KBXII-I-O Rev C Installation & Operation Manual Models: 400 - 801 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. Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Operation Manual The Knight XL - How it works... (continued) 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.
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) KBN400 80 399 373 324 3.4 1-1/2" 1" 4" 4" KBN501 100 500 467 406 4.2 1-1/2" 1" 4" 4" KBN601 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 For closet installations, CPVC or WARNING 1" MINIMUM CLEARANCE stainless steel vent material MUST AROUND HOT WATER BE used in a closet structure due to PIPES AND VENT PIPE elevated temperatures. Failure to follow this warning could result in 13" TOP 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 When using an existing vent system to install a new boiler: WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Installation & Operation Manual 1 Determine boiler location When removing a boiler from existing common vent system: DANGER Do not install the Knight XL into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet Model 400 1. After removing the outer shipping carton from the boiler, 1. Remove the top and front access covers from the unit (no remove the parts box. tools required for removal). 2. Remove the three screws securing the venturi to the blower. 2. Remove the front door to access the lag bolts in front of Note: When separating the venturi from the blower, take the unit (FIG. 2-1).
Installation & Operation Manual 2 Prepare boiler Model 501 1. Remove the top access cover from the unit (no tools required for removal). 2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-3). 3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3). 4.
Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent PVC/CPVC Two Pipe See Figure 4-1A Models 400 - 601 Only Stainless Steel Two Pipe See Figure 4-1C Models 400 - 601 Only PVC/CPVC Alternate Two Pipe See Figure 4-2A Stainless Steel Alternate Two Pipe See Figure 4-2B PVC/CPVC Concentric See Figure 4-7 Models 400 - 601 Only 15
Installation & Operation Manual 3 General venting 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, Sidewall Air PVC/CPVC Vertical Vent, Sidewall Air 16 NOTICE Stainless Steel Vertical Vent, Sidewall Air Stainless steel vent/air design and terminations will vary slightly by manufacturer.
Installation & Operation Manual 3 General venting (continued) 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 6. General venting Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fitting socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fitting socket. e. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket. f. g. h. j.
Installation & Operation Manual 3 General venting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section.
Installation & Operation Manual 3 General venting Table 3B Approved Stainless Steel Terminations and Adapters ProTech Heat Fab Z Flex FasNSeal Saf-T Vent Z-Vent Model Boiler Flue Adapter Termination 400-601 F303759 701-801 F303759 (Intake Only) Intake Intake Boiler Intermediate Flue Boiler Flue Intake Air Air Air Adapter Adapter Termination Adapter Termination Termination Termination Termination FSBS4 FSRC4(R.
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. Vent and air piping Vent and air system: Table 3D Air Intake/Vent Piping Sizes NOTICE Model Air Intake Vent 400 - 601 4 inches (102 mm) 4 inches (102 mm) 701 - 801 4 inches (102 mm) 6 inches (152 mm) NOTICE Increasing or decreasing combustion air or vent piping is not authorized.
Installation & Operation Manual 3 General venting WARNING 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.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate Stainless Steel Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 400 - 601 w/Field Supplied Fittings, Utilizing FasNSeal’s Hood Intake.
Installation & Operation Manual 4 Sidewall direct venting (continued) 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 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 (continued) Sidewall termination – optional concentric vent: Models 400 - 601 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#CVK3007 for 4" (102 mm) diameter - Models 400 - 601). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7.
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. "D" 3" (76 MM) "E" "G" "H" DIA. "B" DIA.
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 400 - 601 Only Figure 4-11 Concentric Vent Sidewall Attachment STRAP (FIELD SUPPLIED) ELBOW (FIELD SUPPLIED) COMBUSTION AIR COMBUSTION AIR VENT 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.
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 Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting - Vertical Vent, Sidewall Air Section.
Installation & Operation Manual 5 Vertical direct venting (continued) 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 Vertical termination – optional concentric vent: Models 400 - 601 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 400 - 601 Only Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. WARNING CAUTION 6.
Installation & Operation Manual 5 Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. Figure 5-8 Concentric Vent Example 1 FLUE EXHAUST SEAL Concentric Venting Arrangement The venting is to be vertical through the roof. The annular space between the O.D.
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 FLUE EXHAUST SEAL EXISTING CAP SEAL FLUE OUTLET *For concept illustration only. Individual installations may vary due to job site specific equipment.
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 (continued) Flow switch, relief valve and Figure 6-1 Flow Switch, Relief Valve and Temperature and temperature and pressure gauge Pressure Gauge Installation_Models 400 - 501 installation Basic steps are listed below to guide you through the installation of the flow switch, relief valve, and temperature and pressure gauge provided with the unit. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Installation & Operation Manual 6 Hydronic piping Flow switch adjustment Near boiler piping components 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. 1.
Installation & Operation Manual 6 Hydronic piping (continued) 12. Boiler purge valve: Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up. Figure 6-4B Near Boiler Piping w/Low Loss Header 13. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction.
Installation & Operation Manual 6 Hydronic piping Figure 6-5 Pressure Drop vs. Flow - Models 400 and 501 Pressure Drop (Feet of Head) Pressure Drop vs Flow (Includes Boiler Secondary Piping) 20 18 16 14 12 KBN501 10 KBN400 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 (continued) Figure 6-7 Single Boiler - Multiple Temperatures TEMPERATURE LOOP 1 TEMPERATURE LOOP 2 TEMPERATURE LOOP 3 STEM TO S Y AIR SEPARATOR M SYSTE FROM MAKE UP WATER PRESSURE GAUGE Y-STRAINER (RECOMMENDED) BACK FLOW PREVENTER FLOW CHECK VALVE (TYPICAL) DRAIN POINT (TYPICAL) BOILER CIRCULATOR BALL VALVE (TYPICAL) PRESSURE REDUCING VALVE PRESSURE RELIEF VALVE EXPANSION TANK INDIRECT DHW TANK HOT WATER OUT UNION (TYPICAL) ANTI-SCALD MI
Installation & Operation Manual 6 Hydronic piping Figure 6-8 Single Boiler - Primary/Secondary Piping AIR SEPARATOR MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT (TYPICAL) OM FR EM ST SY NOT TO EXCEED 4 PIPE DIA OR MAX.
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-9 Multiple Boilers - Multiple Temperatures Number of Units 3 4 5 6 7 Manifold Pipe Sizes in Inches (mm) Model 2 400 501 601 701 801 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)
Installation & Operation Manual 6 Hydronic piping Figure 6-10 Multiple Boilers - Primary/Secondary Piping Number of Units 3 4 5 6 7 Manifold Pipe Sizes in Inches (mm) Model 2 400 501 601 701 801 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) BALL VALVE (TYPICAL) EM ST SY OM FR MAY SUBSTITUTE LOW LOSS HEADER AIR SEPARATOR DRAIN POINT (TYPICAL) SYSTEM SUPPLY SENSOR (WHEN USED) T NO TO 4 ED CE EX P IP 3 1/2 (89) 4 (102) 5 (127) 5 (127) 5 (127) E RM .
Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone TEMPERATURE LOOP 2 TEMPERATURE LOOP 1 TEMPERATURE LOOP 3 TO SYS AIR SEPARATOR PRESSURE GAUGE TEM YS FROM S BALL VALVE (TYPICAL) MAKE UP WATER TEM Y-STRAINER (RECOMMENDED) FLOW CHECK VALVE (TYPICAL) BACK FLOW PREVENTER PRESSURE RELIEF VALVE BOILER CIRCULATOR PRESSURE REDUCING VALVE DRAIN POINT (TYPICAL) EXPANSION TANK INDIRECT DHW TANK HOT WATER OUT ANTI-S
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 (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 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.
Installation & Operation Manual 7 Gas connections 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 974 789 677 595
Installation & Operation Manual 7 Gas connections WARNING (continued) When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. 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. Do not check for gas leaks with an open flame -- use the bubble test.
Installation & Operation Manual 8 Field wiring WARNING ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. NOTICE CAUTION Line voltage connections Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition. 2.
Installation & Operation Manual 8 Field wiring (continued) Thermostat 1. Connect the room thermostats or end switches (isolated contact only) to room thermostat 1, 2, or 3, as shown in FIG. 8-3. 2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunlight, or fireplaces. 3. Thermostat anticipator (if applicable): a. If connected directly to boiler, set for 0.1 amps. b.
Installation & Operation Manual 8 Field wiring Modbus Alarm contacts 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. The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off.
