Lochinvar 50-210 User Manual

Page 1

Installation & Operation Manual

Models: 50 - 210

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, death, or substantial property damage.

 WARNING

Save this manual for future reference.

WB-I-O Rev F

Page 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 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 WALL MOUNT BOILER--HOW IT WORKS . . . 4-5

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. DETERMINE BOILER LOCATION

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . . 9

Wall Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Residential Garage Installation . . . . . . . . . . . . . . . . . . . . . 9

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prevent Combustion Air Contamination . . . . . . . . . . . . . . . 9

Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 10

Removing a Boiler from Existing Common Vent . . . . . . . 10

2. PREPARE BOILER

Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . . 11

Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 14

Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . 14

Requirements for Installation in Canada . . . . . . . . . . . . . 14

Air Intake/Vent Connections . . . . . . . . . . . . . . . . . . . . . . 15

Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Max. Allowable Vent Piping Lengths . . . . . . . . . . . . . . . . 15

Removing from Existing Vent . . . . . . . . . . . . . . . . . . . . . 16

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 17-20

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18

Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 19

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 19

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 19-20

Sidewall Termination - Optional Concentric Vent . . . . . . 20-22

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 23-24

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 24

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 24

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 24

Vertical Termination - Optional Concentric Vent . . . . . . . 25-26

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 27

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 27

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 28

Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 30-35

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 36

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 37

Natural Gas Supply Pressure Requirements . . . . . . . 37

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 37

Propane Supply Pressure Requirements . . . . . . . . . . 37

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 39

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 40

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-50

11. OPERATING INFORMATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-54

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 55-56

Knight Wall Mount Boiler Control Module . . . . . . . . . . . . 57

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 58-61

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 62-65

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

Page 3

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 Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

When servicing boiler –

• 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.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to 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.

• 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 in system components. 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.

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.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where 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 your 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 qualified installer, service agency, or the gas supplier.

 WARNING

NOTICE

 WARNING

Page 4

Installation & Operation Manual

The Knight Wall Mount Boiler - How it works...

1. Stainless steel heat exchanger

Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

2. Heat exchanger access cover

Allows access to the combustion side of the heat exchanger coils.

3. Blower

The blower pulls in air and gas through the venturi (item

5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

4. Gas valve

The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

5. Venturi

The venturi controls air and gas flow into the burner.

6. Flue gas sensor

This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.

7. Boiler outlet temperature sensor (housed with high limit)

This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.

8. Boiler inlet temperature sensor

This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.

9. Temperature and pressure gauge (field installed, not shown)

Monitors the outlet temperature of the boiler as well as the system water pressure.

10. Electronic display

The electronic display consists of 7 buttons and a dual line 32character liquid crystal display.

11. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the boiler.

12. Burner (not shown)

Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

13. Water outlet (system supply)

The water outlet is the water connection for water leaving the boiler and entering the system. Boiler connection is 1".

14. Water inlet (system return)

The water inlet is the water connection for water entering the boiler from the system. Boiler connection is 1".

15. Gas connection pipe

Threaded pipe connection of 1/2". This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

16. SMART Control Module

The SMART Control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the heating demand.

17. Air intake adapter

Allows for the connection of the PVC air intake pipe to the boiler.

18. High voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

19. Automatic air vent

Designed to remove trapped air from the heat exchanger coils.

20. Low voltage connection board

The connection board is used to connect external low voltage devices.

21. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

22. Condensate drain connection

Connects the condensate drain line to a 1/2" pipe.

23. Access door

Provides access to all internal components.

24. Ignition electrode

Provides direct spark for igniting the burner.

25. Flame inspection window

The quartz glass window provides a view of the burner surface and flame.

26. Gas shutoff switch

An electrical switch designed to cut power from the gas valve to prevent releasing any gas.

27. High limit sensor (housed with outlet sensor)

Device that monitors the outlet water temperature. If the temperature exceeds its setting, it will break the control circuit, shutting the boiler down.

28. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve may be set at 30 psi or 50 psi depending on model.

29. Flame sensor

Used by the control module to detect the presence of burner flame.

30. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

31. Air pressure switch

The air pressure switch detects blocked inlet conditions.

Page 5

Installation & Operation Manual

Front View

Left Side (inside unit)

Right Side (inside unit)

The Knight Wall Mount Boiler - How it works... (continued)

Bottom View

Models 50 - 210

FRONT

OF UNIT

Page 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 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 based on a piping and pickup allowance of 1.15.

4. Knight wall mount boilers require special gas venting. Use only the vent materials and methods specified in the Knight Wall Mount Installation and Operation Manual.

5. Standard Knight wall mount boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

6. High altitude Knight wall mount boilers are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The boiler will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG. A) is also affixed to the unit.

Maximum allowed working pressure is located on the rating plate.

NOTICE

Knight Wall Mount Boiler

I=B=R Rating

Model

Number

Note: Change

“N” to “L” for L.P.

gas models.

Input MBH

(Note 5)

Min Max

Heating

Capacity

MBH

(Note 2, 8

Net

I=B=R

Ratings

Water,

MBH

(Note 3, 8)

AFUE

(Note 1, 8)

WBN050 10 50 45 39 95.3

WBN080 16 80 72 63 95.3

WBN105 21 105 94 82 95.4

WBN150 30 150 135 119 95.5

WBN210 42 210 190 165 95.7

7. The Knight Wall Mount boiler input rate, on some models, is reduced for vent lengths beyond the minimum. Models WB(N,L)080 and WB(N,L)105 with 2" vent will reduce 1% for every 10 feet of vent. Models WB(N,L)150 and WB(N,L)210 with 3" vent will reduce

0.5% for every 10 feet of vent.

8. Ratings have been confirmed by the Hydronics Institute, Section of AHRI.

Other Specifications

Boiler Water

Content Gallons

Water

Connections

Gas

Connections

Vent/Air Size

(Note 4)

0.6 1" 1/2" 2"

0.7 1" 1/2" 2"

1.3 1" 1/2" 3"

1.7 1" 1/2" 3"

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

Page 7

Installation & Operation Manual

1 Determine boiler location

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 severe personal injury, death, or substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

4. The Knight wall mount boiler must be installed so that

gas control system components are protected from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

 WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 8 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

Closet and alcove installations

This appliance requires a special venting system. The vent connection to the appliance is made of CPVC. Field supplied vent fittings must be cemented to the CPVC fitting on the boiler. Use only the vent materials, primer, and cement specified in the manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC vent material must be used inside the structure. The two ventilating air openings shown in FIG. 1-1 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

NOTICE

 WARNING

A closet is any room the boiler is installed in which is less than 79 cubic feet for WBN050 through WBN105 models, 104 cubic feet for WBN150 models, and 125 cubic feet for WBN210 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 4 feet long, 4 feet wide, and 9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be considered a closet for a Knight wall mount boiler.

Page 8

Installation & Operation Manual

1 Determine boiler location

Figure 1-2 Alcove Installation - Minimum Required Clearances

Figure 1-1 Closet Installation - Minimum Required Clearances

 WARNING

For closet installations, CPVC material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

Note: Service clearances are recommendations only.

 WARNING

For alcove installations, CPVC material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

Page 9

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, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Knight wall mount boiler in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Knight wall mount boiler.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Knight wall mount boiler because it takes its combustion air from outside (direct vent installation).

Wall mounting location

Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or wooden studs spaced 16" apart from center. Ensure the wall is capable of supporting at least 200 pounds.

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves, pumps, etc.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.

• The appliance shall be located or protected so that it is

not subject to physical damage by a moving vehicle.

Vent and air piping

The Knight wall mount boiler requires a special vent system, designed for pressurized venting.

You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion). Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight wall mount boiler using any other means.

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the Knight wall mount boiler as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

 WARNING

1 Determine boiler location (continued)

Page 10

Installation & Operation Manual

1 Determine boiler location

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

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

Table 1A Corrosive Contaminants and Sources

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 spillage and carbon monoxide emissions, causing severe personal injury or death.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance remaining

connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

 DANGER

 WARNING

Page 11

Installation & Operation Manual

2 Prepare boiler

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 pallet.

3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-1).

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

The gas conversion procedure should be accomplished BEFORE the boiler is installed. For a boiler already installed, you must turn off gas supply, turn off power, and allow the boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual.

You must install the propane orifice to fire the Knight wall mount boiler on propane. Verify when installing that the orifice size marking matches boiler size (Table 2A). Failure to comply could result in severe personal injury, death, or substantial property damage.

1. Remove the front access cover from the unit (no tools required for removal).

2. Disconnect the ribbon cable from the control board. Remove the four (4) screws securing the bezel to the front of the unit and remove the bezel.

3. Locate the power switch on the gas valve and turn the power switch to the “OFF” position (FIG. 2-2).

4. Disconnect the Molex plug from the wiring connector located on the gas valve.

5. Using a 5/16" nut driver, loosen the band clamp securing the air intake coupler to the gas valve venturi. Remove the air intake pipe and coupler from the gas valve venturi.

6. Using a 4mm Allen wrench, remove the two (2) screws securing the gas valve venturi to the inlet of the combustion blower (FIG. 2-2). Remove the gas valve venturi assembly from the unit.

