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KBXII-I-O_100161488_2000013409_Rev P
Installation & Operation Manual
Models: 400 - 801
Th is manual must only be used by a
WARNING
qualifi ed heating installer / service
technician. Read all instructions,
including this manual and the Knight
XL Service Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Table of Contents
Related Manuals for Lochinvar KnightXL KBN400
Summary of Contents for Lochinvar KnightXL KBN400
- Page 1 KBXII-I-O_100161488_2000013409_Rev P Installation & Operation Manual Models: 400 - 801 Th is manual must only be used by a WARNING qualifi ed heating installer / service technician. Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS ............ 2 6. HYDRONIC PIPING System Water Piping Methods ......... 36 PLEASE READ BEFORE PROCEEDING ......3 Low Water Cutoff Device ..........36 THE KNIGHT XL -- HOW IT WORKS ......4-6 Chilled Water System ............36 RATINGS ................ -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Th e California Safe Drinking Water and Installer – Read all instructions, including WARNING WARNING Toxic Enforcement Act requires the this manual and the Knight XL Service Governor of California to publish a list of Manual, before installing. -
Page 4: The Knight Xl - How It Works
Installation & Operation Manual The Knight XL - How it works... 1. Stainless steel heat exchanger 19. High voltage junction box Allows system water to fl ow through specially designed Th e junction box contains the connection points for the line coils for maximum heat transfer, while providing protection voltage power and all pumps. - Page 5 Installation & Operation Manual The Knight XL - How it works... (continued) Model 400 Front View - Model 400 Rear View - Model 400 IMG00858 Left Side (inside unit) - Model 400 Right Side (inside unit) - Model 400...
- Page 6 Installation & Operation Manual The Knight XL - How it works... Model 501 IMG00860 Left Side (inside unit) - Model 501 Rear View - Model 501 Models 601 - 801 IMG00862 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801...
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Page 7: Ratings
Installation & Operation Manual Ratings Knight XL Boiler Other Specifi cations AHRI Rating Input Model Number Boiler Gross AHRI Vent Water Water Output Ratings Size Content Connections Connections Size (Note 4) Water, Note: Change “N” to Gallons “L” for L.P. gas models. (Note 1) (Note 2) (Note 3) -
Page 8: Determine Boiler Location
Installation & Operation Manual Determine boiler location Installation must comply with: Th is appliance is certifi ed as an indoor WARNING appliance. Do not install the appliance • Local, state, provincial, and national codes, laws, outdoors or locate where the appliance will regulations, and ordinances. - Page 9 Installation & Operation Manual Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, WARNING polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fi re, personal injury, or death.
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Page 10: Provide Air Openings To Room
Installation & Operation Manual Determine boiler location Provide air openings to room: Residential garage installation Knight XL alone in boiler room Precautions Take the following precautions when installing the appliance 1. No air ventilation openings into the boiler room are in a residential garage. -
Page 11: Corrosive Contaminants And Sources
Installation & Operation Manual Determine boiler location (continued) When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new boiler: Products to avoid: Failure to follow all instructions can result WARNING Spray cans containing chloro/fl uorocarbons in fl ue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions... -
Page 12: Removing A Boiler From Existing Common Vent
Installation & Operation Manual Determine boiler location When removing a boiler from existing common vent system: Do not install the Knight XL into a g. Any improper operation of the common venting DANGER common vent with any other appliance. system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ Th is will cause fl ue gas spillage or appliance NFPA 54 and/or CAN/CSA B149.1, Natural Gas and... -
Page 13: Prepare Boiler
Installation & Operation Manual Prepare boiler Remove boiler from wood pallet Model 400 1. Aft er 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). -
Page 14: Model 501
Installation & Operation Manual Prepare boiler Model 501 Aft er converting to LP, check combustion WARNING per the Start-up procedure in Section 1. Remove the top access cover from the unit (no tools 10 of this manual. Failure to check and required for removal). -
Page 15: General Venting