COM NO ROOM THERMOSTAT 1 ROOM THERMOSTAT 2 ROOM THERMOSTAT 3 TANK THERMOSTAT FLOW SWITCH LOUVER PROVING SWITCH WIRE AS NEEDED BOILER PUMP SYSTEM PUMP SPEED CONTROL BUILDING MANAGEMENT SYSTEM AB SHIELD NOTE: CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES SYSTEM SUPPLY SENSOR OUTDOOR SENSOR TANK SENSOR Field wiring LOUVER RELAY SHIELD A TO B NEXT BOILER 8 LOW WATER CUTOFF FROM A PREVIOUS B BOILER Installation & Operation Manual (continued) Figure 8-3 Low Voltage Field Wiring Connec
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 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 (continued) 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 58 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 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 (continued) Check flame and combustion (continued) Set space heating operation 4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 67). Determine controlling sensor 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.
Installation & Operation Manual 10 Start-up Set domestic hot water (DHW) operation Verify DHW mode There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum firing rate may be limited in this mode if desired. In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop.
Installation & Operation Manual 11 Operating information General DHW priority How the boiler operates The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the DHW thermostat input is ignored. The Knight XL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation.
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 a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. The Knight XL is equipped with adjustable automatic reset and manual reset high limits.
Installation & Operation Manual 11 Operating information Outdoor reset operation, if used Sequence of the cascade Target temperature with outdoor reset To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals. This feature improves the system’s efficiency as the outdoor temperature warms up. See the Knight XL Service Manual to change the settings. Reset curve The reset curves look at outdoor air temperature and adjusts the set points.
Installation & Operation Manual 11 Operating information (continued) Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The flow switch and/or LWCO must close. 3. The control turns on power to the louver relay.
Installation & Operation Manual 11 Operating information Sequence of operation (continued) OPERATION 8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on first, then the boiler pump will turn off 2 seconds later. This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead.
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 and tank target temperatures by pressing the NAVIGATION dial when “ SETPOINTS” is flashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 60). Installer Most parameters are available only to the installer, accessible by entering the installer password, see the Knight XL Service Manual.
Installation & Operation Manual 11 Operating information (continued) Figure 11-2 Status Display Screen A B (BOILER STATUS) (CALL FOR HEAT) C (OPERATIONAL INFORMATION) F D (RIGHT SELECT KEY) (LEFT SELECT KEY) E (NAVIGATION DIAL) Status Display Screens Section A (Boiler Status Bar) Display Description STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.
Installation & Operation Manual 11 Operating information Status Display Screens (cont’d) Display Section C (Operational Information) D (LEFT SELECT key function) 70 Description SYSTEM: The temperature read by the system supply sensor (if connected). TANK: The temperature read by the tank sensor (if connected). OUTDOOR: The temperature read by the outdoor sensor (if connected). INLET TEMP: The temperature read at the inlet to the heat exchanger.
Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont’d) Display Section Description 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. E (NAVIGATION Dial Function) Pressing the NAVIGATION dial will display the Set Points Screen.
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 (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) 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 Figure 12-4 Burner Assembly - Models 601 - 801 AIR ARM BURNER GASKET SCREWS (QTY. 5) Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode. 3.
Installation & Operation Manual 13 Diagrams Figure 13-1 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL SILENCING SWITCH BELL JUMPER ALARM BELL CONNECTION BOARD ALARM CONTACTS RUN-TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH 1 2 3 4 5 6 7 8 9 10 FLOW SWITCH TANK THERMOSTAT ROOM TSTAT ZONE CONTROL 3 ROOM TSTAT ZONE CONTROL 2 ROOM TSTAT ZONE CONTROL 1 11 12 13 14 15 16 17 18 19
Installation & Operation Manual 13 Diagrams Figure 13-2 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL TERMINAL STRIP 120V SUPPLY "L" TERMINAL STRIP 120V SUPPLY "N" L IN L OUT GROUND SYSTEM PUMP CONTACTS INTEGRATED CONTROL ON / OFF SWITCH BLOWER X1-6 1 X1-1 F2 2 3.15A 3 F1 5A SYSTEM PUMP BOILER PUMP CONTACTS X1-2 SYSTEM PUMP SYSTEM PUMP RELAY RELAY X1-3 DHW PUMP RELAY DHW PUMP RELAY X1-4 BOILER PUMP RELAY F3 .
Installation & Operation Manual Notes 79
Revision Notes: Revision A (ECO #C05747) initial release. Reflects the new model numbers for the Knight XL upgrade. Revision B (ECO #C06188) reflects changes made to FIG. 6-10 (ECR #R03474) remove ghost pipe, changes made to FIG.’s 6-7, 6-9, and 611 (R03563) change the direction of the arrows, and edits made to the ladder and wiring diagrams (ECO #C06158). Revision C (ECO #C06234) reflects changes made to the Service Reminder feature.