Figure 2-1 Boiler Mounted on Shipping Pallet

Gas conversions

LP Conversion Table

Model LP Orifice Stamping

105

150

210 / W150

210

210 / W150

NOTICE

 WARNING

Table 2A LP Conversion Table

Figure 2-2 Gas Valve Power Switch & Venturi Removal

DETAIL

POWER SWITCH

7. Using a 4mm Allen wrench, remove the four (4) screws securing the gas valve to the venturi (FIG. 2-3).

8. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size (50 - 210, see Table 2A).

9. Place the orifice into the black rubber grommet in the side of the gas valve and secure inside the gas valve (see FIG. 2-3).

10. Reposition the gas valve against the venturi and replace the four (4) screws removed in Step 7, securing the valve to the venturi (FIG. 2-3).

11. Reposition the gas valve venturi assembly inside the unit. Secure the gas valve venturi to the combustion blower by replacing the two (2) screws removed in Step 6 (FIG. 2-2).

12. Reattach the air intake pipe and coupler to the gas valve venturi. Tighten the band clamp to secure.

Page 12

Installation & Operation Manual

2 Prepare boiler

Figure 2-4 Mounting the Boiler

Figure 2-3 Installing Propane Orifice

13. Reattach the wiring connector to the gas valve. Tighten the screw on the wiring connector to secure to the gas valve.

14. Turn the gas valve power switch to the “ON” position.

15. Reattach the bezel to the unit. Reconnect the ribbon cable to the control board.

16. After installation is complete, fill out the gas conversion label (in the conversion kit bag) and affix it to the unit under the boiler rating plate inside the unit. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

17. Replace the front access cover.

2. Mount the wall bracket using the 2 1/4" lag bolts provided.

Make sure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the

boiler with two (2) additional lag bolts provided.

Mounting to a metal studded wall:

1. The wall mount bracket is designed for a stud spacing of 16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer.

 WARNING

The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.

2. Mount the wall bracket using two (2) field supplied toggle bolts capable of supporting 100 pounds each. Ensure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) field supplied toggle bolts.

 WARNING

Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.

Mounting the boiler

See page 9 of this manual for boiler mounting location instructions.

NOTICE

The Knight Wall Mount boiler is not intended for floor installation.

Mounting to a wood studded wall:

1. The wall mount bracket is designed for a stud spacing of 16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer.

 WARNING

Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.

Mounting to a concrete wall:

1. Mount the wall bracket using the two (2) wedge anchor bolts provided with the bracket. To mount the wedge anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and insert anchor. Hang the bracket from the anchor and secure with the two nuts provided. Make sure the top edge of the bracket is away from the wall. Ensure bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

Note: If wall thickness does not allow a 1 1/8" deep hole, field supplied hardware suitable for the application should be provided.

2. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) remaining anchors, following the instructions above.

 WARNING

The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.

 WARNING

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

 WARNING

The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.

Page 13

Installation & Operation Manual

3 General venting

Figure 3-1 Two-Pipe Vertical Termination - See page 23 for more details

Figure 3-2 Two-Pipe Sidewall Termination - See page 17 for more details

Figure 3-3 Concentric Vertical Termination - See page 25 for more details

Figure 3-4 Concentric Sidewall Termination - See page 20 for more details

Direct venting options

Page 14

Installation & Operation Manual

3 General venting

Vent piping materials

Use only the materials listed in Table 3A below for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Table 3A Vent Pipe, and Fittings

Install vent and combustion air piping

 DANGER

The Knight wall mount boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

All vent pipes must be glued, properly

supported, and the exhaust must be pitched

a minimum of a 1/4 inch per foot back to the

boiler (to allow drainage of condensate).

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

NOTICE

 WARNING

For closet and alcove installations, CPVC material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

NOTICE

All vent pipe materials and fittings must comply with the following:

Item Material

Standards for installation in:

United States Canada

Vent pipe and fittings

PVC schedule 40 ANSI/ASTM D1785

CPVC and PVC venting must be ULC-

S636 Certified. IPEX is an approved

manufacturer in Canada supplying vent

material listed to ULC-S636.

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM F441

Pipe cement/primer

PVC ANSI/ASTM D2564

IPEX System 636

Cements & Primers

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings.

4. The 2" and 3" Concentric Vent Kits available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 2" and 3" Concentric Vent Kits available from IPEX are approved for use on the Knight wall mount boiler. Both kits are listed to the ULC-S636 standard for use in Canada.

For installations using 2" vent, the first seven (7) equivalent feet of vent must be CPVC (field supplied). See examples below.

 WARNING

Examples: 1. Seven (7) feet vertical

2. Connector + 90° elbow + 2 feet horizontal

3. One (1) foot vertical + 90° elbow + 1 foot horizontal

Page 15

Installation & Operation Manual

3 General venting (continued)

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-5) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG. 3-5) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Combustion air piping to the outside MUST BE used. Use of combustion air from the room via louvers, plenums, or any other device is not authorized.

NOTICE

Figure 3-5 Near Boiler Venting Model 50

Maximum allowable combustion air and vent piping lengths are as follows:

The Knight wall mount boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3B below.

Model 2" Max Vent/Air 3" Max Vent/Air

50 40 feet 100 feet

80 40 feet 100 feet

105 40 feet 100 feet

150 N/A 100 feet

210 N/A 100 feet

Increasing or decreasing the size of the combustion air or vent piping beyond the sizes listed in Table 3B is not authorized.

NOTICE

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow, 3 feet for each 45° elbow, and 3 feet for the concentric vent kit, see example below.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit = 49 equivalent feet of piping.

Table 3B Maximum Combustion Air and Vent Piping Lengths

Note: The minimum combustion air and vent piping length is 12 equivalent feet.

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

For 2" vent / air lengths greater than 40 feet, consult the factory.

NOTICE

VENT

AIR

Page 16

Installation & Operation Manual

3 General venting

Vent, air piping and termination:

The Knight wall mount boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

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 possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. 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 this manual.

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent

terminations to other areas.

Removing from existing vent

Follow the instructions in Section 1, page 10 of this manual when removing a boiler from an existing vent system.

Vent and air piping

Vent and air system:

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion).

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight wall mount boiler using any other means.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only PVC or CPVC pipe and fittings, with primer and cement specifically designed for the material used.

NOTICE

 WARNING

Page 17

Installation & Operation Manual

4 Sidewall direct venting

Vent/air termination – sidewall

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

 WARNING

NOTICE

 WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual.

2. You must consider the surroundings when terminating the

vent and air: a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

Figure 4-1B Alternate Sidewall Termination of Air and Vent w/Field Supplied Fittings

 WARNING

If using the alternate sidewall termination:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation

of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

12"

MIN

TO OVERHANG

POSSIBLE ORIENTATIONS

Figure 4-1A Sidewall Termination of Air and Vent

Model Kit Number Vent Size

50 - 105 KIT30044 2 inch vent

150 - 210 KIT30045 3 inch vent

Table 4A Sidewall Vent Kit

TO BOILER

FROM BOILER

VENT PIPE

CONNECTION

INTAKE AIR

CONNECTION

TERMINATION

PLATE

BIRD SCREEN

GRADE OR

SNOW LINE

BIRD SCREEN

12” MIN

15” MAX

12”

MIN

Page 18

Installation & Operation Manual

4 Sidewall direct venting

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 17 and 18. Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet.

b. Air inlet must terminate at least 12 inches above

grade or snow line; at least 12 inches below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches vertically outside the building.

c. Do not terminate closer than 4 feet horizontally

from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Vent/air termination – sidewall

Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

12"

MIN.

Figure 4-2A Clearance to Gravity Air Inlets

12” MIN

BIRD

SCREEN

(TYPICAL)

12”

MIN

12”

MIN

Figure 4-2B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings

FORCED AIR

INLET

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

Figure 4-3A Clearance to Forced Air Inlets

IF LESS

THAN 10’

36” MIN

FORCED AIR

INLET

BIRD

SCREEN

(TYPICAL)

7’ MIN ABOVE ANY PUBLIC WALKWAY

Figure 4-3B Alternate Clearance to Forced Air Inlets w/Field Supplied Fittings

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD

SCREEN

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

COUPLING

12” MIN

15” MAX

BIRD SCREEN

12”

MIN

Page 19

Installation & Operation Manual

4 Sidewall direct venting (continued)

Termination and fittings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG. 4-1A, page 17.

2. Maintain the required dimensions of the finished termination piping as shown in FIG. 4-1A, page 17.

3. If using the alternate sidewall termination do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

4. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.

Prepare wall penetrations (Alternate Field Supplied Option)

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole as shown in FIG. 4-4B.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-4A Sidewall Termination Assembly

Figure 4-4B Alternate Sidewall Termination Assembly

w/Field Supplied Fittings

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers terminate each vent/air connection as described in this manual (FIG. 4-5A).

2. Place wall penetrations to obtain minimum clearance of 12

inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a direct

vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

 WARNING

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT / AIR

TERMINATION

VENT

AIR

Figure 4-5A Multiple Vent Terminations (must also comply with Figure 4-1A)

Prepare wall penetrations

1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe. For either

combustible or noncombustible construction, size

the vent pipe hole with at least a 1/2 inch clearance

around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

2. Install the vent and air intake piping through the wall into the vent plate openings. Seal all gaps between the pipes and wall. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3A on page 14 to seal the vent pipe.

