Lochinvar KBN080 Installation Manual

Installation & Operation Manual

Models: 80 - 285

Starting Serial #H07H10040039

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Boiler 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.

KB-I-O-16

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 BOILER -- HOW IT WORKS . . . . . . . . . . . 4-6

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. DETERMINE BOILER LOCATION

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10

Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10

Residential Garage Installation . . . . . . . . . . . . . . . . . . . . 10

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prevent Combustion Air Contamination . . . . . . . . . . . . . . 10

Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11

Using an Existing Vent System to Install a New Boiler . . 11

Removing a Boiler from Existing Common Vent . . . . . . . 12

2. PREPARE BOILER

Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . 13

Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Leveling the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 16

PVC/CPVC Vent and Air Piping Materials . . . . . . . . . 16

Requirements for Installation in Canada . . . . . . . . . . . . . 16

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

PVC/CPVC Air Intake/Vent Connections . . . . . . . . . . . . . 18

Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Stainless Steel Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Stainless Steel Air Intake/Vent Connections . . . . . . . . . . 19

Min./Max. Combustion Air & Vent Piping Lengths . . . . . . 19

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Optional Room Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 21-24

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23

Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 23

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

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

Sidewall Termination - Optional Concentric Vent . . . . . . 25-27

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 28-29

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 29

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 29

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 29

Vertical Termination - Optional Concentric Vent . . . . . . . 30-31

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 32

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 32

Relief Valve / T & P Installation . . . . . . . . . . . . . . . . . . . . 32-33

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 33

Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 35

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 42

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 43

Natural Gas Supply Pressure Requirements . . . . . . . 43

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 43

Propane Supply Pressure Requirements . . . . . . . . . . 43

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 45

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 46

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 47

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-56

11. OPERATING INFORMATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-60

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 61-62

Knight Boiler Control Module . . . . . . . . . . . . . . . . . . . . . . 63-64

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 65-68

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 69-73

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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

Contents

Installation & Operation Manual

Please read before proceeding

Installer – Read all instructions, including this manual and the Knight Boiler 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

Installation & Operation Manual

The Knight 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

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)

NPT water connection that supplies hot water to the system, either 1" or 1-1/4", depending on the model.

14. Water inlet (system return)

NPT water connection that returns water from the system to the heat exchanger, either 1" or 1-1/4", depending on the model.

15. Gas connection pipe

Threaded pipe connection, either 1/2" or 3/4", depending on the model. 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. Automatic air vent

Designed to remove trapped air from the heat exchanger coils.

18. Air intake adapter

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

19. High voltage junction box

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

20. Boiler drain port

Location from which the heat exchanger can be drained.

21. Low voltage connection board

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

22. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

23. Condensate drain connection

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

24. Access cover - front

Provides access to the gas train and the heat exchanger.

25. Ignition electrode

Provides direct spark for igniting the burner.

26. Flame inspection window

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

27. Gas shutoff valve

Manual valve used to isolate the gas valve from the gas supply.

28. High limit sensor

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

29. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve may be set at 30 psi.

30. Flame sensor

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

31. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

32. Top panel

Removable panel to gain access to the internal components.

33. Power switch

Turns 120 VAC ON/OFF to the boiler.

34. Leveling legs

Used to allow the heat exchanger to be leveled. This is needed for the proper draining of the condensate from the combustion chamber.

35. Air pressure switch

The air pressure switch detects blocked inlet conditions.

Installation & Operation Manual

Front View - Models 80 - 210

Left Side (inside unit) - Models 80 - 210

Right Side (inside unit) - Models 80 - 210

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

Rear View - Models 80 - 210

Models 80 - 210

4 5

Installation & Operation Manual

The Knight Boiler - How it works...

Model 285

Left Side (inside unit) - Model 285

Right Side (inside unit) - Model 285

Front View - Model 285

Rear View - Model 285

4 5

Installation & Operation Manual

Ratings

Notes:

1. As an Energy Star Partner, Lochinvar has determined that Knight 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 boilers require special gas venting. Use only the vent materials and methods specified in the Knight Installation and Operation Manual.

5. Standard Knight 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 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.

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

Maximum allowed working pressure is located on the rating plate.

NOTICE

Knight Boiler

I=B=R Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Input MBH

(Note 5)

Min Max

Gross

Output

MBH

(Note 2,7)

Net

I=B=R

Ratings

Water,

MBH

(Note 3,7)

KBN080 16 80 72 63

KBN105 21 105 94 82

KBN150 30 150 135 117

KBN210 42 210 190 165

KBN285 57 285 260 226

Other Specifications

Boiler

Water Content Gallons

Water

Connections

Gas

Connections

Air

Size

Vent

Size

(Note 4)

0.6 1" 1/2" 3" 3"

0.7 1" 1/2" 3" 3"

1.3 1" 1/2" 3" 3"

1.7 1" 1/2" 3" 3"

2.4 1-1/4" 3/4" 4" 4"

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

3,000 FT. TO 12,000 FT.

HIGH ALTITUDE

Installation & Operation Manual

The Knight 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 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 9 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 9 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 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. 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.

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

 WARNING

NOTICE

 WARNING

1 Determine boiler location

A closet is any room the boiler is installed in which is less than 67 cubic feet for KBN080 and KBN105 models, 86 cubic feet for KBN150 models, 107 cubic feet for KBN210 models, and 120 cubic feet for KBN285 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, 3 feet wide, and 8 foot ceiling = 4 x 3 x 8 = 96 cubic feet. This would be considered a closet for a Knight Boiler.

Installation & Operation Manual

1 Determine boiler location (continued)

RECOMMENDED SERVICE CLEARANCES:

FRONT - 24” TOP - 24” LEFT SIDE - 24” REAR - 24”

Figure 1-2 Alcove Installation - Minimum Required Clearances

Figure 1-1 Closet Installation - Minimum Required Clearances

 WARNING

For closet installations, CPVC or stainless steel 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.

