Lochinvar KNIGHT 399 manual

Inst allation & Operation Manual Models: 399 - 800 T h i s ma n u a l m u s t o n l y b e u s ed b y a qualified heating installer / serv ice technician. Read all instructions, including this manual and the Knight XL Serv ice M anual, befor e installing. P erform steps in the order given. Failure t o comply could result in severe personal injur[...]

2 Contents Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention t o the presence of hazards of various r isk level s or to important information concerning the life of the product.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazard ous situation which, if not avo[...]

Installation & Operation Manual Please r ead bef or e proceeding Installer – R ead all instructions, including this manual and the Knight XL Serv ice M anual, befor e installing. P erform steps in the order give n. Us e r – This manual is for use only by a qualified heating installer/serv ice technician. Refer t o the U ser’ s Information[...]

Installation & Operation Manual 4 T he Knight XL - How it w or ks... 1. Stainless steel heat exc hanger Allows system wat er to flow through specially designed coils for maximum heat transfer , while pro viding protection against flue gas c orrosion. The c oils are encased in a jacket that c ontains the combustion process. 2. Heat ex changer ac[...]

Installation & Operation Manual Front View - Model 399 4 5 25 30 23 20 28 13 29 14 8 7 27 36 Left Side (inside unit) - Model 399 19 21 16 1 3 34 17 26 2 37 Right Side (inside unit) - Model 399 T he Knight XL - How it w or ks... (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 sw[...]

Installation & Operation Manual 6 T he Knight XL - How it w or ks... 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[...]

Installation & Operation Manual Ra tings Notes: 1. The ratings are based on standard test pr ocedures prescribed by the U nited States Depart ment of Energ y . 2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are [...]

8 Installation & Operation Manual The Knight XL gas manifold and contr ols met safe lighting and other performance criteria when the boiler under went tests specified in ANSI Z21.13 – lat est edition. Failure t o keep boiler area clear and free of combustible mate r ials, gasoline, and other flammable liquids and vapors can result in severe p[...]

9 Installation & Operation Manual 1 Deter mine boiler location (continued) 12" (305 MM) LEFT 13" (330 MM) TOP 1" (25 MM) MINIMUM CLEARANCE AROUND HOT W A TER PIPES AND VENT PIPE 14" (356 MM) REAR 18" (457 MM) FRONT 0" RIGHT OPEN FRONT ALCOVE INST ALLA TION Figure 1-2 Alcove Installation - Minimum Required Clearance[...]

10 Installation & Operation Manual 1 Deter mine boiler location Provide air openings to room: Knight XL alone in boiler room 1. No air v entilation openings into the boiler room are needed when clearances around the K night XL are at least equal to the SER VICE clear ances sho w n in FIG. ’ s 1-1 and 1-2. For spaces that do NO T supply this c[...]

11 Installation & Operation Manual Product s to avoid: Spray cans containing c hloro/fluorocarbons P ermanent wave solutions Chlorinated waxes/cleaners Chlorine-based sw imming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks P aint or varnish remove rs H ydrochloric acid/muriatic acid [...]

Installation & Operation Manual 1 Deter mine boiler location 12 W hen removing a boiler from e xisting common v ent system: Do not install the Knight XL into a common v ent w ith an y other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury , death, or substantial property damage.[...]

Installation & Operation Manual 2 Prepar e boiler 13 R emov e boiler fr om wood pallet 1. After remo ving the outer shipping car ton fr om the boiler , remo ve the parts box. 2. Remo ve the front door t o access the lag bolts in front of the unit (FIG. 2-1). 3. T o re move the boiler from the pallet (aft er removing the front door): a. Re move [...]

Installation & Operation Manual 2 Prepar e boiler 14 SCREWDRIVER SLOT LOWER RAISE Figure 2-5 Leveling Legs on the Boiler Le veling 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 V alve Adjustment - Model 500 Model 500 1. Remov[...]

Installation & Operation Manual 15 PVC/CPVC T wo Pipe See Figure 4-1A Models 399 - 600 Only PVC/CPVC Alternate T wo Pipe See Figure 4-2A Stainless S teel Alternate T wo Pipe See Figure 4-2B Stainless S teel T wo Pipe See Figure 4-1C Models 399 - 600 Only PVC/CPVC Concentric See Figure 4-7 Models 399 - 600 Only Direct venting options - Sidew all[...]

Installation & Operation Manual 16 Direct venting options - V er tical V ent, Sidewall Air 3 Gener al venting Direct venting options - V er tical V ent PVC/CPVC T wo Pipe See Figure 5-1A Stainless S teel T wo Pipe See Figure 5-1B PVC/CPVC Concentric See Figure 5-5 PVC/CPVC V ertical V ent, Sidewall Air Stainless S teel V ertical V ent, Sidewall[...]

Installation & Operation Manual 17 3 Gener al venting (continued) PV C/CPV C vent piping ma terials U se only the materials listed in T able 3A (pg. 18) for v ent pipe, and fittings. Failure to comply c ould result in sever e personal injur y , death, or substantial pr oper ty damage. Installation must c omply w ith local requirements and with [...]

Installation & Operation Manual 18 3 Gener al venting 6. Priming and Cementing: a. Handle fittings and pipes carefully t o prevent contamination of surfaces. b. A pply a liberal e ven c oat of primer to the fitting socket. c. Apply a liberal even coat of pr imer to the pipe end to appro ximately 1/2" beyond the sock et depth. d. Apply a se[...]

Installation & Operation Manual 19 3 Gener al v enting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe mat er ials from the follo wing list: PV C, CPV C or ABS Dr yer V ent or Sealed Flexible Duct (not rec ommended for roofto p air inlet) Galvanized st eel vent pipe with jo[...]

Installation & Operation Manual 20 3 Gener al venting Figure 3-12 Near Boiler S tainless S teel V enting Models 700 - 800 4" S.S. ADAPTER VENT 4" S.S. INTERMEDIATE (FOR SAF-T VENT ONLY ) Figure 3-1 1 Near Boiler S tainless S teel V enting Models 399 - 600 T able 3C S tainless S teel Vent T ermination Kit(s) Model Kit Number 700 - 800 [...]

Installation & Operation Manual 21 Model Kit Number Equivalent V ent Length 399 CVK3007 5 Feet (1.5 m) 500 CVK3007 30 Feet (9 m) 600 CVK3007 30 Feet (9 m) 3 Gener al venting (continued) V ent, air piping and termination: The Knight XL vent and air piping can be installed thr ough the roof or through a sidewall. F ollow the proc edures in this m[...]

Installation & Operation Manual 22 3 Gener al v enting If the boiler combustion air inlet is located in a laundry room or pool facility , for example, these areas w ill alwa ys contain hazardous contaminants. T o prevent the potential of se ver e personal injur y or death, check for areas and pr oducts listed in T able 1A, page 11 before instal[...]

Installation & Operation Manual 23 4 Sidewall direct v enting V ent/air ter mination – sidew all Follo w instructions below when determining vent location t o av oid possibility of severe personal injury , death, or substantial property damage. A gas vent e xtending through an exterior wall shall not terminate adjac ent to a wall or below bui[...]

Installation & Operation Manual 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 Figure 4-1C Alternate S tainless S teel V ent T ermination - T ypical S tainless S teel Sidewall T ermination of Air and V ent Models 399 - 600 w/Field Supplied Fitting[...]

Installation & Operation Manual 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 Cle[...]

Installation & Operation Manual 26 4 Sidewall direct v enting SIDEWALL TERMINA TION PLA TE VENT PIPING GAL V ANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES) ELBOW ELBOW AIR PIPING BIRD SCREEN BIRD SCREEN Figure 4-5B A T ypical Sidewall T ermination Assembly - Models 399 - 800 PVC/CPVC or S tainless S teel T er mination and fittings 1. Prepar e th[...]

Installation & Operation Manual 27 4 Sidewall direct v enting (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) RE DUCER Figure 4-8 Kit Contents_CVK3007 - Models 399 - 600 Sidewall [...]

Installation & Operation Manual 28 4 Sidewall direct v enting Sidewall ter mination – optional concentric v ent: Models 399 - 600 Only Figure 4-9 Concentric V ent Dimensional Drawing - Models 399 - 600 Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw ma y be used to secure the two (2) components to[...]

Installation & Operation Manual 29 4 Sidewall direct v enting (continued) Sidewall ter mination – optional concentric v ent: Models 399 - 600 Only Multiventing sidewall terminations W hen two (2) or more direct v ent appliances are v ented near each other , eac h appliance must be individually vent ed (see FIG. 4-12). NE VER common vent or br[...]

Installation & Operation Manual 30 5 V er tical dir ect v enting V ent/air ter mination – v er tical Follo w instructions below when determining vent location t o av oid possibility of severe personal injury , death or substantial property damage. Installation must c omply w ith local requirements and with the N ational Fuel Gas Code, ANSI Z2[...]

Installation & Operation Manual 31 5 V er tical dir ect v enting (continued) V ent/air ter mination – v er tical Prepar e roof penetr ations 1. Air pipe penetr ation: a. Cu t a hole for the air pipe. Siz e the air pipe hole as close as desired to the air pipe outside diamet er . 2. V ent pipe penetration: a. Cu t a hole for the vent pipe. For[...]

Installation & Operation Manual 32 5 V er tical dir ect v enting V er tical ter mination – optional concentric v ent: Models 399 - 600 Onl y Description and usage Lochin var offers an optional concentric combustion air and vent pipe t ermination kit. Both co mbustion air and vent pipes must attach to the t ermination kit. The te rmination kit[...]

Installation & Operation Manual 33 5 V er tical dir ect v enting (continued) V er tical ter mination – optional concentric v ent: Models 399 - 600 Onl y ELBOW (FIELD SUPPLIED) SUPPORT (FIELD SUPPLIED) ROOF BOOT / FLASHING (FIELD SUPPLIED) VENT COMBUSTI ON AIR VENT 12" (305 MM) ( 18" (457 MM) FOR CANA DA) MINIMUM CLEARANCE ABOVE HIGH[...]

Installation & Operation Manual 34 6 Hy dr onic piping System wa ter piping methods The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kP a). A temperature and pr essure gauge is included to monitor system pressur e and outlet temperature and should be located on the boiler outlet. It is important[...]

Installation & Operation Manual 35 RELIEF V AL VE TEE WITH 3/4” FITTING ON TOP CLOSE NIPPLE (FIELD PROVIDED) CLOSE NIPPLE TEE WITH FITTING ON TOP (FIELD PROVIDED) TEMPERA TURE AND PRESSURE GAUGE P ADDLE FLOW SWITCH CLOSE NIPPLE TEE WITH 1” FITTING ON TOP CLOSE NIPPLE NOTICE Be sure to install the flo w switch so that the arrow on the flo w [...]

Installation & Operation Manual 36 6 Hy dr onic piping Near boiler piping connections Y-STRAINER (RECOMMENDED) BOILER PUMP INDIRECT DOMESTIC HOT WATER TANK SYSTEM PUMP TO FLOOR DRAIN TO FROM FROM SYSTEM TO SYSTEM DOMESTIC HOT WATER PUMP Figure 6-4A Near Boiler Piping w/Y -S trainer Figure 6-3 Flow Switch Adjustment Flow s witch adjustment Refer[...]

Installation & Operation Manual 37 6 Hy dr onic piping (continued) Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500 T able 6B Sizing Information for T emperature Rise Applications_20°F , 25°F , 30°F and 35°F Figure 6-6 Pressure Drop vs. Flow - Models 600 thru 800 0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 20 25 30 35 40 45 KBN500 KBN399 Pr[...]

