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1. DRAIN SWITCH lt lt _ ansa a a CEO 4 rN Sea AIR PRESSURE oe Sa a ser lt a ame lt m d ZN T HIGH LIMIT a GAS VALVE X2 2 SENSOR Se rive S3a qe O lt 2 5 SENSOR NK X2 4 X5 13 s lt lt E eD i BLOWER 13 JTS CONNECTION L iT lt M BOARD _ AAN 1 CN5 1 gt gt lt X4 7 CONTACTS 2 CNS BNN 14 RUN TIME 3 man CONTACTS 4 ENSS lt X4 13 S6 94 CNE ss lt _ SYSTEM XJ 7 SENSOR r lt k 22 cne yy e8 lt lt S5 CNG x6 FLAME ROD oseo lt k WB SPARK x S4 eG CNG y lt TANK SENSOR ae ee 27 CN6 y lt SHIELD 29 OAIN HIGH VOLTAGE SPARK LEAD CASCADE x ae B 31 se gt NOTES SHIELD 32 ONS Sy gee 1 Where possible switches are shown without utilities gas water or BMS 33 cne yy vg gt electricity connected to the unit As such actual switch states may iii 0 10V 34 x6 vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present SYS PUMP Sov S 2 See wiring diagram for additional notes IN _ 36 BLR Pump 87 GUT s ON 38 3 BOX DEPICTS RATE 39 A WARNING OPTIONAL ITEMS OUT _ 40 LOW VOLTAGE SHIELD 41 M DISCONNECT POWER A 42 CN8 1yy lt 1 o X41 lt 22 1 1 20 VAC MODBUS ie ge a BEFORE SERVICING HIGH VOLTAGE 3 X6 3 U SHIELD 44 gt lt s LADDER DIAGRAM a LBL20141 REV D 7g Kee Installation amp Operation Manual Not
2. 23 25 Knight XL Control Module 67 68 Prepare Wall Penetrations 25 26 Status Display Screens 69 71 Multiple Vent Air Terminations 26 12 MAINTENANCE Sidewall Termination Optional Concentric Vent 27 29 Maintenance and Annual Startup 72 76 5 VERTICAL DIRECT VENTING 13 DIAGRAMS Vent Air Termination Vertical 30 31 Wiring Diagram 77 Determine Location 30 Ladder Diagram uu a uasassssssasusussuqa saus 78 Prepare Roof Penetrations 31 Revision Notes Back Cover Multiple Vent Air Terminations 31 Vertical Termination Optional Concentric Vent 32 33 Alternate Vertical Concentric Venting 34 35 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER DANGER indicates an imminently hazardous situation which if not avoided
3. 48 3 GENERAL VENTING Gas Pressure r raasrr aa 49 Direct Venting Options 15 Gas Valve Replacement 49 Install Vent and Combustion Air Piping 16 8 FIELD WIRING Requirements for Installation in Canada 17 Line Voltage Connections 50 RZ MG LIE AEE EA ne rata eae carbene tek us 17 Low Voltage Connections 50 Min Max Combustion Air amp Vent Piping Lengths 17 Wiring of the Cascade 52 Materials uu u u uu Ei 18 9 CONDENSATE DISPOSAL Optional ROOM Air a a 19 Condensate Drain a 54 PVG C PVC snaoisein e EE 19 20 10 STARTUP a 55 60 Polypropyleme sonrisa 21 11 OPERATING INFORMATION Stainless Steel Vent a a 22 COTE All uu u uu u E E E E PEA E 61 4 SIDEWALL DIRECT VENTING ASC AS a u uyannay aspas AE EE kipas kusay A 64 Vent Air Termination Sidewall 23 26 Sequence of Operation 65 66 Determine Location
4. Figure 4 4B Alternate Clearance to Forced Air Inlets w Field Supplied Fittings IF LESS THAN 10 3 M 76 914 MM MIN FORCED AIR INLET BIRD SCREEN TYPICAL 7 2 1 M MIN ABOVE ANY V PUBLIC WALKWAY Prepare wall penetrations 1 Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes 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 Cutahole 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 51 inch hole 140 mm hole for 4 inch 102 mm vent pipe 71 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 2 For Polypropylene Only Install the vent and air intake sidewall adapters from Table 3F on page 21 into the vent plate Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate FIG 4 4B 3 For PVC CPVC Only Install the vent and air intake piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3D on page 20 to seal the vent pipe 3 Mount and secure the vent plate to the wall using stainless steel screws 5
5. GROUND G LINE BK o_o SERVICE SWITCH A Hi eol Ties SYSTEM E H PUMP SE rz 2 pa JIE melf 1 4 E i HES g res a gt Ei 35 BOILER Y PUMP WW a 2 DOMESTIC HOT WATER PUMP L2 N G L1 50 Installation amp Operation Manual ISe COMMERCIAL BOILER Installation must comply with l 2 National Electrical Code and any other national state provincial or local codes or regulations In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections ly Connect 120 VAC power wiring to the line voltage terminal strip in the junction box as shown in FIG 8 1 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 8 1 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 8 1 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 Low voltage connections l Route all low voltage wires through the knockouts in the rear of the boiler as shown in FIG 8 2 Connect low voltage wiring to the low voltage connection board as shown in FIG 8 3 on page 53 of this manual and the boiler wiring diagram Figure 8 2 Routing Field Wiring LOW VOLTAGE CONNECTION BOARD LINE VOLTAGE JUNCTION BOX A GUE 2
6. YOSNOS YNYL qT3IHS yg1109 Emera yg1log DAN S ZIDA snoinaud OL lt V wows TT TT s 53 L LVLSOWYSHL WOOY 0000 LVLSOWYAHL WOOY LVLSOWYAHL WOOdY IVLSOWYSAHL ANVL ON Woo HOLIMS MOJ HOLIMS ONIAOdd AJANT AV 154 YSANO1 Q Condensate disposal Condensate drain 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 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 A Neutralizer Kit FIG 9 1 is available from the factory KIT3087 for Models 400 501 and KIT3046 for Models 601 801 4 Install the 1 2 inch 12 7 mm PVC tee assembly shipped with the unit as shown in FIG 9 1 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 PVC TEE ASSEMBLY FACTORY SUPPLIED DRAIN PAN 54 FLOOR DRAIN OR Installation amp Operation Manual COMMERCIAL BOILER NOTICE Use materials ap
7. 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 e No closer than 12 inches 305 mm below or horizontally from any door or window or any other gravity air inlet 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 E 4 Installation amp Operation Manual Geir COMMERCIAL BOILER 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 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 Figure 4 3A Clearance to Gravity Air Inlets VENT AIR TERMINATION Figure 4 3B Alternate Clearance to Gravity Air Inlets w Field Supplied Fittings lt SCREEN TYPICAL 12 305 MM MIN 12 305 MM MIN Kee Installation amp Operation Manual 4 Sidewall direct venting continues Vent air termination sidewall Figure 4 4A Clearance to Forced Air Inlets IF LESS THAN 10 VENT AIR TERMINATION FORCED AIR INLET 7 MIN ABOVE ANY PUBLIC WALKWAY
8. Rear View Model 501 Left Side inside unit Model 501 Models 601 801 Rear View Models 601 801 Left Side inside unit Models 601 801 eee Installation amp Operation Manual Ratings ares Knight XL Boiler Other Specifications AHRI Rating G Net Model Number AHRI Boiler Ratings Water Water Content MBH Gallons Note 2 Note Change N to L for L P gas modes in KBN400 KBN501 BN KBN701 KBN801 NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 The ratings are based on standard test procedures prescribed 7 Knight XL boilers comply with the requirements of CSD 1 by the United States Department of Energy Section CW 400 requirements as a temperature operation control The manual reset high limit provided with the 2 Net AHRI ratings are based on net installed radiation of Knight XL is listed to UL353 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 Knight XL boilers require special gas venting Use only the vent materials and methods specified in the Knight XL Installation and Operation Manual a 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 UNIT EQUIPPED FOR
9. HIGH ALTITUDE 3000 FT TO 12 000 FT ak 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 A Ratings have been confirmed by the Hydronics Section of Figure A High Altitude Label Location AHRI 1 Determine boiler location Installation must comply with 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 National Electrical Code For Canada only B149 1 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The Knight XL gas manifold and controls 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 Electrical power Locate the appliance so that if water connections should leak water damage wi
10. 31 32 33 34 35 36 37 38 39 Wise The Knight XL How it works Installation amp Operation Manual High voltage junction box The junction box contains the connection points for the line voltage power and all pumps Boiler drain port Location from which the heat exchanger can be drained Low voltage connection board The connection board is used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low voltage connection board Condensate drain connection Connects the condensate drain line to a 1 2 PVC union Access cover front Provides access to the gas train and the heat exchanger Ignition electrode Provides direct spark for igniting the burner Flame inspection window The quartz glass window provides a view of the burner surface and flame Gas shutoff valve Models 501 801 only Manual valve used to isolate the gas valve from the gas supply Relief valve Protects the heat exchanger from an over pressure condition The relief valve provided with the unit is set at 50 PSI Flame sensor Used by the control module to detect the presence of burner flame Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box Top panel Removable panel to gain access to the internal components Power switch Turns 120 VAC ON OFF to the boiler Leveling legs Used to al
11. 5 Seal exterior openings thoroughly with exterior caulk VENT Figure 4 5C A Typical Sidewall Termination Assembly Models 400 801 PVC CPVC Polypropylene or Stainless Steel 12 305 MM MIN 15 381 MM MAX GALVANIZED THIMBLE wren REQUIRED BY LOCAL CODES SIDEWALL TERMINATION PLATE VENT PIPING 12 305 MM MIN BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE RRQ AY NH NAY Wy BIRD SCREEN ELBOW ra BIRD SCREEN a E 55 Kies Installation amp Operation Manual 4 Sidewall direct venting continues Sidewall termination optional concentric vent Models 400 601 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit CVK3007 for 4 102 mm diameter Models 400 601 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 The required combustion vent pipe materials are listed in Table 3D on page 20 of this manual Figure 4 7 Concentric Sidewall Termination Models 400 601 OVERHANG OR ROOF MIN 12 305 MM MIN GRADE SNOW LINE Sidewall termination installation 1 Determine the best location for the termination kit see FIG 4 7 2 Reference the Determine Location Section on page 23 of this manual for general termination considerations 3 Cut one 1 hole 7 inch 178 mm d
12. 610 mm FR NT AREA OF EACH OPENING REAR 24 610 mm 1 SQ INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES Figure 1 2 Alcove Installation Minimum Required Clearances ALCOVE INSTALLATION A waRNING 1 4 6 MM MINIMUM CLEARANCE AROUND HOT WATER PIPES 1 25 MM MINIMUM CLEARANCE AROUND VENT PIPE 13 330 TOP 12 305 MM LEFT 14 356 MM REAR RECOMMENDED SERVICE CLEARANCES FRONT 30 762 mm TOP 24 610 mm os MM LEFT SIDE 24 610 mm REAR 24 610 mm For alcove installations CPVC polypropylene or stainless steel vent 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 OPEN FRONT 0 RIGHT 1 Determine boiler location Provide air openings to room Knight XL alone in boiler room l 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 Knight XL in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation air openings in
13. 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 High limit operations The Knight XL is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has a maximum set point of 200 F and the manual reset high limit has a maximum set point of 210 F When the outlet temperature exceeds 200 F the automatic high limit action occurs The boiler shuts down until the outlet water temperature cools below 190 F and a 60 second timer has expired If the outlet temperature continues to increase the manual reset high limit action will occur at 210 F High limit test procedure NOTICE Please note that the brackets denote screen status 1 Turn ON the main power to the boiler by placing the ON OFF switch in the ON position 2 From the Status Screen press the NAVIGATION dial to access the Set Points Screen 3 Press the LEFT SELECT LIMITS key 4 Select the manual reset high limit MRHL by rotating the NAVIGATION dial counterclockwise then press the NAVIGATION dial 5 Decrease the set point of the MRHL to below the current outlet temperature or to its minimum setting whichever is higher by turning the NAVIGATION dial counterclockwise Press the RIGHT
14. 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 Use only inhibited propylene glycol A WARNING _ 1 BY solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 36 Installation amp Operation Manual e ISe COMMERCIAL BOILER General piping information Basic steps are listed below along with illustrations on the following pages FIG s 6 7 through 6 11 which will guide you through the installation of the Knight XL reference FIG s 6 4A and 6 4B 1 Connect the system return marked Inlet 2 Connect the system supply marked Outlet 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 separatel
15. MSC20086 1 4 x 24 Drill Extension CTN20005 Rear Refractory Cover MSC20083 Nylon 4 Wheel Brush 801 KIT30064 MSC20085 1 4 x 12 Drill Extension MSC20086 1 4 x 24 Drill Extension Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush A CAUTION A CAUTION Figure 12 5 Rope Gasket Heat Exchanger Door ROPE GASKET CAUTION IF GASKET IS DAMAGED Pm Z DO NOT REUSE THE HEAT EXCHANGER DOOR MUST BE REPLACED NOTICE Rope gasket is intended for sealing combustion FIG 12 5 If damaged DO NOT reuse the heat exchanger door must be replaced Consult factory for replacement heat exchanger door kit WTR3080 and WTR3086 Kies Installation amp Operation Manual 13 Diagrams Figure 13 1 Wiring Diagram 7 20 VAC OPTIONAL ITEMS A WAR N IN G DISCONNECT POWER BEFORE SERVICING HIGH VOLTAGE INTEGRATED CONTROL GAS PRESSURE SWITCH ALARM 7 N s RELAY JUNCTION x CONTACTS BOARD BOX o RUN TIME 5 CONTACTS CN1 5 OR ie A 24 VAC LOUVER 5 x B wi RELAY COIL 2 m P BOILER a LOUVER a PROVING SWITCH CN1 4 BR CN1 2 PR ON OFF SWITCH FLOW SWITCH TANK OO THERMOSTAT kara O O DEMAND HEATILOOP 5 Oo DEMAND HEATILOOP 4 DEMAND SILENCING SWITCH nE SYS
16. O KBN801 KBN701 4 KBN601 N O _ O re VU en 9 9 30 Q a VU N N 0 L e Vise Installation amp Operation Manual 6 Hydronic piping continued Figure 6 7 Single Boiler Multiple Temperatures TEMPERATURE TEMPERATURE TEMPERATURE LOOP 2 a j WIRES TO LOOP SENSORS LOOP 1 LOOP SENSOR 3X MAKE UP WATER AIR SEPARATOR PRESSURE GAUGE MULTI TEMP LOOP CONTROL BACK FLOW OPTIONAL PREVENTER 24V SIGNAL TO MIXING VALVES Y STRAINER RECOMMENDED BALL VALVE ert TYPICAL FLOW CHECK VALVE TYPICAL BOILER CIRCULATOR PRESSURE aa REDUCING SHIELDED CABLE VALVE TO BOILER CONTROL INDIRECT DHW TANK BOILER PRESSURE RELIEF VALVE HOT WATER OUT ANTI SCALD MIXING VALVE COLD WATER IN UNION TYPICAL DOMESTIC HOT WATER CIRCULATOR IMG00175 CAUTION Mixing valves are required for the protection of low temperature loops Please note that these illustrations are meant to show system piping concept only the installer is responsible NOTICE l i l for all equipment and detailing required by local codes E 7 Vinse Installation amp Operation Manual 6 Hydronic piping Figure 6 8 Single Boiler Primary Secondary Piping AIR SEPARATOR oo S MAY SUBSTITUTE DRAIN POINT LOW LOSS HEADER N 4 TYPICAL SYSTEM SUPPLY SENSOR WHEN USED BALL VALVE T
17. contaminants and supplied in proper volume Follow the polypropylene manufacturer s instructions when using polypropylene material as an inlet pipe 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 A DANGER Failure to properly seal all joints and 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 3 General venting continued Optional room air Optional room air is intended for NOTICE PO Map commercial applications Combustion air piping to the outside is recommended for residential applications 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 The unit MUST be installed with the appropriate room air kit Table 3C 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 There will be a noticeable increase in the noise level during normal operation from the inlet air opening U
18. will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage CAUTION NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE Please read before proceeding When servicing boiler A WARNING NOTICE A WARNING A WARNING Installer Read all instructions including this manual and the Knight XL Service Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the User s Information Manual for your reference Have this boiler serviced inspected by a qualified service technician at least annually 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 Consider piping and installation when determining boiler location Any claims for damage or shortage in shipme
19. 4 12 Concentric Vent and Combustion Air Termination E 59 5 vertical direct venting Vent air termination vertical A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage Determine location 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 17 of this manual 2 Prepare the vent termination and the air termination elbow FIG 5 1A by inserting bird screens Bird screens should be obtained locally 3 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 4 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 5 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 apa
20. 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 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 NOTICE Be sure to install the flow switch so that the arrow on the flow switch is pointing in the direction of the flow see FIG 6 3 ieee Installation amp Operation Manual Figure 6 1 Flow Switch Relief Valve and Temperature and Pressure Gauge Installation Models 400 501 RELIEF VALVE FLOW SWITCH PADDLE TEMPERATURE AND PRESSURE GAUGE TEE WITH FITTING ON TOP gt FIELD PROVIDED CLOSE NIPPLE FIELD PROVIDED TEE WITH 1 FITTING ON TOP CLOSE NIPPLE TEE WITH 3 4 FITTING ON TOP CLOSE NIPPLE Figure 6 2 Flow Switch Relief Valve and Temperature and Pressure Gauge Installation Models 601 801 RELIEF VALVE FLOW SWITCH PADDLE TEMPERATURE AND PRESSURE GAUGE TEE WITH FITTING ON TOP ee FIELD PROVIDED CLOSE NIPPLE FIELD PROVIDED TEE WITH 1 FITTING ON TOP CLOSE NIPPLE TEE WITH 3 4 FITTING ON TOP CLOSE NIPPLE 6 Hydronic piping Flow switch adjustment Refer to Table 6A for the proper setting of the sensitivity screw For reference the position of the
21. Cascade sequence If another boiler is available the Leader will start it up to take its place The DHW boiler will adjust its set point to the programmed DHW boiler 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 in Cascade Mode When DHW is programmed for Zone Mode connect the DHW thermostat or tank sensor to the Leader boiler When a DHW call is received the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point if higher 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 available when the boilers are part of a Cascade system Kiet Installation amp Operation Manual 11 Operating information continued Sequence of operation OPERATION DISPLAY Upon a call for heat the gas pressure switch es must be closed Once the gas pressure switch es are closed the control turns on the appropriate pumps system and boiler pumps for space heating DHW pump for DHW The flow switch and or LWC
22. 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 Variable speed boiler system circulator Knight XL boilers are capable of controlling a variable speed boiler system circulator Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG s 6 5 and 6 6 on page 40 at full speed 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 Check valves Field supplied Check valves are recommended for installation as shown in FIG s 6 7 through 6 11 Failure to install check valves could result in a reverse flow condition during pump s off cycle Domestic indirect hot water 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 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above 115 F 46 C Unions Field supplied Recommended for unit serviceability Temperature and pressure gauge Factory supplied The temperature and pressure gauge is shipped loose It is the responsi
23. Knight XL Service Manual Saving parameters reference the Parameter Table in the Knight XL Service Manual NOTICE Please note that the brackets denote screen status To save parameters and exit programming Press the RIGHT SELECT SAVE key and then press the RIGHT SELECT HOME key To enter a parameter and continue programming Press the RIGHT SELECT SAVE key 1 time to return to the parameter listings press again to return to the menu listings Remember to press the RIGHT SELECT HOME key 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 68 Installation amp Operation Manual Keegy Installation amp Operation Manual 11 Operating information continued Figure 11 2 Status Display Screen BOILER CALL FOR SYSTEM c TANE STATUS OPERATIONAL E T E E F INFORMATION D LEFT SELECT KEY RIGHT SELECT KEY NAVIGATION DIAL Status Display Screens Section Display Description STANDBY 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 START The unit has begun a burn cycle and is checking all safety circuits PREPURGE The unit has initiated a prepurge period on a call for heat IGNITION The unit has begun a spark period to ignite the main burner A Yo 4 The unit has fired and is running at the d
24. Knight XL Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks l Start boiler and perform checks and tests specified in Section 10 Start up Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame Inspect flame through observation window 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 Remove the burner reference FIG s 12 2 thru 12 4 When replacing the burner ensure gasket is in good condition and positioned correctly FIG s 12 2 thru i Installation amp Operation Manual C Goll COMMERCIAL BOILER Figure 12 2 Burner Assembly Model 400 Figure 12 3 Burner Assembly Model 501 SCREWS oA QTY 5 Figure 12 4 Burner Assembly Models 601 801 SCREWS QTY 5 m 75 ms 12 Maintenance Check flame signal l At high fire the flame signal shown on the display should be at least 10 microamps 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
25. SELECT SAVE key 7 Press the RIGHT SELECT HOME key parameter will upload to the control a The new 8 Ifthe current outlet temperature is above the new MRHL set point the MRHL will function causing boiler lockout If this occurs skip to Step 11 9 Ifthe current outlet temperature is below the new MRHL set point locate the pinhole SERVICE button below the RESET button on the display board Insert a thin probe such as a paper clip into the hole and press the button continuously for five 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 10 Once the outlet temperature rises up to the MRHL set point the MRHL will function causing the boiler to shut down and lock out 11 Repeat Steps 2 3 and 4 12 Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise 13 Repeat Steps 6 and 7 14 Press the RESET button to clear the lockout 15 If needed press the RIGHT SELECT STOP key to exit Service Mode 63 11 Operating information 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 2 Some codes and juris
26. Seal all gaps between the pipes and wall Seal around the plate to the wall assuring no air gaps 6 Assemble the vent cap to the vent plate see FIG s 4 5A and 4 5B Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate 7 Seal all wall cavities 8 PVC CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual 9 Stainless steel terminations are designed to penetrate walls with a thickness up to 9 25 inches of standard construction Figure 4 5A PVC CPVC Sidewall Termination Assembly VENT PIPING VENT PLATE WALL PLATE VENT CAP GALVANIZED THIMBLE Table 4B Sidewall Vent Centerline Dimensions 701 801 4 7a aed Installation amp Operation Manual 4 Sidewall direct venting Figure 4 5B Polypropylene Sidewall Termination Assembly Multiple vent air terminations SIDEWALL PORN I I l ADAPTER 1 When terminating multiple Knight XL s terminate AIR WALL each vent air connection as described in this manual FIG 4 6A SIDEWALL RETAINING JARNING All vent pipes and air inlets must terminate at the same height to avoid possibility of VENT severe personal injury death or substantial PARAE property damage VENT 2 Place wall penetrations to obtain minimum clearance of sl 12 inches 305 mm between vent pip
27. be programmed into the control See page 59 of this manual to program the set point 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 64 Installation amp Operation Manual ISHI COMMERCIAL BOILER 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 The sequence will be changed once every 24 hours The switching on off sequence will be as follows TIME SWITCHING ON SEQUENCE L M1 M2 M3 M4 M5 M6 M7 M1 M2 M3 M4 M5 M6 M7 L If a boiler locks out or is used to heat an indirect DHW tank it will automatically be given the lowest priority for the rest of that 24 hour period DHW Night Setback and Ramp Delay operation with cascade For normal mode 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 or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a DHW call the Leader control will take that boiler out of the
28. electrode See Section 3 Troubleshooting in the Knight XL Service Manual for other procedures to deal with low flame signal Review with owner 1 Review the Knight XL User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Knight XL User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed instructions see Table 12B Heat Exchanger Cleaning Kits l 4 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup e Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside Remove the heat exchanger access cover burner and gas air arm assembly A WARNING The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the Serv
29. may vary due to job site specific equipment Installation amp Operation Manual 6 Hydronic piping System water piping methods The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi 83 kPa A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a minimal amount 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 Observe a minimum of 1 4 inch 6 mm clearance around all un insulated hot water pipes when openings around the pipes are not protected by non combustible materials 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 Chilled water system 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 Freeze protection
30. screw prior to setting 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 Table 6A Paddle Size Sensitivity Screw Adjustment SENSITIVITY SCREW MODEL PADDLE SIZE ADJUSTMENT Note Paddles are included with the flow switch Turn the sensitivity screw clockwise to NOTICE Increase the flow rate required to activate the switch Turn the sensitivity screw counterclockwise to decrease the flow rate required to activate the switch Figure 6 3 Flow Switch Adjustment NORMALLY OPEN S s SENSITIVITY ADJUSTMENT O a O GROUND rey x J COMMON NORMALLY CLOSED FLOW ag DIRECTION Installation amp Operation Manual Near boiler piping components 1 10 11 Boiler system piping 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 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
31. standard schedule 40 PVC for CVK3007 Do not extend dimension D more than 60 inches 1524 mm see FIG 4 9 NOTICE If assembly depth needs to be reduced dimension D can be as short as possible ISHI COMMERCIAL BOILER 4 Sidewall direct venting continues Installation amp Operation Manual Sidewall termination optional concentric vent Models 400 601 Only Figure 4 11 Concentric Vent Sidewall Attachment STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR COMBUSTION AIR VENT CAUTION DO NOT use field supplied couplings Multiventing sidewall terminations to extend pipes Airflow restriction will occur and may cause intermittent When two 2 or more direct vent appliances are vented operation near each other each appliance must be individually vented see FIG 4 12 NEVER common vent or breach vent this 8 Cement appliance combustion air and vent pipes to the appliance When two 2 or more direct vent appliances are concentric vent termination assembly See FIG 4 11 vented near each other two 2 vent terminations may be for proper pipe attachment installed as shown in FIG 4 12 It is important that vent terminations be made as shown to avoid recirculation of flue gases 9 Operate the appliance one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections 12 MINIMUM COMBUSTION AIR Figure
32. to run for a short time after the burner turns off or the Freeze Protection Mode ends The system pump will run whenever there is a space heating call for heat or the boiler goes into Freeze Protection Mode It may be programmed to run during a DHW call for heat when the DHW is programmed for Zone Mode It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode The system pump can be programmed to run continuously if desired except during outdoor shutdown and or a DHW call for heat 61 11 Operating information Temperature control Modulation 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 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 the 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 setti
33. 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 ao aoe 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 4 Refill to correct pressure 55 10 Start up 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 gas leak Use an approved leak detection solution Repair any leaks at once DO NOT adjust 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 th
34. 1 4 Remove any sediment in the trap 5 Fill with fresh water until the water begins to pour out of the drain 6 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 7 Replace the retaining screw Figure 12 1 Condensate Trap RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH PVC TEE ASSEMBLY FACTORY SUPPLIED CONDENSATE aS HEAT EXCHANGER A WARNING 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 TO FLOOR DRAIN Check all piping for leaks Eliminate all system or boiler leaks 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 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections 73 12 Maintenance Flue vent system and air piping 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 properl
