Lochinvar WH 55-399 manual

WH-I-O Rev H Installation & Operation Manual Models: WH 55 - 399 This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Wall Mount Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury[...]

2 Hazard definitions The following defined 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, will result [...]

Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including this manual and the Knight Wall Mount 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 Manua[...]

Installation & Operation Manual 4 The Knight Wall Mount Boiler - How it works... 1. Stainless steel heat exchanger Allows system water to flow around specially designed tubes for maximum heat transfer, while providing protection against flue gas corrosion. 2. Combustion chamber access cover Allows access to the combustion side of the heat excha[...]

Installation & Operation Manual 17 11 28 22 10 Front View IMG00161 11 17 4 3 24 2 6 8 7 26 1 33 Left Side (inside unit) IMG00162 27 23 28 16 19 31 30 18 25 5 33 Right Side (inside unit) The Knight Wall Mount Boiler - How it works... (continued) IMG00117 21 13 14 20 15 29 FRONT OF UNIT 32 Bottom View 5 Models 55 - 399[...]

6 Installation & Operation Manual Ratings Notes: 1. As an Energy Star Partner, Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency. 2. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 3. Net AHRI ratings are based on net installed ra[...]

Installation & Operation Manual The Knight wall mount boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition. Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in s[...]

1/4" MIN IMUM CL EARANCE AROUND HOT W A TE R PIPE S 1" M INI MUM C LE ARA NCE A ROUND VENT PIP E OPEN FRONT LEFT 0" MINIMUM RIGHT 0" MIN IMUM FRONT 6" MIN IMUM BOTTOM 0" MI NIMU M TOP 6" MI NI MUM RECOMMENDED SERVICE CLEARANCES: FRONT : 24” BOTTOM: 24” LEFT SIDE: 12” Figure 1-2 Alcove Installation - Minimum [...]

Installation & Operation Manual Provide air openings to room: Knight wall mount boiler alone in boiler room 1. No air ventilation openings into the boiler room are needed when clearances around the Knight wall mount boiler 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, p[...]

Products to avoid: Spray cans containing chloro/fluorocarbons 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 softeners [...]

When removing a boiler from existing common vent system: Do not install the Knight wall mount boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage. Failure to follow all instructions can result in flue gas s[...]

Installation & Operation Manual 2 Prepare boiler 12 Remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. To remove the boiler from the pallet: a. Remove the two (2) lag bolts securing the bottom of the unit to the pallet. b. Lift the boiler off the wall bracket mounted to the palle[...]

Installation & Operation Manual 2 Prepare boiler (continued) FASTENERS APPROPRIATE FOR W ALL TYPE QTY: 4 MOUNTING BRACKET (FACTORY SUPPLIED) WA L L: W OOD OR MET AL STUDS ON 16" CENTERS -OR- MASONRY / POUR ED CONCRETE Figure 2-4 Mounting the Boiler VENTURI GAS VALVE GROMMET BRASS ORIFICE SCREWS Figure 2-3 Installing Propane Orifice 13. Rea[...]

3 General venting 14 Installation & Operation Manual Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 26 for more details Direct venting options - Sidewall Vent Figure 3-3 Two-Pipe Vertical Termination - See page 29 for more details Figure 3-4 PVC/CPVC Concent[...]

15 Installation & Operation Manual 3 General venting This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed in Tables 3D, 3E, and 3G for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage. Insta[...]

3 General venting Installation & Operation Manual 16 Model 2" Max Vent/ Air 3" Max Vent/ Air 4" Max Vent/ Air 55 *80 feet 100 feet N/A 85 *50 feet 100 feet N/A 110 *40 feet 100 feet N/A 155 N/A 100 feet N/A 199 N/A 100 feet N/A 285 N/A *50 feet 100 feet 399 N/A N/A 100 feet Requirements for installation in Canada 1. Installations[...]

17 Installation & Operation Manual 3 General venting (continued) Materials 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, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent[...]

3 General venting 18 Installation & Operation Manual Air contamination Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possibl[...]

3 General venting (continued) 19 Installation & Operation Manual Installing vent and air piping Use only cleaners, primers, and solvents that are approved for the materials which are joined together. NOTICE 1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping. 2. Cut pipe [...]

3 General venting 20 Installation & Operation Manual The installer must use a specific vent starter adapter at the flue collar connection. The adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. NOTICE All vent connections MUST be secured by the vent manufacturer's joint connec[...]

21 3 General venting (continued) Installation & Operation Manual Table 3H Approved Stainless Steel (S.S.) Terminations and Adapters 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 3H for approved vent adapters. Discard CPVC starter pie[...]

4 Sidewall direct venting Vent/air termination – sidewall TO BOILER INT AKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION TERMINA TION PLA TE BIRD SCREEN GRADE OR SNOW LINE 12” MIN BIRD SCREEN 12” MIN 15” MAX Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could caus[...]