 WARNING

For alcove installations, CPVC or stainless steel 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.

RECOMMENDED SERVICE CLEARANCES:

FRONT - 24” TOP - 24” LEFT SIDE - 24” REAR - 24”

Installation & Operation Manual

1 Determine boiler location

Provide air openings to room:

Knight boiler alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the Knight 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 boiler in same space with other gas or oilfired 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 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 boiler because it takes its combustion air from outside (direct vent installation).

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

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

Flooring and foundation

Flooring

The Knight boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

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 boiler requires a special vent system, designed for pressurized venting.

The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 3, General Venting. 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, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight 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 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 11 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 11. 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

Installation & Operation Manual

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

1 Determine boiler location (continued)

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

 WARNING

When using an existing vent system to install a new boiler:

Check the following venting components before installing:

•Material- For materials listed for use with this appliance, see Section 3 - General Venting, Table 3A. For stainless steel venting, an adapter of the same manufacturer (Table 3B) must be used at the flue collar connection.

•Size- To ensure proper pipe size is in place, see Table 3C. Check to see that this size is used throughout the vent system.

• Manufacturer - For a stainless steel application, you must use only the listed manufacturers and their type product listed in Table 3A for CAT IV positive pressure venting with flue producing condensate.

•Supports- Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

• Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3B for the manufacturer of the installed vent.

•Seal- With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 12.

With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 16.

 WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

1 Determine boiler location

Installation & Operation Manual

When removing a boiler from existing common vent system:

Do not install the Knight 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.

 DANGER

 WARNING

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.

Installation & Operation Manual

2 Prepare boiler

Figure 2-2 Installing Propane Orifice

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler, remove the parts box.

2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1).

3. To remove the boiler from the pallet (after removing the front door):

a. Remove the two lag bolts from the wood pallet

inside the boiler (FIG. 2-1).

b. Detach the boiler from the lag bolts in the rear of the

unit, see FIG. 2-1.

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

For a boiler already installed, you must turn off gas supply, turn off power and allow 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. Failure to comply could result in severe personal injury, death, or substantial property damage.

You must install a propane orifice to operate the Knight boiler on propane gas. Verify when installing that the orifice size marking matches boiler size (Table 2A).

5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

6. Replace the top and front access covers.

Figure 2-1 Boiler Mounted on Shipping Pallet

Gas conversions

NOTICE

 WARNING

Figure 2-3 Leveling Legs on the Boiler

Leveling the boiler

1. Set the boiler in place and check level. a) Adjust legs if necessary to level boiler, see FIG. 2-3

below.

 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.

LP Conversion Table

Model LP Orifice Stamping

105

150

210

210 / W150

285

Table 2A LP Conversion Table

1. Remove the top and front access covers from the unit (no tools required for removal).

2. Remove the three screws securing the gas valve to the venturi (FIG. 2-2).

3. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size (see Table 2A).

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

4. Reposition the gas valve against the venturi and replace the screws (FIG. 2-2) securing the valve to the venturi.

Installation & Operation Manual

3 General venting

Figure 3-1 PVC/CPVC Two-Pipe Sidewall Termination - See page 21 for more details

Figure 3-3 PVC/CPVC Concentric Sidewall Termination - See page 25 for more details

Direct venting options - Sidewall Vent

Figure 3-2 Stainless Steel Two-Pipe - See page 22 for more details

Installation & Operation Manual

Figure 3-5 Stainless Steel Two-

Pipe Vertical Termination - See page 28 for more details

Figure 3-6 PVC/CPVC Concentric Vertical Termination - See page 30 for more details

Figure 3-8 Stainless Steel Vertical Vent, Sidewall Air

- See page 20 for more details

Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 28 for more details

Direct venting options - Vertical Vent

Direct venting options - Vertical Vent, Sidewall Air

Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air See page 20 for more details

3 General venting (continued)

Stainless steel vent/air design and terminations will vary slightly by manufacturer.

NOTICE

Installation & Operation Manual

3 General venting

PVC/CPVC vent piping materials

Use only the materials listed in Table 3A 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.

Install vent and combustion air piping

 DANGER

The Knight 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 PVC 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).

 WARNING

NOTICE

 WARNING

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

NOTICE

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. For concentric vent installations, the inner vent tube must be replaced with field supplied certifiedvent material to comply with this requirement.

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

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 if PVC/CPVC vent is to be used. For stainless steel venting use an adapter from Table 3B (pg. 19) that corresponds with the intended vent manufacturer to be used and discard the CPVC starter piece. 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.

Installing vent and air piping

Improper installation of PVC or CPVC systems may result in injury or death.

 CAUTION

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

NOTICE

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.

Installation & Operation Manual

Table 3A Vent Pipe, and Fittings

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 40/80 ANSI/ASTM F441

AL29-4C UL1738 ULC-S636

Pipe cement/primer

PVC ANSI/ASTM D2564

IPEX System 636

Cements & Primers

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Approved Stainless Steel Vent Manufacturers

Make Model

ProTech Systems (Simpson Dura-Vent Co.) FasNSeal Vent / FasNSeal Flex* Vent

Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent

contamination of surfaces.

b. Apply a liberal even coat of primer to the fitting

socket.

c. Apply a liberal even coat of primer to the pipe end to

approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fitting socket. e. While primer is still wet, apply an even coat of

approved cement to the pipe equal to the depth of

the fitting socket.

f. While primer is still wet, apply an even coat of

approved cement to the fitting socket. g. Apply a second coat of cement to the pipe. h. While the cement is still wet, insert the pipe into the

fitting, if possible twist the pipe a 1/4 turn as you insert

it. NOTE: If voids are present, sufficient cement was

not applied and joint could be defective. i. Wipe excess cement from the joint removing ring or

beads as it will needlessly soften the pipe.

