Lochinvar Knight XL 100 Series Installation & Operation Manual Download Page 22

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Installation & Operation Manual

The installer must use a specific vent starter

adapter at the flue collar connection,

supplied by the vent manufacturer to

adapt to its vent system. See Table 3K for

approved vent adapters. Discard CPVC

starter piece.

NOTICE

General

venting

Stainless steel vent

This product has been approved for use with stainless steel

using the manufacturers listed in Table 3K.

Use only the materials, vent systems, and

terminations listed in Tables 3I and 3K. DO

NOT mix vent systems of different types or

manufacturers. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

⚠

WARNING

Installations must comply with applicable

national, state, and local codes. Stainless

steel vent systems must be listed as a

UL-1738 approved system for the United

States and a ULC-S636 approved system for

Canada.

NOTICE

Installation of a stainless steel vent system

should adhere to the stainless steel vent

manufacturer’s installation instructions

supplied with the vent system.

NOTICE

Table 3L

Approved Stainless Steel Terminations and Adapters

Model

DuraVent

Heat Fab

Z Flex

FasNSeal

Saf-T Vent

Z-Vent

Boiler

Adapter

Flue

Termination

Intake Air

Termination

Boiler

Adapter

Flue

Termination

Intake Air

Termination

Boiler

Adapter

Flue

Termination

Intake Air

Termination

400-500

FSA-4PVC-

4FNS

FSBS4

FSRC4

FSAIH04

9401PVC

9492

5400CI

9414TERM

2SVSLA04 2SVSTP(F,X)04

2SVSRCX04

2SVSTEX0490

650-800

FSA-6PVC-

6FNS

FSBS6

FSRC6

FSAIH04

9601PVC

9690

9692

9414TERM

2SVSTTA06 2SVSTPX06

2SVSRCX06

2SVSTEX0490

1000

FSA-6PVC-

6FNS

FSBS6

FSRC6

FSAIH06

9601PVC

9690

9692

9614TERM

2SVSTTA06 2SVSTPX06

2SVSRCX06

2SVSEE0690

& 2SVSTPX06

Model

Metal Fab

Security Chimney

ICC

Corr/Guard

Secure Seal

VIC

Boiler

Adapter

Flue

Termination

Intake Air

Termination

Boiler

Adapter

Flue

Termination

Intake Air

Termination

Boiler

Adapter

Flue

Termination

Intake Air

Termination

400-500

4CGPVCA 4CGSWHT

4CGSWC

4CGSW90LT

SS4PVCU

SS4STU

SS4RCBU

SS4ST90AU

650-800

6FCGPVCA 6FCGSWMC

6FCGSWC

4CGSW90LT

SS6PVCU

SS6STU

SS6RCBU

SS4ST90AU

HE-6DSA-F

HE-6MC-F

HE-6RC-F

1000

6FCGPVCA 6FCGSWMC

6FCGSWC

6FCGSW90L

SS6PVCU

SS6STU

SS6RCBU

SS6ST90AU

HE-6DSA-F

HE-6MC-F

HE-6RC-F

HE-6E90-F

HE-6SCR-F

DIR #2000585159 00

VENT

HORIZONTAL

ADAPTER

Figure 3-5

Near Boiler Stainless Steel Venting Models

400 - 1000

Approved Stainless Steel Vent Manufacturers

Make

Model

*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 FasNSeal rigid vent using

specially designed adapters and sealing method, see

manufacturer’s instructions.

Dura Vent (M & G Group)

FasNSeal Vent / FasNSeal Flex*

Vent

Z-Flex (Nova Flex Group)

Z-Vent

Heat Fab (Selkirk Corporation)

Saf-T Vent

Metal Fab

Corr/Guard

Security Chimney

Secure Seal

ICC

VIC

Van Packer

UL103/UL1978

Table 3K

Stainless Steel Vent Pipe and Fittings

Summary of Contents for Knight XL 100 Series

Page 1: ...aller service technician Read all instructions including this manual and the Knight XL Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage WARNING Save this manual for future reference 100329949_2000586636_Rev F ...

Page 2: ...15 Install Vent and Combustion Air Piping 16 Requirements for Installation in Canada 17 Sizing 17 Min Max Combustion Air Vent Piping Lengths 17 Materials 18 Optional Room Air 19 PVC CPVC 19 20 Polypropylene 21 Stainless Steel Vent 22 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 23 26 Determine Location 23 25 Prepare Wall Penetrations 25 26 Multiple Vent Air Terminations 26 Sidewall Term...

Page 3: ...ted propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment mu...

Page 4: ...purpose of delivering gas to the boiler 16 SMART TOUCH Control Module The SMART TOUCH Control responds to internal and external signals and controls the blower gas valve and pumps to meet the heating demand 17 Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler 18 High voltage junction box The junction box contains the connection points for the line voltage power ...

Page 5: ...8 7 35 Left Side inside unit Model 400 18 33 20 16 25 27 34 32 Right Side inside unit Model 400 The Knight XL How it works continued Rear View Model 400 5 Model 400 500 10 29 23 26 21 13 11 14 15 28 37 19 17 22 6 Installation Operation Manual ...

Page 6: ...3 Front View Model 1000 DIR 2000582932 00 1 2 4 5 20 33 30 34 7 8 35 16 Rear View Model 1000 Left Side inside unit Model 1000 Left Side inside unit Model 1000 Model 650 1000 DIR 2000582924 00 21 26 13 14 15 11 22 19 28 6 17 37 DIR 2000582937 00 31 18 24 27 3 25 Installation Operation Manual ...

Page 7: ... 4 4 6 2 2 1 1 4 4 6 7 3 2 1 1 4 4 6 8 8 2 1 2 1 1 4 6 6 Installation Operation Manual Notes 1 Knight XL boilers require special gas venting Use only the vent materials and methods specified in the Knight XL Installation Operation Manual 2 For US installations above 2 000 feet elevation reference NFPA 54 for de rate information De rate values are based on proper combustion calibration and CO2 adju...

Page 8: ...er clearance minimums Recommended clearances for service access Front Top Rear 24 Closet and alcove installations This appliance requires a special venting system The vent connection to the appliance For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC or stainless steel WARNING WARNING NOTICE WARNING 1 Determine boiler location A closet is any room the boiler is installed in whi...

Page 9: ...00 Figure 1 1 Closet Installation Minimum Required Clearances WARNING WARNING Installation Operation Manual 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 personal injury or death For closet installations CPVC polypropylene or stainless steel vent mater...

Page 10: ...hat 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 damage by a moving vehicle Vent and air piping The Knight XL requires a special vent system designed for pressurized ve...

Page 11: ...ue collar connection Size To ensure proper pipe size is in place see Table 3A Check to see that this size is used throughout the vent system Manufacturer For a stainless steel or polypropylene application you must use only the listed manufacturers and their type product listed in Tables 3H and 3I for CAT IV positive pressure venting with flue producing condensate Supports Non combustible supports ...

Page 12: ...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 Test for spillage at the draft hood relief opening after 5 minutes...

Page 13: ...turi by loosening the threaded nut on the venturi Replace gasket if damaged For Models 650 1000 Disconnect the gas piping from the venturi by removing the four 4 bolts securing the pipe to the venturi 4 Remove the bolts connecting the venturi to the fan Remove the natural venturi from the unit FIG s 2 2A and 2 2B 5 Install the LP venturi onto the fan taking note of the following a The UP arrow on ...

Page 14: ... to LP check combustion per the Start up procedure in Section 11 of this manual Failure to check and verify combustion could result in severe personal injury death or substantial property damage Installation Operation Manual Combustion air filter This unit has a standard air filter located at the combustion air inlet This air filter is provided to help ensure clean air is used for the combustion p...

Page 15: ... Direct venting options Sidewall Vent DIR 2000583014 00 3 General venting Installation Operation Manual DIR 2000583015 00 Two Pipe Vertical DIR 2000583017 00 Vertical Vent Sidewall Air PVC CPVC Concentric Vertical Models 400 500 Only DIR 2000583016 00 Direct venting options Vertical Vent ...

Page 16: ...al 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 2 thru 3 5 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 Sect...