Installation & Operation Manual General venting Direct venting options - Sidewall Vent PVC/CPVC Concentric Sidewall Models 400 - 601 Only Two Pipe Sidewall See page 27 for more details See page 23 for more details Direct venting options - Vertical Vent Two Pipe Vertical PVC/CPVC Vertical Vent, Sidewall Air... -
Page 16: Install Vent And Combustion Air Piping
Installation & Operation Manual General venting Install vent and combustion air piping Th e Knight XL boiler must be vented and Th e Knight XL boiler vent and air piping can be installed DANGER supplied with combustion and ventilation through the roof or through a sidewall. Follow the procedures air as described in this section. -
Page 17: Requirements For Installation In Canada
45° elbow. material to comply with this requirement. Th e 4" Concentric Vent Kit available from Lochinvar (see EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows + Section 4 – Sidewall Termination – Optional Concentric (3) 45°... -
Page 18: Air Inlet Pipe Materials
Installation & Operation Manual General venting Air inlet pipe materials: Th e PVC, CPVC, or ABS air inlet pipe should be cleaned and Th e air inlet pipe(s) must be sealed. Choose acceptable sealed with the pipe manufacturer’s recommended solvents combustion air inlet pipe materials from the following list: and standard commercial pipe cement for the material used. -
Page 19: Optional Room Air
Installation & Operation Manual General venting (continued) Optional room air Air contamination Pool and laundry products and common household and hobby Optional room air is intended for products oft en contain fl uorine or chlorine compounds. When NOTICE commercial applications. Combustion these chemicals pass through the boiler, they can form strong air piping to the outside is recommended... - Page 20 Installation & Operation Manual General venting Table 3D PVC/CPVC Vent Pipe, and Fittings Dry fi t vent or air piping to ensure proper fi t up before assembling any joint. Th e pipe should go Approved PVC/CPVC Vent Pipe and Fittings a third to two-thirds into the fi tting to ensure Item Material...
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Page 21: Polypropylene
Installation & Operation Manual General venting Th e installer must use a specifi c vent starter (continued) NOTICE Polypropylene adapter at the fl ue collar connection. Th e adapter is supplied by the vent manufacturer Th is product has been approved for use with polypropylene to adapt to its vent system. -
Page 22: Stainless Steel Vent
Installation & Operation Manual General venting Stainless steel vent Figure 3-6 Near Boiler Stainless Steel Venting Models Th is product has been approved for use with stainless steel 400 - 601 using the manufacturers listed in Table 3G. Use only the materials, vent systems, and WARNING terminations listed in Tables 3G and 3I. -
Page 23: Sidewall Direct Venting
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent Follow instructions below when WARNING determining vent location to avoid TO BOILER INTAKE AIR possibility of severe personal injury, death, CONNECTION or substantial property damage. - Page 24 Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, Figure 4-2A Alternate PVC/CPVC/ Polypropylene Sidewall regulator, relief valve, or other equipment. Never Termination Models 400 - 801 w/Field Supplied Fittings terminate above or below any of these within 4 feet (1.2 m) horizontally.
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Page 25: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall For Polypropylene Only: Install the vent and air intake Figure 4-4A Clearance to Forced Air Inlets sidewall adapters from Table 3F on page 21 into the vent IF LESS plate. -
Page 26: Multiple Vent/Air Terminations
Installation & Operation Manual Sidewall direct venting Multiple vent/air terminations Figure 4-5B Polypropylene Sidewall Termination Assembly SIDEWALL 1. When terminating multiple Knight XL’s terminate ADAPTER (AIR) each vent/air connection as described in this manual WALL PLATE (FIG. 4-6A). SIDEWALL RETAINING All vent pipes and air inlets must terminate WARNING PLATE... -
Page 27: Sidewall Termination - Optional Concentric Vent
Sidewall termination – optional concentric vent: Models 400 - 601 Only Description and usage Lochinvar off ers an optional concentric combustion air 3. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 and vent pipe termination kit (#100140484 for 4" (102 mm) installations into the structure to install the termination kit. - Page 28 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent: Models 400 - 601 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 601 "A" "B" DIA. "C" DIA. "D" 3" (76 MM) "E" "G" "H"...
- Page 29 Installation & Operation Manual 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 Multiventing sidewall terminations DO NOT use fi eld-supplied couplings CAUTION to extend pipes.