Installation & Operation Manual 38 6 Hy dr onic piping It is requir ed that near boiler piping systems utilize Primary/Secondar y configurations as shown in FIG. ’ s 6-7 and 6-8 only . The use of other near boiler piping configurations could r esult in improper building and system flo w rates leading to inadv er tent boiler high limit shutdo [...]

Installation & Operation Manual 39 6 Hy dr onic piping (continued) EXP ANSION T ANK AIR SEP ARA TOR PRESSURE REDUCING V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TY PICAL) PRESSURE RELIEF VA LV E FLOW CHE CK V AL VE (TYPICAL) INDIRECT DHW T ANK BOILER TEMPERA TURE / PRESSURE GAUGE PRESSUR E GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER[...]

Installation & Operation Manual 40 EXP ANSION TA N K AIR SEP ARA TOR PRESSURE RE DUCING V AL VE BACK FLOW PREVENTER BALL V AL VE (TYPICAL) UNION (TYPICAL) PRESSURE RELIEF VA LV E FLOW CHECK V AL VE (TYPICAL) INDIRECT DHW T ANK BOILER 1 (LEADER) TEMPERA TURE / PRESSURE GAU GE PRESSURE GA UGE DRAIN DRAIN POINT (TYPICAL) BOILER CIRCULA TOR (TYPICA[...]

Installation & Operation Manual 41 7 Gas connections Connecting gas supply piping 1. Re move the top ac cess panel and refer t o FIG. ’ s 7-1 thr u 7-3 to pipe gas to the boiler . a. Install ground joint union for serv icing, when requ ired . b. Install a manual sh utoff valve in the gas supply piping outside boiler jacket when r equired by l[...]

Installation & Operation Manual 42 7 Gas connections Failure t o apply pipe sealing compound as detailed in this manual can result in severe personal injury , death, or substantial property damage. U se two wrenches when tightening gas piping at boiler (FIG. 7-4), using one wrench to prev ent the boiler gas line connection fr om turning . Failu[...]

Installation & Operation Manual 43 Nominal Iron Pipe Size (inches) Natural Gas Pipe Cap acity Chart Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 14 Inches Wa t e r C o l u m n (0.5 PSIG) or less and a pressure drop of 0.5 Inch Wa t e r C o l u m n (Based on N A T GAS, 1025 Btu/hr [...]

Installation & Operation Manual 44  W ARNING When re-tightening the set scr ew , be sur e to tighten securely t o 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 property damage. 14. T urn on[...]

Installation & Operation Manual 45 8 Field wiring ELECTRICAL SHOCK HAZARD – For your safety , turn off electrical power supply before making an y electr ical connections t o avoid possible electric shock hazard. Failure to d o so can cause severe personal injury or death. W iring must be N.E.C. Class 1. If or iginal wir ing as supplied with b[...]

Installation & Operation Manual 46 Low v olta ge connections 1. Route all lo w voltage wires through the knock outs in the rear of the boiler , as sho wn in FIG. 8-2. 2. Connect lo w voltage wir ing to the lo w voltage connection board as sho w n in FIG. 8-3 on page 48 of this manual and the boiler wir ing diagram. LOW VOL T AGE WIRING KNOCKOUT[...]

Installation & Operation Manual 47 8 Field wiring (continued) System supply sensor 1. By installing the system supply sensor into the supply of the primar y loop, the temperature of the system supply can be contr olled. The SMAR T SYSTEM control aut omatically detects the presenc e of this sensor , and contr ols the boiler firing rate to mainta[...]

Installation & Operation Manual 48 8 Field wiring AU X. D EVIC E PILOT SUPPL Y 24V A C GND AU X. D EVIC E PROVING GAS PRESSURE SWITCH FLOW SWITCH A LARM CONT A C TS RU NTIME CONT A C TS SYSTEM SENSOR DH W T AN K SENSOR OUTDOOR SENSOR SH IELD GROU ND 0-10VDC EXTERNA L G ND C ONT ROL DH W T HER MOS T A T R W RO OM T HER MOS T A T / ZONE CO NTROL [...]

