WB-I-O Rev F Installation & Operation Manual Models: 50 - 210 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Wall Mount Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage. Save this manual for future reference.
Contents HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 THE KNIGHT WALL MOUNT BOILER--HOW IT WORKS . . . 4-5 RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1. DETERMINE BOILER LOCATION Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . . 9 Wall Mounting Location . . . . . . . . . . . . . . .
Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Knight Wall Mount Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for your reference. Have this boiler serviced/inspected by a qualified service technician, at least annually.
Installation & Operation Manual The Knight Wall Mount Boiler - How it works... 1. Stainless steel heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Heat exchanger access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Operation Manual The Knight Wall Mount Boiler - How it works...
Installation & Operation Manual Ratings Knight Wall Mount Boiler I=B=R Rating Model Number Input MBH Other Specifications Heating Capacity MBH Net I=B=R Ratings Water, MBH (Note 2, 8 (Note 3, 8) (Note 1, 8) AFUE % Vent/Air Size Boiler Water Water Gas Content Connections Connections Gallons Note: Change “N” to “L” for L.P. gas models. Min Max WBN050 10 50 45 39 95.3 0.6 1" 1/2" 2" WBN080 16 80 72 63 95.3 0.6 1" 1/2" 2" WBN105 21 105 94 82 95.4 0.
Installation & Operation Manual 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.
Installation & Operation Manual 1 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances WARNING For closet installations, CPVC material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death. Note: Service clearances are recommendations only.
Installation & Operation Manual 1 Determine boiler location (continued) Provide air openings to room: Residential garage installation Knight wall mount boiler alone in boiler room Precautions 1. No air ventilation openings into the boiler room are needed when clearances around the Knight wall mount boiler 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.
Installation & Operation Manual 1 Determine boiler location Table 1A Corrosive Contaminants and Sources Products to avoid: When removing a boiler from existing common vent system: Spray cans containing chloro/fluorocarbons DANGER Do not install the Knight wall mount boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. To remove the boiler from the pallet: a. Remove the two (2) lag bolts securing the bottom of the unit to the pallet. b. Lift the boiler off the wall bracket mounted to the pallet. 3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet.
Installation & Operation Manual 2 Prepare boiler WARNING The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket. 13. Reattach the wiring connector to the gas valve. Tighten the screw on the wiring connector to secure to the gas valve. 14. Turn the gas valve power switch to the “ON” position. 15. Reattach the bezel to the unit. Reconnect the ribbon cable to the control board. 16.
Installation & Operation Manual 3 General venting Direct venting options Figure 3-1 Two-Pipe Vertical Termination - See page 23 for more details Figure 3-3 Concentric Vertical Termination - See page 25 for more details Figure 3-2 Two-Pipe Sidewall Termination - See page 17 for more details Figure 3-4 Concentric Sidewall Termination - See page 20 for more details 13
Installation & Operation Manual 3 General venting Install vent and combustion air piping DANGER The Knight wall mount 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. WARNING This appliance requires a special venting system.
Installation & Operation Manual 3 General venting NOTICE (continued) Combustion air piping to the outside MUST BE used. Use of combustion air from the room via louvers, plenums, or any other device is not authorized. Air intake/vent connections 1. 2. Combustion Air Intake Connector (FIG. 3-5) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection.
Installation & Operation Manual 3 General venting Removing from existing vent Vent, air piping and termination: Follow the instructions in Section 1, page 10 of this manual when removing a boiler from an existing vent system. The Knight wall mount 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.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING WARNING TO BOILER INTAKE AIR CONNECTION 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.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION Figure 4-2B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings COUPLING 12” MIN 15” MAX FROM BOILER VENT PIPE CONNECTION 12” MIN BIRD SCREEN BIRD SCREEN (TYPICAL) 12” MIN BIRD SCREEN 12” MIN ALTERNATE VENTING ARRANGEMENT (IF SPACE PERMITS) Maintain clearances as shown in FIG
Installation & Operation Manual 4 Sidewall direct venting (continued) Prepare wall penetrations 1. 2. 3. 4. 5. 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.
Installation & Operation Manual 4 Sidewall direct venting (continued) Figure 4-5B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1B) Sidewall termination installation 1. Determine the best location for the termination kit (see FIG. 4-6). 2. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual. 3.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent models Figure 4-8 Concentric Vent Dimensional Drawing NOTICE WARNING WARNING Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9).
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-10 Concentric Vent Sidewall Attachment CAUTION DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-10 for proper pipe attachment. 10.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. WARNING 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.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical Prepare roof penetrations Multiple vent/air terminations 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. 1. When terminating multiple Knight wall mount boilers, terminate each vent/air connection as described in this manual (FIG. 5-2). 2. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
Installation & Operation Manual 5 Vertical direct venting Vertical termination – optional concentric vent 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 flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. 6.
Installation & Operation Manual 6 Hydronic piping System water piping methods General piping information The Knight wall mount is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet. Basic steps are listed below along with illustrations on the following pages (FIG.
Installation & Operation Manual 6 Hydronic piping Circulator sizing The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-2 Pressure Drop vs. Flow - Models 50 - 210 Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35° 20°F Temperature Rise Applications Model GPM FT/HD Minimum Pipe Size 50 80 105 150 210 5.1 7.5 9.8 14.0 19.
Installation & Operation Manual 6 Hydronic piping NOTICE NOTICE Pump sizing and flow requirements are based on 20 feet of piping, 4 - 90° elbows, and 2 fully ported ball valves. It is required that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 6-3 - 6-7 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance.
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-3 Single Boiler Zoned with Circulators ZONE #1 PRESSURE GAUGE PRESSURE REDUCING VALVE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER FLOW CHECK VALVE (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR AIR SEPARATOR ZONE CIRCULATORS (TYPICAL) EXPANSION TANK NOT TO EXCEED 4 PIPE DIA. OR A MAX.
Installation & Operation Manual 6 Hydronic piping Figure 6-4 Multiple Boilers Zoned with Circulators Model 2 ZONE #1 PRESSURE REDUCING VALVE PRESSURE GAUGE BACKFLOW PREVENTER 50 80 105 150 210 Number of Units 3 4 5 6 7 Required Pipe Sizes 1" 1-1/4" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4" ZONE #2 ZONE #3 ZONE #4 MAKE UP WATER FLOW CHECK VALVE (TYPICAL) SYSTEM SUPPLY SEN
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-5 Single Boiler Zoned with Valves ZONE #1 PRESSURE REDUCING VALVE PRESSURE GAUGE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED) SYSTEM CIRCULATOR AIR SEPARATOR EXPANSION TANK NOT TO EXCEED 4 PIPE DIA. OR A MAX.
Installation & Operation Manual 6 Hydronic piping Figure 6-6 Multiple Boilers Zoned with Valves Model 2 ZONE #1 PRESSURE BACKFLOW REDUCING VALVE PREVENTER BALL VALVE (TYPICAL) 50 80 105 150 210 3 Number of Units 4 5 6 7 Required Pipe Sizes 1" 1-1/4" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4" ZONE #2 ZONE #3 ZONE #4 PRESSURE GAUGE ZONE VALVES (TYPICAL) MAKE UP WATER DIFFE
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-7 Single Boiler - Non-Zoned Primary/Secondary Piping PRESSURE REDUCING VALVE BACKFLOW PREVENTER PRESSURE GAUGE MAKE UP WATER AIR SEPARATOR SYSTEM SUPPLY SENSOR TO SYSTEM FROM SYSTEM NOT TO EXCEED 4 PIPE DIA. OR A MAX.
Installation & Operation Manual 7 Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler. a. Install a field supplied sediment trap / drip leg upstream of the boiler gas controls. 2. Support piping with hangers, not by the boiler or its accessories. WARNING Figure 7-1 Gas Supply Piping The gas valve and blower will not support the weight of the piping.
Installation & Operation Manual 7 Gas connections (continued) WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. WARNING Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 11).
Installation & Operation Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI Nominal Iron Pipe Size (Inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 267 246 236 210 200 179 164 149 138 1-1/4 1400 974 789 677 595 5
Installation & Operation Manual 7 Gas connections WARNING (continued) When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can 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.
Installation & Operation Manual 8 Field wiring WARNING NOTICE CAUTION ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. Installation must comply with: 1. National Electrical Code and any other national, state, provincial, or local codes, or regulations. 2. In Canada, CSA C22.
Installation & Operation Manual 8 Field wiring (continued) Low voltage connections DHW thermostat 1. Route all low voltage wires through the knockouts in the bottom front right side, just under the control panel, as shown in FIG. 8-3. 1. Connect storage indirect water heater (DHW) thermostat (FIG. 8-4) to the DHW thermostat terminals on the connection board. 2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-4 on page 43 of this manual and the boiler wiring diagram.
Installation & Operation Manual 8 Field wiring System supply sensor 1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected).
Installation & Operation Manual 8 Field wiring (continued) (AUX) DHW TANK SENSOR Figure 8-4 Low Voltage Field Wiring Connections 43
Installation & Operation Manual 9 Condensate disposal Condensate drain NOTICE 1. This boiler is a high efficiency appliance that produces condensate. 2. The bottom of the boiler has a 1/2 inch pipe for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Knight wall mount boiler will be slightly acidic (typically with a pH from 3 to 5).
Installation & Operation Manual 10 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains CAUTION 1. Consult local water treatment companies for hard water areas (above 7 grains hardness). Chlorine concentration less than 200 ppm 1.
Installation & Operation Manual 10 Start-up Check for gas leaks WARNING Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front 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. WARNING DO NOT adjust or attempt to measure gas valve outlet pressure.
Installation & Operation Manual 10 Start-up (continued) Final checks before starting the boiler Check vent piping and air piping Read the Knight Wall Mount Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, page 48 for proper steps to start boiler. 1. Check for gastight seal at every connection, seam of air piping, and vent piping.
Installation & Operation Manual 10 Start-up Figure 10-2 Operating Instructions 48
Installation & Operation Manual 10 Start-up (continued) Check flame and combustion (continued) Set space heating operation 4. Place the boiler into the active position by pressing the ENTER/RESET button on the display board (FIG. 11-1, page 57) until BLR:Standby appears in the display window. Determine controlling sensor 5. Locate the pinhole button in the upper right corner of the “T” in the Knight logo on the display board (FIG. 11-1).
Installation & Operation Manual 10 Start-up Set domestic hot water (DHW) operation Verify DHW circulator mode The DHW Mode is programmed to heat an indirect domestic hot water tank. When the tank thermostat calls for heat, the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump (if running). If the system pump is running, it will remain on. When the DHW call for heat ends, and there is no space heating call for heat, the DHW pump will continue to run for a period of time.
Installation & Operation Manual 11 Operating information General How the boiler operates DHW / space heating (SH) cycling The Knight wall mount boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate.
Installation & Operation Manual 11 Operating information Ramp delay For systems with lower flow, the SMART SYSTEM can limit the firing rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat to a space heating call for heat. There are six (6) limits that can be programmed, as well as six (6) time intervals corresponding to each limit. The sixth limit will also limit the firing rate for the rest of the call for heat.
Installation & Operation Manual 11 Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for external limits such as flow switch, low water cutoff, gas pressure switches, and an auxiliary device proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. When outlet temperature exceeds 200°F, high limit action occurs.
Installation & Operation Manual 11 Operating information Cascade (continued) If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the Knight Wall Mount Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler.
Installation & Operation Manual 11 Operating information (continued) Sequence of operation OPERATION 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for space heating call; DHW pump for DHW call). 2. The control connects 120 vac to the blower. The blower does not run at this time. • If the unit is equipped with a flow switch or low water cutoff, it must close before the control powers up the blower.
Installation & Operation Manual 11 Operating information Sequence of operation (continued) OPERATION DISPLAY 8. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 seconds, and resume modulating based on the space heating set point.
Installation & Operation Manual 11 Operating information (continued) Knight wall mount boiler control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Installation & Operation Manual 11 Operating information Status Display Screens By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows: Description BLR: OFF The unit has been turned OFF by the Enter/Reset button on the SMART SYSTEM display panel.
Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen #3 Display shows: Description SYS: ***.
Installation & Operation Manual 11 Operating information Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows: Description DHW PUMP: OFF The control has not received a DHW call for heat and has not powered the DHW pump.
Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont’d) Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items.
Installation & Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance (see the Knight Wall Mount User’s Information Manual for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check boiler area Daily • Check pressure/temperature gauge ANNUAL START-UP • Check for l
Installation & Operation Manual 12 Maintenance WARNING (continued) 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.
Installation & Operation Manual 12 Maintenance Flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed. 2. Verify that boiler vent discharge and air intake are clean and free of obstructions.
Installation & Operation Manual 12 Maintenance (continued) Perform start-up and checks 1. Start boiler and perform checks and tests specified in Section 10 - Start-up. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. Check burner flame 1. Inspect flame through observation window. 2. If the flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down.
Installation & Operation Manual 13 Diagrams Figure 13-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL TERMINAL STRIP 120V SUPPLY "L" KB MODELS ONLY GROUND TERMINAL STRIP 120V SUPPLY "N" GND INTEGRATED CONTROL ON / OFF SWITCH F5 5A X1-6 X1-2 SYSTEM PUMP "L" X1-4 BOILER PUMP "L" X1-3 DHW PUMP "L" DHW PUMP "N" TERMINAL STRIP TERMINAL STRIP SYSTEM PUMP "N" SYSTEM PUMP RELAY BOILER PUMP "N" BOILER PUMP RELAY X1-8 JUNCTION BOX GND SYSTEM PUMP GND BOILER PUMP DHW PUMP RELAY DHW PUM
Installation & Operation Manual 13 Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE DISPLAY WARNING DISCONNECT POWER BEFORE SERVICING INTEGRATED CONTROL JUNCTION BOX X3 PC INTERFACE CN2-16 CN4-8 CN2-15 AUX.
Revision B (WB-I&O-Rev B) reflects changes made to the ratings page. Revision C (WB-I&O-Rev C) reflects changes made to the orifice on Models 150 and 210. Revision D (ECO #C02407) reflects the addition of air inlet pipe materials, Maintenance Section, high altitude, air pressure switch, new condensate trap image and the addition of the new vent termination.