Lochinvar AQUAS AP 285 Installation & Operation Manual
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Lochinvar AQUAS AP 285 Installation & Operation Manual

Lochinvar AQUAS AP 285 Installation & Operation Manual

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100279257_2000537708_Rev B
Installation & Operation Manual
Models: AP 285
This manual must only be used by
⚠WARNING
a qualified heating installer/service
technician. Read all instructions,
including this manual and the
AQUAS/Knight Fire Tube Boiler
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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  • Page 1 100279257_2000537708_Rev B Installation & Operation Manual Models: AP 285 This manual must only be used by ⚠WARNING a qualified heating installer/service technician. Read all instructions, including this manual and the AQUAS/Knight Fire Tube Boiler Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

  • Page 2: Table Of Contents

    Contents HAZARD DEFINITIONS ..........2 6. HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING ....3-4 AQUAS Fire Tube Installation Instructions ....36-37 THE AQUAS FIRE TUBE -- HOW IT WORKS ... 5-6 Indirect Heat Exchanger Installation Instructions ..... 38 RATINGS ................7 AQUAS Fire Tube Pool Setup .........

  • Page 3: Please Read Before Proceeding

    Installation & Operation Manual Please read before proceeding AQUAS Fire Tube Pool Package The AQUAS Fire Tube pool package system is a high efficiency commercial condensing boiler, pre-piped package system from the factory to an indirect heat exchanger. This pool heater is a low temperature operating system designed to take advantage of the stainless steel heat exchanger and condensing operating temperatures to ensure the highest efficiency possible.
  • Page 4 Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including ⚠WARNING DO NOT install units in rooms or ⚠WARNING this manual and the Knight Fire Tube environments that contain corrosive Boiler Service Manual, before installing. contaminants (see Table 1B on page 11). Perform steps in the order given.

  • Page 5: The Aquas Fire Tube -- How It Works

    Installation & Operation Manual The AQUAS Fire Tube boiler - How it works... 16. Air intake adapter 1. Stainless steel heat exchanger Allows for the connection of the PVC air intake pipe to Allows system water to flow around specially designed tubes the boiler.
  • Page 6 Installation & Operation Manual The AQUAS Fire Tube boiler - How it works... DIR #2000507551 00 DIR #2000507762 00 Top View (inside unit) Front View DIR #2000507764 00 DIR #2000507559 00 Left Side (inside unit) Front View (inside unit)

  • Page 7: Ratings

    8. The AP285 model can be alternatively vented using a 4" vent/air size. If the 3" vent/air size is used, the maximum 1. As an Energy Star Partner, Lochinvar has determined that vent/air pipe lengths are limited to 50 equivalent feet each.

  • Page 8: Determine Boiler Location

    Installation & Operation Manual Determine boiler location Installation must comply with: This appliance is certified as an indoor ⚠WARNING appliance. Do not install the appliance • Local, state, provincial, and national codes, laws, outdoors or locate where the appliance regulations, and ordinances. will be exposed to freezing temperatures •...
  • Page 9 Installation & Operation Manual Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, 12" ⚠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 fire, 6"...

  • Page 10: Provide Air Openings To Room

    Installation & Operation Manual Determine boiler location Residential garage installation If you do not provide the recommended NOTICE service clearances shown, it may not be Precautions possible to service the boiler without Take the following precautions when installing the appliance removing it from the space.

  • Page 11: Corrosive Contaminants And Sources

    Installation & Operation Manual Determine boiler location (continued) When using an existing vent system to Table 1B Corrosive Contaminants and Sources install a new boiler: Products to avoid: Failure to follow all instructions can result ⚠WARNING in flue gas spillage and carbon monoxide Spray cans containing chloro/fluorocarbons emissions, causing severe personal injury or death.
  • Page 12 Installation & Operation Manual Determine boiler location When removing a boiler from existing common vent system: Do not install the AQUAS into a common g. Any improper operation of the common venting system ⚠ DANGER should be corrected so the installation conforms with the vent with any other appliance.

  • Page 13: Prepare Boiler

    Installation & Operation Manual Prepare boiler Gas conversions 1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow For a boiler already installed, you must ⚠WARNING the boiler to cool before proceeding. turn off gas supply, turn off power, and allow boiler to cool before proceeding.
  • Page 14 Installation & Operation Manual Prepare boiler When removing the natural gas ⚠ DANGER venturi, inspect the gasket at the gas connection and the O-ring at the blower. These gaskets must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

  • Page 15: General Venting

    Installation & Operation Manual General venting Direct venting options - Sidewall Vent DIR #2000507755 00 DIR #2000507732 00 Figure 3-1 Two-Pipe Sidewall Termination - See Figure PVC/CPVC Concentric Sidewall page 23 for more details Termination - See page 27 for more details Direct venting options - Vertical Vent DIR #2000507739 00 DIR #2000507759 00...

