Lochinvar KBN701, KBN601, KBN801, KBN400, KBN501 User Manual

KBXII-I-O Rev G

Installation & Operation Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

This manual must only be used by a qualiﬁ ed heating installer / service technician. Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE KNIGHT XL -- HOW IT WORKS ............................ 4-6

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

1. DETERMINE BOILER LOCATION

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

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

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

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

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

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

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

Model 400 ................................................................... 13

Model 501 ................................................................... 14

Models 601 - 801 ........................................................ 14

Leveling the Boiler ............................................................ 14

3. GENERAL VENTING

Direct Venting Options ..................................................... 15

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

Requirements for Installation in Canada .......................... 17

Sizing ............................................................................... 17

Min./Max. Combustion Air & Vent Piping Lengths ............17

Materials ............................................................................18

Optional Room Air ............................................................ 19

PVC/CPVC .................................................................. 19-20

Polypropylene ................................................................... 21

Stainless Steel Vent ......................................................... 22

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 23-26

Determine Location ................................................ 23-25

Prepare Wall Penetrations ..................................... 25-26

Multiple Vent/Air Terminations ......................................... 26

Sidewall Termination - Optional Concentric Vent ....... 27-29

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical .................................... 30-31

Determine Location ..................................................... 30

Prepare Roof Penetrations ......................................... 31

Multiple Vent/Air Terminations ......................................... 31

Vertical Termination - Optional Concentric Vent ......... 32-33

Alternate Vertical Concentric Venting ......................... 34-35

6. HYDRONIC PIPING

System Water Piping Methods ......................................... 36

Low Water Cutoff Device ................................................. 36

Chilled Water System ....................................................... 36

Freeze Protection ............................................................. 36

General Piping Information .............................................. 36

Flow Switch and Relief Valve Installation ....................... 37

Flow Switch Adjustment.............................................. 38

Near Boiler Piping Components .................................. 38-39

Circulator Sizing ............................................................... 39

Near Boiler Piping Connections ....................................... 39

7. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 46

Natural Gas ...................................................................... 47

Pipe Sizing for Natural Gas ........................................ 47

Natural Gas Supply Pressure Requirements ............. 47

Propane Gas .................................................................... 47

Pipe Sizing for Propane Gas ...................................... 47

Propane Supply Pressure Requirements ................... 47

Check Inlet Gas Supply ................................................... 48

Gas Pressure ................................................................... 49

Gas Valve Replacement .................................................. 49

8. FIELD WIRING

Line Voltage Connections ................................................ 50

Low Voltage Connections ................................................ 50

Wiring of the Cascade ...................................................... 52

9. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 54

10. STARTUP ............................................................. 55-60

11. OPERATING INFORMATION

General ............................................................................. 61

Cascade ........................................................................... 64

Sequence of Operation ............................................... 65-66

Knight XL Control Module ........................................... 67-68

Status Display Screens ............................................... 69-71

12. MAINTENANCE

Maintenance and Annual Startup ................................ 72-76

13. DIAGRAMS

Wiring Diagram ........................................................... 77

Ladder Diagram ......................................................... 78

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

Hazard deﬁ nitions

The following deﬁ ned 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.

Please read before proceeding

 WARNING

Installer – Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given.

When servicing boiler –

Installation & Operation Manual

• To avoid electric shock, disconnect electrical supply before performing maintenance.

NOTICE

 WARNING

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 qualiﬁ ed service technician, at least annually.

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

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 ﬁ led immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

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

If the information in this manual is not followed exactly, a ﬁ re 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 ﬂ ammable 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 ﬁ re department.

• Installation and service must be performed by a qualiﬁ ed installer, service agency, or the gas supplier.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation –

• Do not block ﬂ ow 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 ﬂ ooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water –

• Thoroughly ﬂ ush the system (without boiler connected) to remove sediment. The high-efﬁ ciency heat exchanger can be damaged by build-up or corrosion due to sediment.

• 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.

 CAUTION

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.

Freeze protection ﬂ uids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are speciﬁ cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Installation & Operation Manual

The Knight XL - How it works...

1. Stainless steel heat exchanger

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

2. Combustion chamber 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 ﬂ ow only if the gas valve is powered and combustion air is ﬂ owing.

5. Venturi

The venturi controls air and gas ﬂ ow into the burner.

6. Flue gas sensor (limit rated)

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

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

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

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

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

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial and a multiple line 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 ﬁ ber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of ﬁ ring rates.

13. Water outlet (system supply)

A 1-1/2" or 2" NPT (depending on the model) water connection that supplies hot water to the system.

14. Water inlet (system return)

A 1-1/2" or 2" NPT (depending on the model) water connection that returns water from the system to the heat exchanger.

15. Gas connection pipe

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

16. SMART SYSTEM Control Module

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

17. Manual 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 ﬂ ame.

27. Gas shutoff valve (Models 501 - 801 only)

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

28. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 PSI.

29. Flame sensor

Used by the control module to detect the presence of burner ﬂ ame.

30. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

31. Top panel

Removable panel to gain access to the internal components.

32. Power switch

Turns 120 VAC ON/OFF to the boiler.

33. 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.

34. Air shroud (Model 501 only)

The air shroud controls air and gas ﬂ ow into the burner.

35. Air pressure switch

The air pressure switch detects blocked ﬂ ue/inlet conditions. break the control circuit, shutting the boiler down.

36. Pump relay board

The pump relay board is used to connect the boiler, system and DHW pumps.

37. Transformer

The transformer provides 24V power to the integrated control.

38. High limit sensor (housed with the outlet temperature sensor)

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

39. Over-temp switch (located underneath access cover)

An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger, directly above the ﬂ ue connection exceeds 604°F (318°C). This is a one time switch and could warrant a heat exchanger replacement. Check the integrity of the rear refractory at the back of the upper coil if the switch opens.

Installation & Operation Manual

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

Model 400

Front View - Model 400

Rear View - Model 400

Left Side (inside unit) - Model 400

4 5

Right Side (inside unit) - Model 400

The Knight XL - How it works...

Model 501

Installation & Operation Manual

Rear View - Model 501

Left Side (inside unit) - Model 501

Models 601 - 801

Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801

Ratings

Installation & Operation Manual

Knight XL Boiler

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

KBN400 80 399 373 324

KBN501 100 500 467 406

KBN601 120 600 567 493

KBN701 140 700 660 574

KBN801 160 800 752 654

NOTICE

Min Max

Maximum allowed working pressure is located on the rating plate.

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net AHRI ratings are based on net installed radiation of sufﬁ cient 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.

Input MBH

(Note 4)

Gross

Output

MBH

(Note 1)

Other Speciﬁ cations

Net

AHRI

Ratings

Water,

MBH

(Note 2)

7. Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Knight XL is listed to UL353.

Boiler

Water Content Gallons

3.4 1-1/2" 1" 4" 4"

4.2 1-1/2" 1" 4" 4"

4.2 2" 1" 4" 4"

5.0 2" 1" 4" 6"

5.7 2" 1" 4" 6"

Water

Connections

Gas

Connections

Air

Size

Vent Size

(Note 3)

3. Knight XL boilers require special gas venting. Use only the vent materials and methods speciﬁ ed in the Knight XL Installation and Operation Manual.

4. Standard Knight XL 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.

5. High altitude Knight XL boilers are equipped to operate from 3,000 to 12,000 feet only with no ﬁ eld 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 afﬁ xed to the unit.

6. Ratings have been conﬁ rmed by the Hydronics Section of AHRI.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3000 FT. TO 12,000 FT.

Figure A High Altitude Label Location

1 Determine boiler location

Installation & Operation Manual

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.

NOTICE

The Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests speciﬁ ed in ANSI Z21.13 – latest edition.

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 ﬂ ow. 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 ﬂ ammable liquids.

 WARNING

4. The Knight XL 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.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other ﬂ ammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance is certiﬁ ed 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.

Do not install the appliance where the relative humidity may exceed 93%. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.

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

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC/ stainless steel pipe section provided with the appliance. The ﬁ eld provided PVC vent ﬁ ttings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement speciﬁ ed in this manual to make the vent connections. Failure to follow this warning could result in ﬁ re, personal injury, or death.

