Lochinvar Knight KBN400, Knight KBN601, Knight KBN701, Knight KBN801, Knight KBN501 Installation & Operation Manual
Page 1
KBXII-I-O_100161488_2000013409_Rev P
Installation & Operation Manual
Models: 400 - 801
WARNING
Save this manual for future reference.
is manual must only be used by a
quali 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 ............................................................. 55-61
11. OPERATING INFORMATION
General ............................................................................. 62
Cascade ........................................................................... 65
Sequence of Operation ............................................... 66-67
Knight XL Control Module ........................................... 68-69
Status Display Screens ............................................... 70-72
12. MAINTENANCE
Maintenance and Annual Startup ................................ 73-77
13. DIAGRAMS
Wiring Diagram ........................................................... 78
Ladder Diagram ......................................................... 79
Revision Notes .................................................. Back Cover
Hazard defi nitions
e following de 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
2
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
Installation & Operation Manual
WARNING
NOTICE
WARNING
WARNING
Installer – Read all instructions, including
this manual and the Knight XL Service
Manual, before installing. Perform steps in
the order given.
User – is 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 quali 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 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 re or explosion may
result causing property damage, personal
injury or loss of life.
is appliance MUST NOT be installed in
any location where gasoline or 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 re department.
• Installation and service must be
performed by a quali ed installer,
service agency, or the gas supplier.
WARNING
e California Safe Drinking Water and
Toxic Enforcement Act requires the
Governor of California to publish a list of
substances known to the State of California
to cause cancer, birth defects, or other
reproductive harm, and requires businesses
to warn of potential exposure to such
substances.
is product contains a chemical known to
the State of California to cause cancer, birth
defects, or orther reproductive harm. is
boiler can cause low level exposure to some
of the substances listed in the Act.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block ow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut o ,
do not turn o or disconnect electrical supply to
circulator. Instead, shut o the gas supply at a location
external to the appliance.
• Do not use this boiler if any part has been under water.
e possible damage to a ooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Boiler water –
• oroughly ush the system (without boiler connected)
to remove sediment. e high-e ciency heat exchanger
can be damaged by build-up or corrosion due to sediment.
Freeze protection fl uids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are speci cally
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
WARNING
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 11).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
3
Page 4
Installation & Operation Manual
The Knight XL - How it works...
1. Stainless steel heat exchanger
Allows system water to ow through specially designed
coils for maximum heat transfer, while providing protection
against ue gas corrosion. e 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
e 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
e gas valve senses the negative pressure created by the
blower, allowing gas to ow only if the gas valve is powered and
combustion air is owing.
5. Venturi
e venturi controls air and gas ow into the burner.
6. Flue gas sensor (limit rated)
is sensor monitors the ue gas exit temperature. e
control module will modulate and shut down the boiler if the
ue gas temperature gets too hot. is protects the ue pipe from
overheating.
7. Boiler outlet temperature sensor (housed with the
high limit sensor)
is sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control
module adjusts boiler ring rate so the outlet temperature is
correct.
8. Boiler inlet temperature sensor
is sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the boiler ring rate so the inlet temperature is
correct.
9. Temperature and pressure gauge ( eld installed, not
shown)
Monitors the outlet temperature of the boiler as well as the
system water pressure.
10. Electronic LCD display
e 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 ber and stainless steel construction, the
burner uses pre-mixed air and gas and provides a wide range of
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
readed pipe connection of 1". is pipe should be connected
to the incoming gas supply for the purpose of delivering gas to
the boiler.
16. SMART SYSTEM Control Module
e 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.
4
19. High voltage junction box
e 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
e 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
e quartz glass window provides a view of the burner surface
and ame.
27. Gas shuto 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.
e 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
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. is is needed
for the proper draining of the condensate from the combustion
chamber.
34. Air shroud (Model 501 only)
e air shroud controls air and gas ow into the burner.
35. Air pressure switch
e air pressure switch detects blocked ue/inlet conditions.
break the control circuit, shutting the boiler down.
36. Pump relay board
e pump relay board is used to connect the boiler, system and
DHW pumps.
37. Transformer
e 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
ue connection exceeds 604°F (318°C). is 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.
40. Burner door temperature switch
An electrical switch designed to shut down boiler operation
in the event the combustion chamber access cover exceeds
500°F (260°C). is switch may only be reset by a quali ed
boiler service technician AFTER the underlying cause has been
identi ed and corrected. Check the integrity of the front
refractory on the inside of the combustion chamber access
cover if the switch opens.
Page 5
Installation & Operation Manual
The Knight XL - How it works... (continued)
Model 400
31
10
24
Front View - Model 400
37
27
35
8
14
28
13
7
38
20
23
IMG00858
Rear View - Model 400
4
5
25
2
29
26
40
19
21
36
16
1
3
33
17
Left Side (inside unit) - Model 400
Right Side (inside unit) - Model 400
5
Page 6
The Knight XL - How it works...
Model 501
Installation & Operation Manual
34
4
Rear View - Model 501
Models 601 - 801
40
IMG00860
Left Side (inside unit) - Model 501
5
4
Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801
6
40
IMG00862
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. e 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
su 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. e 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 speci 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. e 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. e boiler will de-rate by
2% for each 1,000 feet above sea level. High altitude models
are manufactured with a di erent 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 a xed to the unit.
Derate values are based on proper combustion calibration
and
CO2’s adjusted to the recommended levels.
6. Ratings have been con rmed by the Hydronics Section of
AHRI.
Figure A High Altitude Label Location
7
Page 8
1 Determine boiler location
Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
NOTICE
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. e pan must not restrict combustion air
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 ammable liquids.
WARNING
4. e 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.
6. Check around the boiler for any potential air
contaminants that could risk corrosion to the boiler or
the boiler combustion air supply (see Table 1A on page
11). Prevent combustion air contamination. Remove
any of these contaminants from the boiler area.
WARNING
8
e Knight XL gas manifold and controls
met safe lighting and other performance
criteria when the boiler underwent tests
speci ed in ANSI Z21.13 – latest edition.
Failure to keep boiler area clear and free
of combustible materials, gasoline, and
other ammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 11).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
Installation & Operation Manual
WARNING
WARNING
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. is would
be considered a closet for a Knight XL Boiler.
WARNING
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.
is appliance is certi 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.
is appliance requires a special venting
system. e vent connection to the appliance
must be made with the starter CPVC/
stainless steel pipe section provided with
the appliance. e eld provided PVC vent
ttings must be cemented to the CPVC pipe
section. Use only the vent materials, primer
and cement speci ed in this manual to make
the vent connections. Failure to follow this
warning could result in re, personal injury,
or death.
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. e 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 re, personal injury,
or death.
Page 9
Installation & Operation Manual
1 Determine boiler location (continued)
Figure 1-1 Closet Installation - Minimum Required Clearances
WARNING
For closet installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used in
a closet structure due to elevated
temperatures. Failure to follow
this warning could result in re,
personal injury, or death.
Figure 1-2 Alcove Installation - Minimum Required Clearances
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
this warning could result in re,
personal injury, or death.
9
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).
e 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
e Knight XL is approved for installation on combustible
ooring, but must never be installed on carpeting.
WARNING
If ooding is possible, elevate the boiler su 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.
10
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 oor.
• e appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
Vent and air piping
e Knight XL requires a special vent system, designed for
pressurized venting.
e 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 speci 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.
e 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. ese 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/ uorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water so ening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric so eners 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 re 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 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 ue producing
condensate.
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. e 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 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 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 speci 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 ue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
11
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 de 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 replace dampers.
Do not install the Knight XL into a
common vent with any other appliance.
is will cause 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 dra hood relief opening a e r
5 minutes of main burner operation. Use the ame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. A er 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, replace dampers, and any
other gas-burning appliance to their previous conditions
of use.
12
Page 13
2 Prepare boiler
Installation & Operation Manual
Remove boiler from wood pallet
1. A er 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 (a er removing the
front door):
a. Remove the two lag bolts from the wood pallet
inside the boiler (FIG. 2-1).
b. Detach the boiler from the lag bolts in the rear of the
unit, see FIG. 2-1.
NOTICE
Do not drop the boiler or bump the jacket
on the oor or pallet. Damage to the boiler
can result.
Figure 2-1 Boiler Mounted on Shipping Pallet
. 2
Gas conversions
WARNING
For a boiler already installed, you must
turn o gas supply, turn o power and
allow boiler to cool before proceeding.
You must also completely test the boiler
a er 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 ori ce to operate the Knight XL
on propane gas. Verify when installing that
the ori ce size marking matches boiler size
(Model 400 - 8.0 LP ori ce stamping).
Models 501 - 801 do not require an ori ce
installation for propane operation, but
they will require a valve adjustment.
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 ori ce disk from the conversion kit bag.
Verify that the stamping on the ori ce disk matches the
boiler size (Model 400 - 8.0 LP ori ce stamping).
5. Remove the existing ori ce from the O-ring in the side of
the gas valve and replace it with the ori ce from the kit.
Position and secure the ori 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. A er 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 le side of the unit in the lower le corner.
9. Replace the top and front access covers.
WARNING
DANGER
Figure 2-2 Installing Propane Orifi ce - Model 400
A er converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property damage.
Model 400: Inspect the O-ring when the
blower is disassembled. e 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.
BLOWER
O-RING
VENTURI
SCREWS
QTY. 3
SCREWS
QTY. 4
O-RING
BRASS ORIFICE
GAS VALVE
13
Page 14
2 Prepare boiler
A
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. en 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. A er 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 le side of the unit in the lower le corner.
5. Replace the top access cover.
WARNING
Figure 2-3 Gas Valve Adjustment - Model 501
A er 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.
WARNING
A er converting to LP, check combustion
per the Start-up procedure in Section
10 of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
Figure 2-4 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 CO
is within the range
2
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-4).
5. A er 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 le side of the unit in the lower le corner.
6. Replace the gas valve cover along with the top access cover.
LOWER
RAISE
14
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
15
Page 16
3 General venting
Install vent and combustion air piping
Installation & Operation Manual
DANGER
WARNING
WARNING
NOTICE
WARNING
e 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 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.
is appliance requires a special venting
system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and
ttings listed in Tables 3D, 3E, and 3G for
vent pipe, and ttings. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
DO NOT mix components from di erent
systems. e vent system could fail,
causing leakage of ue products into the
living space. Mixing of venting materials
will void the warranty and certi 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 re, personal injury, or death.
e 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. e 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
tting is provided on the unit for 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 3-7) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition tting is provided on the unit for
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.
16
IMG00873
Page 17
3 General venting (continued)
Installation & Operation Manual
Requirements for installation in
Canada
1. Installations must be made with a vent pipe system
certi ed to ULC-S636.
2. e rst three (3) feet of plastic vent pipe from the
appliance ue outlet must be readily accessible for visual
inspection.
3. e components of the certi ed vent system must not be
interchanged with other vent systems or unlisted
pipe/ ttings. For concentric vent installations, the inner
vent tube must be replaced with eld supplied certi ed vent
material to comply with this requirement.
4. e 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
e Knight XL uses model speci 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 (100140484) = 49
equivalent feet (15 m) of piping.
NOTICE
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Model Kit Number
400 100140484 5 Feet (1.5 m)
501 100140484 30 Feet (9 m)
601 100140484 30 Feet (9 m)
e 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.
17
Page 18
3 General venting
Installation & Operation Manual
Air inlet pipe materials:
e 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
roo op air inlet)
Galvanized steel vent pipe with joints and seams sealed as
speci ed in this section.
Type “B” double-wall vent with joints and seams sealed as
speci ed in this section.
AL29-4C, stainless steel material to be sealed to
speci 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 speci ed can result in personal
injury, death or property damage.
e 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.
e 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.
e 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 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 roo op 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 ue gas recirculation, spillage
of 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 roo op 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.
18
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 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.
• e unit MUST be installed with the appropriate
room air kit (Table 3C).
• e equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
• ere 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 100157601
90° Elbow with Screen 100157616
Air contamination
Pool and laundry products and common household and hobby
products o en contain uorine or chlorine compounds. When
these chemicals pass through the boiler, they can form strong
acids. e acid can eat through the boiler wall, causing serious
damage and presenting a possible threat of 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
WARNING
PVC/CPVC
is 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
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.
e 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. e eld
provided vent 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 speci ed in Table 3D
to make the vent connections. Failure to
follow this warning could result in 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. e use of
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
19
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, ttings and cement/
primer must be ULC-S636 certi 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 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 t vent or air piping to ensure proper t up
before assembling any joint. e pipe should go
a third to two-thirds into the tting to ensure
proper sealing a er cement is applied.
6. Priming and Cementing:
a. Handle ttings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the tting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
c. Apply a second primer coat to the tting
socket.
d. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the tting socket along with an even coat of
approved cement to the tting socket.
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into
the tting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
su 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 so en the
pipe.
Figure 3-2 Near Boiler PVC/CPVC Venting - Models 400 - 601
Figure 3-3 Near Boiler PVC/CPVC Venting - Models
701 - 801
20
Page 21
Installation & Operation Manual
3 General venting (continued)
Polypropylene
is 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 o ering.
For support and special connections required, see the
manufacturer's instructions. All vent is to conform to standard
diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length
for polypropylene single-wall piping:
• 1 foot of Duravent 4 inch single-wall pipe is equivalent
to 1.6 feet of piping
Flexible polypropylene
For use of 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 (FIG. 3-4).
Figure 3-4 Near Boiler Flexible Polypropylene Venting
CHIMNEY
CAP
B
A
Duravent 3”
“A” DIM
3” RIGID
10 FT
20 FT
30 FT
40 FT
50 FT
60 FT
70 FT
80 FT
90 FT
Centrotherm 3”
“A” DIM
3” RIGID
10 FT
20 FT
30 FT
40 FT
50 FT
60 FT
70 FT
80 FT
90 FT
“B” DIM
3” FLEX
60 FT
53 FT
47 FT
40 FT
33 FT
27 FT
20 FT
13 FT
7 FT
“B” DIM
3” FLEX
45 FT
40 FT
35 FT
30 FT
25 FT
20 FT
15 FT
10 FT
5 FT
4” FLEX
90 FT
80 FT
70 FT
60 FT
50 FT
40 FT
30 FT
20 FT
10 FT
4” FLEX
90 FT
80 FT
70 FT
60 FT
50 FT
40 FT
30 FT
20 FT
10 FT
Duravent 4”
“A” DIM
4” FLEX
4” RIGID
10 FT
30 FT
20 FT
27 FT
30 FT
23 FT
40 FT
20 FT
50 FT
17 FT
60 FT
13 FT
70 FT
10 FT
80 FT
7 FT
90 FT
3 FT
Centrotherm 4”
“B” DIM
“A” DIM
4” FLEX
4” RIGID
33 FT
10 FT
29 FT
20 FT
26 FT
30 FT
22 FT
40 FT
18 FT
50 FT
15 FT
60 FT
11 FT
70 FT
7 FT
80 FT
4 FT
90 FT
“B” DIM
5” FLEX
90 FT
80 FT
70 FT
60 FT
50 FT
40 FT
30 FT
20 FT
10 FT
NOTICE
e installer must use a speci c vent starter
adapter at the ue collar connection. e
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.
3-5).
WARNING
Insulation should not be used on polypropylene
venting materials. e use of insulation will
cause increased vent wall temperatures, which
could result in vent pipe failure.
WARNING
Use only the adapters and vent system listed in
Tables 3E and 3F. DO NOT mix vent systems
of di erent types or manufacturers. Failure to
comply could result in severe personal injury,
death, or substantial property damage.
NOTICE
Installations must comply with applicable
national, state, and local codes. For Canadian
installation, polypropylene vent must be listed
as a ULC-S636 approved system.
NOTICE
Installation of a polypropylene vent system
should adhere to the vent manufacturer’s
installation instructions supplied with the
vent system.
Figure 3-5 Near Boiler Polypropylene Venting
*NOTES: 1) FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION
2) ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE
EQUIVALENT LENGTHS.
3) SECTION A IS EQUIVALENT FEET OF RIGID PIPE, WHICH MAY
INCLUDE 45 AND 90° ELBOWS. PLEASE SEE SIZING SECTION
FOR DETERMINING EQUIVALENT FEET.
Table 3E Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make Model
Centrotherm Eco Systems InnoFlue SW/Flex
Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex
Table 3F Approved PolypropyleneTerminations
Centrotherm InnoFlue SW
Model
400-601
701-801
* ese parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 26).
Polypropylene
Adapter
Joint
Connector
Sidewall Retaining
ISAAL0404 IANS04 IATP0404 ISTAGL0404 4PPS-AD 4PPS-LB 4PPS-HLK
ISAAL0606
Not
Required
IMG00840
Duravent Polypro
Polypropylene
Adapter
Bracket*
Sidewall Adapter*
IATP0606 ISTAGL0606 FSA-6PVCM-6PPS Not Required 6PPS-HLK
Joint
Connector
Sidewall Kit*
21
Page 22
3 General venting
Stainless steel vent
is product has been approved for use with stainless steel
using the manufacturers listed in Table 3G.
