Lochinvar WH 55-399 User Manual

Page 1

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.

Page 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

 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.

Page 3

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.

Page 4

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.

Page 5

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)

Page 6

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

Page 7

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.

Page 8

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.

Page 9

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.

Page 10

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.

Page 11

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.

Page 12

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.

Page 13

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

Page 14

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

Page 15

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.

Page 16

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

Page 17

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.

Page 18

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

Page 19

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.

Page 20

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*

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

4 Sidewall direct venting (continued)

Installation & Operation Manual

Prepare wall penetrations (Alternate Field Supplied Option)

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

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

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-4C.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-4C Alternate Sidewall Termination Assembly w/Field Supplied Fittings

Figure 4-5A Multiple Vent Terminations (must also comply with Figure 4-1A)

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT

AIR

VENT / AIR

TERMINATION

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

AIR PIPING

VENT PIPING

GALVANIZED THIMBLE

SIDEWALL TERMINATION PLATE

ELBOW

BIRD SCREEN

ELBOW

BIRD SCREEN

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers terminate each vent/air connection as described in this manual (FIG. 4-5A).

 WARNING

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

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

Page 26

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Description and usage

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

- models 155 - 199, #CVK3008 for 2" diameter - models 55 110, or #CVK3007 for 4" diameter - models 285 - 399). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-6.

The required combustion vent pipe and fittings are listed in Table 3D, on page 19 of this manual.

Figure 4-6 Concentric Sidewall Termination

3. Cut one (1) hole (5 inch diameter for #CVK3003 installations, 4 inch diameter for #CVK3008, or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.

a. Cement the Y concentric fitting to the larger kit pipe (FIG. 4-7). b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-7).

Figure 4-7 Kit Contents - CVK3008 & CVK3003 (reference Table 3B on page 16)

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 4-6).

2. Reference the Determine Location Section on page 22 of this manual for general termination considerations.

Figure 4-8 Kit Contents - CVK3007 (reference Table 3B on page 16)

RAIN CAP

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

6" (152 MM) DIA.

4" (102 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

"FLEXIBLE" PIPE COUPLING

4" CONCENTRIC

VENT KIT

Page 27

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent models

Figure 4-9 2" and 3" Concentric Vent Dimensional Drawing (reference Table 3D on page 19)

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-11).

 WARNING

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

 WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 4-11 Rain Cap to Vent Pipe Alternate Assembly

Figure 4-10 4" Concentric Vent Dimensional Drawing

(reference Table 3D on page 19)

(152 MM)

"B" DIA.

"G"

(76 MM)

(537 MM)

"H" DIA.

(254 MM) (194 MM)

"D"

"F"

(168 MM)

(76 MM)

"C" DIA.

"B" DIA. PVC VENT / EXHAUST

ABC DEF GH

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

(1524 MM)

(102 MM)

5. Install the Y concentric fitting and pipe assembly through the structure’s hole.

NOTICE

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

6. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for #CVK3003 and 3008 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

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

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-6.

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied SDR-26 PVC (D2241) pipe for CVK3003 and 3008, and standard schedule 40 PVC for CVK3007. Do not extend dimension D more than 60 inches (see FIG. 4-9 and FIG. 4-10).

"E"

NOTICE

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

Page 28

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Figure 4-12 Concentric Vent Sidewall Attachment

CAUTION

8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-12 for proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-13). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-13. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

12" MINIMUM

VENT

COMBUSTION AIR

Figure 4-13 Concentric Vent and Combustion Air Termination

Page 29

5 Vertical direct venting

Installation & Operation Manual

Vent/air termination – vertical

 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. Prepare the vent termination and the air termination elbow (FIG. 5-1A) by inserting bird screens. Bird screens should be obtained locally.

3. The vent must terminate at least 3 feet above the highest

place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

4. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

5. The vent piping must terminate in an up-turned coupling

as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel, above the air intake.

6. Maintain the required dimensions of the finished

termination piping as shown in FIG. 5-1A.

7. Do not extend exposed vent pipe outside of building

more than shown in this document. Condensate could freeze and block vent pipe.

 WARNING

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

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent, Sidewall Air Section.

Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent

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

BIRD SCREEN (TYPICAL)

VENT

COUPLING (FIELD SUPPLIED)

VENT OUTLET 12” MINIMUM ABOVE AIR INLET

COMBUSTION

AIR

6” MINIMUM ABOVE ROOF SNOW LINE

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

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

BIRD SCREEN

(TYPICAL)

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

VENT

COM,BUSTION AIR

8. Locate terminations so they are not likely to be damaged by foreign objects or subject to buildup of leaves or sediment.

Prepare roof penetrations

1. Air pipe penetration:

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

2. Vent pipe penetration:

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

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole.

Page 30

5 Vertical direct venting

Installation & Operation Manual

Prepare roof penetrations (continued)

3. Space the air and vent holes to provide the minimum spacing shown in FIG. 5-1A, page 29.

4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent pipe and air pipe.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers, terminate each vent/air connection as described in this manual (FIG. 5-2).

 WARNING

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Vertical termination – optional concentric vent

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and fittings are required to complete the installation.

The required combustion air and vent pipe fittings are listed in Table 3D, on page 19 of this manual.

Vertical termination installation

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

Figure 5-4 Concentric Vertical Termination

3. The air inlet of a Knight wall mount boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 5-2 Vertical Terminations with Multiple Boilers

12” MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET

12” MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER

Figure 5-3 Alternate Vertical Terminations with Multiple Boilers

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

2. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 4 inch diameter for #CVK3008 installations) into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit.

Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG. 4-7, page 26).

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

FIG. 4-7, page 26).

Page 31

5 Vertical direct venting (continued)

Installation & Operation Manual

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9, page

27).

 WARNING

4. Install the Y concentric fitting pipe assembly through the structure’s hole and field supplied roof boot/flashing.

NOTICE

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

5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.

NOTICE

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4, page 30.

NOTICE

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe. Add standard schedule 40 PVC pipe for #CVK3007 Do not extend dimension D more than 60 inches (see FIG. 4-9 and FIG. 4-10, page 27).

CAUTION

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

6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting.

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

8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

Figure 5-6 Concentric Vent Roof Installation

Figure 5-7 Concentric Vent and Combustion Air Vertical

Termination

12”

MINIMUM

COMBUSTION AIR (TYPICAL)

12” (18” FOR CANADA) MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24” ABOVE ROOF.

Page 32

5 Vertical direct venting

Installation & Operation Manual

Alternate vertical concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion

air routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.

The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A.

The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as specified in Table 3D on page 19.

Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.

Figure 5-8 Concentric Vent Example 1

FLUE EXHAUST

SEAL

COMBUSTION AIR

AIR INLET

EXISTING

SEAL

SEALED CAP

FLUE OUTLET

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

12” MIN.

W/ SCREEN

Figure 5-9 Concentric Vent Example 2

FLUE EXHAUST

COMBUSTION AIR

SEAL

EXISTING

SEALED CAP

FLUE OUTLET

SEAL

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.

If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A on page 10 for a list of corrosive contaminants and sources.

Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Vent / Air Inlet Size

Minimum Existing

Vent / Chase Size

2" 4"

3" 5" 4"

*For concept illustration only. Individual installations may

vary due to job site specific equipment.

Existing vent as a chase

Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.

Figure 5-10 Existing Vent as a Chase

FLUE EXHAUST

EXISTING

CAP

AIR INLET

SEAL

FLUE OUTLET

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Page 33

6 Hydronic piping

Installation & Operation Manual

System water piping methods

The Knight wall mount is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.

Observe a minimum of a 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

 WARNING

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.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-3 through 6-12), which will guide you through the installation of the Knight wall mount boiler (reference FIG.’s 6-1A and 6-1B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed makeup water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.

6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system.

10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The safety relief valve is installed at the factory located on the left-hand side of the boiler. Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

See the *piping illustrations included in this section, FIG.’s 6-3 through 6-10 for suggested guidelines in piping the Knight wall mount boiler with either zone valves or circulator pumps.

NOTICE

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 34

6 Hydronic piping

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler circulating pump:

A Grundfos UPS15-58FC pump for Models 55 - 155 and a Grundfos UPS26-99FC pump for Models 199 399 will be provided by the factory as the boiler circulation pump based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

Knight wall mount boilers are capable of controlling a

variable speed boiler circulator. Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG. 6-2 on page 36 at full speed.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in FIG. 6-2. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.

4. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

5. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-3 through 6-10. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

7. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

8. Unions:

Field supplied. Recommended for unit serviceability.

9. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

10. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME specifications.

Installation & Operation Manual

11. Boiler purge valve:

Factory supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.

12. System temperature sensor:

Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.

13. Indirect water heaters:

The Knight wall mount boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. As depicted in the piping diagrams on page 38 thru 47, there are two options when utilizing an indirect water heater.

A. The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.

B. The indirect water heater is connected to the system supply piping. A pump controlled by the Knight (wall mount) boiler’s control will regulate the flow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the Knight (wall mount) boiler’s control.

The Knight wall mount boiler is pre-configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming. The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating.

Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.

 WARNING

14. Y-Strainer:

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

The National Standard Plumbing Code, the

National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th Edition.

Page 35

6 Hydronic piping (continued)

Near boiler piping connections

Installation & Operation Manual

Figure 6-1A Near Boiler Piping

AIR

VENT

OUTLET

INLET

CONDENSATE

DRAIN

BOILER PUMP

TO FLOOR

DRAIN

Y-STRAINER

(RECOMMENDED)

MSY

SEPARATOR

EXPANSION TANK

AIR

DOMESTIC HOT WATER PUMP

INDIRECT DOMESTIC

HOT WATER

TANK

SYSTEM

PUMP

Figure 6-1B Near Boiler Piping w/Low Loss Header

AIR

VENT

OUTLET

INLET

CONDENSATE

DRAIN

SYSTEM SENSOR

AIR

SEPARATOR

TO FLOOR

DRAIN

BOILER

PUMP

Y-STRAINER

(RECOMMENDED)

LOW LOSS HEADER

(TYPICAL)

CHECK VALVE

AIR VENT VALVE

DRAIN VALVE

DRAIN (TYPICAL)

DOMESTIC HOT WATER PUMP

INDIRECT DOMESTIC HOT WATER TANK

TO SYSTEM

FROM SYSTEM

SYSTEM

PUMP

FILL VALVE

EXPANSION TANK

Circulator sizing

The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.

Page 36

6 Hydronic piping

-0.50

0.00

0.50

1.00

1.50

2.00

2.50

3.00

02468101214

FT/HD

FLOW

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

0 2 4 6 8 101214161820

FT/HD

FLOW

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

0 5 10 15 20 25 30 35 40 45

FT/HD

FLOW

399

FLOW

Figure 6-2 Pressure Drop vs. Flow

Installation & Operation Manual

MODEL

3.50

3.00

2.50

2.00

1.50

FT/HD

1.00

0.50

0.00

0 5 10 15 20 25 30 35

MODEL

199

285

Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°

20°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

55 5 0.27 1" UPS 15-58FC (1) 007 NRF-22 E7

85 8 0.94 1" UPS 15-58FC (1) 007 NRF-22 E7 110 10 1.53 1" UPS 15-58FC (2) 007 NRF-22 E7 155 15 4.26 1" UPS 15-58FC (3) 007 NRF-22 E7 199 19 1.13 1.25" UPS26-99F 0011 NRF-36 (1) E7 285 27 2.42 1.25" UPS26-99F 0011 NRF-36 (3) E7 399 38 1.42 1.5" UPS26-99F 0012 PL-55 E11

Pump

25°F Temperature Rise Applications

Model GPM FT/HD

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

55 4 0.17 1" UPS 15-58FC (1) 007 NRF-22 E7

85 7 0.72 1" UPS 15-58FC (1) 007 NRF-22 E7 110 8 0.98 1" UPS 15-58FC (2) 007 NRF-22 E7 155 12 3.13 1" UPS 15-58FC (3) 007 NRF-36 (1) E7 199 15 0.71 1.25" UPS26-99F 0011 NRF-36 (1) E7 285 22 1.61 1.25" UPS26-99F 0011 NRF-36 (3) E7 399 31 0.95 1.5" UPS26-99F 0012 PL-55 E11

Pump

MODEL

110

155

MODEL

Model GPM FT/HD

55 3 0.10 1" UPS 15-58FC (1) 007 NRF-22 E7

85 5 0.37 1" UPS 15-58FC (1) 007 NRF-22 E7 110 6 0.55 1" UPS 15-58FC (2) 007 NRF-22 E7 155 9 1.76 1" UPS 15-58FC (3) 007 NRF-36 (1) E7 199 11 0.38 1.25" UPS 15-58FC (3) 0010 NRF-36 (1) E7 285 16 0.85 1.25" UPS 15-58FC (3) 0010 NRF-36 (1) E7 399 22 0.48 1.5" UPS26-99F 0011 NRF-36 (1) E7

NOTICE

Pumps listed in bold type are provided by the factory as the boiler circulation pump.

The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.

35°F Temperature Rise Applications

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

Pump

Page 37

6 Hydronic piping (continued)

0.00

3.00

6.00

9.00

12.00

15.00

18.00

21.00

24.00

27.00

30.00

33.00

36.00

0246810121416182022242628303234363840

FT/HD

FLOW

VFD PUMP

155

199

285

399

UPS26-96FC/VS

TACO 0013 IFC VS

UPS26-96 FC/VS 50 %

TACO 0013 IFC VS 50%

Variable speed pump option

Table 6B Recommended Variable Speed Pumps

Installation & Operation Manual

Variable speed pumping to maintain a set differential temperature (ΔT) between two (2) sensors allows for the following:

- Automatic adjustment of the pump's performance to match the low of the system or zone

- Eliminate velocity noise in the zone valve systems

- Conserve energy

Since ΔT is directly releated to flow rate, the pump's speed continually adjusts to the required BTU per hour. In almost all applications the design of the system was based on being able to maintain a certain ΔT and figured by using the universal hydronics equation of BTU/hr = GPM x 500 x ΔT. Given that, any time there is a change to the heat load (i.e., warmer day or greater heat loss from a structure) then the GPM should change to match the required BTU/hr. This is achieved when the variable speed circulators automatically and continually adjust their GPM output (by varying speed) to match the required BTU/hr output of the system, no matter the changes in heat load, while always maintaining the designed ΔT between a supply and return sensor.

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control

- Pump is set for external signal control (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module will be required from the vendor

NOTICE

Pump sizing and flow requirements are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

It is recommended that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 6-3 through 6-9 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance if proper pump sizing and system flow rates are not adhered to.

SMART SYSTEM / Multi-temperature loop control option

The Knight wall mount boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help aid with this protection, Lochinvar offers the Multi- Temperature Loop Control Board Kit (RLY30086).

Page 38

6 Hydronic piping

Figure 6-3 Single Boiler - Primary / Secondary Piping

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE GAUGE

Installation & Operation Manual

MAKE UP WATER

SYSTEM SUPPLY

SYSTEM

BALL VALVE

(TYPICAL)

SENSOR

SYSTEM

CIRCULATOR

EXPANSION

TANK

DRAIN POINT

(TYPICAL)

BOILER

CIRCULATOR

AIR SEPARATOR

MAY SUBSTITUTE LOW LOSS HEADER

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

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE

PRESSURE

RELIEF

VALVE

DOMESTIC

HOT WATER

CIRCULATOR

FROM SYSTEM

ANTI-SCALD

MIXING VALVE

HOT

WATER

OUT

COLD

WATER

NOTICE

BOILER

INDIRECT

UNION

(TYPICAL)

TEMPERATURE /

DRAIN

PRESSURE

GAUGE

DHW TANK

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 39

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-4 Single Boiler - Single Temperature with Zone Valves - DHW Priority

ZONE #1

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP

WATER

PRESSURE

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

CIRCULATOR

PRESSURE

BOILER

GAUGE

ZONE #2

SYSTEM

CIRCULATOR

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE

ZONE #3

CIRCULATOR

DOMESTIC

HOT WATER

ZONE #4

ZONE VALVES (TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (RECOMMENDED)

HOT

WATER

OUT

ANTI-SCALD MIXING VALVE

COLD WATER IN

NOTICE

PRESSURE

RELIEF VALVE

BOILER

INDIRECT

DHW TANK

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 40

Installation & Operation Manual

6 Hydronic piping

Figure 6-5 Single Boiler - Single Temperature Zoned with Circulators - DHW Priority

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP

WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

BOILER

CIRCULATOR

PRESSURE

GAUGE

ZONE #2

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

Y-STRAINER (RECOMMENDED)

ZONE #3

DOMESTIC

HOT WATER

CIRCULATOR

ZONE #4

FLOW CHECK VALVE (TYPICAL)

ZONE CIRCULATORS (TYPICAL)

HOT

WATER

OUT

ANTI-SCALD

MIXING

VALVE

COLD WATER IN

NOTICE

PRESSURE

RELIEF VALVE

UNION (TYPICAL)

BOILER

TEMPERATURE /

DRAIN

PRESSURE

GAUGE

INDIRECT

DHW TANK

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 41

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-6 Multiple Boilers - Single Temperature Zoned with Zone Valves - DHW Priority

Number of Units

BACKFLOW

PREVENTER

BALL VALVE

(TYPICAL)

PRESSURE

REDUCING

VALVE

MAKE UP WATER

SYSTEM SUPPLY

AIR SEPARATOR

SENSOR

PRESSURE GAUGE

Model

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

85 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 155 2" 2" 2-1/2" 2-1/2" 3" 3" 4" 199 2" 2" 2-1/2" 3" 4" 4" 4" 285 2-1/2" 2-1/2" 3" 4" 4" 4" 5" 399 2-1/2" 3" 4" 4" 5" 5" 5"

ZONE #1

ZONE #2

234567 8

Required Pipe Sizes

ZONE #3

ZONE #4

ZONE VALVES (TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (RECOMMENDED)

EXPANSION

TANK

DRAIN POINT

TEMPERATURE /

PRESSURE

GAUGE

(TYPICAL)

BOILER CIRCULATOR

SYSTEM

CIRCULATOR

PRESSURE RELIEF VALVE

BOILER 2 (MEMBER 1)

DRAIN

MAY SUBSTITUTE LOW LOSS HEADER

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

Y-STRAINER (RECOMMENDED) (TYPICAL)

ANTI-SCALD

MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

BOILER 1 (LEADER)

INDIRECT

DHW TANK

UNION

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 42

Installation & Operation Manual

6 Hydronic piping

Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority

Number of Units

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE

GAUGE

Model

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

ZONE #1

ZONE #2 ZONE #3 ZONE #4

234567 8

Required Pipe Sizes

MAKE UP

WATER

SYSTEM SUPPLY

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

SENSOR

BOILER CIRCULATOR

PRESSURE

RELIEF VALVE

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

ANTI-SCALD

Y-STRAINER (RECOMMENDED) (TYPICAL)

MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

FLOW CHECK

VALVE

(TYPICAL)

ZONE CIRCULATORS

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

NOTICE

TEMPERATURE /

PRESSURE

GAUGE

BOILER 2 (MEMBER 1)

DRAIN

UNION

(TYPICAL)

BOILER 1 (LEADER)

INDIRECT

DHW TANK

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 43

6 Hydronic piping (continued)

Figure 6-8 Single Boiler - Multiple Temperature - DHW Priority

Installation & Operation Manual

MAKE

WATER

BACKFLOW

PREVENTER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

PRESSURE REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TEMPERATURE

LOOP #1

SYSTEM

SUPPLY SENSOR

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

Y-STRAINER (RECOMMENDED)

BOILER CIRCULATOR

FLOW CHECK

VALVE

TEMPERATURE

LOOP #2

120VAC TO PUMPS

SHIELDED CABLE TO

BOILER CONTROL

DOMESTIC

HOT WATER

CIRCULATOR

24V SIGNAL TO

MIXING VALVES

TEMPERATURE

LOOP #3

HOT WATER

OUT

MIXING VALVES

(TYPICAL)

WIRES TO LOOP SENSORS

MULTI-TEMP LOOP CONTROL

ANTI-SCALD MIXING VALVE

COLD WATER IN

CAUTION

NOTICE

PRESSURE

RELIEF

VALVE

BOILER

INDIRECT

DHW TANK

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

IMG00190

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 44

Installation & Operation Manual

6 Hydronic piping

Figure 6-9 Multiple Boilers - Multiple Temperature - DHW Piped as a Zone

MAKE

WATER

BACKFLOW

PREVENTER

AIR SEPARATOR

PRESSURE REDUCING VALVE

PRESSURE

GAUGE

MIXING VALVES

(TYPICAL)