3 General venting (continued)

PVC/CPVC air intake/vent connections

1. Combustion Air Intake Connector (FIG.’s 3-9 and 3-10) - 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.’s 3-9 and 3-10) - 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.

Figure 3-9 Near Boiler PVC/CPVC Venting Models 80 - 210

Figure 3-10 Near Boiler PVC/CPVC Venting Model 285

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.

AIR

VENT

3” CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

4” CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Installation & Operation Manual

3 General venting

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. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

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

 WARNING

Using vent or air intake materials other than those specified, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.

NOTICE

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either

Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of

horizontal runs.

c. Secure all joints with a minimum of three sheet metal

screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

d. Ensure that the air inlet pipes are properly supported.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

Stainless steel vent

This product has been approved for use with stainless steel using the manufacturers listed in Table 3A.

Use only the materials, vent systems, and terminations listed in Table 3B. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

NOTICE

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

NOTICE

The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3B for approved vent adapters. Discard CPVC starter piece.

NOTICE

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

 DANGER

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

Installation & Operation Manual

Figure 3-11 Near Boiler Stainless Steel Venting Model 285

Stainless steel air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-11) - 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. 3-11) - 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.

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

Model Air Intake Vent

80 - 210 3 inches 3 inches

285 4 inches 4 inches

Table 3C Air Intake/Vent Piping Sizes

Increasing or decreasing combustion air or vent piping is not authorized.

NOTICE

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

Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum

Ve n t = 12 equivalent feet minimum / 100 equivalent feet maximum

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

NOTICE

3 General venting (continued)

Table 3B Approved Stainless Steel Terminations and Adapters

Model

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Boiler

Adapter

Flue

Termination

Intake

Air

Termination

Boiler

Adapter

Intermediate

Adapter

Flue

Termination

Intake

Air

Termination

Boiler

Adapter

Flue

Termination

Intake Air

Termination

80 - 210

300715

FSBS3

FSRC3(R.C)

303889 KB80210 9353BUREZ-1*

9392

5300CI

9314TERM 2SVSLA03

2SVSTP03

2SVSRCX03

2SVSTEX0390

285

F303759

FSBS4

FSRC4(R.C.)

FSAIH04

303888

KB285600 9454BUREZ-1*

9492

5400CI

9414TERM 2SVSLA04

2SVSTP04

2SVSRCX04

2SVSTEX0490

* = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-11, unless approved vent other than standard diameter is used. Consult a Heat Fab representative for questions.

3" S.S. ADAPTER

3" S.S. INTERMEDIATE (FOR SAF-T VENT ONLY)

Installation & Operation Manual

3 General venting

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 11, 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 11 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 12 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 boiler using any other means.

NOTICE

 WARNING

Model Kit Number

Equivalent Vent

Length

80 - 210 CVK3003 3 feet

285 CVK3007 3 feet

Table 3D Concentric Vent Kit Equivalent Vent Lengths

Vent, air piping and termination:

The Knight 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.

Optional room air

 WARNING

When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

• There will be a noticeable increase in the noise level during normal operation from the inlet air opening.

• Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.

• Vent system and terminations must comply with the standard venting instructions set forth in this manual.

Model Kit Number

80 - 210 KIT30052

285 KIT30053

Table 3E Optional Room Air Kit

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

Commercial applications utilizing the Knight boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

• The unit MUST be installed with the appropriate room air kit (Table 3E).

• The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.

NOTICE

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

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.

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 19 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 PVC/CPVC Sidewall Termination of Air and Vent w/Field Supplied Fittings

 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

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

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.

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.

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 PVC/CPVC Sidewall Termination of Air and Vent

Model Kit Number Vent Size

80 - 210 KIT30045 3 inch vent

285 KIT30046 4 inch vent

Table 4A Sidewall Vent Kits

Installation & Operation Manual

Vent/air termination – sidewall

4 Sidewall direct venting

Figure 4-1C Alternate PVC/CPVC 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

BIRD

SCREEN

(TYPICAL)

12”

MIN.

12”

MIN.

12”

MIN.

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

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 21 and 23. 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; and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG. 4-1B.

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.

Figure 4-1D Alternate PVC/CPVC/SS Venting Arrangement - Typical Stainless Steel Sidewall Termination of Air and Vent w/Field Supplied Fittings, Utilizing 90° Elbow Intake

Figure 4-1E Alternate SS Venting Arrangement Typical Stainless Steel Sidewall Termination of Air and Vent w/Field Supplied Fittings, Utilizing FasNSeal’s Hood Intake

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

TO BOILER INTAKE AIR CONNECTION

FROM BOILER VENT PIPE CONNECTION

12" MIN

BIRD SCREEN

MODELS 80 - 285

12" MIN

15" MAX

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

MODEL 285 WITH FASNSEAL ONLY

12" (305 MM) MIN

Installation & Operation Manual

Figure 4-3A Clearance to Forced Air Inlets

4 Sidewall direct venting (continued)

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:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 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

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:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 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 17 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.

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

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.

IF LESS

THAN 10’

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

36"

MIN.

FORCED AIR

INLET

IF LESS THAN 10’

36”

MIN.

FORCED AIR

INLET

BIRD

SCREEN

7’ MIN. ABOVE ANY

PUBLIC WALKWAY

(TYPICAL)

AIR PIPING

VENT PIPING

WALL PLATE

GALVANIZED

THIMBLE

VENT PLATE

VENT CAP

ELBOW

AIR PIPING

VENT PIPING

BIRD SCREEN

GALVANIZED THIMBLE

SIDEWALL TERMINATION PLATE

ELBOW

BIRD SCREEN

Installation & Operation Manual

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)

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 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 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

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

4 Sidewall direct venting

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 21.

2. Maintain the required dimensions of the finished

termination piping as shown in FIG. 4-1A, page 21.

3. If using the alternate sidewall termination do not extend

exposed vent pipe outside of the building more than what is 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.

5. Stainless steel terminations are designed to penetrate

walls with a thickness up to 9.25 inches of standard construction.

Installation & Operation Manual

4 Sidewall direct venting (continued)

Figure 4-7 Kit Contents_CVK3003

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 19 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.

Figure 4-8 Kit Contents_CVK3007

e. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent condensate damage

to exterior finishes.

4. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 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.’s 4-7 and 4-8).

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

(FIG.’s 4-7 and 4-8).

Sidewall termination – optional concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3" diameter

- Models 80 - 210 and #CVK3007 for 4" diameter - Model

285). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as shown below in FIG. 4-6.

The required combustion air and vent pipe materials are listed in Table 3A, on page 17 of this manual.

Figure 4-6 Concentric Sidewall Termination

4" DIA.

SDR-26 PIPE

"Y" CONCENTRIC FITTING

6" (152 MM) TO 4" (102 MM) REDUCER

6" (152 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

"FLEXIBLE" PIPE COUPLING

RAIN CAP

2 1/2" DIA. SDR-26 PIPE

RAIN CAP

6" (152 MM) DIA.

4" (102 MM) DIA.

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Figure 4-9 Concentric Vent Dimensional Drawing Models 80 - 210

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. 4-11).

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 4-11 Rain Cap to Vent Pipe Alternate Assembly

6. Install the Y concentric fitting and pipe assembly through the structure’s hole from an inside wall.

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 from an outside wall. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for #CVK3003 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

8. Secure the assembly to the structure as shown in FIG. 4-12 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, field-supplied SDR-26 PVC (D2241) pipe for CVK3003 and standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 4-9 and 4-10).

NOTICE

 WARNING

NOTICE

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

NOTICE

"B" DIA. PVC VENT / EXHAUST

"A"

"H" DIA.

"D"

"E"

"F"

"G"

(76 MM)

"C" DIA.

"B" DIA.

Figure 4-10 Concentric Vent Dimensional Drawing Model 285

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. 4-13). 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. 4-13. 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. 4-13 represents the distance between pipes or rain shields, as touching or a 2 inch maximum separation.

Figure 4-13 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation

Figure 4-12 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. 4-12 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

Note: CVK3003 shown for illustration purposes.

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 19 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. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. 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 (.6 m) apart and with the vent termination at least 1 foot above the air intake.

Figure 5-1A PVC/CPVC 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, unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent, Sidewall Air Section.

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT

COM,BUSTION AIR

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” (610 MM) OF VENT PIPE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

BIRD SCREEN

(TYPICAL)

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” OF VENT PIPE

BIRD SCREEN (TYPICAL)

VENT

COUPLING (FIELD SUPPLIED)

VENT OUTLET 12” MINIMUM ABOVE AIR INLET

COMBUSTION

AIR

6” MINIMUM ABOVE ROOF / SNOW LINE

Installation & Operation Manual

5 Vertical direct venting (continued)

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:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 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. 5-1A, page 28.

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. Prepare the vent termination coupling and the air

termination elbow (FIG. 5-1A) by inserting bird screens. Bird screens should be obtained locally.

2. The air piping must terminate in a down-turned 180° return bend as shown in FIG. 5-1A. 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. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. 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. 5-1A.

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 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 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

Installation & Operation Manual

5 Vertical direct venting

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 vent pipe and fittings are listed in Table 3A, on page 17 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).

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. 4-11, page 26).

2. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

3. 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.’s 4-7 and 4-8, page 25).

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

FIG.’s 4-7 and 4-8, page 25).

Figure 5-4 Concentric Vertical Termination

NOTICE

 WARNING

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

Installation & Operation Manual

5 Vertical direct venting (continued)

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 30.

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 for CVK3003 and standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 4-9 and 4-10, page 26).

CAUTION

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

6. 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 for #CVK3003 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

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

8. 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) 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)

4. Install the Y concentric fitting pipe assembly up 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.

5. 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

Note: CVK3003 shown for illustration purposes.

Installation & Operation Manual

6 Hydronic piping

System water piping methods

The Knight 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.

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”). 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 6-4 thru 6-9 for suggested guidelines in piping the Knight 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

General piping information

Basic steps are listed in this section along with illustrations on the following pages (FIG.’s 6-4 thru 6-9), which will guide you through the installation of the Knight boiler (reference FIG.’s 6-2A and 6-2B).

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.

Relief valve and temperature and pressure gauge installation

Basic steps are listed below to guide you through the installation of the relief valve and the temperature and pressure (T & P) gauge provided with the unit.

1. Install the tee with the 3/4 inch fitting positioned vertically and on the top as shown in FIG. 6-1.

2. Install the relief valve into the 3/4 inch fitting of the tee installed in Step 1 (FIG. 6-1).

3. Install a field provided close nipple and tee with the fitting positioned vertically on the top on the downstream side of the relief valve (see FIG. 6-1).

4. Install the temperature and pressure gauge provided with the unit into the top fitting of the tee (a bushing may be necessary) installed in Step 3 (FIG. 6-1).

 WARNING

The relief valve, tee and any necessary

fittings are shipped in the install kit with the boiler and are to be field installed (FIG. 6-1).

Installation & Operation Manual

6 Hydronic piping (continued)

Circulator sizing

The Knight boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 6-3 for pressure drop through the Knight boiler heat exchanger.