35. 1 12 13 14 15 16 17 18 Stainless steel heat exchanger 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 Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils 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 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 Venturi The venturi controls air and gas flow into the burner Flue gas sensor limit rated 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 Boiler outlet temperature sensor housed with the high limit 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 Boiler inlet temperature sensor This sensor monitors return water temperature system return If selected as the controlling sensor the control module
36. 2 HOT WATER OUT MEMBER 1 DOMESTIC ana a ee BOILER CIRCULATOR l CIRCULATOR TYPICAL COLD WATER IN ae m REGET eee UNION TYPICAL DRAIN TEMPERATURE VALVE TYPICAL PRESSURE GAUGE CAUTION Indirect water heaters are capable of transferring a limited number of Btu s into the water Ensure boiler output does not not exceed indirect water heater transfer capabilities NOTICE 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 System flow should always remain higher than the required flow for the boiler s when the boiler s is in NOTICE O s ea operation to prevent short cycling and high limit issues 44 Kee Installation amp Operation Manual 6 Hydronic piping continea Figure 6 11 Single Boiler Multiple Temperatures with DHW Piped as a Zone WIRES TO LOOP SENSORS TEMPERATURE TEMPERATURE LOOP 3 LOOP 2 TEMPERATURE LOOP 1 LOOP SENSOR 3X MAKE UP WATER AIR SEPARATOR BACK FLOW PREVENTER PRESSURE GAUGE BALL VALVE SYSTEM MULTI TEMP LOOP CONTROL OPTIONAL ae _ 24VAC SIGNAL IFE 5 TO MIXING VALVES FLOW CHECK VALVE TYPICAL BOILER CIRCULATOR PRESSURE REDUCING VALVE DRAIN POINT TYPICAL SHIELDED CABLE TO BOILER CONTROL EXPANSION TANK INDIRECT DHW TANK HOT WATER OUT ANTI SCALD MIXING VAL
37. 3007 Do not extend dimension D more than 60 inches 1524 mm see FIG 4 9 page 28 CAUTION DO NOT use field supplied couplings to extend pipes Airflow restriction will occur 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 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 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 It is important that vent terminations be made as shown to avoid recirculation of flue gases Figure 5 7 Concentric Vent and Combustion Air Vertical Termination S TNN aor ARA COMBUSTION AIR TYPICAL g st AY n AN N a CSS L 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF 33 5 verti
38. 400 601 Only 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 4 Install the Y concentric fitting pipe assembly up through the structure s hole and field supplied roof boot flashing NOTICE Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 5 Secure the assembly to the roof structure as shown below in FIG 5 6 using field supplied metal strapping or equivalent support material Figure 5 6 Concentric Vent Roof Installation ve 12 305 MM 18 457 MM FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST COMBUSTION ANTICIPATED SNOW LEVEL MAXIMUM OF AIR 24 610 MM ABOVE ROOF ROOF BOOT FLASHING FIELD SUPPLIED SUPPORT FIELD SUPPLIED ELBOW FIELD SUPPLIED VENT COMBUSTION AIR NOTICE 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 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 CVK
39. ATION DISPLAY 8 If the space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump will turn off boiler and DHW pump operation briefly overlap to ensure flow is maintained through the unit This will divert the boiler s outlet water from the heating system and send it to the tank coil instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point If the boiler is not part of a Cascade and both the space heating and DHW calls for heat remain active long enough the boiler will switch back and forth between the two heating modes until one of them is satisfied 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during the postpurge period Any pumps that are running will continue to run for their respective pump delay times before turning off unless programmed to remain on continuously A 60 second anti cycle period will start which will delay any new call for heat until it times out 12 In Standby ready to start a new cycle 66 ISHI COMMERCIAL BOILER Installation amp Operation Manual 1 SYSTEM 11 F TAHE 24 F OUTDOOR 26 F HEHU se SCREEH SHOH SYSTEM TAHE OUTDOOR MEHO sa SCREEH SHOH POST P
40. AU 7 LOW VOLTAGE WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS 8 Field wiring continues Thermostat 1 Connect the room thermostats or end switches isolated contact only to heat loop demand 1 2 or 3 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 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 devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor 1 Mount the sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources 2 Route sensor wires through a knockout at the rear of the boiler see FIG 8 2 3 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 If fixed temperature operation is required do not install outdoor sensor DHW Domestic Hot Water thermostat Connect storage indirect water heater DHW thermostat FIG 8 3 to the DHW thermostat terminals on the connection board If a tank sensor is connected see DHW Tank Sensor below the tank thermostat is ignored DHW tank sensor By installing a t
41. G 4 1B Do not exceed the maximum lengths of the A WARNING 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 Polypropylene Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR BIRD SCREEN FROM sees VENT PIPE 42 MIN CONNECTION 15 MAX TERMINATION PLATE SCREEN GRADE OR SNOW LINE 23 4 Sidewall direct venting Vent air termination sidewall Figure 4 2A Alternate PVC CPVC Polypropylene Sidewall Termination Models 400 801 w Field Supplied Fittings BIRD SCREEN TO BOILER INTAKE AIR CONNECTION FROM BOILER 305 MM MIN 381 MM MAX VENT PIPE CONNECTION BIRD SCREEN 12 305 MM MIN GRADE OR SNOW LINE Figure 4 2B Alternate Stainless Steel Sidewall Termination Models 701 801 w Field Supplied Fittings TO BOILER INTAKE J _ AIR CONNECTION L I i2 305 MM MIN 15 381 MM MAX FROM BOILER VENT PIPE CONNECTION 12 305 MM MIN GRADE OR SNOW LINE 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 At least 6 feet 1 8 m from adjacent walls e No closer than 12 inches 305 mm below roof overhang
42. KBXII I O Rev G COMMERCIAL BOILER Installation amp Operation Manual Models 400 801 This manual must only be used by l a 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 Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters HAZARD DEFINITIONS 2 6 HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING 3 System Water Piping Methods 36 THE KNIGHT XL HOW IT WORKS 4 6 Low Water Cutoff Device 36 RATINGS a aa 7 Chilled Water System 36 1 DETERMINE BOILER LOCATION Freeze Protection a 36 Provide Air Openings to Room 10 General Piping Information 36 Flooring and Foundation 10 Flow Switch and Relief Valve Installation 37 Res
43. MART 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 4 hours Use the following procedure to set the clock 1 Press and hold the LEFT SELECT MENU key for at least 5 seconds 2 The display changes to with four 4 zeros below it 3 Press the RIGHT SELECT SAVE key read PASSWORD 4 The display will then show a menu with the time and date and temperature unit 5 Press the NAVIGATION dial twice 6 Turn the NAVIGATION dial to adjust the hours Press the NAVIGATION dial 60 Installation amp Operation Manual 7 Turn the NAVIGATION dial to adjust the minutes Press the NAVIGATION dial 8 Turn the NAVIGATION dial to adjust the month Press the NAVIGATION dial 9 Turn the NAVIGATION dial to adjust the date Press the NAVIGATION dial 10 Turn the NAVIGATION dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key The internal clock does not adjust for MOCE Daylight Savings Time and therefore will require a manual adjustment The clock is automatically updated whenever a PC is connected and the Win_Pro Installer program is started Configuration of the cascade NOTICE Please note that the brackets denote screen status When installed in a Cascade system the individual controls must be pro
44. NER PREVETER RECOMMENDED R FLOW CHECK VALVE TYPICAL PRESSURE GAUGE EXPANSION DRAIN POINT TANK TYPICAL INDIRECT DHW TANK 1 SA ANTI SCALD MIXING VALVE BOILER 2 PRESSURE RELIEF TEMPERATURE PRESSURE COLD WATER IN VALVE DOMESTIC GAUGE IRCULATOR BOILER 1 BOILER CIRCULATOR IMG00181 CIRCULATOR UNION TYPICAL CAUTION Indirect water heaters are capable of transferring a limited number of Btu s into the water Ensure boiler output does not not exceed indirect water heater transfer capabilities CAUTION Mixing valves are required for the protection of low temperature loops NOTICE 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 ieee Installation amp Operation Manual 6 Hydronic piping Figure 6 10 Multiple Boilers Primary Secondary Piping Number of Units 2 3 4 5 6 7 a Manifold Pipe Sizes in Inches mm SS BALL VALVE pr TYPICAL ox MAY SUBSTITUTE wer S Q LOW LOSS HEADER a pO AIR SEPARATOR 9 S O 9 P g DRAIN POINT lt TYPICAL ae SYSTEM SUPPLY SENSOR WHEN USED SYSTEM CIRCULATOR Y STRAINER TYPICAL MAKE UP WATER RECOMMENDED BACK FLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE BOILER 4 MEMBER 3 INDIRECT DHW TANK BOILER 3 MEMBER 2 ANTI SCALD MIXING VALVE BOILER
45. O must close The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch must close The control starts the prepurge cycle by initiating the blower The control starts the trial for ignition by firing the spark electrode and opening the gas valve If flame is not detected after the sparking ends the control will perform a postpurge then start another prepurge cycle and try to light the burner again On the 501 and larger models the control will lock out if this second attempt also fails On the 400 model the control will perform a total of 4 attempts before locking out If flame is detected it holds the firing rate steady for a few seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal START SYSTEM 1157 F TAHE 12e Folesa OUTDOOR 26 F MENU et SCREEH SHDH START amp SYSTEM 1167 TAHE 1Ze F oles OUTDOOR u MEHO eat SCREEH SHDH START m SYSTEM TAHE OUTDOOR MENU et SCREEH SHDH PRE PURGE ti SYSTEM TAHE OUTDOOR MEHO aI SCEEEH HDH GMITIN fh aio TEP DHW TAHE OUTDOOR HEHU G SCREEH SHOH 1 16 F 12e Foless F SYSTEM TAHE OUTDOOR MEH aI SCEEEH HDH 4246 SYSTEM LiFe TAHE E OUTDOOR a6 F MEHO sa SsCREEH SHDH 1 1 Operating information Sequence of operation continueg OPER
46. Operation Manual COMMERCIAL BOILER 5 Vertical direct venting continued Vent air termination vertical Prepare roof penetrations 1 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 2 Vent pipe penetration a Cuta 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 5 inch hole 140 mm hole for 4 inch 102 mm vent pipe 7 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 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 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple Knight XL boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height A WARNING 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 2 Place roof penetrations to obtain minimum clearance of 12 inches 305 mm between edge
47. Operation Manual 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 Installation the valve lever must e 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 ino
48. R TYPICAL Py p N E M EXPANSION TANK P x o g Oe eS ome FAST FILL VALVE INDIRECT DOMESTIC ge HOT WATER lt 0 TANK Y STRAINER RECOMMENDED BOILER PUMP TO FLOOR DRAIN Variable speed pump option Variable speed pump setup Before operation ensure the following Pump is set for an Input signal of 0 10VDC by the dip switches on the pump control Pump is set for external signal control SYSTEM SENSOR lt 8 een 7 if licable SYSTEM PUMP if applicable a lt TANK a Pump is set for linear output if applicable O i eS If pump does not come equipped with a 7 eA 0 10 VDC input option an optional module PES EUMENE will be required from the vendor BOILER PUMP TO FLOOR DRAIN SMART SYSTEM Multi temperature loop control option The Knight XL boiler is capable of producing up to three 3 set point temperatures to meet different space heating demands When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating To help aid with this protection Lochinvar offers the Multi Temperature Loop Control Board Kit RLY30086 39 Kase Installation amp Operation Manual 6 Hydronic piping Figure 6 5 Pressure Drop vs Flow Models 400 and 501 Pressure Drop vs Flow Includes Boiler Secondary Piping KBN501 KBN400 Pressure Drop vs Flow Includes Boiler Secondary Piping O O Ql O
49. SI 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 2 Prepare boiler Remove boiler from wood pallet 1 After removing the outer shipping carton from the boiler remove the parts box 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 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 NOTICE Do not drop the boiler or bump the jacket on the floor or pallet Damage to the boiler can result Figure 2 1 Boiler Mounted on Shipping Pallet Gas conversions For a boiler already installed you must 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 For the 400 Model you must install a propane orifice to operate the Knight XL on propane ga
50. SUPPLY SEDIMENT TRAP DRIP LEG yg Installation amp Operation Manual 1 COMMERCIAL BOILER Figure 7 3 Gas Supply Piping Models 601 801 MANUAL SHUTOFF VALVE FACTORY SUPPLIED SEDIMENT TRAP DRIP LEG UNION FIELD SUPPLIED 3 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support 4 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 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 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 c The appliance and its gas connection must be leak tested before placing it in operation 4 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 6 Use pipe sea
51. TEM SENSOR LS OUTDOOR SENSOR K S K_ SHIELD i in A CASCADE J j TANK SHIELD BMS IN SYS PUMP IN 34 35 36 i 30 RATE ag SHIELD MODBUS a K 2 J OPTION 435 SHIELD 44 0 10V 0 10V BLR PUMP I O TEMP HEX SW BLOCKED DRAIN SWITCH N coal AIR PRESSURE SWITCH H Ces OPERATING SENSOR S1a DWODOOWD OOO OD HIGH LIMIT SENSOR S1b LOW WATER CUT OFF INLET SENSOR S2 FLUE SENSOR S3a FLUE SENSOR S3b GAS VALVE 24VAC W IR FLAME SENSOR g MIR n SPARK SHIELD ROD GROUNDING oNN HIGH VOLTAGE SPARK LEAD JUMPER 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 a
52. URGE AHTI CYCLIHG S hl ll Feld TAHE ar Fu 1582 OUTDOOR a6 F MEHU aI SCEEEH SHOH BLOCKED AHTI CYCLING SYSTEM ll Er 118 TAHE led E 1582 OUTDOOR a6 F MEHU se SCREEN SHOH STANDBY SYSTEM CHW TAHKE OUTDOOR MENU SETPOINTS SHOH 11 F fer F Claes a6 F Wema Installation amp Operation Manual 11 Operating information continued T SYSTEM Use the control panel FIG 11 1 to set temperatures operating conditions and monitor boiler operation EMEN Knight XL control module Figure 11 1 Control Panel Cy l NAVIGATION DIAL ee ee SS pl PRESS OR TURN 1 i f Co ae par Fi w 4 RESET KEY SYSTEM 17 F lt 119 Select LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key 67 ISe COMMERCIAL BOILER 11 Operating information Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when SETPOINTS is flashing at the bottom of the display The date and time and the temperature units can also be changed see page 60 Installer Most parameters are available only to the installer accessible by entering the installer password see the