SYSTEM

SUPPLY SENSOR

Model

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

TEMPERATURE

LOOP #1

234567 8

TEMPERATURE

LOOP #2

Number of Units

Required Pipe Sizes

TEMPERATURE

LOOP #3

WIRES TO LOOP SENSORS

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

Y-STRAINER

(RECOMMENDED)

BOILER CIRCULATOR

BOILER

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

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

DOMESTIC HOT WATER CIRCULATOR

PRESSURE

RELIEF

VALVE

MIXING VALVES

120VAC TO PUMPS

FLOW

CHECK

VALVE

BOILER

24V SIGNAL TO

MULTI-TEMP TO

LOOP CONTROL

SHIELDED CABLE TO BOILER CONTROL

HOT WATER

OUT

ANTI-SCALD MIXING VALVE

COLD WATER IN

CAUTION

NOTICE

UNION (TYPICAL)

DRAIN

TEMPERATURE / PRESSURE GAUGE

INDIRECT

DHW TANK

IMG00191

Mixing valves are required for the protection of low temperature loops.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 45

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-10 Single Boiler - Full Flow - Single Temperature - Zoned with Zone Valves - DHW Priority

ZONE #1

BACKFLOW

PREVENTER

MAKE UP

WATER

PRESSURE

REDUCING VALVE

AIR SEPARATOR

DRAIN POINT

(TYPICAL)

CIRCULATOR

PRESSURE

GAUGE

SYSTEM SUPPLY

SENSOR

BOILER

EXPANSION

TANK

BALL VALVE (TYPICAL)

Y-STRAINER (RECOMMENDED)

ZONE #2 ZONE #3

FLOW CHECK VALVE

ZONE #4

DOMESTIC HOT WATER CIRCULATOR

ZONE VALVES (TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (RECOMMENDED)

HOT

WATER

OUT

ANTI-SCALD MIXING VALVE

COLD WATER IN

NOTICE

PRESSURE

RELIEF VALVE

BOILER

INDIRECT

DHW TANK

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at all times during boiler operation. If the minimum flow requirements cannot be met at any time the boiler must be hydraulically separated from the system.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 46

Installation & Operation Manual

6 Hydronic piping

Figure 6-11 Single Boiler - Full Flow - Single Temperature Zoned with Valves - DHW Piped as a Zone

ZONE #1

PRESSURE

BACKFLOW

PREVENTER

MAKE UP

WATER

REDUCING VALVE

SYSTEM SUPPLY

AIR SEPARATOR

PRESSURE

SENSOR

GAUGE

ZONE #2

ZONE #3

ZONE #4

ZONE VALVES (TYPICAL)

DIFFERENTIAL PRESSURE BYPASS VALVE (RECOMMENDED)

EXPANSION

TANK

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

BOILER

CIRCULATOR

Y-STRAINER (RECOMMENDED)

PRESSURE

RELIEF VALVE

BOILER

HOT

WATER

OUT

INDIRECT

DHW TANK

ANTI-SCALD MIXING VALVE

COLD WATER IN

NOTICE

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 47

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-12 Single Boiler - Full Flow - Single Temperature Zoned with Circulators - DHW Piped as a Zone

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP

WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

EXPANSION

TANK

Y-STRAINER

(RECOMMENDED)

DRAIN POINT

(TYPICAL)

PRESSURE

GAUGE

ZONE #2

DOMESTIC HOT WATER CIRCULATOR

BALL VALVE (TYPICAL)

ZONE #3

ZONE #4

ANTI-SCALD

MIXING VALVE

FLOW CHECK VALVE (TYPICAL)

ZONE CIRCULATORS (TYPICAL)

HOT

WATER

OUT

COLD

WATER

NOTICE

PRESSURE

RELIEF VALVE

UNION (TYPICAL)

BOILER

INDIRECT

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

DHW TANK

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 48

7 Gas connections

Connecting gas supply piping

Installation & Operation Manual

1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler.

a. Install a field supplied sediment trap / drip leg

upstream of the boiler gas controls.

