Lochinvar KBN399 Installation & Operation Manual Download | Manualshive

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Installation & Operation Manual

Models: 399 - 800

This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight XL Service Manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.



WARNING

Save this manual for future reference.

KBX-I-O Rev D

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Summary of Contents for KBN399

Page 1: ...ller 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 KBX I O Rev D ...

Page 2: ...n in Canada 16 PVC CPVC Air Intake Vent Connections 17 Air Inlet Pipe Materials 17 Stainless Steel Vent and Air Piping 18 Min Max Combustion Air Vent Piping Lengths 19 Removing from Existing Vent 19 Vent and Air Piping 19 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 20 23 Determine Location 20 21 Prepare Wall Penetrations 22 23 Termination and Fittings 23 Multiple Vent Air Terminations ...

Page 3: ...t 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 corro...

Page 4: ...ter inlet system return A 1 1 2 or 2 NPT depending on the model water connection that returns water from the system to the heat exchanger 15 Gas connection pipe Threaded pipe connection either 1 or 1 1 2 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 and e...

Page 5: ...16 1 3 34 17 26 2 37 Right Side inside unit Model 399 The Knight XL How it works continued Rear View Model 399 5 Model 399 10 24 32 18 11 6 15 33 22 31 36 Air pressure switch The air pressure switch detects blocked flue inlet conditions 37 Pump relay board The pump relay board is used to connect the boiler system and DHW pumps ...

Page 6: ...n Operation Manual 6 The Knight XL How it works 18 15 27 Rear View Model 500 27 15 18 Rear View Models 600 800 Left Side inside unit Models 600 800 Left Side inside unit Model 500 Model 500 Models 600 800 35 4 5 4 ...

Page 7: ...nd 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 6 Ratings have been confirmed by the Hydronics Institute Divi...

Page 8: ...ance 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 37 8 C Failure to install the appliance indoors could result in severe personal injury death or substantial property damage Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 25 ...

Page 9: ... SQ INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC or stainless steel 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 RECOMMENDED SERVICE CLEARANCES Front 30 762 mm Top 24 610 mm Left...

Page 10: ...ational 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 not s...

Page 11: ...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 commo...

Page 12: ...no tools required for removal 2 Remove the three screws securing the venturi to the blower Note When separating the venturi from the blower take care not to damage the O ring inside the blower FIG 2 2 3 Remove the four star drive screws securing the gas valve to the venturi FIG 2 2 4 Locate the propane orifice disk from the conversion kit bag Verify that the stamping on the orifice disk matches th...

Page 13: ...ess cover from the unit no tools required for removal 2 Remove the cover on top of the gas valve FIG 2 4 3 Turn the adjustment screw on top of the gas valve clockwise one and three quarter 1 3 4 turns on the 600 Model one and a half 1 1 2 turns on the 700 Model and one turn on the 800 Model see FIG 2 4 4 Use a combustion analyzer to verify CO2 is within the range of 9 6 10 5 If not adjust the scre...

Page 14: ...99 600 Only PVC CPVC Alternate Two Pipe See Figure 4 2A Stainless Steel Alternate Two Pipe See Figure 4 2B Stainless Steel Two Pipe See Figure 4 1C Models 399 600 Only PVC CPVC Concentric See Figure 4 7 Models 399 600 Only Direct venting options Sidewall Vent 3 General venting ...

Page 15: ...nt Optional Room Air 3 General venting continued Direct venting options Vertical Vent PVC CPVC Two Pipe See Figure 5 1A Stainless Steel Two Pipe See Figure 5 1B PVC CPVC Concentric See Figure 5 5 PVC CPVC Room Air See Figure 5 4 Stainless Steel Room Air See Figure 5 4 ...

Page 16: ...e CPVC pipe section using an All Purpose Cement suitable for PVC and CPVC pipe Use only the vent materials primer 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 thi...

