Lochinvar WH 55-399 User Manual

WH-I-O Rev H

Installation & Operation Manual

Models: WH 55 - 399

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

Save this manual for future reference.

DANGER

WARNING

CAUTION

CAUTION

NOTICE

2

Contents

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . .	. . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . .	. . . 3
THE KNIGHT WALL MOUNT BOILER-- HOW IT WORKS . 4-5
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 6
1. DETERMINE BOILER LOCATION
Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 7
Provide Air Openings to Room . . . . . . . . . . . . . . . . . .	. . . 9
Wall Mounting Location . . . . . . . . . . . . . . . . . . . . . . . .	. . 9
Residential Garage Installation . . . . . . . . . . . . . . . . . .	. . . 9
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Prevent Combustion Air Contamination. . . . . . . . . . . .	. . . 9
Corrosive Contaminants and Sources . . . . . . . . . . . . .	. . 10
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
Mounting the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 13
3. GENERAL VENTING
Direct Venting Options .....................................................	14
Install Vent and Combustion Air Piping ...........................	15
Requirements for Installation in Canada..........................	16
Sizing ...............................................................................	16
Materials............................................................................	17
Optional Room Air............................................................	18
PVC/CPVC .......................................................................	19
Polypropylene...................................................................	20
Stainless Steel Vent .........................................................	21
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall...................................	22-28
Determine Location................................................	22-24
Prepare Wall Penetrations..........................................	24
Multiple Vent/Air Terminations .........................................	25
Sidewall Termination - Optional Concentric Vent .......	26-28
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical ....................................	29-30
Determine Location.....................................................	29
Prepare Roof Penetrations .........................................	29
Multiple Vent/Air Terminations....................................	30
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

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

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . . 35

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Variable Speed Pump Option . . . . . . . . . . . . . . . . . . . . . 37

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 48

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 49

Natural Gas Supply Pressure Requirements . . . . . . . 49

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 49

Propane Supply Pressure Requirements . . . . . . . . . . 49

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 51

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9. CONDENSATE DISPOSAL

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

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

11. OPERATING INFORMATION

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 68-69

Knight Wall Mount Boiler Control Module . . . . . . . . . . . . 70

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . 71-73

12. MAINTENANCE

Maintenance and Annual Startup. . . . . . . . . . . . . . . . 74-77

13. DIAGRAMS

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

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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 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.

Installation & Operation Manual

Please read before proceeding

WARNING

NOTICE

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

User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

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

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

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.

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.

	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
WARNING
	page can result in severe personal injury,
	death, or substantial property damage.
	If the information in this manual is not
WARNING
	followed exactly, a fire or explosion may
	result causing property damage, personal
	injury or loss of life.
	This appliance MUST NOT be installed
	in any location where gasoline or
	flammable vapors are likely to be present.
	WHAT TO DO IF YOU SMELL GAS
	• Do not try to light any appliance.
	• Do not touch any electric switch; do
	not use any phone in your building.
	• Immediately call your gas supplier
	from a near by phone. Follow the
	gas supplier’s instructions.
	• If you cannot reach your gas supplier,
	call the fire department.
	• Installation and service must be
	performed by a qualified installer,
	service agency, or the gas supplier.

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.

•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 “boilerCAUTION patent medicines”. Serious damage to

the boiler, personnel, and/or property may result.

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.

3

Installation & Operation Manual

The Knight Wall Mount 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

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 and controls the blower, gas valve, and pumps to meet the heating demand.

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

17.Air intake adapter

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

18.High voltage junction box

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

13.Water outlet (system supply)

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

14.Water inlet (system return)

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

4

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 (knockouts)

Conduit connection points for the low voltage connection board.

21.Condensate drain connection

Connects the condensate drain line.

22.Access door

Provides access to all internal components.

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.Gas shutoff switch

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

26.High limit sensor (housed with outlet sensor)

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

27.Relief valve

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

28.Flame sensor

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

29.Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

30.Transformer

The transformer provides 24V power to the integrated control.

31.ModBus

The optional ModBus option provides intelligent building system communications.

32.On/Off switch

The On/Off switch is used to turn 120 VAC on and off to the unit.

33.Manual air vent

Allows for removal of trapped air from the heat exchanger.

Installation & Operation Manual

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

Models 55 - 399

17

11

	21
	15
22	13
	14

28

29

32	20
	FRONT OF UNIT

IMG00117

10

Front View

Bottom View

	17		33
		27	5
	3
			25
	4
	11	23
	2		28
33	1	16
	24
		19	31
			30
			18

7

26

6	IMG00162
8	IMG00161

Left Side (inside unit) Right Side (inside unit)

5

Installation & Operation Manual

Ratings

A

SME

H

Knight Wall Mount Boiler

AHRI Rating

		Input			Heating	Net
Model Number					Capacity	AHRI	AFUE
		MBH			MBH	Ratings	%
Note: Change		(Note 5)				Water,
“N” to “L” for						MBH
L.P. gas models.
	Min		Max		(Note 2, 8)	(Note 3, 8)	(Note 1, 8)
WHN055	11		55	51		44	96
WHN085	17		85	79		69	96
WHN110	22		110	102		89	96
WHN155	31		155	144		125	96
WHN199	40		199	186		162	96
WHN285	57		285	265		230	96
WHN399	80		399	379		330	95

Other Specifications

			Vent/Air
Boiler Water	Water	Gas	Size
Content
	Connections	Connections
Gallons
			(Note 4)
2.5	1"	1/2"	2"
2.5	1"	1/2"	2"
3.5	1"	1/2"	3"
3.5	1"	1/2"	3"
5.0	1 1/4"	1/2"	3"
5.0	1 1/4"	1/2"	3"
6.5	1 1/2"	3/4"	4"

		NOTICE	Maximum allowed working pressure is located on the rating plate.
	Notes:					7. The Knight Wall Mount boiler input rate, on some models,
						is reduced for vent lengths beyond the minimum. Two inch
	1. As an Energy Star Partner, Lochinvar has determined that
						vent will reduce Models WH(N,L) 055, WH(N,L) 085 and
		Knight wall mount boilers meet the Energy Star guidelines
						WH(N,L)110 by 0.6%, 0.94%, and 1.2% for every 10 feet
		for energy efficiency.
						of vent. Three inch vent will reduce Models WH(N,L)155,
	2. The ratings are based on standard test procedures prescribed
						WH(N,L)199 and WH(N,L) 285 by 0.3%, 0.5%, and 0.6%
		by the United States Department of Energy.				for every 10 feet of vent. Four inch vent will reduce Model
	3. Net AHRI ratings are based on net installed radiation of					WH(N,L) 399 by 0.4% for every 10 feet of vent.
		sufficient quantity for the requirements of the building				8. Ratings have been confirmed by the Hydronics Section of
		and nothing need be added for normal piping and pickup.				AHRI. Model 399 has a thermal efficiency rating.
		Ratings are based on a piping and pickup allowance of 1.15.				9. Knight wall mount boilers comply with the requirements
	4.	Knight wall mount boilers require special gas venting. Use				of CSD-1 Section CW-400 requirements as a temperature
		only the vent materials and methods specified in the Knight				operation control. The manual reset high limit provided
		Wall Mount Installation and Operation Manual.				with the Knight wall mount boiler is listed to UL353.
	5. Standard Knight wall mount boilers are equipped to operate
		from sea level to 4,500 feet only with no adjustments. The
		boiler will de-rate by 4% for each 1,000 feet above sea level
		up to 4,500 feet.
	6.	High altitude Knight		wall mount boilers are	equipped	UNIT EQUIPPED FOR
		to operate	from 3,000	to 12,000 feet only with	no field	HIGH ALTITUDE
		adjustments. The boiler will de-rate by 2% for each 1,000				3,000FT TO 12,000FT
		feet above 3,000 feet. High altitude models are manufactured
		with a different control module for altitude operation, but
		the operation given in this manual remains the same as the
		standard boilers. A high altitude label (as shown in FIG. A)
		is also affixed to the unit.
		6				Figure A High Altitude Label Location

Installation & Operation Manual

1 Determine boiler location

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 wall mount boiler gas
		manifold and controls met safe lighting
		and other performance criteria when the
		boiler underwent tests specified in ANSI
		Z21.13 – latest edition.

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.

Failure to keep boiler area clear and freeWARNING of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or

substantial property damage.

4.The Knight wall mount boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

5.If a new boiler will replace an existing boiler, check for and correct system problems, such as:

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

•Incorrectly-sized expansion tank.

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

WARNING

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

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.

	Model		Room Volume
			(in cubic feet)
	55	- 85	90
	110	- 285	108
	399		178

Example: Room dimensions = 4 feet long, 4 feet wide, and 9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be considered a closet for the WHN399 model.

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 two ventilating air
	openings shown in FIG. 1-1 are required
	for this arrangement. Failure to follow
	this warning could result in fire, personal
	injury, or death.

Provide clearances:

Clearances from combustible materials

1.Hot water pipes—at least 1/4" from combustible materials.

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

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

Clearances for service access

1.See FIG.’s 1-1 and 1-2 on page 8 for recommended service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

7

Installation & Operation Manual

1 Determine boiler location

Figure 1-1 Closet Installation - Minimum Required Clearances

LEFT

0" MINIMUM

1" MINIMUM CLEARANCE AROUND VENT PIPE

BOTTOM 0" MINIMUM

TOP	WARNING
6" MINIMUM

VENTILATING*

AIR OPENING

6"

RIGHT

0" MINIMUM

CLOSED DOOR

6"

VENTILATING*

AIR OPENING

FRONT

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

6" MINIMUM	*AREA OF EACH OPENING:
1/4" MINIMUM CLEARANCE	1 SQ. INCH PER 1000 BTU PER HOUR INPUT
AROUND HOT WATER PIPES	WITH A MINIMUM OF 100 SQ. INCHES.

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24” BOTTOM: 24” LEFT SIDE: 12”

Note: Service clearances are recommendations only.

Figure 1-2 Alcove Installation - Minimum Required Clearances

TOP

6" MINIMUM

LEFT

0" MINIMUM

WARNING

RIGHT

0" MINIMUM 1" MINIMUM CLEARANCE

AROUND VENT PIPE

OPEN FRONT

BOTTOM					FRONT
					6" MINIMUM
0" MINIMUM
		1/4" MINIMUM CLEARANCE
		AROUND HOT WATER PIPES

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.

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24” BOTTOM: 24” LEFT SIDE: 12”

Note: Service clearances are recommendations only.

8

	Installation & Operation Manual
1 Determine boiler location (continued)
Provide air openings to room:	Residential garage installation

Knight wall mount boiler alone in boiler room

1.No air ventilation openings into the boiler room are needed when clearances around the Knight wall mount boiler are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

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

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

WARNING The space must be provided with combustion/ventilation air openings

correctly sized for all other appliances located in the same space as the Knight wall mount boiler.

Do not install the boiler in an attic.

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

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

Wall mounting location

Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or wooden studs spaced 16" apart from center. Ensure the wall is capable of supporting at least 250 pounds for Models 55 - 285 and 300 pounds for the 399 Models.

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

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

Precautions

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

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

•The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.

Vent and air piping

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

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 wall mount boiler using any other means.

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

Prevent combustion air contamination

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

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 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always

contain contaminants.

9

1 Determine boiler location

Table 1A 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

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Installation & Operation Manual

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

WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide

emissions, causing severe personal injury or death.

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 flue 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 flue producing condensate.

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

•Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 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 11.

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 Installing Vent or Air Piping Section on page 19.

If any of these conditions are not met,WARNING 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.

10

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

	DANGER	Do not install the Knight wall mount
		boiler into a common vent with any other
		appliance. This will cause flue gas spillage or
		appliance malfunction, resulting in possible
		severe personal injury, death, or substantial
		property damage.
		Failure to follow all instructions can result
	WARNING
		in flue gas spillage and carbon monoxide
		emissions, causing severe personal injury or
		death.

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

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

b.Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

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

d.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

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

11

2 Prepare boiler

Remove boiler from wood pallet

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

2.To remove the boiler from the pallet:

a.Remove the two (2) lag bolts securing the bottom of the unit to the pallet.

b.Lift the boiler off the wall bracket mounted to the pallet.

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

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

Figure 2-1 Boiler Mounted on Shipping Pallet

REMOVE SHIPPING [WALL] BRACKET DO NOT DISCARDWILL BE NEEDED TO

SECURE THE BOILER TO THE WALL

Gas conversions

WARNING

12

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

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

Installation & Operation Manual

Table 2A LP Conversion Table

	LP Conversion Table
Model		LP Orifice Stamping
55		055
85		085
110		110
155		155
199		199
285		H285
399		8.0

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

2.Models 55 - 285 only, locate the power switch on the gas valve and turn the power switch to the “OFF” position (FIG. 2-2).

3.Model 399 only, shut off power at the source.

4.Disconnect the Molex plug from the gas valve.

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

6.Using an Allen wrench, remove the screws securing the gas valve venturi to the inlet of the combustion blower (FIG. 2-2).

Figure 2-2 Gas Valve Power Switch & Venturi Removal

REMOVE THE SCREWS SECURING

THE GAS VALVE VENTURI TO THE

INLET OF THE COMBUSTION

BLOWER

7.Using an Allen wrench, remove the screws securing the gas pipe to the gas valve. Remove the gas valve venturi assembly from the unit (FIG. 2-3).

8.Using an Allen wrench, remove the venturi from the gas valve.

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

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

11.Reattach the venturi to the gas valve and reposition the gas valve venturi assembly inside the unit. Secure the venturi back to the gas valve (FIG. 2-3).

12.Reattach the gas pipe to the gas valve. Reattach the air intake and coupler and tighten down on the band clamp.

2 Prepare boiler (continued)

13.Reattach the Molex plug to the gas valve.

14.Models 55 - 285 only, turn the gas valve power switch to the “ON” position.

15.Model 399 only, turn on power at the source.

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

17.Replace the front access cover.

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.

Figure 2-3 Installing Propane Orifice

GAS VALVE

GROMMET

BRASS ORIFICE

SCREWS

VENTURI

Mounting the boiler

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

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

Mounting to a wood studded wall:

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

WARNING Do not mount the boiler to a hollow wall.

Be sure to mount the boiler to the studs only.

2.Mount the wall bracket using the 2 1/4" lag bolts provided. Make sure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

3.Hang the boiler on the bracket and secure the bottom of the boiler with two (2) additional lag bolts provided.

Installation & Operation Manual

WARNING The boiler is too heavy for a single person to lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

Mounting to a concrete wall:

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

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

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

The boiler is too heavy for a single person toWARNING lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

Mounting to a metal studded wall:

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

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

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

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

WARNING The boiler is too heavy for a single person to lift. A minimum of two people is needed

for mounting the boiler onto the bracket.

Figure 2-4 Mounting the Boiler

WALL:

WOOD OR METAL STUDS ON 16" CENTERS -OR-

MASONRY / POURED CONCRETE MOUNTING BRACKET (FACTORY SUPPLIED)

FASTENERS APPROPRIATE FOR WALL TYPE

QTY: 4

13

Installation & Operation Manual

3 General venting

Direct venting options - Sidewall Vent

Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details

Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 26 for more details

Figure 3-3 Two-Pipe Vertical Termination - See page 29 for more details

Figure 3-4 PVC/CPVC Concentric Vertical Termination - See page 30 for more details

Figure 3-5 Vertical Vent, Sidewall Air - See page 18 for more details

14

Installation & Operation Manual

3 General venting

Install vent and combustion air piping

DANGER The Knight wall mount boiler must be vented and supplied with combustion and

ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

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

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

WARNING

WARNING

NOTICE

This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed in Tables 3D, 3E, and 3G for vent pipe, and fittings. 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 flue products into the living space. Mixing of venting materials will void the warranty and certification 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.

WARNING

CAUTION NOTICE

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.

Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.

WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a

common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

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

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

You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 18 of this manual. The resultant installation is direct vent (sealed combustion).

Air intake/vent connections

1.Combustion Air Intake Connector (FIG. 3-6) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2.Vent Connector (FIG.'s 3-7 thru 3-9) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 3-6 Near Boiler Air Piping

AIR

15

3 General venting

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

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

Sizing

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

Table 3A Air Intake/Vent Piping Sizes

	Model	2" Max Vent/	3" Max Vent/	4" Max Vent/
		Air	Air	Air
	55	*80 feet	100 feet	N/A
	85	*50 feet	100 feet	N/A
	110	*40 feet	100 feet	N/A
	155	N/A	100 feet	N/A
	199	N/A	100 feet	N/A
	285	N/A	*50 feet	100 feet
	399	N/A	N/A	100 feet

* WARNING

NOTICE

For Models 55, 85, and 110 using 2" venting and Model 285 using 3" venting, the first seven (7) equivalent feet of vent must be CPVC (field supplied). This includes any transition piece used to increase or decrease the vent diameter.

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

Installation & Operation Manual

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

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

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

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

Table 3B Concentric Vent Kit Equivalent Vent Lengths

	Model	Kit Number	Equivalent Vent
			Length
	55 - 110	CVK3008	3 feet
	155 - 199	CVK3003	3 feet
	285 - 399	CVK3007	3 feet

16

3 General venting (continued)

Materials

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.

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

WARNING Using air intake materials other than

	those specified can result in personal
	injury, death or property damage.
	The use of double-wall vent or insulated
NOTICE
	material for the combustion air inlet pipe is
	recommended in cold climates to prevent
	the condensation of airborne moisture in
	the incoming combustion air.

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

a.Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

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

c.Secure all joints with a minimum of three (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.

Installation & Operation Manual

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.

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.

17

3 General venting

Optional room air

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

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

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

Table 3C		Optional Room Air Kit
	Model		Vent Size	Kit Number
	55 - 110		2"	KIT30051
	55 - 285		3"	KIT30052
	199 -	399	4"	KIT30053

Installation & Operation Manual

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

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
WARNING
	injury or death, check for areas and
	products listed in Table 1A, page 10 before
	installing the boiler or air inlet piping.
	If contaminants are found, you MUST:
	• Remove contaminants permanently.
	—OR—
	• Relocate air inlet and vent
	terminations to other areas.

18

Installation & Operation Manual

3 General venting (continued)

PVC/CPVC

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

Installing vent and air piping

WARNING

NOTICE

The vent connection to the appliance must be made with the starter piece provided with the appliance if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3D to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

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

NOTICE	All PVC vent pipes must be glued, properly
	supported, and the exhaust must be
	pitched a minimum of a 1/4 inch per foot
	back to the boiler (to allow drainage of
	condensate).

WARNING	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.

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	PVC - DWV	ANSI/ASTM D2665
	CPVC Schedule 40, 80	ANSI/ASTM F441
	PVC Schedule 40	ANSI/ASTM D2466
Vent fittings	PVC Schedule 80	ANSI/ASTM D2467
	CPVC Schedule 80	ANSI/ASTM F439
Pipe Cement /	PVC	ANSI/ASTM D2564
Primer	CPVC	ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

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. (Moisturewillretardcuringanddirtorgreasewillprevent 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.

Figure 3-7 Near Boiler PVC/CPVC Venting

CPVC STARTER PIECE

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/ primer must be ULC-S636 certified.

19

3 General venting

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 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.

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

NOTICE

Table 3E Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make	Model
Centrotherm Eco Systems	InnoFlue SW/Flex
Duravent (M & G Group)	PolyPro Single-Wall / PolyPro Flex

Installation & Operation Manual

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 specific vent starter
		adapter at the flue collar connection.
		The adapter is supplied by the vent
		manufacturer to adapt to its vent system.
		See Table 3F for approved vent adapters.
		All vent connections MUST be secured by
	NOTICE
		the vent manufacturer's joint connector
		(FIG. 3-8).

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 3-8 Near Boiler Polypropylene Venting

JOINT CONNECTOR REQUIRED

AT ALL COMPONENT CONNECTIONS

OF VENT SYSTEM

POLYPROPYLENE ADAPTER

W/FLUE CLAMP

IMG00130

		Centrotherm InnoFlue SW				Duravent Polypro
Model	Polypropylene		Joint	Sidewall			Joint
	Adapter		Connector	Retaining	Sidewall Adapter*	Polypropylene Adapter	Connector	Sidewall Kit*
				Bracket*
55 - 85	ISAG0202 w/		IANS02	IATP0202	ISTAGL0202	2PPS-AD w/PPS-PAC	2PPS-LB	2PPS-HLK
	IAFC02
110 - 285	ISAG0303 w/		IANS03	IATP0303	ISTAGL0303	3PPS-AD w/PPS-PAC	3PPS-LB	3PPS-HLK
	IAFC03
399	ISAG0404 w/		IANS04	IATP0404	ISTAGL0404	4PPS-AD w/PPS-PAC	4PPS-LB	4PPS-HLK
	IAFC04

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 24).

20

3 General venting (continued)

Stainless steel vent

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

WARNING Use only the materials, vent systems, and terminations listed in Tables 3G and 3H.

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 specific vent starter
		adapter at the flue collar connection,
		supplied by the vent manufacturer to
		adapt to its vent system. See Table 3H for
		approved vent adapters. Discard CPVC
		starter piece.
		Installations must comply with applicable
	NOTICE
		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 & Operation Manual

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

Figure 3-9 Near Boiler Stainless Steel Venting

VENT

REPLACE APPLIANCE

SECURED CPVC ADAPTER

WITH APPROPRIATE

STAINLESS STEEL ADAPTER

FROM TABLE 3H

Table 3G Stainless Steel Vent Pipe and Fittings

Approved Stainless Steel Vent Manufacturers

Make	Model
Dura Vent (M & G Group)	FasNSeal Vent / FasNSeal Flex* Vent
Z-Flex (Nova Flex Group)	Z-Vent
Heat Fab (Selkirk Corporation)	Saf-T Vent

*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 Approved Stainless Steel (S.S.) Terminations and Adapters

		ProTech			Heat Fab				Z Flex
Model		FasNSeal				Saf-T Vent			Z-Vent
	Boiler	Flue	Intake	Boiler		Flue	Intake	Boiler	Flue	Intake Air
	Adapter	Termination	Air	Adapter		Termination	Air	Adapter	Termination	Termination
			Termination				Termination
55 - 85	303005	FSBS3	303889	WH0002		9392	9314TERM	2SVAKA02	2SVSTP03	2SVSTEX0390
		FSRC3(R.C)				5300CI			2SVSRCX03
110 -285	303006			WH0003				2SVAKA03
399	303007	FSBS4	FSAIH04	WH0004		9492	9414TERM	2SVAKA04	2SVSTP04	2SVSTEX0490
		FSRC4(R.C)	303888			5400CI			2SVSRCX04

21

Installation & Operation Manual

4 Sidewall direct venting

Vent/air termination – sidewall

WARNING

WARNING

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.

Figure 4-1A PVC/CPVC/Polypropylene Sidewall

Termination of Air and Vent

		TO BOILER
		INTAKE AIR
		CONNECTION
	FROM BOILER
	VENT PIPE
	CONNECTION	12"
	POSSIBLE ORIENTATIONS
		MIN
		TO
		OVER-
		HANG
		VENT / AIR
		TERMINATION

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 16 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.

12" MIN

		GRADE OR
		SNOW LINE
Table 4A Sidewall Vent Kit
Model	Kit Number	Vent Size
55 - 110	KIT30044	2 inch vent
110 - 285	KIT30045	3 inch vent
399	KIT30046	4 inch vent

If using the alternate sidewall termination:

b.The flue products will form a noticeable plume as 3. The air piping must terminate in a down-turned elbow

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

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

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

e.Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

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

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

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

as shown in FIG. 4-1B. This arrangement avoids recirculation of flue products into the combustion air stream.

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

WARNING Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B.

Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

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

TO BOILER

INTAKE AIR BIRD SCREEN

CONNECTION

	FROM BOILER	12” MIN
	VENT PIPE
		15” MAX
	CONNECTION

TERMINATION

PLATE

12” MIN

BIRD SCREEN

GRADE OR

SNOW LINE

22

Installation & Operation Manual

4 Sidewall direct venting (continued)

Vent/air termination – sidewall

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

TO BOILER

INTAKE AIR COUPLING

CONNECTION

12” MIN

15” MAX

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

12”

MIN

BIRD

SCREEN

GRADE OR

SNOW LINE

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

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

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 4-2A Clearance to Gravity Air Inlets

12"

MIN.

VENT / AIR

TERMINATION

12" MIN.

12" MIN.

BIRD SCREEN

TO BOILER

INTAKE AIR

CONNECTION

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

FROM BOILER

VENT PIPE

CONNECTION

12" (305 MM) MIN

GRADE OR

SNOW LINE

5.Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 22 - 24. Also maintain the following:

a.Vent must terminate:

•At least 6 feet from adjacent walls.

•No closer than 12 inches below roof overhang.

•At least 7 feet above any public walkway.

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

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

b.Air inlet must terminate at least 12 inches above grade or snow line; at least 12 inches below the vent termination; and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG. 4-1B. Condensate could freeze and block vent pipe.

c.Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

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

12”

MIN.

BIRD

SCREEN (TYPICAL)

12” MIN.

12” MIN.

Figure 4-3A Clearance to Forced Air Inlets

IF LESS

THAN 10’

VENT / AIR

TERMINATION 36"

MIN.

FORCED AIR

INLET

7' MIN. ABOVE ANY PUBLIC WALKWAY

23

4 Sidewall direct venting

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

IF LESS

THAN 10’

Installation & Operation Manual

Figure 4-4A PVC/CPVC Sidewall Termination Assembly

36”

MIN.

FORCED AIR

INLET

BIRD

SCREEN

(TYPICAL)

7’ MIN. ABOVE ANY

PUBLIC WALKWAY

Prepare wall penetrations

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

Air pipe penetration:

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

Vent pipe penetration:

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

•4½ inch hole for 3 inch vent pipe

•5½ inch hole for 4 inch vent pipe

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

2.For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3F on page 20 into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate (FIG. 4-4B).

3.For PVC/CPVC Only: 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 Table 3D on page 19 to seal the vent pipe.

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

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

6.Assemble the vent cap to the vent plate (see FIG.'s 4-4A and 4-4B). 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.

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

9.Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.

24

	VENT AIR
AIR PIPING	CENTERLINE WIDTH
VENT PIPING
	VENT PLATE
WALL PLATE	VENT CAP
GALVANIZED
THIMBLE

Table 4B Sidewall Vent Centerline Dimensions

Model	Air	Vent	Centerline Width
151 - 200	3"	3"	5 5/8"
286	4"	4"	5 5/8"

Figure 4-4B Polypropylene Sidewall Termination Assembly

SIDEWALL

ADAPTER

(AIR)

WALL

PLATE

SIDEWALL

RETAINING

PLATE

VENT

PLATE

VENT

CAP

SIDEWALL ADAPTER (VENT)

GALVANIZED	IMG00085
THIMBLE