical direct venting
(continued)
Vertical termination – optional concentric vent: Models 399 - 600 Only
Do not operate the appliance with the rain
DO NOT use field-supplied couplings to
extend pipes. Airflow restriction will
occur.
ƽ WARNING
CAUTION
cap removed or recirculation of
combustion products may occur. Water
may also collect inside the larger
combustion air pipe and flow to the
burner enclosure. Failure to follow this
warning could result in product damage
or improper operation, personal injury, or
death.
6. Install the rain cap and the small diameter pipe assembly
into the roof penetration assembly. Ensure the small
diameter pipe is fastened tightly into the rubber adapter
for #CVK3007 installations.
7. Cement the appliance combustion air and vent pipes to
the concentric vent termination assembly. See FIG. 5-6
for proper pipe attachment.
4. Install the Y concentric fitting pipe assembly up through
the structure’s hole and field supplied roof boot/flashing.
8. Operate the appliance through one (1) heat cycle to
ensure combustion air and vent pipes are properly
connected to the concentric vent termination
connections.
Do not allow insulation or other materials
to accumulate inside the pipe assembly
when installing through the hole.
NOTICE
5. Secure the assembly to the roof structure as shown below
in FIG. 5-6 using field supplied metal strapping or
equivalent support material.
Multiventing vertical terminations
When two (2) or more direct vent appliances are vented near
each other, each appliance must be individually vented (see
FIG. 5-7). NEVER common vent or breach vent this
appliance. When two (2) or more direct vent appliances are
vented near each other, two (2) vent terminations may be
installed as shown in FIG. 5-7. The next two (2) terminations
must be at least 36 inches (914 mm) away from the first two
(2) terminations. It is important that vent terminations be
made as shown to avoid recirculation of flue gases.
Dimension A in FIG. 5-7 represents the distance between
pipes or rain shields, as touching or a 2 inch (51 mm)
maximum separation.
Figure 5-6 Concentric Vent Roof Installation
VENT
12" (305 MM) (18" (457 MM) FOR CANADA)
MINIMUM CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL. MAXIMUM OF
24” (610 MM) ABOVE ROOF.
COMBUSTION
AIR
ROOF BOOT /
FLASHING
(FIELD SUPPLIED)
SUPPORT
(FIELD SUPPLIED)
Figure 5-7 Concentric Vent and Combustion Air Vertical
Termination (Dimension A as Touching or 2 inches
(51 mm) Maximum Separation)
ELBOW
(FIELD SUPPLIED)
"A"
COMBUSTION
AIR
VENT
36" (914 MM)
MIN.
COMBUSTION
AIR (TYPICAL)
Ensure termination height is above the
roof surface or anticipated snow level
(12 inches (305 mm) in U.S.A. or 18
inches (457 mm) in Canada) as shown in
FIG. 5-4, page 32.
NOTICE
NOTICE
VENT
(TYP)
If assembly is too short to meet height
requirement, the two (2) pipes supplied in
the kit may be replaced by using the same
diameter, field supplied standard schedule
40 PVC for CVK3007. Do not extend
dimension D* more than 60 inches
(1524 mm) (see FIG. 4-9, page 28).
12" (305 MM) (18" (457 MM)
FOR CANADA) MINIMUM
CLEARANCE ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL. MAXIMUM OF
24" (610 MM) ABOVE ROOF.
DIMENSTION "A" IS TOUCHING
OR 2" (51 MM) MAXIMUM
SEPARATION
33
Installation & Operation Manual
6 Hydronic piping
System water piping methods
General piping information
The Knight XL is designed to function in a closed loop Basic steps are listed below along with illustrations on the
pressurized system not less than 12 psi (83 kPa). following pages (FIG.’s 6-7 and 6-8), which will guide you
A
temperature and pressure gauge is included to monitor through the installation of the Knight XL (reference FIG.’s 6-4A
system pressure and outlet temperature and should be located and 6-4B).
on the boiler outlet.
1. Connect the system return marked “Inlet”, make sure to
install with pipe sealant compound.
It is important to note that the boiler has a minimal amount
2. Connect the system supply marked “Outlet”, make sure to
install with pipe sealant compound.
of pressure drop which must be figured in when sizing the
circulators. Each boiler installation must have an air
elimination device, which will remove air from the system.
Install the boiler so the gas ignition system components are
protected from water (dripping, spraying, etc.) during
appliance operation or basic service of circulator
replacement, valves, and others.
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
4. Install a backflow preventer on the cold feed make-up water
line.
5. Install a pressure reducing valve on the cold feed make-up
water line, (15 psi (103 kPa) nominal). Check temperature
and pressure gauge (shipped separately), which should read
a minimum pressure of 12 psi (83 kPa).
Observe a minimum of 1 inch (25 mm) clearance around all
un-insulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
6. Install a circulator as shown on the piping diagrams in this
section. Make sure the circulator is properly sized for the
system and friction loss.
Low water cutoff device
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
7. Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
Chilled water system
8. Install an air elimination device on the system supply.
If the boiler supplies hot water to heating coils in air handler
units, flow control valves or other devices must be installed to
prevent gravity circulation of heater water in the coils during
the cooling cycle. A chilled water medium must be piped in
parallel with the heater.
9. Install a drain valve at the lowest point of the system.
Note: The boiler cannot be drained completely of water
without purging the unit with an air pressure of 15 psi
(103 kPa).
10. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). Pipe the discharge of the
safety relief valve to prevent injury in the event of pressure
relief. Pipe the discharge to a drain. Provide piping that is
the same size as the safety relief valve outlet. Never block
the outlet of the safety relief valve.
Freeze protection
Freeze protection for new or existing systems must use glycol
that is specially formulated for this purpose. This includes
inhibitors, which prevent the glycol from attacking the
metallic system components. Make certain to check that the
system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once a
year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
The relief valve, tee and any other necessary
ƽ WARNING
fittings are shipped in the install kit with the
boiler and are to be field installed
(FIG.’s 6-1 and 6-2).
11. On any pre-existing system, it is good practice to install a
field supplied strainer to prevent damage to the heat
exchanger.
Use only inhibited propylene glycol
ƽ WARNING
solutions,
which
are
specifically
formulated for hydronic systems. Ethylene
glycol is toxic and can attack gaskets and
seals used in hydronic systems.
See the piping illustrations included in this section, FIG.’s 6-7
and 6-8 for suggested guidelines in piping the Knight XL.
Please note that these illustrations are meant
NOTICE
to show system piping concept only, the
installer is responsible for all equipment and
detailing required by local codes.
34
Installation & Operation Manual
6 Hydronic piping
(continued)
Flow
switch,
relief
valve
and
Figure 6-1 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 399 - 500
temperature and pressure gauge
installation
Basic steps are listed below to guide you through the
installation of the flow switch, relief valve, and temperature
and pressure gauge provided with the unit.
1. For Models 399 - 500 install the close nipple on the
outlet connection of the heat exchanger. Install the tee
with the 3/4 inch fitting positioned vertically and on
the top as shown in FIG. 6-1. For Models 600 - 800
install the tee directly to the outlet connection of the
heat exchanger with the 3/4 inch fitting positioned
vertically and on the top (see FIG. 6-2).
RELIEF VALVE
FLOW SWITCH
PADDLE
TEMPERATURE AND
PRESSURE
GAUGE
2. For Models 700 - 800 install the 3/4 inch close nipple
in the tee. Install the relief valve on the 3/4 inch close
nipple (FIG. 6-2). For Models 399 - 600 install the
relief valve directly into the 3/4 inch fitting on the tee
(FIG. 6-1).
TEE WITH FITTING ON TOP
(FIELD PROVIDED)
CLOSE NIPPLE (FIELD PROVIDED)
TEE WITH 1” FITTING ON TOP
CLOSE NIPPLE
3. Install the close nipple on the downstream side of
the relief valve tee (FIG. 6-1).
TEE WITH 3/4” FITTING ON TOP
CLOSE NIPPLE
4. Install the tee with the 1 inch fitting positioned
vertically and on the top (FIG. 6-1).
5. Attach paddle #3 to the flow switch per the
manufacturer’s instructions.
Figure 6-2 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 600 - 800
6. Install the assembled flow switch into the 1 inch fitting
of the tee installed in Step 4 (see FIG. 6-1).
7. Install a field provided close nipple on the downstream
side of the flow switch (see FIG.’s 6-1 and 6-2).
8. Install a field provided tee with the gauge fitting
positioned vertically and on the top (FIG.’s 6-1 and
6-2)
RELIEF VALVE
CLOSE NIPPLE
9. Install the temperature and pressure gauge provided
with the unit into the top fitting of the tee (a bushing
may be necessary) installed in Step 8 (FIG.’s 6-1 and
6-2).
FLOW SWITCH
PADDLE
TEMPERATURE AND
PRESSURE
GAUGE
Be sure to install the flow switch so that
NOTICE
the arrow on the flow switch is pointing
in the direction of the flow (see FIG.
6-3).
TEE WITH FITTING ON TOP
(FIELD PROVIDED)
CLOSE NIPPLE (FIELD PROVIDED)
TEE WITH 1” FITTING ON TOP
CLOSE NIPPLE
TEE WITH 3/4” FITTING ON TOP
CLOSE NIPPLE
35
Installation & Operation Manual
6 Hydronic piping
Flow switch adjustment
Near boiler piping connections
Refer to Table 6A for the proper setting of the sensitivity
screw. For reference, the position of the screw prior to setting Figure 6-4A Near Boiler Piping w/Y-Strainer
should be turned clockwise with a Phillips driver until it stops
(FIG. 6-3). Proceed to turn the screw counterclockwise the
amount of turns listed in Table 6A based on the model.
Consult the manufacturer’s instructions for wiring the flow
switch to your system.
DOMESTIC HOT
WATER PUMP
Table 6A Paddle Size / Sensitivity Screw Adjustment
INDIRECT
DOMESTIC
HOT WATER
TANK
SYSTEM PUMP
SENSITIVITY SCREW
MODEL
PADDLE SIZE
ADJUSTMENT
Note: Paddles are included with the flow switch.
399
500
600
700
800
#3
#3
#3
#3
#3
7½ turns
5½ turns
7¼ turns
5¼ turns
3¼ turns
BOILER PUMP
Y-STRAINER
(RECOMMENDED)
Turn the sensitivity screw clockwise to
increase the flow rate required to activate
the switch. Turn the sensitivity screw
counterclockwise to decrease the flow rate
required to activate the switch.
NOTICE
TO FLOOR
DRAIN
Figure 6-3 Flow Switch Adjustment
NORMALLY
OPEN
SENSITIVITY
ADJUSTMENT
Figure 6-4B Near Boiler Piping w/Low Loss Header
SYSTEM PUMP
SYSTEM SENSOR
AIR SEPARATOR
DRAIN
(TYPICAL)
AIR VENT VALVE
LOW LOSS HEADER
(TYPICAL)
GROUND
EXPANSION TANK
NORMALLY
CLOSED
COMMON
FAST FILL VALVE
INDIRECT
DOMESTIC
HOT WATER
TANK
DRAIN VALVE
Circulator sizing
The Knight XL heat exchanger does have a pressure drop,
which must be considered in your system design. Refer to the
graphs in FIG’s 6-5 and 6-6 for pressure drop through the
Knight XL heat exchanger.
Y-STRAINER
(RECOMMENDED)
TO FLOOR
DRAIN
36
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500
Pressure Drop vs Flow
(Includes Boiler Secondary Piping)
20
18
16
14
12
10
8
KBN500
KBN399
6
4
2
0
0
5
10
15
20
25
30
35
40
45
Flow Rate (GPM)
Figure 6-6 Pressure Drop vs. Flow - Models 600 thru 800
Pressure Drop vs Flow
(Includes Boiler Secondary Piping)
60
50
40
30
20
10
0
KBN800
KBN700
KBN600
0
10
20
30
40
50
60
70
80
90
Flow Rate (GPM)
Table 6B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F
TEMPERATURE RISE APPLICATIONS
20°F
25°F
30°F
35°F
MINIMUM
PIPE
Model
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
SIZE
399
500
600
700
800
1 1/2"
1 1/2"
2"
37
46
55
65
74
21
23
31
30
33
30
37
44
52
60
14
16
22
20
23
26
32
38
45
51
11
13
18
16
18
21
26
32
37
42
8
10
13
11
12
2"
2"
37
Installation & Operation Manual
6 Hydronic piping
Pump sizing and flow requirements are 5. Check valves:
NOTICE
based on 20 feet (6 m) of piping, 4 - 90°
elbows, and 2 - fully ported ball valves.
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 6-7 and 6-8. Failure to
install check valves could result in a reverse flow condition
during pump(s) off cycle.
It is required that near boiler piping
NOTICE
systems
utilize
Primary/Secondary
6. Domestic indirect hot water isolation valves:
configurations as shown in FIG.’s 6-7 and
6-8 only. The use of other near boiler
piping configurations could result in
improper building and system flow rates
leading to inadvertent boiler high limit
shutdowns and poor system performance.
Field supplied.
Full port ball valves are
required. Failure to use full port ball valves could
result in a restricted flow rate through the boiler.
7. Anti-scald mixing valve:
Field supplied.
An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F (46°C).
Near boiler piping components
1. Boiler system piping:
8. Unions:
Boiler system piping MUST be sized per the pipe
requirements listed in Table 6B. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on 20 feet (6 m) of
piping, 4 - 90° elbows, and 2 - fully ported ball valves.
Field supplied. Recommended for unit serviceability.
9. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
2. Boiler system circulating pump:
Field supplied. The boiler circulating pump should be
based on 20 feet (6 m) of piping, 4 - 90° elbows, and
2 - fully ported ball valves.
10. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
11. Boiler purge valve:
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG.’s 6-5 and 6-6. Consult the indirect water heater
operating guide to determine flow characteristics for the
selected product used.
Field supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
12. System temperature sensor:
Lochinvar supplies
a
system temperature sensor.
The sensor is to be installed in the heating loop
downstream from the boiler hot water piping and
4. Boiler isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
heating loop junction.
The sensor should be
located far enough downstream to sense system diluted
water temperature.
13. Y-Strainer:
Field supplied. A Y-strainer or equivalent multipurpose
strainer is recommended at the inlet of the heat exchanger
to remove system particles from older hydronic systems and
protect newer systems.
38
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-7 Single Boiler - Primary/Secondary Piping
AIR SEPARATOR
MAY SUBSTITUTE
LOW LOSS HEADER
DRAIN POINT
(TYPICAL)
BALL VALVE
(TYPICAL)
SYSTEM SUPPLY SENSOR
(WHEN USED)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
SYSTEM CIRCULATOR
PRESSURE GAUGE
EXPANSION TANK
BOILER CIRCULATOR
Y-STRAINER
MAKE UP WATER
(RECOMMENDED)
BACK FLOW
PREVENTER
PRESSURE REDUCING
VALVE
INDIRECT DHW
TANK
ANTI-SCALD
MIXING VALVE
HOT WATER OUT
DOMESTIC
HOT WATER
CIRCULATOR
UNION (TYPICAL)
BOILER
COLD WATER IN
TEMPERATURE / PRESSURE
GAUGE
PRESSURE RELIEF
VALVE
DRAIN
FLOW CHECK
VALVE (TYPICAL)
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
NOTICE
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
39
Installation & Operation Manual
6 Hydronic piping
Figure 6-8 Multiple Boilers - Primary/Secondary Piping
Number of Units
Model
2
3
4
5
6
7
8
Manifold Pipe Sizes in Inches (mm)
2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)
3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)
3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)
399
500
600
3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)
4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)
700
800
BALL VALVE
(TYPICAL)
MAY SUBSTITUTE
LOW LOSS HEADER
AIR SEPARATOR
DRAIN POINT
(TYPICAL)
SYSTEM SUPPLY SENSOR
(WHEN USED)
SYSTEM CIRCULATOR
MAKE UP WATER
BOILER CIRCULATOR
(TYPICAL)
EXPANSION
TANK
BACK FLOW
PREVENTER
PRESSURE REDUCING
VALVE
BOILER 4
PRESSURE GAUGE
(MEMBER 3)
INDIRECT DHW
TANK
BOILER 3
(MEMBER 2)
ANTI-SCALD
MIXING VALVE
BOILER 2
(MEMBER 1)
HOT WATER OUT
BOILER 1
(LEADER)
DOMESTIC
HOT WATER
CIRCULATOR
UNION (TYPICAL)
COLD WATER IN
PRESSURE RELIEF
VALVE
DRAIN
FLOW CHECK
Y-STRAINER
(TYPICAL)
VALVE (TYPICAL)
(RECOMMENDED)
TEMPERATURE /
PRESSURE GAUGE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
NOTICE
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
40
Installation & Operation Manual
7 Gas connections
Connecting gas supply piping
Figure 7-3 Gas Supply Piping - Models 600 - 800
1. Remove the top access panel and refer to FIG.’s 7-1 thru
7-3 to pipe gas to the boiler.
a. Install ground joint union for servicing, when
required.
MANUAL
SHUTOFF VALVE
(FACTORY SUPPLIED)
b. Install a manual shutoff valve in the gas supply
piping outside boiler jacket when required by local
codes or utility requirements.
GAS SUPPLY
c. In Canada – When using manual main shutoff
valves, it must be identified by the installer.
2. Install sediment trap / drip leg.
Figure 7-1 Gas Supply Piping - Model 399
DRIP LEG
UNION
UNION
3. Support piping with hangers, not by the boiler or its
accessories.
GAS SUPPLY
The gas valve and blower will not support
ƽ WARNING
the weight of the piping. Do not attempt
to support the weight of the piping with
the boiler or its accessories. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
SEDIMENT TRAP / DRIP LEG
MANUAL
SHUTOFF VALVE
(FIELD SUPPLIED)
4. Purge all air from the gas supply piping.
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
a. The appliance must be disconnected from the gas
supply piping system during any pressure testing of
that system at a test pressure in excess of 1/2 PSIG
(3.5 kPa).
Figure 7-2 Gas Supply Piping - Model 500
b. The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
(3.5 kPa).
UNION
FIELD SUPPLIED
GAS SUPPLY
c. The appliance and its gas connection must be leak
tested before placing it in operation.
Do not check for gas leaks with an open
ƽ WARNING
flame – use the bubble test. Failure to use
the bubble test or check for gas leaks can
cause severe personal injury, death, or
substantial property damage.
SEDIMENT TRAP / DRIP LEG
MANUAL
SHUTOFF VALVE
(FACTORY SUPPLIED)
6. Use pipe sealing compound compatible with propane
gases. Apply sparingly only to male threads of the pipe
joints so that pipe dope does not block gas flow.
41
Installation & Operation Manual
7 Gas connections
Failure to apply pipe sealing compound
Natural gas:
Pipe sizing for natural gas
ƽ WARNING
as detailed in this manual can result in
severe personal injury, death, or
substantial property damage.
1. Refer to Table 7A for pipe length and diameter. Based on
rated boiler input (divide by 1,000 to obtain cubic feet per
hour).
Use two wrenches when tightening gas
piping at boiler (FIG. 7-4), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
ƽ WARNING
a. Table 7A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.5 inches w.c.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
Figure 7-4 Inlet Pipe with Backup Wrench
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.5 kPa) with no flow
(lockup) or with boiler on.
• Minimum 4 inches w.c. (.99 kPa) with gas flowing (verify
during boiler startup).
2. Install 100% lockup gas pressure regulator in supply line if
inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any
time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa)
maximum.
Propane Gas:
Knight XL boilers are typically shipped
ƽ WARNING
ready to fire on natural gas. Check boiler
rating plate to determine which fuel the
boiler is set for. If set to natural gas, it may
be converted to LP by installing an orifice or
by making a gas valve adjustment (see pages
13 and 14). In order to operate on LP gas, an
orifice MUST BE installed or a gas valve
adjustment MUST BE made. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
USE BACK UP WRENCH TO
PREVENT PIPE FROM ROTATING
Maximum inlet gas pressure must not
NOTICE
Pipe sizing for propane gas
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
1. Contact gas supplier to size pipes, tanks, and 100% lockup
gas pressure regulator.
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. (3.2 kPa) maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.2 kPa) with no flow (lockup)
or with boiler on.
• Minimum 8 inches w.c. (1.9 kPa) with gas flowing (verify
during boiler startup).
Ensure that the high gas pressure regulator
is at least 10 feet (3 m) upstream of the
appliance.
ƽ WARNING
42
Installation & Operation Manual
7 Gas connections
Table 7A Natural Gas Pipe Size Chart
(continued)
Maximum
Nominal
Iron Pipe
Size
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet
Capacity of Pipe
in Thousands of
Btu/hr per hour
for gas pressures
of 14 Inches
Water Column
(0.5 PSIG) or less
and a pressure
drop of 0.5 Inch
Water Column
(Based on NAT
GAS, 1025 Btu/hr
per Cubic Foot of
Gas and 0.60
(inches)
10
20
30
97
205
384
789
40
82
174
328
677
50
60
70
80
90 100 125 150 175 200
175
369
697
120
256
477
N/A
155
292
595
N/A N/A N/A N/A N/A N/A N/A N/A N/A
141 128 121 113 106
267 246 236 210 200 179 164 149 138
543 502 472 441 410 369 333 308 287
830 769 707 666 636 564 513 472 441
1/2
3/4
1
1-1/4
1-1/2
2
2-1/2
3
4
95
86
79
74
1400 974
2150 1500 1210 1020 923
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820
6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340
23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720
Specific Gravity)
Check inlet gas supply
CSA or UL listed flexible gas connections
4. Slowly turn on the gas supply at the field installed
manual gas valve.
NOTICE
are acceptable, but you must exercise
caution to ensure that the line has adequate
capacity to allow your boiler to fire at full
rate. Consult with local codes for proper
installation or service procedures.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to call for heat.
7. Observe the gas supply pressure as the burner fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
DO NOT adjust or attempt to measure gas
valve outlet pressure. Attempting to alter
or measure the gas valve outlet pressure
could result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
ƽ WARNING
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
The gas piping must be sized for the proper flow and length of
pipe, to avoid excessive pressure drop. Both the gas meter and
the gas regulator must be properly sized for the total gas load.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
If you experience a pressure drop greater than 1 inch w.c.
(249 Pa), the meter, regulator, or gas line is undersized or in
need of service. Perform the steps below when checking inlet
gas supply:
11. Turn the power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
1. Turn the main power switch to the “OFF” position.
13. Remove the manometer from the pressure tap on top of
the gas valve. On Models 399 - 500 re-tighten the set
screw inside the pressure tap. On Models 600 - 800
remove the 1/8" (3 mm) field supplied fitting and
reinstall the pipe plug removed in Step 3.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
3. On Models 399 - 500 loosen the set screw one (1) full turn
from inside the pressure tap on top of the gas valve. On
Models 600 - 800 remove the 1/8" (3 mm) pipe plug on the
inlet flange to the valve and install a suitable 1/8" (3 mm)
fitting (field supplied) for the manometer tubing. Place
the tubing of the manometer over the tap once the set
screw is loosened or the 1/8" (3 mm) fitting is installed
(depending on model) as shown in FIG.’s 7-5 thru 7-7 on
page 44.
43
Installation & Operation Manual
7 Gas connections
When re-tightening the set screw, be sure
Figure 7-7 Inlet Gas Supply Check - Models 600 - 800
ƽ WARNING
to tighten securely to prevent gas leaks.
REMOVE THE 1/8” (3 MM) PIPE PLUG ON
THE INLET FLANGE TO THE VALVE AND
INSTALL A SUITABLE 1/8” (3 MM) FITTING
(FIELD SUPPLIED) FOR THE MANOMETER
TUBING.
Do not check for gas leaks with an open
flame -- use the bubble test. Failure to use
the bubble test or check for gas leaks can
cause severe personal injury, death, or
substantial property damage.
14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to the desired
water temperature so the appliance will call for heat.
17. Check burner performance by cycling the system while
you observe burner response. The burner should ignite
promptly. Flame pattern should be stable. Turn system
off and allow burner to cool, then cycle burner again to
ensure proper ignition and flame characteristics.
Gas Pressure
Figure 7-5 Inlet Gas Supply Check - Model 399
The gas pressure must remain between 4 inches w.c.
(.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum
for Natural gas and between 8 inches w.c. (1.9 kPa)
minimum and 14 inches w.c. (3.2 kPa) maximum for LP gas
during standby (static) mode and while in operating
(dynamic) mode. If an in-line regulator is used, it must be a
minimum of 10 feet (3 m) from the Knight XL boiler. It is
very important that the gas line is properly purged by the gas
supplier or utility company. Failure to properly purge the
lines or improper line sizing, will result in ignition failure.
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP.
The problem is especially noticeable in NEW LP installations
and also in empty tank situations. This can also occur when
a utility company shuts off service to an area to provide
maintenance to their lines.
Figure 7-6 Inlet Gas Supply Check - Model 500
Gas valve replacement
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP.
The gas valve MUST NOT be replaced with a conventional
gas valve under any circumstances. As an additional safety
feature, this gas valve has a flanged connection to the venturi
and blower.
Failure to follow all precautions could
result in fire, explosion, or death!
ƽ WARNING
DO NOT adjust or attempt to measure
ƽ WARNING
gas valve outlet pressure. Attempting to
alter or measure the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death, or substantial property
damage.
DETAIL
44
Installation & Operation Manual
8 Field wiring
ELECTRICAL SHOCK HAZARD – For
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
ƽ WARNING
your safety, turn off electrical power
supply before making any electrical
connections to avoid possible electric
shock hazard. Failure to do so can cause
severe personal injury or death.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and
any local codes.
Wiring must be N.E.C. Class 1.
NOTICE
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 8-1.
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 8-1).
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
3. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 8-1.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
ƽ CAUTION
4. To activate a system pump, wire as shown in FIG. 8-1. Dry
contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.
Figure 8-1 Line Voltage Field Wiring Connections
120V SUPPLY
NEUTRAL
W
GROUND
G
LINE
BK
SERVICE
SWITCH
BK
G
SYSTEM
PUMP
W
BK
BOILER
PUMP
G
W
BK
DOMESTIC
HOT WATER
PUMP
G
W
L2/N
G
L1
45
Installation & Operation Manual
8 Field wiring
Low voltage connections
DHW tank sensor
By installing a tank sensor, the SMART SYSTEM control can
perform the tank thermostat function. The SMART SYSTEM
control automatically detects the presence of this sensor, and
generates a DHW call for heat when the tank temperature
drops 6°F (3°C) below the tank set point, and finishes the call
for heat when the tank temperature reaches the tank set point.
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 8-2.
2. Connect low voltage wiring to the low voltage connection
board as shown in FIG. 8-3 on page 48 of this manual and
the boiler wiring diagram.
Figure 8-2 Routing Field Wiring
The tank sensor included with the Lochinvar Squire® indirect
DHW tanks (TST2032) is the only sensor suitable for use with
the SMART SYSTEM control. Connect the sensor leads to the
DHW Tank Sensor (AUX) terminals on the low voltage
connection board (FIG. 8-3). Consult the tank manufacturer
for application and performance when used with any other
indirect tank.
LOW VOLTAGE
CONNECTION BOARD
LINE VOLTAGE
JUNCTION BOX
Failure to use the correct sensor may result
ƽ WARNING
in the tank temperature being either above
LOW VOLTAGE
WIRING KNOCKOUTS
or below the set point. Failure to consult the
manufacturer of the indirect tank, when the
Squire is not used, may result in decreased
performance or the risk of scald injury.
LINE VOLTAGE
WIRING KNOCKOUTS
If TST2032 is not compatible with the indirect tank, a tank
thermostat can be used to control the boiler. The tank
thermostat should be installed per the manufacturer’s
instructions and wired to the DHW Thermostat terminals on
the low voltage connection board (FIG. 8-3).
Thermostat
1. Connect the room thermostat or end switch (isolated
contact only) to terminals R and W, as shown in FIG. 8-3.
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
Auxiliary device proving switch
1. When the operation of an auxiliary device needs to be
verified before the boiler fires, remove the jumper wire
from these terminals and connect them to the normally
open contacts on its proving switch (FIG. 8-3).
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to match
total electrical power requirements of connected High gas pressure switch
devices. See device manufacturers’ specifications
and thermostat instructions for details.
1. If a switch is provided to detect excessive gas pressure,
remove the jumper wire from the terminals on the
connection board, and then connect them to its normally
closed contacts (FIG. 8-3).
Outdoor temperature sensor
1. Connect the outdoor temperature sensor (FIG. 8-3) to the
Outdoor Sensor terminals on the connection board to
enable outdoor reset operation of the Knight XL. Do not
install the outdoor sensor.
Low gas pressure switch
1. If a switch is provided to detect low gas pressure, remove
the jumper wire from the terminals on the connection
board and connect them to its normally open contacts
(FIG. 8-3).
2. Mount the sensor on an exterior wall, shielded from direct
sunlight or flow of heat or cooling from other sources.
2. If both a high and low gas pressure switch is used, connect
their respective contacts in series, and connect them to the
terminals on the connection board (FIG. 8-3).
3. Route sensor wires through a knockout at the rear of the
boiler (see FIG. 8-2).
Flow switch
1. A flow switch is used to guarantee flow through the boiler
before allowing it to fire. The flow switch must be installed
in line with the boiler.
DHW
(Domestic
Hot
Water)
thermostat
1. Connect the DHW tank thermostat to the Tank
Thermostat terminals on the connection board (FIG. 8-3).
2. Remove the jumper wire from the terminals on the
connection board and connect these terminals to the
normally open contacts on the flow switch (FIG. 8-3).
46
Installation & Operation Manual
8 Field wiring
(continued)
System supply sensor
Wiring of the cascade
1. By installing the system supply sensor into the supply of the When wiring the boilers for Cascade operation, select one
primary loop, the temperature of the system supply can be boiler as the Leader boiler. The remaining boilers will be
controlled. The SMART SYSTEM control automatically designated as Members. See page 55 “Configuration of the
detects the presence of this sensor, and controls the boiler Cascade” for a detailed explanation of this procedure.
firing rate to maintain the system supply temperature to the
Connect the system supply sensor and outdoor air sensor (if
set point (if the outlet sensor control is currently selected).
used) to the Leader boiler. For the Cascade system to work
See the Knight XL Service Manual for instructions on how
properly the system supply sensor must be installed. The
to use the inlet sensor as the controlling sensor. When the
location of the system supply sensor should be downstream of
inlet sensor is programmed as the controlling sensor, it is
the boiler connections in the main system loop (FIG.’s 6-7 and
vital that the SYSTEM SUPPLY sensor be installed. DO
6-8). The system supply sensor should be wired to the Low
NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO
Voltage Connection Board at the terminals marked for the
THE SYSTEM RETURN.
system supply sensor (see FIG. 8-3). The Leader control will
2. Connect these terminals to the system supply sensor
(FIG. 8-3).
use the water temperature at the system supply sensor to
control the operation of the Cascade.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 8-3). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature
set point that is programmed into the control.
Boiler management system
1. An external control may be connected to control either the
firing rate or the set point of the boiler. Connect the Room
Thermostat / Zone Control terminals to the enable output
of the external control and connect the 0 - 10 VDC
terminals to the 0 - 10 VDC output of the external control.
2. Make sure the ground terminal is connected to the ground
output terminal of the external control, and the 0 - 10 VDC
terminal is connected to the 0 - 10 VDC terminal of the
external control.
If a Thermostat or Zone Control enable output is available, it
should be wired to the Low Voltage Connection Board on the
Leader boiler at the terminals marked for the Room
Thermostat/Zone Control (FIG. 8-3). If the boilers are to run
continuously, connect a jumper wire between the R and W
terminals for the Thermostat/Zone Control input. This will
initiate a call for heat on the Cascade.
Runtime contacts
The SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Communication between the Leader boiler and the Member
boilers is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to terminal A on each of the Low Voltage Connection boards,
and the other wire of the twisted pair to terminal B on each of
the Low Voltage Connection Boards. Connect the shield wires
to one of the shield ground terminals on the Low Voltage
Connection Boards (FIG. 8-3). If more than two boilers are
on the Cascade, daisy chain the wiring from the Sequencing
terminals on the second boiler to the Sequencing terminals on
the third boiler, then from the third to the forth, and so on.
The connections between boilers can be made in any order,
regardless of the addresses of the boilers. Try to keep each
cable as short as possible.
Alarm contacts
The SMART SYSTEM control closes another set of contacts
whenever the boiler is locked out or the power is turned off.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down. Note that these
contacts will close momentarily at the end of each call for heat
or at least every 24 hours.
47
Installation & Operation Manual
8 Field wiring
Figure 8-3 Low Voltage Field Wiring Connections
F F O C U T
R
T A E W W L O
48
Installation & Operation Manual
9 Condensate disposal
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.
Condensate drain
NOTICE
NOTICE
1. This boiler is a high efficiency appliance that produces
condensate.
2. The side of the boiler has a 1/2 inch (12.7 mm) PVC
union for connection of a 1/2 inch (12.7 mm) PVC pipe
(FIG. 9-1).
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 (25 mm).
3. Slope condensate tubing down and away from the boiler
into a drain or condensate neutralizing filter. Condensate
from the Knight XL will be slightly acidic (typically with
a pH from 3 to 5). Install a neutralizing filter if required
by local codes.
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.
A Neutralizer Kit (FIG. 9-1) is available from the factory
(KIT3087 for Models 399 - 500 and KIT3046 for Models
600 - 800).
4. Install the 1/2 inch (12.7 mm) PVC tee assembly (shipped
with the unit) as shown in FIG. 9-1.
8. A condensate removal pump is required if boiler is below
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. The switch should be
wired to the auxiliary device proving switch terminals on
the low voltage connection board.
5. Leave the top of the 1/2 inch (12.7 mm) 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. 9-1).
Figure 9-1 Condensate Disposal
1/2" (12.7 mm) PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
1/2" (12.7 mm) PVC UNION
(FACTORY SUPPLIED)
NEUTRALIZER KIT
FLOOR DRAIN OR
DRAIN PAN
KIT3087 shown for illustration purposes.
49
Installation & Operation Manual
10 Start-up
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Check/control water chemistry
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets in
the system could occur, resulting in
substantial property damage.
Eliminate all system leaks. Continual fresh
ƽ WARNING
makeup water will reduce boiler life.
Minerals can build up in the heat
exchanger, reducing heat transfer,
overheating the heat exchanger, and
causing heat exchanger failure.
Hardness less than 7 grains
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Purge air from water system
Chlorine concentration less than 200 ppm
1. Purge air from system:
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
a. Connect a hose to the purge valve (see purge/drain
valves, in piping diagrams on page 41). Route the
hose to an area where water can drain and be seen.
b. Close the boiler or system isolation valve between
the purge valve and fill connection to the system.
c. Close zone isolation valves.
2. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are much lower.
3. Do not use the boiler to directly heat swimming pool or
spa water.
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
Test/replace freeze protection fluid
f. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close the
zone isolation valves and proceed with the next zone.
Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch
that system pressure rises to correct cold-fill
pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open
the manual air vents in the system one at a time,
beginning with the lowest floor. Close the vent when
water squirts out. Repeat with remaining vents.
1. For systems using freeze protection fluids, follow fluid
manufacturer’s instructions.
2. Freeze protection fluid must be replaced periodically due
to degradation of inhibitors over time. Follow all fluid
manufacturer’s instructions.
Freeze protection (when used)
1. Determine freeze protection fluid quantity using system
water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 7.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
3. When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid may leak before the water begins to leak,
causing concentration to drop, reducing the freeze
protection level.
2. Open automatic air vent (diaphragm-type or bladder-
type expansion tank systems only) one turn.
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
4. Refill to correct pressure.
2. Close manual and automatic air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a
commercial system is 12 psi (82.7 kPa).
b. Pressure will rise when boiler is turned on and
system water temperature increases.
50
Installation & Operation Manual
10 Start-up
(continued)
Propane boilers only – Your propane
supplier mixes an odorant with the
propane to make its presence detectable.
In some instances, the odorant can fade,
and the gas may no longer have an odor.
Before startup (and periodically
thereafter), have the propane supplier
verify the correct odorant level in the gas.
Check for gas leaks
ƽ WARNING
Before starting the boiler, and during
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the top access
panel and smell the interior of the boiler
enclosure. Do not proceed with startup if
there is any indication of a gas leak. Use an
approved leak detection solution. Repair
any leaks at once.
ƽ WARNING
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the room
thermostat terminals on the connection board.
DO NOT adjust or attempt to measure gas
valve outlet pressure. The gas valve is
factory set for the correct outlet pressure.
This setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or
substantial property damage.
ƽ WARNING
2. Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve, and relay in the
external circuit one at a time and check the voltmeter
reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked
and corrected if necessary, reconnect the external
thermostat circuit wires to the connection board. Allow
the boiler to cycle.
Figure 10-1 Condensate Trap
RETAINING
SCREW
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect/fill condensate system
Inspect/check condensate lines and fittings
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
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. 10-1).
2. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 10-1).
CONDENSATE FROM
HEAT EXCHANGER
TO FLOOR
DRAIN
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.
The condensate trap (FIG. 10-1) must be
ƽ WARNING
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.
51
Installation & Operation Manual
10 Start-up
Final checks before starting the boiler
ꢀ Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
ꢀ Read the Knight XL Service Manual to familiarize
yourself with SMART SYSTEM control module
operation. Read this manual, page 53 for proper steps to
start boiler.
Venting system must be sealed gastight to
ƽ WARNING
prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
ꢀ Verify the boiler and system are full of water and all
system components are correctly set for operation.
ꢀ Check gas piping
ꢀ Verify the preparation procedures of Section 10, pages 50
1. Check around the boiler for gas odor following the
procedure on page 41 of this manual (connecting gas
supply piping).
and 51 have been completed.
ꢀ Fill the vent condensate trap with water (removing the
retaining screw in order to remove the 2 inch PVC cap
with the switch located at the top of the trap). Replace
the cap. Press the cap onto the trap until the cap makes
contact with the drain. Replace the retaining screw.
If you discover evidence of any gas leak,
ƽ WARNING
shut down the boiler at once. Find the
leak source with a bubble test and repair
immediately. Do not start the boiler again
until corrected. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
ꢀ Verify electrical connections are correct and securely
attached.
ꢀ Propane boilers – verify conversion
ꢀ Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging. Verify air piping and vent piping are intact and
correctly installed per this manual.
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
DO NOT adjust or attempt to measure
ƽ WARNING
gas valve outlet pressure. The gas valve is
Start the boiler
factory-set for the correct outlet pressure.
This setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or
substantial property damage.
1. Read and follow the Operating instructions in FIG. 10-2,
page 53.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is external limit control (if used) open? Is boiler water
temperature above 200°F (93°C)?
Knight XL boilers are typically shipped
ƽ WARNING
ready to fire on natural gas. Check boiler
rating plate to determine which fuel the
boiler is set for. If set to natural gas, it may
be converted to LP by installing an orifice
or by making a gas valve adjustment (see
pages 13 and 14). In order to operate on
LP gas, an orifice MUST BE installed or a
gas valve adjustment MUST BE made.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Knight XL Service Manual.
Check system and boiler
ꢀ Check water piping
Check flame and combustion
1. Check system piping for leaks. If found, shut down the
boiler and repair immediately. (See WARNINGS on
pages 50 and 51 (startup) regarding failure to repair
leaks.)
1. Turn the main power off to the boiler by placing the
“On/Off” switch in the OFF position.
2. Remove the flue temperature sensor from the flue pipe
connection. NOTE: Combustion measurements will be
made at this point.
2. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation and
cause heat distribution problems and noise.
3. Turn the main power on to the boiler by placing the
“On/Off” switch in the ON position.
52
Installation & Operation Manual
10 Start-up
(continued)
Figure 10-2 Operating Instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury, or loss of life.
• Immediately call your gas supplier from a
A. This appliance does not have a pilot. It is
neighbor’s phone. Follow the gas supplier’s
equipped with an ignition device which
instructions.
• If you cannot reach your gas supplier, call
the fire department.
automatically lights the burner. Do not try
to light the burner by hand.
B. BEFORE OPERATING smell all around
the appliance area for gas. Be sure to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
C. Use only your hand to turn the gas control knob.
Never use tools. If the handle will not turn by
hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result
in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
• Do not try to light any appliance.
service technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
• Do not touch any electric switch; do
not use any phone in your building.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting.
8. Turn gas shutoff valve clockwise to “ON”.
Handle will be parallel to pipe.
9. Install top cover.
10. Turn on all electric power to appliance.
11. Set thermostat to desired setting.
3. Turn off all electric power to the
appliance.
4. This appliance is equipped with an
ignition device which automatically lights
the burner. Do not try to light the burner
by hand.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.
5. Remove top cover.
6. Turn gas shutoff valve counterclockwise
to “OFF”. Handle will be perpendicular to
pipe. Do not force.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B”
in the safety information above on this label.
If you don’t smell gas, go to next step.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed.
4. Turn gas shut off valve counterclockwise to
“OFF”. Handle will be perpendicular to pipe.
Do not force.
5. Install top cover.
3. Remove top cover.
LBL2284 REV -
53
Installation & Operation Manual
10 Start-up
Check flame and combustion (continued)
Set space heating operation
4. Place the boiler into the active position by pressing the
SHUTDOWN button on the display board (FIG. 11-1,
Determine controlling sensor
For space heating systems, the temperature control can be
based on one of three sensors; the inlet, outlet, or system
supply sensor. The SMART SYSTEM control is programmed
at the factory to control the temperature of the outlet sensor.
The control will automatically switch to the system supply
sensor once it is connected. If it is desired to base the
temperature control on the inlet sensor, the appropriate
parameter must be changed in the control. See the Knight XL
Service Manual for a detailed explanation of this procedure.
page 61) until
window.
B
L
R
:
S
t
a
n
d
b
y
a
p
p
e
a
r
s
i
n
t
h
e
d
i
s
p
l
a
y
5. Locate the pinhole button above the “T” in the Knight
XL logo on the display board (FIG. 11-1). Insert a thin
wire (such as a paper clip) into the hole and press the
button once and hold for 5 seconds to place the boiler
into Service Mode. In Service Mode the boiler will fire
at ignition speed and will then modulate up to full fire.
6. Insert the probe from a combustion analyzer into the
hole left by the removal of the flue temperature sensor.
Verify space heat circulator mode
The Space Heating Mode controls both the system (primary)
pump (if connected), and the boiler (secondary) pump.
When the SMART SYSTEM control receives a space heating
call for heat, it turns on the system pump. If the boiler is not
heating an indirect DHW (Domestic Hot Water) tank, it also
turns on the boiler pump. After the space heating call for heat
ends, the system pump continues to run for a short period of
time. If the boiler pump was running, it continues to run for
a short period of time as well. These pump delays are factory
set to 30 seconds. If different delays are desired, the
appropriate parameters in the control must be changed. See
the Knight XL Service Manual for a detailed explanation of
this procedure.
7. Once the boiler has modulated up to full fire, measure
the combustion. The values should be in the range
listed in Table 10A below. The CO levels should be less
than 150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference the Troubleshooting Section of the Knight XL
Service Manual for possible causes and corrective
actions.
Table 10A Flue Products Chart
Set space heating set point temperature
Natural Gas
CO2 O2
Propane
The UP and DOWN keys may be used during normal
operation to adjust the space heating set point temperature.
Once the desired temperature is displayed, press the
ENTER/RESET key to save the new setting. If the
ENTER/RESET key is not pressed, the new setting will be
used for the current heating cycle only. The old setting will
become active after the current heating cycle ends.
CO2
O2
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
8. Once the combustion analysis is complete, test the
safety shutoff device by turning the manual shutoff
valve to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Open the manual
shutoff valve, reset the control, and return to Service
Mode.
9. Turn the main power off to the boiler and replace the
flue temperature sensor into the flue pipe connection.
10. Place the boiler back into normal operation.
You must replace the flue gas
ƽ WARNING
temperature sensor to prevent flue gas
spillage into the room. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
54
Installation & Operation Manual
10 Start-up
(continued)
9. The date and time are displayed as “YY:MM:DD W
hh:mm”, where:
Set domestic hot water (DHW) operation
Verify DHW circulator mode
mm:
hh:
minutes
hour (24 hour time; e.g., 2:00 PM = 14:00)
The DHW Mode is programmed to heat an indirect domestic
hot water tank. When the tank thermostat calls for heat, the
SMART SYSTEM control will turn on the DHW pump and
turn off the boiler pump (if running). If the system pump is
running, it will remain on. When the DHW call for heat ends,
and there is no space heating call for heat, the DHW pump
will continue to run for a period of time. This pump delay is
set at the factory to 30 seconds. If a shorter or longer delay is
desired, the appropriate parameter in the control must be
changed. See the Knight XL Service Manual for a detailed
explanation of this procedure. If there is an active space
heating call for heat, then the boiler pump will be turned on
and the DHW pump will be turned off.
W:
day of the week (1 = Monday, 2 = Tuesday,
3 = Wednesday, etc.,)
date
month
year
DD:
MM:
YY:
The internal clock does not adjust for
Daylight Savings Time and therefore, will
require a manual adjustment.
NOTICE
Use the UP and DOWN keys to increment or decrement the
flashing number, and the NEXT and PREVIOUS keys to select
which number flashes.
Set DHW target temperature
10. Press the ENTER key to save the setting.
When in the DHW Mode, the control will modulate to
maintain the outlet temperature to a set point. This set point
is set at the factory to 180°F. If a different set point is desired,
the appropriate parameter in the control must be changed.
See the Knight XL Service Manual for a detailed explanation
of this procedure.
11. Press the MENU key twice to exit the Programming
Mode.
Configuration of the cascade
When installed in a Cascade system, the individual controls
must be programmed for cascade operation. This is
accomplished by accessing the control parameters.
Set clock
The SMART SYSTEM control has a built-in clock that it uses
for its night setback feature and for logging events. This clock
must be set when the boiler is installed, and anytime the boiler
has been powered off for more than one month. Use the
following procedure to set the clock:
Input the Installer code as described in the Knight XL Service
Manual. Once the control parameters have been accessed, use
the DOWN arrow key to select the H Control Mode parameters.
Press the ENTER key to access these parameters. Use the UP
arrow key to access parameter H2 SH Source. Press the ENTER
key to access this parameter. Use the DOWN arrow key to select
Cascade. Press the ENTER key to program this into the control.
1. Press and hold the MENU key for at least 5 seconds.
2. The display changes to ready “ENTER MENU CODE”,
with four (4) zeros below it.
Press the UP arrow key to select the parameter H3 BLR Address.
Press the ENTER key to access this parameter. Each unit in the
Cascade system must be programmed with its own address. The
boiler designated as the Leader will have an address of 0. The
remaining boilers in the Cascade will be Members and have
addresses from 1 - 7. Use the UP and DOWN arrow keys to
select the appropriate address. Press the ENTER key to program
this into the control.
3. Change the zeros to match the user code (factory set at
“0704”). Use the UP and DOWN keys to
increment or decrement the flashing digit, and the NEXT
and PREVIOUS keys to select which digit flashes.
4. Press the ENTER key.
Press the MENU key twice to exit the control parameters. Repeat
this procedure for all boilers in the Cascade, designating the
Leader control and the Member controls.
5. The display changes to read USER CODE for a few
seconds, then displays a menu.
6. Press the ENTER key.
7. Press the UP key twice to display “A3 DATE AND
TIME”.
8. Press the ENTER key once.
55
Installation & Operation Manual
11 Operating information
General
DHW / space heating (SH) cycling
If a DHW call for heat is received while a space heating call is in
progress, the control will start the DHW pump and shut the
boiler pump off. The system pump will remain on. If the space
heating call is still active while the DHW call is in operation, the
control will wait for 30 minutes (time adjustable by installer)
then it will switch back to the space heating demand. The
control will switch back and forth until one of the heat demands
end. This function does not apply to cascade systems.
How the boiler operates
The Knight XL uses an advanced stainless steel heat exchanger
and electronic control module that allows fully condensing
operation. The blower pulls in air and pushes flue products
out of the boiler through the heat exchanger and flue piping.
The control module regulates blower speed to control the
boiler firing rate. The gas valve senses the amount of air
flowing into the boiler and allows only the right amount of
gas to flow.
Programmable controlling sensor
The control module is programmed to use the outlet sensor as
the control sensor by default. If a system supply sensor is
connected, the control automatically uses it as the control
sensor. The control sensor can be changed by the installer to the
inlet sensor. If the inlet sensor is chosen as the controlling
sensor, it is recommended that the system supply sensor be
installed.
How the control module operates
The SMART SYSTEM control module receives input from
boiler sensors and external inputs. The control module
activates and controls the blower and gas valve to regulate
heat input and switches the boiler, Domestic Hot Water
(DHW), and system pumps on and off as needed. The user
programs the module to meet system needs by adjusting
control parameters. These parameters set operating
temperatures and boiler operating modes. Boiler operation
can be based on boiler outlet water temperature, boiler inlet
water temperature, or system temperature, depending on the
parameter setting.
Anti-cycling
After a space heating demand has been satisfied, the control will
delay the next space heating call for a set time period (time is
adjustable by the installer). The time delay will be bypassed if
the inlet water temperature drops too far during the delay.
Control inputs and outputs
Boiler, system, and DHW pump control
When a space heating call for heat starts and no DHW call is on,
the system and boiler pumps are turned on. As long as the space
heating call for heat is on, the system pump will remain on. If a
DHW call for heat is on, the boiler pump will wait to turn on
until just before the DHW pump turns off. After the space
heating call for heat ends, both pumps will run for an additional
period of time.
Room thermostat / zone control
This input tells the boiler to provide water for space heating.
Domestic Hot Water (DHW) tank thermostat
This input tells the boiler to provide water for heating an
indirect DHW tank.
When a DHW call for heat starts, the DHW pump is turned on.
If a space heating call for heat was on, the boiler pump will turn
off a few seconds after the DHW pump turns on.
0 - 10V input (set point or power)
The Knight XL can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. The control can be
configured by the installer to use this signal to either control
set point or firing rate.
Temperature control
Modulation
DHW priority
The Knight XL is capable of modulating its firing rate from a
minimum of 20% to a maximum of 100%. The firing rate is
dictated by the call for heat (i.e., space heating or domestic hot
water), the heating load, ramp delay (if enabled), and various
other temperature limitations.
The SMART SYSTEM control module allows connection of a
DHW thermostat to the low voltage connection board. When
the DHW thermostat calls for heat, the module activates the
DHW pump, shuts down the boiler pump, and immediately
sets the target outlet water temperature to 180°F (82.2°C).
This provides automatic priority heat allocation to the
indirect water heater for maximum response and recovery.
The DHW pump continues for 30 seconds after the heating
cycle to deliver the most possible heat.
56
Installation & Operation Manual
11 Operating information
(continued)
Ramp delay
Protection features
For systems with lower flow, the SMART SYSTEM can limit
the firing rate (when enabled) when a space heating call for
heat starts, or when switching from a DHW call for heat to
a space heating call for heat. There are six (6) limits that
can be programmed, as well as six (6) time intervals
corresponding to each limit. The sixth limit will also limit
the firing rate for the rest of the call for heat.
Outlet temperature, flue temperature, and
temperature rise limiting
The outlet temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F (90°C) the control will shut the unit
down until it cools off.
Gradient limiting
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F (102°C) the control will reduce the maximum fan speed.
If the flue temperature exceeds 240°F (115°C) the control will
shut the unit down. The unit will restart automatically once the
flue temperature drops 25°F (-4°C) and the minimum off time
has expired.
If during operation of the boiler the outlet water
temperature is rising too quickly, the control will reduce the
firing rate to its lowest setting.
Outdoor air reset
If an outdoor air sensor is connected, the control module
will calculate the set point based on the programmed reset
curve. The installer can change the slope of the reset curve
by several adjustable parameters. The user can limit the
maximum set point for the system using the space heating
set point.
The control monitors the temperature difference between the
inlet and the outlet sensor. If this difference exceeds 55°F
(13°C) the control will reduce the fan speed. If the
temperature difference exceeds 60°F (15°C) the control will
shut the unit down. The unit will restart automatically once the
temperature difference has dropped below 55°F (13°C) and the
minimum off time has expired.
Boost function
If outdoor air reset is active, and a space heating demand
has been active continuously for a set period of time (time
adjustable by installer) and there has been no DHW
demands, the control will increase the set point by a fixed
number of degrees (adjustable by installer). This process
will continue until the space heating demand ends, the set
point reaches the programmed set point or a maximum of
20 increases has occurred. Once the system heat demand is
satisfied, the set point will revert to the value determined by
the reset curve.
Freeze protection
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the SMART SYSTEM control
module provides some protection for the boiler only -- not for
the system.
•
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F (7°C):
Below 45°F (7°C), the boiler and system pumps
operate constantly.
Night setback
The controller may be programmed to reduce the space
heating set point during a certain time each day. A start
and stop time can be programmed for each day of the week.
•
•
Below 37°F (3°C), the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F (7°C).
Flame current support
This feature of the SMART SYSTEM
ƽ CAUTION
control module does not eliminate the
possibility of freezing. The installation
must still use recognized design,
installation and maintenance practice to
prevent freeze potential for the boiler and
system.
To prevent nuisance shutdowns when the boiler is firing at
minimum rates, the control will increase the firing rate
when the flame signal drops too low.
57
Installation & Operation Manual
11 Operating information
Monitor external limits
High limit operations
Connections are provided on the connection board for
external limits such as flow switch, low water cutoff, gas
pressure switches, and an auxiliary device proving switch.
The SMART SYSTEM will shut off the burner and inhibit
relighting whenever any of these external limits open.
When outlet temperature exceeds 200°F (93.3°C), high limit
action occurs. The boiler shuts down until the outlet water
cools down.
Low water cutoff protection
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the flow rate is too low or the outlet
temperature too high, the control module modulates and
shuts the boiler down. This ensures boiler shutdown in the
event of low water or low flow conditions.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler
is firing under 50% of rate. The other timer monitors the
time the boiler is firing over 50% rate.
2. Some codes and jurisdiction may accept these integral
features of the control in lieu of requiring an additional
limit control or low water cutoff. Consult local jurisdiction
to determine. A low water cutoff is available from the
factory (WTR20009).
The control uses four (4) ignition counters to monitor the
amount of boiler cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed. The third and fourth
counters are the same as the first and second respectively,
but can be reset by the installer.
Outdoor reset operation, if used
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
Service reminder
See the Knight XL Service Manual to change the settings.
The control can be programmed for service reminder
notification. This notification will become active when
either a set time frame has expired, or a set amount of
running hours or cycles has expired (all adjustable by the
installer). The display will alternate the standard text on
the display screen with Service Due every 5 seconds. The
service reminder notification can be reset by the installer.
Reset curve
The reset curve looks at outdoor air temperature and adjusts the
set point.
Cascade
When multiple boilers are installed, they can be wired together
in a cascade sequence. A maximum of eight boilers can be
controlled from a single control. In this application one boiler
would be designated as the Leader control and all others would
be designated as Member controls.
Error logging
The control will hold in memory the last 10 error codes as
well as the last 10 turn-off functions. The date and time of
the occurrence will be recorded as well. Only the 10 most
current occurrences will be held in memory.
Once the Leader boiler receives a call for heat from a room
thermostat, the control will determine what the set point will be.
If outdoor air reset is desired, connect the outdoor air sensor to
the terminals on the Low Voltage Connection Board on the
Leader boiler. The set point will be calculated based on the
programmed reset curve parameters. See the Knight XL Service
Manual to program the reset curve. If outdoor air reset is not
desired, do not connect the outdoor air sensor. A fixed
temperature set point can be programmed into the control. See
page 54 of this manual to program the set point.
Boiler temperature regulation
Operating temperature (target)
The SMART SYSTEM control module senses water
temperature and regulates boiler firing and firing rate to
achieve a target temperature. The target temperature can
be set between 70°F (21°C) and 190°F (88°C).
•
Target temperature is fixed when the outdoor
sensor is not installed.
•
Target temperature is calculated as described
on this page under “Outdoor Reset Operation”
and “Target Temperature Boost” when the
outdoor sensor is connected.
58
Installation & Operation Manual
11 Operating information
(continued)
DHW, Night Setback, and Ramp Delay operation with
cascade
Cascade (continued)
If the water temperature at the system supply sensor is less
than the set point + the turn-off offset - the off-on
differential, then the control will initiate a call for heat on
the Cascade (see the Knight XL Service Manual for an
explanation of the offset and differential). The Leader will
energize the lead boiler on the Cascade. For a new startup
this will be the Leader boiler.
For DHW operation any boiler(s) in the Cascade can be selected
to provide heat for a DHW call. Select a boiler to be designated
as the DHW boiler. Connect the DHW thermostat to the
terminals on the Low Voltage Connection Board marked for the
DHW Thermostat. When the boiler receives a DHW call, the
Leader control will take that boiler out of the Cascade sequence.
If another boiler is available, the Leader will start it up to take its
place.
The boiler will fire at its ignition speed and will then
modulate its firing rate to maintain the set point. If the first
boiler reaches 100% of its firing rate, the Leader will
calculate at what point the second boiler could fire at 20%
of its firing rate. At this point, the Leader will fire the second
boiler on the Cascade. For a new startup, this would be the
first Member boiler. The boiler will fire at its ignition speed
and will then modulate its firing rate to maintain the set
point.
The DHW boiler will adjust its set point to the programmed
DHW set point and will adjust its firing rate to maintain this.
Once the DHW call has been satisfied, the Leader control will
place that boiler back into the Cascade sequence.
Switching of the boiler between DHW operation and SH
operation when there is a call for both does not occur. The boiler
will provide heat for the DHW demand until it is satisfied.
If the set point still cannot be met, the Leader will continue
firing more Members until either the heat demand is met or
all boilers on the Cascade are firing. As the heat demand
decreases, the last boiler on will modulate down to 20% of
its firing rate. Once the demand for that boiler is zero, it will
shut down. As the heat demand decreases further, the
second to last boiler will modulate down and shut off. This
will continue until the demand is satisfied and all boilers are
shut off.
Night Setback operation of the boilers within the Cascade is
available. Programming of the Night Setback will be done
through the Leader boiler. Refer to the Knight XL Service
manual for information regarding Night Setback.
Ramp Delay operation of the boilers as described in the Knight
XL Service Manual is not active when the boilers are part of a
Cascade system.
Sequence of the cascade
To equalize the run time of all boilers on the Cascade, the
firing sequence will automatically be changed at set
intervals.
For the first 24 hours after initializing the Cascade, the
sequence will be changed every hour. After that the
sequence will be changed once every 24 hours. The
switching on/off sequence will be as follows:
DAY
Day 1
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
Day 1 + 1 hour
Day 1 + 2 hours
M2-M3-M4-M5-M6-M7-L-M1
59
Installation & Operation Manual
11 Operating information
Sequence of operation
OPERATION
DISPLAY
1. Upon a call for heat, the control turns on the appropriate pumps
(system and boiler pumps for space heating call; DHW pump
for DHW call).
B
L
R
:
:
S
t
a
n
d
b
y
O
U
T
1
2
3
.
8
F
(
1
2
9
)
)
2. The control connects 120 VAC to the blower. The blower
does not run at this time.
• The manual reset high limit must be closed and reset.
• Once the pumps are turned on, the flow switch must close.
• If the unit is equipped with gas pressure switches, they must
close.
• If an auxiliary limit is connected to the unit, it must close.
• The air pressure switch must be closed.
B
L
R
:
:
S
t
a
n
d
b
y
(
O
U
T
1
2
3
.
8
F
1
2
9
B
L
R
:
:
P
R
E
P
U
R
G
E
3. The control then starts a 15 second prepurge cycle.
O
U
T
1
2
3
.
9
F
(
1
2
9
)
4. Once the prepurge cycle is complete, and the blocked drain
switch is closed, the control starts the 4 second trial for ignition
by sending spark voltage to the spark electrode and opening
the gas valve.
B
L
R
:
:
I
G
N
I
T
I
O
N
1
O
U
T
1
2
3
.
9
F
(
2
9
)
5. If the control does not detect flame before the trial for ignition
ends, the control will perform a 10 second postpurge. The 399
model will start another prepurge and trial for ignition. If the
burner does not light after 4 trials on the 399 model, the control
will lock out for one hour and then try again.
B
L
R
:
:
P
O
S
T
P
U
R
G
E
,
9
P
R
E
P
U
R
G
E
O
U
T
1
2
3
.
9
F
(
1
2
)
If the burner does not light after 1 retry on Models 500 - 800 the
control will lock out.
6. If the control detects a flame before the trial for ignition ends, it
begins to modulate the burner in order to maintain the set point.
If the boiler lights due to a space heating call for heat, and the
ramp delay function is active (default is off), the modulation
will be held to a series of increasing limits afterthe burner has lit.
B
L
R
:
:
S
H
2
2
0
%
R
A
T
E
O
U
T
1
4
.
8
F
(
1
2
9
)
7. If the space heating call for heat is active, and the DHW
thermostat or sensor starts a DHW call for heat, the control will
turn on the DHW pump, wait 2 seconds, and then turn off the
boiler pump. This will divert the hot water away from the
heating zone(s) and send it to the DHW tank instead. The
control will then modulate to maintain the outlet temperature to
the DHW boiler set point.
B
L
R
:
:
D
H
W
7
8
5
%
R
A
T
E
O
U
T
1
7
.
8
(
1
8
0
)
8. If the boiler is not part of a cascade, and the DHW call for heat
remains active for more than 30 minutes, and the space heating
call for heat is also active, then the control will turn on the boiler
pump, turn off the DHW pump after 2 seconds, and resume
modulating based on the space heating set point. As long as
both the space heating and DHW calls for heat remain active,
the control will switch back and forth between the two modes
until one of them is satisfied.
B
L
R
:
:
S
H
2
4
1
%
R
A
T
E
O
U
T
1
3
.
0
F
(
1
2
9
)
9. Once both calls for heat are satisfied, the control will turn off the
burner. The blower will remain on for the 10 second postpurge
cycle. Any pumps that are running will continue to run for their
respective pump delay times, then turn off.
B
L
R
:
:
P
O
S
T
P
U
R
G
E
2
O
U
T
1
2
7
.
4
F
(
1
9
)
B
L
R
:
S
t
a
n
d
b
y
(
10. Boiler pump off, system pump continues its delay if longer.
O
U
T
:
1
2
4
.
7
F
1
2
9
)
)
B
L
R
:
:
S
t
a
n
d
b
y
(
11. System pump off.
O
U
T
1
2
2
.
9
F
1
2
9
60
Installation & Operation Manual
11 Operating information
(continued)
Knight XL control module
Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Figure 11-1 Control Panel
• Press to turn boiler off or
back on
• Press to select a menu item
• Press after parameter programming
to store parameter data
• Press to exit Service Mode
• Hold 5 seconds to enter code
Input Mode (Menu Mode)
• Press to move up one level
in Menu Mode or to exit
Menu Mode
SHUTDOWN
ENTER / RESET
MENU / EXIT
DISPLAY SCREEN
SERVICE
BUTTON
PC
CONNECTION
PORT
UP
DOWN
PREVIOUS
NEXT
• Press to toggle display during normal
operation to show outlet and return
temperatures, fan speed, and flame
signal
• Press to toggle between digits when
entering access code or between hour,
minutes, etc., when entering date and
time
• Press to change boiler water
temperature set point during
normal operation
• Press to change displayed data
values in Menu Mode
• Press to navigate through menu
listing in Menu Mode
61
Installation & Operation Manual
11 Operating information
Access modes
User
The user can adjust space heating target temperature by using the UP and
DOWN buttons (FIG. 11-1) at any time during normal operation. By
entering the USER code (0704), the user can also change temperature
units, time and date, and night setback settings. In User Mode, the
following parameters can be viewed but not changed:
• Boiler outlet water target temperature in DHW Mode
• Boiler model number
• Software version
• Total operating hours
• Total cycles
Installer
Most parameters are available only to the installer, accessible only by
entering the installer access code, see the Knight XL Service Manual.
Saving parameters (reference the Parameter Table in the Knight
XL Service Manual)
To save parameters and exit programming:
Press the ENTER/RESET button.
To keep parameter settings only for a current operating cycle:
Press the MENU/EXIT button 3 times after making all desired parameter
changes.
To enter a parameter and continue programming:
Press the MENU/EXIT button 1 time to return to the parameter listings;
press again to return to the menu listings. Remember to press the
ENTER/RESET button when finished programming in order to save the
changes made.
See the Knight XL Service Manual for a detailed description of parameters
and access modes.
62
Installation & Operation Manual
11 Operating information
(continued)
Status Display Screens
By using the Previous/Next (ꢀ, ꢁ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what
they can display:
Screen
Display shows:
Description
The unit has been turned OFF by the Enter/Reset button on the
SMART SYSTEM display panel.
BLR: OFF
The unit has not received a call for heat from a remote thermostat nor
has it received a call for heat from a DHW thermostat.
Standby
The unit has met the water temperature set point, but is still receiving
a call for heat from either a remote thermostat or a DHW thermostat.
Set Point Met
The unit has initiated a 10 second purge period on a call for heat.
Note: On the 800 model the unit will initiate a 20 second purge
period on a call for heat.
Prepurge
Ignition
The unit has begun a 5 second spark period to ignite the main burner.
The unit has fired and is running at the displayed percentage.
SH***% Rate
#1
The call for heat has been satisfied and the unit runs the fan for an
additional 10 seconds to clear the combustion chamber and vent
system of residual flue products.
Postpurge
Service
The unit has been placed in a temporary mode that will allow the unit
to fire at 100% of rate for the purpose of combustion analysis.
When the outlet sensor has been selected as the control sensor
(default), the control will display the outlet temperature as well as the
set point in parenthesis.
OUT: ***.*F(***)
***.*F
If the outlet sensor has not been selected as the control sensor, only
the outlet temperature will be displayed.
Open
The control does not detect the outlet sensor.
Shorted
The outlet sensor wires or the sensor itself has become shorted.
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #2.
If the inlet sensor has not been selected as the control sensor, only the
inlet temperature will be displayed.
IN: ***.*F
When the inlet sensor has been selected as the control sensor, the
control will display the inlet temperature as well as the set point in
parenthesis.
***.*F (***)
#2
Open
The control does not detect the inlet sensor.
Shorted
The inlet sensor wires or the sensor itself has become shorted.
The difference between the inlet temperature and the outlet
temperature.
RISE: ***.*F
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #3.
63
Installation & Operation Manual
11 Operating information
Status Display Screens (cont’d)
By using the Previous/Next (ꢀ, ꢁ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what
they can display:
Screen
Display shows:
Description
If the system supply sensor has not been selected as the control sensor,
only the system temperature will be displayed.
SYS: ***.*F
When the system supply sensor has been selected as the control
sensor, the control will display the system temperature as well as the
set point in parenthesis.
***.*F (***)
Open
The control does not detect the system supply sensor.
The system supply sensor wires or the sensor itself has become
shorted.
#3
Shorted
The control will display the outdoor air temperature as sensed by the
outdoor air sensor.
OUTDOOR: ***.*F
Open
The control does not detect the outdoor air sensor.
Shorted
The outdoor air sensor wires or the sensor itself has become shorted.
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #4.
FLUE: ***.*F
Open
The control will display the flue temperature.
The control does not detect the flue sensor.
Shorted
The flue sensor wires or the sensor itself has become shorted.
The control will display the temperature.
#4
AUX: ***.*F
Open
The control does not detect the auxiliary sensor.
Shorted
The auxiliary sensor wires or the sensor itself has become shorted.
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #5.
FAN SPD: ****RPM
FLAME SIG: **.*uA
The control will display the actual fan motor RPM.
#5
#6
The control will display the flame signal in dc microamps.
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #6.
SH CFH: OFF
ON
The control has not received a call for heat from a remote thermostat.
The control has received a call for heat from a remote thermostat.
The control has not received a call for heat from a SH remote
thermostat.
DHW CFH: OFF
ON
The control has received a call for heat from a DHW thermostat.
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #7.
64
Installation & Operation Manual
11 Operating information
(continued)
Status Display Screens (cont’d)
By using the Previous/Next (ꢀ, ꢁ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8)
display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what
they can display:
Screen
Display shows:
Description
The control has not received a DHW call for heat and has not
powered the DHW pump.
DHW PUMP: OFF
The control has received a DHW call for heat and has powered the
DHW pump.
ON
#7
The DHW call for heat has been satisfied and the DHW pump is
running for a fixed time to remove any residual heat.
Delay
The control will display a 0-10Vdc signal received from a Building
Management System (BMS) connected to the unit.
0-10V IN: **.Vdc
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #8.
The control has not received a call for heat from a remote thermostat
and has not powered the system pump.
SYS PUMP: OFF
ON
The control has received a call for heat from a remote thermostat and
has powered the system pump.
The system call for heat has been satisfied and the system pump is
running for a fixed time to remove any residual heat.
Delay
The control has either not received a call for heat from a remote
thermostat, a remote thermostat is not connected to the unit and the
water temperature has not dropped below the temperature set point
of the control to initiate a call for heat, or the control has received a
DHW call for heat from a DHW thermostat.
BLR PUMP: OFF
#8
The control has received a call for heat from a remote thermostat or a
remote thermostat is not connected and the water temperature has
dropped below the temperature set point of the control to initiate a
call for heat.
ON
The call for heat has been satisfied and the boiler pump is running for
a fixed time to remove any residual heat.
Delay
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #9.
65
Installation & Operation Manual
11 Operating information
Status Display Screens (cont’d)
Operation of the cascade
The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide
information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description
of the individual items and what they can display:
Screen
Display shows:
Description
The Leader control has been turned off by the Enter/Reset button on
the Smart System display.
Cas: Off
The Leader boiler has not received a call for heat from a remote
thermostat.
Cas: Standby
The Cascade is now active. The system supply temperature will be
displayed. The Cascade set point will be displayed in parenthesis.
Cas: 127.4F (130)
The Cascade has met the water temperature set point, but is still
receiving a call for heat from a remote thermostat.
Cas: Setpoint Met
Cas: No Members
Cas: S6 Not Present
PMP: Off
The Leader control could not detect any Member controls to
participate in the Cascade.
#9
The system supply sensor is not connected to the Leader boiler.
The Leader control has not received a call for heat from a remote
thermostat and has not powered the system pump.
The Leader control has received a call for heat from a remote
thermostat and has powered the system pump.
PMP: On
The system call for heat has been satisfied and the system pump is
running for a fixed time to remove any residual heat.
PMP: Delay
Press the Next ꢁ arrow key on the SMART SYSTEM display to access Screen #10.
The first percentage shows the firing rate that is being sent to the last
Cas Pow: ***% ***%
boiler called on. The second percentage shows the total power
available to the Cascade.
Shows the number of boilers connected to the Cascade. The Leader is
designated as 0. Members will be designated 1 - 7. If a “-“ is used in
place of a number, that boiler is either not connected, or in a lockout
mode and not available for the Cascade. If a “d” is used in place of a
number, that boiler is handling a DHW demand and is not available
for the Cascade. If the number is flashing, then that boiler is providing
heat to the Cascade. As the lead boiler is changed from day to day, that
boiler’s address will be shown first in the string of numbers. In the
example, boilers 0 - 3 are present, boiler 2 is the lead boiler, and boiler
0 is heating an indirect DHW tank.
Present: 01234567
#10
Example:
Present: 23----d1
Press the Next ꢁ arrow key on the SMART SYSTEM display to roll back to Screen #1. At any point if you wish to access an
earlier screen, press the Previous ꢀ arrow key on the SMART SYSTEM display.
66
Installation & Operation Manual
12 Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Owner maintenance
Service technician
(see the Knight XL User’s Information Manual for
instructions)
(see the following pages for instructions)
General:
• Address reported problems
• Check boiler area
• Inspect interior; clean and vacuum if
necessary;
Daily
• Check pressure/temperature
gauge
• 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 vent piping
• Check air piping
•Check system water pressure/system
piping/expansion tank
• Check control settings
• Check air and vent termination
Monthly
screens
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check relief valve
• Check wiring and connections
• Check condensate drain system
• Check automatic air vents
• Perform start-up checkout and
performance verification per Section 10.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
•Test low water cutoff (if used)
Periodically
• Reset button (low water cutoff)
• Clean the heat exchanger if flue
temperature is more than 54°F (30°C)
above return water temperature.
If combustion or performance
indicate need:
• Check boiler piping (gas and
Every
6 months
water) for leaks
• Clean heat exchanger
• Operate relief valve
• Remove and clean burner using
compressed air only
• Clean the blower wheel
End
•Shut boiler down (unless boiler
of season
used for domestic hot water)
months
67
Installation & Operation Manual
12 Maintenance
Follow the Service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler
or system. Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
ƽ WARNING
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the boiler designated in Table 12A and explained on the following pages must be performed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
ƽ WARNING
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
ƽ WARNING
Address reported problems
Figure 12-1 Condensate Trap
1. Inspect any problems reported by the owner and correct
before proceeding.
RETAINING
SCREW
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect boiler area
1. Verify that boiler area is free of any combustible
materials, gasoline and other flammable vapors and
liquids.
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
2. Verify that air intake area is free of any of the
contaminants listed in Section 1 of this manual. If any of
these are present in the boiler intake air vicinity, they
must be removed. If they cannot be removed, reinstall
the air and vent lines per this manual and the Knight XL
Service Manual.
CONDENSATE FROM
HEAT EXCHANGER
Inspect boiler interior
TO FLOOR
DRAIN
1. Remove the front access cover and inspect the interior of
the boiler.
The condensate trap 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.
ƽ WARNING
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
Check all piping for leaks
Eliminate all system or boiler leaks.
1. Inspect the condensate drain line, condensate PVC
fittings, and condensate trap.
ƽ WARNING
Continual fresh makeup water will reduce
boiler life. Minerals can build up in sections,
reducing heat transfer, overheating heat
exchanger, and causing heat exchanger
failure. Leaking water may also cause severe
property damage.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 12-1).
3. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 12-1).
4. Remove any sediment in the trap.
1. Inspect all water and gas piping and verify to be leak free.
5. Fill with fresh water until the water begins to pour out of
the drain.
2. Look for signs of leaking lines and correct any problems
found.
6. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
3. Check gas line using the procedure found in Section 7 -
Gas Connections.
7. Replace the retaining screw.
68
Installation & Operation Manual
12 Maintenance
(continued)
Safety relief valves should be re-inspected AT
LEAST ONCE EVERY THREE YEARS, by a
licensed plumbing contractor or authorized
inspection agency, to ensure that the product
has not been affected by corrosive water
conditions and to ensure that the valve and
discharge line have not been altered or
tampered with illegally. Certain naturally
occurring conditions may corrode the valve
or its components over time, rendering the
valve inoperative. Such conditions are not
detectable unless the valve and its
components are physically removed and
inspected. This inspection must only be
conducted by a plumbing contractor or
authorized inspection agency – not by the
owner. Failure to re-inspect the boiler relief
valve as directed could result in unsafe
pressure buildup, which can result in severe
personal injury, death, or substantial
property damage.
Flue vent system and air piping
ƽ WARNING
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe
is connected and properly sealed.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
ƽ WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be
taken to avoid contact with hot water and to
avoid water damage. Before operating lever,
check to see that a discharge line is
connected to this valve directing the flow of
hot water from the valve to a proper place of
disposal. Otherwise severe personal injury
may result. If no water flows, valve is
inoperative. Shut down the boiler until a
new relief valve has been installed.
ƽ WARNING
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
Check expansion tank
1. Expansion tanks provide space for water to move in and
out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder type.
See Section 6 - Hydronic Piping for suggested best
location of expansion tanks and air eliminators.
Check boiler relief valve
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief
valve. Ensure that the reason for relief valve weeping is
the valve and not over-pressurization of the system due to
expansion tank waterlogging or undersizing.
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 6 - Hydronic Piping before
proceeding further.
69
Installation & Operation Manual
12 Maintenance
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove the
burner and clean it thoroughly using a vacuum cleaner or
compressed air. Do not use compressed air to clean burner
if performed inside a building.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Remove the burner, reference FIG.’s 12-2 thru 12-4.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG.’s 12-2 thru 12-4).
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger access
cover to ground terminal strip.
Figure 12-2 Burner Assembly - Model 399
2. Verify all wiring is in good condition and securely
attached.
3. Check ground continuity of wiring using continuity
meter.
AIR / GAS ARM
4. Replace ground wires if ground continuity is not
satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
BURNER
GASKET
Check control settings
SCREWS
(QTY. 5)
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the Knight XL Service Manual. Adjust settings if
necessary. See Section 1 of the Knight XL Service Manual
for adjustment procedures.
Figure 12-3 Burner Assembly - Model 500
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 10 - Start-up.
AIR / GAS ARM
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
BURNER
GASKET
SCREWS
(QTY. 5)
70
Installation & Operation Manual
12 Maintenance
(continued)
Cleaning boiler heat exchanger
Figure 12-4 Burner Assembly - Models 600 - 800
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in Section 10 - Startup.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fluid
in system, do not drain.
AIR ARM
2. Allow time for the boiler to cool to room temperature if
it has been firing.
3. Remove the blower assembly (gas air/arm) from the heat
exchanger access cover. Set bolts aside.
BURNER
GASKET
4. Remove the nuts securing the heat exchanger access cover
to the heat exchanger and set aside.
SCREWS
(QTY. 5)
5. Remove the heat exchanger access cover, cover gasket(s)
and chamber insulation assembly.
The boiler contains ceramic fiber
Check flame signal
ƽ WARNING
materials. Use care when handling these
materials per instructions in the Handling
Ceramic Fibers Section of the Knight XL
Service Manual. Failure to comply could
result in severe personal injury.
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.
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
7. Finish cleaning using a clean cloth dampened with warm
water.
3. See Section 3 - Troubleshooting in the Knight XL Service
Manual for other procedures to deal with low flame
signal.
8. Install access cover gasket, chamber insulation assembly
and cover.
Review with owner
9. Secure nuts on the studs. DO NOT overtighten.
10. Re-install the blower assembly (gas air/arm) using the
bolts set aside in Step 3.
1. Review the Knight XL User’s Information Manual with
the owner.
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.
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.
12. When the boiler has been flushed, restore boiler to
operation.
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.
13. Perform start-up and check-out procedures in Section 10
- Startup.
71
Installation & Operation Manual
13 Diagrams
Figure 13-1 Wiring Diagram
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
BOX DEPICTS
OPTIONAL ITEMS
INTEGRATED CONTROL
X3
JUNCTION
BOX
RELAY
PC
X8
BOARD
INTERFACE
OR
OR
CONNECTION BOARD
X1-3
CN2-4
K1
K2
K3
CN1-5
DHW
PUMP
AUX.
DEVICE
PILOT
CN2
CN2-1
OR
CN1-6
BR
CN1-3
R
CN2-16
CN2-15
CN2-14
CN2-13
CN2-12
CN2-11
SUPPLY
BR
PR
X1-4
X1-2
Y
CN4-8
X6-8
BOILER
PUMP
AUX.
DEVICE
PROVING
BR
CN1-4
PR
CN1-1
OR
P
CN4-2
CN4-9
CN4-3
X6-10
X6-4
X6-5
SYSTEM
PUMP
GAS
PRESSURE
SWITCH
PR
CN1-2
BK
SOLENOID
VALVE
RELAY
ON/OFF
SWITCH
FLOW
CN2-10
CN2-9
CN2-8
CN2-7
CN2-6
CN2-5
CN2-4
CN2-3
CN2-2
CN2-1
SWITCH
L
BK
W
BK
W
X1-6
X1-5
120V
GND
GND
N
BELL JUMPER
SUPPLY
PR
PR
R
CN4-10
CN4-4
X3-4
X3-2
X3-1
X3-3
ALARM
CONTACTS
G
R
X1-8
X1-1
CN4-11
CN4-12
RUN-TIME
CONTACTS
R
DHW
THERMOSTAT
R W G
BLOWER
W
BL
GY
CN4-5
CN4-7
CN4-13
X6-1
X6-2
X6-6
1
2
3
ROOM
THERMOSTAT
ZONE
1 2 3 4
5
CONTROL
R
T
X5-5
X5-13
X5-6
W
CN5-1
CN4-14
24 VAC
LOW
BK
BL
PR
OR
P
CN5-3
CN5-4
X5-12
X5-7
WATER
CUT-OFF
BR
Y
BL
PR
CN4-6
CN4-1
X6-9
X6-3
MANUAL RESET
HI-LIMIT
CN5-2
CN5
COM
X5-14
X5-11
X5-3
AIR PRESS. SWITCH
OR
P
BLOCKED
DRAIN
CN4
OR
GY
BK
S6
X5-4
SYSTEM
CN1-12
CN1-11
CN1-10
CN1-9
CN1-8
CN1-7
CN1-6
CN1-5
CN1-4
CN1-3
CN1-2
CN1-1
BL
SENSOR
X5-10
X5-8
(AUX) DWH
TANK
SENSOR
S4
S5
S2
INLET
SENSOR
R
S1
X5-1
OUTLET
SENSOR
FLUE
SENSOR
OUTDOOR
SENSOR
W
Y
X4
CN3
CN3
S3
X5-2
X5-9
SHIELD
A
B
RS485
BK
Y
X2-2
X2-1
GAS
VALVE
SHIELD
FLAME
ROD
+
-
EXTERNAL
CONTROL
W/R
0-10V
TR1
G
SPARK
ROD
CN1
CAUTION HIGH VOLTAGE SPARK LEAD
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a
minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead
or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
WIRING DIAGRAM
LBL2364 REV D
72
Installation & Operation Manual
13 Diagrams
(continued)
Figure 13-2 Ladder Diagram
BOX DEPICTS
OPTIONAL ITEMS
JUNCTION BOX
120VAC
NEUTRAL
GROUND
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
INTEGRATED CONTROL
F5
ON / OFF
SWITCH
L
IN
L
OUT
SYSTEM PUMP
RELAY
X1-2
SYSTEM
PUMP
5A
SYSTEM PUMP
RELAY
X1-6
X1-8
CONTACTS
BOILER PUMP
RELAY
SYSTEM
X1-4
X1-3
X1-1
PUMP
BOILER
PUMP
CONTACTS
BOILER PUMP
RELAY
DHW PUMP
RELAY
JUNCTION
BOX
BOILER
PUMP
DHW
PUMP
CONTACTS
DHW PUMP
RELAY
BLOWER
F4
1
2
DHW
PUMP
3.5A
BLOWER
RELAY
RELAY BOARD
3
F3
1.25A
X1-5
X6-8
120 VAC
JUNCTION BOX
F2
X5-7
CONNECTION BOARD
24 VAC
X6-7
X6-2
3.5A
RESISTOR
X6-3
CN4-1
CONNECTION
BOARD
CN5-1
CN5-2
CN5-4
CN4-7
INTEGRATED
CONTROL
LWCO
CONNECTION
BOARD
FLOW
SWITCH
CN5-3
CN4-6
X6-9
CN4-14
CN2-10
CN2-9
CN2-2
ROOM THERMOSTAT
ZONE CONTROL
CN4-13 X6-6
CN2-1
CN2-3
DHW
THERMOSTAT
CN4-5
CN4-3
X6-1
X6-5
CN2-4
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
CONNECTION
BOARD
MANUAL RESET
HIGH LIMIT
X6-4
CN4-9
X5-14
CN2-12
CN2-11
CN2-16
INTEGRATED
CONTROL
INTEGRATED
CONTROL
AUX. DEVICE
PILOT SUPPLY
DISPLAY
CN2-15
CN2-14
24VAC
AUX. DEVICE
PROVING
CN4-2
X6-10
CN2-13
X3
AIR PRESSURE
SWITCH
X5-11
X5-4
RIBBON CABLE
PC
X8
INTERFACE
BLOCKED
DRAIN SWITCH
X5-3
X5-8
X5-1
S2
INLET
SENSOR
CN2-15
X5-10
S1
S3
GAS VALVE
BLOWER
OUTLET
SENSOR
X2-2
X2-1
X5-2
X5-9
GAS VALVE
RELAY
CN2-10
CN2-9
CN2-8
CN2-7
FLUE
SENSOR
1
2
4
5
X5-5
X5-13
X5-6
CONNECTION BOARD
CN4-11
CN4-12
X3-1
X3-3
RUN-TIME
CONTACTS
CN2-6
CN2-5
X5-12
CN4-10
CN4-4
X3-4
X3-2
ALARM
CN2-8
CN2-7
TR1
X1-7
CONTACTS
CN3-8
CN3-7
CN3-9
CN3-6
X4-8
X4-7
X4-9
X4-6
S6
SYSTEM
SENSOR
FLAME ROD
CN1-12
CN1-11
CN1-10
CN1-9
CN1-8
CN1-7
CN1-6
CN1-5
CN1-4
CN1-3
CN1-2
CN1-1
SPARK
ROD
(AUX) DHW
TANK
SENSOR
S4
S5
CAUTION HIGH VOLTAGE SPARK LEAD
OUTDOOR
SENSOR
CN3-5
X4-5
NOTES:
1. Where possible, switches are shown without utilities (gas, water or
electricity) connected to the unit. As such, actual switch states may
vary from those shown on diagrams depending upon whether utilities
are connected or a fault condition is present.
SHIELD
CN3-2
CN3-1
CN3-3
X4-2
X4-1
X4-3
A
RS485
B
2. See wiring diagram for additional notes.
SHIELD
CN3-10 X4-10
CN3-4
X4-4
+
-
EXTERNAL
CONTROL
0-10V
LADDER DIAGRAM
LBL2356 REV C
73
Notes
Notes
Revision Notes: Revision B (ECO #C02407) reflects gas valve
adjustment, room air, new sidewall vent termination, piping diagrams,
flow switch, relief valve, T & P gauge, Maintenance Section, FIG. 8-1
(Line Voltage), and high altitude changes.
Revision C (ECO #C02545) reflects the addition of references to the
safety shutoff testing and instructions, sediment trap, periodic cleaning
of screens in vent terminations, removal of B149.2 references, changed
the arrow direction on FIG. 6-8, wall thickness for direct vent
terminations and sidewall vent termination kit number correction.
Revision D (ECO #C02738) reflects updates made to the line voltage
image (FIG. 8-1 on page 43), and edits made to the gas conversion
section for the new orifice on the 399 model (page 12).
Revision E (ECO #C03223) reflects edits made to the high altitude
section on page 7 and updates made to the condensate trap image on
pages 49 and 66.
Revision F (ECO #C03735) reflects, room air, LWCO, pump, hydro and
dirt separator changes.
Revision G (ECO #C04433) reflects the addition of the illustrations
disclaimer on all the piping drawings (ECR #R02431), changing out “dirt
separator” for “Y-Strainer” (ECR #R02455), address Step #5 of the
Sequence of Operation, add a description column in Table 3F, and
change the direction of the arrows on FIG. 6-8.
KBX-I-O Rev G
9/09
|
Pioneer Car Video System AVH P4400BH User Manual
Pioneer Car Stereo System DEH 80PRS User Manual
Philips Car Video System 220SW9 User Manual
Oster IZER 6646 User Manual
Newcon Optik LAM 3 IR User Manual
Lennox Hearth BT 320S User Manual
KitchenAid KFPW760QOB1 User Manual
Kenwood DDX7047 User Manual
JVC KD S5M User Manual
JVC GZ MC500U User Manual