3. Mount and secure the vent plate to the wall using stainless steel screws. Seal around the plate to the wall assuring no air gaps.

4. Assemble the vent cap to the vent plate (see FIG. 4-4A). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.

5. Seal all wall cavities.

AIR PIPING

VENT PIPING

WALL PLATE

GALVANIZED

THIMBLE

VENT PLATE

VENT CAP

AIR PIPING

VENT PIPING

GALVANIZED

THIMBLE

TERMINATION PLATE

SIDEWALL

ELBOW

BIRD SCREEN

ELBOW

BIRD SCREEN

Page 20

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 - 3" or #CVK3008 - 2"). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-6.

The required combustion vent pipe and fittings are listed in Table 3A, on page 14 of this manual.

Figure 4-7 Kit Contents

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 4-6).

2. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual.

3. You must consider the surroundings when terminating

the vent and air: a. Position the vent termination where vapors will not

damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate

and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

4. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 4 inch diameter for #CVK3008 installations) into the structure to install the termination kit.

5. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.

a. Cement the Y concentric fitting to the larger kit pipe

(FIG. 4-7).

b. Cement the rain cap to the smaller diameter kit pipe

(FIG. 4-7).

Figure 4-6 Concentric Sidewall Termination

Figure 4-5B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1B)

Page 21

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent models

Figure 4-8 Concentric Vent Dimensional Drawing

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).

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 4-9 Rain Cap to Vent Pipe Alternate Assembly

6. Install the Y concentric fitting and pipe assembly through the structure’s hole.

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

7. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting.

8. Secure the assembly to the structure as shown in FIG. 4-10 using field-supplied metal strapping or equivalent support material.

Ensure termination location clearance dimensions are as shown in FIG. 4-6.

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, fieldsupplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8).

NOTICE

 WARNING

NOTICE

If assembly needs to be reduced, dimension D can be as short as possible.

NOTICE

Page 22

Installation & Operation Manual

4 Sidewall direct venting (continued)

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. 4-11). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-11. The next two (2) vent terminations must be at least 36 inches away from the first two (2) terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension A in FIG. 4-11 represents the distance between pipes or rain shields, as touching or a 2 inch maximum separation.

Figure 4-11 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation

Figure 4-10 Concentric Vent Sidewall Attachment

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-10 for proper pipe attachment.

10. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

CAUTION

Page 23

Installation & Operation Manual

5 Vertical direct venting

Vent/air termination – vertical

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 15 of this manual.

2. The vent must terminate at least 3 feet above the

highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an up-turned

coupling as shown in FIG. 5-1. The top of the coupling must be at least 1 foot above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake.

Figure 5-1 Vertical Termination of Air and Vent

5. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

 WARNING

NOTICE

 WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone.

Page 24

Installation & Operation Manual

5 Vertical direct venting

Vent/air termination – vertical

Prepare roof penetrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or

noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe hole.

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 5-1, page 23.

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.

Termination and fittings

1. If venting a WB 50 - 105 with 2" vent or a WB 150 - 210 with

3" vent, remove the two bird screens secured inside one of the two elbows and secure it into the vent termination coupling. If venting a WB 50 - 105 with 3" vent, insert the 3" bird screens provided with the boiler inside one field supplied elbow and one into the vent termination coupling.

2. The air piping must terminate in a down-turned 180°

return bend as shown in FIG. 5-1. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

3. The vent piping must terminate in an up-turned coupling as

shown in FIG. 5-1. The top of the coupling must be at least 1 foot above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake.

4. Maintain the required dimensions of the finished

termination piping as shown in FIG. 5-1.

5. Do not extend exposed vent pipe outside of building more

than shown in this document. Condensate could freeze and block vent pipe.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers, terminate each vent/air connection as described in this manual (FIG. 5-2).

Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 5-2 Vertical Terminations with Multiple Boilers

Figure 5-3 Alternate Vertical Terminations with Multiple

Boilers

 WARNING

Page 25

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and fittings are required to complete the installation.

The required combustion air and vent pipe fittings are listed in Table 3A, on page 14 of this manual.

Vertical termination installation

1. Determine the best location for the termination kit (see FIG. 5-4).

2. The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 15 of this manual.

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 21).

3. You must consider the surroundings when terminating the vent and air:

a. Position the vent termination where vapors will not

damage nearby shrubs, plants, or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate

and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

h. Do not attach a U-Bent to the rain cap. Doing so could

cause recirculation (see FIG. 5-5).

4. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 4 inch diameter for #CVK3008 installations) into the structure to install the termination kit.

5. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions. a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG. 4-7, page 20).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-7, page 20).

Figure 5-4 Concentric Vertical Termination

NOTICE

 WARNING

Figure 5-5 Do Not Install U-Bent to Rain Cap

Page 26

Installation & Operation Manual

5 Vertical direct venting

Vertical termination – optional concentric vent

Figure 5-6 Concentric Vent Roof Installation

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4, page 25.

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8, page 21).

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

8. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting.

9. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.

10. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. The next two (2) vent terminations must be at least 36 inches away from the first two (2) terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension A in FIG. 5-7 represents the distance between pipes or rain shields, as touching or a 2 inch maximum separation.

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination (Dimension A as Touching or 2 inches Maximum Separation)

6. Install the Y concentric fitting pipe assembly through the structure’s hole and field supplied roof boot/flashing.

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

7. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.

 WARNING

NOTICE

Page 27

Installation & Operation Manual

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 note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.

Observe a minimum of 1 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-3 - 6-7), which will guide you through the installation of the Knight wall mount boiler (reference FIG. 6-1).

1. Connect the system return marked “Inlet”, make sure to install with pipe sealant compound.

2. Connect the system supply marked “Outlet”, make sure to install with pipe sealant compound.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.

6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.

10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The safety relief valve is installed at the factory located on the left-hand side of the boiler. Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

See the *piping illustrations included in this section, FIG.’s 6-3 6-7 for suggested guidelines in piping the Knight wall mount boiler with either zone valves or circulator pumps.

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

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.

 WARNING

NOTICE

Page 28

Installation & Operation Manual

6 Hydronic piping

Circulator sizing

The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.

Near boiler piping connections

Figure 6-1 Near Boiler Piping

CONDENSATE

DRAIN

VENT

AIR

DOMESTIC HOT

WATER PUMP

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

SYSTEM

BOILER

PUMP

SYSTEM

PUMP

FROM

SYSTEM

Page 29

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-2 Pressure Drop vs. Flow - Models 50 - 210

20°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

50 5.1 11 1" UP26-96F/UPS26-99F 0011 NRF-36 E7 80 7.5 24 1" UP26-96F/UPS26-99F 0011 NRF-36 E7

105 9.8 27 1"

UPS26-99F

0013 NRF-36 E11

150 14.0 20 1"

UPS26-99F

0011 NRF-36 E7

210 19.6 29 1" UPS32-160 1400-50 PL-55 E9

Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°

25°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

50 4.1 7.3 1" UPS15-58FC 0014 PL-30/NRF-36 E7

80 5.9 15.0 1" UPS15-58FC 0014 PL-30/NRF-36 E7 105 7.7 17.5 1" UP26-64F/UPS26-99F 0014 PL-30/NRF-36 E7 150 11.0 12.8 1" UP26-64F/UPS26-99F 0014 PL-30/NRF-36 E7 210 15.5 19.0 1" UP26-99F/UPS26-99F 0013 PL-36/NRF-36 E7

35°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

50 2.9 4.1 1" UPS15-58FC 007 NRF-22 Astro-30

80 4.2 7.3 1" UPS15-58FC 007 NRF-22 Astro-30 105 5.5 9.8 1" UPS15-58FC 007 NRF-22 Astro-30 150 7.9 10 1" UPS15-58FC 008/0010 PL-30/NRF-36 Astro-30 210 11.0 10.1 1" UPS15-58FC 0010 PL-30/NRF-36 Astro-50

Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude models.

NOTICE

Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude models.

NOTICE

The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.

NOTICE

Page 30

Installation & Operation Manual

6 Hydronic piping

It is required that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 6-3 - 6-7 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.

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 based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler system circulating pump:

A Grundfos UPS26-99F pump will be provided by the factory as the boiler circulation pump based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in FIG. 6-2. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.

4. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

5. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-3 - 6-7. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

7. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

8. Unions:

Field supplied. Recommended for unit serviceability.

9. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

10. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME specifications.

11. Boiler purge valve:

Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.

12. System temperature sensor:

Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.

13. Indirect water heaters:

The Knight wall mount boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. As depicted in the piping diagrams on page 31 thru 35, the space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.

The Knight wall mount boiler is pre-configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming. The DHW programming is designed to control and balance the space heating demand with the domestic hot water demand.

Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.

NOTICE

Pump sizing and flow requirements are based on 20 feet of piping, 4 - 90° elbows, and 2 fully ported ball valves.

NOTICE

 WARNING

The National Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5

Edition.

