Knight High Efficiency Condensing Boiler I&O Manual Pg.35-68
Contents
1. Installation amp Operation Manual 6 Hydronic piping continued HE Pipe Hn 30 117 2 pan Figure 46 Multiple Boilers Zoned with Valves Model a 150 2172 Eam LS peu 4 n Up UE ES BACKFLOW PRESSURE PREVENTER REDUCING VALVE PRESSURE BALL VALVE n GAUGE LX TYPICAL lt 1 NW A MAKE UP WATER ZONE 2 ZONE 3 ZONE 4 ZONE VALVES TYPICAL i i DIFFERENTIAL I I PRESSURE BYPASS AIR SEPARATOR CIRCULATOR VALVE IF USED SYSTEM SUPPLY SENSOR WHEN USED EXPANSION 9 L 1 2 J NOT TO EXCEED 12 APART DRAIN POINT BOILER TYPICAL CIRCULATOR zi ANTI SCALD N y MIXING VALVE HOT WATER P OUT 4 v E i COLD WATER IN DOMESTIC x HOT WATER A CIRCULATOR UNION TEMPERATURE TYPICAL 1 PRESSURE GAUGE PRESSURE DRAIN BOILER 2 RELIEF VALVE BOILER 1 INDIRECT SLAVE 1 MASTER DHW TANK m 55 EH Installation amp Operation Manual 6 Hydronic piping Figure 47 Single Boiler Non Zoned Primary Secondary Piping PRESSURE REDUCING VALVE BACKFLOW PREVENTER GA gt lt 9 B ww a MAKE UP WATER pir PRESSURE GAUGE SEPARATOR SYSTEM SUPPLY SYSTEM TO CIRCULATOR SENSOR iin SYSTEM p SYSTEM X imen CN NOT TO EXCEED 12 APART Id a EN BALL VALVE N BOILER ANTI SCALD CIRCULATOR MIXING V2. Installation amp Operation Manual 10 Start up Figure 60 Operating Instructions Models 80 285 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 This appliance does not have a pilot It is Immediately call your gas supplier from equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to C Use only your hand to turn the gas control knob smell next to the floor because some gas Never use tools If the handle will not turn by is heavier than air and will settle on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been N under water Immediately call a qualified service not touch any electric switch do technician to inspect the appliance and to not use any phone in your building replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information 8 Turn gas shut
3. F The control will display the outdoor air temperature as sensed by the outdoor air sensor hor open The control does not detect the outdoor air sensor Shorted The outdoor air sensor wires or the sensor itself has become grounded Press the Next P arrow key on the SMART SYSTEM display to access Screen 4 FLUE F The control will display the flue temperature The control does not detect the flue sensor The flue sensor wires or the sensor itself has become grounded UNS The control will display the temperature The control does not detect the auxiliary sensor The auxiliary sensor wires or the sensor itself has become grounded Press the Next P arrow key the SMART SYSTEM display to access Screen 5 FAN SPD RPM The control will display the actual fan motor RPM 5 FLAME SIG uA The control will display the flame signal in dc microamps Press the Next gt arrow key the SMART SYSTEM display to access Screen 6 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 The control has received a call for heat from a DHW thermostat Press the Next P arrow key on the SMART SYSTEM display to access Screen 7 62 Installation 4 Operation Manual 11 Operating information continued Status Display Screens cont d By using
4. Below 37 F the boiler turns on Boiler and pumps turn off if boiler water temperature rises above 45 F cauTion Ts feature of the SMART SYSTEM control module does not eliminate the possibility of freezing The installation must stil use recognized design installation and maintenance practice to prevent freeze potential for the boiler and system 55 11 Operating information Monitor external limits 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 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 5096 of rate The other timer monitors the time the boiler is firing over 50 rate 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 Service reminder The control can be programme
5. Leave the top of the 1 2 inch tee OPEN This is needed as a vacuum break from the boiler tee resulting in potential water damage to property 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 6 Do not expose condensate line to freezing temperatures 7 Use only plastic tubing or piping as a condensate drain line FIG 58 Figure 58 Condensate Disposal 1 2 PVC TEE ASSEMBLY FACTORY SUPPLIED 1 2 PVC PIPE amp FITTINGS or 1 2 CPVC PIPE amp FITTINGS or 5 8 I D PLASTIC TUBING FIELD SUPPLIED 1 2 PVC UNION FACTORY SUPPLIED FLOOR DRAIN or DRAIN PAN 10 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning Or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh wate
6. If gas supply pressure is within normal range and no adjustments are needed proceed on to Step 11 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 Turn the power switch to the OFF position Shut off the gas supply at the manual gas valve in the gas piping to the appliance Remove the manometer from the pressure tap on top of the gas valve Re tighten the set screw inside the pressure tap Installation amp Operation Manual 7 Gas connections continued A WARNING When re tightening the set screw be sure to tighten securely to prevent gas leaks 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 Figure 54 Inlet Gas Supply Check Model 500 REMOVE THE 1 8 PIPE PLUG ON THE INLET FLANGE TO THE VALVE A ND INSTALL A SUITABLE 1 8 FITTING FIELD SUPPLIED FOR THE MANOMETER TUBING 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 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