WARNING
NOTICE
Use only the materials, vent systems, and
terminations listed in Tables 3G and 3I.
DO NOT mix vent systems of di erent
types or manufacturers. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
e installer must use a speci c vent starter
adapter at the 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.
Installation & Operation Manual
Figure 3-6 Near Boiler Stainless Steel Venting Models
400 - 601
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
Metal Fab Corr/Guard
Security Chimney Secure Seal
ICC VIC
FasNSeal Vent / FasNSeal
Flex* Vent
*Use of FasNSeal Flex smooth inner wall vent is to be used
in vertical or near vertical sections only, taking precaution
to ensure no sagging occurs of the vent system. Connect to
the FasNSeal rigid vent using specially designed adapters and
sealing method, see manufacturer’s instructions.
Figure 3-7 Near Boiler Stainless Steel Venting Models
701 - 801
Table 3H Stainless Steel Sidewall Vent Termination Kit(s)
Model Kit Number
701 - 801 100157755
Table 3I Approved Stainless Steel Terminations and Adapters
ProTech Heat Fab Z Flex
Model
400-601
701-801
Boiler
Adapter
F303759
F303759
(Intake Only)
FasNSeal Saf-T Vent Z-Vent
Flue
Termination
FSBS4
FSRC4(R.C)
FSBS6
Intake Air
Termination
Metal Fab Security Chimney
Corr/Guard Secure Seal VIC
400-601
701-801
4CGPVCA
6FCGPVCA
22
4CGSWHT
4CGSWC
6FCGSWMC
6FCGSWC
4CGSW90LT SS4PVCU
6FCGSW90L SS6PVCU
FSAIH04
303888
FSAIH04
303888
Boiler
Adapter
9401PVC
9601MAD
Flue
Termination
9492
5400CI
9690
9692
SS4STU
SS4RCBU
SS6STU
SS6RCBU
Intake Air
Termination
9414TERM 2SVSLA04
9614TERM
Boiler
Adapter
Flue
Termination
2SVSTP04
2SVSRCX04
Intake Air
Termination
2SVSTEX0490
ICC
SS4ST90AU -- -- --
SS6ST90AU
HE-6DSA-F HE-6MC-F
HE-6RC-F
HE-6E90-F
HE-6SCR-F
Page 23
4 Sidewall direct venting
Installation & Operation Manual
Vent/air termination – sidewall
WARNING
WARNING
Determine location
Locate the vent/air terminations using the following
guidelines:
1. e 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. e 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 ue
products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of ue
products with people or pets.
e. Do not locate the terminations where wind eddies
could a ect 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 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 100157611 4 inch vent
701 - 801 100157613 6 inch vent
If using the alternate sidewall termination:
3. e air piping must terminate in a down-turned elbow
as shown in FIG. 4-1B. is arrangement avoids
recirculation of ue products into the combustion air
stream.
4. e 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.
23
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
24
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 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"
25
Page 26
4 Sidewall direct venting
A
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 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. e air inlet of a Knight XL is part of a direct vent
connection. It is not classi 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
THIMBLE
26
(WHEN REQUIRED BY LOCAL CODES)
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 o ers an optional concentric combustion air
and vent pipe termination kit (#100140484 for 4" (102 mm)
diameter - Models 400 - 601). Both combustion air and vent
pipes must attach to the termination kit. e termination kit
must terminate outside the structure and must be installed as
shown below in FIG. 4-7.
e 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 #100140484
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 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_100140484 - 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.
6" (152 MM) DIA.
4" (102 MM) DIA.
27
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.
(152 MM)
"G"
(537 MM)
NOTICE
"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 eld-supplied stainless
steel screw may be used to secure the
two (2) components together when eld
disassembly is desired for cleaning (see FIG.
4-10).
WARNING
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.
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
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
"H" DIA.
"D"
(76 MM)
"E"
"F"
(168 MM)
3"
(76 MM)
(254 MM) (194 MM)
5. Install the Y concentric 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 tting and large pipe assembly
from an outside wall. Ensure small diameter pipe is
fastened tightly into the rubber adapter for #100140484
installations.
7. Secure the assembly to the structure as shown in
FIG. 4-11 using eld-supplied metal strapping or
equivalent support material.
NOTICE
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,
eld-supplied standard schedule 40 PVC
for 100140484. Do not extend dimension
D* more than 60 inches (1524 mm) (see
FIG. 4-9).
NOTICE
If assembly depth needs to be reduced,
dimension D can be as short as possible.
28
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 eld-supplied couplings
to extend pipes. Air 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 ue
gases.
Figure 4-12 Concentric Vent and Combustion Air Termination
12"
MINIMUM
VENT
COMBUSTION
AIR
29
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. e 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. e 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. e 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. is placement avoids recirculation of
ue products into the combustion air stream.
5. e vent piping must terminate in an up-turned coupling
as shown in FIG. 5-1A. e 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. e
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 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
Roo op vent and air inlet terminations
must terminate in the same pressure
zone, unless vertical vent sidewall air is
set up as shown in the General Venting Vertical Vent, Sidewall Air Section.
30
Page 31
R
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 oors, ceilings, and roofs.
5. Provide 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 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
VENT
12" (305 MM) MINIMUM
VERTICALLY FROM VENT
OUTLET TO ANY AIR INLET
AIR
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. e air inlet of a Knight XL boiler is part of a direct vent
connection. It is not classi ed as a forced air intake with
regard to spacing from adjacent boiler vents.
31
Page 32
A
Installation & Operation Manual
5 Vertical direct venting
Vertical termination – optional concentric vent: Models 400 - 601 Only
Description and usage
Lochinvar o ers an optional concentric combustion air and
vent pipe termination kit. Both combustion air and vent
pipes must attach to the termination kit. e termination kit
must terminate outside the structure and must be installed as
shown in FIG. 5-4.
Field supplied pipe and ttings are required to complete the
installation.
e required combustion vent pipe 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
NTICIPATED SNOW
LEVEL. MAXIMUM OF
24" (610 MM) ABOVE ROOF.
2. Cut one (1) hole (7 inch (178 mm) diameter for #100140484
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 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 eld supplied stainless
steel screw may be used to secure the
two (2) components together when eld
disassembly is desired for cleaning (see
FIG. 4-10, page 28).
WARNING
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.
Figure 5-5 Do Not Install U-Bend to Rain Cap
32
Page 33
Installation & Operation Manual
5 Vertical direct venting (continued)
Vertical termination – optional concentric vent: Models 400 - 601 Only
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 ow to the
burner enclosure. Failure to follow this
warning could result in product damage
or improper operation, personal injury,
or death.
4. Install the Y concentric tting pipe assembly up through
the structure’s hole and eld supplied roof boot/ 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 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 eld-supplied couplings
to extend pipes. Air 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 #100140484 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 ue
gases.
NOTICE
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, eld supplied standard
schedule 40 PVC for 100140484. 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.
33
Page 34
5 Vertical direct venting
A
A
Alternate vertical concentric venting
Installation & Operation Manual
is 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
e venting is to be vertical through the roof. e 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.
e minimum size of the existing vent system required to
achieve enough annular space for combustion air can be
found in Table 5A.
e 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 speci 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.
e 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
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"
701 - 801 6" 10"
34
COMBUSTION AIR
IR INLET
W/ SCREEN
SEAL
SEAL
FLUE OUTLET
*For concept illustration only. Individual installations
may vary due to job site specifi c equipment.
EXISTING
SEALED
CAP
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
SEAL
EXISTING
FLUE OUTLET
35
Page 36
6 Hydronic piping
System water piping methods
e 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.
Installation & Operation Manual
General piping information
IMPORTANT
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).
All boiler piping must contain an oxygen
barrier. is will help prevent any excess
oxygen from entering the system.
It is important to note that the boiler has a minimal amount
of pressure drop which must be 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 cuto device at the time of
installation.
Chilled water system
If the boiler supplies hot water to heating coils in air handler
units, 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. is
includes inhibitors, which prevent the glycol from attacking
the metallic system components. Make certain to check that
the system uid is correct for the glycol concentration and
inhibitor level. e 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.
WARNING
Use only inhibited propylene glycol
solutions, which are speci cally formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
1. Connect the system return marked “Inlet”.
2. Connect the system supply marked “Outlet”.
3. Install purge and balance valve or shuto valve and drain
on system return to purge air out of each zone.
4. Install a back 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 speci 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: e boiler cannot be drained completely of water
without purging the unit with an air pressure of 15 psi
(103 kPa).
10. is 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.