Page 31

Installation & Operation Manual

Figure 6-3 Single Boiler Zoned with Circulators

6 Hydronic piping (continued)

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW PREVENTER

MAKE UP WATER

SYSTEM SUPPLY

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

SENSOR

PRESSURE

GAUGE

ZONE #2

EXPANSION

TANK

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

BOILER CIRCULATOR

ZONE #3

DOMESTIC

HOT WATER

CIRCULATOR

ZONE #4

ANTI-SCALD

MIXING VALVE

FLOW CHECK

VALVE

(TYPICAL)

ZONE CIRCULATORS

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

PRESSURE

RELIEF VALVE

UNION

(TYPICAL)

BOILER

INDIRECT

DHW TANK

DRAIN

Page 32

Installation & Operation Manual

6 Hydronic piping

Figure 6-4 Multiple Boilers Zoned with Circulators

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

50 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

80 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 105 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 150 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 210 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE

GAUGE

MAKE UP WATER

SYSTEM SUPPLY

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

SENSOR

EXPANSION

TANK

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

(TYPICAL)

PRESSURE

RELIEF VALVE

ZONE #2

BOILER CIRCULATOR

DOMESTIC

HOT WATER

CIRCULATOR

ZONE #3

ZONE #4

ANTI-SCALD MIXING VALVE

FLOW CHECK

VALVE

(TYPICAL)

ZONE CIRCULATORS

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

BOILER 2

(MEMBER 1)

DRAIN

BOILER 1

(LEADER)

INDIRECT

DHW TANK

Page 33

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-5 Single Boiler Zoned with Valves

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

SYSTEM SUPPLY

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

SENSOR

(TYPICAL)

PRESSURE

GAUGE

SYSTEM

CIRCULATOR

EXPANSION

TANK

BOILER

CIRCULATOR

PRESSURE

RELIEF VALVE

ZONE #2

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

FLOW CHECK

VALVE

ZONE #3

DOMESTIC

HOT WATER

CIRCULATOR

ZONE #4

ANTI-SCALD

MIXING VALVE

ZONE VALVES

(TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

HOT

WATER

OUT

COLD

WATER

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

BOILER

INDIRECT

DHW TANK

Page 34

Installation & Operation Manual

6 Hydronic piping

Figure 6-6 Multiple Boilers Zoned with Valves

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

50 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

80 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 105 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 150 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 210 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

PRESSURE

BACKFLOW

PREVENTER

BALL VALVE

(TYPICAL)

REDUCING VALVE

PRESSURE

GAUGE

MAKE UP WATER

SYSTEM SUPPLY

SENSOR

AIR SEPARATOR

CIRCULATOR

EXPANSION

ZONE #1

SYSTEM

TANK

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

ZONE #2 ZONE #3

ZONE #4

ZONE VALVES

(TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN POINT

(TYPICAL)

DRAIN

PRESSURE

RELIEF VALVE

BOILER 2

(MEMBER 1)

UNION

(TYPICAL)

BOILER CIRCULATOR

ANTI-SCALD MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

BOILER 1

(LEADER)

HOT

WATER

OUT

COLD

WATER

INDIRECT

DHW TANK

Page 35

Installation & Operation Manual

Figure 6-7 Single Boiler - Non-Zoned Primary/Secondary Piping

6 Hydronic piping (continued)

PRESSURE REDUCING VALVE

BACKFLOW PREVENTER

PRESSURE

GAUGE

MAKE UP WATER

SYSTEM SUPPLY

SYSTEM

BALL VALVE

(TYPICAL)

SENSOR

SYSTEM

CIRCULATOR

EXPANSION

TANK

DRAIN POINT

(TYPICAL)

PRESSURE

RELIEF VALVE

AIR SEPARATOR

FROM

SYSTEM

NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART

BOILER CIRCULATOR

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

BOILER

INDIRECT

DHW TANK

Page 36

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.

Figure 7-1 Gas Supply Piping

2. Support piping with hangers, not by the boiler or its accessories.

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.

3. Purge all air from the gas supply piping.

4. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. Close manual main shutoff valve during any

pressure testing at less than 13 inches w.c.

b. Disconnect the boiler and gas valve from the gas

supply piping during any pressure testing greater than 13 inches w.c.

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

SEDIMENT TRAP / DRIP LEG

Page 37

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 is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 11). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at boiler (FIG. 7-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Figure 7-2 Inlet Pipe with Backup Wrench

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour). a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 4 inches w.c. with gas flowing (verify during

boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum.

Propane Gas:

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 8 inches w.c. with gas flowing (verify during

boiler startup).

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

 WARNING

NOTICE

 WARNING

Ensure that the high gas pressure regulator is at least 6 - 10 feet upstream of the appliance.

Page 38

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

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

697

477

384

328

292

267

246

236

210

200

179

164

149

138

1-1/4

1400

974

789

677

595

543

502

472

441

410

369

333

308

287

1-1/2

2150

1500

1210

1020

923

830

769

707

666

636

564

513

472

441

4100

2820

2260

1950

1720

1560

1440

1330

1250

1180

1100

974

871

820

2-1/2

6460

4460

3610

3100

2720

2460

2310

2100

2000

1900

1700

1540

1400

1300

11200

7900

6400

5400

4870

4410

4000

3800

3540

3330

3000

2720

2500

2340

23500

16100

13100

11100

10000

9000

8300

7690

7380

6870

6150

5640

5130

4720

Table 7A Natural Gas Pipe Size Chart

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

 WARNING

3. Loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG. 7-3.

4. Slowly turn on the gas supply at the field installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap.

Check inlet gas supply

NOTICE

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

 WARNING

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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 property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Gas Pressure

The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Knight wall mount boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the venturi and blower.

Figure 7-3 Inlet Gas Supply Check

Failure to follow all precautions could result in fire, explosion, or death!

 WARNING

Page 40

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 must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Line voltage connections

1. Remove bezel as shown in FIG. 8-1.

2. Connect 120 vac power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-2.

2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code (see FIG. 8-2).

3. Wire the boiler pump as shown in FIG. 8-2.

4. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. 8-2.

5. To activate a system pump, wire as shown in FIG. 8-2. If the motor is larger than 1/8 hp or 1.8 amps, you must install a relay.

Figure 8-2 Line Voltage Field Wiring Connections

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

 WARNING

NOTICE

 CAUTION

Figure 8-1 Remove Bezel

REMOVE BEZEL

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Installation & Operation Manual

Low voltage connections

1. Route all low voltage wires through the knockouts in the bottom front right side, just under the control panel, as shown in FIG. 8-3.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-4 on page 43 of this manual and the boiler wiring diagram.

Figure 8-3 Routing Field Wiring

8 Field wiring (continued)

Thermostat

1. Connect the room thermostat or end switch (isolated contact only) to terminals R and W, 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 fireplaces.

3. Thermostat anticipator (if applicable): a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to

match total electrical power requirements of connected devices. See device manufacturers’ specifications and thermostat instructions for details.

Outdoor temperature sensor

1. Connect outdoor temperature sensor (FIG. 8-4) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight wall mount boiler. If fixed temperature operation is required, do not install outdoor sensor.

2. Mount the sensor on an exterior wall, shielded from direct sunlight or flow of heat or cooling from other sources.

3. Route sensor wires through a knockout in the bottom front right side of the boiler (see FIG. 8-3).

DHW thermostat

1. Connect storage indirect water heater (DHW) thermostat (FIG. 8-4) to the DHW thermostat terminals on the connection board.

Auxiliary device relay

1. If an auxiliary device needs to operate when the boiler fires,

it can be controlled by this output. Connect these terminals to a 24 vac relay coil, which is wired to operate the auxiliary device (FIG. 8-4).

Auxiliary device proving switch

1. When the operation of an auxiliary device needs to be

verified before the boiler fires, remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch (FIG. 8-4).

Flow switch

1. A flow switch is used to guarantee flow through the boiler

before allowing it to fire. The flow switch must be installed in line with the boiler.

2. Connect these terminals to the normally open contacts on

the flow switch (FIG. 8-4).

DHW tank sensor

1. 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 temperature drops 6°F (3°C) below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point.

2. The tank sensor included with the Lochinvar Squire Indirect

DHW tank (TST2032) is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the DHW Tank Sensor (AUX) terminals on the Low Voltage Connection Board. Consult the tank manufacturer for application and performance when used with any other indirect tank.

Failure to use the correct sensor may result in the tank temperature being either above or below the set point. Failure to consult the manufacturer of the indirect tank, when the Squire is not used, may result in decreased performance or the risk of scald injury.

 WARNING

3. If the TST2032 is not compatible with the indirect tank, a tank thermostat can be used to control the boiler. The tank thermostat should be installed per the manufacturers instructions and wired to the DHW Thermostat terminals on the Low Voltage Connection Board.

LOW VOLTAGE CONNECTION BOARD

LOW VOLTAGE WIRING KNOCKOUTS

LINE VOLTAGE JUNCTION BOX

LINE VOLTAGE WIRING KNOCKOUTS

Page 42

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. Connect the Room Thermostat / Zone Control terminals to the enable output of the external control and connect the 0 - 10 vdc terminals to the 0 - 10 vdc output of the external control.

