Knight 81 - 286 Installation & Operation Manual Download

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Installation & Operation Manual

Hydronic piping

IMG00720

BOILER

INDIRECT

DHW TANK

COLD

WATER

HOT

WATER

OUT

BOILER
CIRCULATOR

Y-STRAINER
(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

PRESSURE RELIEF VALVE

PRESSURE

GAUGE

EXPANSION

TANK

ZONE #1

ZONE #2

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE UP WATER

ZONE VALVES

(TYPICAL)

DIFFERENTIAL
PRESSURE BYPASS
VALVE (IF USED)

SYSTEM SUPPLY

SENSOR

(WHEN USED)

SYSTEM

CIRCULATOR

BACKFLOW PREVENTER

PRESSURE REDUCING VALVE

ANTI-SCALD
MIXING VALVE

UNION
(TYPICAL)

TEMPERATURE/
PRESSURE
GUAGE

DRAIN

AIR SEPARATOR

DOMESTIC HOT WATER
CIRCULATOR

ZONE #3

ZONE #4

Figure 6-4 Single Boiler Zoned with Circulators

Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.

NOTICE

Summary of Contents for 81 - 286

Page 1: ...eating 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: ...Combustion Air Piping 15 Requirements for Installation in Canada 16 Sizing 16 Min Max Combustion Air Vent Piping Lengths 16 Materials 17 Optional Room Air 18 PVC CPVC 19 Polypropylene 20 Stainless Steel Vent 21 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 22 25 Determine Location 22 24 Prepare Wall Penetrations 24 Multiple Vent Air Terminations 25 Sidewall Termination Optional Concentri...

Page 3: ...G WARNING When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut...

Page 4: ... air vent Designed to remove trapped air from the heat exchanger coils 18 Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler 19 High voltage junction box The junction box contains the connection points for the line voltage power and all pumps 20 Boiler drain port Location from which the heat exchanger can be drained 21 Low voltage connection board The connection ...

Page 5: ...anual 10 30 24 Front View Models 81 211 Left Side inside unit Models 81 211 Right Side inside unit Models 81 211 The Knight Boiler How it works continued Rear View Models 81 211 Models 81 211 19 21 16 3 1 17 4 5 7 2 26 35 36 34 ...

Page 6: ... Installation Operation Manual The Knight Boiler How it works Model 286 Left Side inside unit Model 286 Right Side inside unit Model 286 Front View Model 286 Rear View Model 286 10 24 IMG00876 33 4 38 34 ...

Page 7: ... in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit Derate values are based on proper combustion calibration and CO2 s adjusted to the recommended levels 7 Ratings have been confirmed by the Hydronics Section of AHRI Maximum allowed working pressure is located on the rating plate NOTICE Knight Boiler AHRI Rating Model Number ...

Page 8: ...tdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Do not install the appliance where the relative humidity may exceed 93 Do not install the appliance where condensation may form on the inside or outside of the appliance or where condensation may fall onto the appliance Failure to install the appliance indoors could result in severe p...

Page 9: ...CPVC 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 personal injury or death WARNING For alcove installations CPVC polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fire perso...

Page 10: ...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 not subject to physical dam...

Page 11: ... stainless steel vent only use terminations listed in Table 3H for the manufacturer of the installed vent Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 12 With polypropylene and stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used with...

Page 12: ...ilding Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e T...

Page 13: ...version 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 2 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 and check level...

Page 14: ... PVC CPVC Concentric Sidewall Termination See page 26 for more details Direct venting options Sidewall Vent Figure 3 3 Two Pipe Vertical Termination See page 29 for more details Direct venting options Vertical Vent Figure 3 4 PVC CPVC Concentric Vertical Termination See page 31 for more details Figure 3 5 Vertical Vent Sidewall Air ...

Page 15: ...final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 7 thru 3 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code ...