NOTICE
11. It is recommended to install an inlet water strainer to
prevent debris from entering the heat exchanger or system.
See the piping illustrations included in this section, FIG.’s 6-7
and 6-11 for suggested guidelines in piping the Knight XL.
e relief valve, tee and any other necessary
ttings are shipped in the install kit with the
boiler and are to be eld installed (FIG.’s 6-1
and 6-2).
36
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 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 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 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 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 tting positioned
vertically and on the top (FIG. 6-1).
5. Attach paddle #3 to the ow switch per the
manufacturer’s instructions.
6. Install the assembled ow switch into the 1 inch tting
of the tee installed in Step 4 (see FIG. 6-1).
7. Install a eld provided close nipple on the downstream
side of the ow switch (see FIG.’s 6-1 and 6-2).
8. Install a eld provided tee with the gauge 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 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
Figure 6-2 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 601 - 801
NOTICE
Be sure to install the ow switch so
that the arrow on the ow switch is
pointing in the direction of the ow
(see FIG. 6-3).
37
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 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 ow rate required to activate
the switch. Turn the sensitivity screw
counterclockwise to decrease the 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 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. e 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. e pump MUST be sized to meet
the speci ed minimum ow requirements listed in
FIG.’s 6-5 and 6-6. Consult the indirect water heater
operating guide to determine 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 speci ed minimum 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 ow
rate through the boiler.
GROUND
COMMON
NORMALLY
CLOSED
38
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 ow
condition during pump(s) o 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 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. e 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. e pressure relief valve is sized to
ASME speci cations.
Page 39
6 Hydronic piping (continued)
Installation & Operation Manual
12. Boiler purge valve:
Field supplied. e 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. e
sensor is to be installed in the heating loop downstream
from the boiler hot water piping and heating loop
junction. e 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
e 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
Near boiler piping connections
Figure 6-4A Near Boiler Piping w/Y-Strainer
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
e Knight XL boiler is capable of producing up to
three (3) set point temperatures to meet di erent
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 o ers the MultiTemperature Loop Control Board Kit (100167843).
39
Page 40
0
2
4
6
8
10
12
14
16
18
20
0 5 10 15 20 25 30 35 40 45
KBN501
KBN400
0
10
20
30
40
50
60
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
(Includes Boiler Secondary Piping)
Pressure Drop (Feet of Head)
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
40
MINIMUM
PIPE
SIZE
TEMPERATURE RISE APPLICATIONS
GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD
Pressure Drop vs Flow
Flow Rate (GPM)
20°F 25°F 30°F 35°F
Page 41
6 Hydronic piping (continued)
Figure 6-7 Single Boiler - Multiple Temperatures
Installation & Operation Manual
CAUTION
NOTICE
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. e installer must follow all manufacturer’s instructions for each system component. e
installer is responsible for compliance with local codes.
41
Page 42
6 Hydronic piping
Figure 6-8 Single Boiler - Primary/Secondary Piping
Installation & Operation Manual
CAUTION
NOTICE
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. e installer must follow all manufacturer’s instructions for each system component. e
installer is responsible for compliance with local codes.
System ow should always remain higher than the required ow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
42
Page 43
6 Hydronic piping (continued)
Figure 6-9 Multiple Boilers - Multiple Temperatures
Model
400
501
601
701
801
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)
CAUTION
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.
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. e installer must follow all manufacturer’s instructions for each system component. e
installer is responsible for compliance with local codes.
43
Page 44
6 Hydronic piping
Figure 6-10 Multiple Boilers - Primary/Secondary Piping
Model
400
501
601
701
801
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)
Installation & Operation Manual
Number of Units
2345678
Manifold Pipe Sizes in Inches (mm)
CAUTION
NOTICE
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. e installer must follow all manufacturer’s instructions for each system component. e
installer is responsible for compliance with local codes.
System ow should always remain higher than the required ow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
44
Page 45
Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone
CAUTION
CAUTION
NOTICE
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.
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. e installer must follow all manufacturer’s instructions for each system component. e
installer is responsible for compliance with local codes.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
45
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 shuto valve in the gas supply
piping outside boiler jacket when required by local
codes or utility requirements.
c. In Canada – When using manual main shuto
valves, it must be identi ed by the installer.
2. Install sediment trap / drip leg.
Figure 7-1 Gas Supply Piping - Model 400
Figure 7-3 Gas Supply Piping - Models 601 - 801
3. Support piping with hangers, not by the boiler or its
accessories.
WARNING
4. Purge all air from the gas supply piping.
e 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.
Figure 7-2 Gas Supply Piping - Model 501
46
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
a. e 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. e appliance must be isolated from the gas supply
piping system by closing a manual shuto 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. e appliance and its gas connection must be leak
tested before placing it in operation.
WARNING
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 ow.
Do not check for gas leaks with an open
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.
Page 47
7 Gas connections (continued)
Installation & Operation Manual
WARNING
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 speci c gravity
0.60 inches, with a pressure drop through the gas
piping of 0.3 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 ow
(lockup) or with boiler on.
• Minimum 4 inches w.c. (.99 kPa) with gas 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 speci 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 ow (lockup)
or with boiler on.
• Minimum 8 inches w.c. (1.9 kPa) with gas owing (verify
during boiler startup).
Knight XL boilers are typically shipped
ready to 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 ori ce
or by making a gas valve adjustment (see
pages 13 and 14). In order to operate on LP
gas, an ori 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.
47
Page 48
7 Gas connections
Table 7A Natural Gas Pipe Size Chart
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 speci c gravity, 0.30" w.c. pressure drop)
Installation & Operation Manual
Pipe
Size
(Inches)
1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A
3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A
1 514 353 284 243 215 195 179 167 157 148 131 119 109 102
1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209
1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313
2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602
2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960
3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700
4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460
10 20 30 40 50 60 70 80 90 100 125 150 175 200
Length of Pipe in Straight Feet
Check inlet gas supply
NOTICE
WARNING
e gas piping must be sized for the proper 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 o 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 ange to the valve and install a suitable 1/8" (3 mm)
tting ( 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) tting is installed
(depending on model) as shown in FIG.’s 7-5 thru 7-7 on
page 49.
CSA or UL listed exible gas connections
are acceptable, but you must exercise
caution to ensure that the line has adequate
capacity to allow your boiler to 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.
4. Slowly turn on the gas supply at the 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 res at
100% of rated input. Percent of burner input will be
displayed on the control panel.
8. Ensure inlet pressure is within speci ed range.
Minimum and maximum gas supply pressures are
speci 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, quali 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 o 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) eld supplied tting and
reinstall the pipe plug removed in Step 3.
48
Page 49
A
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
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. e burner should ignite
promptly. Flame pattern should be stable. Turn system
o and allow burner to cool, then cycle burner again to
ensure proper ignition and 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
e 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.
e problem is especially noticeable in NEW LP installations
and also in empty tank situations. is can also occur when
a utility company shuts o 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
e gas valve MUST NOT be replaced with a conventional
gas valve under any circumstances. As an additional safety
feature, this gas valve has a anged connection to the venturi
and blower.
WARNING
WARNING
Failure to follow all precautions could
result in re, explosion, or death!
DO NOT adjust gas valve outlet pressure.
Attempting to alter the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death, or substantial property
DETAIL
damage.
49
Page 50
8 Field wiring
X
Installation & Operation Manual
WARNING
ELECTRICAL SHOCK HAZARD – For
your safety, turn o 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
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
120V SUPPLY
NEUTRAL
GROUND
SERVICE
SWITCH
SYSTEM
PUMP
BOILER
PUMP
DOMESTIC
HOT WATER
PUMP
LINE
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 8-2.
W
G
BK
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
BK
G
W
LOW VOLTAGE
CONNECTION BOARD
BK
G
W
LOW VOLTAGE
WIRING KNOCKOUTS
BK
G
W
LINE VOLTAGE
WIRING KNOCKOUTS
LINE VOLTAGE
JUNCTION BO
L2/N
L1
G
50
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
in uences of dra s, hot or cold water pipes, lighting
xtures, television, sunlight, or replaces.
3. ermostat 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’ speci cations
and thermostat instructions for details.
Outdoor temperature sensor
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or 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 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. e 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 nishes the call
for heat when the tank temperature reaches the tank set point.
e tank sensor included with the Lochinvar Squire® indirect
DHW tanks (100170544) 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 100170544 is not compatible with the indirect tank, a
tank thermostat can be used to control the boiler. e
tank thermostat should be installed per the manufacturer’s
instructions and wired to the DHW ermostat terminals on
the low voltage connection board (FIG. 8-3).
Louver proving switch
1. When the operation of the louvers needs to be veri ed
before the boiler 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
ow increases and decreases.
Boiler pump speed output
is 0 - 10V output is available to control the speed of a variable
speed boiler pump. e 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 ow in the primary loop is extremely low. Connect this
output to the 0 - 10V input on the boiler pump speed control.
Rate output
is output provides a 0 - 10V signal that is proportional to the
ring rate of the boiler. is may be used by a BMS system to
monitor the actual rate of the boiler.
51
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 ow switch is used to guarantee ow through the boiler
before allowing it to re. e 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 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. e SMART SYSTEM control automatically
detects the presence of this sensor, and controls the boiler
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. e 100170581 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 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
e SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. is is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
e SMART SYSTEM control closes another set of contacts
whenever the boiler is locked out or the power is turned o .
is 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. e remaining boilers will be
designated as Members. See page 61 “Con 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. e
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). e system supply sensor should be wired to
the Low Voltage Connection Board at the terminals marked
for the system sensor (see FIG. 8-3). e 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 xed water temperature
set point that is programmed into the control.
If a ermostat 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. is 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. e 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.
52
Page 53
8 Field wiring (continued)
Figure 8-3 Low Voltage Field Wiring Connections
SYSTEM SUPPLY SENSOR
OUTDOOR SENSOR
TO
A
NEXT
BOILER
B
TANK SENSOR
Installation & Operation Manual
IMG00127
NOTE:
CONNECTION BOARD SPLIT FOR
ILLUSTRATION PURPOSES
A
B
FROM
BOILER
PREVIOUS
SHIELD
SHIELD
LOW WATER
CUTOFF
SPEED
CONTROL
SYSTEM PUMP
PUMP
BOILER
B
A
SYSTEM
BUILDING
MANAGEMENT
NEEDED
WIRE AS
LOUVER RELAY
LOUVER
PROVING SWITCH
COM
FLOW SWITCH
NO
TANK THERMOSTAT
ROOM THERMOSTAT 3
ROOM THERMOSTAT 2
ROOM THERMOSTAT 1
53
Page 54
9 Condensate disposal
Installation & Operation Manual
Condensate drain
1. is boiler is a high e ciency appliance that produces
condensate.
2. e 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 lter. Condensate
from the Knight XL will be slightly acidic (typically with
a pH from 3 to 5). Install a neutralizing lter if required
by local codes.
A Neutralizer Kit (FIG. 9-1) is available from the factory
(100157721 for Models 400 - 501 and 100157700 for
Models 601 - 801).
4. Install the 1/2 inch (12.7 mm) PVC elbow ( eld supplied)
as shown in FIG. 9-1.
5. Do not expose condensate line to freezing temperatures.
6. Use only plastic tubing or piping as a condensate drain
line (FIG. 9-1).
NOTICE
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 certi ed
PVC or CPVC pipe, ttings, and cement.
NOTICE
To allow for proper drainage on large
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch (25 mm).
The condensate line must remain
unbstructed, allowing free 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.
7. 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.
e pump should have an over ow switch to prevent
property damage from condensate spillage. e switch
should be wired in series with the blocked drain switch
inside the boiler (see FIG. 10-1 on page 57).
Figure 9-1 Condensate Disposal
1/2" (12.7mm) PVC ELBOW
(FIELD SUPPLIED)
FLOOR DRAIN OR
DRAIN PAN
NEUTRALIZER KIT
IMG00869
1/2" PVC UNION
(FACTORY SUPPLIED)
100157721 shown for illustration purposes.
54
Page 55
10 Start-up
Installation & Operation Manual
Fill water
Check/control fi ll water chemistry
IMPORTANT
e manufacturer recommends the following for properly
lling your boiler with the appropriate water chemistry for
closed loop boilers. Good ll water quality will help extend
the life of the appliance by reducing the e ects of lime scale
buildup and corrosion in closed loop systems.
Hardness between 5 and 15 grains per gallon
1. Consult local water treatment companies for hard water
areas (above 15 grains per gallon hardness).
2. Hardness levels that are above 15 grains/gallon can lead
to lime scale buildup throughout the boiler system. If the
ll water is below 5 grains/gallons, usually due to use of a
water so ener, it is recommended to mix in some potable
water at the inlet to increase the hardness of the water to
above 5 grains/gallons.
pH between 6.5 and 9.5
1. pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 9.5 or higher can potentially cause lime
scale buildup.
Total Dissolved Solids (TDS) below 2,000 ppm
Conduct water quality testing prior to
installing the appliance. Various solutions
are available to adjust water quality.
Freeze protection
WARNING
1. Use glycol only if needed for freeze protection.
2. Propylene glycol is the recommended freeze protection.
3. Make sure to ush the boiler system before adding glycol.
4. Determine the freeze protection uid quantity using
system water content, following the uid manufacturer's
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
5. Local codes may require a back ow preventer or actual
disconnect from city water supply.
6. When using freeze protection uid with automatic ll, it is
suggested to install a water meter to monitor water makeup.
Freeze protection uid may leak before the water begins to
leak, causing the concentration to drop, which reduces the
freeze protection level.
7. e freeze protection set points may be lowered when freeze
protection uid is used (see the Knight XL Service Manual).
8. Consult the glycol manufacturer for details on the suggested
mix of glycol and water for the desired freeze protection
level and the de-rate e ect it will have on the boiler output.
Ethylene glycol is toxic, DO NOT use as
your freeze protection. Ethylene glycol has a
sweet aroma which children and pets could
mistake as food and ingest; leading to death.
1. Total dissolved solids are all minerals, salts, metals, and
charged particles that are dissolved in water.
2. e greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.
3. If using so ened water to ll the boiler, it is still possible
to have high TDS. is water can be corrosive. It is
recommended to mix in some potable water with the
so ened water to reduce this a ect.
Chlorine concentration less than 200 ppm
1. Do not ll boiler or operate with water containing
chlorine in excess of 200 ppm.
2. Filling with fresh drinking water should be acceptable.
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 uids, follow the uid
manufacturer's instructions.
2. Freeze protection uid must be replaced periodically due to
degradation of inhibitors over time.
3. It is recommended to test the glycol concentration annually
and adjust within the desired set points.
55
Page 56
10 Start-up
Installation & Operation Manual
Oxygen prevention
CAUTION
Dissolved oxygen can have a negative e ect on the boiler
system. Oxygen can cause iron oxide to generate iron
deposits. Oxygen may also increase the rate of corrosion
on non-stainless steel parts of the system. A low pH level
combined with oxygen further enhances its corrosive e ects.
A er boiler installation, check for air leaks in the following
areas:
• Suction gasket
• Pump
• Air valve
• O-ring gaskets
Precautions include installing a water meter to evaluate the
fresh water volume entering the system. Additional volumes
of fresh water could indicate that a leak is present.
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.
Boiler water
CAUTION
CAUTION
• Monitoring pH, TDS and hardness levels can
prolong the life of the appliance by reducing lime
scale buildup, corrosion, and erosion. Check for
leaks to ensure that fresh water is not entering the
system.
• 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.
• e addition of oxygen carried in by make-up water
can cause internal corrosion in system components.
• Leaks in the boiler or piping must be repaired at
once to prevent make-up water. It could be helpful
to install a water meter for this purpose to easily
check the amount of make-up water entering the
system.
Do not use petroleum based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. is can result in substantial
property damage.
DO NOT use "homemade cures" or
"boiler patent medicines". Serious
damage to boiler, personnel, and/or
property may result.
Fill and test water system
1. Fill system only a er ensuring the water meets the
requirements of this manual.
2. Close automatic and manual air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. e minimum cold water ll pressure for a system is
12 psi.
b. Pressure will rise when the boiler is turned ON and
system water temperature increases.
4. At initial ll and during boiler startup and testing, check
the system thoroughly for any leaks. Repair all leaks before
proceeding further.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valve in the piping diagrams on pages 42 through 47).
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 ll connection to the system.
c. Close zone isolation valves.
d. Open the quick- ll valve on the cold water makeup
line.
e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air 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- ll water valve and purge valve and
remove the hose. Open all isolation valves. Watch that
system pressure rises to correct cold- ll pressure.
h. A er 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 oor. Close the vent when water
squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder
type expansion tank systems only) one turn.
3. Open other vents:
a. Starting on the lowest oor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Re ll to correct pressure.
56
Page 57
10 Start-up (continued)
Installation & Operation Manual
Check for gas leaks
WARNING
WARNING
Figure 10-1 Condensate Trap
Before starting the boiler, and during
initial operation, smell near the 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.
e gas valve is factory set for the correct
outlet pressure. is setting is suitable
for natural gas and propane, requiring
no 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.
