continued - Rundle
Contents
1. 6 B Temperature Settings oo nn 13 Check Vent Piping en 6 C Data Logging ws cscs are a eee 13 Cheek Air PIPING rara zn aia acara a krack acta Bae ee 6 E DHW Settings eo ceca ag eneen arene eases 14 Check Relief Valve asten genere aad rard 6 F Outdo r Air Rest aanta eet ideen 14 Check Condensate Drain System anaana 6 7 Status Display Screens eneen 15 18 Check Automatic Air Vents an 8 NOTES wanten endet iere dend 19 Test Low Water Cutoff if installed 8 Revision Notes neen Back Cover Reset Button low water cutoff 8 Check Boiler Piping gas and water 8 Operate Relief Valve nnen 8 Shut Boiler DOWN rer ane sonen rn KE ee 8 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 A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOT2. 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 corrosion Leaks in boiler or piping must be repaired at once to prevent makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 3 User s Information Manual Bed 1 Prevent combustion air contamination If the boiler combustion air inlet is located in any area likely to cause contamination or if products which would contaminate the air cannot be removed you must have the combustion air and vent re piped and terminated to another location Contaminated combustion air will damage the boiler resulting in possible severe personal injury death or substantial property damage If the boiler combustion air inlet is located A WARNING ca in a laundry room or pool facility for example these areas will always contain hazardous contaminants Pool and laundry products and common household and hobby products often contain fluorine or chlorine co
3. Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops User s Information Manual 2 Maintenance schedule Service technician Owner maintenance see the Knight XL Service Manual see pages 6 8 for detailed instructions General e Check boil e Address reported problems hen e Inspect interior clean and vacuum if e Check pressure temperature necessary gauge e Clean condensate trap and fill with fresh water eCheck for leaks water gas flue condensate e Check vent piping e Verify flue and air lines in good condition and sealed tight e Check air piping eCheck system water pressure system e Check air and vent termination piping expansion tank screens e Check control settings ar e Check relief valve e Check ignition and flame sense electrodes sand off any deposits clean and reposition e Check condensate drain system e Check wiring and connections Check automaticair vents Perform start up checkout and performance verification per Section 10 in the Knight XL Installation and Operation Manual Periodically e Flame inspection stable uniform e Reset button low water cutoff e Test low water cutoff if used a gt lt n N
4. l lt D z zZ lt x e Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C Every above return water temperature 6 months e Check boiler piping gas and water for leaks e Operate relief valve If combustion or performance indicate need e Clean heat exchanger e Remove and clean burner using compressed air only e Clean the blower wheel End e Shut boiler down unless boiler of season used for domestic hot water months A WARNING Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the boiler or system resulting in severe personal injury death or substantial property damage 2 Maintenance schedule Maintenance procedures Boiler must be serviced and maintained The boiler must be inspected and started annually at the beginning of the heating season by a qualified service technician In addition the maintenance and care of the boiler designated on page 5 of this manual and explained on pages 6 through 8 must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure causing possible severe personal injury death or substantial property damage The following information provides detailed instructions for completing the
5. accessed The date and time are displayed as YY MM DD W hh mm YY year MM month DD date W day 1 Sunday 2 Monday etc hh hour 24 hour time 2 00 PM 14 00 mm minutes The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Software version The software version allows the user to view the software version in use by the control This software controls the operation of the boiler When a new software version becomes available the existing control can be replaced with a new control to update the software Temperature units The control can be configured to display temperature in either C or F This parameter can be changed by the user or the installer by accessing parameter A5 The default is F Night setback temperature Once the internal clock has been set correctly the night setback feature can be used to program a lower water temperature set point for space heating This parameter can be changed by the user or the installer by accessing parameter A6 The temperature range for this parameter is 32 F 0 C to 140 F 60 C The feature is turned off with a setting of 32 F 0 C The default value is 32 F 0 C Night setback times If parameter A6 is set to anything other than 32 F 0 C the night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures a
6. air they must be removed immediately or the boiler combustion air and vent termination must be relocated to another area Check pressure temperature gauge 1 Make sure the pressure reading on the boiler pressure temperature gauge does not exceed 24 psi 165 5 kPa Higher pressure may indicate a problem with the expansion tank 2 Contact a qualified service technician if problem persists Check vent piping 1 Visually inspect the flue gas vent piping for any signs of blockage leakage or deterioration of the piping Notify your qualified service technician at once if you find any problems Failure to inspect the vent system as noted above and have it repaired by a qualified service technician can result in vent system failure causing severe personal injury or death Check air piping 1 Visually inspect the air inlet termination to be sure it is unobstructed Inspect the entire length of air piping to ensure piping is intact and all joints are properly sealed 2 Call your qualified service technician if you notice any problems Check relief valve 1 Inspect the boiler relief valve and the relief valve discharge pipe for signs of weeping or leakage 2 If the relief valve often weeps the expansion tank may not be working properly Immediately contact your qualified service technician to inspect the boiler and system Check condensate drain system 1 Inspect the condensate drain line condensate PVC fittings a
7. not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step 8 Turn gas shutoff valve clockwise to ON Handle will be parallel to pipe 9 Install top cover 10 Turn on all electric power to appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier Gas Valve Gas Valve OPEN CLOSED on nk to CLOSE i x N to OPEN i S TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove top cover 4 Turn gas shut off valve counterclockwise to OFF Handle will be perpendicular to pipe Do not force 5 Install top cover LBL2284 REV Wam User s Information Manual 4 SMART SYSTEM control module aT Knight XL control module Use the control panel FIG 4 1 to set temperatures operating conditions and monitor boiler operation Figure 4 1 Control Panel Hold 5 seconds to enter code e Press to turn boiler off or Input Mode Menu Mode back on e Press to move up one level e Press to select a menu item SHUTDOWN in Menu Mode or to exit e Press after parameter programming Ce Menu Mode to store parameter data Press to exit Serv
8. page 12 of this manual To save parameters and exit programming Press the ENTER RESET button FIG 4 1 To keep parameter settings only for a current operating cycle Press the MENU EXIT button FIG 4 1 3 times after making all desired parameter changes To enter a parameter and continue programming Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Remember to press the ENTER RESET button when finished programming in order to save the changes made Have your qualified service technician reference the Knight XL Service Manual for a detailed description of parameters and access modes XL User s Information Manual 11 Geer 4 SMART SYSTEM control module Parameter table User s Information Manual SEE USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Boiler Model 13 Yes No Yes No z 2 User Code 13 Yes Yes Yes Yes W 3 Date and Time 13 Yes Yes Yes Yes 2 oftware Version es o es o W A 4 Software Versi 13 Y N Y N 5 Temperature Units 13 Yes Yes Yes Yes 6 Night Setback Temperature 13 Yes Yes Yes Yes 7 Night Setback Times 13 Yes Yes Yes Yes w S s E B 1 SH Set Point User 13 Yes Yes Yes Yes Lijn a w ij Ee 1 Hours Running SH 13 Yes No Yes No d Z 2
9. COMMERCIAL BOILER User s Information Manual Models 399 800 A WARNING If the information in this manual is not followed exactly a fire o explosion may result causing property damage personal injury o loss of life This appliance MUST NOT be installed in any location wher gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in you building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualifie installer service agency or the gas supplier Save this manual for future reference High Efficiency Water Heaters Boilers and Pool Heaters HAZARD DEFINITIONS eneen 2 3 OPERATING INSTRUCTIONS 9 PLEASE READ BEFORE PROCEEDING 3 4 SMART SYSTEM CONTROL MODULE 1 PREVENT COMBUSTION AIR CONTAMINATION 4 Knight XL Control Module on 10 2 MAINTENANCE SCHEDULE 5 Access Modes riesite ape eke See niksen 11 Maintenance Procedures 202 000 005 6 Saving Parameters oane 11 Boiler Must Be Serviced and Maintained 6 Parame t r Table u zaan aten rard tot bees 12 Check Boiler Area annette nett aoe 6 A General sassen derbi wip bee 13 Check Pressure Temperature Gauge
10. Hours Running DHW 13 MES No Yes No E 5 C lt 3 Ignition Attempts 13 Yes No Yes No 26 l Show Last 10 Errors 13 Yes No Yes No 6 1 DHW Boiler Set Point 14 Yes Yes Yes Yes zZ Z E E 2 SH DHW Switching Time 14 Yes Yes Yes Yes A a 3 DHW Tank Set Point 14 Yes Yes Yes Yes 4 d 5 Outdoor Air Shutdown 14 Yes Yes Yes Yes te m 6 Outdoor Aif Shutdown 14 Yes Yes Yes Yes 8 7 F Differential a a 8 Boost Temperature 14 Yes Yes Yes Yes 3 9 Boost Time 14 Yes Yes Yes Yes 12 User s Information Manual 4 SMART SYSTEM control module continues A General Boiler model The control will display Knight Boiler as the model number because the same control is used on several models This will be displayed when parameter Al has been accessed This parameter is not changeable User code The User Code allows the user to access and change a limited number of control parameters The access code can be changed by the user or the installer to a code of their choosing To change the code parameter A2 must be accessed The default code is 0704 The code can be changed one digit at a time by using the arrow keys on the display Date and time The control uses an internal clock for the night setback feature and for logging of events For these features to work correctly the clock must be set when the boiler is first installed or anytime the boiler has been powered off for more than 30 days To set the clock parameter A3 must be
11. ICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Please read before proceeding NOTICE NOTICE The Knight XL Installation and Operation Manual along with the Knight XL Service Manual are for use only by a qualified heating installer service technician Refer only to this User s Information Manual for your reference Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instruction before installing servicing or removing this boiler This boiler contains materials that have been identified as carcinogenic or possibly carcinogenic to humans When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or substan
12. Notes 19 t Loc High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision Notes Revision B KBX USER Rev B reflects changes made to the Check Air Piping section on page 6 Revision C ECO C02545 reflects the addition of references to periodic cleaning of screens in vent terminations KBX USER Rev C 11 08
13. available from the factory Kit 3087 for Models 399 500 and Kit 30002 for Models 600 800 Call your qualified service technician to install 4 Install the 1 2 inch PVC tee assembly shipped with the unit as shown in FIG 2 2 Call your qualified service technician to inspect the boiler and system 5 Leave the top of the 1 2 inch tee OPEN This is needed as a vacuum break 6 Do not expose condensate line to freezing temperatures 7 Use only plastic tubing or piping as a condensate drain line FIG 2 2 NOTICE NOTICE Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement To allow for proper drainage on large horizontal runs a second line vent may be required and tubing size may need to increase to 1 inch The condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manner condensate can exit from the boiler tee resulting in potential water damage to property Call your qualified service technician to inspect the boiler and system A condensate removal pump is required if the boiler is below the drain When installing a condensate pump select one approved for use with condensing
14. boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage Call to your qualified service technician the boiler and system inspect Figure 2 2 Condensate Disposal 1 2 12 FACTORY SUPPLIED 7 mm PVC TEE ASSEMBLY 1 2 12 7 mm PVC UNION FACTORY SUPPLIED NEUTRALIZER KIT FLOOR DRAIN OR DRAIN PAN 2 Maintenance schedule Check automatic air vents 1 Reference FIG 2 3 below 2 Remove the caps FIG 2 3 A from the automatic air vents in the system and check operation by slightly depressing valve B FIG 2 3 with the tip of a screwdriver 3 If the air vent valve appears to be working freely and not leaking replace cap A twisting the cap all the way on 4 Loosen cap A one turn to allow vent to operate 5 Have the automatic air vent s replaced if it does not operate correctly Figure 2 3 Automatic Air Vent CAP A REMOVE CAP A TO ACCESS VALVE B Test low water cutoff if installed 1 If the system is equipped with a low water cutoff test the low water cutoff periodically during the heating season following the low water cutoff manufacturer s instructions Reset button low water cutoff 1 Testing the low water cutoff shuts the unit off Press the RESET button on the low water cutoff to turn the unit back on Check boiler piping gas and water 1 Remove the boiler front acc
15. ch automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control knob Never use tools If the handle will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label 2 Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Remove top cover Turn gas shutoff valve counterclockwise to OFF Handle will be perpendicular to pipe Do