Page 16: ...minimum 100 equivalent feet maximum The appliance output rating will reduce by up to 1 5 for each 25 feet of vent length except when using the alternative 3 vent for the Knight 286 model which may de rate by up to 4 for each 25 feet of vent length NOTICE Model Kit Number Equivalent Vent Length 81 211 CVK3003 3 feet 286 CVK3007 3 feet Table 3B Concentric Vent Kit Equivalent Vent Lengths Sizing The ...

Page 17: ...ty UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported Th...

Page 18: ...on and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Model Kit Number 81 211 KIT30052 286 KIT30053 Table 3C Optional Room Air Kit Commercial a...

Page 19: ...resent sufficient cement was not applied and joint could be defective g Wipeexcesscementfromthejointremovingringor beads as it will needlessly soften the pipe PVC CPVC Table 3D PVC CPVC Vent Pipe and Fittings All PVC vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the boiler to allow drainage of condensate NOTICE WARNING The vent...

Page 20: ...codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system Installation of a polypropylene vent system should adhere to the vent manufacturer s installation instructions supplied with the vent system Approved Polypropylene Vent Manufacturers Make Model Centrotherm Eco Systems InnoFlue SW Flex Duravent M G Group PolyPro Single Wall PolyPro Flex Table 3E Polyprop...

Page 21: ...x Group Z Vent Heat Fab Selkirk Corporation Saf T Vent Metal Fab Corr Guard Security Chimney Secure Seal Table 3G Stainless Steel Vent Pipe and Fittings Installation Operation Manual 3 General venting continued 21 Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only taking precaution to ensure no sagging occurs of the vent system Connect to the FasNS...

Page 22: ...rners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas WARNING WARNING WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone f Do not terminate above any door or window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes TO BOILER INTAKE AIR CO...

Page 23: ...elow or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG 4 1B Condensate could freeze and block vent pipe c Do not terminate closer than 4 feet horizontally from ...

Page 24: ...e piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3D on page 19 to seal the vent pipe 4 Mount and secure the vent plate to the wall using stainless steel screws 5 Seal all gaps between the pipes and wall Seal around the plate to the wall assuring no air gaps 6 Assemble the vent cap to the vent plate see FIG s ...

Page 25: ...WARNING Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B 4 Sidewall direct venting continued Prepare wall penetrations Alternate Field Supplied Option 1 Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For e...

Page 26: ... to install the termination kit 4 Partially assemble the concentric vent termination kit Clean and cement using the procedures found in these instructions a Cement the Y concentric fitting to the larger kit pipe FIG s 4 7 and 4 8 b Cement the rain cap to the smaller diameter kit pipe FIG s 4 7 and 4 8 Sidewall termination optional concentric vent Description and usage Lochinvar offers optional con...

Page 27: ...5 Install 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 6 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 ...

Page 28: ...vent terminations be made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 13 Concentric Vent and Combustion Air Termination Figure 4 12 Concentric Vent Sidewall Attachment DO NOT use field supplied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 8 Cement appliance combustion air and vent pipes to the concentric ven...

Page 29: ...above the air inlet 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 6 m apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel above the air intake 6 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 7 Do not extend exposed vent pipe outside of bu...

Page 30: ... and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple Knight boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury death or substantial property damage 2 Pla...

Page 31: ...he two 2 components together when field disassembly is desired for cleaning see FIG 4 11 page 27 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could...

Page 32: ...entric vent termination connections Multiventing vertical terminations 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 It is important that vent t...

Page 33: ...tion must comply with local requirements and with the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existing unused venting system is converted for use with this method of concentric venting the installer must ensure that the existing venting system is clean and free from ...

Page 34: ...wable 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 FLUE OUTLET EXISTING CAP SEAL SEAL AIR INLET 5 Vertical direct venting For concept illustration only Individual installations may vary due to job site specific equipment ...

Page 35: ...si nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi 6 Install a circulator as shown on the piping diagrams in this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank inst...

Page 36: ...t full speed 3 Domestic hot water circulating pump Field supplied The pump MUST be sized to meet the specified minimum flow requirements listed in FIG 6 3 Consult the indirect water heater operating guide to determine flow characteristics for the selected product used 4 Boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a ...

Page 37: ...hich is a series of indirect water heaters The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger WARNING The National Standard Plumbing Code the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum Also the heat ...

Page 38: ...6 99F 0014 NRF 36 E7 151 11 0 12 8 1 UPS26 99F 0014 NRF 36 E7 211 15 5 19 0 1 UPS26 99F 0013 NRF 36 E7 286 21 0 11 5 1 1 4 UPS26 99F 0011 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 Temperature Rise Applications Model GPM FT HD Minimum Pipe Size Pump Grundfos TACO B G Armstrong 81 4 2 7 3 1 UPS15 58FC 007 NR...

Page 39: ...ired to connect the 230V pump listed in the shaded area in Table 6B to the boiler high voltage terminal strip Variable speed pump setup Before operation ensure the following Pump is set for an input signal of 0 10Vdc by the dip switches on the pump control Pump is set for external signal control if applicable Pump is set for linear output if applicable If pump does not come equipped with a 0 10 Vd...

Page 40: ...ZONE VALVES TYPICAL DIFFERENTIAL PRESSURE BYPASS VALVE IF USED SYSTEM SUPPLY SENSOR WHEN USED SYSTEM CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE ANTI SCALD MIXING VALVE UNION TYPICAL TEMPERATURE PRESSURE GUAGE DRAIN AIR SEPARATOR DOMESTIC HOT WATER CIRCULATOR ZONE 3 ZONE 4 Figure 6 4 Single Boiler Zoned with Circulators Please note that these illustrations are meant to show system piping...

Page 41: ...PICAL UNION TYPICAL DRAIN DRAIN POINT TYPICAL MAKE UP WATER HOT WATER OUT ZONE CIRCULATORS TYPICAL FLOW CHECK VALVE TYPICAL BOILER CIRCULATOR SYSTEM SUPPLY SENSOR WHEN USED Y STRAINER RECOMMENDED MAY SUBSTITUTE LOW LOSS HEADER CHECK VALVE IMG00638 PRESSURE RELIEF VALVE Figure 6 5 Single Boiler Single Temperature Zoned with Circulators Please note that these illustrations are meant to show system p...

Page 42: ... BOILER 1 LEADER SYSTEM SUPPLY SENSOR TEMPERATURE PRESSURE GAUGE DRAIN MAY SUBSTITUTE LOW LOSS HEADER Y STRAINER RECOMMENDED TYPICAL IMG00639 CHECK VALVE PRESSURE RELIEF VALVE ZONE 3 ZONE 4 Figure 6 6 Multiple Boilers Single Temperature Zoned with Circulators Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detaili...

Page 43: ...L VALVE TYPICAL UNION TYPICAL DRAIN POINT TYPICAL MAKE UP WATER HOT WATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE GAUGE EXPANSION TANK MIXING VALVES TYPICAL FLOW CHECK VALVE SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED MAY SUBSTITUTE LOW LOSS HEADER TEMPERATURE LOOP 1 TEMPERATURE LOOP 2 TEMPERATURE LOOP 3 NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART LOOP SENSOR TYPICAL PRESSURE REDUC...

Page 44: ...GAUGE UNION TYPICAL DRAIN Y STRAINER RECOMMENDED NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BOILER IMG00641 PRESSURE RELIEF VALVE Figure 6 8 Multiple Boilers Multiple Temperatures Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 81 1 1 4 1 1 2 2 2 2 1 2 2 1 2 2 1 2 106 1 1 2 2 2 2 1 2 2 1 2 2 1 2 3 151 2 2 2 1 2 2 1 2 3 3 3 1 2 211 2 2 1 2 3 3 3 1 2 4 4 286 2 1 2 2 1 2 3 3 1 2 3 1 2 4 5 Pl...

Page 45: ...Y SUBSTITUTE LOW LOSS HEADER TEMPERATURE LOOP 1 TEMPERATURE LOOP 2 TEMPERATURE LOOP 3 NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART LOOP SENSOR TYPICAL PRESSURE REDUCING VALVE PRESSURE RELIEF VALVE IMG00654 Figure 6 9 Single Boiler Multiple Temperatures with DHW Piped as a Zone Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equi...

Page 46: ...UPPLY SENSOR WHEN USED SYSTEM CIRCULATOR DRAIN Y STRAINER RECOMMENDED TYPICAL MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART IMG00642 FLOW CHECK VALVE PRESSURE RELIEF VALVE ZONE 3 ZONE 4 Figure 6 10 Multiple Boilers Single Temperature Zoned with Valves Please note that these illustrations are meant to show system piping concept only the installer is responsible for all ...

Page 47: ...M SUPPLY SENSOR DRAIN SYSTEM CIRCULATOR NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART Y STRAINER RECOMMENDED TYPICAL MAY SUBSTITUTE LOW LOSS HEADER HOT WATER OUT IMG00643 PRESSURE RELIEF VALVE Figure 6 11 Multiple Boilers Non Zoned Primary Secondary Piping Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing re...

Page 48: ...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 49: ...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 50: ... on to Step 11 10 If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control 11 Turn the power switch to the OFF position 12 Shut off the gas supply at the manual gas valve in the gas piping to the appliance 13 Remove the manometer from the pressure tap on top of the g...

Page 51: ...by static mode and while in operating dynamic mode If an in line 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 ...

Page 52: ...wn in FIG 8 1 If the motor is larger than 1 8 hp or 1 8 amps you must isolate with a relay Figure 8 1 Line Voltage Field Wiring Connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation WARNING NOTICE CAUTION Low voltage connections 1 Route all low voltage wires through the knockouts in the rear of the boiler as shown in FIG...

Page 53: ...oint WARNING DHW thermostat Connect storage indirect water heater DHW thermostat FIG 8 3 to the DHW thermostat terminals on the connection board If a tank sensor is connected see DHW Tank Sensor below the tank thermostat is ignored DHW tank sensor 1 By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the prese...

Page 54: ...em that the boiler is down Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 62 Configuration of the Cascade for a detailed explanation of this procedure Connect the system supply sensor and outdoor air sensor if used to the Leader boiler For the Cascade system to work properly the...

Page 55: ...NAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO LOW WATER CUTOFF OUTDOOR SENSOR TANK SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER ROOM THERMOSTAT 1 ROOM THERMOSTAT 2 A B NOTE CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES WIRE AS NEEDED SYSTEM PUMP SPEED CONTROL BOILER PUMP IMG00127 Figure 8 3 Low Voltage Field Wiring Connections ...

Page 56: ...ence 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 the boiler is below the drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have a...

Page 57: ...em 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 system 1 Purge air from system a Connect a hose to the purge valve see purge drain valves in piping diagrams on pages 40 through 47 Route the hose to an area where water can drain and ...

Page 58: ...ls 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 valves...

Page 59: ...rculation 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 procedur...

Page 60: ...60 Installation Operation Manual 10 Start up Figure 10 2 Operating Instructions ...

Page 61: ... main power off to the boiler and replace the flue temperature sensor into the flue pipe connection 10 Place the boiler back into normal operation You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage WARNING Natural Gas Propane CO2 O2 CO2 O2 8 0 10 3 0 6 5 9 0 11 4 1...

Page 62: ...oiler is installed and anytime the boiler has been powered off for more than 4 hours Use the following procedure to set the clock 1 Press and hold the LEFT SELECT MENU key for at least 5 seconds 2 The display changes to read PASSWORD with four 4 zeros below it 3 Press the RIGHT SELECT SAVE key 4 The display will then show a menu with the time and date and temperature unit 5 Press the NAVIGATION di...