Page 17: ...Vent Kit Equivalent Vent Lengths Minimum Maximum allowable combustion air and vent piping lengths are as follows Combustion Air 12 equivalent feet 3 7 m minimum 150 equivalent feet 30 5 m maximum Vent 12 equivalent feet 3 7 m minimum 150 equivalent feet 30 5 m maximum When determining equivalent combustion air and vent length add 5 feet 1 5m for each 90 elbow and 3 feet 9 m for each 45 elbow EXAMP...

Page 18: ... connection and the air inlet cap connection Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume Follow the polypropylene manufacturer s instructions when using polypropylene material as an inlet pipe When a ...

Page 19: ...mber 400 1000 90 Elbow with Screen 100157616 Installing vent and air piping Use only cleaners primers and solvents that are approved for the materials which are joined together NOTICE PVC CPVC 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 connection to t...

Page 20: ...will needlessly soften the pipe Table 3H PVC CPVC Vent Pipe and Fittings Approved PVC CPVC Vent Pipe and Fittings Item Material Standard Vent pipe PVC Schedule 40 80 ANSI ASTM D1785 PVC DWV ANSI ASTM D2665 CPVC Schedule 40 80 ANSI ASTM F441 Vent fittings PVC Schedule 40 ANSI ASTM D2466 PVC Schedule 80 ANSI ASTM D2467 CPVC Schedule 80 ANSI ASTM F439 PVC DWV ANSI ASTM D2665 Pipe Cement Primer PVC AN...

Page 21: ...e vent manufacturer s joint connector FIG 3 4 NOTICE IMG00840 NOTES 1 FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION 2 ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE EQUIVALENT LENGTHS 3 SECTION A IS EQUIVALENT FEET OF RIGID PIPE WHICH MAY INCLUDE 45 AND 90 ELBOWS PLEASE SEE SIZING SECTION FOR DETERMINING EQUIVALENT FEET B DIM 3 RIGID 3 FLEX 4 FLEX Duravent 3 10 FT 20 FT 30 FT 40 FT 50 FT 6...

Page 22: ... FSAIH04 9401PVC 9492 5400CI 9414TERM 2SVSLA04 2SVSTP F X 04 2SVSRCX04 2SVSTEX0490 650 800 FSA 6PVC 6FNS FSBS6 FSRC6 FSAIH04 9601PVC 9690 9692 9414TERM 2SVSTTA06 2SVSTPX06 2SVSRCX06 2SVSTEX0490 1000 FSA 6PVC 6FNS FSBS6 FSRC6 FSAIH06 9601PVC 9690 9692 9614TERM 2SVSTTA06 2SVSTPX06 2SVSRCX06 2SVSEE0690 2SVSTPX06 Model Metal Fab Security Chimney ICC Corr Guard Secure Seal VIC Boiler Adapter Flue Termi...

Page 23: ... 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 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 con...

Page 24: ...st 3 feet 9 m above any forced air intake within 10 feet 3 m No closer than 12 inches 305 mm below or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches 305 mm above grade or snow line at least 12 inches 305 mm below the vent termination FIG 4 1B and the vent pipe must not extend more than 24 inches 610 mm vertically outside the buildi...

Page 25: ...tion Manual 2 For Polypropylene Only Install the vent and air intake sidewall adapters from Table 3H into the vent plate Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate FIG 4 4B 3 For PVC CPVC Only Install the vent and air intake piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in...

Page 26: ...ltiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B WARNING 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 either combustible or noncombustible construction size the ve...

Page 27: ...he Y concentric fitting to the larger kit pipe FIG 4 8 b Cement the rain cap to the smaller diameter kit pipe FIG 4 8 Sidewall termination optional concentric vent Models 400 500 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit 100140484 for 4 102 mm diameter Models 400 500 Both combustion air and vent pipes must attach to the terminat...

Page 28: ...IN VENT PIPE Figure 4 10 Rain Cap to Vent Pipe Alternate Assembly 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...

Page 29: ...n to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 12 Concentric Vent and Combustion Air Termination COMBUSTION AIR VENT VENT COMBUSTION AIR STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED Figure 4 11 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 co...

Page 30: ...d 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 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 building more than shown in this document Condensate could freeze and block vent p...

Page 31: ...le Knight XL 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 recirculation of flue products and the possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches 305 mm between edge of air intake elb...

Page 32: ...g see FIG 4 10 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 result in personal injury or death 2 Cut one 1 hole 7 inch 178 mm diameter for 10...

Page 33: ...e combustion air and vent pipes are properly connected to the concentric 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 termination...

Page 34: ...ional 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 particulate contamination that will harm this appliance a...

Page 35: ...pe lengths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase DIR 2000585169 00 FLUE EXHAUST AIR INLET EXISTING SEAL CAP SEAL FLUE OUTLET For concept illustration only Individual installations may vary due to job site specific equipment Installation Operation Manual ...

Page 36: ...onal outdoor kit All vent materials must be field supplied and supported per the vent manufacturer s instructions Combustion air supply must be free of contaminants see the Combustion and Ventilation Air Requirements section of this manual To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section WARNING Model DuraVent Z Flex Heat Fab Metal...

Page 37: ...ete brick block or other non combustible pad Do not locate unit so that high winds can deflect off of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Multiple unit outdoor installations require 48 1 22 m clearance between each vent cap Locate outdoor cap at least 48 1 22m below and 48 1 2...

Page 38: ...2A and 7 2B 1 Connect the system return marked Inlet 2 Connect the system supply marked Outlet 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 make up water line 5 Install a pressure reducing valve on the cold feed make up water line 15 psi 103 kPa nominal Check temperature and pressure gaug...

Page 39: ...5 00 RELIEF VALVE FLOW SWITCH TEMPERATURE PRESSURE GAUGE TEE WITH FITTING ON TOP FIELD PROVIDED Figure 7 1 Temperature and Pressure Gauge Installation 7 Hydronic piping continued See the piping illustrations included in this section FIG s 7 4 thru 7 8 for suggested guidelines in piping the Knight XL Please note that these illustrations are meant to show system piping concept only the installer is ...

Page 40: ...ed Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 8 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above 115 F 46 C 9 Unions Field supplied Recommended for unit serviceability 10 Temperature and pressure gauge Factory supplied The temperature and pres...

Page 41: ...OR BACKFLOW PREVENTER MAGNETIC SEPARATOR WATER METER STRAINER FILTER PRESSURE REDUCING VALVE PRESSURE RELIEF VALVE BALL VALVE EXPANSION TANK PIPING DRAIN PORT DIR 20005857530 00 Figure 7 2B Near Boiler Piping w Low Loss Header Variable speed pump option 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...

Page 42: ... FT HD FLOW RATE GPM PRESSURE DROP VS FLOW HEAT EXCHANGER ONLY 400 500 650 800 1000 TEMPERATURE RISE APPLICATIONS Model MINIMUM PIPE SIZE 20 F 25 F 30 F 35 F GPM FT HD GPM FT HD GPM FT HD GPM FT HD 400 2 38 10 30 7 25 5 22 4 500 2 48 14 38 12 32 9 27 8 650 2 62 16 50 11 41 9 36 7 800 2 76 17 61 13 51 10 44 9 1000 2 1 2 96 18 76 11 64 8 54 6 7 Hydronic piping Installation Operation Manual ...

Page 43: ...ESSURE GAUGE T P SYSTEM SUPPLY SENSOR BACKFLOW PREVENTER MAGNETIC SEPARATOR WATER METER STRAINER FILTER PRESSURE REDUCING VALVE PRESSURE RELIEF VALVE BALL VALVE EXPANSION TANK PIPING DRAIN PORT DIFFERENTIAL PRESSURE BYPASS VALVE 2 WAY MOTORIZED VALVE OPTIONAL MIXING VALVE ANTI SCALD FLOW SWITCH WIRING Figure 7 4 Single Boiler Multiple Temperatures Please note that these illustrations are meant to ...

Page 44: ...WATER IN DHW HOT WATER OUT DIR 2000585755 00 Figure 7 5 Single Boiler Primary Secondary Piping NOTICE System flow should always remain higher than the required flow for the boiler s when the boiler s is in operation to prevent short cycling and high limit issues Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment The inst...

Page 45: ...BYPASS VALVE 2 WAY MOTORIZED VALVE OPTIONAL MIXING VALVE ANTI SCALD FLOW SWITCH WIRING BOILER 2 T P COLD WATER IN DHW HOT WATER OUT Figure 7 6 Multiple Boilers Multiple Temperatures Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment The installer must follow all manufacturer s instructions for each system component The i...

Page 46: ...le Boilers Primary Secondary Piping NOTICE System flow should always remain higher than the required flow for the boiler s when the boiler s is in operation to prevent short cycling and high limit issues Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment The installer must follow all manufacturer s instructions for each ...

Page 47: ...ALVE 1 SENSOR 3 SENSOR 2 PUMP 3 PUMP 2 VALVE 3 VALVE 2 SENSOR 1 SENSOR 2 SENSOR 3 PUMP 1 PUMP 2 PUMP 3 VALVE 1 VALVE 2 VALVE 3 DWH HOT WATER OUT Figure 7 8 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 equipment The installer must follow all manufacturer s instructi...

Page 48: ... appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa b The appliance 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 ...

Page 49: ... gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c 3 5 kPa at any time Adjust lockup regulator for 14 inches w c 3 5 kPa 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 3...

Page 50: ...ualified 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 gas valve On Models 400 500 re tighten the set screw inside the pressure tap On Models 650 10...

Page 51: ...Knight XL 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 shuts off service to an area to provide maintenance to t...

Page 52: ...witch 15 amp recommended as required by the code see FIG 9 1 3 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 9 1 4 To activate a system pump wire as shown in FIG 9 1 Dry contacts are sized for 1 5 hp 120V 3 hp 240V or 30 amps DOMESTIC HOT WATER PUMP BOILER PUMP SYSTEM PUMP 120V SUPPLY LINE GROUND NEUTRAL W G BK SERVICE SWITCH L2...

Page 53: ...ation of the louvers 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 proving switch FIG 9 3 High gas pressure switch 1 If a switch is provided to detect excessive gas pressure remove the jumper wire from the terminals on the connection board and then connect them to its normally closed contacts FIG 9 3 L...

Page 54: ...is desired the outdoor air sensor should be wired to the low voltage connection board at the terminals marked for the outdoor air sensor FIG 9 3 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature...

Page 55: ...EM SUPPLY SENSOR BUILDING MANAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO LOW WATER CUTOFF OUTDOOR SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER ROOM THERMOSTAT 1 ROOM THERMOSTAT 2 TANK SENSOR A B NOTE CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES WIRE AS NEEDED SYSTEM PUMP SPEED CONTROL BOILER PUMP 2000608490 00 RECIRC PUMP RELAY DHW RECIRC SENSOR ...

Page 56: ...h to prevent property damage from condensate spillage The switch should be wired in series with the blocked drain switch inside the boiler see FIG 11 1 Use materials 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 CP...

Page 57: ... mistake as food and ingest leading to death WARNING Pre CommissioningCleaning 1 Prior to fill and start up flush the entire heating system 2 Clean the entire heating system with an approved pre commissioning cleaner comparable to Sentinel X300 or Fernox F3 in accordance with the manufacturer s recommendation to remove debris and prolong the life of the heat exchanger 3 Clean all water filtering d...

Page 58: ...e that a leak is present Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close automatic and manual air vents and boiler drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a system is 12 psi b Pressure will rise when the boiler is turned ON and syste...

Page 59: ...rantwiththepropane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to each of the heat loop demand terminals on the connection board 2 Connect a voltmet...

Page 60: ... 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 an overflow switch to prevent property damage from condensate spillage The switch should be wired in series with the air pressure switch inside the boiler Use materials approved by the authority having jurisdiction In the absence of other authori...

Page 61: ...ight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death q Check gas piping 1 Check around the boiler for gas odor following the procedure on page 48 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start ...

Page 62: ...ol which has been under water If you cannot reach your gas supplier call the fire department 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Remove top cover 6 Turn gas shutof...

Page 63: ...on of this procedure Verify space heat circulator mode The Space Heating Mode controls both the system pump if connected and the boiler pump When the SMART TOUCH 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 and the set point is not met it also turns on the boiler pump After the space heating call for...

Page 64: ...FIG 11 3 2 Once the set point has been adjusted to the desired setting press the Door Menu slider top left or the Setup button 3 Press the APPLY CHANGES button on the top of the screen NOTE The APPLY CHANGES button must be pressed to complete programming of the controls Failure to press the APPLY CHANGES button will result in an unprogrammed control The Door Menu button will become highlighted whe...

Page 65: ...m supply temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in the control must be changed See the Knight XL Service Manual for a detailed explanation of this procedure 11 Start up continued Installation Operation Manual Set maximum DHW fan speed If the rated input of the indirect tank is less than the maximum outp...

Page 66: ...ch unit must have a unique address set The leader has more options which are described in the Knight XL Service Manual 5 Once all the updates are complete press the Door Menu slider top left or the Setup button 6 Press the APPLY CHANGES button on the top of the screen NOTE The APPLY CHANGES button must be pressed to complete programming of the controls Failure to press the APPLY CHANGES button wil...

Page 67: ...ty The SMART TOUCH 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 input is ignored When a boiler is programmed for DHW Normal Mode the maximum firing rate can be limited to match the input rating of the indirect tank coil DHW space heating SH cycling If a DHW call for heat is received while a s...

Page 68: ...even start and stop times for the DHW setback 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 outlet temperature sensor When the outlet tem...

Page 69: ...t temperature can be set between 70 F 21 C and 190 F 88 C Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described on this page under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations The Knight XL is equipped with adjustable automatic reset and manual reset high limits The autom...

Page 70: ...ler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it 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 ...

Page 71: ...ze then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal 8 If the space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump will turn off boiler and DHW pu...

Page 72: ... and displays both factory installed and field installed sensor including Outdoor Air Hot Water Temperature System Supply System Return Inlet Water Delta T Outlet Water Flue Temperature and Flame Current The Navigation Section is located down the left side of the screen There are five 5 sections located below the Lochinvar icon Home View Setup Information About and Settings The Home Section is the...

Page 73: ...s shall be less than 150 ppm 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 30 C above return water temperature Test low water flow conditions reference the Knight XL Service Manual If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean th...

Page 74: ...ons The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death WARNING WARNING WARNING WARNING Figure 13 1 Condensate Trap Installation Operation Manual Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and conden...

Page 75: ...cally removed and inspected This inspection must only be conducted 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 e...

Page 76: ...T TOUCH control module display to Parameter Mode and check all settings See Section 1 of the Knight XL Service Manual Adjust settings if necessary See Section 1 of the Knight XL 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 11 Start up 2...

Page 77: ... the heat exchanger access cover burner and gas air arm assembly 6 Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure wate...

Page 78: ...ties gas water electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or fault condition is persent 100329773 REV C FAN RELAY PUMP RELAYS 3 OUTLET SENSOR OPERATING S1a OUTLET SENSOR HIGH LIMIT S1b SHIELD 0 10V BMS 0 10V 0 10V 0 10V IN A B SHIELD SHIELD SYS PUMP IN BLR PUMP OUT RATE OUT MODBUS GA 23 24 25 2...

Page 79: ...S VALVE RELAY X5 7 X5 16 X5 8 X5 15 1 2 4 5 TR2 X1 7 FLAME ROD ROD CAUTION HIGH VOLTAGE SPARK LEAD BLOWER X2 2 X5 2 X5 11 X5 10 AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH OPTIONAL ETHERNET CABLE E GND SW1 J2 J9B J9A J12 J4 OPTIONAL USB WIFI EXTENSION CABLE LCD DISPLAY 24V J3 J11 COMMUNICATION CONTROL BOARD WIFI DONGLE OR OR BR OR BR CN2 4 CN1 5 CN1 6 CN1 3 K1 K2 JUNCTION BOX INTEGRATED CONTROL X1 3 ...

Page 80: ...000045192 CN 500032877 reflects the addition of air filter size information Revision E PCP 3000046037 CN 500033557 reflects an update to the side service clearance common venting information and the addition of Category II venting information and a 4 vent option for the 650 models Revision F PCP 3000048425 CN 500035754 reflects an update to Table 3L on page 22 Figure 9 3 on page 55 Figure 14 1 on ...

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