16. e Leader control has received a call for heat from a remote PMP On thermostat and has powered the system pump The system call for heat has been satisfied and the system pump is PMP Delay i running for a fixed time to remove any residual heat Press the Next De arrow key on the SMART SYSTEM display to access Screen 10 The first percentage shows the firing rate that is being sent to the last Cas Pow boiler called on The second percentage shows the total power available to the Cascade Shows the number of boilers connected to the Cascade The Leader is designated as 0 Members will be designated 1 7 If a is used in lace of a number that boiler is either not connected or in a lockout 10 et hen ode and not available for the Cascade If a d is used in place of a ple number that boiler is handling a DHW demand and is not available for OT ee the Cascade If the number is flashing then that boiler is providing heat to the Cascade As the lead boiler is changed from day to day that boiler s address will be shown first in the string of numbers In the example boilers 0 3 are present boiler 2 is the lead boiler and boiler 0 is heating an indirect DHW tank Press the Next gt arrow key on the SMART SYSTEM display to roll back to Screen 1 At any point if you wish to access an earlier screen press the Previous arrow key on the SMART SYSTEM display 18 Timet User s Information Manual XL
17. ess door and perform a gas leak inspection per steps 1 through 7 of the Operating Instructions on page 9 If gas odor or leak is detected immediately shut down the boiler following the procedure on page 9 Call a qualified service technician 2 Visually inspect for leaks around water piping Also inspect the circulators relief valve and fittings Immediately call a qualified service technician to repair any leaks 8 User s Information Manual A WARNING Have leaks fixed at once by a qualified service technician Failure to comply could result in severe personal injury death or substantial property damage 3 Replace the front access door Operate relief valve 1 Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water To avoid water damage or scalding due to valve operation a metal discharge line must be connected to the relief valve outlet and run to a safe place of disposal This discharge line must be installed by a qualified heating installer or service technician in accordance with the instructions in the Knight XL Installation and Operation Manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge 2 Read the boiler pressure temperature gauge to make sure the system is pressurized Lift the relief valve top lever slightly allowing wa
18. for heat The call for heat has been satisfied and the boiler 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 9 17 sa User s Information Manual 4 SMART SYSTEM control module Status Display Screens cont d Operation of the cascade The boiler designated as the Leader will have two 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 description of the individual items and what they can display Display shows The Leader control has been turned off by the Enter Reset button on Cas Off the Smart System display The Leader boiler has not received a call for heat from a remote Cas Standby thermostat The Cascade is now active The system supply temperature will be Ges LETAR IIAN displayed The Cascade set point will be displayed in parenthesis The Cascade has met the water temperature set point but is still Cas Setpoint Met 2i P receiving a call for heat from a remote thermostat The Leader control could not detect any Member controls to AST O MENDE participate in the Cascade Cas S6 Not Present The system supply sensor is not connected to the Leader boiler The Leader control has not received a call for heat from a remote PMP Off thermostat and has not powered the system pump Th
19. ice Mode ENTER RESET DISPLAY SCREEN SERVICE le BUTTON COMMERCIAL BOILER PC CONNECTION DOWN 4 Lochinvar h Efficiency Water Heaters Boilers and Pool Heaters _ 5D DD UP DOWN PREVIOUS NEXT Press to change boiler water e Press to toggle display during normal temperature set point during operation to show outlet and return normal operation temperatures fan speed and flame e Press to change displayed data signal values in Menu Mode e Press to toggle between digits when e Press to navigate through menu entering access code or between hour listing in Menu Mode minutes etc when entering date and time mm 70 4 SMART SYSTEM control module continues Access modes User The user can adjust space heating target temperature by using the UP and DOWN buttons FIG 4 1 at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In User Mode the following parameters can be viewed but not changed Boiler outlet water target temperature in DHW Mode Boiler model number Software version Total operating hours Total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code Have your qualified service technician reference the Knight XL Service Manual Saving parameters reference parameter table on
20. individual items and what they can display Display shows DHW PUMP OFF The control has not received a DHW call for heat and has not powered the DHW pump The control has received a DHW call for heat and has powered the ON DHW pump 7 The DHW call for heat has been satisfied and the DHW pump is Delay running for a fixed time to remove any residual heat The control will display a 0 10Vdc signal received from a Building i e A A EN Nle Management System BMS connected to the unit Press the Next De arrow key on the SMART SYSTEM display to access Screen 8 The control has not received a call for heat from a remote thermostat EERE and has not powered the system pump The control has received a call for heat from a remote thermostat di and has powered the system pump The system call for heat has been satisfied and the system pump is running for a fixed time to remove any residual heat The control has either not received a call for heat from a remote thermostat a remote thermostat is not connected to the unit and the BLR PUMP OFF water temperature has not dropped below the temperature set point of the control to initiate a call for heat or the control has received a DHW call for heat from a DHW thermostat The control has received a call for heat from a remote thermostat or a remote thermostat is not connected and the water temperature has dropped below the temperature set point of the control to initiate a call
21. l log the 10 most current errors with the date and time the error occurred This parameter can be viewed by the user and the installer by accessing parameter C4 13 NEE User s Information Manual XL 4 SMART SYSTEM control module E DHW settings DHW boiler set point When a DHW call for heat becomes active the control will use the DHW boiler set point to determine the firing rate of the boiler based on the actual water temperature This parameter can be changed by the installer by accessing parameter El The temperature range of this parameter is 50 F 10 C to 190 F 88 C The default value is 180 F 82 C SH DHW switching time The SH DHW switching time parameter sets the length of time the control will stay in DHW Mode when a SH call has been received After this time period has expired the control will revert to SH Mode If a DHW call is still active the timer will reset After the time period has expired the control will revert back to DHW Mode This will continue until one of the demands has been satisfied This parameter can be changed by the installer by accessing parameter E2 The time range of this parameter is 10 minutes to 240 minutes The default value is 30 minutes DHW tank set point By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank tempera
22. maintenance items listed in the maintenance schedule on page 5 In addition to this maintenance the boiler must be serviced and started up at the beginning of each heating season by a qualified service technician Check boiler area A WARNING To prevent potential of severe personal injury death or substantial property damage eliminate all materials discussed below from the boiler vicinity and the vicinity of the boiler combustion air inlet If contaminants are found Remove products immediately from the area If they have been there for an extended period call a qualified service technician to inspect the boiler for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to re pipe vent and air piping and locate vent termination air intake away from contaminated areas 1 Combustible flammable materials Do not store combustible materials gasoline or any other flammable vapors or liquids near the boiler Remove immediately if found 2 Air contaminants Products containing chlorine or fluorine if allowed to contaminate the boiler intake air will cause acidic condensate in the boiler This will cause significant damage to the boiler if allowed to continue 6 Khue User s Information Manual Read the list of potential materials listed in Table 1A on page 4 of this manual If any of these products are in the room from which the boiler takes its combustion
23. mpounds 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 possible threat of flue gas spillage or boiler water leakage into the building Please read the information listed in Table 1A If contaminating chemicals will be present near the location of the boiler combustion air inlet have your installer pipe the boiler combustion air and vent to another location per the Knight XL Installation and Operation Manual To prevent the potential of severe personal SINS injury or death check for areas and products listed in Table 1A before installing the boiler or air inlet piping If contaminants are found you MUST e Remove contaminants permanently OR e Relocate air inlet and vent terminations to other areas Table 1A Corrosive Contaminants and Sources 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 used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants
24. nd condensate trap Fill condensate trap with water 1 Remove the PVC cap retaining screw from the PVC cap FIG 2 1 2 Remove the 2 PVC cap with the switch located at the top of the trap FIG 2 1 Ge User s Information Manual XL 2 Maintenance schedule continue 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 5 Replace the retaining screw The condensate trap FIG 2 1 must be q filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Figure 2 1 Condensate Trap 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE FROM JS HEAT EXCHANGER PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN Condensate disposal 1 This boiler is a high efficiency appliance that produces condensate 2 The side of the boiler has a 1 2 inch PVC union for connection of a 1 2 inch PVC pipe FIG 2 2 3 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the Knight XL will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes Call your qualified service technician to inspect the boiler and system A Neutralizer Kit is
25. ontrol sensor the OEP 20 control will display the inlet temperature as well as the set point in arenthesis 2 P The control does not detect the inlet sensor Shorted The inlet sensor wires or the sensor itself has become shorted The difference between the inlet temperature and the outlet RISE F P temperature Press the Next De arrow key on the SMART SYSTEM display to access Screen 3 15 ney User s Information Manual 4 SMART SYSTEM control module Status Display Screens cont d By using the Previous Next lt gt arrow keys on the SMART SYSTEM display panel you can navigate through the eight 8 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display shows Description SYS tE If the system supply sensor has not been selected as the control sensor only the system temperature will be displayed When the system supply sensor has been selected as the control sensor w AB 29 the control will display the system temperature as well as the set point in parenthesis Open The control does not detect the system supply sensor 3 The system supply sensor wires or the sensor itself has become grounded OUTDOOR F The control will display the outdoor air temperature as sensed by the outdoor air sensor hor Open The control does not detect the outdoor air sensor The outdoor air sensor wires or the sen
26. perature set point but is still Set Point Met receiving a call for heat from either a remote thermostat or a DHW thermostat The unit has initiated a 10 second purge period on a call for heat Prepurge Note On the 800 model the unit will initiate a 20 second purge period on a call for heat ii The unit has begun a 5 second spark period to ignite the main Ignition burner SH Rate The unit has fired and is running at the displayed percentage 1 The call for heat has been satisfied and the unit runs the fan for an Postpurge additional 10 seconds to clear the combustion chamber and vent system of residual flue products f The unit has been placed in a temporary mode that will allow the Service unit to fire at 100 of rate for the purpose of combustion analysis When the outlet sensor has been selected as the control sensor OUT F default the control will display the outlet temperature as well as the set point in parenthesis spot eB If the outlet sensor has not been selected as the control sensor only f the outlet temperature will be displayed Open The control does not detect the outlet sensor Shorted The outlet sensor wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 2 IN OO4B If the inlet sensor has not been selected as the control sensor only et the inlet temperature will be displayed When the inlet sensor has been selected as the c
27. re required These times can be changed by the user or the installer by accessing parameter A7 Each day of the week Sunday through Saturday will have an on and off time Example Monday ON 22 30 Tuesday OFF 6 45 If you wish to skip a day and have no night setback leave the on and off times the same The default times for each day will be 00 00 midnight B Temperature settings SH set point user The SH set point user sets the water temperature set point for fixed operation or the maximum temperature set point when the outdoor air sensor is used This parameter can be changed by the user or the installer by accessing parameter Bl The temperature range of this parameter is 50 F 10 to 190 F 88 C The default value is 125 F 52 C C Data logging Hours running SH The hours running SH parameter shows the total number of hours the boiler has been in the SH firing position This parameter can be viewed by the user and the installer by accessing parameter C1 Hours running DHW The hours running DHW parameter shows the total number of hours the boiler has been in the DHW firing position This parameter can be viewed by the user and the installer by accessing parameter C2 Ignition attempts The ignition attempts parameter shows the total number of times the boiler has attempted to fire This parameter can be viewed by the user and the installer by accessing parameter C3 Show last 10 errors The control wil
28. sor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 4 Ee AE The control will display the flue temperature The control does not detect the flue sensor The flue sensor wires or the sensor itself has become shorted 4 a ENA The control will display the temperature The control does not detect the auxiliary sensor The auxiliary sensor wires or the sensor itself has become shorted Press the Next arrow key on the SMART SYSTEM display to access Screen 5 FAN SPD RPM The control will display the actual fan motor RPM 5 FLAME SIG uA The control will display the flame signal in dc microamps Press the Next arrow key on the SMART SYSTEM display to access Screen 6 The control has not received a call for heat from a remote thermostat The control has received a call for heat from a remote thermostat The control has not received a call for heat from a SH remote thermostat N The control has received a call for heat from a DHW thermostat Press the Next arrow key on the SMART SYSTEM display to access Screen 7 16 Was AT User s Information Manual XL 4 SMART SYSTEM control module continues Status Display Screens cont d By using the Previous Next lt lt gt arrow keys on the SMART SYSTEM display panel you can navigate through the eight 8 display screens Each screen will contain two 2 viewable items The following is a description of the
29. ter to relieve through the valve and discharge piping 3 If water flows freely release the lever and allow the valve to seat Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain If the valve weeps lift the seat again to attempt to clean the valve seat If the valve continues to weep afterwards contact your qualified service technician to inspect the valve and system 4 If water does not flow from the valve when you lift the lever completely the valve or discharge line may be blocked Immediately shut down the boiler following the operating instructions on page 9 of this manual Call your qualified service technician to inspect the boiler and system Shut boiler down unless boiler is used for Domestic Water 1 Follow To Turn Off Gas to Appliance on page 9 of this manual 2 Do not drain the system unless exposure to freezing temperatures will occur 3 Do not drain the system if it is filled with an antifreeze solution 4 DO NOT shut down boilers used for domestic water heating they must operate year round 3 Operating instructions User s Information Manual FOR YOUR SAFETY READ BEFORE OPERATING WARNING 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 whi
30. the SH demand ends a maximum of 20 increases has occurred or the maximum set point has been reached Once the SH demand has been satisfied the set point will revert back to its calculated setting The boost temperature can be changed by the installer by accessing parameter F8 The temperature range of this parameter is 0 F 0 C to 45 F 25 C The default value is 0 F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C Boost time The boost time parameter sets the amount of time that must elapse with a SH demand before the water temperature set point will be increased This parameter can be changed by the installer by accessing parameter F9 The time range for this parameter is 1 minute to 60 minutes The default value is 20 minutes Khe User s Information Manual XL 4 SMART SYSTEM control module continues Status Display Screens By using the Previous Next lt lt gt arrow keys on the SMART SYSTEM display panel you can navigate through the eight 8 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display shows BLR OFF The unit has been turned OFF by the Enter Reset button on the SMART SYSTEM display panel Standb The unit has not received a call for heat from a remote thermostat angdby nor has it received a call for heat from a DHW thermostat The unit has met the water tem
31. tial property damage User s Information Manual Boiler service and maintenance To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler This boiler is equipped with a control which will automatically shut down the boiler should air or vent be blocked If vent or air blockage is easily accessible and removable remove it The boiler should attempt to restart If blockage is not obvious or cannot be removed have the boiler and system checked by a qualified service technician Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to the circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage
32. ture drops 6 F 3 5 C below the tank set point and finishes the call for heat when the tank temperature goes 4 F 2 C above the tank set point This parameter can be changed by the installer by accessing parameter E3 The temperature range of this parameter is 32 F 0 C to 212 F 100 C The default value is 125 F 52 C 14 F Outdoor air reset Outdoor air shutdown When the outdoor temperature rises above this point the control will block all SH demands DHW demands will still be active This parameter can be changed by the user or the installer by accessing parameter F5 The temperature range of this parameter is 0 F 18 C to 120 F 49 C The default value is 70 F 21 C Outdoor air shutdown differential The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before the boiler will respond to a SH demand This parameter can be changed by the user or the installer by accessing parameter F6 The temperature range of this parameter is 0 F 0 to 90 F 50 C The default value is 10 F 5 C Boost temperature If a SH demand lasts longer than the programmed time delay setting F9 and there have been no DHW demands the control will increase the water temperature set point by the amount in this parameter If the SH demand continues through another time period the set point will be increased again This will continue until either
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