Lochinvar Knight XL 400 - 801 Installation & Operation Manual
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Lochinvar Knight XL 400 - 801 Installation & Operation Manual

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KBXII-I-O Rev H
Installation & Operation Manual
Models: 400 - 801
This manual must only be used by
WARNING
a 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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Summary of Contents for Lochinvar Knight XL 400 - 801

  • Page 1 KBXII-I-O Rev H Installation & Operation Manual Models: 400 - 801 This manual must only be used by WARNING a 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.

  • 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 Installer – Read all instructions, including When servicing boiler – WARNING this manual and the Knight XL Service • To avoid electric shock, disconnect electrical supply Manual, before installing. Perform steps in before performing maintenance.

  • Page 4: The Knight Xl - How It Works

    Installation & Operation Manual The Knight XL - How it works... Stainless steel heat exchanger 19. High voltage junction box Allows system water to fl ow through specially designed The 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 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 Rear View - Model 501 Left Side (inside unit) - Model 501 Models 601 - 801 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801...

  • 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: This 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, CLOSET INSTALLATION WARNING 1/4" (6 MM) MINIMUM CLEARANCE polypropylene or stainless steel AROUND HOT WATER PIPES vent material MUST BE used in 1”...

  • 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...

  • 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/NFPA This will cause fl...

  • Page 13: Prepare Boiler

    Installation & Operation Manual 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.

  • Page 14: Model 501

    Installation & Operation Manual Prepare boiler Model 501 After 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 The Knight XL boiler must be vented and The 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. The 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: Materials

    Installation & Operation Manual General venting 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 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 often 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 acids.

  • Page 20: Pvc/Cpvc

    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. The pipe should go a third to Approved PVC/CPVC Vent Pipe and Fittings two-thirds into the fi...

  • Page 21: Polypropylene

    Installation & Operation Manual General venting (continued) Polypropylene Insulation should not be used on WARNING This product has been approved for use with polypropylene polypropylene venting materials. The use vent with the manufacturers listed in Table 3E. of insulation will cause increased vent wall temperatures, which could result in vent All terminations must comply with listed options in this manual pipe failure.

  • Page 22: Stainless Steel Vent

    Installation & Operation Manual General venting Stainless steel vent Figure 3-5 Near Boiler Stainless Steel Venting Models This 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 Vent/Air Termination - Sidewall

    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.

  • 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 offers an optional concentric combustion air 3. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007 and vent pipe termination kit (#CVK3007 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: Sidewall Termination - Optional Concentric Vent

    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...

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

    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 ALTERNATE INTAKE LOCATIONS: or substantial property damage. INTAKE PIPES MAY BE LOCATED Determine location ANYWHERE WITHIN 24"...

  • 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 #CVK3007 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: 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.

  • 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 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...

  • Page 36: Hydronic Piping

    Installation & Operation Manual Hydronic piping System water piping methods General piping information The Knight XL is designed to function in a closed loop Basic steps are listed below along with illustrations on the pressurized system not less than 12 psi (83 kPa). A temperature following pages (FIG.’s 6-7 through 6-11), which will guide you and pressure gauge is included to monitor system pressure through the installation of the Knight XL (reference FIG.’s 6-4A...

  • 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...

  • 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

    When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help TO FLOOR aid with this protection, Lochinvar offers the Multi- DRAIN Temperature Loop Control Board Kit (RLY30086).
  • 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 TEMPERATURE TEMPERATURE LOOP 3 TEMPERATURE LOOP 2 WIRES TO LOOP SENSORS LOOP 1 LOOP SENSOR (3X) 120VAC TO PUMPS MAKE UP WATER AIR SEPARATOR PRESSURE MULTI-TEMP GAUGE LOOP CONTROL BACK FLOW...
  • Page 42 Installation & Operation Manual Hydronic piping Figure 6-8 Single Boiler - Primary/Secondary Piping MAY SUBSTITUTE LOW LOSS HEADER AIR SEPARATOR DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART (TYPICAL) BALL VALVE SYSTEM SUPPLY SENSOR (TYPICAL) (WHEN USED) SYSTEM CIRCULATOR PRESSURE GAUGE...
  • 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 WIRES TO TEMPERATURE LOOP SENSORS LOOP 3 TEMPERATURE LOOP 2 TEMPERATURE LOOP 1 LOOP SENSOR (3X) 120VAC TO PUMPS MAKE UP WATER AIR SEPARATOR BACK FLOW PREVENTER...

  • Page 46: Gas Connections Connecting Gas Supply Piping

    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 Nominal Maximum Natural Gas Pipe Capacity Chart Capacity of Pipe Iron Pipe Length of Pipe in Straight Feet in Thousands of Size Btu/hr per hour (inches) 175 200 for gas pressures of 14 Inches Water Column...

  • 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

    fl ow in the primary loop is extremely low. Connect this The 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 The 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...

  • Page 54: Condensate Disposal Condensate Drain

    Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. This boiler is a high effi ciency appliance that produces authority, PVC and CPVC pipe must comply condensate.

  • Page 55: Startup

    Installation & Operation Manual Start-up Check/control water chemistry 3. Fill to correct system pressure. Correct pressure will vary with each application. Do not use petroleum-based cleaning or CAUTION The minimum cold water fi ll pressure for a sealing compounds in the boiler system. commercial system is 12 psi (82.7 kPa).

  • Page 56: Check For Gas Leaks

    Installation & Operation Manual Start-up 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 57: Start The Boiler

    Installation & Operation Manual Start-up (continued) 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.

  • Page 58: For Your Safety Read Before Operating

    Installation & Operation Manual 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. • Immediately call your gas supplier from a A.

  • Page 59: Set Space Heating Operation

    Installation & Operation Manual Start-up (continued) 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 60 Installation & Operation Manual Start-up Set domestic hot water (DHW) operation Verify DHW mode There are two (2) modes of operation for DHW. In Normal Turn the NAVIGATION dial to adjust the minutes. Press 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.

  • Page 61: 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 RLY30086). for a short time after the end of the heat demand or the Freeze Protection Mode.

  • Page 62: Temperature Control

    Installation & Operation Manual Operating information Temperature control Protection features Modulation Outlet temperature, fl ue temperature, and temperature The Knight XL is capable of modulating its fi ring rate rise limiting from a minimum of 20% to a maximum of 100%. The fi...
  • Page 63 Installation & Operation Manual Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for The Knight XL is equipped with adjustable automatic reset and external limits such as fl ow switch, low water cutoff, manual reset high limits.

  • Page 64: Cascade

    Installation & Operation Manual Operating information Low water cutoff protection Sequence of the cascade The 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 65: Sequence Of Operation

    Installation & Operation Manual 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).
  • Page 66 Installation & Operation Manual Operating information 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.

  • Page 67: Knight Xl Control Module

    Installation & Operation Manual Operating information (continued) 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 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 68: Access Modes

    Installation & Operation Manual Operating information Access modes User The 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. The date and time, and the temperature units can also be changed (see page 60).

  • Page 69: Status Display Screens

    Installation & Operation Manual Operating information (continued) 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 The 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 70 Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display 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.

  • Page 71: Status Display Screens

    Installation & Operation Manual Operating information (continued) 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...

  • Page 72: 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 73: Address Reported Problems

    Installation & Operation Manual Maintenance (continued) 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 74: Check Expansion Tank

    Installation & Operation Manual Maintenance 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 75: Check Control Settings

    Installation & Operation Manual Maintenance (continued) 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 76: Review With Owner

    Installation & Operation Manual Maintenance 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 77: 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 78: Ladder Diagram

    Installation & Operation Manual Diagrams 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 CONTACTS...
  • Page 79 Installation & Operation Manual Notes...

  • 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).

This manual is also suitable for:

Knight xl kbn400Knight xl kbn501Knight xl kbn601Knight xl kbn701Knight xl kbn801

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