Figure 6-2A Near Boiler Piping w/Y-Strainer

Figure 6-1 Relief Valve / T & P Installation

Figure 6-2B Near Boiler Piping w/Low Loss Header

RELIEF VALVE

TEMPERATURE AND

PRESSURE

GAUGE

TEE WITH FITTING ON TOP

(FIELD PROVIDED)

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 3/4” FITTING ON TOP

CLOSE NIPPLE

DOMESTIC HOT

SYSTEM

PUMP

BOILER

PUMP

Y-STRAINER (RECOMMENDED)

DRAIN

(TYPICAL)

TO FLOOR

DRAIN

WATER PUMP

INDIRECT

DOMESTIC

HOT WATER

TAN K

AIR VENT VALVE

LOW LOSS HEADER (TYPICAL)

Y-STRAINER (RECOMMENDED)

SYSTEM SENSOR

AIR SEPARATOR

DRAIN (TYPICAL)

DRAIN VALVE

FILL VALVE

INDIRECT

DOMESTIC

HOT WATER

EXPANSION TANK

TO FLOOR DRAIN

Installation & Operation Manual

6 Hydronic piping

3 4 5 6 7 8 9 10111213141516171819202122232425

105

150

210

285

Flow Rate (GPM)

Pressure Drop vs. Flow (Includes Secondary Piping)

Pressure Drop (Feet of Head)

Figure 6-3 Pressure Drop vs. Flow

20°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

80 7.5 24 1"

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 285 26.5 15 1-1/4" UPS32-80 1400-20 PL-36 E11

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

80 5.9 15.0 1" UPS15-58FC 0014 NRF-36 E7

105 7.7 17.5 1"

UPS26-99F

0014 NRF-36 E7

150 11.0 12.8 1"

UPS26-99F

0014 NRF-36 E7

210 15.5 19.0 1"

UPS26-99F

0013 NRF-36 E7

285 21.0 11.5 1-1/4"

UPS26-99F

0011 NRF-36 E7

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

NOTICE

35°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

80 4.2 7.3 1" UPS15-58FC 007 NRF-22 Astro-30 105 5.5 9.3 1" UPS15-58FC 007 NRF-22 Astro-30 150 7.9 9.5 1" UPS15-58FC 008/0010 NRF-36 Astro-30 210 11.0 9.1 1" UPS15-58FC 0010 NRF-36 Astro-50 285 15.0 7.3 1-1/4" UP26-64F 008/0010 NRF-36 E7

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

Installation & Operation Manual

6 Hydronic piping (continued)

It is required that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 6-4 thru 6-9 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance.

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. 6-3. 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 6-4 thru 6-9. 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 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 pages 36 thru 41, 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 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.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems.

Installation & Operation Manual

6 Hydronic piping

Figure 6-4 Single Boiler Zoned with Circulators

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.

NOTICE

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

PRESSURE

GAUGE

SYSTEM SUPPLY

SENSOR

(WHEN USED)

ZONE #2

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

BOILER CIRCULATOR

ZONE #3

DOMESTIC

HOT WATER

CIRCULATOR

ZONE #4

FLOW CHECK

ZONE CIRCULATORS

ANTI-SCALD

MIXING VALVE

VALVE

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

Y-STRAINER (RECOMMENDED)

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

PRESSURE

RELIEF VALVE

BOILER

INDIRECT

DHW TANK

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-5 Multiple Boilers Zoned with Circulators

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

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" 3-1/2" 210 2" 2-1/2" 3" 3" 3-1/2" 4" 4" 285 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 5"

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.

NOTICE

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

AIR SEPARATOR

SYSTEM SUPPLY

PRESSURE

GAUGE

SENSOR

(WHEN USED)

EXPANSION

TANK

ZONE #2

ZONE #3

ZONE #4

FLOW CHECK

VALVE

(TYPICAL)

ZONE CIRCULATORS

(TYPICAL)

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

MAY SUBSTITUTE LOW LOSS HEADER

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

BOILER CIRCULATOR

DRAIN

PRESSURE

RELIEF VALVE

Y-STRAINER (RECOMMENDED)

HOT WATER

CIRCULATOR

BOILER

DOMESTIC

ANTI-SCALD

MIXING VALVE

INDIRECT

DHW TANK

HOT

WATER

OUT

COLD

WATER

Installation & Operation Manual

6 Hydronic piping

Figure 6-6 Single Boiler Zoned with Valves

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.

NOTICE

PRESSURE

REDUCING VALVE

PRESSURE

BACKFLOW

PREVENTER

GAUGE

ZONE #1

ZONE #2

ZONE #4

ZONE #3

ZONE #4

ZONE VALVES

(TYPICAL)

MAKE UP WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

SYSTEM SUPPLY

SENSOR

(WHEN USED)

SYSTEM

CIRCULATOR

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

BOILER CIRCULATOR

FLOW CHECK

VALVE

Y-STRAINER (RECOMMENDED)

DOMESTIC

HOT WATER

CIRCULATOR

DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

HOT

WATER

OUT

ANTI-SCALD

MIXING VALVE

COLD

WATER

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

PRESSURE

RELIEF VALVE

BOILER

INDIRECT

DHW TANK

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-7 Multiple Boilers Zoned with Valves

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

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" 3-1/2" 210 2" 2-1/2" 3" 3" 3-1/2" 4" 4" 285 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 5"

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.

NOTICE

ZONE #1

PRESSURE

BACKFLOW

PREVENTER

BALL VALVE

(TYPICAL)

REDUCING VALVE

PRESSURE

GAUGE

ZONE #2

ZONE #3

ZONE #4

ZONE VALVES

(TYPICAL)

MAKE UP WATER

AIR SEPARATOR

SYSTEM SUPPLY

(WHEN USED)

DRAIN POINT

(TYPICAL)

SENSOR

SYSTEM

CIRCULATOR

EXPANSION

TANK

DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

MAY SUBSTITUTE LOW LOSS HEADER

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

BOILER CIRCULATOR

Y-STRAINER (RECOMMENDED) (TYPICAL)

ANTI-SCALD

MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

HOT

WATER

OUT

COLD

WATER

TEMPERATURE /

UNION

(TYPICAL)

PRESSURE

GAUGE

BOILER 2

(MEMBER 1)

DRAIN

PRESSURE

RELIEF VALVE

BOILER 1

(LEADER)

INDIRECT

DHW TANK

Installation & Operation Manual

6 Hydronic piping

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

FROM

SYSTEM

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

BOILER CIRCULATOR

SYSTEM

CIRCULATOR

SYSTEM

SYSTEM SUPPLY SENSOR

DRAIN

Y-STRAINER (RECOMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

HOT

WATER

OUT

Figure 6-8 Single Boiler - Non-Zoned Primary/Secondary Piping

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.

NOTICE

Installation & Operation Manual

6 Hydronic piping (continued)

BOILER 1

(LEADER)

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

FROM

SYSTEM

BOILER CIRCULATOR

SYSTEM

BOILER 2

(MEMBER 1)

BOILER CIRCULATOR

BOILER 3

(MEMBER 2)

BOILER 4

(MEMBER 3)

SYSTEM SUPPLY SENSOR

DRAIN

SYSTEM

CIRCULATOR

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

Y-STRAINER

(RECOMMENDED)

(TYPICAL)

MAY SUBSTITUTE LOW LOSS HEADER

HOT

WATER

OUT

Figure 6-9 Multiple Boilers - Non-Zoned Primary/Secondary Piping

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

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" 3-1/2" 210 2" 2-1/2" 3" 3" 3-1/2" 4" 4" 285 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 5"

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.

NOTICE

Installation & Operation Manual

7 Gas connections

Connecting gas supply piping

1. Remove the top access panel and refer to FIG.’s 7-1 and 7-2 to pipe gas to the boiler. a. Install ground joint union for servicing, when

required.

b. Install a manual shutoff valve in the gas supply

piping outside boiler jacket when required by local codes or utility requirements.

c. In Canada – When using manual main shutoff

valves, it must be identified by the installer.

2. Install sediment trap / drip leg.

Figure 7-1 Gas Supply Piping - Models 80 - 210

3. 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.

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. The appliance must be disconnected from the gas

supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply

piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak

tested before placing it in operation.

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

6. 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

Figure 7-2 Gas Supply Piping - Model 285

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

Knight 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 13). 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.

 WARNING

SEDIMENT TRAP / DRIP LEG

Installation & Operation Manual

7 Gas connections (continued)

Use two wrenches when tightening gas piping at boiler (FIG. 7-3), 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 7-3 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.

Installation & Operation Manual

7 Gas connections

Nominal

Iron Pipe

Size (Inches)

Single Unit

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. 7-4.

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

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 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 7-4 Inlet Gas Supply Check

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

 WARNING

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP.

DETAIL

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. Connect 120 vac power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-1.

2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code (see FIG. 8-1).

3. The boiler pump is shipped loose. Wire the boiler pump as shown in FIG. 8-1.

4. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. 8-1.

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

Figure 8-1 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

Installation & Operation Manual

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 8-2.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-3 on page 49 of this manual and the boiler wiring diagram.

Figure 8-2 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. 8-3.

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. 8-3) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight 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 at the rear of the boiler (see FIG. 8-2).

DHW thermostat

1. Connect storage indirect water heater (DHW) thermostat (FIG. 8-3) to the DHW thermostat terminals on the

connection board.

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 (FIG. 8-3). Consult the tank manufacturer for application and performance when used

with any other indirect tank.

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.

Auxiliary device relay

1. If an auxiliary device (e.g., louvers) 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. 8-3).

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. 8-3).

High gas pressure switch

1. If a switch is provided to detect excessive gas pressure, remove the jumper wire from the terminals on the connection board, and then connect them to its normally closed contacts (FIG. 8-3).

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

Installation & Operation Manual

8 Field wiring

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 Boiler Service Manual for instructions on how to use the inlet sensor as the controlling sensor. When the inlet sensor is programmed as the controlling sensor, it is vital 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. 8-3).

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 56 “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, 6-6, and 6-8). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor (see FIG. 8-3). 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. 8-3). 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. 8-3). 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. 8-3). 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.

Low gas pressure switch

1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts (FIG. 8-3).

2. If both a high and low gas pressure switch is used, connect their respective contacts in series, and connect them to the terminals on the connection board (FIG. 8-3).

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. 8-3).

Installation & Operation Manual

8 Field wiring (continued)

AUX. DEVICE

PILOT SUPPLY

24VAC

GND

AUX. DEVICE

PROVING

GAS PRESSURE

SWITCH

FLOW

SWITCH

ALARM

CONTACTS

RUNTIME

CONTACTS

SYSTEM

SENSOR

DHW TANK

SENSOR

OUTDOOR

SENSOR

SHIELD GROUND

0-10VDC EXTERNAL

GND CONTROL

DHW THERMOSTAT

ROOM THERMOSTAT /

ZONE CONTROL

SHIELD GROUND

SEQUENCING

LOW WATER

CUTOFF

CN1

CN2

CN3

CN4

CN5

AUX. DEVICE

RELAY

FLOW SWITCH

TAN K T HE RMOSTAT

WALL THERMOSTAT /

ZONE CONTROL

OUTDOOR SENSOR

BUILDING

MANAGMENT

SYSTEM

AUX. DEVICE

PROVING SWITCH

COM

SHIELD

FROM

BOILER

(AUX) DHW SENSOR

LOW WATER

CUTOFF

Figure 8-3 Low Voltage Field Wiring Connections

Installation & Operation Manual

9 Condensate disposal

Condensate drain

1. This boiler is a high efficiency appliance that produces condensate.

2. The side of the boiler has a 1/2 inch PVC union 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 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 (FIG. 9-1) is available from the factory (Kit 3087).