Closet and alcove installations

A closet is any room the boiler is installed in which is less than 171 cubic feet for KBN400 models, 193 cubic feet for KBN501 models, 223 cubic feet for KBN601 models, 247 cubic feet for KBN701 models and 278 cubic feet for KBN801 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 = 5 feet long, 4 feet wide, and 8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would be considered a closet for a Knight XL Boiler.

 WARNING

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 ﬁ re, personal injury, or death.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" (6 mm) from combustible materials.

2. Vent pipe – at least 1" (25 mm) 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.

Installation & Operation Manual

1 Determine boiler location (continued)

Figure 1-1 Closet Installation - Minimum Required Clearances

1/4" (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPE

12" (305 MM) LEFT

14" (356 MM) REAR

RECOMMENDED SERVICE CLEARANCES:

FRONT - 30” (762 mm) TOP - 24” (610 mm) LEFT SIDE - 24” (610 mm) REAR - 24” (610 mm)

CLOSET INSTALLATION

6" (152 MM) FRONT

 WARNING

For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated

13" TOP

temperatures. Failure to follow this warning could result in ﬁ re, personal injury, or death.

VENTILATING AIR OPENING

CLOSED DOOR

VENTILATING AIR OPENING

0" RIGHT

AREA OF

1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES.

EACH OPENING:

Figure 1-2 Alcove Installation - Minimum Required Clearances

1/4" (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

ALCOVE INSTALLATION

 WARNING

For alcove installations, CPVC, polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow

13" (330)

12" (305 MM) LEFT

14" (356 MM) REAR

RECOMMENDED SERVICE CLEARANCES:

FRONT - 30” (762 mm) TOP - 24” (610 mm) LEFT SIDE - 24” (610 mm) REAR - 24” (610 mm)

18" (457 MM) FRONT

TOP

this warning could result in ﬁ re, personal injury, or death.

OPEN FRONT

RIGHT

1 Determine boiler location

Installation & Operation Manual

Provide air openings to room:

Knight XL alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the Knight XL 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 XL in same space with other gas or oil-ﬁ red 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.

 WARNING

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 XL because it takes its combustion air from outside (direct vent installation).

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

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.

Flooring and foundation

Flooring

The Knight XL is approved for installation on combustible ﬂ ooring, but must never be installed on carpeting.

 WARNING

If ﬂ ooding is possible, elevate the boiler sufﬁ ciently to prevent water from reaching the boiler.

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

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 ﬂ oor.

• 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 XL 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 the General Venting Section. 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 speciﬁ ed. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight XL 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 XL 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.

 WARNING

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.

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/ﬂ uorocarbons

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 reﬁ nishing areas and establishments

New building construction

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

 WARNING

Check the following venting components before installing:

• Material - For materials listed for use with this appliance, see Section 3 - General Venting. For polypropylene or stainless steel venting, an adapter of the same

manufacturer must be used at the ﬂ ue collar connection.

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

• Manufacturer - For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with ﬂ ue 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 ﬁ t 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 3H 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.

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

Remodeling areas

Garages with workshops

With polypropylene and stainless steel vent, seal and connect all pipe and components as speciﬁ ed by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on pages 19 and 20.

 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 ﬂ ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

1 Determine boiler location

When removing a boiler from existing common vent system:

Installation & Operation Manual

 DANGER

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 deﬁ ciencies, 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 ﬁ replace dampers.

Do not install the Knight XL into a common vent with any other appliance. This will cause ﬂ ue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

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.

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 ﬂ ame 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, ﬁ replace dampers, and any other gas-burning appliance to their previous conditions of use.

2 Prepare boiler

Installation & Operation Manual

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.

NOTICE

Figure 2-1 Boiler Mounted on Shipping Pallet

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

. 2

Model 400

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

2. Remove the three screws securing the venturi to the blower. Note: When separating the venturi from the blower, take care not to damage the O-ring inside the blower (FIG. 2-2).

3. Remove the four star-drive screws securing the gas valve to the venturi (FIG. 2-2).

4. Locate the propane oriﬁ ce disk from the conversion kit bag. Verify that the stamping on the oriﬁ ce disk matches the boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

5. Remove the existing oriﬁ ce from the O-ring in the side of the gas valve and replace it with the oriﬁ ce from the kit. Position and secure the oriﬁ ce in the valve as shown in FIG. 2-2.

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

7. Inspect the O-ring inside the blower. Handle the O-ring with care, do not damage. Reposition the venturi against the blower and replace the screws securing the venturi to the blower (FIG. 2-2).

8. 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.

9. Replace the top and front access covers.

Gas conversions

 WARNING

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.

For the 400 Model you must install a propane oriﬁ ce to operate the Knight XL on propane gas. Verify when installing that the oriﬁ ce size marking matches boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

Models 501 - 801 do not require an oriﬁ ce installation for propane operation, but they will require a valve adjustment.

 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.

 DANGER

Model 400: Inspect the O-ring when the blower is disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Figure 2-2 Installing Propane Oriﬁ ce - Model 400

BLOWER

SCREWS QTY. 4

O-RING

BRASS ORIFICE

VENTURI

SCREWS QTY. 3

GAS VALVE

2 Prepare boiler

Installation & Operation Manual

Model 501

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

2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-3).

3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3).

4. After adjustment 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.

5. Replace the top access cover.

 WARNING

Figure 2-3 Gas Valve Adjustment - Model 501

 WARNING

Figure 2-4 Gas Valve Adjustment - Models 601 - 801

COVER

LLEN WRENCH

ADJUSTMENT SCREW

ALLEN WRENCH

Leveling the boiler

1. Set the boiler in place and check level.

a) Adjust legs if necessary to level boiler, see FIG. 2-5 below.

Figure 2-5 Leveling Legs on the Boiler

ADJUSTMENT SCREW

SCREWDRIVER SLOT

Models 601 - 801

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

2. Remove the cover on top of the gas valve (FIG. 2-4).

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 601 Model, one and a half (1 1/2) turns on the 701 Model, and one turn on the 801 Model (see FIG. 2-4).

4. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-4).

5. After adjustment 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 gas valve cover along with the top access cover.

LOWER

RAISE

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

Two Pipe Sidewall

See page 23 for more details

Direct venting options - Vertical Vent

PVC/CPVC Concentric Sidewall

Models 400 - 601 Only

See page 27 for more details

Two Pipe Vertical

See page 30 for more details

PVC/CPVC

Concentric Vertical

Models 400 - 601 Only

See page 32 for more details

Vertical Vent, Sidewall Air

See page 19 for more details

3 General venting

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

 WARNING

NOTICE

 WARNING

The Knight XL 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 ﬁ nished 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.

This appliance requires a special venting system. Use only approved stainless steel,

PVC, CPVC or polypropylene pipe and ﬁ ttings listed in Tables 3D, 3E, and 3G for vent pipe, and ﬁ ttings. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT mix components from different systems. The vent system could fail, causing leakage of ﬂ ue products into the

living space. Mixing of venting materials will void the warranty and certiﬁ cation of the appliance.

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.

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

The Knight XL 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.

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

You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 19 of this manual. The resultant installation is direct vent (sealed combustion).

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-1) - Used to provide combustion air directly to the unit from outdoors. A ﬁ tting is provided on the unit for ﬁ nal 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 3-2 thru 3-6) - Used to provide a passageway for conveying combustion gases to the outside. A transition ﬁ tting is provided on the unit for ﬁ nal connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 3-1 Near Boiler Air Piping

AIR

 CAUTION

NOTICE

 WARNING

Improper installation of venting systems may result in injury or death.

Follow the instructions in Section 1, page 12 of this manual when removing a boiler from an existing vent system.

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.

3 General venting (continued)

Installation & Operation Manual

Requirements for installation in Canada

1. Installations must be made with a vent pipe system

certiﬁ ed to ULC-S636.

2. The ﬁ rst three (3) feet of plastic vent pipe from the

appliance ﬂ ue outlet must be readily accessible for visual inspection.

3. The components of the certiﬁ ed vent system must not be

interchanged with other vent systems or unlisted pipe/ﬁ ttings. For concentric vent installations, the inner vent tube must be replaced with ﬁ eld supplied certiﬁ ed vent material to comply with this requirement.

4. The 4" Concentric Vent Kit available from Lochinvar (see

Section 4 – Sidewall Termination – Optional Concentric Vent) and the 4" Concentric Vent Kit available from IPEX are both approved for use on the Knight XL (400 - 601 models only) boiler. Both kits are listed to the ULC-S636 standard for use in Canada.

Sizing

The Knight XL uses model speciﬁ c combustion air intake and vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

Model Air Intake Vent

400 - 601 4 inches (102 mm) 4 inches (102 mm)

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

Combustion Air = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

Vent = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows + (3) 45° elbows + (1) concentric vent kit (CVK3007) = 49 equivalent feet (15 m) of piping.

NOTICE

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Model Kit Number

400 CVK3007 5 Feet (1.5 m) 501 CVK3007 30 Feet (9 m) 601 CVK3007 30 Feet (9 m)

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

Equivalent

Vent Length

701 - 801 4 inches (102 mm) 6 inches (152 mm)

NOTICE

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

3 General venting

Installation & Operation Manual

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, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as speciﬁ ed in this section. Type “B” double-wall vent with joints and seams sealed as speciﬁ ed in this section. AL29-4C, stainless steel material to be sealed to speciﬁ cation 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

NOTICE

Using air intake materials other than those speciﬁ ed can result in personal injury, death or property damage.

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.

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 ﬂ ex 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.

Follow the polypropylene manufacturer’s instructions when using polypropylene material as an inlet pipe.

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 ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide emissions causing severe personal injury or death.

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 (3) 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.

3 General venting (continued)

Installation & Operation Manual

Optional room air

NOTICE

Commercial applications utilizing the Knight XL boiler may be installed with a single pipe carrying the ﬂ ue 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 3C).

• 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.

• 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.

 WARNING

Table 3C Optional Room Air Kit

Model Description Kit Number

400 - 801

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

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.

Filter Box Assembly KIT30022

90° Elbow with Screen KIT30053

Air contamination

Pool and laundry products and common household and hobby products often contain ﬂ uorine 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 ﬂ ue 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.

 WARNING

PVC/CPVC

This product has been approved for use with the PVC/CPVC vent materials listed in Table 3D on page 20.

Installing vent and air piping

 WARNING

NOTICE

 WARNING

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.

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. The ﬁ eld provided vent ﬁ ttings 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 speciﬁ ed in Table 3D to make the vent connections. Failure to follow this warning could result in ﬁ re, personal injury, or death. Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

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). Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

3 General venting

Installation & Operation Manual

Table 3D PVC/CPVC Vent Pipe, and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe

Vent ﬁ ttings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

NOTE: In Canada, CPVC and PVC vent pipe, ﬁ ttings and cement/ primer must be ULC-S636 certiﬁ ed.

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 ﬁ ttings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

PVC - DWV ANSI/ASTM D2665 CPVC Schedule 40, 80 ANSI/ASTM F441 PVC Schedule 40 ANSI/ASTM D2466 PVC Schedule 80 ANSI/ASTM D2467 CPVC Schedule 80 ANSI/ASTM F439 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493

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

6. Priming and Cementing: a. Handle ﬁ ttings and pipes carefully to prevent contamination of surfaces.

b. Apply a liberal even coat of primer to the ﬁ tting socket and to the pipe end to approximately 1/2" beyond the socket depth.

c. Apply a second primer coat to the ﬁ tting socket.

d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the ﬁ tting socket along with an even coat of approved cement to the ﬁ tting socket.

e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into

the ﬁ tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufﬁ cient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Figure 3-2 Near Boiler PVC/CPVC Venting - Models 400 - 601

VENT

* 4” CPVC STREET ELBOW MAY BE SUBSTITUTED

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

NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND

LCOVE INSTALLATIONS.

Figure 3-3 Near Boiler PVC/CPVC Venting - Models 701 - 801

VENT

6” COUPLING

(FIELD SUPPLIED)

6” CPVC

STARTER

PIECE

(FACTORY SUPPLIED)

THE 6” STAINLESS STEEL ADAPTER SUPPLIED WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC/CPVC. THE 6” CPVC STARTER PIECE MUST BE USED FOR PVC ONLY.

3 General venting (continued)

Polypropylene

This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E.

All terminations must comply with listed options in this manual and be a single-wall vent offering.

For use of ﬂ ex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations.

For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.