Vent/air termination – sidewall 23 Installation & Operation Manual AL TERNA TE VENTING ARRANGEMENT (IF SP ACE PERMITS) BIRD SCREEN 12” MIN 12” MIN 15” MAX COUPLING TO BOILER INT AKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION BIRD SCREEN GRADE OR SNOW LINE Figure 4-1C Alternate PVC/CPVC/SS/ Polypropylene Venting Arrangement (if Spac[...]

4 Sidewall direct venting 24 Installation & Operation Manual VENT PIPING GAL V ANIZED THIMBLE VENT CAP AIR PIPING WALL PLA TE VENT PLA TE VENT AIR CENTERLINE WIDTH Figure 4-4A PVC/CPVC Sidewall Termination Assembly Prepare wall penetrations 1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting[...]

4 Sidewall direct venting (continued) 25 Installation & Operation Manual 12" MIN. BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET VENT / AIR TERMINA TION VENT AIR Figure 4-5A Multiple Vent Terminations (must also comply with Figure 4-1A ) All vent pipes and air inlets must terminate at the same height to avoid possibility of severe pers[...]

4 Sidewall direct venting Sidewall termination – optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3" diameter - models 155 - 199, #CVK3008 for 2" diameter - models 55 - 110, or #CVK3007 for 4" diameter - models 285 - 399). Bot[...]

4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent models Figure 4-9 2" and 3" Concentric Vent Dimensional Drawing (reference Table 3D on page 19) Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when fie[...]

28 Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent Multiventing sidewall terminations When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-13). NEVER common vent or breach vent this appliance. When two (2) or mor[...]

5 Vertical direct venting Vent/air termination – vertical AL TERNA TE INT AKE LOCA TIONS: INT AKE PIPES MA Y BE LOCA TED ANYWHERE WITHIN 24” OF VENT PIPE BIRD SCREEN (TYPICAL) COUPLING (FIELD SUPPLIED) VENT OUTLET 12” MINIMUM ABOVE AIR INLET 6” MINIMUM ABOVE ROOF / SNOW LINE VENT COMBUSTION AIR 8. Locate terminations so they are not likely [...]

5 Vertical direct venting 3. Space the air and vent holes to provide the minimum spacing shown in FIG. 5-1A, page 29. 4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs. 5. Provide flashing and sealing boots sized for the vent pipe and air pipe. Multiple vent/air terminations 1. When terminating mu[...]

5 Vertical direct venting (continued) Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9, page 27). When using the alternate screw assembly method, drill a clearance hole in the rain cap and a[...]

32 Installation & Operation Manual Alternate vertical concentric venting Vent / Air Inlet Size Minimum Existing Vent / Chase Size 2" 4" 3" 5" 4" 7" Table 5A Alternate Vertical Concentric Vent / Chase Sizes Figure 5-8 Concentric Vent Example 1 12” MIN. FLUE EXHAUST SEAL COMBUSTION AIR FLUE OUTLET SEALED CAP EXISTI[...]

Installation & Operation Manual 33 6 Hydronic piping System water piping methods The Knight wall mount is designed to function in a closed loop pressurized system not less than 12 psi. 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 not[...]

Installation & Operation Manual 34 6 Hydronic piping Near boiler piping components 1. Boiler system piping: Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are ba[...]

Installation & Operation Manual 35 Near boiler piping connections AIR Y-STRAINER (RECOMMENDED) DOMESTIC HOT W A TER PUMP CONDENSAT E DRAIN SYSTEM PUMP BOILER PUMP F R O MS Y S T E M T O S Y S T E M T O F R O M INDIRECT DOMESTIC HOT W A TER TANK TO FLOOR DRAIN AIR SEPARATOR EXPANSION TANK VENT OUTLET INLET Figure 6-1A Near Boiler Piping VENT AIR[...]

Installation & Operation Manual 36 6 Hydronic piping -0 .5 0 0.00 0.50 1.00 1.50 2.00 2.50 3.00 02468 1 0 1 2 1 4 FT/HD FLOW 55 85 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 0 2 4 6 8 1 01 21 41 61 82 0 FT/HD FLOW 110 155 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 0 5 10 15 20 25 30 35 40 45 FT/HD FLOW 399 MODEL MODEL MODEL 1[...]

6 Hydronic piping (continued) It is recommended that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 6-3 through 6-9 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance [...]

38 Installation & Operation Manual BOILER INDIRECT DHW TAN K DOMESTIC HOT WATER CIRCULAT OR BACKFLOW PREVENTER PRESSURE REDUCING VA LVE PRESSURE GAUGE ANTI-SCALD MIXING VA LVE COLD WATE R IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATOR EXPAN SION TANK BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN PO INT (TYPICAL) MA KE UP W A [...]