2. Make sure the ground terminal is connected to the ground output terminal of the external control, and the 0 - 10 vdc terminal is connected to the 0 - 10 vdc terminal of the external control.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the boiler is down. Note that these contacts will close momentarily at the end of each call for heat.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See page 50 “Configuration of the Cascade” for a detailed explanation of this procedure.

Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop (FIG.’s 6-4 and 6-6). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor (see FIG. 8-4). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 8-4). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters. If the outdoor air sensor is not connected, the Leader control will maintain the fixed water temperature set point that is programmed into the control.

If a Thermostat, Zone Control enable output, or Building Management System enable output are available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for the Room Thermostat/Zone Control (FIG. 8-4). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the Thermostat/Zone Control input. This will initiate a call for heat on the Cascade.

Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield ground terminals on the Low Voltage Connection Boards (FIG. 8-4). If more than two boilers are on the Cascade, daisy chain the wiring from the Sequencing terminals on the second boiler to the Sequencing terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible.

System supply sensor

1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected). If it is desired to control the system return temperature, then program the SMART SYSTEM control to use the inlet sensor as the controlling sensor. See the Knight Wall Mount Service Manual for instructions on how to do this. When the inlet sensor is programmed as the controlling sensor, it is strongly recommended that the SYSTEM SUPPLY sensor be installed. DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN.

2. Connect these terminals to the system supply sensor (FIG. 8-4).

Page 43

Installation & Operation Manual

8 Field wiring (continued)

Figure 8-4 Low Voltage Field Wiring Connections

(AUX) DHW

TANK SENSOR

Page 44

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 1/2 inch pipe for connection of a 1/2 inch PVC pipe (FIG. 9-1).

3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Knight wall mount boiler will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.

A Neutralizer Kit is available from the factory (Kit 3087).

4. Do not expose condensate line to freezing temperatures.

5. Use only plastic tubing or piping as a condensate drain line (FIG. 9-1).

6. Leave the top of the tee assembly installed in the unit open, this is needed as a vacuum break. The blocked drain switch will shut the boiler down before any condensate can flow out of the tee.

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.

7. A condensate removal pump is required if boiler is below drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage. The switch should be wired to the auxiliary device proving switch terminals on the low voltage connection board.

NOTICE

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.

Figure 9-1 Condensate Disposal

Page 45

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 water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not fill boiler or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or spa water.

Test/replace freeze protection fluid

1. For systems using freeze protection fluids, follow fluid manufacturer’s instructions.

2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.

Freeze protection (when used)

1. Determine freeze protection fluid quantity using system water content, following fluid manufacturer’s instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.

2. Local codes may require a backflow preventer or actual disconnect from city water supply.

3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close manual and automatic air vents and boiler drain valve.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water fill pressure for a

residential system is 12 psi.

b. Pressure will rise when boiler is turned on and

system water temperature increases.

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Purge air from water system

1. Purge air from system: a. Connect a hose to the purge valve (see purge/drain

valves, in piping diagrams on pages 31 through 35). Route the hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between

the purge valve and fill connection to the system. c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air.

Run until no noticeable air flow is present. Close the

zone isolation valves and proceed with the next zone.

Follow this procedure until all zones are purged. g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch

that system pressure rises to correct cold-fill

pressure. h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located

throughout the system. i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time,

beginning with the lowest floor. Close the vent when

water squirts out. Repeat with remaining vents.

2. Open automatic air vent (diaphragm-type or bladder-type expansion tank systems only) one turn.

3. Open other vents: a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Refill to correct pressure.

4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

 WARNING

 CAUTION

Page 46

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 leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to the room thermostat terminals on the connection board.

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board. Allow the boiler to cycle.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate PVC fittings and condensate trap.

Fill condensate trap with water

1. Remove the bezel as depicted in FIG. 8-1 on page 40 of this manual.

2. Remove the PVC cap retaining screw from the PVC cap (FIG. 10-1).

3. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 10-1).

4. Fill with fresh water until the water begins to pour out of the drain.

5. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

6. Replace the retaining screw.

7. Reinstall bezel.

The condensate trap (FIG. 10-1) must be 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 10-1 Condensate Trap

 WARNING

Clean/Inspect Trap Assembly

1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

2. Refill the trap according to the instructions above.

Page 47

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, page 48 for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages

45 and 46 have been completed.

 Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap). Replace the cap. Press the cap onto the trap until the cap makes contact with the drain. Replace the retaining screw.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of

deterioration from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 10-2, page 48.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is external limit control (if used) open? Is boiler water temperature above 200°F?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the Troubleshooting Section of the Knight Wall Mount Service Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 45 and 46 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

 Check vent piping and air piping

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 36 of this manual (connecting gas supply piping).

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

Check flame and combustion

1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.

2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point.

3. Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

 WARNING

Page 48

Installation & Operation Manual

10 Start-up

Figure 10-2 Operating Instructions

Page 49

Installation & Operation Manual

10 Start-up (continued)

Check flame and combustion (continued)

4. Place the boiler into the active position by pressing the ENTER/RESET button on the display board (FIG. 11-1, page 57) until BLR:Standby appears in the display window.

5. Locate the pinhole button in the upper right corner of

the “T” in the Knight logo on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the

hole left by the removal of the flue temperature sensor.

7. Once the boiler has modulated up to full fire, measure

the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range, reference the Troubleshooting Section of the Knight Wall Mount Service Manual for possible causes and corrective actions.

Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be based on one of three sensors; the inlet, outlet, or system supply sensor. The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor. The control will automatically switch to the system supply sensor once it is connected. If it is desired to base the temperature control on the inlet sensor, the appropriate parameter must be changed in the control. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system (primary) pump (if connected), and the boiler (secondary) pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect DHW (Domestic Hot Water) tank, it also turns on the boiler pump. After the space heating call for heat ends, the system pump continues to run for a short period of time. If the boiler pump was running, it continues to run for a short period of time as well. These pump delays are factory set to 30 seconds. If different delays are desired, the appropriate parameters in the control must be changed. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Set space heating set point temperature

The UP and DOWN keys may be used during normal operation to adjust the space heating set point temperature. Once the desired temperature is displayed, press the ENTER/RESET key to save the new setting. If the ENTER/RESET key is not pressed, the new setting will be used for the current heating cycle only. The old setting will become active after the current heating cycle ends.

Table 10A Flue Products Chart

8. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down and registers an alarm. Open the manual shutoff valve, reset the control, and return to Service Mode.

9. Turn the main power off to the boiler and replace the

flue temperature sensor into the flue pipe connection.

10. Place the boiler back into normal operation.

You must replace the flue gas temperature sensor to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

Page 50

Installation & Operation Manual

10 Start-up

Set domestic hot water (DHW) operation

Verify DHW circulator mode

The DHW Mode is programmed to heat an indirect domestic hot water tank. When the tank thermostat calls for heat, the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump (if running). If the system pump is running, it will remain on. When the DHW call for heat ends, and there is no space heating call for heat, the DHW pump will continue to run for a period of time. This pump delay is set at the factory to 30 seconds. If a shorter or longer delay is desired, the appropriate parameter in the control must be changed. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure. If there is an active space heating call for heat, then the boiler pump will be turned on and the DHW pump will be turned off.

Set DHW target temperature

When in the DHW Mode, the control will modulate to maintain the outlet temperature to a set point. This set point is set at the factory to 180°F. If a different set point is desired, the appropriate parameter in the control must be changed. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Set clock

The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than one month. Use the following procedure to set the clock:

1. Press and hold the MENU key for at least 5 seconds.

2. The display changes to ready “ENTER MENU CODE”, with four (4) zeros below it.

3. Change the zeros to match the user code (factory set at “0704”). Use the UP and DOWN keys to increment or decrement the flashing digit, and the NEXT and PREVIOUS keys to select which digit flashes.

4. Press the ENTER key.

5. The display changes to read USER CODE for a few seconds, then displays a menu.

6. Press the ENTER key.

7. Press the UP key twice to display “A3 DATE AND TIME”.

8. Press the ENTER key once.

9. The date and time are displayed as “YY:MM:DD W hh:mm”, where: mm: minutes hh: hour (24 hour time; e.g., 2:00 PM = 14:00) W: day of the week (1 = Sunday, 2 = Monday,

3 = Tuesday, etc.,) DD: date MM: month YY: year

NOTICE

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Use the UP and DOWN keys to increment or decrement the flashing number, and the NEXT and PREVIOUS keys to select which number flashes.

10. Press the ENTER key to save the setting.

11. Press the MENU key twice to exit the Programming Mode.

Configuration of the cascade

When installed in a Cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters.

Input the Installer code as described in the Knight Wall Mount Service Manual. Once the control parameters have been accessed, use the DOWN arrow key to select the H Control Mode parameters. Press the ENTER key to access these parameters. Use the UP arrow key to access parameter H2 SH Source. Press the ENTER key to access this parameter. Use the DOWN arrow key to select Cascade. Press the ENTER key to program this into the control.