Table 3E Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems

Duravent (M & G Group)

PolyPro Single-Wall / PolyPro Flex

InnoFlue SW/Flex

Installation & Operation Manual

 WARNING

NOTICE

Use only the adapters and vent system listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

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

NOTICE

The installer must use a speciﬁ c vent starter adapter at the ﬂ ue collar connection. The adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. Discard CPVC starter piece.

NOTICE

All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-4).

 WARNING

Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

Table 3F Approved PolypropyleneTerminations

Figure 3-4 Near Boiler Polypropylene Venting

IMG00128

POLYPROPYLENE ADAPTER

JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM

Centrotherm InnoFlue SW

Model

400-601 701-801

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 26).

Polypropylene

Adapter

ISAAL0404 IANS04 IATP0404 ISTAGL0404 4PPS-AD 4PPS-LB 4PPS-HLK ISAAL0606

Joint

Connector

Not

Required

Sidewall Retaining

Bracket*

IATP0606 ISTAGL0606 FSA-6PVCM-6PPS Not Required 6PPS-HLK

Sidewall Adapter*

Polypropylene

Adapter

Duravent Polypro

Joint

Connector

Sidewall Kit*

3 General venting

Stainless steel vent

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

Installation & Operation Manual

Figure 3-5 Near Boiler Stainless Steel Venting Models 400 - 601

 WARNING

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

NOTICE

The installer must use a speciﬁ c vent starter adapter at the ﬂ ue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3I for approved vent adapters. Discard CPVC starter piece.

NOTICE

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.

Table 3G Stainless Steel Vent Pipe and Fittings

Approved Stainless Steel Vent Manufacturers

Make Model

Dura Vent (M & G Group) Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

FasNSeal Vent / FasNSeal

Flex* Vent

VENT

4" S.S. ADAPTER

Figure 3-6 Near Boiler Stainless Steel Venting Models 701 - 801

*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.

Table 3H Stainless Steel Sidewall Vent Termination Kit(s)

Model Kit Number

701 - 801 KIT3137

Table 3I Approved Stainless Steel Terminations and Adapters

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Model

400-601

701-801

Boiler

Adapter

F303759 F303759

(Intake

Only)

Flue

Termination

FSBS4

FSRC4(R.C)

FSBS6

Intake Air

Termination

FSAIH04

303888

FSAIH04

303888

Boiler

Adapter

9401PVC

Flue

Termination

9492

5400CI

Intake Air

Termination

9414TERM 2SVSLA04

Boiler

Adapter

Flue

Termination

2SVSTP04

2SVSRCX04

Intake Air

Termination

2SVSTEX0490

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

 WARNING

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 17 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 ﬂ ue 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 ﬂ ue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of ﬂ ue 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.

 WARNING

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 ﬁ nishes.

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.

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

Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVERHANG

12"

MIN

Table 4A Sidewall Vent Kits

Model Kit Number Vent Size

400 - 601 KIT30046 4 inch vent 701 - 801 KIT30048 6 inch vent

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 ﬂ ue 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.

 WARNING

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

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.

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

Figure 4-2A Alternate PVC/CPVC/ Polypropylene Sidewall Termination Models 400 - 801 w/Field Supplied Fittings

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

12" (305 MM) MIN

GRADE OR SNOW LINE

Figure 4-2B Alternate Stainless Steel Sidewall Termination Models 701 - 801 w/Field Supplied Fittings

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

BIRD SCREEN

c. Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) 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 4-3A Clearance to Gravity Air Inlets

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

TO BOILER INTAKE

NOTICE

AIR CONNECTION

FROM BOILER VENT PIPE CONNECTION

GRADE OR SNOW LINE

PVC/CPVC or ABS is acceptable air inlet pipe material.

12" (305 MM) MIN 15" (381 MM) MAX

12" (305 MM) MIN

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4B, pages 23 thru 25. Also maintain the following:

a. Vent must terminate:

• At least 6 feet (1.8 m) from adjacent walls.

• No closer than 12 inches (305 mm) below roof overhang.

• At least 7 feet (2.1 m) above any public walkway.

• At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m).

• No closer than 12 inches (305 mm) below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches (305 mm) above grade or snow line; at least 12 inches (305 mm) below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches (610 mm) vertically outside the building.

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

12” (305 MM)

MIN

BIRD

SCREEN

(TYPICAL)

12” (305 MM)

MIN

12” (305 MM)

MIN

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