39 Installation & Operation Manual BOILER INDIRECT DHW TANK DOMESTIC HOT W A TER CIRCULAT OR ANTI-SCALD MIXING VA LVE COLD WAT ER IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATO R BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POI NT (TYPICAL) MAKE UP WAT ER HOT WAT ER OUT BOILER CIRCULAT OR BACKFLOW PREVENTER PRESSURE REDUCING [...]

40 Installation & Operation Manual 6 Hydronic piping BOILER INDIRE CT DHW TAN K DOMESTIC HOT WA TER CIRCULAT OR BACKFLOW PREVENTER PRESSURE REDUCING VA LVE PRESSURE GAUGE ANTI-SCALD MIXING VALVE COLD WAT ER IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATO R EXPAN SION TANK BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN DRAIN PO INT (TYPICAL) MA K E U [...]

6 Hydronic piping (continued) INDIRE CT DHW T AN K BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE ANTI-SCALD MIXING V AL VE TEMPERATURE / PRESSURE GAUGE AIR SEPARATOR EXPANSIO N TANK BALL VALVE (TYPICAL) DRAIN POIN T (TYPICAL) MAKE UP WA TER ZONE VALVES (TYPICAL) BOILER CIRCULATOR BOILER 2 (MEMBE R 1) DOMESTIC HOT W ATE R CIRCULATO R UNI[...]

6 Hydronic piping Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority INDIRE CT DHW TANK BACKFLOW PREVENTER PRESSURE REDUCING VAL VE PRESSURE GAUGE ANTI-SCALD MIXING VAL VE AIR SEPARATO R EXPAN SION TANK BALL VALVE (TYPICAL) DRAIN POIN T (TYPICAL) MA KE UP WAT E R ZONE CIRCULAT ORS (TYPICAL) FLOW CHECK VALVE (TYPI[...]

Installation & Operation Manual 43 6 Hydronic piping (continued) BOILER INDIRE CT DHW TANK DOMESTIC HOT WATER CIRCULATOR ANTI-SCALD MIXING VAL VE COLD WATE R IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATO R BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN POI NT (TYPICAL) MA KE UP WATE R HOT W ATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE RED[...]

Installation & Operation Manual 44 6 Hydronic piping DOMESTIC HOT W ATER CIRCULATOR ANTI-SCALD MIXING V ALV E COLD WATE R IN AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) MA KE UP WATER HOT WATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSIO N TANK MIX ING VALVES (TYPICAL) FLOW CHECK VALVE S[...]

Installation & Operation Manual 45 BOILER INDIRECT DHW TANK DOMESTIC HOT WA TER CIRCULATOR ANTI-SCALD MIXING VAL VE COLD WATE R IN TEMPERATURE / PRESSURE GAUGE AIR SEPARATOR BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POIN T (TYPICAL) MAKE UP WATE R HOT WATE R OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALV [...]

Installation & Operation Manual 46 BOILER INDIRECT DHW TANK ANTI-SCALD MIXING VAL VE COLD WATE R IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATOR BALL VALVE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VALVE DRAIN POIN T (TYPICAL) MA KE UP WAT E R HOT WATE R OUT BACKFLOW PREVENTER PRESSURE REDUCING VALV E PRESSURE GAUGE EXPAN SION TANK ZONE VALVES ([...]

Installation & Operation Manual 47 BOILER INDIRE CT DHW TANK DOMESTIC HOT WATER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VAL VE PRESSURE GAUGE ANTI-SCALD MIXING VA LVE COLD WATE R IN TEMPERATURE / PRESSURE GAUGE AIR SEPARATO R EXPAN SION TANK UNION (TYPICAL) DRAIN DRAIN POIN T (TYPICAL) MAKE UP WATE R HOT WATE R OUT ZONE CIRCULATORS (TYP[...]

48 Installation & Operation Manual 7 Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler. a. Install a field supplied sediment trap / drip leg upstream of the boiler gas controls. MANUAL SHUT OFF VALV E (FIELD SUPPLIED) UNION DRIP L EG GAS SUPPLY Figure 7-1 Gas Supply Pip[...]

49 Installation & Operation Manual 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. Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler[...]

50 Installation & Operation Manual 7 Gas connections Nominal Iron Pipe Size (Inches) Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 26[...]

51 Installation & Operation Manual 7 Gas connections (continued)  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 flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial prope[...]

52 Installation & Operation Manual 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 mu[...]

53 Installation & Operation Manual 8 Field wiring (continued) Thermostat 1. Connect the room thermostat or end switch (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in FIG. 8-4. 2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunlight, or fire[...]

54 Installation & Operation Manual 8 Field wiring Boiler management system 1. An external control may be connected to control either the firing rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the Heat/Loop Demand 1 terminals. Otherwise, the SMART SYSTEM control wi[...]

55 Installation & Operation Manual 8 Field wiring (continued) Figure 8-4 Low Voltage Field Wiring Connections LOUVER RELAY TANK THERMOSTAT HEAT / LOOP DEMAND 3 SYSTEM SU PPLY SENSOR BUILDIN G MANAG EME NT SYSTEM LOW W ATE R CUTOFF OUTDOOR SEN SOR TANK SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER NOTE: CO NN ECT IO N B O ARD [...]

56 Installation & Operation Manual 9 Condensate disposal Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The bottom of the boiler has a 1 1/4 inch pipe for connection of the condensate trap (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing fil[...]

57 Installation & Operation Manual 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 wat[...]

58 Installation & Operation Manual 10 Start-up Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas[...]

59 Installation & Operation Manual 10 Start-up (continued) Final checks before starting the boiler  Read the Knight Wall Mount Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, pages 60 and 61 for proper steps to start boiler.  Verify the boiler and system are full of water and all system[...]

60 Installation & Operation Manual 10 Start-up o Figure 10-2 Operating Instructions - Models 55 - 285[...]

Installation & Operation Manual 61 10 Start-up (continued) Figure 10-3 Operating Instructions - Model 399[...]

Installation & Operation Manual 10 Start-up 62 Please note that the brackets ([]) denote screen status. NOTICE 4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 70). 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) in[...]

63 Installation & Operation Manual 10 Start-up (continued) 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 p[...]

Installation & Operation Manual 11 Operating information General How the boiler operates The Knight wall mount boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping.[...]

65 Installation & Operation Manual 11 Operating information (continued) Ramp delay For systems with lower flow, the SMART SYSTEM can limit the firing 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[...]

66 Installation & Operation Manual 11 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow 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[...]

67 Installation & Operation Manual 11 Operating information (continued) DHW, Night Setback, and Ramp Delay operation with cascade For Normal Mode 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 or sensor to the terminals on [...]

68 Installation & Operation Manual 11 Operating information 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 flow switch and/or [...]

69 Installation & Operation Manual 11 Operating information (continued) Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “  SETPOINTS” is flashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 63). Installer Mos[...]

70 Installation & Operation Manual Knight wall mount boiler 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. 11 Operating information The information on the bottom of the display shows the functions of the two SELECT keys (on eit[...]

71 Installation & Operation Manual 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 ci[...]

72 Installation & Operation Manual 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 conne[...]

Installation & Operation Manual 73 11 Operating information (continued) Status Display Screens (cont’d) Section Display Description D (LEFT SELECT key function) MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu Screen. EXIT Press the LEFT SELECT key to exit the current screen or setting. YES Press the LEFT SELECT key to [...]

Installation & Operation Manual 74 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 fill with fresh water • Check for leaks (water, ga[...]

Installation & Operation Manual 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 li[...]

Installation & Operation Manual Check expansion tank 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks[...]

Installation & Operation Manual 77 12 Maintenance (continued) BURNER BURNER GASKET INSULATION, BURNER DOOR GASKET, BURNER PLAT E BURNER PLAT E Figure 12-2 Burner Assembly Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense [...]

Installation & Operation Manual 78 13 Diagrams BOX DEPI CTS OPTION AL ITEMS LADDER DIAGRAM LBL20170 REV D 120 VAC 24 VAC 120VAC TERMINA L S TRIP 120V SUPPLY "L" ON / O FF SWITCH X1-6 F2 NEUTRAL INTEGRA TED CONTROL X2-1 GAS VA LVE GAS VA LVE RELAY X5-7 X5-16 X5-8 X5-15 1 2 4 5 3.15A F1 5A TR2 X1-7 FLAME ROD SPARK ROD INTEGRATED CON TRO[...]

Installation & Operation Manual X1 -7 ON/OFF SW ITCH 1 2 3 4 5 G R R W R T W BK Y BL BLOWE R -T HIGH LI MIT SENSOR S1b OPERATI NG SENSOR S1a INLET SENSOR S2 FLUE SE NSOR S3a FLUE SE NSOR S3b INTEGRAT ED CONT ROL BK Y GAS VALVE @24VA C SPARK ROD TRANSFO RMER TR2 G HIGH VOLTAGE SPARK LEAD CAUTION FLAME SENSO R ALARM CONTACT S RUN-TIME CONTACT S 2[...]

Revision A (ECO #C06854) initial release. Revision B (ECO #C08222) reflects the changes to the water pipe clearances from 1" to a 1/4" (ECR #R04077), pages 7, 8, and 33 and changes made to the service clearances (left side) from 24" to 12" (ECR R04002). Revision C (ECO #C08645) reflects additional cleaning and inspection instruc[...]