Lochinvar KHB055N, KHB085N, KHB110N, KHB155N, KHB199N Installation Manual

...

100305277_2000558126 Rev B

Installation & Operation Manual

Models: 55 - 285

Series 100 & 101

 WARNING

Save this manual for future reference.

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

Contents

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

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

THE KNIGHT FIRE TUBE BOILER -- HOW IT WORKS 4-5

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

1. DETERMINE BOILER LOCATION

Before Locating the Boiler, Check ......................................7

Closet and Alcove Installations ........................................... 7

Provide Clearances ............................................................ 9

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

Flooring and Foundation ................................................... 9

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

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

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

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

Using an Existing Vent System to Install a New Boiler ... 10

Removing a Boiler from Existing Common Vent .............. 11

2. PREPARE BOILER

Remove Boiler from Wood Pallet ..................................... 12

Gas Conversions ......................................................... 12-13

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

3. GENERAL VENTING

Direct Venting Options ..................................................... 14

Install Vent and Combustion Air Piping ........................... 15

Air Intake / Vent Location .................................................. 16

Optional Room Air ............................................................. 16

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

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

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

PVC/CPVC ....................................................................... 19

Polypropylene ................................................................... 20

Stainless Steel Vent ......................................................... 21

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 22-25

Determine Location ................................................ 22-24

Multiple Vent/Air Terminations .................................... 22

Prepare Wall Penetrations .......................................... 24

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

5. VERTICAL DIRECT VENTING

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

Determine Location ................................................ 28-29

Multiple Vent/Air Terminations ............................... 28-29

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

Existing Vent as a Chase ............................................ 29

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

Alternate Vertical Concentric Venting ......................... 32

6. HYDRONIC PIPING

System Water Piping Methods ......................................... 33

Low Water Cutoff Device ................................................. 33

Chilled Water System ....................................................... 33

Freeze Protection ............................................................. 33

General Piping Information .............................................. 33

Smart System / Multi-Temperature Loop .......................... 33

Near Boiler Piping Components ....................................... 34

Pressure Drop vs. Flow / Boiler Flow Requirements ...... 35

Piping Diagrams .......................................................... 36-46

7. GAS CONNECTIONS

Connecting Gas Supply Piping ................................... 47-48

Natural Gas ...................................................................... 48

Pipe Sizing for Natural Gas ........................................ 48

Natural Gas Supply Pressure Requirements ............. 48

Propane Gas .................................................................... 48

Pipe Sizing for Propane Gas ...................................... 48

Propane Supply Pressure Requirements ................... 48

Check Inlet Gas Supply .............................................. 49-50

Gas Pressure ................................................................... 50

Gas Valve Replacement .................................................. 50

8. FIELD WIRING ....................................................... 51-55

Line Voltage Connections ................................................ 51

Low Voltage Connections ................................................ 51

Wiring of the Cascade ................................................. 53-54

9. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 56

10. STARTUP ............................................................. 57-63

11. OPERATING INFORMATION

General ........................................................................ 64-67

Cascade ........................................................................... 68

Sequence of Operation ............................................... 69-70

Knight Fire Tube Boiler Control Module ........................... 71

Status Display Screens ............................................... 72-74

12. MAINTENANCE

Maintenance and Annual Startup ................................ 75-79

13. DIAGRAMS

Ladder Diagram ............................................................... 80

Wiring Diagram................................................................. 81

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

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.

Please read before proceeding

Installation & Operation Manual

 WARNING

NOTICE

 WARNING

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.

When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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

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

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.

Fire Tube

 WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B). Failure to comply could 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.

 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.

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.

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.

Installation & Operation Manual

The Knight Fire Tube Boiler - How it works...

1. Stainless steel heat exchanger

Allows system water to flow around specially designed tubes for maximum heat transfer, while providing protection against flue gas corrosion.

2. Combustion chamber access cover

Allows access to the combustion side of the heat exchanger.

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 (limit rated)

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

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

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

10. Electronic LCD display

The display features a high resolution liquid crystal screen, four (4) buttons, and a navigation dial. A serial and USB port support additional communication with the control.

11. Flue pipe adapter

Universal vent adapter allows connection of PVC/CPVC, polypropylene, or stainless steel venting systems 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)

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

14. Water inlet (system return)

Copper 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. 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 to regulate the blower, gas valve, and pump functions to meet heating demand. Optional remote connectivity allows boiler settings to be monitored and modified when connected to the internet.

17. Air intake adapter (Models 110 - 285 only)

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

18. High voltage junction box

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

19. Low voltage connection board

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

20. Low voltage wiring connections

Conduit connection points for the low voltage connection board.

21. Condensate trap

The condensate trap has a 1/2" PVC outlet connection pipe.

22. Access cover - front

Provides access to the gas valve, control panel, and heat exchanger.

23. Ignition electrode

Provides direct spark for igniting the burner.

24. Flame inspection window

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

25. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 30 psi.

26. Flame sensor

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

27. Line voltage wiring connections

Conduit connection points for the high voltage junction box.

28. Top panel

Removable panel allows access to the gas train and combustion chamber.

29. Side access panels (not shown)

Remove panels to gain access to temperature sensors.

30. Power switch

Turns 120 VAC ON/OFF to the boiler.

31. 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.

32. Flue and temperature access door

Provides access to the flue and temperature sensor.

33. Transformer

The transformer provides 24V power to the integrated control.

34. 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.

35. Stainless steel flue collector (not shown)

Flue gas and condensate enter the stainless flue collector through the fire tubes. A 1" drain connection allows condensate to flow through the collector into a condensate trap for disposal.

36. Line voltage receptacle

Equipment outlet for use with a condensate pump or other low power equipment. Do not exceed 7 amp load. Note: The power outlet is on a separate circuit than the boiler ON/ OFF switch, and will remain powered when the boiler is turned off.

Installation & Operation Manual

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

Front View

DIR #2000507762 00

DIR #2000557480 00

Top View (inside unit)

DIR #

2000557480 00

DIR #

2000557480

Left Side (inside unit) Front View (inside unit)

Ratings

Installation & Operation Manual

Knight Fire Tube Boiler

Other Specifications

AHRI Rating

Model Number

KHB(XXX)(N,L)

XXX = Input (MBH)

N = Natural Gas

L = Propane Gas

KHB055(N,L) 8.2 55 51 44 95

KHB085(N,L) 8.5 85 79 69 95

KHB110(N,L) 11 110 102 89 95

KHB155(N,L) 15.5 155 144 125 95

KHB199(N,L) 20 199 184 160 95

KHB285(N,L) 28.5 285 264 229 95

NOTICE

Min Max

Maximum allowed working pressure is located on the rating plate.

Input

MBH

(Note 5)

Heating

Capacity

MBH

(Note 2,7)

Net

AHRI

Ratings

Water,

MBH

(Note 3,7)

Notes:

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

5. Standard Knight Fire Tube boilers are equipped to operate from sea level to 4,500 feet only. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

6. High altitude Knight Fire Tube boilers are equipped to operate from 3,000 to 9,600 feet.  e boiler will de-rate

1.7% between 5,000 to 9,600 feet. For any units installed past 9,600 feet there is an additional de-rate of 4% per 1,000 feet beyond 9,600 feet per the National Fuel Gas Code. Boilers con gured for high altitude shall not be installed below 3000 feet.

 e operation given in this manual remains the same as the

standard boilers. A high altitude label (as shown in FIG A.) is also a xed to the unit.

De-rate values are based on proper combustion calibration

and

7. Ratings have been confirmed by the Hydronics Section of

CO2’s adjusted to the recommended levels.

AHRI.

AFUE

(Note 1, 7)

Boiler

Water Content Gallons

2.3 1" 1/2" 2" 2"

2.2 1" 1/2" 2" 2"

2.3 1" 1/2" 3" 3"

3.2 1" 1/2" 3" 3"

5.2 1-1/4" 1/2" 3" 3"

4.9 1-1/4" 1/2" 3" 3"

Water

Connections

Gas

Connections

Air

Size

Vent Size

(Note 4,8)

8. Models 055 - 085 can be alternatively vented using a 3" vent/ air size, the 110 model can be alternatively vented using a 2" vent/air size, and the 285 model can be alternatively vented using a 4" vent/air size. See the General Venting

- Sizing Section of this manual for maximum allowable lengths.

9. The manual reset high limit provided with the Knight Fire Tube is listed to UL353.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 9,600 FT.

DIR #

2000557484

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 Fire Tube boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified 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 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.

 WARNING

4. The Knight Fire Tube 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.

• Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.

6. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1B). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

 WARNING

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.

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B). Failure to comply could result in severe personal injury, death, or substantial property damage.

 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.

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. 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.

Closet and alcove installations

A closet is any room the boiler is installed in which the room volume is less than the room volume listed in the table below. An alcove is any room which meets the criteria for a closet, but it does not have a door.

Table 1A Room Volume

Model Room Volume (in cubic feet)

55 - 285 124

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 285 model.

