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Installation & Operation Manual

66

13

Diagrams

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM
LBL7083 REV G

120 VAC

24 VAC

120VAC

TERMINAL STRIP

120V SUPPLY "L"

ON / OFF

SWITCH

X1-6

BOILER PUMP

RELAY

DHW PUMP

RELAY

SYSTEM PUMP

RELAY

BLOWER

RELAY

X1-4

X1-3

X1-2

X1-1

BOILER

PUMP "L"

DHW

PUMP "L"

SYSTEM

PUMP "L"

BOILER

PUMP

DHW

PUMP

SYSTEM

PUMP

BOILER

PUMP "N"

DHW

PUMP "N"

SYSTEM

PUMP "N"

1

2

3

BLOWER

JUNCTION BOX

X1-5

X6-8

X6-3

F5

X5-7

X6-7

NEUTRAL

CN4-1

CONNECTION

BOARD

CN4-7

CN5-1

TERMINAL STRIP
120V SUPPLY "N"

JUNCTION

BOX

X1-8

FLOW

SWITCH

CONNECTION

BOARD

CN5-3

LWCO

CN5-2

CN5-4

ROOM THERMOSTAT

ZONE CONTROL

DHW

THERMOSTAT

CONNECTION

BOARD

CONNECTION BOARD

CN4-6

CN4-13

CN4-5

CN4-3

X6-9

X6-6

X6-1

X6-5

INTEGRATED

CONTROL

MANUAL RESET

HIGH LIMIT

X5-14

CN4-9

X6-4

CONNECTION

BOARD

LOW GAS

PRESSURE

SWITCH

HIGH GAS

PRESSURE

SWITCH

AUX. DEVICE

PILOT SUPPLY

24VAC

AUX. DEVICE

PROVING

CN4-2

X6-10

BLOCKED

DRAIN

SWITCH

AUTO RESET

HI-LIMIT

X5-11

X5-3

X5-10

X5-4

X2-1

GAS VALVE

GAS VALVE

RELAY

X5-5

X5-13

X5-6

X5-12

1

2

4

5

5A

F4

3.5A

F2

3.5A

F3

1.25A

TR1

X1-7

FLAME ROD

SPARK

ROD

INTEGRATED CONTROL

GROUND

JUNCTION BOX

INTEGRATED

CONTROL

120 VAC

LOW VOLTAGE

HIGH VOLTAGE

CAUTION

HIGH VOLTAGE SPARK LEAD

BLOWER

TERMINAL

STRIP

TERMINAL

STRIP

CN3-8

CN3-7

CN3-9

CN3-6

CN3-4

CN3-3

CN3-1

CN3-10

DISPLAY

CONNECTION BOARD

INLET

SENSOR

OUTLET

SENSOR

FLUE

SENSOR

X4-8

X4-7

X4-9

X4-6

X4-4

X4-3

X4-1

X4-10

INTEGRATED

CONTROL

CN4-11

CN4-12

CN4-10

CN4-4

ALARM

CONTACTS

RUN-TIME

CONTACTS

X3-1

X3-3

X3-4

X3-2

X5-8

X5-1

X5-2

X5-9

X3

RIBBON CABLE

CN3-5

X4-5

X8

SYSTEM

SENSOR

(AUX) DHW

TANK

SENSOR

OUTDOOR

SENSOR

0-10V

+

-

RS485

A

B

SHIELD

SHIELD

EXTERNAL

CONTROL

CN1-1

CN3-2

X4-2

CN1-2

CN1-3

CN1-4

CN1-5

CN1-6

CN1-7

CN1-8

CN1-9

CN1-10

CN1-11

CN1-12

CN2-8

CN2-7

CN2-6

CN2-5

PC

INTERFACE

CN2-7

CN2-8

CN2-9

CN2-10

CN2-15

SILENCING

SWITCH

AL

ARM

B

E

LL

S6

S4

S5

S2

S1

S3

CN2-9

CN2-2

CN2-10

CN2-12

CN2-1

CN2-3

CN2-11

CN2-16

CN2-15

CN2-14

CN2-13

CN2-4

X2-2

GND

GND

GND

X6-2

CN4-14

NOTES:
1. Where possible, switches are shown without utilities (gas, water or
  electricity) connected to the unit.  As such, actual switch states may
  vary from those shown on diagrams depending upon whether utilities
    are connected or a fault condition is present.
2. See wiring diagram for additional notes.

KB

MODELS

ONLY

AIR PRESSURE

SWITCH

RESISTOR

Figure 13-1

Ladder Diagram

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Summary of Contents for 210

Page 1: ...taller service technician Read all instructions including this manual and the Knight Wall Mount Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage WARNING Save this manual for future reference ...

Page 2: ... Vent Piping Materials 14 Requirements for Installation in Canada 14 Air Intake Vent Connections 15 Air Inlet Pipe Materials 15 Max Allowable Vent Piping Lengths 15 Removing from Existing Vent 16 Vent and Air Piping 16 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 17 20 Determine Location 17 18 Prepare Wall Penetrations 19 Termination and Fittings 19 Multiple Vent Air Terminations 19 20 ...

Page 3: ...esult in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal c...

Page 4: ... provides a wide range of firing rates 13 Water outlet system supply The water outlet is the water connection for water leaving the boiler and entering the system Boiler connection is 1 14 Water inlet system return The water inlet is the water connection for water entering the boiler from the system Boiler connection is 1 15 Gas connection pipe Threaded pipe connection of 1 2 This pipe should be c...

Page 5: ...ration Manual Front View 8 20 7 3 14 13 29 6 31 16 7 27 Left Side inside unit 24 25 1 2 4 5 22 18 26 Right Side inside unit The Knight Wall Mount Boiler How it works continued FRONT OF UNIT Bottom View 5 Models 50 210 ...

Page 6: ...ith no field adjustments For high altitude models output ratings will be reduced by 2 for each 1 000 feet above sea level High altitude models have a different control module for altitude operation but the operation given in this manual for standard models remains the same Maximum allowed working pressure is located on the rating plate NOTICE Knight Wall Mount Boiler I B R Rating Model Number Note...

Page 7: ...ized expansion tank Lack of freeze protection in boiler water causing system and boiler to freeze and leak WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Failure to install the appliance indoors could result in severe personal injury death or...

Page 8: ...MUST BE used in a closet structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death Note Service clearances are recommendations only Note Service clearances are recommendations only WARNING For alcove installations CPVC material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fi...

Page 9: ...on of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that ...

Page 10: ...in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all doors between the space in which the app...

Page 11: ...e unit and remove the bezel 3 Locate the power switch on the gas valve and turn the power switch to the OFF position FIG 2 2 4 Disconnect the Molex plug from the wiring connector located on the gas valve 5 Using a 5 16 nut driver loosen the band clamp securing the air intake coupler to the gas valve venturi Remove the air intake pipe and coupler from the gas valve venturi 6 Using a 4mm Allen wrenc...

Page 12: ...Hang the boiler on the bracket and secure the bottom of the boiler with two 2 field supplied toggle bolts WARNING Do not mount the boiler to a hollow wall Be sure to mount the boiler to the studs only Mounting the boiler See page 9 of this manual for boiler mounting location instructions NOTICE The Knight Wall Mount boiler is not intended for floor installation Mounting to a wood studded wall 1 Th...

Page 13: ...l Termination See page 23 for more details Figure 3 2 Two Pipe Sidewall Termination See page 17 for more details Figure 3 3 Concentric Vertical Termination See page 25 for more details Figure 3 4 Concentric Sidewall Termination See page 20 for more details Direct venting options ...

Page 14: ... connections Failure to follow this warning could result in fire personal injury or death WARNING NOTICE WARNING WARNING For closet and alcove installations CPVC material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death NOTICE All vent pipe materials and fittings must comply with the following Item Material Standards for install...

Page 15: ...l 2 Max Vent Air 3 Max Vent Air 50 40 feet 100 feet 80 40 feet 100 feet 105 40 feet 100 feet 150 N A 100 feet 210 N A 100 feet Increasing or decreasing the size of the combustion air or vent piping beyond the sizes listed in Table 3B is not authorized NOTICE When determining equivalent combustion air and vent length add 5 feet for each 90 elbow 3 feet for each 45 elbow and 3 feet for the concentri...

Page 16: ...or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal injury or death check for areas and products listed in Table 1A page 10 before installing the boiler or air inlet piping If contaminants are found you MUST Remove contaminants permanently OR Relocate air inlet and vent terminations to other areas Removing from existing ve...

Page 17: ... where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjac...

Page 18: ...ver terminate above or below any of these within 4 feet horizontally 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment Vent air termination sidewall ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS BIRD SCREEN 12 MIN 12 MIN 15 MAX COUPLING TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION B...

Page 19: ...onal injury death or substantial property damage Multiple vent air terminations 1 When terminating multiple Knight wall mount boilers terminate each vent air connection as described in this manual FIG 4 5A 2 Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet as shown in FIG 4 5A for U S installations For Canadian installations provid...

Page 20: ...rubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with peopl...

Page 21: ...to follow this warning could result in product damage or improper operation personal injury or death Figure 4 9 Rain Cap to Vent Pipe Alternate Assembly 6 Install the Y concentric fitting and pipe assembly through the structure s hole Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 Install the rain cap and small diameter pipe ass...

Page 22: ...hat vent terminations be made as shown to avoid recirculation of flue gases Dimension A in FIG 4 11 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation Figure 4 11 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation Figure 4 10 Concentric Vent Sidewall Attachment DO NOT use field supplied couplings to ex...

Page 23: ...ate in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an up turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake The air inlet pipe and vent pipe can be located in any desired position on t...

Page 24: ...the vent pipe This placement avoids recirculation of flue products into the combustion air stream 3 The vent piping must terminate in an up turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termi...

Page 25: ...onsider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup...

Page 26: ...near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 5 7 The next two 2 vent terminations must be at least 36 inches away from the first two 2 terminations It is important that vent terminations be made as sh...

Page 27: ...he installation of the Knight wall mount boiler reference FIG 6 1 1 Connect the system return marked Inlet make sure to install with pipe sealant compound 2 Connect the system supply marked Outlet make sure to install with pipe sealant compound 3 Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone 4 Install a backflow preventer on the cold feed...

Page 28: ...t be considered in your system design Refer to the graph in FIG 6 2 for pressure drop through the Knight wall mount boiler heat exchanger Near boiler piping connections SYSTEM PUMP DOMESTIC HOT WATER PUMP BOILER PUMP VENT AIR INDIRECT DOMESTIC HOT WATER TANK FROM TO TO SYSTEM FROM SYSTEM TO FLOOR DRAIN CONDENSATE DRAIN Figure 6 1 Near Boiler Piping ...

Page 29: ...4 PL 30 NRF 36 E7 105 7 7 17 5 1 UP26 64F UPS26 99F 0014 PL 30 NRF 36 E7 150 11 0 12 8 1 UP26 64F UPS26 99F 0014 PL 30 NRF 36 E7 210 15 5 19 0 1 UP26 99F UPS26 99F 0013 PL 36 NRF 36 E7 35 F Temperature Rise Applications Model GPM FT HD Minimum Pipe Size Pump Grundfos TACO B G Armstrong 50 2 9 4 1 1 UPS15 58FC 007 NRF 22 Astro 30 80 4 2 7 3 1 UPS15 58FC 007 NRF 22 Astro 30 105 5 5 9 8 1 UPS15 58FC ...

Page 30: ...unit serviceability 9 Temperature and pressure gauge Factory supplied The temperature and pressure gauge is shipped loose It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet 10 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 11 Boiler purge valve Field supplied The boiler purge valve is...

Page 31: ... REDUCING VALVE PRESSURE GAUGE ANTI SCALD MIXING VALVE COLD WATER IN TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE DRAIN POINT TYPICAL MAKE UP WATER HOT WATER OUT BOILER CIRCULATOR SYSTEM SUPPLY SENSOR DRAIN NOT TO EXCEED 4 PIPE DIA OR A MAX OF 12 APART Figure 6 3 Single Boiler Zoned with Circulators 6 Hydronic piping continued ...

Page 32: ...L BOILER CIRCULATOR BOILER 2 MEMBER 1 DOMESTIC HOT WATER CIRCULATOR UNION TYPICAL PRESSURE RELIEF VALVE HOT WATER OUT COLD WATER IN BOILER 1 LEADER FLOW CHECK VALVE TYPICAL SYSTEM SUPPLY SENSOR DRAIN NOT TO EXCEED 4 PIPE DIA OR A MAX OF 12 APART Figure 6 4 Multiple Boilers Zoned with Circulators Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 50 1 1 1 4 1 1 2 2 2 2 2 80 1 1 4 1 1 2 2 2 2 1...

Page 33: ...VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE DRAIN POINT TYPICAL MAKE UP WATER HOT WATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE VALVES TYPICAL FLOW CHECK VALVE DIFFERENTIAL PRESSURE BYPASS VALVE IF USED SYSTEM CIRCULATOR SYSTEM SUPPLY SENSOR DRAIN NOT TO EXCEED 4 PIPE DIA OR A MAX OF 12 APART Figure 6 5 S...

Page 34: ...R BOILER 2 MEMBER 1 DOMESTIC HOT WATER CIRCULATOR UNION TYPICAL PRESSURE RELIEF VALVE HOT WATER OUT COLD WATER IN BOILER 1 LEADER DIFFERENTIAL PRESSURE BYPASS VALVE IF USED SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR DRAIN NOT TO EXCEED 4 PIPE DIA OR A MAX OF 12 APART Figure 6 6 Multiple Boilers Zoned with Valves Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 50 1 1 1 4 1 1 2 2 2 2 2 80 1 1 4 ...

Page 35: ...D WATER IN TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE DRAIN POINT TYPICAL MAKE UP WATER FROM SYSTEM BOILER CIRCULATOR SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR DRAIN NOT TO EXCEED 4 PIPE DIA OR A MAX OF 12 APART Figure 6 7 Single Boiler Non Zoned Primary Secondary Piping 6 Hydronic piping continued ...

Page 36: ...urge all air from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at less than 13 inches w c b Disconnect the boiler and gas valve from the gas supply piping during any pressure testing greater than 13 inches w c The gas valve and blower will not support the weight of the ...

Page 37: ...atural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane Gas ...

Page 38: ... appliance WARNING 3 Loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG 7 3 4 Slowly turn on the gas supply at the field installed manual gas valve 5 Turn the power switch to the ON position 6 Adjust the temperature set point on the control panel of the SMART SYSTEM ...

Page 39: ...le in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the Knight wall mount boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank ...

Page 40: ...adian Electrical Code Part 1 and any local codes Line voltage connections 1 Remove bezel as shown in FIG 8 1 2 Connect 120 vac power wiring to the line voltage terminal strip in the junction box as shown in FIG 8 2 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 8 2 3 Wire the boiler pump as shown in FIG 8 2 4 When connecting a domestic...

Page 41: ...ce needs to operate when the boiler fires it can be controlled by this output Connect these terminals to a 24 vac relay coil which is wired to operate the auxiliary device FIG 8 4 Auxiliary device proving switch 1 When the operation of an auxiliary device needs to be verified before the boiler fires remove the jumper wire from these terminals and connect them to the normally open contacts on its p...

Page 42: ...culate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat Zone Control enable output or Building Management System enable output are available it should be wired to the Low Voltage Connection Board on the L...

Page 43: ...Installation Operation Manual 43 8 Field wiring continued AUX DHW TANK SENSOR Figure 8 4 Low Voltage Field Wiring Connections ...

Page 44: ...aterials 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 7 A condensate removal pump is required if boiler is below drain When installing a condensate pump select one approved for use wi...

Page 45: ...cation a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water ...

Page 46: ...e external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wi...

Page 47: ...ith circulation and cause heat distribution problems and noise Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the pr...

Page 48: ...Installation Operation Manual 48 10 Start up Figure 10 2 Operating Instructions ...

Page 49: ...e Verify space heat circulator mode The Space Heating Mode controls both the system primary pump if connected and the boiler secondary pump When the SMART SYSTEM control receives a space heating call for heat it turns on the system pump If the boiler is not heating an indirect DHW Domestic Hot Water tank it also turns on the boiler pump After the space heating call for heat ends the system pump co...

Page 50: ...select which digit flashes 4 Press the ENTER key 5 The display changes to read USER CODE for a few seconds then displays a menu 6 Press the ENTER key 7 Press the UP key twice to display A3 DATE AND TIME 8 Press the ENTER key once 9 The date and time are displayed as YY MM DD W hh mm where mm minutes hh hour 24 hour time e g 2 00 PM 14 00 W day of the week 1 Sunday 2 Monday 3 Tuesday etc DD date MM...

Page 51: ...r for maximum response and recovery The DHW pump continues for 30 seconds after the heating cycle to deliver the most possible heat DHW space heating SH cycling If a DHW call for heat is received while a space heating call is in progress the control will start the DHW pump and shut the boiler pump off The system pump will remain on If the space heating call is still active while the DHW call is in...

Page 52: ...wns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low Protection features Outlet temperature flue temperature and temperature rise limiting The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exce...

Page 53: ...rogrammed into the control See page 49 of this manual to program the set point Monitor external limits Connections are provided on the connection board for external limits such as flow switch low water cutoff gas pressure switches and an auxiliary device proving switch The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm out...

Page 54: ...peration any boiler s in the Cascade can be selected to provide heat for a DHW call Select a boiler to be designated as the DHW boiler Connect the DHW thermostat to the terminals on the Low Voltage Connection Board marked for the DHW Thermostat When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will sta...

Page 55: ...blocked drain and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve BLR IGNITION OUT 123 9F 129 5 If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge another prepurge and tries to light the burner again If the burner does not l...

Page 56: ...perature by using the UP and DOWN buttons FIG 11 1 on page 57 at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In User Mode the following parameters can be viewed but not changed Boiler outlet water target temperature in DHW Mode Boiler model number Software version Total operating hours Total cyc...

Page 57: ...ration Manual 57 Knight wall mount boiler control module Figure 11 1 Control Panel Use the control panel FIG 11 1 to set temperatures operating conditions and monitor boiler operation 11 Operating information continued ...

Page 58: ...r an additional 10 seconds to clear the combustion chamber and vent system of residual flue products Service The unit has been placed in a temporary mode that will allow the unit to fire at 100 of rate for the purpose of combustion analysis OUT F When the outlet sensor has been selected as the control sensor default the control will display the outlet temperature as well as the set point in parent...

Page 59: ... wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 4 4 FLUE F The control will display the flue temperature Open The control does not detect the flue sensor Shorted The flue sensor wires or the sensor itself has become shorted AUX F The control will display the temperature Open The control does not detect the auxiliary sensor Shorte...

Page 60: ...OFF The control has not received a call for heat from a remote thermostat and has not powered the system pump ON The control has received a call for heat from a remote thermostat and has powered the system pump Delay The system call for heat has been satisfied and the system pump is running for a fixed time to remove any residual heat BLR PUMP OFF The control has either not received a call for hea...

Page 61: ...P On The Leader control has received a call for heat from a remote thermostat and has powered the system pump PMP Delay The system call for heat has been satisfied and the system pump is running for a fixed time to remove any residual heat Press the Next arrow key on the SMART SYSTEM display to access Screen 10 10 Cas Pow The first percentage shows the firing rate that is being sent to the last bo...

Page 62: ...al Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ANNUAL START UP Owner maintenance see the Knight Wall Mount User s Information Manual ...

Page 63: ... that air intake area is free of any of the contaminants listed in Section 1 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight Wall Mount Service Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any s...

Page 64: ...ed by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring miner...

Page 65: ...on fluid in system do not drain 2 Allow time for the boiler to cool to room temperature if it has been firing 3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 5 Remove the heat exchanger access cover cover gasket s and chamber insulation assembly The boiler co...

Page 66: ... SPARK ROD INTEGRATED CONTROL GROUND JUNCTION BOX INTEGRATED CONTROL 120 VAC LOW VOLTAGE HIGH VOLTAGE CAUTION HIGH VOLTAGE SPARK LEAD BLOWER TERMINAL STRIP TERMINAL STRIP CN3 8 CN3 7 CN3 9 CN3 6 CN3 4 CN3 3 CN3 1 CN3 10 DISPLAY CONNECTION BOARD INLET SENSOR OUTLET SENSOR FLUE SENSOR X4 8 X4 7 X4 9 X4 6 X4 4 X4 3 X4 1 X4 10 INTEGRATED CONTROL CN4 11 CN4 12 CN4 10 CN4 4 ALARM CONTACTS RUN TIME CONTA...

Page 67: ...AUTO RESET HI LIMIT CAUTION HIGH VOLTAGE SPARK LEAD CN5 3 CN5 4 CN5 2 24 VAC COM L N L N L N GND GND GND GND TR1 X8 120 VAC LOW VOLTAGE HIGH VOLTAGE X3 PC INTERFACE CN4 14 CN1 12 CN1 11 CN1 10 CN1 9 CN1 8 CN1 7 CN1 6 CN1 5 CN1 4 CN1 3 CN1 2 CN1 1 Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada ...

Page 68: ...r pressure switch new condensate trap image and the addition of the new vent termination Revision E ECO C02545 reflects the addition of references to the safety shutoff testing and instructions sediment trap periodic cleaning of screens in vent terminations wall thickness for direct vent terminations removal of B149 2 references approval of the 2 and 3 concentric vent kits for ULC S636 and sidewal...

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