Installation & Operation Manual 49 9 Condensa te disposal Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) PV C union for connection of a 1/2 inch (12.7 mm) PV C pipe (FIG. 9-1). 3. Slope condensate tubing do wn and away from the boiler into a drain or co[...]

Installation & Operation Manual 50 10 Star t-up Check/control wa ter chemistr y Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gask ets in the system could oc cur , resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water tr eatment companies for h[...]

Installation & Operation Manual 51 10 Star t-up (continued) Check f or gas leaks Before starting the boiler , and during initial operation, smell near the floor and around the boiler for gas odorant or an y unusual odor . R emov e the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is an y i[...]

Installation & Operation Manual 52 10 Star t-up Final chec ks before star ting the boiler  Read the K night XL Ser vice Manual t o familiar ize yourself w ith SMAR T SYSTEM control module operation. R ead this manual, page 53 for proper steps to start boiler .  V erify the boiler and system are full of water and all system components ar e[...]

Installation & Operation Manual 53 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 . D[...]

Installation & Operation Manual 54 10 Star t-up Check flame and combustion (continued) 4. Place the boiler into the acti ve position by pr essing the SHUTDO WN button on the display board (FIG. 11-1, page 61) until BLR:Standby appears in the display window . 5. Locate the pinhole button abov e the “ T” in the Knight XL logo on the display b[...]

Installation & Operation Manual 55 Set domestic hot wa ter (DHW) oper ation V erify DHW circulator mode The DHW M ode is progr ammed to heat an indir ect domestic hot water tank. W hen the tank thermostat calls for heat, the SMAR T SYSTEM contr ol w ill turn on the DHW pump and turn off the boiler pump (if running). If the system pump is runnin[...]

Installation & Operation Manual 56 General How the boiler operates The Knight XL uses an advanced stainless st eel heat exc hanger and electronic contr ol module that allows fully condensing operation. The blo wer pulls in air and pushes flue products out of the boiler through the heat ex changer and flue piping. The control module r egulates b[...]

Installation & Operation Manual 57 11 Oper a ting infor mation (continued) Ramp delay For syst ems w ith low er flow , the SMAR T 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 t o a space heating call for heat. There are six (6) limits that can be programmed[...]

Installation & Operation Manual 58 11 Oper a ting infor mation High limit operations W hen outlet temperature ex ceeds 200°F (93.3°C), hig h limit action occurs. The boiler shuts down until the outlet water cools down. Low water cutoff protection 1. The SMAR T SYSTEM contr ol module uses temperature sensing of both supply and return areas of [...]

Installation & Operation Manual 59 11 Oper a ting infor mation (continued) Cascade (continued) If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the Knight XL Serv ice M anual for an explanation of th[...]

Installation & Operation Manual 60 11 Oper a ting infor mation Sequence of oper a tion OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pump s (system and boiler pumps for sp ace heating call; DHW pump for DHW call). BLR: Standby OUT: 123.8F(129) 2. The control connect s 120 V AC to the blower . The blower does no[...]

Installation & Operation Manual 61 11 Oper a ting infor mation (continued) Knight XL control module • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level in Menu Mode or to exit Menu Mode • Press to turn boiler off or back on • Press to select a menu item • Press after parameter programming to store parame[...]

Installation & Operation Manual 62 Access modes User The user can adjust space heating target temperatur e by using the UP and DO WN buttons (FIG. 11-1) at an y time during normal oper ation. By entering the USER code (0704), the user can also change temperature units, time and date, and nig ht setback settings. In U ser Mode, the following par[...]

Installation & Operation Manual 63 11 Oper a ting infor mation (continued) Status Display Screens By using the Pr ev ious/N ext (  ,  ) arrow k eys on the SMART SY STEM display panel, you can navigate thr oug h the eight (8) display scr eens. Each scr een w ill co ntain two (2) viewable items. The follo w ing is a description of the indiv[...]

Installation & Operation Manual 64 Status Display Screens (cont ’ d) By using the Pr ev ious/N ext (  ,  ) arrow k e ys on the SMAR T SYSTEM display panel, you can na v igate thr oug h the eight (8) display scr eens. Each scr een w ill co ntain two (2) viewable items. The follo w ing is a description of the individual items and what the[...]

Installation & Operation Manual 65 11 Oper a ting infor mation (continued) Status Display Screens (cont ’ d) By using the Pr ev ious/N ext (  ,  ) arrow k eys on the SMART SY STEM display panel, you can navigate thr oug h the eight (8) display scr eens. Each scr een w ill co ntain two (2) viewable items. The follo w ing is a description[...]

Installation & Operation Manual 66 Status Display Screens (cont ’ d) Operation of the cascade The boiler designated as the Leader will have tw o additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a descr ipt[...]

Installation & Operation Manual 67 Maintenance and annual star tup T able 12A Service and Maintenance Schedules Ser vice tec hnician (see the following p ages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (wate[...]

Installation & Operation Manual 68 12 Maintenance Follo w the Ser vice and maintenance pr ocedures giv en throughout this manual and in component literatur e shipped with the boiler . Failure to perform the serv ice and maintenanc e could result in damage to the boiler or system. Failure t o follow the directions in this manual and component li[...]

Installation & Operation Manual 69 12 Maintenance (continued) Flue vent system and air piping 1. Visually inspect the entire flue gas v enting system and air piping for blockage, deterioration or leakage. R epair any joints that show signs of leakage. V erify that air inlet pipe is connected and pr operly sealed. 2. V erify that boiler vent dis[...]

Installation & Operation Manual 70 12 Maintenance Inspect ignition and flame sense electrodes 1. R emov e the ig nition and flame sense electrodes fr om the boiler heat ex changer access c over . 2. R emov e any deposits accumulat ed on the ignition/flame sense electrode using sandpaper . I f the electrodes cannot be cleaned satisfactorily , r [...]

Installation & Operation Manual 71 12 Maintenance (continued) Check flame signal 1. A t high fire the flame signal shown on the display should be at least 10 microamps. 2. A lo wer flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not impro ve, ground wir ing is in good condition, an[...]

Installation & Operation Manual 72 Figure 13-1 Wiring Diagram 13 Diag r ams DISPLA Y X1-8 X5-5 X5-13 X5-6 X5-12 INTEGRA TED CONTROL BLOW ER X1-1 X2-2 X2-1 X1-7 GAS VA LV E FLAME ROD SP ARK ROD W/ R G R R T W BK G R 13 2 W G BOX DEPICTS OPTIONAL ITEMS WI R I NG D IA GR AM LBL2364 REV D INLET SENSOR OUTLET SENSOR FLUE SENSOR MANUAL RE SET HI-LIMI[...]

Installation & Operation Manual 73 Figure 13-2 Ladder Diagram BOX DEPICTS OPTIONAL ITEMS LADDER DIAGRAM LBL2356 REV C 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPL Y "L" ON / OFF SWIT CH X1-6 BOILER PUMP RELAY DHW PUMP RELAY SYSTEM PUM P RELAY BLOWER RELAY X1-4 X1-3 X1-2 X1-1 12 3 BLOWER JUNCTION BOX X1-5 X6-8 X6-3 F5 X5-7 X6-7 NEUT[...]

Notes 74[...]

Notes 75[...]

Revision Notes: Revision B (ECO #C02407) reflects gas valve adjustment, room air , new sidewall vent termination, piping diagrams, flow switch, relief valve, T & P gauge, Maintenance Section, FIG . 8-1 (Line V oltage), and high altitude changes. Revision C (ECO #C02545) reflects the addition of references to the safety shutoff testing and instr[...]