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Page 30: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when WARNING Figure 5-1A PVC/CPVC/Polypropylene Vertical determining vent location to avoid Termination of Air and Vent possibility of severe personal injury, death or substantial property damage. ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED Determine location... -
Page 31: Prepare Roof Penetrations
Installation & Operation Manual Vertical direct venting (continued) Vent/air termination – vertical Prepare roof penetrations Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as Figure 5-2 Vertical Terminations with Multiple Boilers close as desired to the air pipe outside diameter. 12"... -
Page 32: Vertical Termination - Optional Concentric Vent
Description and usage 2. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 Lochinvar off ers an optional concentric combustion air and installations) into the structure to install the termination vent pipe termination kit. Both combustion air and vent kit. - Page 33 Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 400 - 601 Only Do not operate the appliance with DO NOT use fi eld-supplied couplings WARNING CAUTION the rain cap removed or recirculation to extend pipes. Airfl ow restriction will of combustion products may occur.
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Page 34: Alternate Vertical Concentric Venting
Installation & Operation Manual Vertical direct venting Alternate vertical concentric venting Th is appliance may be installed with a concentric vent Figure 5-8 Concentric Vent Example 1 arrangement where the vent pipe is routed through an FLUE EXHAUST existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. - Page 35 Installation & Operation Manual 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 FLUE EXHAUST AIR INLET SEAL...
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Page 36: Hydronic Piping
Installation & Operation Manual General piping information Hydronic piping All boiler piping must contain an oxygen IMPORTANT System water piping methods barrier. Th is will help prevent any excess oxygen from entering the system. Th e Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). -
Page 37: Flow Switch And Relief Valve Installation
Installation & Operation Manual Hydronic piping (continued) Flow switch, relief valve and temperature Figure 6-1 Flow Switch, Relief Valve and Temperature and and pressure gauge installation Pressure Gauge Installation_Models 400 - 501 Basic steps are listed below to guide you through the installation of the fl ow switch, relief valve, and temperature and pressure gauge provided with the unit. -
Page 38: Flow Switch Adjustment
Installation & Operation Manual Hydronic piping Flow switch adjustment Near boiler piping components Refer to Table 6A for the proper setting of the sensitivity 1. Boiler system piping: screw. For reference, the position of the screw prior to setting Boiler system piping MUST be sized per the pipe should be turned clockwise with a Phillips driver until it stops requirements listed in Table 6B. -
Page 39: Circulator Sizing
(3) set point temperatures to meet diff erent space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help aid with this protection, Lochinvar off ers the Multi- Temperature Loop Control Board Kit (100167843). - Page 40 Installation & Operation Manual Hydronic piping Figure 6-5 Pressure Drop vs. Flow - Models 400 and 501 Pressure Drop vs Flow (Includes Boiler Secondary Piping) KBN501 KBN400 Flow Rate (GPM) Figure 6-6 Pressure Drop vs. Flow - Models 601 thru 801 Pressure Drop vs Flow (Includes Boiler Secondary Piping) KBN801...
- Page 41 Installation & Operation Manual Hydronic piping (continued) Figure 6-7 Single Boiler - Multiple Temperatures Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment.
- Page 42 Installation & Operation Manual Hydronic piping Figure 6-8 Single Boiler - Primary/Secondary Piping Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION output does not not exceed indirect water heater transfer capabilities. Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment.
- Page 43 Installation & Operation Manual Hydronic piping (continued) Figure 6-9 Multiple Boilers - Multiple Temperatures Number of Units Model Manifold Pipe Sizes in Inches (mm) 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152) 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)
- Page 44 Installation & Operation Manual Hydronic piping Figure 6-10 Multiple Boilers - Primary/Secondary Piping Number of Units Model Manifold Pipe Sizes in Inches (mm) 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152) 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 3 1/2 (89) 4 (102)
- Page 45 Installation & Operation Manual Hydronic piping (continued) Figure 6-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION output does not not exceed indirect water heater transfer capabilities. Mixing valves are required for the protection of low temperature loops.