Page 63: ... to either control set point or firing rate The Knight boiler can also be programmed to accept a call for heat from a 0 10V signal reference the Knight Boiler Service Manual for a detailed explanation of this procedure DHW priority The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the DHW thermostat...

Page 64: ...ack event scheduled within the next seven 7 days can be temporarily bypassed if desired Flame current support To prevent nuisance shutdowns 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 out...

Page 65: ...oor sensor is connected If the outdoor sensor is not connected the target temperature is fixed at SH 1 3 set points An outdoor sensor fault will remain on the display screen until the outdoor sensor is reconnected High limit operations The Knight boiler is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has a maximum set point of 200 F and the m...

Page 66: ...t up to take its place The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its firing rate to maintain this Once the DHW call has been satisfied the Leader control will place that boiler back into the Cascade sequence Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode When DHW is pr...

Page 67: ...y initiating the blower 5 The control starts the trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected after the sparking ends the control will perform a post purge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts before locking out 7 If flame is detected it holds the firing rate stead...

Page 68: ...t temperature to the DHW boiler set point 9 If the boiler is not part of a Cascade and both the space heating and DHW calls for heat remain active long enough the boiler will switch back and forth between the two heating modes until one of them is satisfied 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during the postpurge period 11 ...

Page 69: ...he date and time and the temperature units can also be changed see page 61 Installer Most parameters are available only to the installer accessible by entering the installer password see the Knight Boiler Service Manual Saving parameters reference the Parameter Table in the Knight Boiler Service Manual Please note that the brackets denote screen status NOTICE To save parameters and exit programmin...

Page 70: ...n additional postpurge period to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a condition that has temporarily interrupted the current call for heat B Call for Heat Indicators Heat Loop Demand 1 has a call for heat Heat L...

Page 71: ...t measured by the flame sense circuit FAN SPEED The speed of the combustion blower BOILER PUMP The status of the boiler pump output SYSTEM PUMP The status of the system pump output DHW PUMP The status of the DHW pump output BMS VOLTAGE The voltage received from a BMS system BLR PUMP OUTPUT The speed signal sent to a variable speed boiler pump in percent SYS PUMP INPUT The speed signal received fro...

Page 72: ...Dial Function Turning the NAVIGATION dial will select the next or previous Status Screen Pressing the NAVIGATION dial will show the next fault NSB Night Setback trigger or ramp delay setting Pressing the NAVIGATION dial will select the setting indicated by the cursor Pressing the NAVIGATION dial will display the Set Points Screen Turning the NAVIGATION dial will move the cursor up or down Turning ...

Page 73: ...ection 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 Informat...

Page 74: ... 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 line condensate PVC fittings and condensate trap 2 Remove the PVC cap retaining s...

Page 75: ...fore 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 val...

Page 76: ...t 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 boiler and perform checks and tests specified in Section 10 Start up 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame 1 Inspect flame through observation window 2 If the flame is un...

Page 77: ...on valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler 12 Perform start up and check out procedures in the Check Flame and Combustion Section 10 Startup on pages 59 and 61 of this manual 13 Replace the access cover and restore boiler ...

Page 78: ... X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 21 22 26 27 23 24 30 31 32 33 35 36 37 38 39 40 41 42 43 44 3 4 1 2 ALARM CONTACTS M O D B U S 29 34 9 5 6 7 8 X2 2 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 ...

Page 79: ...ced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from ...

Page 80: ... information Revision H ECO C11102 reflects outdoor air reset updates along with revised product ratings on page 7 ECR R05610 Revision I ECO C11736 reflects changes made to the ratings page page 7 Revision J ECO C11821 reflects the sidewall vent kit changes Revision K ECO C11814 reflects the addition of Metal Fab and Security Chimney as approved suppliers the addition of Single Boiler Zoned with C...

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