Press the UP arrow key to select the parameter H3 BLR Address. Press the ENTER key to access this parameter. Each unit in the Cascade system must be programmed with its own address. The boiler designated as the Leader will have an address of 0. The remaining boilers in the Cascade will be Members and have addresses from 1 - 7. Use the UP and DOWN arrow keys to select the appropriate address. Press the ENTER key to program this into the control.

Press the MENU key twice to exit the control parameters. Repeat this procedure for all boilers in the Cascade, designating the Leader control and the Member controls.

Page 51

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. The control module regulates blower speed to control the boiler firing rate. The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow.

How the control module operates

The SMART SYSTEM control module receives input from boiler sensors and external inputs. The control module activates and controls the blower and gas valve to regulate heat input and switches the boiler, Domestic Hot Water (DHW), and system pumps on and off as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature, boiler inlet water temperature, or system temperature, depending on the parameter setting.

Control inputs and outputs

Room thermostat / zone control

This input tells the boiler to provide water for space heating.

Domestic Hot Water (DHW) tank thermostat

This input tells the boiler to provide water for heating an indirect DHW tank.

0 - 10V input (set point or power)

The Knight wall mount boiler can be controlled by a Building Management System (BMS) using a 0 - 10 vdc signal. The control can be configured by the installer to use this signal to either control set point or firing rate.

DHW priority

The SMART SYSTEM control module allows connection of a DHW thermostat to the low voltage connection board. When the DHW thermostat calls for heat, the module activates the DHW pump, shuts down the boiler pump, and immediately sets the target outlet water temperature to 180°F. This provides automatic priority heat allocation to the indirect water heater for maximum response and recovery. The DHW pump continues for 30 seconds after the heating cycle to deliver the most possible heat.

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is in progress, the control will start the DHW pump and shut the boiler pump off. The system pump will remain on. If the space heating call is still active while the DHW call is in operation, the control will wait for 30 minutes (time adjustable by installer) then it will switch back to the space heating demand. The control will switch back and forth until one of the heat demands end.

Programmable controlling sensor

The control module is programmed to use the outlet sensor as the control sensor by default. If a system supply sensor is connected, the control automatically uses it as the control sensor. The control sensor can be changed by the installer to the inlet sensor. If the inlet sensor is chosen as the controlling sensor, it is recommended that the system supply sensor be installed.

Anti-cycling

After a space heating demand has been satisfied, the control will delay the next space heating call for a set time period (time is adjustable by the installer). The time delay will be bypassed if the inlet water temperature drops too far during the delay.

Boiler, system, and DHW pump control

When a space heating call for heat starts and no DHW call is on, the system and boiler pumps are turned on. As long as the space heating call for heat is on, the system pump will remain on. If a DHW call for heat is on, the boiler pump will wait to turn on until just before the DHW pump turns off. After the space heating call for heat ends, both pumps will run for an additional period of time.

When a DHW call for heat starts, the DHW pump is turned on. If a space heating call for heat was on, the boiler pump will turn off a few seconds after the DHW pump turns on.

Temperature control

Modulation

The Knight wall mount boiler is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations.

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11 Operating information

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 as six (6) time intervals corresponding to each limit. The sixth limit will also limit the firing rate for the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the firing rate to its lowest setting.

Outdoor air reset

With the outdoor air sensor connected, the control module will calculate the set point based on the programmed reset curve. The installer can change the slope of the reset curve by several adjustable parameters. The user can limit the maximum set point for the system using the space heating set point.

Boost function

If outdoor air reset is active, and a space heating demand has been active continuously for a set period of time (time adjustable by installer) and there has been no DHW demands, the control will increase the set point by a fixed number of degrees (adjustable by installer). This process will continue until the space heating demand ends, the set point reaches the programmed set point or a maximum of 20 increases has occurred. Once the system heat demand is satisfied, the set point will revert to the value determined by the reset curve.

Night setback

The controller may be programmed to reduce the space heating set point during a certain time each day. A start and stop time can be programmed for each day of the week.

Flame current support

To prevent nuisance shutdowns when the boiler is firing at minimum rates, the control will increase the firing rate when the flame signal drops too low.

Protection features

Outlet temperature, flue temperature, and temperature rise limiting

The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds 185°F, the unit will reduce the fan speed. If the outlet water temperature exceeds 195°F the control will shut the unit down until it cools off.

The control module monitors the flue temperature by a sensor located in the flue exhaust. If the flue temperature exceeds 215°F the control will reduce the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the control will reduce the fan speed. If the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F and the minimum off time has expired.

Freeze protection

DO NOT install the boiler in a room likely to freeze.

The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system.

• The SMART SYSTEM control module provides

freeze-up protection as follows when the boiler water temperature drops below 45°F:

• Below 45°F, the boiler and system pumps operate

constantly.

• Below 37°F, the boiler turns on.

• Boiler and pumps turn off if boiler water

temperature rises above 45°F.

This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.

 CAUTION

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11 Operating information (continued)

High limit operations

When outlet temperature exceeds 200°F, high limit action occurs. The boiler shuts down until the outlet water cools down.

If local codes require manual reset, an Adjustable Manual Reset High Limit kit is available.

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature

sensing of both supply and return areas of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral

features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff kit(s) is available (Kit

3057).

Outdoor reset operation, if used

Target temperature with outdoor reset

This feature improves the system’s efficiency as the outdoor temperature warms up.

See Knight Wall Mount Service Manual to change the settings.

Reset curve

The reset curve looks at outdoor air temperature and adjusts the set point.

Cascade

When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls.

Once the Leader boiler receives a call for heat from a room thermostat, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve parameters. See the Knight Wall Mount Service Manual to program the reset curve. If outdoor air reset is not desired, do not connect the outdoor air sensor. A fixed temperature set point can be programmed into the control. See page 49 of this manual to program the set point.

Monitor external limits

Connections are provided on the connection board for external limits such as flow switch, low water cutoff, gas pressure switches, and an auxiliary device proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the boiler is running, and when it is unable to operate.

Run-time and cycle counting

The control uses two timers to monitor the total hours of burner operation. One timer monitors the time the boiler is firing under 50% of rate. The other timer monitors the time the boiler is firing over 50% rate.

The control uses four (4) ignition counters to monitor the amount of boiler cycles. The first counter counts all ignitions of the control. The second counter counts only ignition attempts that have failed. The third and fourth counters are the same as the first and second respectively, but can be reset by the installer.

Service reminder

The control can be programmed for service reminder notification. This notification will become active when either a set time frame has expired, or a set amount of running hours or cycles has expired (all adjustable by the installer). The display will alternate the standard text on the display screen with Service Due every 5 seconds. The service reminder notification can be reset by the installer.

Error logging

The control will hold in memory the last 10 error codes as well as the last 10 turn-off functions. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature. The target temperature can be set between 70°F and 190°F.

• Target temperature is fixed when the outdoor sensor is not installed.

• Target temperature is calculated as described in this section under “Outdoor Reset Operation” and “Target Temperature Boost” when the outdoor sensor is connected.

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11 Operating information

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 Wall Mount Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler.

The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point. If the first boiler reaches 100% of its firing rate, the Leader will calculate at what point the second boiler could fire at 20% of its firing rate. At this point, the Leader will fire the second boiler on the Cascade. For a new startup, this would be the first Member boiler. The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point.

If the set point still cannot be met, the Leader will continue firing more Members until either the heat demand is met or all boilers on the Cascade are firing. As the heat demand decreases, the last boiler on will modulate down to 20% of its firing rate. Once the demand for that boiler is zero, it will shut down. As the heat demand decreases further, the second to last boiler will modulate down and shut off. This will continue until the demand is satisfied and all boilers are shut off.

DHW, Night Setback, and Ramp Delay operation with cascade

For 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 to the terminals on the Low Voltage Connection Board marked for the DHW Thermostat. When the boiler receives a DHW call, the Leader control will take that boiler out of the Cascade sequence. If another boiler is available, the Leader will start it up to take its place.

The DHW boiler will adjust its set point to the programmed DHW set point and will adjust its firing rate to maintain this. Once the DHW call has been satisfied, the Leader control will place that boiler back into the Cascade sequence.

Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur. The boiler will provide heat for the DHW demand until it is satisfied.

Night Setback operation of the boilers within the Cascade is available. Programming of the Night Setback will be done through the Leader boiler. Refer to the Knight Wall Mount Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the Knight Wall Mount Service Manual is not active when the boilers are part of a Cascade system.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals.

For the first 24 hours after initializing the Cascade, the sequence will be changed every hour. After that the sequence will be changed once every 24 hours. The switching on/off sequence will be as follows:

DAY SWITCHING ON SEQUENCE

Day 1 L-M1-M2-M3-M4-M5-M6-M7

Day 1 + 1 hour M1-M2-M3-M4-M5-M6-M7-L

Day 1 + 2 hours M2-M3-M4-M5-M6-M7-L-M1

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11 Operating information (continued)

OPERATION DISPLAY

1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for space heating call; DHW pump for DHW call).

BLR: Standby OUT: 123.8F(129)

2. The control connects 120 vac to the blower. The blower does

not run at this time.

• If the unit is equipped with a flow switch or low water cutoff, it

must close before the control powers up the blower.

• If the unit is equipped with a manual reset high limit it must be

closed before the control powers up the blower.