Page 17: ...his section Plastic pipe may require an adapter not provided to transition between the air inlet connection on the appliance and the plastic air inlet pipe WARNING Using vent or air intake materials other than those specified failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of vent...

Page 18: ...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 installation instructions supplied with the vent system NOTICE The installer must use a specific vent starter adapter supplied by the vent manufacturer to adapt to different ven...

Page 19: ...ctions in Section 1 page 11 of this manual when removing a boiler from an existing vent system Vent and air piping Vent and air system Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations You must also install air piping from outside to the boiler air intake adapter The resultant installation...

Page 20: ... could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves court...

Page 21: ... in FIG s 4 1A thru 4 4B pages 20 thru 22 Also maintain the following a Vent must terminate At least 6 feet 1 8 m from adjacent walls No closer than 12 inches 305 mm below roof overhang At least 7 feet 2 1 m above any public walkway At least 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 a...

Page 22: ...ir pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 5 inch hole 140 mm hole for 4 inch 102 mm vent pipe 7 inch hole 191 mm hole for 6 inch 152 mm vent pipe Drill 3 16...

Page 23: ... this manual FIG 4 6A 2 Place wall penetrations to obtain minimum clearance of 12 inches 305 mm between vent pipe and adjacent air inlet elbow as shown in FIG 4 6A for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Knight XL is part of a direct vent connection It is not classified as a forced air intake with regard to s...

Page 24: ...VK3007 for 4 102 mm diameter Models 399 600 Both combustion air and vent pipes must attach to the termination kit The termination kit must terminate outside the structure and must be installed as shown below in FIG 4 7 Field supplied pipe and fittings are required to complete the installation The required combustion vent pipe materials are listed in Table 3A on page 16 of this manual OVERHANG OR R...

Page 25: ...E HOLE IN RAIN CAP PILOT HOLE IN VENT PIPE Figure 4 10 Rain Cap to Vent Pipe Alternate Assembly 6 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 7 Install the rain cap and small diameter pipe assembly into the Y concentric fitting a...

Page 26: ...tion of flue gases Dimension A in FIG 4 12 represents the distance between pipes or rain shields as touching or a 2 inch 51 mm maximum separation VENT COMBUSTION AIR 36 914 MM A Figure 4 12 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches 51 mm Maximum Separation COMBUSTION AIR VENT VENT COMBUSTION AIR STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED Figure 4 11 Concentr...

Page 27: ...e When the vent termination uses a rain cap as illustrated in FIG 5 1B maintain at least 36 914 mm 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 above the air intake ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 ...

Page 28: ...nt termination uses a rain cap as illustrated in FIG 5 1B maintain at least 36 914 mm 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 3 m above the air intake 4 Maintain the required dimensions of the finished termination piping as shown in FIG s...

Page 29: ...l Room Air Filter Box 5 Vertical direct venting continued The Knight XL may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room The vent pipe may terminate vertically above the roof line in a conventional vent manner see FIG 5 4 Follow the requirements in the General Venting and Vertical Direct Venting sections for vent mater...

Page 30: ...mination 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 products impinge on building surfaces or plants d Avoid possibility of...

Page 31: ...r more direct vent appliances are vented near each other each appliance must be individually vented see FIG 5 8 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 8 The next two 2 terminations must be at least 36 inches 914 mm away from the first two 2 terminations It is imp...

Page 32: ...system return marked Inlet make sure to install with pipe sealant compound 2 Connect the system supply marked Outlet make sure to install with pipe sealant compound 3 Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone 4 Install a backflow preventer on the cold feed make up water line 5 Install a pressure reducing valve on the cold feed make up...

Page 33: ... 2 For Models 700 800 install the 3 4 inch close nipple in the tee Install the relief valve on the 3 4 inch close nipple FIG 6 2 For Models 399 600 install the relief valve directly into the 3 4 inch fitting on the tee FIG 6 1 3 Install the close nipple on the downstream side of the relief valve tee FIG 6 1 4 Install the tee with the 1 inch fitting positioned vertically and on the top FIG 6 1 5 At...

Page 34: ...rence the position of the screw prior to setting should be turned clockwise with a Phillips driver until it stops FIG 6 3 Proceed to turn the screw counterclockwise the amount of turns listed in Table 6A based on the model Consult the manufacturer s instructions for wiring the flow switch to your system NORMALLY OPEN SENSITIVITY ADJUSTMENT NORMALLY CLOSED COMMON GROUND NOTICE Turn the sensitivity ...

Page 35: ...ndary Piping Flow Rate GPM Pressure Drop Feet of Head 0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80 90 KBN800 KBN700 KBN600 Pressure Drop vs Flow Includes Boiler Secondary Piping Flow Rate GPM Pressure Drop Feet of Head 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 399 1 1 2 37 21 30 14 26 11 21 8 500 1 1 2 46 23 37 16 32 13 26 10...

Page 36: ...cted flow rate through the boiler 5 Check valves Field supplied Check valves are recommended for installation as shown in FIG s 6 7 and 6 8 Failure to install check valves could result in a reverse flow condition during pump s off cycle 6 Domestic indirect hot water isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted ...

Page 37: ...UGE DRAIN DRAIN POINT TYPICAL BOILER CIRCULATOR COLD WATER IN ANTI SCALD MIXING VALVE SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR TO SYSTEM FROM SYSTEM DOMESTIC HOT WATER CIRCULATOR HOT WATER OUT MAKE UP WATER NOT TO EXCEED 4 PIPE DIAMETERS OR A MAXIMUM OF 12 APART Figure 6 7 Single Boiler Primary Secondary Piping NOTICE System flow should always remain higher than the required flow for the boiler s wh...

Page 38: ... WATER CIRCULATOR COLD WATER IN HOT WATER OUT MAKE UP WATER NOT TO EXCEED 4 PIPE DIAMETERS OR A MAXIMUM OF 12 APART Figure 6 8 Multiple Boilers Primary Secondary Piping Model Number of Units 2 3 4 5 6 7 8 Manifold Pipe Sizes in Inches mm 399 2 1 2 64 3 76 3 1 2 89 4 102 4 102 5 127 6 152 500 3 76 3 1 2 89 4 102 5 127 5 127 6 152 6 152 600 3 1 2 89 4 102 5 127 5 127 6 152 6 152 8 203 700 3 1 2 89 5...

Page 39: ... Before placing the boiler in operation check the boiler and its gas connection for leaks a The 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 ...

Page 40: ...up 2 Install 100 lockup 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 suppl...

Page 41: ...ge to the valve and install a suitable 1 8 3 mm fitting field supplied for the manometer tubing Place the tubing of the manometer over the tap once the set screw is loosened or the 1 8 3 mm fitting is installed depending on model as shown in FIG s 7 5 thru 7 7 on page 42 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 ...

Page 42: ...ery 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 their lines Gas valve rep...

Page 43: ...an 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 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as show...

Page 44: ...t when the tank temperature reaches the tank set point The tank sensor included with the Lochinvar Squire indirect DHW tanks TST2032 is the only sensor suitable for use with the SMART SYSTEM control Connect the sensor leads to the DHW Tank Sensor AUX terminals on the low voltage connection board FIG 8 3 Consult the tank manufacturer for application and performance when used with any other indirect...

Page 45: ...to the control If a Thermostat or Zone Control enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for the Room Thermostat Zone Control FIG 8 3 If the boilers are to run continuously connect a jumper wire between the R and W terminals for the Thermostat Zone Control input This will initiate a call for heat on the Cascade Co...

Page 46: ...MOSTAT ZONE CONT ROL A B SHIELD GROUN D SEQUENCING LOW WATER CUTOFF CN1 CN2 CN3 CN4 CN5 C NO NC C NO NC AUX DEVICE RELAY HIGH GAS PRESSURE SWITCH 500 ONLY LOW GAS PRESSURE SWITCH 500 ONLY 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 BOILE...

Page 47: ...nce 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 boilers and furnaces The pump should have an overflo...

Page 48: ...lication a The minimum cold water fill pressure for a commercial system is 12 psi 82 7 kPa 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 f...

Page 49: ...se 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 5 Once the external thermostat circuit wiring is checked a...

Page 50: ...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 procedure on page 39 of this manual connecting...

Page 51: ... system and any gas control 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 to...

Page 52: ...irculator mode The Space Heating Mode controls both the system primary pump if connected and the boiler secondary pump When the SMART SYSTEM control receives a space heating call for heat it turns on the system pump If the boiler is not heating an indirect DHW Domestic Hot Water tank it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a ...

Page 53: ...shes 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 Monday 2 Tuesday 3 Wednesday etc DD date MM month YY year NOTI...

Page 54: ...inues 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 operation the control will wait for 30 minutes time ...

Page 55: ...s 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 exceeds 195 F 90 C the co...

Page 56: ...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 contacts for indicating w...

Page 57: ...For DHW 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...

Page 58: ...efore the trial for ignition ends it begins to modulate the burner in order to maintain the set point If the boiler lights due to a space heating call for heat and the ramp delay function is active default is off the modulation will be held to a series of increasing limits afterthe burner has lit BLR SH 20 RATE OUT 124 8F 129 7 If the space heating call for heat is active and the DHW thermostat or...

Page 59: ...peration to show outlet and return temperatures fan speed and flame signal Press to toggle between digits when entering access code or between hour minutes etc when entering date and time Press to change boiler water temperature set point during normal operation Press to change displayed data values in Menu Mode Press to navigate through menu listing in Menu Mode DISPLAY SCREEN MENU EXIT SHUTDOWN ...

Page 60: ...accessible only by entering the installer access code see the Knight XL Service Manual Saving parameters reference the Parameter Table in the Knight XL 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 and...

Page 61: ...at has been satisfied and the unit runs the fan for an additional 10 seconds to clear the combustion chamber and vent system of residual flue products Service The unit has been placed in a temporary mode that will allow the unit to fire at 100 of rate for the purpose of combustion analysis OUT F When the outlet sensor has been selected as the control sensor default the control will display the out...

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

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: ...me 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 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 XL User s Information Manual for instr...

Page 66: ...annot be removed reinstall the air and vent lines per this manual and the Knight XL 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...

Page 67: ...iping 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...

Page 68: ...ontrol 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 10 Start up 2 Verify c...

Page 69: ...ion fluid in system do not drain 2 Allow time for the boiler to cool to room temperature if it has been firing 3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 5 Remove the heat exchanger access cover cover gasket s and chamber insulation assembly The boiler c...

Page 70: ...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 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated f...

Page 71: ...IGH VOLTAGE SPARK LEAD BLOWER CN3 8 CN3 7 CN3 9 CN3 6 CN3 4 CN3 3 CN3 1 CN3 10 DISPLAY CONNECTION BOARD INLET SENSOR OUTLET SENSOR FLUE SENSOR X4 8 X4 7 X4 9 X4 6 X4 4 X4 3 X4 1 X4 10 INTEGRATED CONTROL CN4 11 CN4 12 CN4 10 CN4 4 ALARM CONTACTS RUN TIME CONTACTS X3 1 X3 3 X3 4 X3 2 X5 8 X5 1 X5 2 X5 9 X3 RIBBON CABLE CN3 5 X4 5 X8 SYSTEM SENSOR AUX DHW TANK SENSOR OUTDOOR SENSOR 0 10V RS485 A B SH...

Page 72: ...ences to the safety shutoff testing and instructions sediment trap periodic cleaning of screens in vent terminations removal of B149 2 references changed the arrow direction on FIG 6 8 wall thickness for direct vent terminations and sidewall vent termination kit number correction Revision D ECO C02738 reflects updates made to the line voltage image FIG 8 1 on page 43 and edits made to the gas conv...

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