53. VE COLD WATER IN BOILER DOMESTIC g o UNION TYPICAL CIRCULATOR DRAIN PRESSURE RELIEF TEMPERATURE PRESSURE VALVE GAUGE IMG00183 CAUTION Indirect water heaters are capable of transferring a limited number of Btu s into the water Ensure boiler output does not not exceed indirect water heater transfer capabilities CAUTION Mixing valves are required for the protection of low temperature loops NOTICE 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 Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone 45 a f Gas connections Connecting gas supply piping 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 b Install a manual shutoff valve in the 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 2 Install sediment trap drip leg Figure 7 1 Gas Supply Piping Model 400 UNION FIELD SUPPLIED GAS SUPPLY SEDIMENT TRAP DRIP LEG MANUAL SHUTOFF VALVE FACTORY SUPPLIED UNION FACTORY INSTALLED MANUAL SHUTOFF VALVE FACTORY SUPPLIED GAS
54. Vent M amp G Group 701 801 KIT3137 Table 3I Approved Stainless Steel Terminations and Adapters ProTech Heat Fab PZ Flex FasNSeal Saf T Vent Intake Air Intake Air Intake Air Adapter Termination Termination Adapter Termination Termination Adapter Termination Termination FSBS4 FSAIH04 9492 2SVSTP04 400 601 F303759 FSRCA R C 303888 9401PVC 5400C 9414TERM 2SVSLA04 5SVSRCX04 2SVSTEX0490 F303759 FSAIH04 701 801 Intake FSBS6 303888 Only 22 4 Sidewall direct venting Vent air termination sidewall A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage A gas vent extending through an exterior wall shall not terminate adjacent to a wall 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 Determine location 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 17 of this manual 2 You must consider the surroundings when terminating the 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 con
55. YPICAL SYSTEM CIRCULATOR PRESSURE GAUGE EXPANSION TANK Y STRAINER RECOMMENDED MAKE UP WATER BOILER CIRCULATOR BACK FLOW PREVENTER PRESSURE REDUCING VALVE INDIRECT DHW TANK ANTI SCALD MIXING VALVE HOT WATER OUT DOMESTIC HOT WATER CIRCULATOR COLD WATER IN UNION TYPICAL BOILER TEMPERATURE PRESSURE PRESSURE RELIEF GAUGE VALVE DRAIN FLOW CHECK VALVE TYPICAL CAUTION Indirect water heaters are capable of transferring a limited number of Btu s into the water Ensure boiler output does not not exceed indirect water heater transfer capabilities NOTICE 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 System flow should always remain higher than the required flow for the boiler s when the boiler s is in NOTICE l of lass operation to prevent short cycling and high limit issues 42 a ieee Installation amp Operation Manual 6 Hydronic piping c continuea Figure 6 9 Multiple Boilers Multiple Temperatures Number of Units 2 3 4 5 56 7 5 Manifold Pipe Sizes in Inches mm WIRES TO LOOP SENSORS TEMPERATURE LOOP 3 TEMPERATURE Ban MULTI TEMP 2 a LOOP CONTROL OPTIONAL 24V SIGNAL TO LOOP SENSOR 3X MIXING VALVES AIR SEPARATOR SHIELDED CABLE TO BOILER CONTROL MAKE UP WATER BACK FLOW Y STRAI
56. ade system to work properly the system supply sensor must be installed The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 6 7 through 6 11 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor see FIG 8 3 The Leader control will 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 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 one of the heat loop demands 1 3 FIG 8 3 If the boilers are to run continuously connect a jumper wire between the R and W terminals for the heat loop demand input This will initiate a call for heat on the Cascade Communication between the Leader boiler and the Member boilers is accomplished by using shielded 2 wire twisted pair communication cabl
57. adjusts the boiler firing rate so the inlet temperature is correct Temperature and pressure gauge field installed not shown Monitors the outlet temperature of the boiler as well as the system water pressure Electronic LCD display The electronic display consists of 4 buttons a navigation dial and a multiple line liquid crystal display Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler 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 Water outlet system supply A 1 1 2 or 2 NPT depending on the model water connection that supplies hot water to the system Water inlet system return A 1 1 2 or 2 NPT depending on the model water connection that returns water from the system to the heat exchanger Gas connection pipe Threaded pipe connection of 1 This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals and controls the blower gas valve and pumps to meet the heating demand Manual air vent Designed to remove trapped air from the heat exchanger coils Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler 4 19 20 21 22 23 24 25 26 27 28 29 30
58. ag 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 A WARNING 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 400 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 A DANGER Figure 2 2 Installing Propane Orifice Model 400 BLOWER VENTURI BRASS ORIFICE GAS VALVE 2 Prepare boiler Model 501 1 Remove the top access cover from the unit no tools required for removal 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 Use a combustion analyzer to verify CO is within the range of 9 6 10 5 If not adjust the screw counterclockwise incrementally to raise CO and clockwise to lower CO FIG 2 3 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 cor
59. al injury or death Q Check gas pipin 1 Verify the preparation procedures of Section 10 pages 55 gas piping and 56 have been completed 1 Check around the boiler for gas odor following the f l procedure on page 46 of this manual connecting gas LI Fill the vent condensate trap with water removing the supply piping retaining screw in order to remove the 2 inch PVC cap if vou os s us OSP anv cus ha with the switch located at the top of the trap Replace A WARNING U Ys U shut down the boiler at once Find the the cap Press the cap onto the trap until the cap makes l S u qhaya a pos ash na leak source with a bubble test and repair SSS s 8 7 y immediately Do not start the boiler again LI Verify electrical connections are correct and securely until corrected Failure 1o comply could attached result in severe personal injury death or substantial property damage LI Inspect vent piping and air piping for signs of deterioration Q Propane boilers verify conversion from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler ls Read and follow the Operating instructions in FIG 10 2 page 58 If boiler does not start correctly l Verify propane conversion has been completed per the Propane Conversion instructions A WARNING DO NOT adjust gas valve outlet pressure The gas valve is factory set for the correct outlet
60. al property damage Installation amp Operation Manual eo Sein COMMERCIAL BOILER The Knight XL boiler 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 You may use any of the vent air piping methods covered in this manual Do not attempt to install the Knight XL boiler using any other means You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 19 of this manual The resultant installation is direct vent sealed combustion Air intake vent connections 1 Combustion Air Intake Connector FIG 3 1 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 2 thru 3 6 Used to provide a passageway for conveying combustion 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 Figure 3 1 Near Boiler Air Piping 3 General venting continued Requirements for Canada 1 Installation
61. alve in the gas 2 Shut off gas supply at the manual gas valve in the gas piping to the appliance piping to the appliance 13 Remove the manometer from the pressure tap on top of the gas valve On Models 400 501 re tighten the set screw inside the pressure tap On Models 601 801 remove the 1 8 3 mm field supplied fitting and reinstall the pipe plug removed in Step 3 3 On Models 400 501 loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve On Models 601 801 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 49 48 Kee Installation amp Operation Manual f Gas connections continued A WARNING Ven re tightening the set screw be sure Ejgure 7 7 Inlet Gas Supply Check Models 601 801 to tighten securely to prevent gas leaks REMOVE THE 1 8 3 MM PIPE PLUG ON Do not check for gas leaks with an open THE INLET FLANGE TO THE VALVE AND __ INSTALL A SUITABLE 1 8 3 MM FITTING flame use the bubble test Failure to FIELD SUPPLIED FOR THE MANOMETER use the bubble test or check for gas leaks TUBING can cause severe personal injury death or substantial property damage 14 Turn on the
62. anagement system 1 An external control may be connected to control either the firing rate or the set point of the boiler If the external control uses a set of contacts to enable the boiler connect the contacts to the heat loop demand 1 terminals Otherwise the SMART SYSTEM control will be enabled by the 0 10V signal 2 Make sure the terminal is connected to the or common output terminal of the external control and the terminal is connected to the 0 10 VDC or terminal of the external control Make sure that the voltage is not below ground 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 52 Installation amp Operation Manual COMMERCIAL BOILER j 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 Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 60 Configuration of the Cascade for a detailed explanation of this procedure Connect the system supply sensor and outdoor air sensor if used to the Leader boiler For the Casc
63. ank 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 The tank sensor included with the Lochinvar Squire indirect DHW tanks TST20015 is the only sensor suitable for use with the SMART SYSTEM control Connect the sensor leads to the Tank Sensor terminals on the low voltage connection board FIG 8 3 Failure to use the correct sensor ma A WARNING ens result in the tank temperature being either above or below the set point Installation amp Operation Manual COMMERCIAL BOILER If TST20015 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 Louver proving switch 1 When the operation of the louvers 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 High gas pressure switch 1 If a switch is provided to detect excessive gas pressure remove the jumper wire from the terminals on the connection board and then conn
64. are required for the protection of any low temperature loops SMART SYSTEM Multi temp loop control The Knight XL boiler is capable of producing up to three 3 set point temperatures to meet different space heating demands This device controls the temperatures of up to three 3 separate loops based on the settings for the three 3 heat loop demands reference Lochinvar kit RLY30086 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 The Knight XL can also be programmed to accept a call for heat from a 0 10V signal reference the Knight XL Service Manual for a detailed explanation of this procedure Installation amp Operation Manual COMMERCIAL BOILER DHW priority The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the DHW thermostat input is ignored When a boiler is programmed for DHW Normal Mode the maximum firing rate can be limited to match the input rating of the indirect tank coil DHW space heating SH cycling If a DHW call for heat is received while a space heating call is in progress and the DHW is in Normal Mode the control will start the DHW pump and shut the boiler pump off The system pump will remain on Fo
65. ating call for heat ends the system pump continues to run for a short period of time The system pump can be programmed to run continuously except during outdoor shutdown 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 Adjust set point temperature s NOTICE Please note that the brackets denote screen status The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures 1 From the Status Screen press the NAVIGATION dial Turn the NAVIGATION dial counterclockwise to select the appropriate set point 3 Press the NAVIGATION dial to adjust the temperature 4 Once the desired temperature is displayed press the RIGHT SELECT SAVE key 5 If necessary repeat Steps 3 and 4 to make adjustments to additional set points 6 Press the RIGHT SELECT HOME key to upload the changes 7 If the RIGHT SELECT SAVE key is not pressed the new settings will be discarded 59 10 Start up Set domestic hot water DHW operation Verify DHW mode There are two 2 modes of operation for DHW In Normal Mode when a DHW demand begins the control will start the DHW pump turn off the boiler pump if running and modulate to br
66. bility of the contractor to install the temperature and pressure gauge on the boiler water outlet Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 6 Hydronic piping continea 12 Boiler purge valve Field supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up 13 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 heating loop junction The sensor should be located far enough downstream to sense system diluted water temperature 14 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 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 Near boiler piping connections Figure 6 4A Near Boiler Piping w Y Strainer g RO DOMESTIC HOT DIRT SEPARATOR WATER PUMP INDIRECT Installation amp Operation Manual COMMERCIAL BOILER Figure 6 4B Near Boiler Piping w Low Loss Header SYSTEM PUMP SYSTEM SENSOR AIR SEPARATOR TYPICAL gt AIR VENT VALVE LOW LOSS HEADE
67. bstantial property damage Figure 2 4 Gas Valve Adjustment Models 601 801 SHEEN REINO fe ADJUSTMENT SCREW 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 SCREWDRIVER ieee Installation amp Operation Manual 3 General venting Direct venting options Sidewall Vent SON Tis Se a 7 L lt C 2 ea S 3 Kets a weer PVC CPVC Concentric Sidewall Two Pipe Sidewall Models 400 601 Only See page 23 for more details i See page 27 for more details Direct venting options Vertical Vent ee ss Two Pipe Vertical PVC CPVC See page 30 for more details Concentric Vertical Vertical Vent Sidewall Air Models 400 601 Only See page 19 for more details See page 32 for more details 15 3 General venting Install vent and combustion air piping A DANGER A WARNING A WARNING NOTICE A WARNING A CAUTION NOTICE A WARNING The Knight XL boiler must be vented and 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 Inspect finished vent and air piping thoroughly to ensu
68. cal direct venting Installation amp Operation Manual C GE COMMERCIAL BOILER Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system or by using the existing unused venting system as a chase for vent and combustion air routing Concentric Venting Arrangement The venting is to be vertical through the roof The annular space between the O D of the vent pipe and the I D of the existing unused venting system is utilized for the combustion air source The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG s 5 8 and 5 9 Approved venting materials must be used as specified in Table 3D on page 20 Follow all vent air termination and clearance requirements per this section to the appropriate example Installation must comply with local requirements and with the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existing unused venting system is converted for use with this method of concentric venting the instal