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Page 46: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping Figure 7-3 Gas Supply Piping - Models 601 - 801 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the boiler. Install ground joint union for servicing, when required. -
Page 47: Natural Gas
Installation & Operation Manual Gas connections (continued) Natural gas: Failure to apply pipe sealing compound WARNING as detailed in this manual can result Pipe sizing for natural gas in severe personal injury, death, or substantial property damage. 1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per Use two wrenches when tightening gas WARNING... -
Page 48: Check Inlet Gas Supply
Installation & Operation Manual Gas connections Table 7A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specifi c gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4... -
Page 49: Gas Pressure
Installation & Operation Manual Gas connections (continued) When re-tightening the set screw, be sure Figure 7-7 Inlet Gas Supply Check - Models 601 - 801 WARNING to tighten securely to prevent gas leaks. REMOVE THE 1/8” (3 MM) PIPE PLUG ON Do not check for gas leaks with an open THE INLET FLANGE TO THE VALVE AND INSTALL A SUITABLE 1/8”... -
Page 50: Field Wiring
Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply before making any electrical 1. National Electrical Code and any other national, state, connections to avoid possible electric provincial, or local codes, or regulations. -
Page 51: Outdoor Temperature Sensor
Connect this Th e tank sensor included with the Lochinvar Squire® indirect output to the 0 - 10V input on the boiler pump speed control. -
Page 52: Wiring Of The Cascade
Installation & Operation Manual Field wiring Modbus Alarm contacts When the optional ModBus interface module is installed, the Th e SMART SYSTEM control closes another set of contacts RS-485 ModBus cable is connected to these terminals. Use whenever the boiler is locked out or the power is turned off . shielded, 2-wire twisted pair cable. - Page 53 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections...
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Page 54: Condensate Disposal
Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. Th is boiler is a high effi ciency appliance that produces authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. -
Page 55: Startup
Installation & Operation Manual Start-up Freeze protection Fill water Check/control fi ll water chemistry Ethylene glycol is toxic, DO NOT use as WARNING your freeze protection. Ethylene glycol has a Conduct water quality testing prior to IMPORTANT sweet aroma which children and pets could installing the appliance. -
Page 56: Boiler Water
Installation & Operation Manual Start-up Oxygen prevention Fill and test water system 1. Fill system only aft er ensuring the water meets the Eliminate all system leaks. Continual CAUTION requirements of this manual. fresh makeup water will reduce boiler life. Minerals can build up in the 2. -
Page 57: Check For Gas Leaks
Installation & Operation Manual Start-up (continued) Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the propane Before starting the boiler, and during to make its presence detectable. In some WARNING initial operation, smell near the fl oor and instances, the odorant can fade, and the around the boiler for gas odorant or any gas may no longer have an odor. -
Page 58: Start The Boiler
Installation & Operation Manual Start-up Final checks before starting the boiler Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air Read the Knight XL Service Manual to familiarize yourself piping, and vent piping. with SMART SYSTEM control module operation. -
Page 59: For Your Safety Read Before Operating
Installation & Operation Manual 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. •... - Page 60 Installation & Operation Manual Start-up Check fl ame and combustion Set space heating operation (continued) 4. Place the boiler into the active position by pressing the Determine controlling sensor RIGHT SELECT [ON] key (FIG. 11-1, page 67). For space heating systems, the temperature control can be 5.
- Page 61 Installation & Operation Manual Start-up (continued) Set domestic hot water (DHW) operation Verify DHW mode Turn the NAVIGATION dial to adjust the minutes. Press Th ere are two (2) modes of operation for DHW. In Normal the NAVIGATION dial. Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and Turn the NAVIGATION dial to adjust the month.
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Page 62: Operating Information General
(3) separate loops, based on the settings for the three DHW is programmed for Zone Mode. It will continue to run (3) heat/loop demands (reference Lochinvar kit 100167843). for a short time aft er the end of the heat demand or the Freeze Protection Mode. -
Page 63: Temperature Control
Installation & Operation Manual Operating information (continued) Temperature control Protection features Modulation Outlet temperature, fl ue temperature, and temperature Th e Knight XL is capable of modulating its fi ring rate rise limiting from a minimum of 20% to a maximum of 100%. Th e fi ring rate is dictated by the call for heat (i.e., space heating Th e outlet temperature is monitored by the boiler outlet or domestic hot water), the heating load, ramp delay (if... - Page 64 Installation & Operation Manual Operating information Monitor external limits High limit operations Connections are provided on the connection board for Th e Knight XL is equipped with adjustable automatic reset and external limits such as fl ow switch, low water cutoff , manual reset high limits.