  • Page 16: Install Vent And Combustion Air Piping

    Installation & Operation Manual General venting Install vent and combustion air piping The AQUAS Fire Tube boiler must be The AQUAS Fire Tube boiler vent and air piping can be ⚠ DANGER vented and supplied with combustion and installed through the roof or through a sidewall. Follow the ventilation air as described in this section.

  • Page 17: Requirements For Installation In Canada

    Table 3B Approved Concentric Vent Systems The 3" and 4" Concentric Vent Kit available from Part Number Lochinvar (see Section 4 – Sidewall Termination – Optional Vent Vent Vent Lochinvar SAP / Concentric Vent) and the 3"...

  • Page 18: Materials

    Installation & Operation Manual General venting Materials Air inlet pipe materials: The PVC, CPVC, or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: sealed with the pipe manufacturer’s recommended solvents 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 NOTICE products often contain fluorine or chlorine compounds. When commercial applications. Combustion these chemicals pass through the boiler, they can form strong air piping to the outside is recommended acids.

  • Page 20: Pvc/Cpvc

    Installation & Operation Manual General venting PVC/CPVC Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air This product has been approved for use with the PVC/CPVC or vent piping. vent materials listed in Table 3D.

  • Page 21: Polypropylene

    Installation & Operation Manual General venting (continued) Polypropylene Insulation should used This product has been approved for use with polypropylene ⚠WARNING polypropylene venting materials. The use vent with the manufacturers listed in Table 3E. of insulation will cause increased vent wall All terminations must comply with listed options in this temperatures, which could result in vent manual and be a single-wall vent offering.

  • Page 22: Stainless Steel Vent

    Installation & Operation Manual General venting Stainless steel vent Installation of a stainless steel vent system NOTICE should adhere to the stainless steel vent This product has been approved for use with stainless steel manufacturer’s installation instructions using the manufacturers listed in Table 3F. supplied with the vent system.

  • Page 23: Sidewall Direct Venting Vent/Air Termination - Sidewall

    Vent Supplier Part Number buildings or surfaces, window wells, stairwells, Diameter alcoves, courtyards, or other recessed areas. 3 inch Lochinvar 100157610 4 inch Lochinvar 100157611 Sidewall vent and air inlet terminations ⚠WARNING must terminate in the same pressure zone.
  • Page 24 Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall 6. Locate terminations so they are not likely to be damaged Figure 4-1C Alternate PVC/CPVC/SS/ Polypropylene Venting by foreign objects, such as stones or balls, or subject to Arrangement (if Space Allows) w/Field Supplied Fittings buildup of leaves or sediment.

  • Page 25: Prepare Wall Penetrations

    Installation & Operation Manual Sidewall direct venting (continued) 9. Stainless steel terminations are designed to penetrate Figure 4-3B Alternate Clearance to Forced Air Inlets w/ walls with a thickness up to 9.25 inches of standard Field Supplied Fittings construction. IF LESS THAN 10’...

  • Page 26: Multiple Vent/Air Terminations

    Installation & Operation Manual Sidewall direct venting Prepare wall penetrations (Alternate - Figure 4-5A Multiple Vent Terminations (must also Field Supplied Option) comply with Figure 4-1A) Air pipe penetration: 12" MIN. BETWEEN EDGE OF AIR Cut a hole for the air pipe. Size the air pipe hole as INLET AND ADJACENT VENT OUTLET close as desired to the air pipe outside diameter.

  • Page 27: Sidewall Termination - Optional Concentric Vent

    Sidewall termination – optional concentric vent Description and usage 3. Cut one (1) hole (5 inch diameter for #100140480 and Lochinvar offers optional concentric combustion air and 7 inch diameter for #100140484 installations) into the vent pipe termination kits (Factory Kit #100140484 for 4"...
  • Page 28 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-9 3" Concentric Vent Dimensional Drawing Figure 4-10 4" Concentric Vent Dimensional Drawing (reference Table 3B on page 17) (reference Table 3B on page 17) "B" DIA. "C"...
  • Page 29 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-12 Concentric Vent Sidewall Attachment Note: 100140480 shown for illustration purposes. Multi-venting sidewall terminations DO NOT use field-supplied couplings CAUTION to extend pipes. Airflow restriction When two (2) or more direct vent appliances are vented near will occur and may cause intermittent each other, each appliance must be individually vented (see...

  • Page 30: Vertical Direct Venting Vent/Air Termination - Vertical

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent Follow instructions below when ⚠WARNING determining vent location to avoid ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED possibility of severe personal injury, death, ANYWHERE WITHIN 24”...

  • Page 31: Prepare Roof Penetrations

    Installation & Operation Manual Vertical direct venting (continued) Vent/air termination – vertical Prepare roof penetrations Figure 5-2 Vertical Terminations with Multiple Boilers Air pipe penetration: 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: Cut a hole for the vent pipe.

  • Page 32: Vertical Termination - Optional Concentric Vent

    Vertical termination – optional concentric vent Description and usage 2. Cut one (1) hole (7 inch diameter for #100140484 Lochinvar offers 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 Do not operate the appliance with DO NOT use field-supplied couplings ⚠WARNING CAUTION the rain cap removed or recirculation to extend pipes. Airflow restriction will of combustion products may occur. occur.

  • Page 34: Alternate Vertical Concentric Venting

    Installation & Operation Manual Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent Figure 5-8 Concentric Vent Example 1 arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing FLUE EXHAUST 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...

  • Page 36: Hydronic Piping

    Installation & Operation Manual Hydronic piping Installation Instructions Piping To achieve the optimum operating efficiency of your AQUAS it is recommended that you keep the pool water flow of each Pool / spa connections to the indirect heat exchanger are SCH 80 appliance within plus or minus five gallons per minute of CPVC glue fittings.
  • Page 37 Installation & Operation Manual Hydronic piping (continued) The system can be installed in either a Full Flow or Diverted If the total system flow of the swimming pool or spa system Flow orientation: is within five gallons per minute of the recommended system wate Full Flow The limit will be mounted in a 3/8"...

  • Page 38: Indirect Heat Exchanger Installation Instructions

    Installation & Operation Manual Hydronic piping Indirect Heat Exchanger Installation Instructions Heat exchangers should be installed downstream of the pumping and filtration equipment (reference FIG. 6-1). Makeup Water Assembly Figure 6-2 Connecting the Makeup Water Assembly In the following steps, a backup wrench is NOTICE necessary to properly attach the makeup water assembly.

  • Page 39: Aquas Fire Tube Pool Setup

    Installation & Operation Manual Hydronic piping (continued) Figure 6-4 Bypass (if flow is greater than required by heat exchanger) FROM POOL CPVC VALVE THROTTLING 115ºF LIMIT TO POOL RECOMMENDED ISOLATION VALVE TEMPERATURE FLOW SWITCH AND PRESSURE GAUGE FACTORY POOL RETURN SENSOR LOCATION RELIEF VALVE DIR# 2000538951 00...
  • Page 40 Installation & Operation Manual Hydronic piping Auxiliary Heat Exchanger / Domestic Hot Water This system received factory installed auxiliary tappings for Domestic Hot Water (DHW) or Spa operation. The heat exchanger kits listed in Tables 6C and 6D include all the necessary parts to install the auxiliary heat exchanger in the field. Piping is not included with this package and should be field-supplied.
  • Page 41 Installation & Operation Manual Hydronic piping (continued) Set DHW/Spa boiler target temperature Set maximum DHW/Spa fan speed When in the DHW/Spa Mode, the control will modulate If the rated input of the indirect tank is less than the maximum to maintain the boiler outlet temperature or system supply output of the boiler, change the maximum DHW/Spa fan speed temperature to a set point.

  • Page 42: Low Water Cutoff Device

    Installation & Operation Manual Hydronic piping Low water cutoff device 7. Install an expansion tank on the system supply. Consult the On a boiler installed above radiation level, some states and tank manufacturer’s instruction for specific information local codes require a low water cutoff device at the time of relating to tank installation.

  • Page 43: Gas Connections Connecting Gas Supply Piping

    Installation & Operation Manual Gas connections (continued) Connecting gas supply piping 3. Support piping with hangers, not by the boiler or its accessories. 1. Refer to FIG. 7-1 to pipe gas to the boiler. The gas valve and blower will not support Install ground joint union for servicing, when ⚠WARNING the weight of the piping.

  • Page 44: Natural Gas

    Installation & Operation Manual Gas connections Natural gas: Use two wrenches when tightening gas ⚠WARNING piping at boiler (FIG. 7-2), using one Pipe sizing for natural gas wrench to prevent the boiler gas line connection from turning. Failure to 1. Refer to Table 7A for pipe length and diameter. Based on support the boiler gas connection pipe to rated boiler input (divide by 1,000 to obtain cubic feet per prevent it from turning could damage gas...

  • Page 45: Check Inlet Gas Supply

    Installation & Operation Manual Gas connections (continued) Table 7A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4...

  • Page 46: Gas Pressure

    Installation & Operation Manual Gas connections Gas Pressure When re-tightening the set screw, be sure ⚠WARNING to tighten securely to prevent gas leaks. The gas pressure must remain between 4 inches w.c. (natural), Do not check for gas leaks with an open 8 inches w.c.

  • Page 47: Field Wiring

    Installation & Operation Manual Field wiring Label all wires prior to disconnection ⚠CAUTION ELECTRICAL SHOCK HAZARD – For your when servicing controls. Wiring errors ⚠WARNING safety, turn off electrical power supply before can cause improper and dangerous making any electrical connections to avoid operation.
  • Page 48 A system supply sensor must be installed. Connect this 2. The tank sensor included with the Lochinvar Squire output to the 0 - 10V input on the boiler pump speed control. Indirect DHW tank (#100170544) is the only sensor Rate output suitable for use with the SMART SYSTEM control.

  • Page 49: Wiring Of The Cascade

    Installation & Operation Manual Field wiring (continued) Flow switch Runtime contacts 1. A flow switch is used to guarantee flow through the The SMART SYSTEM control closes a set of dry contacts boiler before allowing it to fire. The flow switch must be whenever the burner is running.
  • Page 50 Installation & Operation Manual Field wiring If outdoor air reset is desired, the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 8-3). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters.
  • Page 51 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections...

  • Page 52: Condensate Disposal Condensate Drain

    Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of 1. The AQUAS Fire Tube boiler is a high efficiency other authority, PVC and CPVC pipe must comply with ASTM D1785 or appliance that produces condensate.

  • Page 53: Startup

    Installation & Operation Manual Start-up Fill water Chlorinators must feed downstream of the boiler and have an anti-siphoning device to prevent chemical backup Check/control fill water chemistry in the heater when the pump is shut off. Conduct water quality testing prior to IMPORTANT High chemical...
  • Page 54 Installation & Operation Manual Start-up Boiler water Determine the freeze protection fluid quantity using system water content, following the fluid manufacturer's Do not use petroleum based cleaning or instructions. Boiler water content is listed on page 7. CAUTION sealing compounds in the boiler system. Remember to include expansion tank water content.
  • Page 55 Installation & Operation Manual Start-up (continued) Purge air from water system Figure 10-3 Condensate Trap 1. Purge air from system: Connect a hose to the purge valve. Route the hose to an area where water can drain and be seen. FROM CONDENSATE VENT ON APPLIANCE Close the boiler or system isolation valve between the...
  • Page 56 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 Fire Tube Boiler Service Manual to piping, and vent piping. familiarize yourself with SMART SYSTEM control Venting system must be sealed gastight module operation.
  • Page 57 Installation & Operation Manual Start-up (continued) Set space heating operation Please note that the brackets ([]) denote NOTICE screen status. Determine controlling sensor 4. Place the boiler into the active position by pressing the For space heating systems, the temperature control can be RIGHT SELECT [ON] key (FIG.
  • Page 58 Installation & Operation Manual Start-up Set domestic hot water (DHW) operation Turn the NAVIGATION dial to adjust the minutes. Press Verify DHW mode the NAVIGATION dial. There are two (2) modes of operation for DHW. In Normal Turn the NAVIGATION dial to adjust the month. Press the Mode, when a DHW demand begins, the control will start NAVIGATION dial.
  • Page 59 Installation & Operation Manual Start-up (continued) Figure 10-4 Operating Instructions...

  • Page 60: Operating Information

    Installation & Operation Manual Operating information General SMART SYSTEM Multi-temp loop control The Aquas Fire Tube Pool Heater is capable of controlling two How the boiler operates different bodies of water. The main body of water is controlled from Heat/Loop demand 1. If your Aquas is setup to control The AQUAS Fire Tube boiler uses an advanced stainless steel two bodies of water, the DHW operation is used for the second heat exchanger and electronic control module that allows...
  • Page 61 Installation & Operation Manual Operating information (continued) Anti-cycling Ramp delay After the burner turns off, the control will delay the next For systems with lower flow, the SMART SYSTEM can burner cycle for a set time period (time is adjustable by the limit the firing rate (when enabled) when a pool heating installer).
  • Page 62 Installation & Operation Manual Operating information Protection features Low voltage blocking The blower and gas valve require a minimum amount of Outlet temperature, flue temperature, voltage in order to operate properly. If an ignition attempt is temperature rise limiting made when the line voltage is temporarily low (such as during a The outlet temperature is monitored by the boiler outlet brownout), the control could enter a manual reset lockout.
  • Page 63 Installation & Operation Manual Operating information (continued) Boiler temperature regulation If the current outlet temperature is below the new MRHL set point, locate the pinhole (SERVICE button) above the Operating temperature (target) RESET button on the display board. Insert a thin probe (such as a paper clip) into the hole and press the button The SMART SYSTEM control module senses water continuously for five (5) seconds to place the boiler into...

  • Page 64: Cascade

    Installation & Operation Manual Operating information Cascade Sequence of the cascade When multiple boilers are installed, they can be wired together To equalize the run time of all boilers on the Cascade, the firing in a cascade sequence. A maximum of eight boilers can be sequence will automatically be changed at set intervals.
  • Page 65 Installation & Operation Manual Operating information (continued) Wiring of the Cascade DHW, Night Setback, and Ramp Delay operation with cascade When wiring the boilers for Cascade operation, select one boiler For Normal Mode DHW operation any boiler(s) in the as the Leader boiler. The remaining boilers will be designated Cascade can be selected to provide heat for a DHW call.

  • 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 7. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command (such as a 0-10V BMS signal).

  • Page 68: Aquas Fire Tube Control Module

    Installation & Operation Manual Operating information AQUAS Fire Tube control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel USB Memory Drive PC Connection Reset The 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: Display Panel Menu Access

    Installation & Operation Manual Operating information (continued) Display panel menu access Table 11A Use this procedure to access menus from the display panel SCREEN BUTTON OPERATION DISPLAY STATUS [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES]. Press and hold the LEFT SELECT soft key [MENU] [MENU] for five (5) seconds.

  • Page 70: Status Display Screens

    Installation & Operation Manual Operating information Figure 11-2 Status Display Screen (BOILER (CALL FOR STATUS) HEAT) (OPERATIONAL INFORMATION) (LEFT SELECT (RIGHT SELECT KEY) KEY) (NAVIGATION DIAL) Status Display Screens NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description...
  • Page 71 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description a. SYSTEM TEMP b. TANK TEMP c. OUTDOOR TEMP DETAILS SCREEN 1 d.
  • Page 72 Installation & Operation Manual Operating information Status Display Screens (cont’d) NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description a. CASCADE STATUS CASCADE STATUS b. CASCADE POWER (Operational c. PRESENT Information a. TRIGGER 1 - Next Space Heat (SH) night setback trigger. cont.) NIGHT SETBACK b.

  • 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 Fire Tube User’s Information Manual (see the following pages for instructions) for instructions) • Check boiler area General: •...
  • Page 74 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 Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected ⚠WARNING AT LEAST ONCE EVERY THREE Visually inspect the entire flue gas venting system and air YEARS, by a licensed plumbing contractor piping for blockage, deterioration or leakage.
  • Page 76 Installation & Operation Manual Maintenance Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from the 2. If the flame is unsatisfactory at either high fire or low fire, boiler heat exchanger access cover.
  • Page 77 Installation & Operation Manual Maintenance (continued) Review with owner 5. Loosen both unions on the top of the heat exchanger to isolate it from the boiler piping. Remove the two bolts 1. Review the Knight Fire Tube Boiler User’s Information from the two part heat exchanger brackets to remove the Manual with the owner.

  • Page 78: Diagrams

    Installation & Operation Manual Diagrams Figure 13-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" INTEGRATED CONTROL BLOWER ON / OFF SWITCH SYSTEM SYSTEM X1-6 X1-1 PUMP "L" PUMP "N" X1-2 3.15A SYSTEM PUMP...

  • Page 79: Wiring Diagram

    Installation & Operation Manual Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING CONNECTION BOARD INTEGRATED BOX DEPICTS CONTROL 24 VAC DHW RECIRC CN5-15 JUNCTION OPTIONAL PUMP RELAY COIL ITEMS ALARM X1-3...

  • Page 80: Revision Notes

    Revision Notes: Revision A (PCP# 3000005197 / CN# 500005965) initial release. Revision B (PCP #3000044010 / CN #500031602) reflects an update to FIG. 8-1. 100279257_2000537708_Rev B 02/21...

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