69. ctual components for proper connector block locations when using WIRING DIAGRAM diagrams to troubleshoot unit LBL20116 REV E Kee Installation amp Operation Manual 13 Diagrams Figure 13 2 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL 62 TERMINAL STRIP TERMINAL STRIP o CS 120V SUPPLY L 120V SUPPLY N O GROUND SYSTEM ON OFF INTEGRATED CONTROL PUMP SWITCH BLOWER CONTACTS X1 6 X1 1 1 2 3 BOILER X1 2 PUMP CONTACTS SYSTEM PUMP x 3 RELAY DHW PUMP RELAY X1 4 BOILER PUMP RELAY CONNECTION BOARD INTEGRATED CONTROL CN5 14 X4 8 2 gt lt CN5 10 X4 12 2 gt ofo SWITCH HEAT LOOP DEMAND CN5 7 X4 1 HEAT LOOP DEMAND HEAT LOOP DEMAND EN 6 22 THERMOSTAT O O LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH SWITCH OA O OTO CN5 11 X4 11 CN5 3 X4 5 INTEGRATED CONTROL LOUVER RELAY COIL Q HO 24VAC S LOUVER O PROVING SWITCH Chea ae RIBBON CABLE O TEMP HEX SW q ened oe
70. dapter at the flue collar connection The adapter is supplied by the vent manufacturer to adapt to its vent system See Table 3F for approved vent adapters Discard CPVC starter piece NOTICE All vent connections MUST be secured by the vent manufacturer s joint connector Figure 3 4 Near Boiler Polypropylene Venting FIG 3 4 A WARNING Insulation should not be used on polypropylene venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure i Z x O IMG00128 NN POLYPROPYLENE ADAPTER JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM Table 3F Approved Polypropylene Terminations Centrotherm InnoFlue SW Duravent Polypro Polypropylene Joint Sidewall Retaining a Polypropylene Joint w Adapter Connector Bracket eW qap Adapter Connector Sidewall Kit 400 601 ISAAL0404 IANS04 IATP0404 ISTAGL0404 4PPS AD 4PPS LB 4PPS HLK N 701 801 ISAALO606 K s IATP0606 ISTAGL0606 FSA 6PVCM 6PPS Not Required 6PPS HLK These parts are only needed if the sidewall termination assembly is used see FIG 4 5B on page 26 Kee Installation amp Operation Manual 3 General venting Stainless steel vent Figure 3 5 Near Boiler Stainless Steel Venting Models This product has been approved for use with stainless steel 400 601 using the manufacturers listed in Table 3G Use only the materials vent systems and AWVARNING terminations lis
71. dense 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 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 A 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 Sidewall vent and air inlet terminations must terminate in the same pressure zone Installation amp Operation Manual Figure 4 1A PVC CPVC Polypropylene Sidewall Termination of Air and Vent TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION VENT AIR TERMINATION SNOW LINE Table 4A Sidewall Vent Kits modei Kit Number Vent Size 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 The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown in FI
72. diction 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 Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the Knight XL Service Manual to change the settings Reset curve The reset curves look at outdoor air temperature and adjusts the set points 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 The Leader control can be programmed to use Lead Lag or Efficiency Optimization control methods Once the Leader boiler receives a call for heat from a room thermostat BMS or Modbus 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
73. e Apply a second coat of cement to the pipe f 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 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 2 Cut pipe to the required lengths and deburr the inside and outside of the pipe ends Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe 3 Chamfer outside of each pipe end to ensure even cement distribution when joining 4 Clean all pipe ends and fittings using a clean dry rag Moisture will retard curing and dirt or grease will prevent adhesion Figure 3 2 Near Boiler PVC CPVC Venting Models 400 601 Figure 3 3 Near Boiler PVC CPVC Venting Models 701 801 6 COUPLING FIELD SUPPLIED 6 CPVC ie STARTER PIECE gt 4 CPVC STREET ELBOW MAY BE SUBSTITUTED 4 CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION NOTE CPVC VENT OR STAINLESS STEEL PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND THE 6 STAINLESS STEEL ADAPTER SUPPLIED ALCOVE INSTALLATIONS WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC CPVC THE 6 CPVC STARTER PIECE MUST BE USED FOR PVC ONLY 20 3 General venting continued Polypropylene This produc
74. e Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards Connect the shield wires to one of the shield 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 Cascade terminals on the second boiler to the Cascade 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 Installation amp Operation Manual COMMERCIAL BOILER YOSNAS AlddNS WALSAS c Figure 8 3 Low Voltage Field Wiring Connections 8 Field wiring continues WALSAS INANSSDVNVIA ONIC AG LcLOOOW SASOduYNd NOILVYLSNTII YO4 Lids GYVOd NOILOANNOO Q 1STHS NOLLAG al E ONYWSd sngdow Y doo 1 1y3H __ GQ T8IHS F ON WAT Ino SLVH s RZ 007 L3H a A I LMG diitd H18 A I O NI did SAS A HI Q A D O O TaHsS 8 qdvosva V Geet HOLIMS S NIAOH4d q EIlHS 5 o Pde i YIANGT YOSNIS 103 AV Tay o PINV 1 YAANOT DYAPZ S 13D LNOD IWILL Nr tz OSN3S 812y1NO2 Wasis Fee We Ty 1 Fa Fr II II I p d Ve fe bal Fa A fy fe T Aj YOSNAS YOO0ALNO L 44HOLNO YALVM MOJ
75. e and adjacent air SIDEWALL inlet elbow as shown in FIG 4 6A for U S installations RENT For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Knight XL is part of a direct vent GALVANIZED IMG00085 connection It is not classified as a forced air intake with THIMBLE regard to spacing from adjacent boiler vents Prepare wall penetrations Alternate Field Figure 4 6A Multiple Vent Terminations must also Supplied Option comply with Figure 4 1A 1 Air pipe penetration 12 MIN BETWEEN EDGE OF AIR a Cut a hole for the air pipe Size the air pipe hole as INLET AND ADJACENT VENT OUTLET close as desired to the air pipe outside diameter VENT 2 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 5 inch hole 140 mm hole for 4 inch 102 mm vent pipe 7 inch hole 191 mm hole for 6 inch 152 mm vent pipe b Insert a galvanized metal thimble in the vent pipe Pf hole as shown in FIG 4 5C ig VENT AIR TERMINATION AIR 3 Use a sidewall termination plate as a template for correct location of hole centers Figure 4 6B Alternate Multiple Vent Terminations 4 Follow all local codes for isolation of vent pipe when passing w Field Supplied Fittings must also comply with through floors or walls Figure 4 1B
76. e flue temperature sensor from the flue pipe eaks connection NOTE Combustion measurements will be 2 Vent any remaining air from the system using manual mage arse oun vents Air in the system will interfere with circulation 3 Turn the main power on to the boiler by placing the and cause heat distribution problems and noise On Off switch in the ON position 57 Keegy Installation amp Operation Manual 10 Start u D 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 e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand e If you cannot reach your gas supplier call the fire department BEFORE OPERATING smell all around C Use only your hand to turn the gas control knob the appliance area for gas Be sure to Never use tools If the handle will not turn by smell next to the floor because some gas hand don t try to repair it call a qualified service is heavier than air and will settle on the technician Force or attempted repair may result floor in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has be
77. e gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 10 1 Condensate Trap RETAINING CONDENSATE von J HEAT EXCHANGER 56 SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH TO FLOOR DRAIN PVC TEE ASSEMBLY FACTORY SUPPLIED COMMERCIAL BOILER I Installation amp Operation Manual A WARNING 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 l Disconnect the two external wires connected to each of the heat loop demand terminals on the connection board 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 There should NEVER be a voltage reading 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 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the boil
78. e optional ModBus interface module is installed the RS 485 ModBus cable is connected to these terminals Use shielded 2 wire twisted pair cable If desired the shield can be connected to ground by installing a Jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus Interface module 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 at the boiler outlet 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 System supply sensor 1 By installing the system supply sensor into the supply of the primary loop the temperature of the system 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 See the Knight XL Service Manual for instructions on how to use the inlet sensor as the controlling sensor When the inlet sensor is programmed as the controlling sensor it is vital that the SYSTEM SUPPLY sensor be installed DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN 2 The TST2032 sensor provided with the boiler must be used for the system sensor 3 Connect these terminals to the system supply sensor FIG 8 3 Boiler m
79. e time the boiler is firing in the DHW Mode The control uses two 2 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 Service reminder 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 show a Maintenance Required screen The installers name and phone number can be programmed into the control This information will appear on the Maintenance Required screen The service reminder notification can be reset or disabled by the installer The time dependent feature has been disabled by the manufacturer To enable this feature change the parameter to the desired time interval reference the Knight XL Service Manual for details regarding parameters Error logging The control will hold in memory the last 10 lockouts as well as the last 10 blockings The date and time of the occurrence will be recorded as well Only the 10 most current occurrences of each will be held in memory 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
80. e to their lines DETAIL Figure 7 6 Inlet Gas Supply Check Model 501 Gas valve replacement LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER The gas valve MUST NOT be replaced with a conventional THE PRESSURE TAP gas valve under any circumstances As an additional safety A VAN feature this gas valve has a flanged connection to the venturi W a and blower A WARNING Failure to follow all precautions could result in fire explosion or death A WARNING DO NOT adjust gas valve outlet pressure Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property DETAIL anaes 49 8 Field wiring A WARNING 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 see lt when servicing controls Wiring errors can cause improper and dangerous operation Figure 8 1 Line Voltage Field Wiring Connections 120V SUPPLY NEUTRAL
81. ect them to its normally closed contacts FIG 8 3 Low gas pressure switch 1 Ifa 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 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 Variable speed system pump If a variable speed pump is used in the primary loop and a 0 10V signal is available from the pump speed control this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load By connecting this 0 10V signal to the 0 10V SYS PUMP IN terminals the boiler or cascade can modulate up and down as the primary flow increases and decreases Boiler pump speed output This 0 10V output is available to control the speed of a variable speed boiler pump The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum AT across the heat exchanger as well as prevent high limit lockouts when the flow in the primary loop is extremely low Connect this output to the 0 10V input on the boiler pump speed control Rate output This output provides a 0 10V signal that is proportional to the firing rate of the boiler This may be used by a BMS system to monitor the actual rate of the boiler 51 8 Field wiring Modbus When th
82. ection features 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 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 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 maximum 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 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 tempera
83. en Do not try to light any appliance under water Immediately call a qualified h aci ad service technician to inspect the appliance and Do not touch any electric switch do to replace any part of the control system and not use any phone in your building any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe 2 Set the thermostat to lowest setting 9 Install top cover 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 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 5 Remove top cover OPEN CLOSED 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 Set the thermostat to lowest setting 4 Turn gas shut off valve counterclockwise to OFF Handle will be perpendicular to pipe D
84. er on e 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 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 Pipe sizing for propane gas 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 e Maximum 14 inches w c 3 2 kPa with no flow lockup or with boiler on e Minimum 8 inches w c 1 9 kPa with gas flowing verify during boiler startup A WARNING Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the appliance 47 Kee Installation amp Operation Manual f Qas connections Table 7A Natural Gas Pi
85. er to cycle Inspect fill condensate system Inspect check condensate lines and fittings i Inspect the condensate drain line condensate PVC fittings and condensate trap Fill condensate trap with water 1 oS Remove the PVC cap retaining screw from the PVC cap FIG 10 1 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 10 1 Fill with fresh water until the water begins to pour out of the drain Replace the cap Press the cap onto the trap until the cap makes contact with the drain Replace the retaining screw The condensate trap FIG 10 1 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 Installation amp Operation Manual Yaa 1 0 Start u D continued Final checks before starting the boiler O Check vent piping and air piping Q Read the Knight XL Service Manual to familiarize yourself L Check for gastight seal at every connection seam of air with SMART SYSTEM control module operation Read piping and vent Pino this manual page 58 for proper steps to start boiler A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon LI Verify the boiler and system are full of water and all monoxide emissions which will result in system components are correctly set for operation severe person