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Page 65: Cascade
Installation & Operation Manual Operating information (continued) Low water cutoff protection Sequence of the cascade Th e SMART SYSTEM control module uses temperature To equalize the run time of all boilers on the Cascade, the fi ring sensing of both supply and return areas of the heat sequence will automatically be changed at set intervals. -
Page 66: Sequence Of Operation
Installation & Operation Manual Operating information Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). - Page 67 Installation & Operation Manual Operating information (continued) Sequence of operation (continued) OPERATION DISPLAY 8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode.
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Page 68: Knight Xl Control Module
Installation & Operation Manual Operating information Knight XL control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel NAVIGATION DIAL Th e information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in the center): MENU = Left SELECT Key SETPOINTS = NAVIGATION Dial - Pressing Down... -
Page 69: Access Modes
Installation & Operation Manual Operating information (continued) Access modes User Th e user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is fl ashing at the bottom of the display. Th e date and time, and the temperature units can also be changed (see page 60). -
Page 70: Status Display Screens
Installation & Operation Manual Operating information Figure 11-2 Status Display Screen (CALL FOR (BOILER HEAT) STATUS) (OPERATIONAL INFORMATION) (RIGHT SELECT KEY) (LEFT SELECT KEY) (NAVIGATION DIAL) Status Display Screens Section Display Description Th e unit has not received a call for heat from a remote thermostat nor STANDBY has it received a call for heat from a DHW thermostat. - Page 71 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) Section Display Description SYSTEM: Th e temperature read by the system supply sensor (if connected). TANK: Th e temperature read by the tank sensor (if connected). OUTDOOR: Th e temperature read by the outdoor sensor (if connected). INLET TEMP: Th e temperature read at the inlet to the heat exchanger.
- Page 72 Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen. EXIT Press the LEFT SELECT key to exit the current screen or setting. Press the LEFT SELECT key to confi rm that the boiler needs to shutdown.
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Page 73: Maintenance Maintenance And Annual Startup
Installation & Operation Manual Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the Knight XL User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •... -
Page 74: Address Reported Problems
Installation & Operation Manual Maintenance Follow the Service and maintenance procedures given throughout this manual and in component literature WARNING 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. -
Page 75: Check Expansion Tank
Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire fl ue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage. -
Page 76: Check Control Settings
Installation & Operation Manual Maintenance Inspect ignition and fl ame sense Figure 12-2 Burner Assembly - Model 400 electrodes 1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/fl ame sense electrode using sandpaper. -
Page 77: Review With Owner
Installation & Operation Manual Maintenance (continued) Check fl ame signal 6. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent. 1. At high fi re the fl ame signal shown on the display should 7. -
Page 78: Diagrams
Installation & Operation Manual Diagrams Figure 13-1 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONNECTION BOARD CONTROL ALARM JUNCTION RELAY CONTACTS BOARD PUMP RUN-TIME CONTACTS X1-3 CN2-4 CN1-5 24 VAC LOUVER CN1-6 RELAY COIL... -
Page 79: Ladder Diagram
Installation & Operation Manual Diagrams (continued) Figure 13-2 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" GROUND SYSTEM INTEGRATED CONTROL PUMP ON / OFF CONTACTS SWITCH BLOWER X1-6 X1-1 3.15A SYSTEM PUMP BOILER X1-2 PUMP... -
Page 80: Revision Notes
Revision Notes: Revision A (ECO #C05747) initial release. Refl ects the new model numbers for the Knight XL upgrade. Revision B (ECO #C06188) refl ects changes made to FIG. 6-10 (ECR #R03474) remove ghost pipe, changes made to FIG.’s 6-7, 6-9, and 6-11 (R03563) change the direction of the arrows, and edits made to the ladder and wiring diagrams (ECO #C06158).