7. Outlet temperature flue and temperature rise limiting temperature The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 190 E the unit will reduce the fan speed If the outlet water temperature exceeds 193 F the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F and the minimum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 55 F the control will reduce the fan speed If the temperature difference exceeds 60 F the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 55 F and the minimum off time has expired 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 Below 45 F the boiler and system pumps operate constantly
8. 6 Insertthe probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Oncethe boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 8 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 Boiler Service Manual for possible causes and corrective actions Table 8 Flue Products Chart Propane CO CO CO CO min max min max om es oe e nn n e 8 Once the combustion analysis is complete press the SHUTDOWN button on the display board FIG 62 to take the boiler out of Service Mode The boiler will go to shutdown and the display will show BOILER OFF 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 A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death substantial property damage 52 Installation amp Operation Manual Set space heating operation Determine controlling sensor For space heating systems the temperature control can be based on one of three sensors the inlet outlet or optional system sensor The SMART SYSTEM control
9. O VALVE VENT j VALVE i SYSTEM BL SENSOR S PR CEO MANUALRESET SER stn HI LIMIT AUXILIARY OR amp s uen OUTDOOR SENSOR AUTO RESET l KT mcum H Gv HI LIMIT SHIELD SLAVE INLET RS485 SENSOR SHIELD MASTER EXTERNAL 0 10V X52 E a X5 9 CJ sensor SZ GAS LOW VOLTAGE wn FLAME 1 120 VAC N HIGH VOLTAGE v ROD NIO 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 WIRING DIAGRAM diagrams to troubleshoot unit LBL7082 REV EH 64 Em Kist Installation amp Operation Manual 11 Operating information continued Figure 64 Ladder Diagram 120 60 TERMINA
10. Operation Manual Kist 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further Eliminate all system leaks Continual fresh 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 Purge air from water system 1 Purge air from system a Connect a hose to the purge valve see purge drain valves in piping diagrams on pages 32 through 37 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 Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve 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 v
11. 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 Figure 52 Inlet Gas Supply Check Models 80 285 LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE _ PRESSURE TAP DETAIL Figure 53 Inlet Gas Supply Check Model 399 LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP f 7 d 2 DETAIL Gas Pressure The gas pressure must remain between 4 inches w c natural 8 inches w c LP minimum and 10 5 inches w c natural 13 inches w c LP maximum during stand by static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the Knight 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 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 Gas valve replacement 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 connectio
12. causing property damage personal injury or loss of life This appliance does not have a pilot It is Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the te for gas Be sure to C Use only your hand to turn the gas control knob ne a tho jj a Never use tools If the handle will not turn by is heavier than air and will settle on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been E under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe Set the thermostat to lowest setting 9 Install top cover Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to
13. heating cycle only The old setting will become active after the current heating cycle ends 1 0 Start up continued Set domestic hot water DHW operation Verify DHW circulator mode 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 Boiler 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 Set DHW target temperature 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 Boiler Service Manual for a detailed explanation of this procedure 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 inst