86. es 79 Revision Notes Revision A ECO C05747 initial release Reflects the new model numbers for the Knight XL upgrade Revision B ECO C06188 reflects changes made to FIG 6 10 ECR R03474 remove ghost pipe changes made to FIG s 6 7 6 9 and 6 11 RO3563 change the direction of the arrows and edits made to the ladder and wiring diagrams ECO C06158 Revision C ECO C06234 reflects changes made to the Service Reminder feature Revision D ECO 007981 reflects the layout in InDesign edits made ECR04077 combustible water pipes change from 1 to a 1 4 changes made to Table 3B on page 20 ECR03940 addition of the rope gasket warning ECRO3740 changes made to FIG s 7 1 thru 7 4 pages 46 and 47 changes made to Table 3A on page 18 ECR0O3727 400 601 reference applied incorrectly on pages 15 and 16 add O temp switch Revision E ECO 009197 reflects additional information added to the humidity warning on page 8 edits made to the O Temp switch definition on page 4 along with updates made to the SMART SYSTEM control ECR R04523 Revision F ECO C09803 reflects the addition of the new Polypropylene Vent material section rearranging the vent section and the addition of AL r the AHRI and ASME logos R05009 Y High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Revision G ECO C10143 reflects updates made to the ignition timing Lebanon TN 37090 informat
87. 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 DETAIL Gas pressure Figure 7 5 Inlet Gas Supply Check Model 400 The gas pressure must remain between 4 inches w c 99 LOOSEN THE SET SCREW ONE 1 FULL TURN kPa minimum and 14 inches w c 3 5 kPa maximum for AND PLACE THE MANOMETER TUBING OVER Natural gas and between 8 inches w c 1 9 kPa minimum THE PRESSURE TAP 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 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 maintenanc
88. gested guidelines in piping the Knight XL NOTICE 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 6 Hydronic piping continued Flow switch relief valve and 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 400 501 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 601 801 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 2 For Models 701 801 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 400 601 install the relief valve directly into the 3 4 inch fitting on the tee FIG 6 1 3 Install the close nipple on the downstream side of the relief valve tee FIG 6 1 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 6 Install the assembled flow switch into the 1 inch fitting of the tee installed in Step 4 see FIG
89. grammed for cascade operation This is accomplished by accessing the control parameters Press the MENU key for at least five 5 seconds Input the Installer code as described in the Knight XL Service Manual Once the control parameters have been accessed use the NAVIGATION DIAL to select the Control Mode parameters Press the NAVIGATION DIAL to access these parameters Rotate the NAVIGATION dial to select the parameter Cascade Address Press the NAVIGATION dial to access this parameter Each appliance 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 Rotate the NAVIGATION dial to select the appropriate address Press the RIGHT SELECT SAVE key Press the RIGHT SELECT HOME key to upload the address into the control Repeat this procedure for all boilers in the Cascade designating the Leader control and the Member controls 11 Operating information General 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 on
90. he 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 The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle Vent and air piping The Knight XL requires a special vent system designed for pressurized venting 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 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 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 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 conta
91. iameter for CVK3007 installations into the structure to install the termination kit 4 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 Figure 4 8 Kit Contents_CVK3007 Models 400 601 RAIN CAP 6 152 MM TO 4 102 MM REDUCER 6 152 MM DIA 6 152 MM DIA 4 102 MM DIA Y CONCENTRIC FITTING 6 152 MM DIA FLEXIBLE PIPE COUPLING EE 57 ms 4 Sidewall direct venting Installation amp Operation Manual Ser COMMERCIAL BOILER Sidewall termination optional concentric vent Models 400 601 Only Figure 4 9 Concentric Vent Dimensional Drawing Models 400 601 B DIA PVC VENT EXHAUST 21 1 8 10 7 5 8 6 5 8 MM 102 MM P MM 537 MM 254 MM 194 MM m MM 168 MM Instead of cementing the smaller pipe to NOTICE Oe Si the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 10 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 combu
92. ice Manual Failure to comply could result in severe personal injury Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan Using field supplied means cover the refractory in the back of the combustion chamber of the heat exchanger 76 Installation amp Operation Manual COMMERCIAL BOILER 6 Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 11 Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler 12 Perform start up and check out procedures in the Check Flame and Combustion Section 10 Startup on pages 57 and 59 of this manual 13 Replace the access cover and restore boiler to operation Table 12B Heat Exchanger Cleaning Kits e pe S Number Description MSC20084 3mm Allen Wrench 400 KIT30063
93. idential Garage Installation 10 Flow Switch Adjustment 38 Vent and Air Piping 10 Near Boiler Piping Components 38 39 Prevent Combustion Air Contamination 10 Girculatol SIZING eose onr iS 39 Corrosive Contaminants and Sources 11 Near Boiler Piping Connections 39 Using an Existing Vent System to Install a New Boiler 11 7 GAS CONNECTIONS Removing a Boiler from Existing Common Vent 12 Connecting Gas Supply Piping 46 2 PREPARE BOILER Natural Qa uuu ua Sasa basi 47 Remove Boiler from Wood Pallet 13 Pipe Sizing for Natural Gas 47 Gas Conversions a a arar 13 Natural Gas Supply Pressure Requirements 47 Model 400 l a 13 Propane Gas uuu uu akar ennnenkuin iiie 47 NMICGE 30M serren ier E 14 Pipe Sizing for Propane Gas 47 Models GOT 801 14 Propane Supply Pressure Requirements 47 Leveling the Boiler 14 Check Inlet Gas Supply
94. ing 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 ieee Installation amp Operation Manual g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code AN
95. ing the outlet temperature to the DHW boiler set point The maximum firing rate may be limited in this mode if desired In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop When a DHW demand begins the control will turn on the DHW pump output and raise the system temperature set point to the DHW boiler set point if higher The boiler pump will be turned on The system pump may be forced on forced off or not changed depending on the System Pump Mode selected reference the Knight XL Service Manual for details In this mode any low temperature zones such as radiant heating may need additional controls to limit the water temperature sent to those zones Set DHW boiler target temperature When in the DHW Mode the control will modulate to maintain the boiler outlet temperature or system supply 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 Set maximum DHW fan speed If the rated input of the indirect tank is less than the maximum output of the boiler change the maximum DHW fan speed setting to limit the boiler output accordingly see the Knight XL Service Manual for a detailed explanation of this procedure Set clock NOTICE Please note that the brackets denote screen status The S
96. ion 615 889 8900 Fax 615 547 1000 www Lochinvar com KBXII I O Rev G 04 12
97. isplayed percentage Boiler Status The call for heat has been satisfied and the unit runs the fan for an Bar POSTPURGE additional postpurge period to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position CE TPL I HT MET The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a condition that has temporarily interrupted the current call for heat 1 Room Thermostat 1 has a call for heat Room Thermostat 2 has a call for heat B Room Thermostat 3 has a call for heat Call for Heat The tank thermostat or sensor has a call for heat Indicators Indicates which room thermostat demand shows priority The unit is being controlled by a 0 10V BMS signal The member unit is supplying heat while in Cascade Mode 69 COMMERCIAL BOILER waT Installation amp Operation Manual 11 Operating information Status Display Screens cont d Section Display _ Description SYSTEM The temperature read by the system supply sensor if connected TANK The temperature read by the tank sensor if connected OUTDOOR The temperature read by the outdoor sensor if connected INLET TEMP The temperature read at the inlet to the heat exchanger OUTLET TEMP The temperature read at the outlet of the heat exchanger DELTA T The temperature difference between the inlet and the outlet of the heat exchanger FLUE TEMP The
98. ive humidity may exceed 93 Do not install the appliance where condensation may form on the inside or outside of the appliance or where condensation may fall onto the appliance Failure to install the appliance indoors could result in severe personal injury death or substantial property damage 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 Closet and alcove installations A WARNING A closet is any room the boiler is installed in which is less than 171 cubic feet for KBN400 models 193 cubic feet for KBN501 models 223 cubic feet for KBN601 models 247 cubic feet for KBN701 models and 278 cubic feet for KBN801 models 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 For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC or stainless steel vent material must be used inside the structure The ventilati
99. lator Instead shut off the gas supply at a location external to the appliance e 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 Boiler water 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 e 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 A CAUTION Po not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be property damage Do not use homemade cures or boiler damaged This can result in substantial A CAUTION patent medicines Serious damage to the boiler personnel and or property may result 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 1 10 1
100. ler must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance See Table 1A on page 11 for a list of corrosive contaminants and sources Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG s 5 8 and 5 9 Table 5A Alternate Vertical Concentric Vent Chase Sizes Vent Air Inlet Size Minimum Existing Vent Chase Size s e t 3 mms Figure 5 8 Concentric Vent Example 1 FLUE EXHAUST AIR INLET W SCREEN EXISTING SEALED CAP FLUE OUTLET we A For concept illustration only Individual installations may vary due to job site specific equipment Figure 5 9 Concentric Vent Example 2 SEAL FLUE EXHAUST COMBUSTION AIR AIR INLET W SCREEN SEAL EXISTING SEALED CAP FLUE OUTLET For concept illustration only Individual installations may vary due to job site specific equipment ET COMMERCIAL BOILER 5 Vertical direct venting continued Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase FLUE EXHAUST AIR INLET EXISTING FLUE OUTLET For concept illustration only Individual installations
101. lied pipe and fittings are required to complete the eaten ais installation a Cement the Y concentric fitting to the larger The required combustion vent pipe fittings are listed in Table 3D on page 20 of this manual Vertical termination installation f f f f f NOTICE l See Section 5 Vertical Direct Venting Determine Location where applicable Figure 5 4 Concentric Vertical Termination A WARNING 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 Bend to Rain Cap 32 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 Instead of cementing the smaller pipe to the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 10 page 28 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 Installation amp Operation Manual 5 Vertical direct venting continued Vertical termination optional concentric vent Models
102. ling compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow f Gas A WARNING Figure 7 4 Inlet NOTICE connections continued Failure to apply pipe sealing compound as detailed in this manual can result In severe personal injury death or substantial property damage 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 Pipe with Backup Wrench USE BACKUP WRENCH TO PREVENT PIPE FROM ROTATING Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment Wema Installation amp Operation Manual Natural gas Pipe sizing for natural gas 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 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 1 Pressure required at the gas valve inlet pressure port e Maximum 14 inches w c 3 5 kPa with no flow lockup or with boil
103. ll 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 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids A WARNING Failure to keep boiler area clear and free of combustible materials gasoline and other 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 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 8 Installation amp Operation Manual COMMERCIAL BOILER 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 A WARNING Do not install the appliance where the relat
104. low the heat exchanger to be leveled This is needed for the proper draining of the condensate from the combustion chamber Air shroud Model 501 only The air shroud controls air and gas flow into the burner Air pressure switch The air pressure switch detects blocked flue inlet conditions break the control circuit shutting the boiler down Pump relay board The pump relay board is used to connect the boiler system and DHW pumps Transformer The transformer provides 24V power to the integrated control High limit sensor housed with the outlet temperature sensor Device that monitors the outlet water temperature If the temperature exceeds its setting the integrated control will break the control circuit shutting the boiler down Over temp switch located underneath access cover An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger directly above the flue connection exceeds 604 F 318 C This is a one time switch and could warrant a heat exchanger replacement Check the integrity of the rear refractory at the back of the upper coil if the switch opens Kies Installation amp Operation Manual The Knight XL How it works continued Model 400 Front View Model 400 Rear View Model 400 Left Side inside unit Model 400 Right Side inside unit Model 400 Wiese Installation amp Operation Manual The Knight XL How it works Model 501
105. ly the right amount of gas to flow How the control module operates The SMART SYSTEM control module receives inputs from boiler sensors and external devices 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 system temperature a 0 10V signal or Modbus depending on the parameter settings Control inputs and outputs Room thermostat There are three 3 heat loop demand connections available on this control These inputs tell the boiler to provide water for space heating Each demand connection has its own set point and outdoor air reset curve When multiple demands have a call for heat the control will give priority to the demand with the highest set point Example Assume that both heat loop demand 1 and heat loop demand 2 have a call for heat Demand 1 has a set point of 110 F Demand 2 has a set point of 140 F The boiler will regulate the system temperature to 140 F until Demand 2 has been satisfied Once Demand 2 has been satisified the boiler will provide 110 F water to the system A CAUTION When multiple temperature loops are used mixing valves
