Lochinvar KBN701, KBN601, KBN801, KBN400, KBN501 User Manual

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Page 1

KBXII-I-O Rev G

Installation & Operation Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

This manual must only be used by a qualiﬁ ed 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.

Page 2

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE KNIGHT XL -- HOW IT WORKS ............................ 4-6

RATINGS ........................................................................... 7

1. DETERMINE BOILER LOCATION

Provide Air Openings to Room ........................................ 10

Flooring and Foundation ................................................. 10

Residential Garage Installation ........................................ 10

Vent and Air Piping .......................................................... 10

Prevent Combustion Air Contamination ........................... 10

Corrosive Contaminants and Sources ............................. 11

Using an Existing Vent System to Install a New Boiler ... 11

Removing a Boiler from Existing Common Vent .............. 12

2. PREPARE BOILER

Remove Boiler from Wood Pallet ..................................... 13

Gas Conversions .............................................................. 13

Model 400 ................................................................... 13

Model 501 ................................................................... 14

Models 601 - 801 ........................................................ 14

Leveling the Boiler ............................................................ 14

3. GENERAL VENTING

Direct Venting Options ..................................................... 15

Install Vent and Combustion Air Piping ........................... 16

Requirements for Installation in Canada .......................... 17

Sizing ............................................................................... 17

Min./Max. Combustion Air & Vent Piping Lengths ............17

Materials ............................................................................18

Optional Room Air ............................................................ 19

PVC/CPVC .................................................................. 19-20

Polypropylene ................................................................... 21

Stainless Steel Vent ......................................................... 22

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 23-26

Determine Location ................................................ 23-25

Prepare Wall Penetrations ..................................... 25-26

Multiple Vent/Air Terminations ......................................... 26

Sidewall Termination - Optional Concentric Vent ....... 27-29

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical .................................... 30-31

Determine Location ..................................................... 30

Prepare Roof Penetrations ......................................... 31

Multiple Vent/Air Terminations ......................................... 31

Vertical Termination - Optional Concentric Vent ......... 32-33

Alternate Vertical Concentric Venting ......................... 34-35

6. HYDRONIC PIPING

System Water Piping Methods ......................................... 36

Low Water Cutoff Device ................................................. 36

Chilled Water System ....................................................... 36

Freeze Protection ............................................................. 36

General Piping Information .............................................. 36

Flow Switch and Relief Valve Installation ....................... 37

Flow Switch Adjustment.............................................. 38

Near Boiler Piping Components .................................. 38-39

Circulator Sizing ............................................................... 39

Near Boiler Piping Connections ....................................... 39

7. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 46

Natural Gas ...................................................................... 47

Pipe Sizing for Natural Gas ........................................ 47

Natural Gas Supply Pressure Requirements ............. 47

Propane Gas .................................................................... 47

Pipe Sizing for Propane Gas ...................................... 47

Propane Supply Pressure Requirements ................... 47

Check Inlet Gas Supply ................................................... 48

Gas Pressure ................................................................... 49

Gas Valve Replacement .................................................. 49

8. FIELD WIRING

Line Voltage Connections ................................................ 50

Low Voltage Connections ................................................ 50

Wiring of the Cascade ...................................................... 52

9. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 54

10. STARTUP ............................................................. 55-60

11. OPERATING INFORMATION

General ............................................................................. 61

Cascade ........................................................................... 64

Sequence of Operation ............................................... 65-66

Knight XL Control Module ........................................... 67-68

Status Display Screens ............................................... 69-71

12. MAINTENANCE

Maintenance and Annual Startup ................................ 72-76

13. DIAGRAMS

Wiring Diagram ........................................................... 77

Ladder Diagram ......................................................... 78

Revision Notes .................................................. Back Cover

Hazard deﬁ nitions

The following deﬁ ned 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.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Page 3

Please read before proceeding

 WARNING

Installer – Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given.

When servicing boiler –

Installation & Operation Manual

• To avoid electric shock, disconnect electrical supply before performing maintenance.

NOTICE

 WARNING

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 qualiﬁ ed 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 shipment must be ﬁ led 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 ﬁ re 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 ﬂ ammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

• Installation and service must be performed by a qualiﬁ ed installer, service agency, or the gas supplier.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation –

• Do not block ﬂ ow of combustion or ventilation air to the boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under water. The possible damage to a ﬂ ooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water –

• Thoroughly ﬂ ush the system (without boiler connected) to remove sediment. The high-efﬁ ciency heat exchanger can be damaged by build-up or corrosion due to sediment.

• 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.

 CAUTION

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

Freeze protection ﬂ uids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are speciﬁ cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

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Installation & Operation Manual

The Knight XL - How it works...

1. Stainless steel heat exchanger

Allows system water to ﬂ ow through specially designed coils for maximum heat transfer, while providing protection against ﬂ ue gas corrosion. The coils are encased in a jacket that contains the combustion process.

2. Combustion chamber access cover

Allows access to the combustion side of the heat exchanger coils.

3. Blower

The blower pulls in air and gas through the venturi (item 5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

4. Gas valve

The gas valve senses the negative pressure created by the blower, allowing gas to ﬂ ow only if the gas valve is powered and combustion air is ﬂ owing.

5. Venturi

The venturi controls air and gas ﬂ ow into the burner.

6. Flue gas sensor (limit rated)

This sensor monitors the ﬂ ue gas exit temperature. The control module will modulate and shut down the boiler if the ﬂ ue gas temperature gets too hot. This protects the ﬂ ue pipe from overheating.

7. 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 ﬁ ring rate so the outlet temperature is correct.

8. Boiler inlet temperature sensor

This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler ﬁ ring rate so the inlet temperature is correct.

9. Temperature and pressure gauge (ﬁ eld installed, not shown)

Monitors the outlet temperature of the boiler as well as the system water pressure.

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial and a multiple line liquid crystal display.

11. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the boiler.

12. Burner (not shown)

Made with metal ﬁ ber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of ﬁ ring rates.

13. Water outlet (system supply)

A 1-1/2" or 2" NPT (depending on the model) water connection that supplies hot water to the system.

14. 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.

15. 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.

16. 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.

17. Manual air vent

Designed to remove trapped air from the heat exchanger coils.

18. Air intake adapter

Allows for the connection of the PVC air intake pipe to the boiler.

19. High voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

20. Boiler drain port

Location from which the heat exchanger can be drained.

21. Low voltage connection board

The connection board is used to connect external low voltage devices.

22. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

23. Condensate drain connection

Connects the condensate drain line to a 1/2" PVC union.

24. Access cover - front

Provides access to the gas train and the heat exchanger.

25. Ignition electrode

Provides direct spark for igniting the burner.

26. Flame inspection window

The quartz glass window provides a view of the burner surface and ﬂ ame.

27. Gas shutoff valve (Models 501 - 801 only)

Manual valve used to isolate the gas valve from the gas supply.

28. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 PSI.

29. Flame sensor

Used by the control module to detect the presence of burner ﬂ ame.

30. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

31. Top panel

Removable panel to gain access to the internal components.

32. Power switch

Turns 120 VAC ON/OFF to the boiler.

33. Leveling legs

Used to allow the heat exchanger to be leveled. This is needed for the proper draining of the condensate from the combustion chamber.

34. Air shroud (Model 501 only)

The air shroud controls air and gas ﬂ ow into the burner.

35. Air pressure switch

The air pressure switch detects blocked ﬂ ue/inlet conditions. break the control circuit, shutting the boiler down.

36. Pump relay board

The pump relay board is used to connect the boiler, system and DHW pumps.

37. Transformer

The transformer provides 24V power to the integrated control.

38. 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.

39. 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 ﬂ ue 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.

Page 5

Installation & 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

4 5

Right Side (inside unit) - Model 400

Page 6

The Knight XL - How it works...

Model 501

Installation & Operation Manual

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

Page 7

Ratings

Installation & Operation Manual

Knight XL Boiler

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

KBN400 80 399 373 324

KBN501 100 500 467 406

KBN601 120 600 567 493

KBN701 140 700 660 574

KBN801 160 800 752 654

NOTICE

Min Max

Maximum allowed working pressure is located on the rating plate.

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net AHRI ratings are based on net installed radiation of sufﬁ cient 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.

Input MBH

(Note 4)

Gross

Output

MBH

(Note 1)

Other Speciﬁ cations

Net

AHRI

Ratings

Water,

MBH

(Note 2)

7. Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Knight XL is listed to UL353.

Boiler

Water Content Gallons

3.4 1-1/2" 1" 4" 4"

4.2 1-1/2" 1" 4" 4"

4.2 2" 1" 4" 4"

5.0 2" 1" 4" 6"

5.7 2" 1" 4" 6"

Water

Connections

Gas

Connections

Air

Size

Vent Size

(Note 3)

3. Knight XL boilers require special gas venting. Use only the vent materials and methods speciﬁ ed in the Knight XL Installation and Operation Manual.

4. Standard Knight XL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

5. High altitude Knight XL boilers are equipped to operate from 3,000 to 12,000 feet only with no ﬁ eld 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 afﬁ xed to the unit.

6. Ratings have been conﬁ rmed by the Hydronics Section of AHRI.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3000 FT. TO 12,000 FT.

Figure A High Altitude Label Location

Page 8

1 Determine boiler location

Installation & Operation Manual

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 speciﬁ ed 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

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air ﬂ ow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other ﬂ ammable liquids.

 WARNING

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.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other ﬂ ammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance is certiﬁ ed 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.

Do not install the appliance where the relative 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 ﬁ eld provided PVC vent ﬁ ttings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement speciﬁ ed in this manual to make the vent connections. Failure to follow this warning could result in ﬁ re, personal injury, or death.

Closet and alcove installations

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.

 WARNING

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 ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in ﬁ re, 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

1. See FIG.’s 1-1 and 1-2 on page 9 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

Page 9

Installation & Operation Manual

1 Determine boiler location (continued)

Figure 1-1 Closet Installation - Minimum Required Clearances

1/4" (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPE

12" (305 MM) LEFT

14" (356 MM) REAR

RECOMMENDED SERVICE CLEARANCES:

FRONT - 30” (762 mm) TOP - 24” (610 mm) LEFT SIDE - 24” (610 mm) REAR - 24” (610 mm)

CLOSET INSTALLATION

6" (152 MM) FRONT

 WARNING

For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated

13" TOP

temperatures. Failure to follow this warning could result in ﬁ re, personal injury, or death.

VENTILATING AIR OPENING

CLOSED DOOR

VENTILATING AIR OPENING

0" RIGHT

AREA OF

1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES.

EACH OPENING:

Figure 1-2 Alcove Installation - Minimum Required Clearances

1/4" (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

ALCOVE INSTALLATION

 WARNING

For alcove installations, CPVC, polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow

13" (330)

12" (305 MM) LEFT

14" (356 MM) REAR

RECOMMENDED SERVICE CLEARANCES:

FRONT - 30” (762 mm) TOP - 24” (610 mm) LEFT SIDE - 24” (610 mm) REAR - 24” (610 mm)

18" (457 MM) FRONT

TOP

this warning could result in ﬁ re, personal injury, or death.

OPEN FRONT

RIGHT

Page 10

1 Determine boiler location

Installation & Operation Manual

Provide air openings to room:

Knight XL alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the Knight XL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Knight XL in same space with other gas or oil-ﬁ red 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 into the space.

 WARNING

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).

The space must 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.

Flooring and foundation

Flooring

The Knight XL is approved for installation on combustible ﬂ ooring, but must never be installed on carpeting.

 WARNING

If ﬂ ooding is possible, elevate the boiler sufﬁ ciently to prevent water from reaching the boiler.

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

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 Z223.1 and/or CAN/CGA-B149 Installation Code.

• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the ﬂ oor.

• 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 speciﬁ ed. 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 contaminated combustion air.

 WARNING

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.

Page 11

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/ﬂ uorocarbons

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

Auto body shops

Plastic manufacturing plants

Furniture reﬁ nishing areas and establishments

New building construction

When using an existing vent system to install a new boiler:

 WARNING

Check the following venting components before installing:

• 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 ﬂ ue 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 ﬂ ue 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 ﬁ t the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3H for the manufacturer of the installed vent.

• 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.

Failure to follow all instructions can result in ﬂ ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Remodeling areas

Garages with workshops

With polypropylene and stainless steel vent, seal and connect all pipe and components as speciﬁ ed by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on pages 19 and 20.

 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 ﬂ ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Page 12

1 Determine boiler location

When removing a boiler from existing common vent system:

Installation & Operation Manual

 DANGER

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deﬁ ciencies, 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 ﬁ replace dampers.

Do not install the Knight XL into a common vent with any other appliance. This will cause ﬂ ue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

g. Any improper operation of the common venting

system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

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 ﬂ ame 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, ﬁ replace dampers, and any other gas-burning appliance to their previous conditions of use.

Page 13

2 Prepare boiler

Installation & Operation Manual

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

Figure 2-1 Boiler Mounted on Shipping Pallet

Do not drop the boiler or bump the jacket on the ﬂ oor or pallet. Damage to the boiler can result.

. 2

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 oriﬁ ce disk from the conversion kit bag. Verify that the stamping on the oriﬁ ce disk matches the boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

5. Remove the existing oriﬁ ce from the O-ring in the side of the gas valve and replace it with the oriﬁ ce from the kit. Position and secure the oriﬁ ce 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 bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

9. Replace the top and front access covers.

Gas conversions

 WARNING

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 oriﬁ ce to operate the Knight XL on propane gas. Verify when installing that the oriﬁ ce size marking matches boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

Models 501 - 801 do not require an oriﬁ ce installation for propane operation, but they will require a valve adjustment.

 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.

 DANGER

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.

Figure 2-2 Installing Propane Oriﬁ ce - Model 400

BLOWER

SCREWS QTY. 4

O-RING

BRASS ORIFICE

VENTURI

SCREWS QTY. 3

GAS VALVE

Page 14

2 Prepare boiler

Installation & Operation Manual

Model 501

1. Remove the top access cover from the unit (no tools required for removal).

2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-3).

3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3).

4. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

5. Replace the top access cover.

 WARNING

Figure 2-3 Gas Valve Adjustment - Model 501

 WARNING

Figure 2-4 Gas Valve Adjustment - Models 601 - 801

COVER

LLEN WRENCH

ADJUSTMENT SCREW

ALLEN WRENCH

Leveling the boiler

1. Set the boiler in place and check level.

a) Adjust legs if necessary to level boiler, see FIG. 2-5 below.

Figure 2-5 Leveling Legs on the Boiler

ADJUSTMENT SCREW

SCREWDRIVER SLOT

Models 601 - 801

1. Remove the top access cover from the unit (no tools required for removal).

2. Remove the cover on top of the gas valve (FIG. 2-4).

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 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).

4. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-4).

5. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

6. Replace the gas valve cover along with the top access cover.

LOWER

RAISE

Page 15

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

Two Pipe Sidewall

See page 23 for more details

Direct venting options - Vertical Vent

PVC/CPVC Concentric Sidewall

Models 400 - 601 Only

See page 27 for more details

Two Pipe Vertical

See page 30 for more details

PVC/CPVC

Concentric Vertical

Models 400 - 601 Only

See page 32 for more details

Vertical Vent, Sidewall Air

See page 19 for more details

Page 16

3 General venting

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

 WARNING

NOTICE

 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 ﬁ nished vent and air piping thoroughly to ensure 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 ﬁ ttings listed in Tables 3D, 3E, and 3G for vent pipe, and ﬁ ttings. 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 ﬂ ue products into the

living space. Mixing of venting materials will void the warranty and certiﬁ cation 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, CPVC, polypropylene or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in ﬁ re, personal injury, or death.

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 ﬁ tting is provided on the unit for ﬁ nal 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 ﬁ tting is provided on the unit for ﬁ nal 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

AIR

 CAUTION

NOTICE

 WARNING

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 substantial property damage.

Page 17

3 General venting (continued)

Installation & Operation Manual

Requirements for installation in Canada

1. Installations must be made with a vent pipe system

certiﬁ ed to ULC-S636.

2. The ﬁ rst three (3) feet of plastic vent pipe from the

appliance ﬂ ue outlet must be readily accessible for visual inspection.

3. The components of the certiﬁ ed vent system must not be

interchanged with other vent systems or unlisted pipe/ﬁ ttings. For concentric vent installations, the inner vent tube must be replaced with ﬁ eld supplied certiﬁ ed 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 speciﬁ c combustion air intake and vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

Model Air Intake Vent

400 - 601 4 inches (102 mm) 4 inches (102 mm)

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) minimum / 100 equivalent feet (30.5 m) maximum

When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

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.

NOTICE

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Model Kit Number

400 CVK3007 5 Feet (1.5 m) 501 CVK3007 30 Feet (9 m) 601 CVK3007 30 Feet (9 m)

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

Equivalent

Vent Length

701 - 801 4 inches (102 mm) 6 inches (152 mm)

NOTICE

Increasing or decreasing combustion air or vent piping sizes is not authorized.

Page 18

3 General venting

Installation & Operation Manual

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 speciﬁ ed in this section. Type “B” double-wall vent with joints and seams sealed as speciﬁ ed in this section. AL29-4C, stainless steel material to be sealed to speciﬁ cation 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.

 WARNING

NOTICE

Using air intake materials other than those speciﬁ ed can result in personal injury, death or property damage.

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

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 ﬂ ex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

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.

 DANGER

Failure to properly seal all joints and seams as required in the air inlet piping may result in ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide emissions causing severe personal injury or death.

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 or a 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.

Page 19

3 General venting (continued)

Installation & Operation Manual

Optional room air

NOTICE

Commercial applications utilizing the Knight XL boiler may be installed with a single pipe carrying the ﬂ ue 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.

• Using the room air kit makes the unit vulnerable to

combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.

• Vent system and terminations must comply with the

standard venting instructions set forth in this manual.

 WARNING

Table 3C Optional Room Air Kit

Model Description Kit Number

400 - 801

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

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.

Filter Box Assembly KIT30022

90° Elbow with Screen KIT30053

Air contamination

Pool and laundry products and common household and hobby products often contain ﬂ uorine 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 ﬂ ue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1A, page 11, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

 WARNING

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

 WARNING

NOTICE

 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 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:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations

to other areas.

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 ﬁ eld provided vent ﬁ ttings 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 speciﬁ ed in Table 3D to make the vent connections. Failure to follow this warning could result in ﬁ re, 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 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.

Page 20

3 General venting

Installation & Operation Manual

Table 3D PVC/CPVC Vent Pipe, and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe

Vent ﬁ ttings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

NOTE: In Canada, CPVC and PVC vent pipe, ﬁ ttings and cement/ primer must be ULC-S636 certiﬁ ed.

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.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and ﬁ ttings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

PVC - DWV ANSI/ASTM D2665 CPVC Schedule 40, 80 ANSI/ASTM F441 PVC Schedule 40 ANSI/ASTM D2466 PVC Schedule 80 ANSI/ASTM D2467 CPVC Schedule 80 ANSI/ASTM F439 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493

5. Dry ﬁ t vent or air piping to ensure proper ﬁ t up before assembling any joint. The pipe should go a third to two-thirds into the ﬁ tting to ensure proper sealing after cement is applied.

6. Priming and Cementing: a. Handle ﬁ ttings and pipes carefully to prevent contamination of surfaces.

b. Apply a liberal even coat of primer to the ﬁ tting socket and to the pipe end to approximately 1/2" beyond the socket depth.

c. Apply a second primer coat to the ﬁ tting socket.

d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the ﬁ tting socket along with an even coat of approved cement to the ﬁ tting socket.

e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into

the ﬁ tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufﬁ cient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Figure 3-2 Near Boiler PVC/CPVC Venting - Models 400 - 601

VENT

* 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

LCOVE INSTALLATIONS.

Figure 3-3 Near Boiler PVC/CPVC Venting - Models 701 - 801

VENT

6” COUPLING

(FIELD SUPPLIED)

6” CPVC

STARTER

PIECE

(FACTORY SUPPLIED)

THE 6” STAINLESS STEEL ADAPTER SUPPLIED WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC/CPVC. THE 6” CPVC STARTER PIECE MUST BE USED FOR PVC ONLY.

Page 21

3 General venting (continued)

Polypropylene

This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E.

All terminations must comply with listed options in this manual and be a single-wall vent offering.

For use of ﬂ ex 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 diameter and equivalent length requirements established.

Table 3E Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems

Duravent (M & G Group)

PolyPro Single-Wall / PolyPro Flex

InnoFlue SW/Flex

Installation & Operation Manual

 WARNING

NOTICE

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.

Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.

NOTICE

The installer must use a speciﬁ c vent starter adapter at the ﬂ ue 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 (FIG. 3-4).

 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.

Table 3F Approved PolypropyleneTerminations

Figure 3-4 Near Boiler Polypropylene Venting

IMG00128

POLYPROPYLENE ADAPTER

JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM

Centrotherm InnoFlue SW

Model

400-601 701-801

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 26).

Polypropylene

Adapter

ISAAL0404 IANS04 IATP0404 ISTAGL0404 4PPS-AD 4PPS-LB 4PPS-HLK ISAAL0606

Joint

Connector

Not

Required

Sidewall Retaining

Bracket*

IATP0606 ISTAGL0606 FSA-6PVCM-6PPS Not Required 6PPS-HLK

Sidewall Adapter*

Polypropylene

Adapter

Duravent Polypro

Joint

Connector

Sidewall Kit*

Page 22

3 General venting

Stainless steel vent

This product has been approved for use with stainless steel using the manufacturers listed in Table 3G.

Installation & Operation Manual

Figure 3-5 Near Boiler Stainless Steel Venting Models 400 - 601

 WARNING

Use only the materials, vent systems, and terminations listed in Tables 3G and 3I. 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 speciﬁ c vent starter adapter at the ﬂ ue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3I for approved vent adapters. Discard CPVC starter piece.

NOTICE

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

NOTICE

Installation of a stainless steel vent system 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

Make Model

Dura Vent (M & G Group) Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

FasNSeal Vent / FasNSeal

Flex* Vent

VENT

4" S.S. ADAPTER

Figure 3-6 Near Boiler Stainless Steel Venting Models 701 - 801

*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)

Model Kit Number

701 - 801 KIT3137

Table 3I Approved Stainless Steel Terminations and Adapters

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Model

400-601

701-801

Boiler

Adapter

F303759 F303759

(Intake

Only)

Flue

Termination

FSBS4

FSRC4(R.C)

FSBS6

Intake Air

Termination

FSAIH04

303888

FSAIH04

303888

Boiler

Adapter

9401PVC

Flue

Termination

9492

5400CI

Intake Air

Termination

9414TERM 2SVSLA04

Boiler

Adapter

Flue

Termination

2SVSTP04

2SVSRCX04

Intake Air

Termination

2SVSTEX0490

Page 23

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

 WARNING

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 ﬂ ue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where ﬂ ue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of ﬂ ue 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.

 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 ﬁ nishes.

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.

Sidewall vent and air inlet terminations must terminate in the same pressure zone.

Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVERHANG

12"

MIN

Table 4A Sidewall Vent Kits

Model Kit Number Vent Size

400 - 601 KIT30046 4 inch vent 701 - 801 KIT30048 6 inch vent

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 ﬂ ue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.

 WARNING

Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings

Do not exceed the maximum lengths of the 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.

Page 24

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

Figure 4-2A Alternate PVC/CPVC/ Polypropylene Sidewall Termination Models 400 - 801 w/Field Supplied Fittings

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

12" (305 MM) MIN

GRADE OR SNOW LINE

Figure 4-2B Alternate Stainless Steel Sidewall Termination Models 701 - 801 w/Field Supplied Fittings

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

BIRD SCREEN

c. Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally.

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

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

TO BOILER INTAKE

NOTICE

AIR CONNECTION

FROM BOILER VENT PIPE CONNECTION

GRADE OR SNOW LINE

PVC/CPVC or ABS is acceptable air inlet pipe material.

12" (305 MM) MIN 15" (381 MM) MAX

12" (305 MM) MIN

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.

• No closer than 12 inches (305 mm) below roof overhang.

• At least 7 feet (2.1 m) above any public walkway.

• At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m).

• No closer than 12 inches (305 mm) below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches (305 mm) above grade or snow line; at least 12 inches (305 mm) below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches (610 mm) vertically outside the building.

Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings

12” (305 MM)

MIN

BIRD

SCREEN

(TYPICAL)

12” (305 MM)

MIN

12” (305 MM)

MIN

Page 25

Installation & Operation Manual

4 Sidewall direct venting (continued)

Vent/air termination – sidewall

Figure 4-4A Clearance to Forced Air Inlets

IF LESS

THAN 10’

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

36"

MIN.

FORCED AIR

INLET

Figure 4-4B Alternate Clearance to Forced Air Inlets w/Field Supplied Fittings

IF LESS

THAN 10’ (3 M)

36” (914 MM)

MIN

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 ﬂ ush 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. 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

FORCED AIR

INLET

BIRD

SCREEN

(TYPICAL)

7’ (2.1 M) MIN ABOVE ANY

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. 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:

• 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe

• 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

VENT

AIR

CENTERLINE WIDTH

VENT PLATE

VENT CAP

VENT PIPING

WALL PLATE

GALVANIZED

THIMBLE

AIR PIPING

Table 4B Sidewall Vent Centerline Dimensions

Model Air Vent Centerline Width

400 - 601 4" 4" 5 5/8" 701 - 801 4" 6" 7 3/4"

Page 26

4 Sidewall direct venting

Installation & Operation Manual

Figure 4-5B Polypropylene Sidewall Termination Assembly

SIDEWALL ADAPTER

SIDEWALL

DAPTER

(VENT)

GALVANIZED THIMBLE

(AIR)

WALL PLATE

SIDEWALL RETAINING PLATE

IMG00085

VENT PLATE

VENT CAP

Prepare wall penetrations (Alternate - Field Supplied Option)

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. 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:

• 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe

• 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-5C.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when passing

through ﬂ oors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Multiple vent/air terminations

1. When terminating multiple Knight XL’s terminate each vent/air connection as described in this manual (FIG. 4-6A).

 WARNING

2. Place wall penetrations to obtain minimum clearance of 12 inches (305 mm) between vent pipe and adjacent air inlet elbow, as shown in FIG. 4-6A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Knight XL is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 4-6A Multiple Vent Terminations (must also comply with Figure 4-1A)

VENT

Figure 4-6B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1B)

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

AIR

VENT / AIR

TERMINATION

VENT

Figure 4-5C A Typical Sidewall Termination Assembly - Models 400 - 801 PVC/CPVC/ Polypropylene or Stainless Steel

SIDEWALL

TERMINATION PLATE

VENT

PIPING

BIRD SCREEN

ELBOW

BIRD SCREEN

GALVANIZED

(WHEN REQUIRED BY LOCAL CODES)

THIMBLE

ELBOW

AIR PIPING

AIR

12” (305 MM) MIN 15” (381 MM) MAX

12” (305 MM) MIN. BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE

Page 27

Installation & Operation Manual

4 Sidewall direct venting (continued)

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

3. Cut one (1) hole (7 inch (178 mm) diameter 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 ﬁ tting 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

12" (305 MM)

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.

"FLEXIBLE" PIPE COUPLING

6" (152 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

4" (102 MM) DIA.

Page 28

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent: Models 400 - 601 Only

Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 601

"A"

"C" DIA.

"B" DIA.

NOTICE

 WARNING

(76 MM)

(152 MM)

"G"

(537 MM)

"B" DIA. PVC VENT / EXHAUST

ABC DEFGH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

(1524 MM)

(102 MM)

Instead of cementing the smaller pipe to the rain cap, a ﬁ eld-supplied stainless steel screw may be used to secure the two (2) components together when ﬁ eld 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 combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

"H" DIA.

"D"

(76 MM)

"E"

"F"

(168 MM)

(254 MM) (194 MM)

5. Install the Y concentric ﬁ tting 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 ﬁ tting 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 ﬁ eld-supplied metal strapping or equivalent support material.

 WARNING

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 ﬂ ow 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 & PILOT HOLE

IN VENT PIPE

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-7.

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, ﬁ eld-supplied standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9).

If assembly depth needs to be reduced, dimension D can be as short as possible.

Page 29

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent: Models 400 - 601 Only

Figure 4-11 Concentric Vent Sidewall Attachment

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

COMBUSTION AIR

VENT

STRAP

COMBUSTION AIR

VENT

CAUTION

DO NOT use ﬁ eld-supplied couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-11 for proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-12). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-12. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gases.

12" MINIMUM

VENT

COMBUSTION AIR

Figure 4-12 Concentric Vent and Combustion Air Termination

Page 30

5 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

 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 ﬂ ue 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) apart and with the vent termination at least 1 foot above the air intake.

6. Maintain the required dimensions of the ﬁ nished termination piping as shown in FIG. 5-1A.

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

BIRD SCREEN (TYPICAL)

COUPLING

(FIELD SUPPLIED)

VENT OUTLET 12" MINIMUM ABOVE AIR INLET

VENT

6" (152 MM) MINIMUM ABOVE ROOF / SNOW LINE

COMBUSTION AIR

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

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

VENT

COM,BUSTION AIR

8. 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.

7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

 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.

Page 31

Installation & Operation Manual

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.

Figure 5-2 Vertical Terminations with Multiple Boilers

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:

• 5½ inch hole (140 mm) hole for 4 inch (102 mm)

vent pipe

• 7½ inch hole (191 mm) hole for 6 inch (152 mm)

vent pipe

b. Insert a galvanized metal thimble in the vent pipe hole (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 ﬂ oors, ceilings, and roofs.

5. Provide ﬂ ashing 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).

 WARNING

Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of ﬂ ue products and the possibility of severe personal injury, death, or substantial property damage.

12" (305 MM) MINIMUM VERTICALLY FROM VENT

VENT

AIR

VENT

AIR

OUTLET TO ANY AIR INLET

12" (305 MM) MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILE

Figure 5-3 Alternate Vertical Terminations with Multiple Boilers

VENT

12" (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET

AIR

2. Place roof penetrations to obtain minimum clearance of 12 inches (305 mm) between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Knight XL boiler is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Page 32

Installation & Operation Manual

5 Vertical direct venting

Vertical termination – optional concentric vent: Models 400 - 601 Only

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and ﬁ ttings are required to complete the installation.

The required combustion vent pipe ﬁ ttings are listed in Table 3D, on page 20 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).

Figure 5-4 Concentric Vertical Termination

VENT

COMBUSTION AIR

12" (305 MM) (18" (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24" (610 MM) ABOVE ROOF.

2. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007 installations) into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric ﬁ tting to the larger

diameter kit pipe (see FIG. 4-8, page 27).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-8, page 27).

NOTICE

Instead of cementing the smaller pipe to the rain cap, a ﬁ eld supplied stainless steel screw may be used to secure the two (2) components together when ﬁ eld disassembly is desired for cleaning (see FIG. 4-10, page 28).

 WARNING

Figure 5-5 Do Not Install U-Bend to Rain Cap

Page 33

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent: Models 400 - 601 Only

 WARNING

4. Install the Y concentric ﬁ tting pipe assembly up through the structure’s hole and ﬁ eld supplied roof boot/ﬂ ashing.

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 ﬁ eld supplied metal strapping or equivalent support material.

Figure 5-6 Concentric Vent Roof Installation

COMBUSTION

AIR

ROOF BOOT / FLASHING (FIELD SUPPLIED)

VENT

12" (305 MM) (18" (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24” (610 MM) ABOVE ROOF.

CAUTION

DO NOT use ﬁ eld-supplied couplings to extend pipes. Airﬂ ow 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 ﬂ ue gases.

NOTICE

SUPPORT (FIELD SUPPLIED)

ELBOW (FIELD SUPPLIED)

VENT

COMBUSTION

AIR

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, ﬁ eld supplied standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9, page 28).

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination

12”

MINIMUM

COMBUSTION AIR (TYPICAL)

12” (18” FOR CANADA) MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24” ABOVE ROOF.

Page 34

5 Vertical direct venting

Alternate vertical concentric venting

Installation & Operation Manual

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 speciﬁ ed 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.

Figure 5-8 Concentric Vent Example 1

FLUE EXHAUST

SEAL

COMBUSTION AIR

IR INLET

W/ SCREEN

12"

MIN.

EXISTING

SEAL

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

SEALED CAP

FLUE OUTLET

Figure 5-9 Concentric Vent Example 2

SEAL

FLUE EXHAUST

If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and

IR INLET

W/ SCREEN

COMBUSTION AIR

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

Model

Vent / Air

Inlet Size

Minimum Existing

Vent / Chase Size

400 - 601 4" 7"

SEAL

EXISTING

SEALED CAP

FLUE OUTLET

701 - 801 6" 10"

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

Page 35

Installation & Operation Manual

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

AIR INLET

CAP

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

FLUE EXHAUST

SEAL

EXISTING

FLUE OUTLET

Page 36

6 Hydronic piping

Installation & Operation Manual

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 ﬁ gured 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, ﬂ ow 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

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 ﬂ uid 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.

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 backﬂ ow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).

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 speciﬁ c 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.

 WARNING

The relief valve, tee and any other necessary ﬁ ttings are shipped in the install kit with the boiler and are to be ﬁ eld installed (FIG.’s 6-1 and 6-2).

 WARNING

Use only inhibited propylene glycol solutions, which are speciﬁ cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

11. On any pre-existing system, it is good practice to install a ﬁ eld 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 suggested 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.

Page 37

6 Hydronic piping (continued)

Installation & Operation Manual

Flow switch, relief valve and temperature and pressure gauge installation

Basic steps are listed below to guide you through the installation of the ﬂ ow 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 ﬁ tting 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 ﬁ tting 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 ﬁ tting 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 ﬁ tting positioned vertically and on the top (FIG. 6-1).

5. Attach paddle #3 to the ﬂ ow switch per the manufacturer’s instructions.

6. Install the assembled ﬂ ow switch into the 1 inch ﬁ tting of the tee installed in Step 4 (see FIG. 6-1).

7. Install a ﬁ eld provided close nipple on the downstream side of the ﬂ ow switch (see FIG.’s 6-1 and 6-2).

8. Install a ﬁ eld provided tee with the gauge ﬁ tting 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 ﬁ tting of the tee (a bushing may be necessary) installed in Step 8 (FIG.’s 6-1 and 6-2).

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

(FIELD PROVIDED)

CLOSE NIPPLE (FIELD PROVIDED)

TEE WITH 1” FITTING ON TOP

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

NOTICE

Be sure to install the ﬂ ow switch so that the arrow on the ﬂ ow switch is pointing in the direction of the ﬂ ow (see FIG. 6-3).

TEE WITH FITTING ON TOP

(FIELD PROVIDED)

CLOSE NIPPLE (FIELD PROVIDED)

TEE WITH 1” FITTING ON TOP

TEE WITH 3/4” FITTING ON TOP

CLOSE NIPPLE

Page 38

6 Hydronic piping

Installation & Operation Manual

Flow switch adjustment

Refer to Table 6A for the proper setting of the sensitivity screw. For reference, the position of the 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 ﬂ ow switch to your system.

Table 6A Paddle Size / Sensitivity Screw Adjustment

MODEL PADDLE SIZE

Note: Paddles are included with the ﬂ ow switch.

400 #3 7½ turns 501 #3 5½ turns 601 #3 7¼ turns 701 #3 5¼ turns 801 #3 3¼ turns

NOTICE

Turn the sensitivity screw clockwise to increase the ﬂ ow rate required to activate the switch. Turn the sensitivity screw counterclockwise to decrease the ﬂ ow rate required to activate the switch.

Figure 6-3 Flow Switch Adjustment

SENSITIVITY SCREW

ADJUSTMENT

NORMALLY OPEN

SENSITIVITY ADJUSTMENT

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 6B. Reducing the pipe size can restrict the ﬂ ow 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.

2. Boiler system circulating pump:

Field supplied. The boiler circulating pump should be based on 20 feet (6 m) of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet the speciﬁ ed minimum ﬂ ow requirements listed in FIG.’s 6-5 and 6-6. Consult the indirect water heater operating guide to determine ﬂ ow characteristics for the selected product used.

4. 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 speciﬁ ed minimum ﬂ ow requirements listed in FIG.’s 6-5 and 6-6 on page 40 at full speed.

5. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

GROUND

COMMON

NORMALLY CLOSED

6. 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 ﬂ ow condition during pump(s) off cycle.

7. 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 ﬂ ow rate through the boiler.

8. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F (46°C).

9. Unions:

Field supplied. Recommended for unit serviceability.

10. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

11. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME speciﬁ cations.

Page 39

6 Hydronic piping (continued)

Installation & Operation Manual

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.

Figure 6-4B Near Boiler Piping w/Low Loss Header

SYSTEM PUMP

LOW LOSS HEADER (TYPICAL)

Y-S T RA I NE R

(RECOMMENDED)

BOILER PUMP

SYSTEM SENSOR

AIR SEPARATOR

DRAIN (TYPICAL)

AIR VENT VALVE

DRAIN VALV E

EXPANSION TANK

FAST FILL VALVE

INDIRECT DOMESTIC HOT WATER TANK

Near boiler piping connections

Figure 6-4A Near Boiler Piping w/Y-Strainer

DOMESTIC HOT

DIRT SEPARATOR

SYSTEM SENSOR

SYSTEM PUMP

Y-STRAINER (RECOMMENDED)

BOILER PUMP

TO FLOOR DRAIN

WATER PUMP

INDIRECT DOMESTIC HOT WATER TANK

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 (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 VDC input option, an optional module will be required from the vendor

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 MultiTemperature Loop Control Board Kit (RLY30086).

Page 40

0 5 10 15 20 25 30 35 40 45

KBN501

KBN400

0 102030405060708090

KBN801

KBN701

KBN601

6 Hydronic piping

Figure 6-5 Pressure Drop vs. Flow - Models 400 and 501

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Pressure Drop (Feet of Head)

Flow Rate (GPM)

Installation & Operation Manual

Figure 6-6 Pressure Drop vs. Flow - Models 601 thru 801

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Pressure Drop (Feet of Head)

Flow Rate (GPM)

Table 6B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F

Model

400 1 1/2" 37 21 30 14 26 11 21 8

501 1 1/2" 46 23 37 16 32 13 26 10

601 2" 55 31 44 22 38 18 32 13

701 2" 65 30 52 20 45 16 37 11

801 2" 74 33 60 23 51 18 42 12

MINIMUM

PIPE SIZE

TEMPERATURE RISE APPLICATIONS

20°F 25°F 30°F 35°F

GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD

Page 41

6 Hydronic piping (continued)

Figure 6-7 Single Boiler - Multiple Temperatures

Installation & Operation Manual

TEMPERATURE

LOOP 1

LOOP SENSOR (3X)

MAKE UP W ATER

AIR SEPARATOR

PRESSURE

GAUGE

BACK FLOW PREVENTER

PRESSURE

REDUCING

VALVE

TEMPERATURE

LOOP 2

BALL VALVE

(TYPICAL)

EXPANSION TANK

INDIRECT DHW

TANK

PRESSURE RELIEF VALVE

TEMPERATURE

LOOP 3

WIRES TO LOOP SENSORS

120VAC TO PUMPS

TO SYSTEM

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE (TYPICAL)

BOILER CIRCULATOR

MULTI-TEMP LOOP CONTROL (OPTIONAL)

FROM SYSTEM

SHIELDED CABLE

TO BOILER CONTROL

24V SIGNAL TO MIXING VALVES

BOILER

HOT WATER OUT

CAUTION

NOTICE

ANTI-SCALD

MIXING VALVE

COLD WATER IN

DOMESTIC

HOT WATER

CIRCULATOR

UNION (TYPICAL)

IMG00175

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 for all equipment and detailing required by local codes.

Page 42

6 Hydronic piping

Figure 6-8 Single Boiler - Primary/Secondary Piping

AIR SEPARATOR

MAY SUBSTITUTE

DRAIN POINT

(TYPICAL)

SYSTEM SUPPLY SENSOR

SYSTEM CIRCULATOR

(WHEN USED)

LOW LOSS HEADER

Installation & Operation Manual

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BALL VALVE (TYPICAL)

MAKE UP WATER

BACK FLOW PREVENTER

PRESSURE REDUCING

VALVE

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

HOT WATER OUT

DOMESTIC

HOT WATER

CIRCULATOR

COLD WATER IN

PRESSURE GAUGE

EXPANSION TANK

FLOW CHECK

VALVE (TYPICAL)

UNION (TYPICAL)

TEMPERATURE / PRESSURE

GAUGE

Y- ST R A IN E R (RECOMMENDED)

BOILER CIRCULATOR

PRESSURE RELIEF VALV E

DRAIN

BOILER

CAUTION

NOTICE

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.

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 ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Page 43

6 Hydronic piping (continued)

Figure 6-9 Multiple Boilers - Multiple Temperatures

Model

400 501

601 701

801

TEMPERATURE

LOOP 3

BALL VALVE

(TYPICAL)

TEMPERATURE

LOOP 1

LOOP SENSOR (3X)

AIR SEPARATOR

MAKE UP W ATER

BACK FLOW PREVETER

TEMPERATURE

LOOP 2

Installation & Operation Manual

Number of Units

2 3 4 5678

Manifold Pipe Sizes in Inches (mm)

2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

WIRES TO LOOP SENSORS

120VAC TO PUMPS

TO SYSTEM

FROM SYSTEM

MULTI-TEMP LOOP CONTROL (OPTIONAL)

24V SIGNAL TO MIXING VALVES

SHIELDED CABLE TO BOILER CONTROL

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE (TYPICAL)

PRESSURE

GAUGE

DRAIN POINT

(TYPICAL)

CAUTION

NOTICE

EXPANSION TANK

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

COLD WATER IN

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.

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 for all equipment and detailing required by local codes.

DOMESTIC

HOT WATER

CIRCULATOR

PRESSURE RELIEF VALVE

UNION (TYPICAL)

BOILER 1

TEMPERATURE/PRESSURE GAUGE

BOILER CIRCULATOR

BOILER 2

IMG00181

Page 44

6 Hydronic piping

Figure 6-10 Multiple Boilers - Primary/Secondary Piping

Model

2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

AIR SEPARATOR

DRAIN POINT

(TYPICAL)

SYSTEM SUPPLY SENSOR

SYSTEM CIRCULATOR

(WHEN USED)

MAKE UP WATER

MAY SUBSTITUTE

LOW LOSS HEADER

400 501

601 701 801

Installation & Operation Manual

Number of Units

2345678

Manifold Pipe Sizes in Inches (mm)

BALL VALVE (TYPICAL)

Y-STRAINER (TYPICAL) (RECOMMENDED)

BACK FLOW

PREVENTER

PRESSURE REDUCING

VALVE

PRESSURE GAUGE

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

HOT WATER OUT

DOMESTIC

HOT WATER

CIRCULATOR

COLD WATER IN

FLOW CHECK

VALVE (TYPICAL)

CAUTION

NOTICE

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.

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.

EXPANSION TANK

BOILER CIRCULATOR

(TYPICAL)

UNION (TYPICAL)

BOILER 1 (LEADER)

PRESSURE RELIEF VALVE

DRAIN TEMPERATURE / PRESSURE GAUGE

BOILER 2 (MEMBER 1)

BOILER 3 (MEMBER 2)

BOILER 4 (MEMBER 3)

NOTICE

System ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Page 45

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone

TEMPERATURE

LOOP 1

LOOP SENSOR (3X)

MAKE UP W ATER

AIR SEPARATOR

BACK FLOW PREVENTER

PRESSURE

GAUGE

PRESSURE REDUCING VALVE

DRAIN POINT

(TYPICAL)

EXPANSION TANK

INDIRECT DHW

TANK

TEMPERATURE

LOOP 2

BALL VALVE

(TYPICAL)

TEMPERATURE

LOOP 3

WIRES TO LOOP SENSORS

120VAC TO PUMPS

TO SYSTEM

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE (TYPICAL)

BOILER CIRCULATOR

FROM SYSTEM

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

24VAC SIGNAL TO MIXING VALVES

SHIELDED CABLE

TO BOILER CONTROL

HOT WATER OUT

ANTI-SCALD

MIXING VALVE

COLD WATER IN

CAUTION

NOTICE

BOILER

DOMESTIC

HOT WATER

CIRCULATOR

PRESSURE RELIEF VALVE

UNION (TYPICAL)

TEMPERATURE / PRESSURE

DRAIN

GAUGE

IMG00183

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.

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 for all equipment and detailing required by local codes.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

Page 46

7 Gas connections

Installation & Operation Manual

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 identiﬁ ed 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)

Figure 7-3 Gas Supply Piping - Models 601 - 801

MANUAL

SHUTOFF VALVE

(FACTORY SUPPLIED)

GAS SUPPLY

SEDIMENT TRAP/

DRIP LEG

(FIELD SUPPLIED)

UNION

3. Support piping with hangers, not by the boiler or its accessories.

 WARNING

The gas valve and blower will not support 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.

Figure 7-2 Gas Supply Piping - Model 501

(FACTORY INSTALLED)

SHUTOFF VALVE

(FACTORY SUPPLIED)

GAS SUPPLY

SEDIMENT TRAP/

DRIP LEG

UNION

MANUAL

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.

 WARNING

Do not check for gas leaks with an open ﬂ ame – 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 sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas ﬂ ow.

Page 47

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

Figure 7-4 Inlet Pipe with Backup Wrench

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.

USE BACKUP WRENCH TO

PREVENT PIPE FROM ROTATING

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 speciﬁ c 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:

• Maximum 14 inches w.c. (3.5 kPa) with no ﬂ ow (lockup) or with boiler on.

• Minimum 4 inches w.c. (.99 kPa) with gas ﬂ owing (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.

NOTICE

Maximum inlet gas pressure must not exceed the value speciﬁ ed. Minimum value listed is for the purposes of input adjustment.

Propane Gas:

 WARNING

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:

• Maximum 14 inches w.c. (3.2 kPa) with no ﬂ ow (lockup) or with boiler on.

• Minimum 8 inches w.c. (1.9 kPa) with gas ﬂ owing (verify during boiler startup).

Knight XL boilers are typically shipped ready to ﬁ re 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 oriﬁ ce or by making a gas valve adjustment (see pages 13 and 14). In order to operate on LP gas, an oriﬁ ce 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.

 WARNING

Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the appliance.

Page 48

7 Gas connections

Table 7A Natural Gas Pipe Size Chart

Installation & Operation Manual

Nominal

Iron Pipe

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet

Size

(inches)

1/2 3/4

1 1-1/4 1-1/2

2 2-1/2

10 20 30 40 50 60 70 80 90 100 125 150 175 200

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 369 256 205 174 155 141 128 121 113 106 95 86 79 74

697 477 384 328 292 267 246 236 210 200 179 164 149 138 1400 974 789 677 595 543 502 472 441 410 369 333 308 287 2150 1500 1210 1020 923 830 769 707 666 636 564 513 472 441 4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820 6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300

11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340 23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720

Check inlet gas supply

NOTICE

 WARNING

The gas piping must be sized for the proper ﬂ ow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

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 ﬂ ange to the valve and install a suitable 1/8" (3 mm) ﬁ tting (ﬁ eld 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) ﬁ tting is installed (depending on model) as shown in FIG.’s 7-5 thru 7-7 on page 49.

CSA or UL listed ﬂ exible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to ﬁ re at full rate. Consult with local codes for proper installation or service procedures.

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 damage.

Maximum Capacity of Pipe in Thousands of Btu/hr per hour

for gas pressures

of 14 Inches

Water Column

(0.5 PSIG) or less

and a pressure

drop of 0.5 Inch

Water Column (Based on NAT GAS, 1025 Btu/

hr per Cubic Foot

of Gas and 0.60

Speciﬁ c Gravity)

4. Slowly turn on the gas supply at the ﬁ eld installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner ﬁ res at 100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within speciﬁ ed range. Minimum and maximum gas supply pressures are speciﬁ ed in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualiﬁ ed installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

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) ﬁ eld supplied ﬁ tting and reinstall the pipe plug removed in Step 3.

Page 49

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open ﬂ ame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and ﬂ ame characteristics.

Figure 7-5 Inlet Gas Supply Check - Model 400

LOOSEN THE SET SCREW ONE (1) FULL TURN

ND PLACE THE MANOMETER TUBING OVER

THE PRESSURE TAP.

Figure 7-7 Inlet Gas Supply Check - 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.

Gas pressure

The gas pressure must remain between 4 inches w.c. (.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for Natural gas and between 8 inches w.c. (1.9 kPa) minimum and 14 inches w.c. (3.2 kPa) maximum for LP gas during standby (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet (3 m) from the Knight XL boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Figure 7-6 Inlet Gas Supply Check - Model 501

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a ﬂ anged connection to the venturi and blower.

 WARNING

Failure to follow all precautions could result in ﬁ re, explosion, or death!

DETAIL

damage.

Page 50

8 Field wiring

Installation & Operation Manual

 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.

 CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Figure 8-1 Line Voltage Field Wiring Connections

120V SUPPLY

NEUTRAL

GROUND

SERVICE

SWITCH

LINE

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Line voltage connections

1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-1.

2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code (see FIG. 8-1).

3. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. 8-1.

4. To activate a system pump, wire as shown in FIG. 8-1. Dry contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 8-2.

2. Connect low voltage wiring to the low voltage connection board as shown in FIG. 8-3 on page 53 of this manual and the boiler wiring diagram.

Figure 8-2 Routing Field Wiring

SYSTEM

PUMP

BOILER

PUMP

DOMESTIC

HOT WATER

PUMP

G W

L2/N

LOW VOLTAGE

CONNECTION BOARD

LINE VOLTAGE

JUNCTION BO

LOW VOLTAGE

WIRING KNOCKOUTS

LINE VOLTAGE

WIRING KNOCKOUTS

Page 51

8 Field wiring (continued)

Installation & Operation Manual

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 inﬂ uences of drafts, hot or cold water pipes, lighting ﬁ xtures, television, sunlight, or ﬁ replaces.

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’ speciﬁ cations and thermostat instructions for details.

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from direct sunlight or ﬂ ow 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 ﬁ xed 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 tank sensor, the SMART SYSTEM control can perform the tank thermostat function. The SMART SYSTEM control automatically detects the presence of this sensor, and generates a DHW call for heat when the tank temperature drops 6°F (3°C) below the tank set point, and ﬁ nishes 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).

 WARNING

Failure to use the correct sensor may result in the tank temperature being either above or below the set point.

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 veriﬁ ed before the boiler ﬁ res, 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 connect them to its normally closed contacts (FIG. 8-3).

Low gas pressure switch

1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts (FIG. 8-3).

2. 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 ﬂ ow 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 T across the heat exchanger, as well as prevent high limit lockouts when the ﬂ ow 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 ﬁ ring rate of the boiler. This may be used by a BMS system to monitor the actual rate of the boiler.

Page 52

8 Field wiring

Installation & Operation Manual

Modbus

When the 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 ﬂ ow switch is used to guarantee ﬂ ow through the boiler before allowing it to ﬁ re. The ﬂ ow 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 ﬂ ow 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 ﬁ ring 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 management system

1. An external control may be connected to control either the ﬁ ring 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.

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 “Conﬁ guration 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 Cascade 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 ﬁ xed 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 cable. 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.

Page 53

8 Field wiring (continued)

Figure 8-3 Low Voltage Field Wiring Connections

SYSTEM SUPPLY SENSOR

OUTDOOR SENSOR

TANK SENSOR

BOILER

Installation & Operation Manual

IMG00127

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

FROM

BOILER

SHIELD

B A

SYSTEM

BUILDING

MANAGEMENT

SPEED

CONTROL

SYSTEM PUMP

CUTOFF

LOW WATER

PUMP

BOILER

NEEDED

WIRE AS

COM

LOUVER

LOUVER RELAY

PROVING SWITCH

FLOW SWITCH

TANK THERMOSTAT

ROOM THERMOSTAT 3

ROOM THERMOSTAT 2

ROOM THERMOSTAT 1

Page 54

9 Condensate disposal

Installation & Operation Manual

Condensate drain

1. This boiler is a high efﬁ ciency 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 ﬁ lter. Condensate from the Knight XL will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing ﬁ lter 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).

NOTICE

8. 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 overﬂ ow 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).

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certiﬁ ed PVC or CPVC pipe, ﬁ ttings, and cement.

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch (25 mm).

The condensate line must remain unbstructed, allowing free ﬂ ow 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.

Figure 9-1 Condensate Disposal

1/2" PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

FLOOR DRAIN OR

DRAIN PAN

1/2" PVC UNION (FACTORY SUPPLIED)

NEUTRALIZER KIT

KIT3087 shown for illustration purposes.

Page 55

10 Start-up

Installation & Operation Manual

Check/control water chemistry

 CAUTION

Hardness less than 7 grains

1. Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not ﬁ ll 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 ﬂ uid

1. For systems using freeze protection ﬂ uids, follow ﬂ uid manufacturer’s instructions.

2. Freeze protection ﬂ uid must be replaced periodically due to degradation of inhibitors over time. Follow all ﬂ uid manufacturer’s instructions.

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.

Freeze protection (when used)

1. Determine freeze protection ﬂ uid quantity using

system water content, following ﬂ uid manufacturer’s instructions. Boiler water content is listed on page 7. Remember to include expansion tank water content.

2. Local codes may require a backﬂ ow preventer or actual

disconnect from city water supply.

3. When using freeze protection ﬂ uid with automatic ﬁ ll,

install a water meter to monitor water makeup. Freeze protection ﬂ uid 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 ﬂ uid is used (see the Knight XL Service Manual).

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water ﬁ ll 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 ﬁ ll and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

 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.

b. Close the boiler or system isolation valve between

the purge valve and ﬁ ll connection to the system.

c. Close zone isolation valves. d. Open quick-ﬁ ll valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air. Run until no noticeable air ﬂ ow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-ﬁ ll water valve and purge valve and

remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-ﬁ ll 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 ﬂ oor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open automatic air vent (diaphragm-type or bladdertype expansion tank systems only) one turn.

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close manual and automatic air vents and boiler drain valve.

3. Open other vents: a. Starting on the lowest ﬂ oor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Reﬁ ll to correct pressure.

Page 56

10 Start-up

Installation & Operation Manual

Check for gas leaks

 WARNING

Figure 10-1 Condensate Trap

Before starting the boiler, and during initial operation, smell near the ﬂ oor 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 ﬁ eld adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

RETAINING

SCREW

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

 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)

1. Disconnect the two external wires connected to each of the heat/loop demand terminals on the connection board.

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board. Allow the boiler to cycle.

CONDENSATE FROM

HEAT EXCHANGER

TO FLOOR

DRAIN

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

Inspect/ﬁ ll condensate system

Inspect/check condensate lines and ﬁ ttings

1. Inspect the condensate drain line, condensate PVC ﬁ ttings and condensate trap.

Fill condensate trap with water

1. Remove the PVC cap retaining screw from the PVC cap (FIG. 10-1).

2. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 10-1).

3. Fill with fresh water until the water begins to pour out of the drain.

4. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

5. Replace the retaining screw.

 WARNING

The condensate trap (FIG. 10-1) must be ﬁ lled with water during all times of boiler operation to avoid ﬂ ue gas emission from the condensate drain line. Failure to ﬁ ll the trap could result in severe personal injury or death.

Page 57

10 Start-up (continued)

Final checks before starting the boiler

Installation & Operation Manual

 Check vent piping and air piping

 Read the Knight XL Service Manual to familiarize yourself

with SMART SYSTEM control module operation. Read this manual, page 58 for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 55

and 56 have been completed.

 Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap). Replace the cap. Press the cap onto the trap until the cap makes contact with the drain. Replace the retaining screw.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 10-2, page 58.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

 WARNING

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 46 of this manual (connecting gas supply piping).

 WARNING

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

 WARNING

Venting system must be sealed gastight to prevent ﬂ ue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

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 ﬁ eld adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

2. Is boiler water temperature above 200°F (93°C)?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?

If none of the above corrects the problem, refer to the Troubleshooting Section of the Knight XL Service Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 55 and 56 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

 WARNING

Check ﬂ ame and combustion

1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.

2. Remove the ﬂ ue temperature sensor from the ﬂ ue pipe connection. NOTE: Combustion measurements will be made at this point.

3. Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

Page 58

10 Start-up

Figure 10-2 Operating Instructions

Installation & Operation Manual

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.

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.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Remove top cover.

6. Turn gas shutoff valve counterclockwise to “OFF”. Handle will be perpendicular to pipe. Do not force.

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to next step.

OPERATING INSTRUCTIONS

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas control knob. Never use tools. If the handle will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

8. Turn gas shutoff valve clockwise to “ON”. Handle will be parallel to pipe.

9. Install top cover.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove top cover.

TO TURN OFF GAS TO APPLIANCE

4. Turn gas shut off valve counterclockwise to “OFF”. Handle will be perpendicular to pipe. Do not force.

5. Install top cover.

LBL2284 REV -

Page 59

10 Start-up (continued)

Installation & Operation Manual

Check ﬂ ame 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 ﬁ re at ignition speed and will then modulate up to full ﬁ re.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the ﬂ ue temperature sensor.

7. Once the boiler has modulated up to full ﬁ re, 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 speciﬁ ed range,

reference the Troubleshooting Section of the Knight XL Service Manual for possible causes and corrective actions.

Table 10A Flue Products Chart

Natural Gas Propane

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 manual shutoff switch to the ON position and reset the control.

9. Turn the main power off to the boiler and replace the

ﬂ ue temperature sensor into the ﬂ ue pipe connection.

10. Place the boiler back into normal operation.

 WARNING

You must replace the flue gas temperature sensor to prevent ﬂ ue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

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 heating 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

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.

2. 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.

Please note that the brackets ([]) denote screen status.

Page 60

10 Start-up

Set domestic hot water (DHW) operation

Verify DHW mode

Installation & Operation Manual

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 bring the outlet temperature to the DHW boiler set point. The maximum ﬁ ring 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

The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 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 read [PASSWORD], with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and date and temperature unit.

5. Press the NAVIGATION dial twice.

Please note that the brackets ([]) denote screen status.

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.

NOTICE

The clock is automatically updated whenever a PC is connected and the Win_Pro-Installer program is started.

Conﬁ guration of the cascade

NOTICE

When installed in a Cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters.

Press the [MENU] key for at least ﬁ ve (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.

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Please note that the brackets ([]) denote screen status.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

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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 ﬂ ue products out of the boiler through the heat exchanger and ﬂ ue piping. The control module regulates blower speed to control the boiler ﬁ ring rate. The gas valve senses the amount of air ﬂ owing into the boiler and allows only the right amount of gas to ﬂ ow.

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 satisﬁ ed. Once Demand 2 has been satisiﬁ ed the boiler will provide 110°F water to the system.

 CAUTION

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 conﬁ gured by the installer to use this signal to either control set point or ﬁ ring 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.

When multiple temperature loops are used, mixing valves are required for the protection of any low temperature loops.

Installation & Operation Manual

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 ﬁ ring 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. For 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 ﬁ ring, 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 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.

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11 Operating information

Installation & Operation Manual

Temperature control

Modulation

The Knight XL is capable of modulating its ﬁ ring rate from a minimum of 20% to a maximum of 100%. The ﬁ ring 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 ﬂ ow, the SMART SYSTEM can limit the ﬁ ring 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 ﬁ ring 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 ﬁ ring rate to its lowest setting.

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 ﬁ xed 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 satisﬁ ed, 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 ﬁ ring at minimum rates, the control will increase the ﬁ ring rate when the ﬂ ame signal drops too low.

Protection features

Outlet temperature, ﬂ ue 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 ﬂ ue temperature by a sensor located in the ﬂ ue exhaust. If the ﬂ ue temperature exceeds 215°F (102°C) the control will reduce the maximum fan speed. If the ﬂ ue temperature exceeds 240°F (115°C) the control will shut the unit down. The unit will restart automatically once the ﬂ ue 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 temperature drops below 45°F (7°C):

• Below 45°F (7°C), the boiler and system pumps operate constantly.

• 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.

NOTICE

 CAUTION

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.

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.

Page 63

Installation & Operation Manual

11 Operating information (continued)

Monitor external limits

Connections are provided on the connection board for external limits such as ﬂ ow 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 the time the boiler is ﬁ ring in the DHW Mode.

The control uses two (2) ignition counters to monitor the amount of boiler cycles. The ﬁ rst 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 notiﬁ cation. This notiﬁ cation 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 installer’s name and phone number can be programmed into the control. This information will appear on the Maintenance Required screen. The service reminder notiﬁ cation 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 ﬁ ring and ﬁ ring rate to achieve a target temperature. The target temperature can be set between 70°F (21°C) and 190°F (88°C).

• Target temperature is ﬁ xed 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

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.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control.

8. If the 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. If the 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 ﬁ ve (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will ﬁ re at ignition speed and will then modulate up to full ﬁ re.

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.

Please note that the brackets ([]) denote screen status.

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11 Operating information

Installation & Operation Manual

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 ﬂ ow 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 ﬂ ow conditions.

2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available from the factory (WTR20009).

Outdoor reset operation, if used

Target temperature with outdoor reset

This feature improves the system’s efﬁ ciency 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 Efﬁ ciency 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 ﬁ xed temperature set point can 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.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the ﬁ ring 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

Start L-M1-M2-M3-M4-M5-M6-M7

1 hour M1-M2-M3-M4-M5-M6-M7-L

2 hours M2-M3-M4-M5-M6-M7-L-M1

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 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 ﬁ ring rate to maintain this. Once the DHW call has been satisﬁ ed, 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.

Page 65

Installation & Operation Manual

11 Operating information (continued)

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. 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 ﬂ ow switch and/or LWCO must close.

3. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by ﬁ ring the spark

electrode and opening the gas valve.

6. If ﬂ ame 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.

7. If ﬂ ame is detected, it holds the ﬁ ring rate steady for a few seconds to let the ﬂ ame stabilize, then it begins to modulate the ﬁ ring rate based on a set point or some other command (such as a 0-10V BMS signal).

Page 66

11 Operating information

Sequence of operation (continued)

OPERATION 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 ﬁ rst, then the boiler pump will turn off (boiler and DHW pump operation brieﬂ y overlap to ensure ﬂ ow 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.

9. 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 satisﬁ ed.

Installation & Operation Manual

10. Once both calls for heat are satisﬁ ed, the control will turn off the burner.The blower will continue to run during the postpurge period.

11. 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.

Page 67

Installation & Operation Manual

11 Operating information (continued)

Knight XL control module

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

Figure 11-1 Control Panel

NAVIGATION DIAL

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

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Installation & Operation Manual

11 Operating information

Access modes

User

The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is ﬂ ashing 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 Knight XL Service Manual.

Saving parameters (reference the Parameter Table in the Knight

XL Service Manual)

NOTICE

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 ﬁ nished programming in order to save the changes made.

See the Knight XL Service Manual for a detailed description of parameters and access modes.

Please note that the brackets ([]) denote screen status.

Page 69

Installation & Operation Manual

11 Operating information (continued)

Figure 11-2 Status Display Screen

(BOILER

STATUS)

(OPERATIONAL INFORMATION)

(LEFT SELECT

KEY)

(NAVIGATION DIAL)

Status Display Screens

Section Display Description

STANDBY

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.

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.

(CALL FOR

HEAT)

(RIGHT SELECT KEY)

(Boiler Status

Bar)

(Call for Heat

Indicators)

IGNITION The unit has begun a spark period to ignite the main burner.

The unit has ﬁ red and is running at the displayed percentage.

The call for heat has been satisﬁ ed and the unit runs the fan for an

POSTPURGE

SHUTDOWN The unit has been placed in the OFF position.

BLOCKED

additional postpurge period to clear the combustion chamber and vent system of residual ﬂ ue products.

The controlled temperature has exceeded its set point and its offset.

The unit has detected a condition that has temporarily interrupted the current call for heat.

Room Thermostat 1 has a call for heat.

Room Thermostat 2 has a call for heat.

Room Thermostat 3 has a call for heat.

The tank thermostat or sensor has a call for heat.

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.

Page 70

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.

Installation & Operation Manual

(Operational

Information)

DELTA T:

FLUE TEMP: The temperature read by the ﬂ ue sensor.

FLAME CURRENT: The current measured by the ﬂ ame sense circuit.

FAN SPEED: The speed of the combustion blower.

BOILER PUMP: The status of the boiler pump output.

SYSTEM PUMP: The status of the system pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT: The speed signal received from a variable speed system pump control.

RATE OUTPUT: A 0 - 10V signal indicating the ﬁ ring rate of the boiler.

SH RUN HOURS: The total hours of operation in the Space Heating Mode.

SH CYCLES: The total burner cycles in the Space Heating Mode.

The temperature difference between the inlet and the outlet of the heat exchanger.

DHW RUN HOURS: The total hours of operation in the DHW Mode.

DHW CYCLES: The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:* The last 10 lockouts.

NIGHT SETBACK Shows the next Night Setback trigger (if active).

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Installation & Operation Manual

11 Operating information (continued)

Status Display Screens (cont’d)

Section Display Description

EXIT Press the LEFT SELECT key to exit the current screen or setting.

Press and hold the LEFT SELECT key for 5 seconds to enter the Menu Screen.

(LEFT SELECT

key function)

(NAVIGATION

Dial Function)

YES

LIMITS

HOME

SKIP

Press the LEFT SELECT key to conﬁ rm that the boiler needs to shutdown.

Press the LEFT SELECT key to enter the screen that allows you to adjust the limit settings.

Press the LEFT SELECT key to return to the Status Screen and upload parameter changes.

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 Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by the cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current setting.

(RIGHT SELECT

key function)

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME

Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes.

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Installation & Operation Manual

12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and ﬁ ll with fresh water

• Check for leaks (water, gas, ﬂ ue, condensate)

• Verify ﬂ ue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and ﬂ ame sense electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and

ANNUAL START-UP

performance veriﬁ cation per Section 10.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high ﬁ re)

• Clean the heat exchanger if ﬂ ue temperature is more than 54°F (30°C) above return water temperature.

Owner maintenance

(see the Knight XL User’s Information Manual for

instructions)

• Check boiler area

Daily

• Check pressure/temperature gauge

• Check vent piping

• Check air piping

Monthly

Periodically

• Check air and vent termination screens

• Check relief valve

• Check condensate drain system

• Check air vents

• Test low water cutoff (if used)

• Reset button (low water cutoff)

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

Every

6 months

End

of season

months

• Check boiler piping (gas and water) for leaks

• Operate relief valve

• Shut boiler down (unless boiler used for domestic hot water)

Page 73

12 Maintenance (continued)

Installation & Operation Manual

 WARNING

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

 WARNING

The boiler should be inspected annually only by a qualiﬁ ed service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efﬁ ciency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

 WARNING

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

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 ﬂ ammable 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.

Figure 12-1 Condensate Trap

RETAINING

SCREW

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

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 ﬁ ttings, 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. 12-1).

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.

CONDENSATE FROM

HEAT EXCHANGER

 WARNING

The condensate trap must be ﬁ lled with water during all times of boiler operation to

TO FLOOR

DRAIN

avoid ﬂ ue gas emission from the condensate drain line. Failure to ﬁ ll the trap could result in severe personal injury or death.

Check all piping for leaks

 WARNING

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.

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.

7. Replace the retaining screw.

Page 74

12 Maintenance

Installation & Operation Manual

Flue vent system and air piping

1. Visually inspect the entire ﬂ ue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

 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 ﬁ ll 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 brieﬂ y press push valve to ﬂ ush 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 ﬂ ow.

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.

 WARNING

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.

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.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the ﬂ ow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water ﬂ ows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

Page 75

12 Maintenance (continued)

Installation & Operation Manual

Inspect ignition and ﬂ ame sense electrodes

1. Remove the ignition and ﬂ ame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/ﬂ ame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/ﬂ ame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

Figure 12-2 Burner Assembly - Model 400

AIR / GAS ARM

BURNER

GASKET

SCREWS

(QTY. 5)

Figure 12-3 Burner Assembly - Model 501

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of the Knight XL Service Manual. Adjust settings if necessary. See Section 1 of the Knight XL Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests speciﬁ ed in

Section 10 - Start-up.

2. Verify cold ﬁ ll pressure is correct and that operating

pressure does not go too high.

Check burner ﬂ ame

1. Inspect ﬂ ame through observation window.

2. If the ﬂ ame is unsatisfactory at either high ﬁ re or low ﬁ re,

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.

3. Remove the burner, reference FIG.’s 12-2 thru 12-4.

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG.’s 12-2 thru 12-4).

AIR / GAS ARM

BURNER

GASKET

SCREWS

(QTY. 5)

Figure 12-4 Burner Assembly - Models 601 - 801

AIR ARM

BURNER

GASKET

SCREWS

(QTY. 5)

Page 76

12 Maintenance

Installation & Operation Manual

Check ﬂ ame signal

1. At high ﬁ re the ﬂ ame signal shown on the display should be at least 10 microamps.

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

3. See Section 3 - Troubleshooting in the Knight XL Service Manual for other procedures to deal with low ﬂ ame signal.

Review with owner

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

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

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

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

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 12B - Heat Exchanger Cleaning Kits.

1. Shut down boiler:

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

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

2. Allow time for the boiler to cool to room temperature if

it has been ﬁ ring.

3. Remove the nuts securing the heat exchanger access cover

to the heat exchanger and set aside.

4. Remove the heat exchanger access cover, burner, and

gas/air arm assembly.

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 ﬁ eld 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 ﬂ ush boiler thoroughly with clean water by using purging valves to allow water to ﬂ ow 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

Model

400 KIT30063

501 - 801 KIT30064

Kit

Number

 CAUTION

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

Part

Number

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20084 3mm Allen Wrench MSC20086 1/4" x 24" Drill Extension

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20085 1/4" x 12" Drill Extension MSC20086 1/4" x 24" Drill Extension

Component Description

replacement nylon brush.

Figure 12-5 Rope Gasket - Heat Exchanger Door

ROPE GASKET

 WARNING

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions in the Service Manual. Failure to comply could result in severe personal injury.

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

NOTICE

CAUTION: IF GASKET IS DAMAGED

DO NOT REUSE, THE HEAT EXCHANGER DOOR

MUST BE REPLACED.

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).

Page 77

13 Diagrams

Figure 13-1 Wiring Diagram

Installation & Operation Manual

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

CONNECTION BOARD

ALARM BELL

SILENCING SWITCH

BELL JUMPER

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK THERMOSTAT HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

SHIELD

3 2 1

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32

CN5-1 CN5-8 CN5-2 CN5-9 CN5-3 CN5-10 CN5-11 CN5-4 CN5-5 CN5-14 CN5-12 CN5-6 CN5-13 CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

BMS

0-10V

OUT

RATE

OUT

OPTION

SHIELD

LOW

WATER

SHIELD

JUMPER

SHIELD

0-10V

24 VAC

COM

SYS PUMP

BLR PUMP

MODBUS

CUT-OFF

GROUNDING

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 wi minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector blo diagrams to troubleshoot unit.

X5-1 X5-2

33 34 35 36 37 38 39 40 41 42 43 44

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

MTR-01

CN8-1

CN8-2

CN8-3

X6-3

X6-2

X6-1

X6-4

X4-1 X4-2 X4-3 X4-4

X1-1 X1-2 X1-3

INTEGRATED

CONTROL

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

X9-1

X9-2 X9-3

X9-4

W G

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

RELAY

BOARD

CN2-4

X1-3

CN2-2

X1-4

CN2-3

X1-2

CN2-1

ON/OFF

X1-6 X1-5

X1-8

X1-1

SWITCH

BK W

BLOWER

1 2 3 4 5

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

BLOCKED DRAIN SWITCH

X5-10

X5-11

O/BK

X5-4

R/BK

X5-12

X5-6

P/BK

X5-5

W/BK

X5-13

X5-14

X2-2

X2-1

X1-7

W/R

TR2

CAUTION

re gauge (AWG) and rated for a

ck locations when using

JUNCTION

CN1-5

FLAME SENSOR SPARK

ROD

CN1-6

CN1-3

CN1-4

CN1-1

CN1-2

TRANSFORMER

1 2G3

O-TEMP HEX SW

AIR PRESSURE SWITCH

-T

OPERATING SENSOR S1a

-T

HIGH LIMIT SENSOR S1b

-T

INLET SENSOR S2

-T

FLUE SENSOR S3a

-T

FLUE SENSOR S3b

GAS VALVE @24VAC

HIGH VOLTAGE SPARK LEAD

BOX

3.5A

KB 801

ONLY

DHW PUMP

BOILER PUMP

SYSTEM PUMP

120V

GND

SUPPLY

WIRING DIAGRAM

LBL20116 REV E

Page 78

13 Diagrams

Figure 13-2 Ladder Diagram

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF SWITCH

X1-6

X4-3

CN5-5

PC INTERFACE

BELL

ALARM

SWITCH

SILENCING

ALARM

CONTACTS

RUN-TIME

CONTACTS

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

0-10V

SYS PUMP

0-10V

BLR PUMP

0-10V

OUT

RATE

0-10V

OUT

SHIELD

MODBUS

SHIELD

X5-9

3.5A

KB 801

ONLY

CONNECTION

JUNCTION BOX

INTEGRATED CONTROL

3.15A

SYSTEM PUMP

BOILER PUMP

.8A

SUPPLY

120 VAC

24 VAC

CN7-3

CN7-1

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

BOARD

21 22

CN8-1

CN8-2

CN8-3 X6-3

RELAY

DHW PUMP

RELAY

24V DC

LWCO

24 VAC

HEAT/LOOP

THERMOSTAT

LOW GAS

PRESSURE

SWITCH

RIBBON CABLE

CN5-1

CN5-8

CN5-2

CN5-9

CN6

CN6 X6

CN6

X6-1

X6-2

DEMAND

TANK

M O

D B U S

X1-1

X1-2

SYSTEM PUMP

X1-3

DHW PUMP

X1-4

BOILER PUMP

X5-1

HIGH GAS

PRESSURE

SWITCH

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X4-1

X4-2

X4-3

NEUTRAL

TERMINAL STRIP 120V SUPPLY "N"

BLOWER

RELAY

CONNECTION BOARD

CN7-4

CN7-2

INTEGRATED

CONTROL

X9-2

X9-1

X9-3

Installation & Operation Manual

GROUND

SYSTEM

PUMP

CONTACTS

BOILER

PUMP

CONTACTS

DHW

PUMP

CONTACTS

RELAY BOARD

FLOW

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

O-TEMP HEX SW

AIR PRESSURE

GAS VALVE

BLOWER

SPARK

ROD

DRAIN SWITCH

SWITCH

BLOCKED

CN5-14 X4-8

CN5-10

CN5-7 X4-1

CN5-13

CN5-6

CN5-12

CN5-11

CN5-3

CN5-4 X4-4

X5-2

X5-10

X5-11

X2-2

X2-1

TR2

X1-7

FLAME ROD

X4-12

X4-9

X4-2

X4-10

X4-11

X4-5

X5-7

X5-16

X5-8

X5-15

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possible, switches are shown wit hout utilities (gas, water or electricity) connect ed to the unit. As such, actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present.

2. See wiring diagram for additional notes.

OUT

SYSTEM

PUMP

BOILER

PUMP

DHW PUMP

INTEGRATED

CONTROL

GAS VALVE

RELAY

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

LADDER DIAGRAM

LBL20141 REV D

Page 79

Notes

Installation & Operation Manual

Page 80

Revision Notes: Revision A (ECO #C05747) initial release. Reﬂ ects

the new model numbers for the Knight XL upgrade.

Revision B (ECO #C06188) reﬂ ects changes made to FIG. 6-10 (ECR

#R03474) remove ghost pipe, changes made to FIG.’s 6-7, 6-9, and

6-11 (R03563) change the direction of the arrows, and edits made to

the ladder and wiring diagrams (ECO #C06158).

Revision C (ECO #C06234) reﬂ ects changes made to the Service

Reminder feature.

Revision D (ECO #C07981) reﬂ ects 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, ECR03740 - changes made to FIG’s 7-1 thru 7-4 pages 46

and 47, changes made to Table 3A on page 18, ECR03727 - 400 - 601

reference applied incorrectly on pages 15 and 16, add O-temp switch.

Revision E (ECO #C09197) reﬂ ects additional information added to the

humidity warning on page 8, edits made to the O-Temp switch deﬁ nition

on page 4, along with updates made to the SMART SYSTEM control

(ECR #R04523).

Revision F (ECO #C09803) reﬂ ects the addition of the new Polypropylene

Vent material section, rearranging the vent section, and the addition of

the AHRI and ASME logos (R05009).

Revision G (ECO #C10143) reﬂ ects updates made to the ignition timing

information.

KBXII-I-O Rev G

04/12