4. Install the 1/2 inch PVC tee assembly (shipped with the unit) as shown in FIG. 9-1.

5. Leave the top of the 1/2 inch tee OPEN. This is needed as a vacuum break.

6. Do not expose condensate line to freezing temperatures.

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

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.

8. 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

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 7. 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 36 through 41). 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

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

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

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

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

5. Replace the retaining screw.

The condensate trap (FIG. 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

RETAINING

SCREW

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

CONDENSATE FROM

HEAT EXCHANGER

TO FLOOR

DRAIN

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

Installation & Operation Manual

10 Start-up (continued)

Final checks before starting the boiler

 Read the Knight Boiler Service Manual to familiarize

yourself with SMART SYSTEM control module operation. Read this manual, page 54 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 51

and 52 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 54.

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 Boiler 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 51 and 52 (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 42 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

Installation & Operation Manual

10 Start-up

Figure 10-2 Operating Instructions

Installation & Operation Manual

Check flame and combustion (continued)

4. Place the boiler into the active position by pressing the SHUTDOWN button on the display board (FIG. 11-1, page 63) until BLR:Standby appears in the display window.

5. Locate the pinhole button above 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 Boiler 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 Boiler 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 Boiler 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%

10 Start-up (continued)

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 Boiler 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 Boiler 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 Boiler 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.

Installation & Operation Manual

11 Operating information

General

How the boiler operates

The Knight 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 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 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.

Installation & Operation Manual

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

Installation & Operation Manual

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 is available from the factory (WTR20009).

Outdoor reset operation, if used

Target temperature with outdoor reset

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

See the Knight Boiler 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 Boiler 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 55 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 below under “Outdoor Reset Operation” and “Target Temperature Boost” when the outdoor sensor is connected.

11 Operating information (continued)

Installation & Operation Manual

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 Boiler 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 Boiler Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the Knight Boiler 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

Installation & Operation Manual

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

11 Operating information (continued)

Installation & Operation Manual

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)

Installation & Operation Manual

Knight 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)

Installation & Operation Manual

Access modes

User

The user can adjust space heating target temperature by using the UP and DOWN buttons (FIG. 11-1) at any time during normal operation. By entering the USER code (0704), the user can also change temperature units, time and date, and night setback settings. In User Mode, the following parameters can be viewed but not changed:

• Boiler outlet water target temperature in DHW Mode

• Boiler model number

• Software version

• Total operating hours

• Total cycles

Installer

Most parameters are available only to the installer, accessible only by entering the installer access code, see the Knight Boiler Service Manual.

Saving parameters (reference the Parameter Table in the

Knight Boiler 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 Boiler Service Manual for a detailed description of parameters and access modes.

11 Operating information

Installation & Operation Manual

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.

11 Operating information (continued)

Installation & Operation Manual

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

Installation & Operation Manual

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.

11 Operating information (continued)

Installation & Operation Manual

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

Installation & Operation Manual

12 Maintenance

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 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 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)

Installation & Operation Manual

12 Maintenance

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

2. Remove the PVC cap retaining screw from the PVC cap

(FIG. 12-1).

3. Remove the 2 inch PVC cap with the switch located at the

top of the trap (FIG. 12-1).

4. Remove any sediment in the trap.

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

the drain.

6. Replace the cap. Press the cap onto the trap until the cap

makes contact with the drain.

7. Replace the retaining screw.

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

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

TO FLOOR

DRAIN

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

Figure 12-1 Condensate Trap

Installation & Operation Manual

12 Maintenance (continued)

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 above warning directions, 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

Installation & Operation Manual

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 Knight Boiler Service Manual. Adjust settings if necessary. See Section 1 of the Knight Boiler Service Manual for adjustment procedures.

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

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

Installation & Operation Manual

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

Review with owner

1. Review the Knight Boiler User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specified in the Knight Boiler User’s Information Manual (and in this manual as well).

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.

Oiled bearing circulators

1. The circulator shipped with the Knight boiler is waterlubricated. 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.

12 Maintenance (continued)

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions in the Service Manual. Failure to comply could result in severe personal injury.

 WARNING

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 12B - Heat Exchanger Cleaning Kits.

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

4. Remove the heat exchanger access cover, burner, and

gas/air arm assembly.

5. Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4" diameter hose to a drain pan. Using field supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.

6. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.

7. Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

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. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 - Startup on pages 53 and 55 of this manual.

13. Replace the access cover and restore boiler to operation.

Table 12B Heat Exchanger Cleaning Kits

Model

Kit

Number

Part

Number

Component Description

105

KIT30062

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20085 1/4" x 12" Drill Extension

150

285

KIT30063

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20084 3mm Allen Wrench

MSC20086 1/4" x 24" Drill Extension

* Do NOT use a metal brush. Only use the kit provided brush or an equivalent replacement nylon brush.

 CAUTION

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

HIGH LIMIT

INTERFACE

CN2-15

CN2-10

CN2-9

CN2-8

CN2-7

SILENCING SWITCH

SYSTEM

SENSOR

TAN K

SENSOR

OUTDOOR

SENSOR

SHIELD

RS485

SHIELD

BOX

CN4-14

RUN-TIME

CONTACTS

X1-6

X1-8

X5-7

X6-7

X6-2

CN4-7

ALARM

0-10V

X5-14

1.25A

CONNECTION

DISPLAY

INTEGRATED CONTROL

SYSTEM PUMP

BOILER PUMP

DHW PUMP

3.5A

120 VAC

24 VAC

3.5A

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

RELAY

X1-4

RELAY

BLOWER

RELAY

CN5-1

FLOW

SWITCH

ROOM THERMOSTAT

ZONE CONTROL

DHW

THE RMO STAT

CN4-9X6-4

RIBBON CABLE

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

X1-2

X1-3

X1-1

X1-5

X6-8

X6-3

CONNECTION

SYSTEM

PUMP "L"

BOILER

PUMP "L"

DHW

PUMP "L"

TERMINAL

STRIP

BOARD

CN2-10

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

LOW GAS

PRESSURE

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

DRAIN

SWITCH

AUTO RESET

HI-LIMIT

GAS VALVE

BLOWER

NEUTRAL

CONNECTION BOARD

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 cond ition is present.

2. See wiring diagram for addi tional notes.

INTEGRATED

CONTROL

GAS VALVE

RELAY

LADDER DIAGRAM LBL7083 REV G

Installation & Operation Manual

DISPLAY

X1-8

X5-5

X5-13

X5-6

X5-12

INTEGRATED CONTROL

BLOWER

X1-1

X2-2

X2-1

X1-7

GAS VALV E

FLAME ROD

SPARK

ROD

W/R

BOX DEPICTS

OPTIONAL ITEMS

WIRING DIAGRAM LBL7082 REV F

WARNING

DISCONNECT POWER

BEFORE SERVICING

INLET SENSOR

OUTLET SENSOR

FLUE SENSOR

MANUAL RESET HI-LIMIT

BLOCKED DRAIN

X5-8

X5-1

X5-2

X5-9

X5-7

X5-14

X5-11

X5-3

X5-4

X5-10

OR/BK

245

SYSTEM

SENSOR

(AUX) DHW

TAN K

SENSOR

OUTDOOR

SENSOR

0-10V

RS485

CONNECTION BOARD

CN3

X1-3

X1-5

X1-2

X1-6

X1-4

120V SUPPLY

BOILER PUMP

DHW PUMP

SYSTEM PUMP

JUNCTION

BOX

TERMINAL STRIP

ON/OFF SWITCH

GND

SHIELD

FLOW

SWITCH

GAS

PRESSURE

SWITCH

AUX.

DEVICE

PROVING

LOW

WATER

CUT-OFF

CN5-1

CN4-6

CN4-1

CN4-9

CN4-3

CN4-2

X6-9

X6-3

X6-4

X6-5

X6-10

CN4-11

CN4-12

CN4-10

CN4-4

ALARM

CONTACTS

RUN-TIME

CONTACTS

X3-1

X3-3

X3-4

X3-2

AUX.

DEVICE

PILOT

SUPPLY

CN4-8

X6-8

DHW

THERMOSTAT

CN4-5

X6-1

ROOM

THERMOSTAT

ZONE

CONTROL

CN4-7

CN4-13

X6-2

X6-6

EXTERNAL

CONTROL

AUTO RESET HI-LIMIT

CAUTION HIGH VOLTAGE SPARK LEAD

CN5-3

CN5-4

CN5-2

24 VAC

COM

GND

TR1

120 VAC

LOW VOLTAGE

HIGH VOLTAGE

INTERFACE

CN4-14

CN1-12

CN1-11

CN1-10

CN1-9

CN1-8

CN1-7

CN1-6

CN1-5

CN1-4

CN1-3

CN1-2

CN1-1

Notes:

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

lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead

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.

CN2-1

CN2-2

CN2-3

CN2-4

CN2-5

CN2-6

CN2-7

CN2-8

CN2-9

CN2-10

CN2-11

CN2-12

CN2-13

CN2-14

CN2-15

CN2-16

CN1

CN2

CN5

CN4

CN3

BELL JUMPER

ALARM BELL

SILENCING SWITCH

MODELS

ONLY

AIR PRESSURE SWITCH

RESISTOR

Figure 13-2 Wiring Diagram

13 Diagrams (continued)

Revision Notes: Revision 7 (KB-I&O-07) reflects the addition of the Dungs information to the manual.

Revision 8 (KB-I&O-08) reflects edits made to all the plumbing diagrams.

Revision 9 (KB-I&O-09) reflects changes made to the ratings page.

Revision 10 (KB-I&O-10) reflects changes made to Model 210 orifice.

Revision 11 (KB-I&O-11) reflects an additional LP warning on page 13.

Revision 12 (ECO #C02407) reflects the removal of Models 399 - 500 from the manual, the addition of high altitude, relief valve and T & P install instructions, Maintenance Section and the new sidewall vent termination.

Revision 13 (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 3" concentric vent kit for ULC-S636 and sidewall vent termination kit number correction.

Revision 14 (ECO #C03223) reflects edits made to the high altitude section on page 7 and updates made to the condensate trap image on 48 and 66.

Revision 15 (ECO #C03735) reflects the addition/changes to room air, stainless steel venting, LWCO, pipe sizing chart, hydro and dirt separator changes.

Revision 16 (ECO #C05457) reflects the addition of the illustrations disclaimer on all the piping drawings (ECR #R02431), changing out “dirt separator” for “Y-Strainer” (ECR #R02455), update the vent table to reflect Schedule 80 as acceptable CPVC material (R02799), add stainless steel as acceptable material in a closet or alcove installation (R02900), add flex-smooth wall to the FasNSeal material (ECR #R02845), update the HEX cleaning procedure to reflect the new HEX cleaning kit (R02634), and update the ceramic fiber warning.

KB-I-O-16

4/10

Lochinvar KBN080 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual