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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.
ƽ DANGER
ƽ WARNING
ƽ CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3
THE KNIGHT XL -- HOW IT WORKS . . . . . . . . . . . . . . . 4-6
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. DETERMINE BOILER LOCATION
Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10
Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10
Residential Garage Installation . . . . . . . . . . . . . . . . . . . . 10
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prevent Combustion Air Contamination . . . . . . . . . . . . . . 10
Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11
Removing a Boiler from Existing Common Vent . . . . . . . 11
2. PREPARE BOILER
Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . 12
Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Model 399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Model 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Models 600 - 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Leveling the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. GENERAL VENTING
Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 16
PVC/CPVC Vent Piping Materials . . . . . . . . . . . . . . . 16
Requirements for Installation in Canada . . . . . . . . . . . . . 16
PVC/CPVC Air Intake/Vent Connections . . . . . . . . . . . . . 17
Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stainless Steel Vent and Air Piping . . . . . . . . . . . . . . . . . 18
Min./Max. Combustion Air & Vent Piping Lengths . . . . . . 19
Removing from Existing Vent . . . . . . . . . . . . . . . . . . . . . 19
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 20-23
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 22-23
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 23
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 23
Sidewall Termination - Optional Concentric Vent . . . . . . 24-26
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 27-28
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 28
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 28
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 28
Vertical Termination - Optional Room Air . . . . . . . . . . . . . 29
Vertical Termination - Optional Concentric Vent . . . . . . . 30-31
6. HYDRONIC PIPING
System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 32
Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 32
Flow Switch and Relief Valve Installation . . . . . . . . . . . . 33
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . 33
Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 34
Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 36
7. GAS CONNECTIONS
Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 39
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 40
Natural Gas Supply Pressure Requirements . . . . . . . 40
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 40
Propane Supply Pressure Requirements . . . . . . . . . . 40
Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. FIELD WIRING
Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 43
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9. CONDENSATE DISPOSAL
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-53
11. OPERATING INFORMATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-57
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Knight XL Control Module . . . . . . . . . . . . . . . . . . . . . . . . 59-60
Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 61-64
12. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 65-69
13. DIAGRAMS
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover