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.

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

 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 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.

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.

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.

• 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.

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.

 CAUTION

Do not use “homemade cures” or “boiler 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.

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

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 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.

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.

17. Air intake adapter

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

18. High voltage junction box

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

19. 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

Front View

IMG00117

FRONT OF UNIT

Bottom View

Left Side (inside unit)

IMG00161

IMG00162

Right Side (inside unit)

Ratings

Knight Wall Mount Boiler

AHRI Rating

Installation & Operation Manual

Other Specifications

Model Number

Note: Change

“N” to “L” for

L.P. gas models.

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

WHN399

NOTICE

Input MBH

(Note 5)

Min Max

57 285 265 230 96

80 399 379 330 95

Maximum allowed working pressure is located on the rating plate.

Heating

Capacity

MBH

(Note 2, 8)

Notes:

1. As an Energy Star Partner, Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency.

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

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

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

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

Net

AHRI

Ratings

Water,

MBH

(Note 3, 8)

AFUE

(Note 1, 8)

Boiler Water

Content Gallons

2.5 1" 1/2" 2"

3.5 1" 1/2" 3"

5.0 1 1/4" 1/2" 3"

6.5 1 1/2" 3/4" 4"

Water

Connections

Gas

Connections

Vent/Air

Size

(Note 4)

7. The Knight Wall Mount boiler input rate, on some models, is reduced for vent lengths beyond the minimum. Two inch vent will reduce Models WH(N,L) 055, WH(N,L) 085 and WH(N,L)110 by 0.6%, 0.94%, and 1.2% for every 10 feet of vent. Three inch vent will reduce Models WH(N,L)155, WH(N,L)199 and WH(N,L) 285 by 0.3%, 0.5%, and 0.6% for every 10 feet of vent. Four inch vent will reduce Model WH(N,L) 399 by 0.4% for every 10 feet of vent.

8. Ratings have been confirmed by the Hydronics Section of AHRI. Model 399 has a thermal efficiency rating.

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

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000FT TO 12,000FT

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 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.

 WARNING

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.

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.

 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

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.

Room Volume

(in cubic feet)

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.

1 Determine boiler location

Figure 1-1 Closet Installation - Minimum Required Clearances

LEFT 0" MINIMUM

1" MINIMUM CLEARANCE

AROUND VENT PIPE

TOP 6" MINIMUM

VENTILATING AIR OPENING

Installation & Operation Manual

 WARNING

RIGHT 0" MINIMUM

CLOSED DOOR

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.

FRONT

BOTTOM 0" MINIMUM

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24” BOTTOM: 24” LEFT SIDE: 12”

1/4" MINIMUM CLEARANCE AROUND HOT WATER PIPES

6" MINIMUM

Figure 1-2 Alcove Installation - Minimum Required Clearances

TOP

LEFT 0" MINIMUM

1" MINIMUM CLEARANCE

ROUND VENT PIPE

6" MINIMUM

VENTILATING AIR OPENING

ARE

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

A OF

EACH O

PENING:

Note: Service clearances are recommendations only.

 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

RIGHT 0" MINIMUM

OPEN FRONT

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

BOTTOM 0" MINIMUM

1/4" MINIMUM CLEARANCE AROUND HOT WATER PIPES

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24” BOTTOM: 24” LEFT SIDE: 12”

FRONT 6" MINIMUM

Note: Service clearances are recommendations only.

Installation & Operation Manual

1 Determine boiler location (continued)

Provide air openings to room:

Knight wall mount boiler alone in boiler room

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

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

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

 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 wall mount 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 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.

Wall mounting location

Residential garage installation

Precautions

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

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

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

Vent and air piping

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

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.

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.

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.

1 Determine boiler location

Installation & Operation Manual

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

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

 WARNING

Check the following venting components before installing:

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

manufacturer must be used at the 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.

 WARNING

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

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.

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

 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.

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

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

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.

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.

2 Prepare boiler

Installation & Operation Manual

Remove boiler from wood pallet

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

2. 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

Figure 2-1 Boiler Mounted on Shipping Pallet

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

REMOVE SHIPPING [WALL] BRACKET

DO NOT DISCARDWILL BE NEEDED TO SECURE THE BOILER TO THE WALL

Table 2A LP Conversion Table

LP Conversion Table

Model LP Orifice Stamping

55 055

85 085 110 110 155 155 199 199 285 399

H285

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

Gas conversions

 WARNING

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.

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

Figure 2-3 Installing Propane Orifice

SCREWS

Mounting the boiler

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

NOTICE

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

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.

GAS VALVE

GROMMET

BRASS ORIFICE

VENTURI

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

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

Installation & Operation Manual

 WARNING

Mounting to a concrete wall:

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

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

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

 WARNING

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

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

Figure 2-4 Mounting the Boiler

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.

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

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.

WALL: WOOD OR METAL STUDS ON 16" CENTERS -ORMASONRY / POURED CONCRETE

MOUNTING BRACKET (FACTORY SUPPLIED)

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.

FASTENERS APPROPRIATE FOR WALL TYPE QTY: 4

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

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

3 General venting

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

 WARNING

NOTICE

 WARNING

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.

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.

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.

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

 CAUTION

NOTICE

 WARNING

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.

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

3 General venting

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 concentric vent installations, the inner vent tube must be replaced with field supplied certified vent 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.

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

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Model Kit Number

55 - 110 CVK3008 3 feet

155 - 199 CVK3003 3 feet

285 - 399 CVK3007 3 feet

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

Equivalent Vent

Length

Table 3A Air Intake/Vent Piping Sizes

Model

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

2" Max Vent/

Air

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.

3" Max Vent/

Air

4" Max Vent/

Air

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

NOTICE

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.

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.

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

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

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

c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

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

3 General venting

Optional room air

NOTICE

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

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.

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 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.

Table 3C Optional Room Air Kit

Model Vent Size Kit Number

55 - 110 2" KIT30051 55 - 285 3" KIT30052

199 - 399 4" KIT30053

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 3D.

Installing vent and air piping

 WARNING

NOTICE

 WARNING

Table 3D PVC/CPVC Vent Pipe, and Fittings

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.

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 80 ANSI/ASTM F439

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.

Figure 3-7 Near Boiler PVC/CPVC Venting

CPVC STARTER PIECE

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

3 General venting

Installation & Operation Manual

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.

Table 3E Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems

Duravent (M & G Group)

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.

PolyPro Single-Wall / PolyPro Flex

InnoFlue SW/Flex

 WARNING

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.

NOTICE

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

NOTICE

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

Figure 3-8 Near Boiler Polypropylene Venting

NOTICE

All vent connections MUST be secured by 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

Centrotherm InnoFlue SW

Model

55 - 85

110 - 285

399

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

Polypropylene

Adapter

ISAG0202 w/

IAFC02

ISAG0303 w/

IAFC03

ISAG0404 w/

IAFC04

Joint

Connector

IANS02 IATP0202 ISTAGL0202 2PPS-AD w/PPS-PAC 2PPS-LB 2PPS-HLK

IANS03 IATP0303 ISTAGL0303 3PPS-AD w/PPS-PAC 3PPS-LB 3PPS-HLK

IANS04 IATP0404 ISTAGL0404 4PPS-AD w/PPS-PAC 4PPS-LB 4PPS-HLK

Sidewall

Retaining

Bracket*

Sidewall Adapter* Polypropylene Adapter

JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM

POLYPROPYLENE ADAPTER W/FLUE CLAMP

IMG00130

Duravent Polypro

Joint

Connector

Sidewall Kit*

3 General venting (continued)

Installation & Operation Manual

Stainless steel vent

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

 WARNING

NOTICE

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.

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

NOTICE

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

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

55 - 85

110 -285

399

Boiler

Adapter

303005 303006 WH0003 2SVAKA03 303007

FasNSeal Saf-T Vent Z-Vent

Flue

Termination

FSBS3

FSRC3(R.C)

FSBS4

FSRC4(R.C)

Intake

Air

Termination

303889

FSAIH04

303888

Boiler

Adapter

WH0002

WH0004

Flue

Termination

9392

5300CI

9492

5400CI

Intake

Air

Termination

9314TERM

9414TERM 2SVAKA04

Boiler

Adapter

2SVAKA02

Flue

Termination

2SVSTP03

2SVSRCX03

2SVSTP04

2SVSRCX04

Intake Air

Termination

2SVSTEX0390

2SVSTEX0490

4 Sidewall direct venting

Installation & Operation Manual

Vent/air termination – sidewall

 WARNING

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 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. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

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

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVER HANG

12"

MIN

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:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation of flue products into the combustion air stream.

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

 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.

 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.

Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall

Termination of Air and Vent w/Field Supplied Fittings

TO BOILER

FROM BOILER

VENT PIPE

CONNECTION

INTAKE AIR

CONNECTION

TERMINATION

PLATE

BIRD SCREEN

SNOW LINE

GRADE OR

BIRD SCREEN

12” MIN

15” MAX

12”

MIN

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

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER INTAKE AIR

CONNECTION

COUPLING

12” MIN

15” MAX

BIRD SCREEN

6. Locate terminations so they are not likely to be damaged

Figure 4-2A Clearance to Gravity Air Inlets

Installation & Operation Manual

by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

12”

BIRD

SCREEN

GRADE OR SNOW LINE

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

MIN

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

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

GRADE OR SNOW LINE

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

12" (305 MM) MIN

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.

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

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

7' MIN. ABOVE ANY

PUBLIC WALKWAY

36"

MIN.

FORCED AIR

INLET

4 Sidewall direct venting

Installation & Operation Manual

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

Figure 4-4A PVC/CPVC Sidewall Termination Assembly

Field Supplied Fittings

IF LESS THAN 10’

7’ MIN. ABOVE ANY PUBLIC WALKWAY

36”

MIN.

FORCED AIR

(TYPICAL)

INLET

BIRD

SCREEN

VENT PIPING

WALL PLATE

GALVANIZED

THIMBLE

AIR PIPING

VENT PLATE

VENT CAP

VENT

AIR

CENTERLINE WIDTH

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.

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

SIDEWALL

DAPTER

(VENT)

GALVANIZED THIMBLE

(AIR)

WALL PLATE

SIDEWALL RETAINING PLATE

IMG00085

VENT PLATE

VENT CAP

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