106. manual shutoff switch to the ON position and reset the control 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 or substantial property damage Installation amp Operation Manual e IEE COMMERCIAL BOILER 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 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 Verify space heat circulator mode The Space Heating Mode controls both the system pump if connected and the boiler 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 and the set point is not met it also turns on the boiler pump After the space he
107. meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve Installation amp Operation Manual C COMMERCIAL BOILER 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 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING 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 page 46 Route the hose to an area where water can drain and be seen 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
108. minated combustion air You must pipe combustion air to the 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 1 Determine boiler location Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops I
109. mum 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 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 es by up to 1 5 for each 25 feet of vent length Table 3B Concentric Vent Kit Equivalent Vent Lengths Equivalent Vent Length CVK3007 5 Feet 1 5 m CVK3007 30 Feet 9 m CVK3007 30 Feet 9 m 17 3 General venting 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 Polypropylene 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 AL29 4C stainless steel material to be sealed to specification of its manufacturer Plastic pipe may require an adapter not provided to transition between the air inlet connection on the appliance and the plastic air inlet pipe A WARNING Using air intake materials other than those specified can result in personal injury death or property damage NOTICE The use of double wall vent or insulated material for
110. ner Replace the top access cover ING 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 Figure 2 3 Gas Valve Adjustment Model 501 ALLEN WRENCH ADJUSTMENT SCREW N Models 601 801 1 Remove the top access cover from the unit no tools required for removal Remove the cover on top of the gas valve FIG 2 4 Turn the adjustment screw on top of the gas valve clockwise one and three quarter 1 3 4 turns on the 601 Model one and a half 1 1 2 turns on the 701 Model and one turn on the 801 Model see FIG 2 4 Use a combustion analyzer to verify CO is within the range of 9 6 10 5 If not adjust the screw counterclockwise incrementally to raise CO and clockwise to lower CO FIG 2 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 Replace the gas valve cover along with the top access cover 14 al Kheee Installation amp Operation Manual Hain After converting to LP check combustion S 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 su
111. ng Outdoor air reset If an outdoor air sensor is connected the control module will calculate the set points of the three 3 space heating demands based on the programmed reset curves The installer can change the slope of the reset curves by several adjustable parameters The user can limit the maximum set point for the system using the space heating set points Boost function If outdoor air reset is active and any 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 of that demand 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 and DHW set points during certain times each week Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback Flame current support 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 62 Installation amp Operation Manual C COMMERCIAL BOILER Prot
112. ng 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 Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 4 6 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 Clearances for service access l 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 1 COMMERCIAL BOILER 1 Determine boiler location continued Installation amp Operation Manual Figure 1 1 Closet Installation Minimum Required Clearances CLOSET INSTALLATION 1 4 6 MM MINIMUM CLEARANCE AROUND HOT WATER PIPES 1 25 MM MINIMUM CLEARANCE AROUND VENT PIPE TOP VENTILATING AIR OPENING 305 MM For closet installations CPVC polypropylene or stainless steel vent 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 CLOSED DOOR VENTILATING LEFT AIR OPENING 6 Z 14 356 MM at REAR 0 RECOMMENDED SERVICE CLEARANCES RIGHT FRONT 30 762 mm TOP 24 610 mm 6 152MM LEFT SIDE 24
113. nstallation amp Operation Manual ISHI COMMERCIAL BOILER continued When using an existing vent system to install a new boiler Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Check the following venting components before installing e Material For materials listed for use with this appliance see Section 3 General Venting For polypropylene or stainless steel venting an adapter of the same manufacturer must be used at the flue collar connection Size To ensure proper pipe size is in place see Table 3A Check to see that this size is used throughout the vent system Manufacturer For a stainless steel or polypropylene application you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with flue producing condensate 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 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 Ve
114. nt must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage 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 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 e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions 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 Installation amp Operation Manual COMMERCIAL BOILER To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e 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 circu
115. nting Section For stainless steel vent only use terminations listed in Table 3H for the manufacturer of the installed vent e 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 With polypropylene and 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 pages 19 and 20 A WARNING If any of these conditions are not met the 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 1 Determine boiler location When removing a boiler from existing common vent system A DANGER Do not install the Knight XL into a 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 vent
116. o not force to CLOSE Turn off all electric power to the appliance if service is to be performed Remove top cover 5 Install top cover LBL2284 REV 58 1 0 Start up continued Check flame and combustion continued 4 Place the boiler into the active position by pressing the RIGHT SELECT ON key FIG 11 1 page 67 5 Locate the pinhole button below the RESET button 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 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 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 Turn the
117. 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 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 Figure 5 2 Vertical Terminations with Multiple Boilers 12 305 MM MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET 12 805 MM MINIMUM FROM EDGE VENT JY OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER Figure 5 3 Alternate Vertical Terminations with Multiple Boilers 12 305 MM MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET 31 e COMMERCIAL BOILER 5 Vertical direct venting Vertical termination optional concentric vent Description and usage Installation amp Operation Manual Models 400 601 Only Lochinvar offers an optional concentric combustion air and 2 Cutone 1 hole 7 inch 178 mm diameter for CVK3007 vent pipe termination kit Both combustion air and vent installations into the structure to install the termination pipes must attach to the termination kit The termination kit kit must terminate outside the structure and must be installed as shown Hic SA 3 Partially assemble the concentric vent termination kit Clean and cement following the cleaning procedures in Field supp
118. oint on the control panel of installation or service procedures the SMART SYSTEM control module to call for heat DO NOT adjust gas valve outlet pressure 7 Observe the gas supply pressure as the burner fires at A WARNING l l Attempting to alter the gas valve outlet 100 of rated input Percent of burner input will be pressure could result in damage to the valve displayed on the control panel causing potential severe personal injury 8 Ensure inlet pressure is within specified range death or substantial property damage Minimum and maximum gas supply pressures are specified in this section of the manual The gas piping must be sized for the proper flow and length of 9 If gas supply pressure is within normal range and no pipe to avoid excessive pressure drop Both the gas meter and adjustments are needed proceed on to Step 11 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 If you experience a pressure drop greater than 1 inch w c pas supplier qualified installer or service agency to 249 Pa the meter regulator or gas line is undersized or in determine the necessary steps to provide proper gas need of service Perform the steps below when checking inlet pressure to the control gas supply 11 Turn the power switch to the OFF position 1 Turn the main power switch to the OFF position 12 Shut off the gas supply at the manual gas v
119. ollowing 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 Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING ere l noted otherwise in this Instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 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 Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 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
120. pe Size Chart Nominal Natural Gas Pipe Capacity Chart Maximum Iron Pipe ee Capacity of Pipe Size Length of Pipe in Straight Feet B inches Btu hr per hour 125 150 200 for gas pressures N A N A t 3 4 369 256 205 174 15 sia rara 1 697 477 384 328 29 6 and a Pressure drop of0 5 Inch 92 aad Mater Conn 2 ato 2820 2260 1950 172 7 EAS as Be 272 1540 hr per Cubic Foot a rac zoo seo saoo a 720 of Gas and 060 4 essoo teroo taroo tttoo oooo 900 e150 5640 aia Check inlet gas supply CSA or UL listed flexible gas connections 4 Slowly turn on the gas supply at the field installed are acceptable but you must exercise manual gas valve caution to ensure that the line has adequate capacity to allow your boiler to fire at full B a O O O gt Z 215 gt lt gt lt gt lt gt N N O1 N O N NI AIN OO N GD O N N OIO OIO N oo N A mS 00 GD Oo k on O _ AIG c Oo m w I O k N On Oo k o O O on oo 9 XO N N k Q G o o Q sl ello ojaj gt oo IN 246 NO O N NO NJ aN h O oo Oo oe oO O g O O O B o 5 Turn the power switch to the ON position rate Consult with local codes for proper 6 Adjust the temperature set p
121. perative Shut down the boiler until a new relief valve has been installed 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 12 Maintenance continued Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover 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 Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring l Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring l Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings l 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
122. performance indicate need e Clean heat exchanger e Remove and clean burner compressed air only using e Clean the blower wheel Installation amp Operation Manual Owner maintenance see the Knight XL User s Information Manual for Monthly Periodically Every 6 months End of season months instructions e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system e Check air vents e Test low water cutoff if used e Reset button low water cutoff e Check boiler piping water for leaks gas and e Operate relief valve e Shut boiler down unless boiler used for domestic hot water 1 2 Maintenance continued Installation amp Operation Manual EH COMMERCIAL BOILER Follow the Service and maintenance procedures given throughout this manual and in component literature A WARNING i i i l l 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 A 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 f
123. pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or 1 Check for loose connections blown fuse or service switch substantial property damage off 2 Is boiler water temperature above 200 F 93 C A WARNING Knight XL boilers are typically shipped ready to fire on natural gas Check boiler 3 Is thermostat set below room temperature rating plate to determine which fuel the boiler is set for If set to natural gas it may 4 Is gas turned on at meter or boiler be converted to LP by installing an orifice or by making a gas valve adjustment see 5 Is incoming gas pressure less than 4 inches w c 99 kPa pages 13 and 14 In order to operate on If none of the above corrects the problem refer to the Troubleshooting Section of the Knight XL Service Manual Check system and boiler Q Check water piping 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 Check flame and combustion 1 Check system piping for leaks If found shut down 1 Turn the main power off to the boiler by placing the the boiler and repair immediately See WARNINGS On Off switch in the OFF position w 55 and 56 startup regarding failure to repair 2 Remove th
124. proved 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 8 be required and tubing size may need to increase to 1 inch 25 mm The condensate line must remain unbstructed 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 condensate removal pump is required if the boiler is below the 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 in series with the blocked drain switch inside the boiler see FIG 10 1 on page 56 1 2 PVC UNION FACTORY SUPPLIED NEUTRALIZER KIT KIT3087 shown for illustration purposes 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 Consul
125. r stand alone boilers 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 There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating The control will switch back and forth until one of the heat demands end This function does not apply to cascade systems 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 For stand alone boilers 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 in the system supply in order to provide the best control of the inlet temperature Anti cycling After the burner turns off the control will delay the next burner cycle 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 Boiler and system pump control The boiler pump will run whenever the burner is firing unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank The boiler pump will run during Freeze Protection Mode as well It will continue
126. r up or down Turning the NAVIGATION dial will increase or decrease the current g SHDN Press the RIGHT SELECT key to turn the boiler OFF Press the RIGHT SELECT key to turn the boiler ON F RIGHT SELECT NO Press the RIGHT SELECT key to cancel the shutdown operation key function SAVE Press the RIGHT SELECT key to save the current change Press the RIGHT SELECT key to return to the Status Screen and HOME upload parameter changes 71 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician see the following pages for instructions O u oc lt F 0 lt lt lt lt 72 General e Address reported problems e Inspect interior clean and vacuum if necessary e Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check control settings eCheck ignition and flame sense electrodes sand off any deposits clean and reposition e Check wiring and connections e Perform start up checkout and performance verification per Section 10 e Flame inspection stable uniform e Flame signal at least 10 microamps at high fire e Clean the heat exchanger if flue temperature is more than 54 F 30 C above return water temperature If combustion or
127. re all are airtight and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death This appliance requires a special venting system Use only approved stainless steel PVC CPVC or polypropylene pipe and fittings listed in Tables 3D 3E and 3G for vent pipe and fittings Failure to comply could result in severe personal injury death or substantial property damage DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Mixing of venting materials will void the warranty and certification of the appliance Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S Installations or CSA B149 1 for Canadian Installations For closet and alcove installations CP VC polypropylene or stainless steel material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death Improper installation of venting systems may result in injury or death Follow the instructions in Section 1 page 12 of this manual when removing a boiler from an existing vent system Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substanti
128. rt and with the vent termination at least 1 foot above the air intake 6 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 7 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe A WARNING 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 30 BIRD SCREEN FIELD SUPPLIED VENT OUTLET Wiee Installation amp Operation Manual Figure 5 1A PVC CPVC Polypropylene Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE TYPICAL COUPLING 6 152 MM MINIMUM ABOVE ROOF SNOW LINE 12 MINIMUM ABOVE AIR INLET N AIR N d 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 BIRD SCREEN TYPICAL 6 152 MM MINIMUM ABOVE ROOF SNOW LINE lt COM BUSTION AIR _ g VENT OUTLET 36 914 MM MINIMUM ABOVE AIR INLET 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 Kas Installation amp
129. s Verify when installing that the orifice size marking matches boiler size Model 400 8 0 LP orifice stamping Models 501 801 do not require an orifice installation for propane operation but they will require a valve adjustment Installation amp Operation Manual e ISe COMMERCIAL BOILER Model 400 1 Remove the top and front access covers from the unit no tools required for removal 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 3 Remove the four star drive screws securing the gas valve to the venturi FIG 2 2 4 Locate the propane orifice disk from the conversion kit bag Verify that the stamping on the orifice disk matches the boiler size Model 400 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 6 Reposition the gas valve against the venturi and replace the star drive screws FIG 2 2 securing the valve to the venturi 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 b
130. s must be made with a vent pipe system certified to ULC S636 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 certified vent material to comply with this requirement 4 The 4 Concentric Vent Kit available from Lochinvar see Section 4 Sidewall Termination Optional Concentric Vent and the 4 Concentric Vent Kit available from IPEX are both approved for use on the Knight XL 400 601 models only boiler Both kits are listed to the ULC S636 standard for use in Canada Sizing The Knight XL uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below Table 3A Air Intake Vent Piping Sizes modei _Armae vem 400 601 4 inches 102 mm 4 inches 102 mm 701 801 4 inches 102 mm 6 inches 152 mm NOTICE Increasing or decreasing combustion air or vent piping sizes is not authorized installation in Installation amp Operation Manual t ii COMMERCIAL BOILER Minimum Maximum allowable combustion air and vent piping lengths are as follows Combustion Air 12 equivalent feet 3 7 m minimum 100 equivalent feet 30 5 m maximum Vent 12 equivalent feet 3 7 m mini
131. sing 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 When utilizing the single pipe method 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 Table 3C Optional Room Air Kit Modei Description Kit Number Filter Box Assembly KIT30022 400 801 90 Elbow with Screen KIT30053 Installation amp Operation Manual C COMMERCIAL BOILER 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 comb
132. stion products to be recirculated Failure to follow this warning could result in personal injury or death 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 Figure 4 10 Rain Cap to Vent Pipe Alternate Assembly STAINLESS STEEL SCREW FIELD SUPPLIED DRILL CLEARANCE HOLE IN RAIN CAP amp PILOT HOLE IN VENT PIPE 28 5 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 6 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 7 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 dlieis dimensions are as shown in FIG 4 7 NOTICE If assembly needs to be extended to allow sidewall thickness requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied
133. t has been approved for use with polypropylene vent with the manufacturers listed in Table 3E Allterminations must comply with listed options in this manual and be a single wall vent offering For use of flex pipe it is recommended to have the vent material in 32 F or higher ambient space before bending at installation No bends should be made to greater than 45 and ONLY installed in vertical or near vertical installations For support and special connections required see the manufacturer s instructions All vent is to conform to standard A WARNING Installation amp Operation Manual Use only the adapters and vent system listed in Tables 3E and 3F DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage Installations must comply with applicable national state and local codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system NOTICE Installation of a polypropylene vent on should adhere to the vent manufacturer s installation instructions supplied with the Table 3E Polypropylene Vent Pipe and Fittings vent system Approved Polypropylene Vent Manufacturers diameter and equivalent length requirements established Centrotherm Eco Systems InnoFlue SW Flex Duravent M amp G Group PolyPro Single Wall PolyPro Flex NOTICE The installer must use a specific vent starter a
134. t 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 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 Test replace freeze protection fluid 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 4 The freeze protection set points may be lowered when freeze protection fluid is used see the Knight XL Service Manual Fill and test water system 1 Fill system only after ensuring the water
135. ted in Tables 3G and 31I DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage NOTICE The installer must use a specific vent starter adapter at the flue collar connection supplied by the vent manufacturer to adapt to its vent system See Table 3I for approved vent adapters Discard CPVC starter piece Installations must comply with applicable NOTICE national state and local codes Stainless 4 S S ADAPTER steel vent systems must be listed as a Figure 3 6 Near Boiler Stainless Steel Venting Models UL 1738 approved system for the United 701 801 States and a ULC S636 approved system for Canada Installation of a stainless steel vent system NOTICE i y should adhere to the stainless steel vent manufacturer s installation instructions supplied with the vent system Table 3G Stainless Steel Vent Pipe and Fittings Approved Stainless Steel Vent Manufacturers FasNSeal Vent FasNSeal Flex Vent Z Flex Nova Flex Group Z Vent Heat Fab Selkirk Corporation Saf T Vent Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only taking precaution to ensure no sagging occurs of the vent system Connect to the FasNSeal rigid vent using specially designed adapters and sealing method see manufacturer s instructions Table 3H Stainless Steel Sidewall Vent Termination Kit s Dura
136. temperature read by the flue sensor FLAME CURRENT The current measured by the flame sense circuit B ms Information SYS PUMP INPUT The speed signal received from a variable speed system pump control RATE OUTPUT A 0 10V signal indicating the firing rate of the boiler 70 teed Installation amp Operation Manual 11 Operating information continued Status Display Screens cont d Section Display _ Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen EXIT Press the LEFT SELECT key to exit the current screen or setting D YES Press the LEFT SELECT key to confirm that the boiler needs to shutdown Lab ELSE P he LEFT SELECT k h hat all ress the ey to enter the screen that allows you to key function ne adjust the limit settings HOME Press the LEFT SELECT key to return to the Status Screen and upload parameter changes SKIP Press the LEFT SELECT key when in the Night Setback Screen to access the Night Setback Skip Screen Turning the NAVIGATION dial will select the next or previous Status 4I SCREEN Son Pressing the NAVIGATION dial will show the next fault NSB Night HEST Setback trigger or ramp delay setting E SELECT Pressing the NAVIGATION dial will select the setting indicated by the cursor NAVIGATION Dial Function 5ETPOINTS Pressing the NAVIGATION dial will display the Set Points Screen aa SC ROLL Turning the NAVIGATION dial will move the curso
137. the boiler to allow drainage of condensate Insulation should not be used on PVC or CPVC venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure 19 Kee Installation amp Operation Manual 3 General venting Table 3D PVC CPVC Vent Pipe and Fittings 5 Dryfitventor air pipingto ensure proper fit up before s aE assembling any joint The pipe should go a third to Approved PVC CPVC Vent Pipe and Fittings oan ae two thirdsintothe fittingto ensurepropersealing after Standard cement is applied ANSI ASTM D1785 6 Priming and Cementing ANSI ASTM D2665 a Handle fittings and pipes carefully to prevent ANSI ASTM F441 contamination of surfaces ANSVASTM D2466 b Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1 2 ANSI ASTM D2467 beyond the socket depth ANSI ASTM F439 c Apply a second primer coat to the fitting ANSI ASTM D2564 socket ANSI ASTM F493 d While primer is still wet apply an even coat of PVC Schedule 40 80 Vent pipe PVC DWV CPVC Schedule 40 80 PVC Schedule 40 PVC Schedule 80 CPVC Schedule 80 Pipe Cement PVC Primer CPVC Vent fittings NOTICE DO NOT USE CELLULAR FOAM CORE PIPE I i p eau to ta SPL the fitting socket along with an even coat of NOTE In Canada CPVC and PVC vent pipe fittings and cement approved cement to the fitting socket primer must be ULC S636 certified
138. the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air 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 a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P ora high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 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 18 aed Installation amp Operation Manual 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
139. to the space A WARNING The T rae be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the Knight XL 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 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 Flooring and foundation Flooring The Knight XL is approved for installation on combustible flooring but must never be installed on carpeting A WARNING Do not install the boiler on carpeting even 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 10 Installation amp Operation Manual mase COMMERCIAL BOILER Residential garage installation Precautions 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 2223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages and in adjacent spaces that open to t
140. ture drops below 45 F 7 C Below 45 F 7 C the boiler and system pumps operate constantly e Below 37 F 3 C the boiler turns on Boiler and pumps turn off if boiler water temperature rises above 45 F 7 C Lower temperatures may be programmed for systems with anti freeze solutions When System return temperatures are maintained below the dew point condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust A CAUTION This feature of the SMART SYSTEM 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 Installation amp Operation Manual 11 Operating information continued Monitor external limits Connections are provided on the connection board for external limits such as flow switch low water cutoff gas pressure switches and a louver 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 in the Space Heating Mode The other timer monitors th
141. ustion air inlet have your installer pipe the boiler combustion air and vent to another location per this manual A WARNING If the boiler combustion air inlet is located in a laundry room or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal A WARNING injury or death check for areas and products listed in Table 1A page 11 before installing the boiler or air inlet piping If contaminants are found you MUST e Remove contaminants permanently OR e Relocate air inlet and vent terminations to other areas PVC CPVC This product has been approved for use with the PVC CPVC vent materials listed in Table 3D on page 20 Installing vent and air piping A WARNINGI 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 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 Table 3D to make the vent connections Failure to follow this warning could result in fire personal injury or death Use only cleaners primers and solvents that are approved for the materials which are joined together All PVC vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to
142. y which should read a minimum pressure of 12 psi 83 kPa 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 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 8 Install an air elimination device on the system supply 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 A WARNING The relief valve tee and any other necessary 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 See the piping illustrations included in this section FIG s 6 7 and 6 11 for sug
143. y sealed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death 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 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 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 74 Wiee Installation amp

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