Lochinvar 400 manual

Installation & Operation Manual Models: 400 - 801 This manual must only be used by a qualifi ed 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 substanti[...]

2 Contents Hazard de fi nitions The following defi ned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.  DANGER  WARNING  CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which, if not avoided[...]

Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for you[...]

4 The Knight XL - How it works... 1. Stainless steel heat exchanger Allows system water to fl ow through specially designed coils for maximum heat transfer, while providing protection against fl ue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Combustion chamber access cover Allows access to the combust[...]

Front View - Model 400 27 35 8 7 20 13 28 23 14 29 25 4 5 37 38 Left Side (inside unit) - Model 400 19 21 36 16 1 3 17 33 26 2 Right Side (inside unit) - Model 400 The Knight XL - How it works... (continued) Rear View - Model 400 5 Model 400 10 31 24 30 22 11 15 32 6 18 39 Installation & Operation Manual[...]

6 The Knight XL - How it works... 18 15 27 39 Rear View - Model 501 27 15 18 39 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801 Left Side (inside unit) - Model 501 Model 501 Models 601 - 801 34 4 5 4 Installation & Operation Manual[...]

Ratings Notes: 1. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 2. Net I=B=R ratings are based on net installed radiation of suffi cient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance o[...]

8 The Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specifi ed in ANSI Z21.13 – latest edition. Failure to keep boiler area clear and free of combustible materials, gasoline, and other fl ammable liquids and vapors can result in severe personal injury, death, or substantial [...]

9 1 Determine boiler location (continued) ALCOVE INST ALLA TION OPEN FRONT 1/4" (6 MM) MIN IMU M C LEARA NCE AROUND HO T WA T ER PIPES 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE 18" (457 MM ) FRONT 0" RIGHT 13" (330) TOP 12" (305 MM) LEFT 14" ( 356 MM) REAR RECOMMENDED SERVICE CLEARANCES: FRONT - 30” (762 mm) TO[...]

10 1 Determine boiler location Provide air openings to room: Knight XL alone in boiler room 1. No air ventilation openings into the boiler room are needed when clearances around the Knight XL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG[...]

11 Products to avoid: Spray cans containing chloro/fl uorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softe[...]

1 Determine boiler location 12 When removing a boiler from existing common vent system: Do not install the Knight XL into a common vent with any other appliance. This will cause fl ue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage. At the time of removal of an existing boi[...]

2 Prepare boiler 13 Remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1). 3. To remove the boiler from the pallet (after removing the front door): a. Remove the two lag bolts from the wood pallet inside the b[...]

2 Prepare boiler 14 SCREWDRIVER SLOT LOWER RAISE Figure 2-5 Leveling Legs on the Boiler Leveling the boiler 1. Set the boiler in place and check level. a) Adjust legs if necessary to level boiler, see FIG. 2-5 below. ALLEN WRENCH ADJUSTMENT SCREW Figure 2-3 Gas Valve Adjustment - Model 501 Model 501 1. Remove the top access cover from the unit (no [...]

15 PVC/CPVC Two Pipe See Figure 4-1A 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 PVC/CPVC Concentric See Figure 4-7 Models 400 - 601 Only Direct venting options - Sidewall Vent 3 General venting Installation & Operation Manual[...]

16 Direct venting options - Vertical Vent, Sidewall Air 3 General venting 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 Models 400 - 601 Only PVC/CPVC Vertical Vent, Sidewall Air Stainless Steel Vertical Vent, Sidewall Air Stainless steel vent/air[...]

17 3 General venting (continued) PVC/CPVC vent piping materials Use only the materials listed in Table 3A (pg. 18) for vent pipe, and fi ttings. Failure to comply could result in severe personal injury, death, or substantial property damage. Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. [...]

18 3 General venting 6. Priming and Cementing: a. Handle fi ttings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fi tting socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fi tting socket[...]

19 3 General venting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specifi ed in this sec[...]

20 3 General venting Figure 3-12 Near Boiler Stainless Steel Venting Models 701 - 801 4" S.S. ADAPTER VENT 4" S.S. INTERMEDIATE (FOR SAF-T VENT ONLY ) Figure 3-11 Near Boiler Stainless Steel Venting Models 400 - 601 Table 3C Stainless Steel Vent Termination Kit(s) Model Kit Number 701 - 801 KIT3137 Stainless steel air intake/vent connecti[...]

21 Model Kit Number Equivalent Vent Length 400 CVK3007 5 Feet (1.5 m) 501 CVK3007 30 Feet (9 m) 601 CVK3007 30 Feet (9 m) 3 General venting (continued) Vent, air piping and termination: The Knight XL vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the [...]

22 3 General venting If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants. To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 11 before installing the boiler or air inlet piping. If contami[...]

23 4 Sidewall direct venting Vent/air termination – sidewall Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balc[...]

12" (305 MM) MIN 15" (381 MM) M AX 12" (305 MM) MI N FROM BOILER VENT PIPE CONNECTION TO BOILER INT AKE AIR CONNECTION BIRD SCREEN GRADE OR SNOW LINE Figure 4-1C Alternate Stainless Steel Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 400 - 601 w/Field Supplied Fittings, Utilizing FasNSeal’s [...]

25 12” (305 MM) MIN BIRD SCREEN (TYPICAL) 12” (305 MM) MIN 12” (305 MM) MIN Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings 36” (914 MM) MIN 7’ (2.1 M) MIN ABOVE ANY PUBLIC WALKW A Y IF LESS THAN 10’ (3 M) FORCED AIR INLET BIRD SCREEN (TYPICAL) Figure 4-4B Alternate Clearance to Forced Air Inlets w/Field [...]

26 4 Sidewall direct venting SIDEWALL TERMINA TION PLATE VENT PIPING GAL VANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES) ELBOW ELBOW AIR PIPING BIRD SCREEN BIRD SCREEN Figure 4-5B A Typical Sidewall Termination Assembly - Models 400 - 801 PVC/CPVC or Stainless Steel Termination and fi ttings 1. Prepare the vent termination elbow and the air termina[...]

27 4 Sidewall direct venting (continued) 4" (102 MM) DIA. 6" (152 MM) DIA. RAIN CAP "Y" CONCENT RIC FITTING "FLEXIBLE" PIPE COUPLING 6" (152 MM) DIA. 6" (152 MM) DIA. 6" (152 MM) TO 4" (102 MM) R E DUCER Figure 4-8 Kit Contents_CVK3007 - Models 400 - 601 Sidewall termination installation 1. Determin[...]

28 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 400 - 601 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 601 Instead of cementing the smaller pipe to the rain cap, a fi eld-supplied stainless steel screw may be used to secure the two (2) components together when fi eld disassembly is desi[...]

29 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 400 - 601 Only Multiventing sidewall terminations When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-12). NEVER common vent or breach vent this appliance. When two (2) or more[...]

30 5 Vertical direct venting Vent/air termination – vertical Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. 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 Canad[...]

31 5 Vertical direct venting (continued) Vent/air termination – vertical Prepare roof penetrations 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, s[...]

32 5 Vertical direct venting Vertical termination – optional concentric vent: Models 400 - 601 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be [...]

33 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 400 - 601 Only ELBOW (FIELD SUPPLIED) SUPPORT (FIELD SUPPLIED) ROOF BOOT / FLASHING (FIELD SUPPLIED) VENT COMBUSTI ON AIR VENT 12" (305 MM) ( 18" (457 MM) F OR CAN ADA ) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIP A TED SNOW LEVEL. MAXIMUM OF 24[...]

34 5 Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. Concentric Venting Arrangement The venting is to[...]

35 5 Vertical direct venting (continued) Existing vent as a chase Follow all existing termination and clearance requirements and allowable 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 AIR INLET FLUE OUTLET EX ISTING CAP SEAL SEAL *For concep[...]

36 6 Hydronic piping System water piping methods The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet. It is important to note that the boiler has a minimal amo[...]

37 RELIEF V ALVE FLOW SWITCH P ADDLE TEMPERA TURE AND PRESSURE GAUGE TEE WITH FITTING ON TOP (FIELD PROVIDED) CLOSE NIPPLE (FIELD PROVIDED) TEE WITH 1” FITTING ON TOP CLOSE NIPPLE TEE WITH 3/4” FITTING ON TOP CLOSE NIPPLE NOTICE Be sure to install the fl ow switch so that the arrow on the fl ow switch is pointing in the direction of the fl o[...]

6 Hydronic piping Figure 6-3 Flow Switch Adjustment Flow switch adjustment Refer to Table 6A for the proper setting of the sensitivity screw. For reference, 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 [...]

39 6 Hydronic piping (continued) Near boiler piping connections Y -ST RAINER (RECOMMENDED) BOILER PUMP INDIRECT DOMESTIC HOT WA TER T ANK SYSTEM PUMP TO FLOOR DRAIN T O F R O M F R O M S Y S T E M T O S Y S T E M DOMESTI C HOT WA TER P UM P SYSTEM SENSOR DIRT SEP ARAT OR Figure 6-4A Near Boiler Piping w/Y-Strainer Circulator sizing The Knight XL he[...]

40 Figure 6-5 Pressure Drop vs. Flow - Models 400 and 501 Table 6B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F Figure 6-6 Pressure Drop vs. Flow - Models 601 thru 801 0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 20 25 30 35 40 45 KBN501 KBN400 Pressure Drop vs Flow (Includes Boiler Secondary Piping) Flow Rate (GPM) P[...]

41 6 Hydronic piping (continued) EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE CT DHW TANK BOILER TEMPERATURE / PRESSURE G AUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER CIRCULAT OR COLD WATER IN ANTI-SCALD MIXING V ALV E [...]

42 6 Hydronic piping EXP ANSION T ANK AIR SEP ARA TOR PRESSURE RE DUCI NG V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VA LV E FLOW CHECK V AL VE (T YPICAL) INDIRE CT DHW T ANK BOILER TEMPERA TURE / PRESSURE GAUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER C IRCULA TOR COLD WA TER IN ANTI-SCALD MIXING V [...]

43 6 Hydronic piping (continued) EXPANSION TANK AIR SEPARATOR PRESSURE REDUCING VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (T YPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE CT DHW TANK BOILER 1 TEMP ERATU RE / PRESSURE GAUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER CIRCULATOR COLD WATER IN ANTI-SCALD MIX ING VALV[...]

44 6 Hydronic piping EX PAN SIO N TANK AIR SEPARATOR PRESSURE REDU CING V ALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRECT D HW T ANK BOILER 1 (LEADER ) TEMP ERATU RE / PRESSURE GAUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER CIRCULAT OR (TYPICAL) ANTI-SCALD MIXING VALVE[...]

45 6 Hydronic piping (continued) EX PANSION TANK AIR SEPARATOR PRESSURE REDUCIN G VALVE BACK FLOW PREVENTER BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) INDIRE CT DHW TANK BOILER TEMPERATURE / PRESSURE GAUGE PRESSURE GAUGE DRAIN DRAIN PO INT (TYPICAL) BOILE R CIRCUL ATOR COLD WATER IN ANTI-SCALD MIX ING VALV[...]

46 7 Gas connections Connecting gas supply piping 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the boiler. a . Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canad[...]

47 7 Gas connections (continued) Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Use two wrenches when tightening gas piping at boiler (FIG. 7-4), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas c[...]

48 Nominal Iron Pipe Size (inches) Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on NAT GAS, 1025 Btu/ hr per Cubic Foot of Gas and 0.60 Specifi c Gravity) 10 [...]

49  WARNING When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open fl ame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 14. Turn on the gas supply at the manual gas valve. [...]

50 8 Field wiring ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 105°C[...]

51 8 Field wiring (continued) Thermostat 1. Connect the room thermostats or end switches (isolated contact only) to room thermostat 1, 2, or 3, as shown in FIG. 8-3. 2. Install the thermostat on the inside wall away from infl uences of drafts, hot or cold water pipes, lighting fi xtures, television, sunlight, or fi replaces. 3. Thermostat antici[...]

52 8 Field wiring Modbus When the optional ModBus interface module is installed, the RS-485 ModBus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module. Flow switc[...]

53 8 Field wiring (continued) LOUVER RE LA Y FLOW SW ITCH TA N K T H E R M O S TAT ROOM T HERMO STA T 3 SYSTEM SUPPL Y SENSOR BUIL DI NG MAN AG EME NT SYSTEM LOUVER PROVING SW ITCH COM NO LOW W A TER CUTOFF OUTDOO R SENSOR T ANK SENSOR SHIE LD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER ROOM T HERMO STA T 1 ROOM T HERMO STA T 2 A B NOTE : CO[...]

54 9 Condensate disposal Condensate drain 1. This boiler is a high effi ciency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) PVC union for connection of a 1/2 inch (12.7 mm) PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing fi lter. Conden[...]

55 10 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard water areas (above 7 grains hardness). [...]

56 10 Start-up Check for gas leaks Before starting the boiler, and during initial operation, smell near the fl oor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detectio[...]

57 10 Start-up (continued) Final checks before starting the boiler  Read the Knight XL Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, page 58 for proper steps to start boiler.  Verify the boiler and system are full of water and all system components are correctly set for operation.  Ver[...]

58 FOR YOUR SAFETY READ BEFORE OPERA TING W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury , or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner . Do not try to light the burner by han[...]

59 10 Start-up (continued) Check fl ame and combustion (continued) 4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 67). 5. Locate the pinhole button below the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold [...]

60 Set domestic hot water (DHW) operation Verify DHW mode There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum fi ring rate may be limited in this mode [...]

General How the boiler operates The Knight XL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes fl ue products out of the boiler through the heat exchanger and fl ue piping. The control module regulates blower speed to control the boiler fi rin[...]

62 11 Operating information Ramp delay For systems with lower fl ow, the SMART SYSTEM can limit the fi ring rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat to a space heating call for heat. There are six (6) limits that can be programmed, as well as six (6) time intervals corresponding to [...]

63 11 Operating information (continued) Monitor external limits Connections are provided on the connection board for external limits such as fl ow switch, low water cutoff, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. Run-time and al[...]

64 11 Operating information Outdoor reset operation, if used Target temperature with outdoor reset This feature improves the system’s effi ciency as the outdoor temperature warms up. See the Knight XL Service Manual to change the settings. Reset curve The reset curves look at outdoor air temperature and adjusts the set points. Cascade When multi[...]

65 11 Operating information (continued) Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The fl ow switch and/or LWCO must close. 3. Th[...]

66 OPERATION DISPLAY 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 fi rst, then the boiler pump will turn off 2 seconds later. This will divert the boiler’s out[...]

67 11 Operating information (continued) Knight XL control module NA VIGA TION DIAL Figure 11-1 Control Panel Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (i[...]

68 Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “  SETPOINTS” is fl ashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 60). Installer Most parameters are available only to the installer, accessible by enterin[...]

69 11 Operating information (continued) Status Display Screens Section Display Description A (Boiler Status Bar) STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat. START The unit has begun a burn cycle and is checking all safety circuits. PREPURGE The unit has initia[...]

70 11 Operating information Status Display Screens (cont’d) Section Display Description C (Operational Information) SYSTEM: The temperature read by the system supply sensor (if connected). TANK: The temperature read by the tank sensor (if connected). OUTDOOR: The temperature read by the outdoor sensor (if connected). INLET TEMP: The temperature r[...]

71 11 Operating information (continued) Status Display Screens (cont’d) Section Display Description E (NAVIGATION 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 se[...]

72 Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fi ll with fresh water • Check for leaks (water, gas, fl ue, condensate) • Verify [...]

73 12 Maintenance (continued) Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe p[...]

74 12 Maintenance Flue vent system and air piping 1. Visually inspect the entire fl ue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed. 2. Verify that boiler vent discharge and air intake are clean and free of obstruc[...]

75 AIR ARM SCREW S (QTY . 5) GASKET BURNER Figure 12-4 Burner Assembly - Models 601 - 801 12 Maintenance (continued) Inspect ignition and fl ame sense electrodes 1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/fl ame sense electrode using sandpaper[...]

76 12 Maintenance Check fl ame signal 1. At high fi re the fl ame signal shown on the display should be at least 10 microamps. 2. A lower fl ame signal may indicate a fouled or damaged fl ame sense electrode. If cleaning the fl ame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, rep[...]

77 Figure 13-1 Wiring Diagram 13 Diagrams X1- 7 OR OR BR PR OR BR BR PR PR CN2-4 CN2- 1 CN1-5 CN1-6 CN1-3 CN1-4 CN1-1 CN1- 2 K1 K2 K3 RELAY BOARD ON/OF F SW ITCH JUNCTION BOX BK W 1 2 3 4 5 G R R W 3.5A R T W BK Y BL KB 801 ONLY BLOWER -T HIGH LIMIT SENSOR S1b OPE RAT ING SENSO R S 1a INLET SENS OR S2 FLUE SENSOR S3a FLUE SENSOR S3b INT EGR ATED CO[...]

Figure 13-2 Ladder Diagram BOX DEPICTS OPTION AL ITEMS LADDER DIAGRAM LBL20141 REV C 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPLY "L" ON / OFF SWITCH X1-6 X1-2 F2 NEUTRAL TERMINA L S TRIP 120V SUPPLY "N" FLOW CN5-6 CN5-12 CN5-11 X4-2 X4-10 X4-11 INTEGRATED CONTROL LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWI TCH LOUVER RELA[...]

Notes 79 Installation & Operation Manual[...]

Revision Notes: Revision A (ECO #C05747) initial release. Re fl ects the new model numbers for the Knight XL upgrade. Revision B (ECO #C0 6188) re fl ects changes made to FIG. 6-10 (ECR #R03474) remove ghost pipe, changes made to FIG.’s 6-7, 6-9, and 6-11 (R03563) change the direction of the arrows, and edits made to the ladder and wiring diagr[...]