 WARNING

Recommended clearances for service access

- Front / Left / Top ........................................................ 24"

- Back / Right ................................................................. 0"

NOTICE

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

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

1 Determine boiler location

Figure 1-1 Closet Installation - Minimum Required Clearances

Installation & Operation Manual

12"

LEFT

REAR

For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in

TOP 12:"

 WARNING

a closet structure due to elevated temperatures. Failure to follow

this warning could result in fire, personal injury, or death.

Required Clearances to Combustible Materials

- Front .........................................................................6"

- Top / Le Side ........................................................ 12"

- Back / Right Side .....................................................0"

VENTILATING* AIR OPENING

AREA OF EACH OPENING:

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

FRONT

RIGHT

VENTILATING* AIR OPENING

DIR #2000507564 00

Figure 1-2 Alcove Installation - Minimum Required Clearances

TOP

12"

REAR

RIGHT

 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 this warning could result in fire, personal injury, or death.

Required Clearances to Combustible Materials

- Front .........................................................................6"

- Top / Le Side ........................................................ 12"

- Back / Right Side .....................................................0"

FRONT

12"

LEFT

DIR #2000507571 00

1 Determine boiler location (continued)

Installation & Operation Manual

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 8 for other clearance

minimums.

Provide air openings to room:

Knight Fire Tube boiler alone in boiler room

1. No air ventilation openings into the boiler room are needed when the total room volume is greater than the value given for closet installations (see Table 1A). 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 Fire Tube boiler in same space with other gas or oil-fired appliances

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

 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 Fire Tube boiler 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 Fire Tube 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.

Flooring and foundation

Flooring

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

 WARNING

If flooding is possible, elevate the boiler sufficiently 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 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 Fire Tube 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 Fire Tube 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 Fire Tube boiler as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1B, 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 1B. 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.

1 Determine boiler location

Installation & Operation Manual

Table 1B Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

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.

• Size - To ensure proper pipe size is in place, see the General Venting - Sizing Section of this manual. 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 the General Venting Section 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.

• 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.

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

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

With polypropylene and stainless steel vent, seal and connect

all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the General Venting - Install Vent and Combustion Air Piping Section.

 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 (continued)

When removing a boiler from existing common vent system:

Installation & Operation Manual

 DANGER

 WARNING

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.

Do not install the Knight Fire Tube 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.

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 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.

2 Prepare boiler

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

FRONT

Gas conversions

 WARNING

You must install a propane venturi and any additional components supplied in the kit to operate the Knight Fire Tube boiler on propane gas. Verify when installing that the venturi label and orifice marking matches the boiler size (see Table 2A).

Table 2A LP Conversion Table

Model Kit #

100268040 20 mm 2.45 mm 2.65 mm 100150434 N/A

100268104 20 mm 2.45 mm 2.55 mm 100150434 N/A

100285815 22 mm 3.00 mm 2.85 mm 100284510 .250

110

100285817 24 mm 3.35 mm 2.95 mm 100284509 .302

155

100285818 24 mm 3.40 mm 3.00 mm 100150947 .302

199

100268109 30 mm 4.20 mm 4.00 mm 100150434 N/A

285

*NOTE:  e 199 LP air shutter should have the hole oriented towards the back right corner of the unit.

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

REAR

DIR #

LAG BOLTS

(QTY. 2)

2000557487

LAG BOLTS

(QTY. 2)

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.

Venturi Ø

(mm)

Orifice Ø

Bottom Top

Air

Shutter

Stamping

Orifice

Installation & Operation Manual

1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow the boiler to cool before proceeding.

2. Remove the top panel front access cover from the unit (no tools required for removal) and remove the bezel.

3. Disconnect the air inlet piping from the venturi by loosening the band clamp around the rubber boot coupling. Slide the rubber boot off of the venturi.

4. Disconnect gas piping from the venturi by loosening the threaded nut on the venturi. Remove the gasket between the gas piping and venturi.

5. Remove the bolts connecting the venturi to the fan and proceed to remove the natural gas venturi from the unit, making sure not to damage the blower O-ring gasket (FIG. 2-2).

6. a. Disconnect the wiring from the fan and remove the bolts securing the fan to the combustion chamber access cover.

b. Remove the fan and gasket, and install

the air shutter provided in the kit. NOTE: On 199 LP models, the air shutter MUST be installed in the proper direction. Install the air shutter so that the hole in the corner is oriented towards the back right corner of the unit (opposite the front door and gas piping).

c. Replace all torn or damaged gaskets.

Reassemble the fan.

d. Reconnect the wiring harness before

operation.

7. Install the propane venturi and verify the following:

a. The UP arrow on the plastic housing is

pointing up.

b. The threaded connection for the gas piping is

facing towards the front of the unit.

8. LP models 110 - 199 ONLY require an orifice to be installed in the threaded venturi connection:

a. Locate the propane orifice from the

conversion kit bag and verify the stamping on the orifice matches the boiler size (see Table 2A).

b. With the stamped side facing inwards,

place the orifice in the cavity provided in the threaded connection.

9. Reassemble the gas pipe to the threaded connection on the venturi. Replace torn or damaged gasket(s) and ensure the venturi gasket is seated properly before tightening the nut on the venturi.

2 Prepare boiler (continued)

Installation & Operation Manual

10. Reconnect the rubber boot on the air inlet to the venturi inlet and tighten the band clamp at this connection.

11. After installation is complete, attach the propane conversion label (inside the conversion kit) next to the boiler rating plate. Attach the LP caution label (inside the conversion kit bag) to the left side of the boiler underneath the gas supply piping.

12. Replace the top bezel and front access cover removed in Step 1 and resume operation.

 DANGER

When removing the natural gas venturi, inspect the gasket at the gas connection and the O-ring at the blower. These gaskets 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 Remove Natural Gas Venturi

BLOWER O-RING

FAN/BLOWER

GASKET

VENTURI ORIFICE

(LP MODELS 110 - 199 ONLY)

VENTURI GASKET

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.

Figure 2-3 Leveling Legs on the Boiler

GASKET

AIR SHUTTER

GASKET

 WARNING

DIR #2000544505 00

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.

3 General venting

Direct venting options - Sidewall Vent

DIR #2000507755 00

Installation & Operation Manual

Figure 3-1 Two-Pipe Sidewall Termination

Direct venting options - Vertical Vent

DIR #2000507732 00

Figure 3-2 PVC/CPVC Concentric Sidewall Termination

DIR #2000507759 00

Figure 3-3 Two-Pipe Vertical Termination

DIR #2000507752 00

Figure 3-4 PVC/CPVC Concentric Vertical Termination

DIR #2000507739 00

Figure 3-5 Vertical Vent, Sidewall Air

3 General venting (continued)

Install vent and combustion air piping

 DANGER

The Knight Fire Tube 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.

Installation & Operation Manual

 WARNING

This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

 CAUTION

NOTICE

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Mixing of venting materials will void the warranty and certification of the appliance.

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.

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 fire, personal injury, or death.

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

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 may use any of the vent / air piping methods covered in this manual. Do not attempt to install the Knight Fire Tube boiler using any other means. Follow the procedures in this manual for the method chosen.

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-6) - Used to provide combustion air directly to the unit from outdoors. On Models 110 - 285 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 - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting sized for PVC/CPVC, polypropylene, or stainless steel is provided on the unit for final connection. Reference the appropriate venting section to determine if an adapter is needed to connect to the specific manufacturer’s vent. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Approved Air Intake

Terminations

• Elbow with Screen

• Stainless Steel Hood Intake

• Room Air Kit (see Table 3?)

Approved Vent Kits

• Sidewall Vent Kit (see Table 3A)

• Concentric Vent Kit (see Table 3B)

NOTE: When using the Sidewall Vent Kit with polypropylene, an adapter kit must be used.

Approved Vent

Terminations

• Elbow with Screen

• Coupling with Screen

• Rain Cap

• Chimney Cover

Figure 3-6 Near Boiler Air Intake / Vent Connections

UNIVERSAL PVC/CPVC POLYPROPYLENE OR STAINLESS STEEL VENT ADAPTER

Air intake / vent terminations

The Knight Fire Tube boiler vent and air piping can be installed through the roof or through a sidewall. Intake air must be supplied from outside to the boiler air intake adapter unless following the Optional Room Air instructions in this manual. The resultant installation is direct vent (sealed combustion). Use only approved stainless steel, PVC, CPVC, or polypropylene vent terminations listed. The location and

IR INTAKE

CONNECTOR

orientation of vent and air terminations must comply with the requirements given in Section 3 through 5. Vent and air must terminate near one another unless otherwise specified. Ensure the location and orientation of the vent and air terminations are met and comply with the requirements given in the

DIR #2000556896 00

Sidewall Direct Venting or Vertical Direct Venting Section.

3 General venting

Air intake / vent location

The total length of piping for vent or air must not exceed the limits given in the General Venting - Sizing Section. Follow all instructions given in the specific venting section. Locate the vent / air terminations using the following guidelines:

1. Position the vent termination where vapors will not damage nearby shrubs, plants, air conditioning equipment, or be objectionable.

2. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

3. Prevailing winds could cause freezing of condensate and water /ice buildup where flue products impinge on building surfaces or plants.

4. Avoid possibility of accidental contact of flue products with people or pets.

5. 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.

6. Do not terminate above any door or window. Condensate can freeze, causing ice formations.

7. Locate or guard vent to prevent condensate damage to exterior finishes.

8. 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.

9. 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.

10. 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.

11. Air inlet must terminate at least 12 inches above grade or snow line, and at least 12 inches below the vent.

Optional room air

Commercial applications utilizing the Knight Fire Tube boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room.

Table 3A Optional Room Air Kit

Model Vent Size Kit Number

55 - 85 2 inch 100157614

110 - 285 3 inch 100157615

Installation & Operation Manual

NOTICE

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.

• 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. Take precautions to ensure proper installation.

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

 WARNING

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 1B, 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

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.

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 1B 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.

3 General venting (continued)

Installation & Operation Manual

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certified 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 existing concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.

4. The 2", 3" and 4" Concentric and Sidewall Vent Kits available from Lochinvar and IPEX (see Tables 3B and 3C) are approved for use on the Knight Fire Tube boiler. All kits are listed to the ULC S636 standard for use in Canada.

Table 3B Approved Sidewall Vent Kits

Vent Diameter

2 inch Lochinvar 100157609 3 inch Lochinvar 100157610 4 inch Lochinvar 100157611

Vent

Supplier

Part Number

EXAMPLE: 20 feet of 2" polypropylene pipe + (4) 90° elbows + (2) 45° elbows = 20 + 4(5) + 2(3) = 46 equivalent feet

Table 3C Approved Concentric Vent Systems

Vent Diameter Lochinvar PVC IPEX PVC IPEX CPVC

2 inch 100140485 196005 --

3 inch 100274637 196006 197009

4 inch 100140484 196021 197021

Sizing

The Knight Fire Tube boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3D. When venting with flexible polypropylene, refer to the General Venting - Polypropylene Section for allowable vent diameters and maximum lengths.

Table 3E Equivalent Length Guidelines - Polypropylene

Vent Ø Vent Pipe 45° Elbow 90° Elbow Tee

2 inch 1 ft 3 ft 5 ft 9 ft

3 inch 1 ft 4 ft 7 ft 15 ft

4 inch 1 ft 5 ft 10 ft 20 ft

See the Polypropylene Venting Section for flexible vent installation guidelines and specific manufacturer equivalent lengths.

Table 3F Equivalent Length - Concentric Vent Kits

Vent Diameter Kit Number Equivalent Length

2 inch 100140485 30 ft 3 inch 100269005 30 ft 4 inch 100140484 30 ft

NOTICE

Increasing or decreasing combustion air or vent piping sizes is not authorized, unless referenced in manual.

NOTICE

For Models 55 - 110 using 2" venting and Model 285 using 3" venting, the first seven (7) equivalent feet of vent must be CPVC polypropylene, or stainless steel (field supplied). This includes any transition piece used to increase or decrease the vent diameter.

NOTICE

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

The appliance output rating will reduce by up to 2.3% for each 25 feet of vent length. Consult factory to determine de-rate values.

If the specific polypropylene vent manufacturer's instructions do not list equivalent lengths for standard fittings, reference Table 3E for guidelines.

Unless otherwise stated by the vent manufacturer, add 5 feet for each 90° elbow and 3 feet for each 45° elbow of PVC/CPVC or stainless steel venting material.

Table 3D Air Intake/Vent Piping Sizes

Model

55 2 inches / 3 inches 2 inches / 3 inches 80 feet / 100 feet

85 2 inches / 3 inches 2 inches / 3 inches 50 feet / 100 feet

110 2 inches / 3 inches 2 inches / 3 inches 40 feet / 100 feet

155 3 inches 3 inches 100 feet

199 3 inches 3 inches 100 feet

285 3 inches / 4 inches 3 inches / 4 inches 50 feet / 100 feet

Inlet

Diameter

Vent

Diameter

Maximum

Length

3 General venting

Materials

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 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. An adapter may be required to transition between the air inlet connection on the appliance and the air inlet pipe.

 WARNING

NOTICE

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.

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.

Using air intake materials other than those specified 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.

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.

Vent pipe materials:

The Knight Fire Tube boiler requires a special vent system, designed for pressurized venting. Use only approved manufacturers and materials for vent pipe and fittings.

Refer to the appropriate PVC/CPVC, Polypropylene, or Stainless Steel Vent Section of this manual for approved manufacturers and additional information.

Approved materials certified for Category IV and Direct Vent appliance venting:

1. PVC - Schedule 40, Schedule 80, DWV

2. CPVC - Schedule 40, Schedule 80

3. AL29-4C Stainless Steel - UL-1738 and ULC S636 Listed from approved manufacturers

4. Polypropylene - ULC S636 Listed from approved manufacturers

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

3 General venting (continued)

Installation & Operation Manual

PVC/CPVC

This product has been approved for use with the PVC/CPVC vent materials listed in Table 3G.

NOTE: Closet and alcove installations require CPVC vent pipe be used.

Installing vent and air piping

NOTICE

 WARNING

Table 3G PVC/CPVC Vent Pipe, and Fittings

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.

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe

Vent fittings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

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 40 ANSI/ASTM F438

CPVC Schedule 80 ANSI/ASTM F439

PVC - DWV ANSI/ASTM D2665

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

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.

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 and to the pipe end to approximately 1/2" beyond the socket depth.

c. Apply a second primer coat to the fitting socket.

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

e. Apply a second coat of cement to the pipe. f. 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.

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

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

3 General venting

Polypropylene

This product has been approved for use with polypropylene venting from the manufacturers listed in Table 3H.

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

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

The vent connector provided with the unit is sized for PVC/ CPVC, polypropylene, or stainless steel venting. No adapter is required to connect to listed venting options.

Flexible polypropylene

For use of flex 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.

When venting with flexible polypropylene it is acceptable to increase piping sizes by one vent diameter. Up-sized flexible polypropylene may be considered as equivalent to one (1) foot of smaller diameter rigid pipe. Do not exceed the maximum flexible vent lengths given in Table 3I. When venting with same diameter flexible and rigid pipe refer to Table 3J for manufacturer equivalent vent lengths.

Sidewall vent kits

When using the Sidewall Vent Kit (see Table 3B), an adapter kit provided by the vent manufacturer must be used to make the final connection. Reference Table 3K for specific manufacturer's part numbers.

 WARNING

NOTICE

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

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.

All vent connections MUST be secured by the vent manufacturer's joint connector. Installation of a polypropylene system should adhere to the manufacturer's installation instructions supplied with the vent system.

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 & Operation Manual

Table 3H Approved Polypropylene Vent Manufacturers

Manufacturers Model Type

DuraVent PolyPro Single Wall / Flex

Centrotherm InnoFlue Single Wall / Flex

Heat Fab PolyFlue Single Wall / Flex

Z-Vent Z-Dens Single Wall / Flex

Table 3I Flexible Polypropylene Maximum Vent Lengths

Maximum Flexible Vent Length

Model

2 inch Flex 3 inch Flex 4 inch Flex

110

155 --

199 --

285 --

40 ft

(80 ft 2 inch)*

25 ft

(50 ft 2 inch)*

20 ft

(40 ft 2 inch)*

*Length shown in parentheses reflects the maximum rigid pipe vent length.

NOTE: Maximum vent lengths are based on 2 foot rigid equivalent. Reference Table 3J for specific manufacturer equivalent lengths.

Table 3J Flexible Polypropylene Equivalent Length

Manufacturer

DuraVent 2 ft 2 ft 2 ft

Centrotherm 2 ft 2 ft 2.7 ft

Heat Fab 2.5 ft 2.3 ft 2.7 ft

Z-Flex 3.2 ft 2 ft 2 ft

Table 3K Sidewall Vent Kit Adapters

Manufacturer

DuraVent (2", 3", 4") (2,3,4)PPS-HLKL

Centrotherm (2", 3", 4") ISLTK0(2,3,4)

Z-Flex (2", 3", 4") 2ZDHKLPA(2,3,4)

(Rigid Equivalent)

50 ft

(100 ft 3 inch)*

50 ft

(100 ft 3 inch)*

50 ft

(100 ft 3 inch)*

50 ft

(100 ft 3 inch)*

50 ft

(100 ft 3 inch)*

25 ft

(50 ft 3 inch)*

100 ft

(100 ft 3 inch)*

100 ft

(100 ft 3 inch)*

100 ft

(100 ft 3 inch)*

100 ft

(100 ft 3 inch)*

100 ft

(100 ft 3 inch)*

50 ft

(100 ft 3 inch)*

Flexible Vent Diameter

2 inch 3 inch 4 inch

Vent Diameter Sidewall Adapter

3 General venting (continued)

Stainless steel vent

This product has been approved for use with stainless steel venting from the manufacturers listed in Table 3L. The vent connector provided with the unit is sized for stainless steel venting. No additional vent adapter is needed to connect to the unit.

All terminations must comply with listed options in this manual and be a single-wall vent offering. See Table 3M for specific manufacturer terminations.

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

 WARNING

NOTICE

Installation & Operation Manual

Use only the materials, vent systems, and terminations from listed manufacturers. 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. 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.

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

FasNSeal Flex

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 3L Approved Stainless Steel Vent

Manufacturer Model

DuraVent FasNSeal / FasNSeal Flex

Heat Fab Saf-T Vent EZ Seal

Z-Flex Z-Vent

NOTE: DuraVent FasNSeal Flex stainless steel vent may be used as an equivalent substitute for rigid pipe.

Table 3M Stainless Steel Vent Terminations

Manufacturer

DuraVent (3", 4") FSBS(3,4)

Heat Fab (3", 4") 9(3,4)90 9(3,4)14TERM 5(3,4)00CI

Z-Flex (3", 4") 2SVSTPF0(3,4) 2SVSTEX0(3,4)90 2SVSRCF0(3,4)

Vent

Diameter

Screen

Termination*

Elbow with

Screen*

FSELB900(3,4) with FSBS(3,4)

Rain Cap*

FSRC(3,4)

*To the best of our knowledge, manufacturer part numbers are accurate as of the date of publication, but may be subject to change. Contact the manufacturer to verify specific terminations.

4 Sidewall direct venting

Vent/air termination – sidewall

Installation & Operation Manual

 WARNING

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

 WARNING

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.

 WARNING

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

Determine location

Reference the General Venting - Air Intake / Vent Location Section of this manual for required clearances and guidelines on locating vent and air intake terminations.

When using a sidewall termination, follow installation instructions and maintain clearances as shown in this section:

1. Air inlet must terminate at least 12 inches above grade or snow line, and at least 12 inches below the vent termination.

2. For installations where the vent terminates in an elbow

outside the building, the vent piping must not extend more than 24 inches vertically (FIG. 4-1). To prevent blockages due to freezing condensate, the recommended maximum length of vent piping is 15 inches.

 WARNING

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

Sidewall vent kit

When venting out a sidewall using PVC, CPVC, or polypropylene vent material, an optional sidewall vent termination kit can be ordered (FIG. 4-5A). See General Venting Section for kit numbers.

Field supplied fittings

The air piping must terminate in a down-turned elbow. This arrangement avoids recirculation of flue products into the combustion air stream. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-5B.

Figure 4-1 Field Supplied Fittings with Vent Termination Elbow

FACTORY PROVIDED BIRD SCREEN

24” MAX

Do not exceed the maximum lengths of the outside vent piping. Excessive length exposed to the low temperatures could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

3. Vent piping must terminate no closer than 12 inches

below a roof overhand, or 12 inches below or horizontally from any door, window, or other gravity air inlet (FIG. 4-2).

4. Vent must terminate at least 3 feet above any forced air

intake within 10 feet (FIG. 4-3).

Multiple vent / air terminations

Multiple vent terminations must be placed to maintain a minimum clearance of 12 inches (U.S. installations) between the edge of the air inlet and adjacent vent outlet (FIG. 4-4).

For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

The air inlet of a Knight Fire Tube 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.

FACTORY PROVIDED BIRD SCREEN

Figure 4-2 Clearance to Gravity Air Inlets (Field Supplied Fittings Shown)

12”

MIN.

BIRD

SCREEN

(TYPICAL)

12”

MIN.

12”

MIN.

4 Sidewall direct venting (continued)

Vent/air termination – sidewall

Installation & Operation Manual

Figure 4-3 Clearance to Forced Air Inlets (Sidewall Vent Kit Shown)

IF LESS

THAN 10’

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

36"

MIN.

FORCED AIR

INLET

Figure 4-4 Multiple Vent Terminations (Field Supplied Fittings Shown)

Figure 4-5B Field Supplied Fittings with Vent Termination Coupling

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER INTAKE AIR

CONNECTION

BIRD

SCREEN

GRADE OR SNOW LINE

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

COUPLING

12” MIN

BIRD SCREEN

12”

MIN

Figure 4-5C Typical Stainless Steel Sidewall Termination with Field Supplied Fittings and Hood Intake

TO BOILER INTAKE AIR

CONNECTION

BIRD SCREEN

12" MIN.

24” MAX.

Figure 4-5A Sidewall Vent Kit

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

FROM BOILER

VENT PIPE

CONNECTION

12" MIN.

GRADE OR SNOW LINE

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

Prepare wall penetrations - Sidewall vent kit

The PVC/CPVC and polypropylene sidewall vent terminations are designed to accommodate any wall thickness of standard construction.

Install the sidewall vent kit as shown in FIG. 4-6 and per the directions found in this manual.

1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.

2. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

3. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

4. Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

5. Polypropylene Venting: Install the vent and air intake sidewall adapters listed in the General Venting Polypropylene Section into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate.

PVC/CPVC Venting: Install the vent and air intake piping through the wall into the vent plate openings. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in the General Venting - PVC/ CPVC Section to seal the vent pipe.

6. Mount and secure the vent plate to the wall, using stainless steel screws.

7. Seal all gaps between the pipes and wall. Seal around the plate to the wall assuring no air gaps.

8. Assemble the vent cap to the vent plate. Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.

7. Seal all wall cavities and exterior openings.

2. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

3. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-7.

4. For installations using a vent elbow termination, use the sidewall termination plate as a template for correct location of hole centers.

5. Follow all local codes for isolation of vent pipe when passing through floors or walls.

6. Seal exterior openings thoroughly with exterior caulk.

Figure 4-6 Sidewall Vent Kit Assembly

PVC/CPVC PIPE OR POLYPROPYLENE ADAPTER (AIR)

WALL

PVC/CPVC PIPE OR POLYPROPYLENE ADAPTER (VENT)

GALVANIZED THIMBLE

PLATE

IMG00085

SIDEWALL RETAINING PLATE

VENT PLATE

VENT CAP

Figure 4-7 Field Supplied Termination Assembly

AIR PIPING

VENT PIPING

ELBOW

BIRD SCREEN

Prepare wall penetrations - Field supplied fittings

PVC/CPVC and polypropylene sidewall vent terminations are designed to accommodate any wall thickness of standard construction. Stainless steel terminations are designed to penetrate a wall with a thickness up to 9.25 inches of standard construction.

1. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

GALVANIZED THIMBLE

SIDEWALL TERMINATION PLATE

ELBOW

BIRD SCREEN

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent pipe termination kits (see the General Venting Section for part numbers). 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 described in the General Venting - Air Intake / Vent Location Section, and as shown below in FIG. 4-8.

The required combustion air and vent pipe materials are listed in the General Venting - PVC/CPVC Section of this manual.

Concentric sidewall installation

1. Cut one (1) hole into the structure to install the termination kit.

• 5 inch diameter for 2 inch concentric vent kit

• 4 inch diameter for 3 inch concentric vent kit

• 7 inch diameter for 4 inch concentric vent kit

2. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions (FIG.'s 4-9A and 4-9B).

a. Cement the Y concentric fitting to the larger kit pipe. b. Cement the rain cap to the smaller diameter kit pipe.

Figure 4-8 Concentric Sidewall Termination

Figure 4-9A 2 and 3 Inch Concentric Vent Kits (reference

the General Venting Section)

Figure 4-9B 4 Inch Concentric Vent Kit (reference the General Venting Section)

RAIN CAP

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

6" (152 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

"FLEXIBLE" PIPE COUPLING

6" (152 MM) DIA.

4" (102 MM) DIA.

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Figure 4-10A 2 and 3 Inch Concentric Vent Dimensions (reference the General Venting Section)

NOTICE

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).

 WARNING

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.

 WARNING

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

Figure 4-10B 4 Inch Concentric Vent Dimensions

(reference the General Venting Section)

(152 MM)

"B" DIA.

"G"

(76 MM)

(537 MM)

"H" DIA.

(254 MM) (194 MM)

"D"

"F"

(168 MM)

(76 MM)

"C" DIA.

"B" DIA. PVC VENT / EXHAUST

ABC DEF GH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

(1524 MM)

(102 MM)

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

NOTICE

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

4. 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 2 and 3 inch installations and fastened tightly into the rubber adapter for 4 inch installations.

5. Secure the assembly to the structure as shown in FIG. 4-12 using field-supplied metal strapping or equivalent support material.

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-8.

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 2 and 3 inch kits and standard Schedule 40 PVC for 4 inch. Do not exceed dimension "D" more than 60 inches (see FIG.'s 4-10A and 4-10B).

"E"

NOTICE

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

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