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 therea er), 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. ere should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring. ( is is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked
and corrected if necessary, reconnect the external
thermostat circuit wires to the connection board. Allow
the boiler to cycle.
Inspect/fi ll condensate system
Inspect/check condensate lines and fi ttings
1. Inspect the condensate drain line, condensate PVC
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
e condensate trap (FIG. 10-1) must be
lled with water during all times of boiler
operation to avoid ue gas emission from
the condensate drain line. Failure to ll
the trap could result in severe personal
injury or death.
57
Page 58
10 Start-up
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 59 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
through 57 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 59.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
o ?
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 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.
e gas valve is factory-set for the correct
outlet pressure. is setting is suitable
for natural gas and propane, requiring
no 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 through 57 (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.
58
WARNING
Knight XL boilers are typically shipped
ready to 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 ori ce
or by making a gas valve adjustment (see
pages 13 and 14). In order to operate on
LP gas, an ori 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.
Check fl ame and combustion
1. Turn the main power o to the boiler by placing the
“On/O ” switch in the OFF position.
2. Remove the ue temperature sensor from the 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/
O ” switch in the ON position.
Page 59
10 Start-up (continued)
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 -
59
Page 60
10 Start-up
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 re at ignition
speed and will then modulate up to full re.
6. Insert the probe from a combustion analyzer into the
hole le by the removal of the ue temperature sensor.
7. Once the boiler has modulated up to full re, measure
the combustion. e values should be in the range
listed in Table 10A below. e CO levels should be less
than 150 ppm for a properly installed unit.
If the combustion is not within the speci 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
CO
2
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
8. Once the combustion analysis is complete, test the
safety shuto device by turning the manual shuto
valve to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Turn the manual
shuto switch to the ON position and reset the control.
9. Turn the main power o to the boiler and replace the
ue temperature sensor into the ue pipe connection.
10. Place the boiler back into normal operation.
WARNING
O
2
You must replace the flue gas
temperature sensor to prevent ue gas
spillage into the room. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
CO
2
O
2
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. e SMART SYSTEM control is programmed
at the factory to control the temperature of the outlet
sensor. e 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
e 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. A er the
space heating call for heat ends, the system pump continues
to run for a short period of time. e 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. ese pump delays are
factory set to 30 seconds. If di erent 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
e 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.
60
Page 61
10 Start-up (continued)
Set domestic hot water (DHW) operation
Verify DHW mode
Installation & Operation Manual
ere are two (2) modes of operation for DHW. In Normal
Mode, when a DHW demand begins, the control will start
the DHW pump, turn o the boiler pump (if running), and
modulate to bring the outlet temperature to the DHW boiler
set point. e maximum 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). e boiler pump will be turned on. e
system pump may be forced on, forced o , 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. is set point is set at the factory
to 180°F. If a di erent 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
e SMART SYSTEM control has a built-in clock that it
uses for its night setback feature and for logging events. is
clock must be set when the boiler is installed, and anytime the
boiler has been powered o 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.
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
e 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. is is accomplished by
accessing the control parameters.
Press the [MENU] key for at least 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. e boiler designated as the
Leader will have an address of 0. e 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.
e internal clock does not adjust for
Daylight Savings Time and therefore, will
require a manual adjustment.
Please note that the brackets ([]) denote
screen status.
4. e display will then show a menu with the time and
date and temperature unit.
5. Press the NAVIGATION dial twice.
6. Turn the NAVIGATION dial to adjust the hours. Press
the NAVIGATION dial.
61
Page 62
11 Operating information
General
How the boiler operates
e Knight XL uses an advanced stainless steel heat exchanger
and electronic control module that allows fully condensing
operation. e blower pulls in air and pushes ue products
out of the boiler through the heat exchanger and ue piping.
e control module regulates blower speed to control the
boiler ring rate. e gas valve senses the amount of air
owing into the boiler and allows only the right amount of
gas to ow.
How the control module operates
e SMART SYSTEM control module receives inputs from
boiler sensors and external devices. e 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 o as needed. e user
programs the module to meet system needs by adjusting
control parameters. ese 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
ere are three (3) heat/loop demand connections available
on this control. ese 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. e boiler will
regulate the system temperature to 140°F until Demand 2 has
been satis ed. Once Demand 2 has been satisi ed the boiler
will provide 110°F water to the system.
CAUTION
SMART SYSTEM Multi-temp loop control
e Knight XL boiler is capable of producing up to three
(3) set point temperatures to meet di erent space heating
demands. is 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 100167843).
0 - 10V input (set point or power)
e Knight XL can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. e control can be
con gured by the installer to use this signal to either control
set point or ring rate.
e 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.
62
When multiple temperature loops are
used, mixing valves are required for the
protection of any low temperature loops.
Installation & Operation Manual
DHW priority
e 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 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 o . e 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. ere is
a timer to switch from space heating to DHW and a timer to
switch from DHW to space heating. e control will switch
back and forth until one of the heat demands end. is function
does not apply to cascade systems.
Programmable controlling sensor
e 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
A er the burner turns o , the control will delay the next burner
cycle for a set time period (time is adjustable by the installer).
e time delay will be bypassed if the inlet water temperature
drops too far during the delay.
Boiler and system pump control
e boiler pump will run whenever the burner is ring, unless
the DHW is programmed for Normal Mode and the boiler is
heating the DHW tank. e boiler pump will run during Freeze
Protection Mode as well. It will continue to run for a short time
a er the burner turns o or the Freeze Protection Mode ends.
e 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 a er the end of the heat demand or the Freeze
Protection Mode. e system pump can be programmed to run
continuously if desired, except during outdoor shutdown and/
or a DHW call for heat.
Page 63
Installation & Operation Manual
11 Operating information (continued)
Temperature control
Modulation
e Knight XL is capable of modulating its ring rate
from a minimum of 20% to a maximum of 100%. e
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 ow, the SMART SYSTEM can
limit the 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. ere are six (6) limits
that can be programmed, as well as six (6) time intervals
corresponding to each limit. e sixth limit will also limit
the 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 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. e
installer can change the slope of the reset curves by several
adjustable parameters. e 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 xed number of degrees (adjustable by
installer). is 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 satis ed, the set point will revert to
the value determined by the reset curve.
Night setback
e controller may be programmed to reduce the space
heating and DHW set points during certain times
each week. Seven di erent 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 ring
at minimum rates, the control will increase the ring rate
when the ame signal drops too low.
Protection features
Outlet temperature, fl ue temperature, and temperature
rise limiting
e 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 o .
e control module monitors the ue temperature by a sensor
located in the ue exhaust. If the ue temperature exceeds
215°F (102°C) the control will reduce the maximum fan speed.
If the ue temperature exceeds 240°F (115°C) the control will
shut the unit down. e unit will restart automatically once the
ue temperature drops 25°F (-4°C) and the minimum o time
has expired.
e control monitors the temperature di erence between
the inlet and the outlet sensor. If this di erence exceeds 55°F
(13°C) the control will reduce the maximum fan speed. If the
temperature di erence exceeds 60°F (15°C) the control will
shut the unit down. e unit will restart automatically once the
temperature di erence has dropped below 55°F (13°C) and the
minimum o time has expired.
Freeze protection
DO NOT install the boiler in a room likely to freeze.
e following integral feature of the SMART SYSTEM control
module provides some protection for the boiler only -- not for
the system.
• e 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.
is feature of the SMART SYSTEM
control module does not eliminate the
possibility of freezing. e installation must
still use recognized design, installation and
maintenance practice to prevent freeze
potential for the boiler and system.
63
Page 64
11 Operating information
Monitor external limits
Connections are provided on the connection board for
external limits such as ow switch, low water cuto ,
gas pressure switches, and a louver proving switch. e
SMART SYSTEM will shut o the burner and inhibit
relighting whenever any of these external limits open.
Run-time and alarm outputs
e boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
e 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. e other timer monitors the
time the boiler is ring in the DHW Mode.
e control uses two (2) ignition counters to monitor
the amount of boiler cycles. e rst counter counts all
ignitions of the control. e second counter counts only
ignition attempts that have failed.
Service reminder
e control can be programmed for service reminder
noti cation. is noti 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). e display will show a Maintenance Required
screen. e installer’s name and phone number can be
programmed into the control. is information will appear
on the Maintenance Required screen. e service reminder
noti cation can be reset or disabled by the installer.
e 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
e control will hold in memory the last 10 lockouts as
well as the last 10 blockings. e 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)
e SMART SYSTEM control module senses water
temperature and regulates boiler ring and ring rate to
achieve a target temperature. e target temperature can
be set between 70°F (21°C) and 190°F (88°C).
• Target temperature is 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.
64
Installation & Operation Manual
High limit operations
e Knight XL is equipped with adjustable automatic reset and
manual reset high limits. e 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. e 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. e 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 ve (5) seconds to place the boiler into
Service Mode. In Service Mode, the boiler will re at
ignition speed and will then modulate up to full 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.
Page 65
Installation & Operation Manual
11 Operating information (continued)
Low water cutoff protection
1. e SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the ow rate is too low or the outlet
temperature too high, the control module modulates and
shuts the boiler down. is ensures boiler shutdown in
the event of low water or low 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 cuto . Consult local jurisdiction
to determine. A low water cuto is available from the
factory (100173646).
Outdoor reset operation, if used
Target temperature with outdoor reset
is feature improves the system’s e ciency as the outdoor
temperature warms up.
See the Knight XL Service Manual to change the settings.
Reset curve
e 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. e Leader
control can be programmed to use Lead/Lag or E 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. e 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 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-o o set - the o -on di erential,
then the control will initiate a call for heat on the Cascade
(see the Knight XL Service Manual for an explanation of
the o set and di erential). e 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 ring
sequence will automatically be changed at set intervals.
e sequence will be changed once every 24 hours. e
switching on/o 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.
e DHW boiler will adjust its set point to the programmed
DHW boiler set point and will adjust its ring rate to maintain
this. Once the DHW call has been satis 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.
65
Page 66
11 Operating information
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.
Installation & Operation Manual
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).
66
Page 67
Installation & Operation Manual
11 Operating information (continued)
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.
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.
67
Page 68
Installation & Operation Manual
11 Operating information
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
e 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 = Le SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
68
Page 69
Installation & Operation Manual
11 Operating information (continued)
Access modes
User
e user can adjust space heating and tank target temperatures by pressing
the NAVIGATION dial when “SETPOINTS” is ashing at the bottom
of the display. e 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:
Please note that the brackets ([]) denote screen status.
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 nished programming in order to
save the changes made.
See the Knight XL Service Manual for a detailed description of parameters
and access modes.
69
Page 70
11 Operating information
Figure 11-2 Status Display Screen
Installation & Operation Manual
A
(BOILER
STATUS)
C
(OPERATIONAL
INFORMATION)
D
(LEFT SELECT
KEY)
E
(NAVIGATION DIAL)
Status Display Screens
Section Display Description
STANDBY
START e unit has begun a burn cycle and is checking all safety circuits.
PREPURGE e unit has initiated a prepurge period on a call for heat.
e unit has not received a call for heat from a remote thermostat nor
has it received a call for heat from a DHW thermostat.
B
(CALL FOR
HEAT)
F
(RIGHT SELECT KEY)
A
(Boiler Status
Bar)
B
(Call for Heat
Indicators)
IGNITION e unit has begun a spark period to ignite the main burner.
e unit has red and is running at the displayed percentage.
%
e call for heat has been satis ed and the unit runs the fan for an
POSTPURGE
SHUTDOWN e unit has been placed in the OFF position.
BLOCKED
additional postpurge period to clear the combustion chamber and
vent system of residual ue products.
e controlled temperature has exceeded its set point and its o set.
e unit has detected a condition that has temporarily interrupted
the current call for heat.
Room ermostat 1 has a call for heat.
Room ermostat 2 has a call for heat.
Room ermostat 3 has a call for heat.
e tank thermostat or sensor has a call for heat.
Indicates which room thermostat demand shows priority.
e unit is being controlled by a 0 - 10V BMS signal.
e member unit is supplying heat while in Cascade Mode.
70
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Installation & Operation Manual
11 Operating information (continued)
Status Display Screens (cont’d)
Section Display Description
SYSTEM: e temperature read by the system supply sensor (if connected).
TANK: e temperature read by the tank sensor (if connected).
OUTDOOR: e temperature read by the outdoor sensor (if connected).
INLET TEMP: e temperature read at the inlet to the heat exchanger.
OUTLET TEMP: e temperature read at the outlet of the heat exchanger.
C
(Operational
Information)
DELTA T:
FLUE TEMP: e temperature read by the ue sensor.
FLAME CURRENT: e current measured by the ame sense circuit.
FAN SPEED: e speed of the combustion blower.
BOILER PUMP: e status of the boiler pump output.
SYSTEM PUMP: e status of the system pump output.
DHW PUMP: e status of the DHW pump output.
BMS VOLTAGE: e voltage received from a BMS system.
BLR PUMP OUTPUT: e speed signal sent to a variable speed boiler pump in percent.
SYS PUMP INPUT: e speed signal received from a variable speed system pump control.
RATE OUTPUT: A 0 - 10V signal indicating the ring rate of the boiler.
SH RUN HOURS: e total hours of operation in the Space Heating Mode.
SH CYCLES: e total burner cycles in the Space Heating Mode.
e temperature di erence between the inlet and the outlet of the
heat exchanger.
DHW RUN HOURS: e total hours of operation in the DHW Mode.
DHW CYCLES: e total burner cycles in the DHW Mode.
LAST 10 FAULTS NO:* e last 10 lockouts.
NIGHT SETBACK Shows the next Night Setback trigger (if active).
71
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11 Operating information
Status Display Screens (cont’d)
Section Display Description
MENU
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.
Installation & Operation Manual
D
(LEFT SELECT
key function)
E
(NAVIGATION
Dial Function)
YES
LIMITS
HOME
SKIP
Press the LEFT SELECT key to con 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.
SHDN Press the RIGHT SELECT key to turn the boiler OFF.
ON Press the RIGHT SELECT key to turn the boiler ON.
F
(RIGHT SELECT
key function)
72
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.
Page 73
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.
• Test low water flow conditions
(reference the Knight XL Service
Manual).
If combustion or performance
indicate need:
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
Every
6 months
• 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)
• Check boiler piping (gas and
water) for leaks
• Operate relief valve
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheel
End
of season
months
• Shut boiler down (unless boiler
used for domestic hot water)
73
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12 Maintenance
Installation & Operation Manual
WARNING
WARNING
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.
e boiler should be inspected annually only by a quali 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 e ciency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
Electrical shock hazard – Turn o power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn o 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 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
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
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.
WARNING
e condensate trap must be lled with
water during all times of boiler operation to
avoid ue gas emission from the condensate
drain line. Failure to 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.
74
Page 75
12 Maintenance (continued)
Installation & Operation Manual
Flue vent system and air piping
1. Visually inspect the entire 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 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 brie y press push valve to 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 li the lever to verify 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
WARNING
2. A er 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 a ected 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. is 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 ow of
hot water from the valve to a proper place
of disposal. Otherwise severe personal
injury may result. If no water ows, valve
is inoperative. Shut down the boiler until a
new relief valve has been installed.
75
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12 Maintenance
Installation & Operation Manual
Inspect ignition and fl ame sense
electrodes
1. Remove the ignition and ame sense electrodes from the
boiler heat exchanger access cover.
2. Remove any deposits accumulated on the ignition/ ame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Replace ignition/ 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 speci ed in
Section 10 - Start-up.
2. Verify cold ll pressure is correct and that operating
pressure does not go too high.
Check burner fl ame
1. Inspect ame through observation window.
2. If the ame is unsatisfactory at either high re or low re,
turn o 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)
76
Page 77
12 Maintenance (continued)
Installation & Operation Manual
Check fl ame signal
1. At high re the ame signal shown on the display should
be at least 10 microamps.
2. A lower ame signal may indicate a fouled or damaged
ame sense electrode. If cleaning the ame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the ame
sense electrode.
3. See Section 3 - Troubleshooting in the Knight XL Service
Manual for other procedures to deal with low 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
speci 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 O 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 uid
in system, do not drain.
2. Allow time for the boiler to cool to room temperature if
it has been 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 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 ush boiler
thoroughly with clean water by using purging valves to
allow water to 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 100157627
501 - 801 100157628
CAUTION
Kit
Number
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
Part
Number
100140243 Rear Refractory Cover
100162565* Nylon 4" Wheel Brush*
100162566 3mm Allen Wrench
100162568 1/4" x 24" Drill Extension
100140243 Rear Refractory Cover
100162565* Nylon 4" Wheel Brush*
100162567 1/4" x 12" Drill Extension
100162568 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 eld supplied 3/4” diameter hose to
a drain pan. Using 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 100173794 and 100173799).
77
Page 78
13 Diagrams
Figure 13-1 Wiring Diagram
Installation & Operation Manual
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
CONNECTION BOARD
BELL JUMPER
ALARM BELL
SILENCING SWITCH
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
SHIELD
A
B
CASCADE
3
2
1
1
2
3
4
5
6
7
8
9
10
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
BK
BK
BK
BK
BK
CN6
BMS
+
0-10V
IN
OUT
RATE
OUT
OPTION
SHIELD
LOW
WATER
SHIELD
JUMPER
IN
SHIELD
+
+
+
A
B
-
-
-
-
0-10V
0-10V
0-10V
24 VAC
COM
SYS PUMP
BLR PUMP
MODBUS
CUT-OFF
GROUNDING
Notes:
1. All wiring must be install ed in accordance w ith:
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced
minimum of 105°C. Exceptions: Replacement high vo
or ribbon cables can lead to operational problems w
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
33
34
35
36
37
38
39
40
41
42
43
44
X5-1
X5-2
CN7-1
CN7-2
CN7-3
CN7-4
MODBUS BOARD
MTR-01
CN8-1
CN8-2
CN8-3
BL
BL
R
R
G
G
X6-3
X6-2
X6-1
X6-4
X4-1
X4-2
X4-3
X4-4
X1-1
X1-2
X1-3
local, s tate, prov incial and n ational code requir
ltage spark lead and ribbon cables must be purchase
hich could result in non-repairable damage to the i
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
X6
O
X9-1
GY
X9-2
X9-3
G
X9-4
BK
W
G
ement s per either N.E.C. in USA or C.S.A. in Cana da
with wire hav ing same w ire gauge (AWG ) and rated for a
d from t he factory. Use of a non-a pproved sp ark le
ntegrat ed control ler or other c omponents .
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE H OUSING
CN2-4
OR
X1-3
CN2-2
BR
X1-4
CN2-3
PR
X1-2
CN2-1
X1-6
BK
X1-5
W
G
X1-8
X1-1
R
X5-7
R
T
X5-16
X5-8
W
BK
X5-15
Y
X5-9
BL
X5-1
O
X5-2
BLOCKED DRAIN SWITCH
P
X5-10
X5-11
O/BK
X5-4
R/BK
X5-12
GY
P/BK
X5-6
X5-5
W/BK
PR
X5-13
X5-14
Y
BK
X2-2
Y
X2-1
X1-7
W/R
TR2
RELAY
BOARD
CN1-5
K1
CN1-6
CN1-3
K2
CN1-4
CN1-1
K3
CN1-2
ON/OFF
SWITCH
R
G
W
1
3
2
BLOWER
1 2 3 4 5
AIR PRESSURE SWITCH
-T
-T
-T
-T
-T
GAS VALVE
@24VAC
FLAME SENSOR
SPARK
ROD
CAUTION
HIGH VOLTAGE SPARK LEAD
OR
OR
BR
BR
PR
PR
TRANSFORMER
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
.
JUNCTION
BOX
O-TEMP
HEX SW
G
3.5A
KB 801
ONLY
DOOR
TEMP
ad
SW
L
L
120V
GND
SUPPLY
N
WIRING DIAGRAM
LBL20401 REV A
DHW
PUMP
BOILER
PUMP
SYSTEM
PUMP
N
78
Page 79
13 Diagrams (continued)
Figure 13-2 Ladder Diagram
120VAC
TERMINAL STRIP
120V SUPPLY "L"
X4-3
CN5-5
X1-6
S6
S5
S4
0-10V
0-10V
0-10V
0-10V
X5-9
3.5A
KB 801
ONLY
CONNECTION
INTEGRATED CONTROL
F2
3.15A
F1
5A
F3
.8A
120 VAC
24 VAC
CN7-3
CN7-1
19
17
15
13
10
INLET
SENSOR
OPERATING
SENSOR
HIGH LIMIT
SENSOR
FLUE
SENSOR
FLUE
SENSOR
BOARD
1
2
3
4
21
22
23
24
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
CN8-1
42
CN8-2
43
CN8-3 X6-3
44
ON / OFF
SWITCH
PC INTERFACE
ALARM
BELL
SWITCH
SILENCING
CONTACTS
CONTACTS
SYSTEM
SENSOR
OUTDOOR
SENSOR
TANK
SENSOR
SHIELD
CASCADE
SHIELD
BMS
IN
SYS PUMP
IN
BLR PUMP
OUT
RATE
OUT
SHIELD
MODBUS
SHIELD
1
2
6
13
ALARM
RUN-TIME
A
B
+
+
+
+
-
A
B
JUNCTION BOX
SYSTEM PUMP
RELAY
DHW PUMP
RELAY
BOILER PUMP
RELAY
24V DC
SUPPLY
LOW GAS
PRESSURE
SWITCH
RIBBON CABLE
S2
S1a
S1b
S3a
S3b
CN6
CN6
CN6
CN6
CN6 X6
CN6
CN6
CN6
CN6
CN6
CN6
CN6
CN6
CN6
CN6
LWCO
24 VAC
HEAT/LOOP
DEMAND
HEAT/LOOP
DEMAND
HEAT/LOOP
DEMAND
TANK
THERMOSTAT
CN5-1
CN5-8
CN5-2
CN5-9
M
O
X6-1
D
X6-2
B
U
S
TERMINAL STRIP
120V SUPPLY "N"
BLOWER
12
X1-1
X1-2
SYSTEM PUMP
RELAY
X1-3
DHW PUMP
RELAY
X1-4
BOILER PUMP
RELAY
X5-1
CONNECTION BOARD
CN7-4
CN7-2
1
2
3
HIGH GAS
PRESSURE
SWITCH
INTEGRATED
CONTROL
X7
X5-6
X5-4
X5-12
X5-5
X5-13
X5-14
X4-7
X4-14
X4-6
X4-13
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X6
X4-1
X9-2
X4-2
X9-1
X4-3
X9-3
Installation & Operation Manual
NEUTRAL
L
FLOW
SWITCH
LOUVER
RELAY COIL
24VAC
LOUVER
DOOR
TEMP
SW
IN
O-TEMP
HEX SW
AIR PRESSURE
GAS VALVE
BLOWER
SPARK
ROD
12
5
6
7
8
DRAIN SWITCH
SWITCH
SYSTEM
PUMP
CONTACTS
BOILER
PUMP
CONTACTS
DHW
PUMP
CONTACTS
RELAY BOARD
CN5-14 X4-8
CN5-10
CN5-7 X4-1
CN5-13
CN5-6
CN5-12
CN5-11
CN5-3
CN5-4 X4-4
BLOCKED
FLAME ROD
X5-2
X5-10
X5-11
X2-2
X2-1
1
2
4
5
TR2
X1-7
GROUND
3
11
20
18
16
14
9
9
PROVING SWITCH
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.
SYSTEM
PUMP
BOILER
PUMP
DHW
PUMP
INTEGRATED
X4-12
X4-9
X4-2
X4-10
X4-11
X4-5
GAS VALVE
X5-7
X5-16
X5-8
X5-15
BOX DEPICTS
OPTIONAL ITEMS
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
L
OUT
CONTROL
RELAY
LADDER DIAGRAM
LBL20400 REV A
79
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.
Revision H (ECO #C11814) refl ects the addition of Metal Fab and
Security Chimney as approved suppliers along with placing check
valves on the outlet side of the pump on all of the piping diagrams and
updates made to the polypropylene de-rate amounts (R06316).
Revision I (ECO #C14411) refl ects the removal of the page number
reference on page 15, the addition of the corrosive contaminant
warning on pages 3 and 8 (R06313), changes made to Table 7A - Gas
Piping Chart on page 48 (R6621), along with condensate trap changes
(R6594) and updating the fl ex piping information (R06464) on page 21.
Revision J (ECO #C14713) refl ects high altitude updates.
Revision K (ECO #C15251) refl ects the addition of the burner door
temperature switch updates (R6322).
Revision L (ECO C17014) refl ects the standardization of pressure drop
information on pages 47 and 48.
Revision M (Change# 500000695) refl ects the addition of ICC venting
options on page 22 (R06799) along with edits made to the piping
diagrams on pages 41 - 45 (C16461) and the addition of the California
contaminant warning on page 3 (R07228).
Revision N (PCP# 3000001144 / CN# 500002277) refl ects the addition
of edits made to Boiler Water on page 3, along with the addition of the
Important and Notice items under General Piping Information on page
36, as well as edits to section 10 (Start-up) on pages 55 and 56. SAP
part numbers have been updated.
Revision P (PCP# 3000002352 / CN# 500002601) refl ects an update to
the venting materials in Table 31 on page 22.
KBXII-I-O_MM #100161488_DIR #2000013409_Rev P
03/16
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