• If the unit is equipped with a solenoid valve and/or a vent

valve, they will be energized along with the blower.

• If the unit is equipped with a gas pressure switch, it must close

at this time.

• If there is an auxiliary device connected to the unit, the unit will

then provide 24 vac to its enable relay. If the auxiliary device has a proving switch, it must close before the sequence continues.

BLR: Standby OUT: 123.8F(129)

3. The control then starts a 10 second prepurge cycle.

BLR: PREPURGE OUT: 123.9F(129)

4. Once the prepurge cycle is complete, and the blocked drain

and auto-reset high limit are closed, the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve.

BLR: IGNITION OUT: 123.9F(129)

5. If the control does not detect flame by the end of the trial for

ignition, the control performs a 10 second postpurge, another prepurge and tries to light the burner again. If the burner does not light after 4 trials, the control locks out for 1 hour and then tries another set of 4 trials.

BLR: POSTPURGE, PREPURGE OUT: 123.9F(129)

6. If the control detects a flame before the trial for ignition ends, it

begins to modulate the burner in order to maintain the set point. If the boiler lights due to a space heating call for heat, and the ramp delay function is active (default is active), the modulation will be held to a series of increasing limits after the burner has lit.

BLR: SH 20% RATE OUT: 124.8F(129)

7. If the space heating call for heat is active, and the DHW thermostat closes, the control will turn on the DHW pump, wait 2 seconds, and then turn off the boiler pump. This will divert the hot water away from the heating zone(s) and send it to the DHW tank instead. The control will then modulate to maintain the outlet temperature to the DHW boiler set point.

BLR: DHW 85% RATE OUT: 177.8(180)

Sequence of operation

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11 Operating information

Sequence of operation (continued)

OPERATION DISPLAY

8. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 seconds, and resume modulating based on the space heating set point. As long as both the space heating and DHW calls for heat remain active, the control will switch back and forth between the two modes until one of them is satisfied.

BLR: SH 41% RATE OUT: 123.0F(129)

9. Once both calls for heat are satisfied, the control will turn off the burner. The blower will remain on for the 10 second postpurge cycle. Any pumps that are running will continue to run for their respective pump delay times, then turn off.

BLR: POSTPURGE OUT: 127.4F(129)

10. Boiler pump off, system pump continues its delay if longer.

BLR: Standby OUT: 124.7F(129)

11. System pump off.

BLR: Standby OUT: 122.9F(129)

Access modes

User

The user can adjust space heating target temperature by using the UP and DOWN buttons (FIG. 11-1 on page 57) 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, see the Knight Wall Mount Service Manual.

Saving parameters (reference the Parameter Table in

the Knight Wall Mount Service Manual)

To save parameters and exit programming:

Press the ENTER/RESET button.

To keep parameter settings only for a current operating cycle:

Press the MENU/EXIT button 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.

See the Knight Wall Mount Service Manual for a detailed description of parameters and access modes.

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Knight wall mount boiler control module

Figure 11-1 Control Panel

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

11 Operating information (continued)

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11 Operating information

Status Display Screens

By using the Previous/Next (, ) 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:

Screen Display shows: Description

BLR: OFF

The unit has been turned OFF by the Enter/Reset button on the SMART SYSTEM display panel.

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.

Set Point Met

The unit has met the water temperature set point, but is still receiving a call for heat from either a remote thermostat or a DHW thermostat.

Prepurge

The unit has initiated a 10 second purge period on a call for heat.

Ignition

The unit has begun a 5 second spark period to ignite the main burner.

SH***% Rate

The unit has fired and is running at the displayed percentage.

Postpurge

The call for heat has been satisfied and the unit runs the fan for an additional 10 seconds to clear the combustion chamber and vent system of residual flue products.

Service

The unit has been placed in a temporary mode that will allow the unit to fire at 100% of rate for the purpose of combustion analysis.

OUT: ***.*F(***)

When the outlet sensor has been selected as the control sensor (default), the control will display the outlet temperature as well as the set point in parenthesis.

***.*F

If the outlet sensor has not been selected as the control sensor, only 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: ***.*F

If the inlet sensor has not been selected as the control sensor, only the inlet temperature will be displayed.

***.*F (***)

When the inlet sensor has been selected as the control sensor, the control will display the inlet temperature as well as the set point in parenthesis.

Open

The control does not detect the inlet sensor.

Shorted

The inlet sensor wires or the sensor itself has become shorted.

RISE: ***.*F

The difference between the inlet temperature and the outlet temperature.

Press the Next  arrow key on the SMART SYSTEM display to access Screen #3.

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Status Display Screens (cont’d)

Screen Display shows: Description

SYS: ***.*F

If the system supply sensor has not been selected as the control sensor, only the system temperature will be displayed.

***.*F (***)

When the system supply sensor has been selected as the control sensor, 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.

Shorted

The system supply sensor wires or the sensor itself has become shorted.

OUTDOOR: ***.*F

The control will display the outdoor air temperature as sensed by the outdoor air sensor.

Open

The control does not detect the outdoor air sensor.

Shorted

The outdoor air sensor wires or the sensor itself has become shorted.

Press the Next  arrow key on the SMART SYSTEM display to access Screen #4.

FLUE: ***.*F

The control will display the flue temperature.

Open

The control does not detect the flue sensor.

Shorted

The flue sensor wires or the sensor itself has become shorted.

AUX: ***.*F

The control will display the temperature.

Open

The control does not detect the auxiliary sensor.

Shorted

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.

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.

SH CFH: OFF

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.

DHW CFH: OFF

The control has not received a call for heat from a SH remote thermostat.

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.

11 Operating information (continued)

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11 Operating information

Status Display Screens (cont’d)

Screen Display shows: Description

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 DHW pump.

Delay

The DHW call for heat has been satisfied and the DHW pump is running for a fixed time to remove any residual heat.

0-10V IN: **.Vdc

The control will display a 0-10Vdc signal received from a Building Management System (BMS) connected to the unit.

Press the Next  arrow key on the SMART SYSTEM display to access Screen #8.

SYS PUMP: OFF

The control has not received a call for heat from a remote thermostat and has not powered the system pump.

The control has received a call for heat from a remote thermostat and has powered the system pump.

Delay

The system call for heat has been satisfied and the system pump is running for a fixed time to remove any residual heat.

BLR PUMP: OFF

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 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 for heat.

Delay

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.

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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:

Screen Display shows: Description

Cas: Off

The Leader control has been turned off by the Enter/Reset button on the Smart System display.

Cas: Standby

The Leader boiler has not received a call for heat from a remote thermostat.

Cas: 127.4F (130)

The Cascade is now active. The system supply temperature will be displayed. The Cascade set point will be displayed in parenthesis.

Cas: Setpoint Met

The Cascade has met the water temperature set point, but is still receiving a call for heat from a remote thermostat.

Cas: No Members

The Leader control could not detect any Member controls to participate in the Cascade.

Cas: S6 Not Present The system supply sensor is not connected to the Leader boiler.

PMP: Off

The Leader control has not received a call for heat from a remote thermostat and has not powered the system pump.

PMP: On

The Leader control has received a call for heat from a remote thermostat and has powered the system pump.

PMP: Delay

The system call for heat has been satisfied and the system 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 #10.

#10

Cas Pow: ***% ***%

The first percentage shows the firing rate that is being sent to the last boiler called on. The second percentage shows the total power available to the Cascade.

Present: 01234567

Example: Present: 23----d1

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 place of a number, that boiler is either not connected, or in a lockout mode and not available for the Cascade. If a “d” is used in place of a number, that boiler is handling a DHW demand and is not available for 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  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.

11 Operating information (continued)

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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, gas, flue,

condensate)

• Verify flue and air lines in good condition

and sealed tight

• Check system water pressure/system

piping/expansion tank

• Check control settings

• Check ignition and flame sense

electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and

performance verification per Section 10 of this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high fire)

• Clean the heat exchanger if flue

temperature is more than 54°F above return water temperature.

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

ANNUAL START-UP

Owner maintenance

(see the Knight Wall Mount User’s Information

Manual for instructions)

Daily

• Check boiler area

• Check pressure/temperature gauge

Monthly

• Check vent piping

• Check air piping

• Check air and vent termination

screens

• Check relief valve

• Check condensate drain system

• Check automatic air vents

Periodically

• Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check boiler piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

• Shut boiler down (unless boiler used for domestic hot water)

12 Maintenance

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12 Maintenance (continued)

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual and the Knight Wall Mount Service Manual.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of the boiler.

2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.

Clean condensate trap

1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

2. Fill with fresh water until the water begins to pour out of the drain.

3. Replace the clean out cap and resume operation.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Check all piping for leaks

The condensate trap must be 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.

 WARNING

Figure 2-1 Condensate Trap

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Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold fill pressure for the system. Verify it is

correct (must be a minimum of 12 psi).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect automatic air vents and air separators. Remove

air vent caps and briefly press push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

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 and air eliminators.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify flow.

Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - Hydronic Piping before proceeding further.