14. the Previous Next gt arrow keys 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 Display shows DHW PUMP OFE The control has not received a DHW call for heat and has not powered the DHW pump The control has received a DHW call for heat and has powered the ON DHW pump 7 The DHW call for heat has been satisfied and the DHW pump is running for a fixed time to remove any residual heat The control will display a 0 10 Vdc signal received from a Building N 2 Management System BMS connected to the unit Press the Next gt arrow key on the SMART SYSTEM display to access Screen 8 SYS PUMP The control has not received a call for heat from a remote thermostat and has not powered the system pump N 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 The control has either not received a call for heat from a remote thermostat a remote thermostat is not connected to the unit and BLR PUMP OFF 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 DH
15. 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 59 must be A 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 1 0 Start up continued Final checks before starting the boiler A Read the Knight Boiler Service Manual to familiarize yourself with SMART SYSTEM control module operation Read this manual pages 50 and 51 for proper steps to start boiler Verify the boiler and system are full of water and all system components are correctly set for operation Verify the preparation procedures of Section 10 pages 47 and 48 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 Verify electrical connections are correct and securely attached A 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 Start the boiler 1 Read and follow the Opera
16. ALVE SOLD WATER EXPANSION e TANK B 4 f N EA 3 DRAIN POINT a E p rs TYPICAL TYPICAL DOMESTIC HOT WATER A CIRCULATOR UNION TYPICAL e n TEMPERATURE PRESSURE GAUGE IN BOILER INDIRECT PRESSURE DHW TANK RELIEF VALVE m 36 Installation amp Operation Manual 6 Hydronic piping continued Figure 48 Multiple Boilers Non Zoned Primary Secondary Piping N ber of Units Modell 2 3 4 5 6 Required Pipe Sizes 117 7 pan 2 1 2 2 1 2 2172 2 172 3 17 2 1 2 3 1 2 2 17 3 17 PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER D AIR E hes Y e SEPARATOR MAKE UP WATER SYSTEM SYSTEM SUPPLY CIRCULATOR SENSOR FROM TO 4 SYSTEM SYSTEM 5 X S NOT TO EXCEED 12 APART BALL VALVE D 4 TYPICAL EXPANSION TANK DRAIN POINT TYPICAL 5 BOILER CIRCULATOR BOILER CIRCULATOR ANTI SCALD MIXING VALVE CO WATER IN BOILER x CIRCULATOR lt q Szo 23 DOMESTIC E HOT WATER CIRCULATOR DRAIN TEMPERATURE d UNION PRESSURE PRESSURE GAUGE BOILER 4 BOILER 3 TYPICAL BOILER 2 RELIEF VALVE BOILER 1 INDIRECT SLAVE 3 SLAVE 2 SLAVE 1 MASTER DHW TANK EH 57 7 Gas connections Connecting gas supply piping 1 Remove the top access panel and refer to FIG s 49 and 50 to pipe gas to the boiler a Instal ground joint union for servicing when required b Install manual shu
17. H M HOLIMS 391430 Xnv E Xnv 8 Field wi FINO continued Figure 57 Low Voltage Field Wiring Connections Installation amp Operation Manual O Condensate disposal Condensate drain Notice JP materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement NOTICE 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 1 This boiler is a high efficiency appliance that produces condensate 2 The side of the boiler has a 1 2 inch PVC union for connection of a 1 2 inch PVC pipe FIG 58 3 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the Knight boiler will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes 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 A Neutralizer Kit is available from the factory Kit 4004 4 Install the 1 2 inch PVC tee assembly shipped with the unit as shown in FIG 58
18. L STRIP TERMINAL STRIP 120V SUPPLY 17 120V SUPPLY W A WARNING DISCONNECT POWER BEFORE SERVICING Boxpepicts OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE ee HIGH VOLTAGE SPARK LEAD NOTES 1 Where possible saiiches are shown without utiifies gas water or mectroty connected to unit As such actual switch states may very from those shown on depending upon whether utilities are connected or a taui condition is present 2 See winng diagram for additional nobis LADDER DIAGRAM LBL7083 REV EN 65 EH Installation 4 Operation Manual 12 Notes 66 Installation amp Operation Manual 12 Notes 67 4 lt Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com KB i amp o 01 CP 3M 09 05
19. T EXCHANGER Kiser Installation amp Operation Manual 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 thermostat circuit s 1 Disconnect the two external wires connected to the room thermostat terminals on the connection board 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 Ifa 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 Inspect fill condensate system Inspect check condensate lines and fittings 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 59 2 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 59 3 Fill with fresh water
20. W thermostat 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 The call for heat has been satisfied and the boiler pump is running Dela y for a fixed time to remove any residual heat Press the Next P arrow key on the SMART SYSTEM display to roll back to Screen 1 At any point if you wish to access earlier screen press the Previous lt arrow key on the SMART SYSTEM display 63 Keser Installation amp Operation Manual 11 Operating information Figure 63 Wiring Diagram DISPLAY AWARNING DISCONNECT POWER BEFORE SERVICING INTEGRATED CONTROL DHW THERMOSTAT 1 ON Depicts mm e INTERFACE P BK O O BK L 52 O NI ee qM BOARD 3 1 L pe ee AUX DEVICE 9 9e e PILOT SUPPLY 09216 8 9 Aux pevce PROVING L 6 A system L o9 E FLOW w BOILER SWITCH W UMP AARM TERMINAL STRIP Fae CONTACTS JN DHW RUN TIME CONTACTS a ROOM THERMOSTAT ZONE CONTROL EJ 1 Ts R SI SI LOW WATER CUT OFF vu BLOWER ZS LN SOLENOID N
21. alled and anytime the boiler has been powered off for more than one month Use the following procedure to set the clock 1 Press and hold the MENU key for a least 5 seconds 2 display changes to ready ENTER MENU CODE with four 4 zeros below it 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 5 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 DATE AND TIME 8 Press the ENTER key once Installation amp Operation Manual Kist 9 The date and time are displayed as W hh mm where mm minutes hh hour 24 hour time e g 2 00 PM 14 00 W day of the week 1 Sunday 2 Monday 3 Tuesday etc DD date MM month YY year Use the UP and DOWN keys to increment or decrement the flashing number and the NEXT and PREVIOUS keys to select which number flashes 10 Press the ENTER key to save the setting 11 Press the MENU key twice to exit the Programming Mode 53 11 Operating information General How the boiler operates The Knight boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blower pulls in air and push
22. connections Installation amp Operation Manual Table 7 Natural Gas Pipe Size Chart Nominal Iron Pipe Size Inches a 1400 2150 830 4100 6460 11200 E 3 ELS ELS Ea EZA Eg KES 23500 wp o ja f rr s se psa pea pow 3 636 769 1500 1210 ses e ves 707 Single Unit Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet ELS 79 1100 KUNKIN EXER KINKS CACA 1700 3000 28 MEN A 6150 Knight boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which A WARNING n i fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check inlet gas supply NOTICE CSA or UL listed flexible gas connections 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 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 ad
23. d before the boiler fires remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 57 High gas pressure switch l Ifa 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 57 Low gas pressure switch 1 Ifaswitch 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 57 2 If both a high and low gas pressure switch are used connect their respective contacts in series and connect them to the terminals on the connection board FIG 57 Flow switch 1 Aflow 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 2 Connect these terminals to the normally open contacts on the flow switch FIG 57 43 8 Field wiring continued System supply sensor 1 By installing an optional system supply sensor into the supply of the primary loop the temperature of the primary supply can be controlled The SMART SYSTEM control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point if the outlet sensor control is currently selected Connect these terminals to the sys
24. d 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 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 56 Installation amp Operation Manual 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 and 190 F Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described below under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations When outlet temperature exceeds 20092 high limit action occurs The boiler shuts down until the outlet water cools down If local codes require manual reset an Adjustable Manual Reset High Limit Kit is available Low water cutoff protection 1 The SMART SYSTEM control module us
25. desired setting This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Turn Off Gas To Appliance and the burner Do not try to light the burner call your service technician or gas supplier by hand i Gas Valve Gas Valve Remove top cover OPEN CLOSED Turn gas shutoff valve counterclockwise to OFF Handle will be perpendicular to pipe Do not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step to CLOSE TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve counterclockwise to Turn off all electric power to the appliance OFF Handle will be perpendicular to pipe if service is to be performed Do not force Remove top cover Install top cover LBL2284 REV EH 54 EH 10 Start up Check flame and combustion continued 4 Place the boiler into the active position by pressing the SHUTDOWN button on the display board FIG 62 page 59 until BOILER Standby appears in the display window 5 Locate the pinhole button above the T in the Knight logo on the display board FIG 62 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
26. e 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 Boiler Service Manual Saving parameters reference the Parameter Table in the Knight Boiler 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 Boiler Service Manual for a detailed description of parameters and access modes 60 Installation amp Operation Manual Kist Installation amp Operation Manual 11 Operating information continued Status Display Screens By using the Previous Next gt arrow keys 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 D
27. e rest of the call for heat Gradient limiting 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 With the outdoor air sensor 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 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 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 Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase fan speed when the flame signal drops too low Protection features
28. ents in the system one at a time beginning with the lowest floor Close the vent when water squirts out Repeat with remaining vents 2 Open automatic air vent diaphragm type 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 4 Refill to correct pressure 47 1 0 Start up continued Check for gas leaks A WARNING A 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 gasleak Use approved leak detection solution Repair any leaks at once 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 Figure 59 Condensate Trap PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN 48 NN 2 PVC WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE FROM HEA
29. es 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 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 Control inputs and outputs 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 0 10V input set point or power The Knight boiler 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 DHW priority The SMART SYSTEM control module allows connection of a DHW thermos
30. es temperature sensing of both supply and return areas of the heat exchanger If the flow rate is too low or either 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 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 kit s is available Kit 3057 Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See Knight Boiler Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Installation amp Operation Manual 11 Operating information continued Sequence of operation OPERATION DISPLAY Upon a call for heat the control turns on the appropriate pumps BLR Standby system and boiler pumps for space heating call DHW pump for 80 DHW call The control connects 120 vac to the blower The blower does not run at this time f the unit is equipped with a flow switch or low water cutoff it must close before the control powers up the blower f the unit is equipped with a manual reset high limit it must be closed before the control powers up the bl
31. ger 58 Kist Installation amp Operation Manual 11 Operating information continued SMART E A Knight boiler control module SYSTEM Use the control panel FIG 62 to set temperatures operating conditions and monitor boiler operation Figure 62 Control Panel Press to turn boiler off or Hold 5 seconds to enter code Backo SHUTDOW 4 JAN Press to select a menu item dn in Menu to exit Press after parameter programming Menu Mode to store parameter data Press to exit Service Mode ENTER RESET DISPLAY SCREEN O HEATING BOILER KNIGGE SERVICE BUTTON PC CONNECTION PORT 6 Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters eee PREVIOUS NEXT A inan v Press to toggle display during normal 8 se 9 operation to show outlet and return Press to change displayed data TT Tar Speed and flame values m Menu Mode Press to toggle between digits when d Press t o navigate through menu entering access code or between hour listing in Menu minutes etc when entering date and time m 50027 11 Operating information Access modes User The user can adjust space heating target temperature by using the UP and DOWN buttons FIG 62 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 th
32. is programmed at the factory to control the temperature of the outlet sensor The control will automatically switch to the system 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 Boiler Service Manual for a detailed explanation of this procedure 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 different delays are desired the appropriate parameters in the control must be changed See the Knight Boiler Service Manual for a detailed explanation of this procedure Set space heating set point temperature 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
33. isplay shows BLR OFF The unit has been turned OFF by the Enter Reset button on the SMART SYSTEM display panel Standb The unit has not received a call for heat from a remote thermostat sie nor has it received a call for heat from a DHW thermostat The unit has met the water temperature set point but is still Set Point Met receiving a call for heat from either a remote thermostat or a DHW thermostat Prepurge The unit has initiated a 10 second purge period on a call for heat ignition The unit has begun a 5 second spark period to ignite the main burner SH Rate The unit has fired and is running at the displayed percentage 1 The call for heat has been satisfied and the unit runs the fan for an Postpurge additional 10 seconds to clear the combustion chamber and vent system of residual flue products The unit has been placed in a temporary mode that will allow the Service unit to fire at 100 of rate for the purpose of combustion analysis When the outlet sensor has been selected as the control sensor OUT F default the control will display the outlet temperature as well as the set point in parenthesis XF 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 grounded Press the Next arrow key on the SMART SYSTEM di
34. justment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death substantial property damage 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 If you experience a pressure drop greater than 1 inch w c the meter regulator or gas line is undersized or in need of service Perform the steps below when checking inlet gas supply 1 Turn the main power switch to the OFF position 2 Shut off gas supply at the manual gas valve in the gas piping to the appliance 40 10 11 12 13 Loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve Place the tubing of the manometer over the tap once the set screw is loosened as shown in 52 54 Slowly turn on the gas supply at the field installed manual gas valve Turn the power switch to the position Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat Observe the gas supply pressure as the burner fires at 10096 of rated input Percent of burner input will be displayed on the control panel Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in this section of the manual
35. le threads of the pipe joints so that pipe dope does not block gas flow 7 Gas connections continued Failure to apply pipe sealing compound as J detailed in this manual can result in severe personal injury death or substantial property damage Knight boilers are typically shipped ready J 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 see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Use two wrenches when tightening gas piping at boiler FIG 51 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 Figure 51 Inlet Pipe with Backup Wrench USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING NOTICE Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment Installation amp Operation Manual Natural gas Pipe sizing for natural gas 1 Refer to Table 7 for pipe length and diameter Based on rated boiler input divide by 1 000 to obtain cubic feet per hour a Table 7 is only for natural gas with specific gravity 0 60 inches with a pressure drop thr
36. n to the venturi and blower Awarning to follow all precautions could result in fire explosion or death A WARNING 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 41 8 Field wiring ELECTRICAL SHOCK HAZARD For 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 NOTICE Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Label all wires prior to disconnection A CAUTION when servicing controls Wiring errors can cause improper and dangerous operation Installation amp Operation Manual Installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connec
37. nlet water temperature drops too far during the delay 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 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 Temperature control Modulation The Knight boiler is capable of modulating its firing rate from a minimum of 20 to a maximum of 10096 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 Installation amp Operation Manual 11 Operating information continued Ramp delay 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 th
38. odulation will be held to a series of increasing limits after the burner has lit If the space heating call for heat is active and the DHW thermostat closes the control will turn on the DHW pump wait 2 DHW 85 RATE seconds and then turn off the boiler pump This will divert the 177 8 180 hot water away from the heating zone s and send it to the DHW N 5 tank instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point 57 Installation amp Operation Manual 11 Operating information Sequence of operation continued OPERATION DISPLAY 8 If the DHW thermostat remains on for more than 30 minutes and the space heating call for heat is also on then the control will turn on the boiler pump turn off the DHW pump after 2 seconds SH 41 RATE and resume modulating based on the space heating set point As long as both the space heating and DHW calls for heat 123 0F 129 remain active the control will switch back and forth between the two modes until one of them is satisfied Once both calls for heat are satisfied the control will turn off the burner The blower will remain on for the 10 second postpurge POSTPURGE cycle Any pumps that are running will continue to run for their 127 4F 129 respective pump delay times then turn off Standby 124 7F 129 11 System pump off Standby 122 9F 129 10 Boiler pump off system pump continues its delay if lon
39. off valve counterclockwise to open above on this label valve Handle will be parallel to pipe Set the thermostat to lowest setting 9 Install top cover Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Turn Off Gas To Appliance and the burner Do not try to light the burner call your service technician or gas supplier by hand Gas Valve Gas Valve Remove top cover CLOSED Turn gas shutoff valve clockwise to close valve Handle will be perpendicular to pipe Do not force Wait five 5 minutes to clear out any gas to CLOSE If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve clockwise to close valve Turn off all electric power to the Handle will be perpendicular to pipe Do not appliance if service is to be performed force Remove top cover 5 Install top cover LBL2274 REV B mm 50 Kuer Installation amp Operation Manual 1 0 Start up continued Figure 61 Operating Instructions Models 399 500 FOR YOUR SAFETY READ BEFORE OPERATING WARNING you do not follow these instructions exactly a fire or explosion may result
40. ough the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 or B149 2 for Canadian installations Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 10 5 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 10096 lockup gas pressure regulator in supply line if inlet pressure can exceed 10 5 inches w c at any time Adjust lockup regulator for 10 5 inches w c maximum Propane Gas Knight boilers are typically shipped 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 see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 10096 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 13 inches w c maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 13 inches w c with no flow lockup or with boiler on Minimum 8 inches w c with gas flowing verify during boiler startup EN 39 EH 7 Gas
41. ower BLR Standby If the unit is equipped with a solenoid valve and or a vent valve 4 they will be energized along with the blower OUT 123 8F 129 If the unit is equipped with a gas pressure switch it must close at this time If there is an auxiliary device connected to the unit the unit will then provide 24 vac to its enable relay If the auxiliary device has a proving switch it must close before the sequence continues The control then starts a 10 second prepurge cycle PREPURGE 123 9F 129 Once the prepurge cycle is complete and the blocked drain and IGNITION auto reset high limit are closed the control starts the 5 second 3 trial for ignition by sending spark voltage to the spark electrode 123 9F 129 and opening the gas valve If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge another POSTPURGE PREPURGE prepurge and tries to light the burner again If the burner does 2 not light after 4 trials 1 trial on the 500 model the control locks 123 9 129 out for 1 hour and then tries another set of 4 trials except on the 500 model which is 100 lockout If the control detects flame before the trial for ignition ends it begins to modulate the burner in order to maintain the set point SH 20 RATE If the boiler lights due to a space heating call for heat and the 124 8F 129 ramp delay function is active default is active the m
42. r 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 Test replace freeze protection fluid l 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 Fill and test water system l Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 Fillto correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Installation amp
43. splay to access Screen 2 IN If the inlet sensor has not been selected as the control sensor only TT the inlet temperature will be displayed When the inlet sensor has been selected as the control sensor the OPES control will display the inlet temperature as well as the set point in arenthesis 2 The control does not detect the inlet sensor Shorted The inlet sensor wires or the sensor itself has become grounded The difference between the inlet temperature and the outlet RISE F p temperature Press the Next gt arrow key the SMART SYSTEM display to access Screen 3 61 Installation 4 Operation Manual 11 Operating information Status Display Screens By using the Previous Next gt 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 Display shows Description SYS 9 If the system sensor has not been selected as the control sensor only the system temperature will be displayed When the system sensor has been selected as the control sensor the 979 control will display the system temperature as well as the set point in parenthesis The control does not detect the system sensor 3 Shorted The system sensor wires or the sensor itself has become grounded OUTDOOR
44. stall the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces 3 Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b Ifconnected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor 1 Connect outdoor temperature sensor FIG 57 to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight boiler If fixed temperature operation is required do not install outdoor sensor 2 Mount the sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources 3 Route sensor wires through a knockout at the rear of the boiler see FIG 56 Installation amp Operation Manual DHW thermostat 1 Connect storage indirect water heater DHW thermostat FIG 57 to the DHW thermostat terminals on the connection board Auxiliary device relay l If an auxiliary device e g louvers needs to operate when the boiler fires it can be controlled by this output Connect these terminals to a 24 vac relay coil which is wired to operate the auxiliary device FIG 57 Auxiliary device proving switch 1 When the operation of an auxiliary device needs to be verifie
45. tat 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 E 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 54 Installation amp Operation Manual 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 Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default If a system 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 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 i
46. tem supply sensor FIG 57 Boiler management system 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 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 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 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 44 Installation amp Operation Manual m 45 EH E 1 15 n HOLIMS MOTH B sva mol 44OLNO W31SAS YILVM o INJWOVNVN NIA UN LIG eel MOSN3S 1 i YOSNIS i 2 WALSAS f 1 3NOZ T 1 vM EM S NON 009 HOLIMS 55 d V SVOHII
47. ting instructions in 10 5 60 and 61 pages 50 and 51 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 3 Isthermostat set below room temperature 4 Is gas turned on at meter or boiler 5 Isincoming gas pressure less than 4 inches w c If none of the above corrects the problem refer to the Troubleshooting Section of the Knight Boiler Service Manual Check system and boiler Check water piping 1 Check system piping for leaks If found shut down the boiler and repair immediately See WARNINGS on pages 47 and 48 startup regarding failure to repair leaks 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 Installation amp Operation Manual Kist Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the procedure on page 38 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source
48. tions 1 Connect 120 vac power wiring to the line voltage terminal strip in the junction box as shown in FIG 55 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 55 3 On Models 80 285 the boiler pump is shipped loose Wire the boiler pump as shown in FIG 55 4 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 55 5 activate a system pump wire as shown in FIG 55 If the motor is larger than 1 3 HP you must install a relay Figure 55 Line Voltage Field Wiring Connections SERVICE SWITCH DOMESTIC HOT WATER BOILER SYSTEM 120V SUPPLY PUMP PUMP PUMP LINE GROUND NEUTRAL E n a 9 DHW SEC PUMP PUMP PUMP SUPPLY SYS 120V 8 Field wi ring continued Low voltage connections 1 Route alllow voltage wires through the knockouts in the rear of the boiler as shown in FIG 56 2 Connect low voltage wiring to low voltage connection board as shown in FIG 57 on page 45 of this manual and the boiler wiring diagram Figure 56 Routing Field Wiring LOW VOLTAGE CONNECTION BOARD LINE VOLTAGE LOW VOLTAGE JUNCTION BOX WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS Thermostat 1 Connect the room thermostat or end switch isolated contact only to terminals R and W as shown in FIG 57 2 In
49. toff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements c In Canada When using manual main shutoff valves it must be identified by the installer Figure 49 Gas Supply Piping Models 80 210 MANUAL SHUT OFF VALVE FIELD SUPPLIED Keser Installation amp Operation Manual Figure 50 Gas Supply Piping Models 285 500 GAS SUPPLY DRIP LEG MANUAL SHUT OFF VALVE 2 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support warnine 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 3 Purgeallair from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a b Close manual main shutoff valve during any pressure testing at less than 13 inches w c Disconnect the boiler and gas valve from the gas supply piping during any pressure testing greater than 13 inches w c A warnine 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 5 Use pipe sealing compound compatible with propane gases Apply sparingly only to ma
50. 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 Propane boilers verify conversion 1 Verify propane conversion has been completed per the Propane Conversion instructions 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 substantial property damage Knight boilers are typically shipped 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 see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check flame and combustion 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 3 Turn the main power on to the boiler by placing the On Off switch in the ON position 49
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