KBX-I-O Rev D Installation & Operation Manual Models: 399 - 800 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage. Save this manual for future reference.
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 . . . . . . . .
Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for your reference. NOTICE • To avoid electric shock, disconnect electrical supply before performing maintenance.
Installation & Operation Manual The Knight XL - 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 XL - How it works... (continued) 37. Pump relay board 36. Air pressure switch The pump relay board is used to connect the boiler, system and DHW pumps. The air pressure switch detects blocked flue/inlet conditions.
Installation & Operation Manual The Knight XL - How it works...
Installation & Operation Manual Ratings Knight XL Boiler I=B=R Rating Model Number Input MBH Note: Change “N” to “L” for L.P. gas models. (Note 4) Other Specifications Gross Output MBH Net I=B=R Ratings Water, MBH Boiler Water Content Gallons Vent Air Water Gas Connections Connections Size Size Min Max (Note 1) (Note 2) KBN399 80 399 373 324 3.4 1-1/2" 1" 4" 4" KBN500 100 500 467 406 4.2 1-1/2" 1" 4" 4" KBN600 120 600 567 493 4.
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 (continued) Figure 1-1 Closet Installation - Minimum Required Clearances CLOSET INSTALLATION 1" (25 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES AND VENT PIPE WARNING 13" (330 MM) TOP For closet installations, CPVC or stainless steel 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.
Installation & Operation Manual 1 Determine boiler location Provide air openings to room: Residential garage installation Knight XL alone in boiler room Precautions 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.
Installation & Operation Manual 1 Determine boiler location Table 1A Corrosive Contaminants and Sources Products to avoid: (continued) When removing a boiler from existing common vent system: DANGER Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Do not install the Knight XL into a common vent with any other appliance.
Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet Model 399 1. After removing the outer shipping carton from the boiler, remove the parts box. 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.
Installation & Operation Manual 2 Prepare boiler (continued) Model 500 1. Remove the top access cover from the unit (no tools required for removal). 2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-3). 3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3).
Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent PVC/CPVC Two Pipe See Figure 4-1A Models 399 - 600 Only Stainless Steel Two Pipe See Figure 4-1C Models 399 - 600 Only PVC/CPVC Alternate Two Pipe See Figure 4-2A Stainless Steel Alternate Two Pipe See Figure 4-2B 14 PVC/CPVC Concentric See Figure 4-7 Models 399 - 600 Only
Installation & Operation Manual 3 General venting (continued) Direct venting options - Vertical Vent PVC/CPVC Two Pipe See Figure 5-1A Stainless Steel Two Pipe See Figure 5-1B PVC/CPVC Concentric See Figure 5-5 Direct venting options - Vertical Vent Optional Room Air PVC/CPVC Room Air See Figure 5-4 Stainless Steel Room Air See Figure 5-4 15
Installation & Operation Manual 3 General venting Install vent and combustion air piping DANGER The Knight XL 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.
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. PVC/CPVC air intake/vent connections 1. 2. Combustion Air Intake Connector (FIG.’s 3-9 and 3-10) - 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 When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume. Stainless steel connections Stainless steel vent This product has been approved for use with stainless steel FasNseal vent systems manufactured by Protech. Use only the materials, vent terminations listed in Table 3B. vent systems.
Installation & Operation Manual 3 General venting (continued) The Knight XL uses model specific combustion air intake and vent piping sizes as detailed in Table 3D below. Table 3D Air Intake/Vent Piping Sizes Model Air Intake Vent 399 - 600 4 inches (102 mm) 4 inches (102 mm) 700 - 800 4 inches (102 mm) 6 inches (152 mm) NOTICE You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion).
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.
Installation & Operation Manual 4 Sidewall direct venting (continued) Vent/air termination – sidewall Figure 4-1C Alternate Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 399 - 600 w/Field Supplied Fittings BIRD SCREEN TO BOILER INTAKE AIR CONNECTION 12" (305 MM) MIN 15" (381 MM) MAX FROM BOILER VENT PIPE CONNECTION 12" (305 MM) MIN Figure 4-2A Alternate PVC/CPVC Sidewall Termination Models 399 - 800 w/Field Supplied Fittings BIRD SCREEN TO BOILER INTAKE AIR CO
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings Prepare wall penetrations 1. 12” (305 MM) MIN BIRD SCREEN (TYPICAL) 12” (305 MM) MIN 2. 12” (305 MM) MIN Figure 4-4A Clearance to Forced Air Inlets IF LESS THAN 10’ VENT / AIR TERMINATION 3. 36" MIN. 4. FORCED AIR INLET 5.
Installation & Operation Manual 4 Sidewall direct venting (continued) Prepare wall penetrations (Alternate Field Supplied Option) 1. 2. 3. 4. 5. 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 Sidewall termination – optional concentric vent: Models 399 - 600 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#CVK3007 for 4" (102 mm) diameter - Models 399 - 600). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7.
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 399 - 600 "A" "C" DIA. "B" DIA. "D" 3" (76 MM) "E" "G" "H" DIA. "B" DIA.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-11 Concentric Vent Sidewall Attachment STRAP (FIELD SUPPLIED) ELBOW (FIELD SUPPLIED) COMBUSTION AIR COMBUSTION AIR VENT VENT 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.
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 XL 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 room air The Knight XL may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. The vent pipe may terminate vertically above the roof line in a conventional vent manner (see FIG. 5-4).
Installation & Operation Manual 5 Vertical direct venting Vertical termination – optional concentric vent: Models 399 - 600 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-5. Field supplied pipe and fittings are required to complete the installation.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 399 - 600 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 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 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. Basic steps are listed below along with illustrations on the following pages (FIG.
Installation & Operation Manual 6 Hydronic piping Flow switch, relief valve and temperature and pressure gauge installation Figure 6-2 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 600 - 800 Basic steps are listed below to guide you through the installation of the flow switch, relief valve, and temperature and pressure gauge provided with the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Installation & Operation Manual 6 Hydronic piping Flow switch adjustment Circulator sizing 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. The Knight XL heat exchanger does have a pressure drop, which must be considered in your system design.
Installation & Operation Manual 6 Hydronic piping Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500 Pressure Drop (Feet of Head) Pressure Drop vs Flow (Includes Boiler Secondary Piping) 20 18 16 14 12 KBN500 10 KBN399 8 6 4 2 0 0 5 10 15 20 25 30 35 40 45 Flow Rate (GPM) Figure 6-6 Pressure Drop vs.
Installation & Operation Manual 6 Hydronic piping NOTICE NOTICE Pump sizing and flow requirements are based on 20 feet (6 m) 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 6-7 and 6-8 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 6-7 Single Boiler - Primary/Secondary Piping AIR SEPARATOR OM FR EM ST SY DRAIN POINT (TYPICAL) BALL VALVE (TYPICAL) SYSTEM SUPPLY SENSOR NOT TO EXCEED 4 PIPE DIAMETERS OR A MAXIMUM OF 12” APART SYSTEM CIRCULATOR PRESSURE GAUGE EXPANSION TANK BOILER CIRCULATOR M TE TO S SY MAKE UP WATER BACK FLOW PREVENTER PRESSURE REDUCING VALVE INDIRECT DHW TANK ANTI-SCALD MIXING VALVE HOT WATER OUT DOMESTIC HOT WATER CIRCULATOR COLD W
Installation & Operation Manual 6 Hydronic piping Figure 6-8 Multiple Boilers - Primary/Secondary Piping Number of Units 3 4 5 6 7 Manifold Pipe Sizes in Inches (mm) Model 2 399 500 600 700 800 2 1/2 (64) 3 (76) 3 1/2 (89) 3 1/2 (89) 4 (102) 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 5 (127) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203) 8 6 (152) 6 (152) 8 (203) 8 (203) 8 (203) S R TE
Installation & Operation Manual 7 Gas connections Connecting gas supply piping 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the boiler. a. Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada – When using manual main shutoff valves, it must be identified by the installer.
Installation & Operation Manual 7 Gas connections WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. WARNING 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. Natural gas: Pipe sizing for natural gas 1.
Installation & Operation Manual 7 Gas connections (continued) Table 7A Natural Gas Pipe Size Chart Nominal Iron Pipe Size (inches) 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet 10 20 30 40 50 60 175 120 97 82 N/A N/A 369 256 205 174 155 141 70 80 90 100 125 150 175 200 N/A N/A 128 121 N/A N/A N/A N/A N/A N/A 113 106 95 86 79 74 697 477 384 328 292 267 246 236 210 200 179 164 149 138 1400 974 78
Installation & Operation Manual 7 Gas connections WARNING When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Figure 7-7 Inlet Gas Supply Check - Models 600 - 800 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. Do not check for gas leaks with an open flame -- use the bubble test.
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. 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.
Installation & Operation Manual 8 Field wiring Low voltage connections DHW tank sensor 1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 8-2. By installing a tank sensor, the SMART SYSTEM control can perform the tank thermostat function.
Installation & Operation Manual 8 Field wiring (continued) System supply sensor Wiring of the cascade 1. By installing the system supply sensor into the supply of the primary loop, the temperature of the system supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected).
BUILDING MANAGMENT SYSTEM OUTDOOR SENSOR (AUX) DHW TANK SENSOR SYSTEM SUPPLY SENSOR WALL THERMOSTAT / ZONE CONTROL TANK THERMOSTAT FLOW SWITCH LOW GAS PRESSURE SWITCH (500 ONLY) HIGH GAS PRESSURE SWITCH (500 ONLY) C NC NO C NC NO NO COM AUX.
Installation & Operation Manual 9 Condensate disposal Condensate drain 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 certified PVC or CPVC pipe, fittings, and cement. NOTICE 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.
Installation & Operation Manual 10 Start-up Check/control water chemistry CAUTION Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard water areas (above 7 grains hardness). Chlorine concentration less than 200 ppm 1.
Installation & Operation Manual 10 Start-up (continued) Check for gas leaks WARNING WARNING Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.
Installation & Operation Manual 10 Start-up Final checks before starting the boiler 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 51 for proper steps to start boiler. 1. Check for gastight seal at every connection, seam of air piping, and vent piping. Verify the boiler and system are full of water and all system components are correctly set for operation.
Installation & Operation Manual 10 Start-up (continued) Figure 10-2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. 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.
Installation & Operation Manual 10 Start-up Check flame and combustion (continued) Set space heating operation 4. Place the boiler into the active position by pressing the SHUTDOWN button on the display board (FIG. 11-1, page 59) until BLR:Standby appears in the display window. Determine controlling sensor 5. Locate the pinhole button above the “T” in the Knight XL logo on the display board (FIG. 11-1).
Installation & Operation Manual 10 Start-up (continued) Set domestic hot water (DHW) operation Verify DHW circulator mode 9. The date and time are displayed as “YY:MM:DD W hh:mm”, where: mm: minutes hh: hour (24 hour time; e.g., 2:00 PM = 14:00) W: day of the week (1 = Monday, 2 = Tuesday, 3 = Wednesday, etc.,) DD: date MM: month YY: year The DHW Mode is programmed to heat an indirect domestic hot water tank.
Installation & Operation Manual 11 Operating information General How the boiler operates The Knight XL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate.
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 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 (93.3°C), 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 XL Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler.
Installation & Operation Manual 11 Operating information 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. • The manual reset high limit must be closed and reset. • Once the pumps are turned on, the flow switch must close. • If the unit is equipped with gas pressure switches, they must close.
Installation & Operation Manual 11 Operating information (continued) Knight XL control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Installation & Operation Manual 11 Operating information Access modes User The user can adjust space heating target temperature by using the UP and DOWN buttons (FIG. 11-1) at any time during normal operation. By entering the USER code (0704), the user can also change temperature units, time and date, and night setback settings.
Installation & Operation Manual 11 Operating information (continued) 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 #1 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 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 (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 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 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 XL User’s Information Manual for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check boiler area Daily • Check pressure/temperature gauge • Clean condensate trap and fill with fresh water • Check for leaks (water, gas, flue, co
Installation & Operation Manual 12 Maintenance 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.
Installation & Operation Manual 12 Maintenance (continued) 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 Inspect ignition and flame sense electrodes Check burner flame 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. If the flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building. 2.
Installation & Operation Manual 12 Maintenance (continued) Figure 12-4 Burner Assembly - Models 600 - 800 Cleaning boiler heat exchanger 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. AIR ARM 2. Allow time for the boiler to cool to room temperature if it has been firing. 3.
Installation & Operation Manual 13 Diagrams Figure 13-1 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE DISPLAY BOX DEPICTS OPTIONAL ITEMS INTEGRATED CONTROL X3 PC INTERFACE CONNECTION BOARD AUX.
Installation & Operation Manual 13 Diagrams (continued) Figure 13-2 Ladder Diagram BOX DEPICTS OPTIONAL ITEMS JUNCTION BOX 120VAC NEUTRAL TERMINAL STRIP 120V SUPPLY "L" GROUND LOW VOLTAGE 120 VAC HIGH VOLTAGE TERMINAL STRIP 120V SUPPLY "N" INTEGRATED CONTROL ON / OFF SWITCH F5 X1-2 5A X1-6 L IN SYSTEM PUMP RELAY L OUT SYSTEM PUMP CONTACTS SYSTEM PUMP RELAY X1-4 BOILER PUMP RELAY X1-8 X1-3 JUNCTION BOX SYSTEM PUMP BOILER PUMP CONTACTS BOILER PUMP RELAY DHW PUMP RELAY BOILER PUMP
Revision Notes: Revision B (ECO #C02407) reflects gas valve adjustment, room air, new sidewall vent termination, piping diagrams, flow switch,relief valve, T & P gauge, Maintenance Section, FIG. 8-1 (Line Voltage), and high altitude changes. Revision C (ECO #C02545) reflects the addition of references to the safety shutoff testing and instructions, sediment trap, periodic cleaning of screens in vent terminations, removal of B149.2 references, changed the arrow direction on FIG.