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

2. After following the warning directions in this manual, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

 WARNING

12 Maintenance

Inspect ignition and flame sense electrodes

1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of the Knight Wall Mount Service Manual. Adjust settings if necessary. See Section 1 of the Knight Wall Mount Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Page 65

Installation & Operation Manual

12 Maintenance (continued)

Perform start-up and checks

1. Start boiler and perform checks and tests specified in Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 below.

4. When replacing the burner, ensure gasket is in good condition and positioned correctly (FIG. 12-2).

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 electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode.

3. See Section 3 - Troubleshooting of the Knight Wall

Mount Service Manual for other procedures to deal with low flame signal.

Review with owner

1. Review the Knight Wall Mount User’s Information

Manual with the owner.

2. Emphasize the need to perform the maintenance

schedule specified in the Knight Wall Mount User’s Information Manual (and in this manual as well).

Cleaning boiler heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup.

• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it has been firing.

3. Remove the blower assembly (gas air/arm) from the heat exchanger access cover. Set bolts aside.

4. Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

5. Remove the heat exchanger access cover, cover gasket(s) and chamber insulation assembly.

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 3 of this manual. Failure to comply could result in severe personal injury.

6. Use a vacuum cleaner to remove any accumulation on the

boiler heating surfaces. Do not use any solvent.

7. Finish cleaning using a clean cloth dampened with warm

water.

8. Install access cover gasket, chamber insulation assembly and

cover.

9. Secure nuts on the studs. DO NOT overtighten.

10. Re-install the blower assembly (gas air/arm) using the bolts

set aside in Step 3.

11. Close isolation valves on piping to isolate boiler from

system. Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler.

12. When the boiler has been flushed, restore boiler to

operation.

13. Perform start-up and check-out procedures in Section 10 -

Startup.

Oiled bearing circulators

1. The circulator shipped with the Knight wall mount boiler is water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

3. Replace the boiler front access cover.

 WARNING

3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Page 66

Installation & Operation Manual

13 Diagrams

Figure 13-1 Ladder Diagram

MODELS

ONLY

ALARM BELL

(AUX) DHW

EXTERNAL

CONTROL

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF SWITCH

JUNCTION

MANUAL RESET

INTERFACE

CN2-15

CN2-10

CN2-9

CN2-8

CN2-7

SILENCING SWITCH

SYSTEM SENSOR

TAN K

SENSOR

OUTDOOR

SENSOR

SHIELD

RS485

SHIELD

BOX

HIGH LIMIT

CONTACTS

X1-6

X1-8

X5-7

X6-7

X6-2

CN4-7

CN4-14

RUN-TIME

ALARM

INTEGRATED CONTROL

1.25A

3.5A

CONNECTION

X5-14

DISPLAY

0-10V

3.5A

120 VAC

24 VAC

BOARD

CN2-9

CN2-2

CN2-4

INTEGRATED

CONTROL

INLET

SENSOR

OUTLET SENSOR

FLUE

SENSOR

CONNECTION BOARD

CN2-6

CN2-5

CN2-8

CN2-7

CN1-12

CN1-11

CN1-10

CN1-9

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN1-1

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

BLOWER

RELAY

CN5-1

FLOW

SWITCH

ROOM THERMOSTAT

ZONE CONTROL

DHW

THE RMO STAT

CN4-9X6-4

RIBBON CABLE

X1-2

X1-4

X1-3

X1-1

X1-5

X6-8

X6-3

CN4-11

CN4-12

CN4-10

CN4-4

CN3-8

CN3-7

CN3-9

CN3-6

CN3-5

CN3-2

CN3-1

CN3-3

CN3-10

CN3-4

JUNCTION BOX

SYSTEM

PUMP "L"

BOILER

PUMP "L"

DHW

PUMP "L"

TERMINAL

STRIP

CONNECTION

BOARD

CN2-10

CONNECTION

BOARD

CN2-12

X5-8

X5-1

X5-2

X5-9

X3-1

X3-3

X3-4

X3-2

X4-8

X4-7

X4-9

X4-6

X4-5

X4-2

X4-1

X4-3

X4-10

X4-4

RESISTOR

CN5-3

INTEGRATED

CONTROL

SYSTEM

PUMP

BOILER

PUMP

DHW PUMP

PRESSURE

LOW GAS

SWITCH

TERMINAL STRIP 120V SUPPLY "N"

GND

SYSTEM

PUMP "N"

GND

BOILER

PUMP "N"

GND

DHW

PUMP "N"

TERMINAL

STRIP

BLOWER

JUNCTION BOX

CN4-1

CN5-2

LWCO

CN5-4

HIGH GAS

PRESSURE

SWITCH

AUX. DEVICE

PILOT SUPPLY

24VAC

AUX. DEVICE

PROVING

BLOCKED

SWITCH

AUTO RESET

HI-LIMIT

GAS VALVE

NEUTRAL

CONNECTION BOARD

DRAIN

BLOWER

SPARK

ROD

CN2-1

CN2-3

CN2-11

CN2-16

CN2-15

CN2-14

CN2-13

AIR PRESSURE

SWITCH

GROUND

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

CN4-6

X6-9

CN4-13

X6-6

CN4-5

X6-1

CN4-3

X6-5

CN4-2

X6-10

X5-11

X5-4

X5-3

X5-10

X2-2

X2-1

X5-5

X5-13

X5-6

X5-12

TR1

X1-7

FLAME ROD

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possible, switches are shown wit hout utilities (gas, water or electricity) connected t o the unit. As such, actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present.

2. See wiring diagram for addi tional notes.

INTEGRATED

CONTROL

GAS VALVE

RELAY

LADDER DIAGRAM LBL7083 REV G

Page 67

Installation & Operation Manual

Figure 13-2 Wiring Diagram

13 Diagrams (continued)

ALARM BELL

SILENCING SWITCH

INTERFACE

AUX.

DEVICE

PILOT

SUPPLY

AUX.

DEVICE

PROVING

GAS

PRESSURE

SWITCH

FLOW

SWITCH

BELL JUMPER

ALARM

CONTACTS

RUN-TIME

CONTACTS

DHW

THERMOSTAT

ROOM

THERMOSTAT

ZONE

CONTROL

LOW

WATER

CUT-OFF

SYSTEM

SENSOR

(AUX) DHW

TAN K

SENSOR

OUTDOOR

SENSOR

SHIELD

RS485

SHIELD

EXTERNAL

CONTROL

DISPLAY

24 VAC

COM

0-10V

CONNECTION BOARD

CN2-16

CN2-15

CN2-14

CN2-13

CN2-12

CN2-11

CN2-10

CN2-9

CN2-8

CN2-7

CN2-6

CN2-5

CN2-4

CN2-3

CN2-2

CN2-1

CN5-1

CN5-3

CN5-4

CN5-2

CN5

CN1-12

CN1-11

CN1-10

CN1-9

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN1-1

CN2

CN1

CN4-8

CN4-2

CN4-9

CN4-3

CN4-10

CN4-4

CN4-11

CN4-12

CN4-5

CN4-7

CN4-13

CN4-14

CN4-6

CN4-1

CN4

CN3

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

INTEGRATED CONTROL

X1-3

X1-5

X1-4

X1-2

X1-6

X1-8

X1-1

X5-5

X5-13

X5-6

X5-12

X5-7

X5-14

X5-11

X5-3

X5-4

X5-10

X5-8

X5-1

X5-2

X5-9

X2-2

X2-1

X1-7

TR1

X6-8

X6-10

X6-4

X6-5

RESISTOR

X3-4

X3-2

X3-1

X3-3

X6-1

X6-2

X6-6

X6-9

X6-3

BLOWER

OR/BK

W/R

ON/OFF

SWITCH

MODELS

ONLY

245

FLAME ROD

SPARK

ROD

WARNING

DISCONNECT POWER

BEFORE SERVICING

JUNCTION

BOX

GND

TERMINAL STRIP

GAS VALV E

MANUAL RESET HI-LIMIT

AIR PRESSURE SWITCH

BLOCKED DRAIN

AUTO RESET HI-LIMIT

BOX DEPICTS

OPTIONAL ITEMS

DHW PUMP

BOILER PUMP

SYSTEM PUMP

120V

GND

SUPPLY

INLET SENSOR

OUTLET SENSOR

FLUE SENSOR

Notes:

CAUTION HIGH VOLTAGE SPARK LEAD

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

lead and ribbon cables must be purchased from the factory. Use

of a non-approved spark lead

WIRING DIAGRAM LBL7082 REV E

Page 68

Revision B (WB-I&O-Rev B) reflects changes made to the ratings page.

Revision C (WB-I&O-Rev C) reflects changes made to the orifice on Models 150 and 210.

Revision D (ECO #C02407) reflects the addition of air inlet pipe materials, Maintenance Section, high altitude, air pressure switch, new condensate trap image and the addition of the new vent termination.

Revision E (ECO #C02545) reflects the addition of references to the safety shutoff testing and instructions, sediment trap, periodic cleaning of screens in vent terminations, wall thickness for direct vent terminations, removal of B149.2 references, approval of the 2" and 3" concentric vent kits for ULC-S636 and sidewall vent termination kit number correction.

Revision F (ECO #C03223) reflects edits made to the high altitude section on page 6.

WB-I-O Rev F

3/09

Lochinvar 50-210 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual