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Installation & Operation Manual

32

6

Hydronic piping

BOILER

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE

GAUGE

SYSTEM SUPPLY

SENSOR

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

DRAIN POINT

(TYPICAL)

ANTI-SCALD

MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

PRESSURE

RELIEF VALVE

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

BOILER
CIRCULATOR

DRAIN

INDIRECT

DHW TANK

BALL VALVE

(TYPICAL)

EXPANSION

TANK

HOT

WATER

OUT

ZONE #1

ZONE #2

ZONE #3

ZONE #4

AIR SEPARATOR

COLD

WATER

IN

FLOW CHECK

VALVE

(TYPICAL)

MAKE UP WATER

ZONE CIRCULATORS

(TYPICAL)

Figure 6-4

Single Boiler Zoned with Circulators

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Summary of Contents for 285

Page 1: ...ified heating installer service technician Read all instructions including this manual and the Knight 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 WARNING Save this manual for future reference ...

Page 2: ... Air Piping Materials 14 Requirements for Installation in Canada 14 Air Intake Vent Connections 15 Min Max Combustion Air 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 20 Sidewall Termination Op...

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: ...ter inlet system return NPT water connection that returns water from the system to the heat exchanger either 1 or 1 1 4 depending on the model 15 Gas connection pipe Threaded pipe connection either 1 2 or 3 4 depending on the model This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler 16 SMART Control Module The SMART Control responds to internal ...

Page 5: ...ew Models 80 210 23 8 10 13 14 15 18 20 12 25 30 29 34 35 Left Side inside unit Models 80 210 1 3 4 2 27 7 28 26 21 19 16 17 5 Right Side inside unit Models 80 210 The Knight Boiler How it works continued Rear View Models 80 210 Models 80 210 ...

Page 6: ...nstallation Operation Manual 6 The Knight Boiler How it works 15 18 Model 285 Left Side inside unit Model 285 Right Side inside unit Model 285 Front View Model 285 Rear View Model 285 32 24 10 27 5 4 35 ...

Page 7: ...a high altitude label affixed to the unit as shown in FIG A and are equipped for operation of 4 501 feet to 12 000 feet only with 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 ...

Page 8: ...nd 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 substantial property damage Provide clearances Clearances from combustible ma...

Page 9: ...SIDE 24 REAR 24 Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC material MUST BE used in a closet structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death WARNING For alcove installations CPVC material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this wa...

Page 10: ... 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 it is...

Page 11: ...s 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 appliances remaining connected to the com...

Page 12: ...ch the propane conversion label in the conversion kit bag next to the boiler rating plate Attach the LP caution label in the conversion kit bag to the left side of the unit in the lower left corner 6 Replace the top and front access covers Figure 2 1 Boiler Mounted on Shipping Pallet Gas conversions NOTICE WARNING Figure 2 3 Leveling Legs on the Boiler Leveling the boiler 1 Set the boiler in place...

Page 13: ...l Termination See page 24 for more details Figure 3 2 Two Pipe Sidewall Termination See page 17 for more details Figure 3 3 Concentric Vertical Termination See page 26 for more details Figure 3 4 Concentric Sidewall Termination See page 21 for more details Direct venting options ...

Page 14: ...mer and cement specified in this manual to make the vent 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 compl...

Page 15: ...model specific combustion air intake and vent piping sizes as detailed in Table 3B below Model Air Intake Vent 80 210 3 inches 3 inches 285 4 inches 4 inches Table 3B Air Intake Vent Piping Sizes Increasing or decreasing combustion air or vent piping is not authorized NOTICE Minimum Maximum allowable combustion air and vent piping lengths are as follows Combustion Air 12 equivalent feet minimum 10...

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 11 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: ...cate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Do not exceed the maximum lengths of the outside vent piping shown in FIG 4 1B Excessive length exposed to the outside could cause freezing of condensate in the vent pipe result...

Page 18: ...r regulator relief valve or other equipment Never 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 4 Sidewall direct venting ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS BIRD SCREEN 12 MIN 12 MIN 15 MAX COU...

Page 19: ...on of vent pipe when passing through floors or walls 5 Seal exterior openings thoroughly with exterior caulk VENT PIPING GALVANIZED THIMBLE VENT CAP AIR PIPING WALL PLATE VENT PLATE Figure 4 4A Sidewall Termination Assembly Figure 4 4B Alternate Sidewall Termination Assembly w Field Supplied Fittings Prepare wall penetrations 1 Use the factory supplied wall plate as a template to locate the vent a...

Page 20: ...nate 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 provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Knight boiler is part of a direct vent connection It is not clas...

Page 21: ...G 6 152 MM DIA 6 152 MM DIA 6 152 MM TO 4 102 MM REDUCER Figure 4 8 Kit Contents_CVK3007 e Do not terminate above any door or window Condensate can freeze causing ice formations f Locate or guard vent to prevent condensate damage to exterior finishes 4 Cut one 1 hole 5 inch diameter for CVK3003 installations or 7 inch diameter for CVK3007 installations into the structure to install the termination...

Page 22: ...tall the Y concentric fitting and pipe assembly through the structure s hole from an inside wall 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 assembly into the Y concentric fitting and large pipe assembly from an outside wall Ensure small diameter pipe is bottomed and cemented in th...

Page 23: ...be made as shown to avoid recirculation of flue gases Dimension A in FIG 4 13 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation Figure 4 13 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation Figure 4 12 Concentric Vent Sidewall Attachment DO NOT use field supplied couplings to extend pipes Airflow res...

Page 24: ...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 25: ...ulation 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 termination at least 1 foot above the air intak...

Page 26: ...undings 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 where flue produ...

Page 27: ...rminations When two 2 or more direct vent appliances are vented 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 terminations must be at least 36 inches away from the first two 2 termin...

Page 28: ...on tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity 8 Install an air elimination device on the system supply 9 Install a drain valve at the lowest point of the system Note The boiler cannot be drained completely of water without purging the unit with an ai...

Page 29: ...o the graph in FIG 6 3 for pressure drop through the Knight boiler heat exchanger FROM TO INDIRECT DOMESTIC HOT WATER TANK TO FLOOR DRAIN TO SYSTEM FROM SYSTEM Figure 6 2 Near Boiler Piping Connections RELIEF VALVE TEE WITH 3 4 FITTING ON TOP CLOSE NIPPLE FIELD PROVIDED CLOSE NIPPLE TEE WITH FITTING ON TOP FIELD PROVIDED TEMPERATURE AND PRESSURE GAUGE Figure 6 1 Relief Valve T P Installation ...

Page 30: ...9 15 0 1 UPS15 58FC 0014 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 285 21 0 11 5 1 1 4 UP26 99F UPS26 99F 0011 PL 36 NRF 36 E7 Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude models NOTICE 35 F Tempera...

Page 31: ...lied Recommended for 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 ...

Page 32: ... POINT TYPICAL ANTI SCALD MIXING VALVE DOMESTIC HOT WATER CIRCULATOR PRESSURE RELIEF VALVE UNION TYPICAL TEMPERATURE PRESSURE GAUGE BOILER CIRCULATOR DRAIN INDIRECT DHW TANK BALL VALVE TYPICAL EXPANSION TANK HOT WATER OUT ZONE 1 ZONE 2 ZONE 3 ZONE 4 AIR SEPARATOR COLD WATER IN FLOW CHECK VALVE TYPICAL MAKE UP WATER ZONE CIRCULATORS TYPICAL Figure 6 4 Single Boiler Zoned with Circulators ...

Page 33: ...URE PRESSURE GAUGE BOILER CIRCULATOR DRAIN INDIRECT DHW TANK BALL VALVE TYPICAL EXPANSION TANK HOT WATER OUT ZONE 1 ZONE 2 ZONE 3 ZONE 4 AIR SEPARATOR COLD WATER IN FLOW CHECK VALVE TYPICAL MAKE UP WATER ZONE CIRCULATORS TYPICAL BOILER 2 MEMBER 1 Figure 6 5 Multiple Boilers Zoned with Circulators Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 80 1 1 4 1 1 2 2 2 1 2 2 1 2 2 1 2 2 1 2 105 1...

Page 34: ...ATOR ANTI SCALD MIXING VALVE DOMESTIC HOT WATER CIRCULATOR PRESSURE RELIEF VALVE UNION TYPICAL TEMPERATURE PRESSURE GAUGE BOILER CIRCULATOR DRAIN BOILER INDIRECT DHW TANK BALL VALVE TYPICAL EXPANSION TANK HOT WATER OUT ZONE 1 ZONE 2 ZONE 3 ZONE 4 AIR SEPARATOR COLD WATER IN FLOW CHECK VALVE ZONE VALVES TYPICAL DIFFERENTIAL PRESSURE BYPASS VALVE IF USED MAKE UP WATER Figure 6 6 Single Boiler Zoned ...

Page 35: ...RE GAUGE BOILER CIRCULATOR DRAIN BOILER LEADER INDIRECT DHW TANK BALL VALVE TYPICAL EXPANSION TANK HOT WATER OUT ZONE 1 ZONE 2 ZONE 3 ZONE 4 AIR SEPARATOR COLD WATER IN ZONE VALVES TYPICAL DIFFERENTIAL PRESSURE BYPASS VALVE IF USED MAKE UP WATER BOILER 2 MEMBER 1 Figure 6 7 Multiple Boilers Zoned with Valves Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 80 1 1 4 1 1 2 2 2 1 2 2 1 2 2 1 2...

Page 36: ...DIA OR A MAX OF 12 APART DRAIN POINT TYPICAL SYSTEM CIRCULATOR ANTI SCALD MIXING VALVE DOMESTIC HOT WATER CIRCULATOR PRESSURE RELIEF VALVE UNION TYPICAL TEMPERATURE PRESSURE GAUGE BOILER CIRCULATOR DRAIN INDIRECT DHW TANK BALL VALVE TYPICAL EXPANSION TANK AIR SEPARATOR COLD WATER IN MAKE UP WATER FROM SYSTEM Figure 6 8 Single Boiler Non Zoned Primary Secondary Piping ...

Page 37: ... TYPICAL TEMPERATURE PRESSURE GAUGE BOILER CIRCULATOR BOILER CIRCULATOR BOILER CIRCULATOR DRAIN BOILER 2 MEMBER 1 BOILER 1 LEADER INDIRECT DHW TANK BOILER 3 MEMBER 2 BOILER 4 MEMBER 3 SYSTEM CIRCULATOR BALL VALVE TYPICAL EXPANSION TANK TO SYSTEM MAKE UP WATER Figure 6 9 Multiple Boilers Non Zoned Primary Secondary Piping Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 80 1 1 4 1 1 2 2 2 1 ...

Page 38: ...iance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation The gas valve and blower will not support the weight of the piping Do not attempt to support the weigh...

Page 39: ...ressure 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 Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure 2 Pres...

Page 40: ...e 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 4 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 41: ...regulator is used it must be a minimum of 10 feet from the Knight 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 situations This can also occur when a utility company ...

Page 42: ...Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections 1 Connect 120 vac power wiring to the line voltage terminal strip in the junction box as shown in FIG 8 1 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 8 1 3 The boiler pump is shipped loose Wire the boiler pump as shown in FIG 8 1 4 When con...

Page 43: ...control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6 F 3 C below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point 2 The tank sensor included with the Lochinvar Squire Indirect DHW tank TST2032 is the only sensor suitable for use with the SMART SYSTEM control Connect the se...

Page 44: ... of the boiler connections in the main system loop FIG s 6 4 6 6 and 6 8 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor see FIG 8 3 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wi...

Page 45: ...ERNAL GND CONTROL DHW THERMOST AT R W ROOM THERMOSTAT ZONE CONT ROL A B SHIELD GROUN D SEQUENCING LOW WATER CUTOFF CN1 CN2 CN3 CN4 CN5 AUX DEVICE RELAY FLOW SWITCH TANK THERMOSTAT WALL THERMOSTAT ZONE CONTROL SYSTEM SUPPLY SENSOR OUTDOOR SENSOR BUILDING MANAGMENT SYSTEM LOW WATER CUTOFF AUX DEVICE PROVING SWITCH COM NO A A B A B SHIELD SHIELD FROM PREVIOUS BOILER TO NEXT BOILER AUX DHW TANK SENSOR...

Page 46: ...y 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 8 A condensate removal pump is required if boiler is below drain When installing a condensate pump select one approved for use with condensing boile...

Page 47: ...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 48: ...nals on the connection board 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the 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 valv...

Page 49: ... with 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 ...

Page 50: ...Installation Operation Manual 50 10 Start up Figure 10 2 Operating Instructions ...

Page 51: ...he 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 continues to run for a short period of ...

Page 52: ...lect 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 m...

Page 53: ... 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 oper...

Page 54: ...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 55: ...age 51 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 outputs The boiler provides dry con...

Page 56: ... operation 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 s...

Page 57: ...imit 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 light after 4 trials the control loc...

Page 58: ...he space heating and DHW calls for heat remain active the control will switch back and forth between the two modes until one of them is satisfied BLR SH 41 RATE OUT 123 0F 129 9 Once both calls for heat are satisfied the control will turn off the burner The blower will remain on for the 10 second postpurge cycle Any pumps that are running will continue to run for their respective pump delay times ...

Page 59: ...n Operation Manual 59 Knight 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 60: ...ible only by entering the installer access code see the Knight Boiler Service Manual Saving parameters reference the Parameter Table in the Knight Boiler Service Manual To save parameters and exit programming Press the ENTER RESET button To keep parameter settings only for a current operating cycle Press the MENU EXIT button 3 times after making all desired parameter changes To enter a parameter a...

Page 61: ...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 parenthesis F If the outlet sensor h...

Page 62: ...ensor 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 S...

Page 63: ...ed 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 heat from a remote thermostat a r...

Page 64: ...mp PMP 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 la...

Page 65: ...tion 10 of this manual 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 User s Informatio...

Page 66: ...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 Boiler Service Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain l...

Page 67: ... before proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the ...

Page 68: ... and securely attached Check control settings 1 Set the SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of Knight Boiler Service Manual Adjust settings if necessary See Section 1 of the Knight Boiler Service Manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks 1 Start boile...

Page 69: ...e 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 contains ceramic fiber materials Use care when handling these materials per instructions in the Knight Boiler Service Manua...

Page 70: ... 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 71: ...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 72: ...ision 12 ECO C02407 reflects the removal of Models 399 500 from the manual the addition of high altitude relief valve and T P install instructions Maintenance Section and the new sidewall vent termination Revision 13 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...

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