Figure 7-1 Gas Supply Piping

MANUAL SHUTOFF VALVE

(FIELD SUPPLIED)

UNION

2. Support piping with hangers, not by the boiler or its accessories.

 WARNING

3. Purge all air from the gas supply piping.

4. Before placing the boiler in operation, check the boiler and its gas connection for leaks.

a. Close manual main shutoff valve during any

pressure testing at less than 13 inches w.c.

b. Disconnect the boiler and gas valve from the gas

supply piping during any pressure testing greater than 13 inches w.c.

 WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

GAS SUPPLY

DRIP LEG

5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

Page 49

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

Figure 7-2 Inlet Pipe with Backup Wrench

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

Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 13). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at boiler (FIG. 7-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on

rated boiler input (divide by 1,000 to obtain cubic feet per hour).

a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 4 inches w.c. with gas flowing (verify during

boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if

inlet pressure can exceed 14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum.

Propane Gas:

NOTICE

USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

 WARNING

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with boiler on.

• Minimum 8 inches w.c. with gas flowing (verify during boiler startup).

 WARNING

Ensure that the high gas pressure regulator is at least 6 - 10 feet upstream of the appliance.

Page 50

7 Gas connections

Table 7A Natural Gas Pipe Size Chart

Installation & Operation Manual

Nominal

Iron Pipe

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet for 1/2 PSI

Size (Inches)

1/2

3/4

1-1/4

1-1/2

2-1/2

 WARNING

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

369

697

1400

2150

4100

6460

11200

23500

256

477

974

1500

2820

4460

7900

16100

205

384

789

1210

2260

3610

6400

13100

174

328

677

1020

1950

3100

5400

11100

155

292

595

923

1720

2720

4870

10000

1560

2460

4410

9000

Check inlet gas supply

NOTICE

 WARNING

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Shut off power at source.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

141

267

543

830

128

246

502

769

1440

2310

4000

8300

121

236

472

707

1330

2100

3800

7690

113

210

441

666

1250

2000

3540

7380

100

106

200

410

636

1180

1900

3330

6870

125

179

369

564

1100

1700

3000

6150

150

164

333

513

974

1540

2720

5640

175

149

308

472

871

1400

2500

5130

3. Loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG. 7-3.

4. Slowly turn on the gas supply at the field installed manual gas valve.

5. Turn on power at source..

6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Shut off power at source.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap.

200

138

287

441

820

1300

2340

4720

Page 51

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

14. Turn on the gas supply at the manual gas valve.

15. Turn on power at source.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Figure 7-3 Inlet Gas Supply Check

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Gas Pressure

The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Knight wall mount boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure. The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the venturi and blower.

 WARNING

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

IMG00163

LOOSEN SET SCREW [1] FULL TURN THEN PLACE TUBING OVER PRESSURE TAP

DETAIL A

Page 52

8 Field wiring

Installation & Operation Manual

 WARNING

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

NOTICE

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

 CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Figure 8-1 Remove Bezel

4. Wire the boiler pump as shown in FIG. 8-2.

5. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. 8-2.

6. To activate a system pump, wire as shown in FIG. 8-2. If the motor is larger than 1/8 hp or 1.8 amps, you must isolate with a relay.

Figure 8-2 Line Voltage Field Wiring Connections

REMOVE BEZEL

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Line voltage connections

1. Remove bezel as shown in FIG. 8-1.

2. Connect 120 vac power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-2.

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

Low voltage connections

1. Route all low voltage wires through the knockouts in the bottom front right side, just under the control panel, as shown in FIG. 8-3.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-4 on page 55 of this manual and the boiler wiring diagram.

Figure 8-3 Routing Field Wiring

LINE VOLTAGE JUNCTION BOX

LOW VOLTAGE CONNECTION BOARD

LOW VOLTAGE KNOCKOUTS

LINE VOLTAGE KNOCKOUTS

IMG00164

Page 53

8 Field wiring (continued)

Installation & Operation Manual

Thermostat

1. Connect the room thermostat or end switch (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in FIG. 8-4.

2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunlight, or fireplaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to

match total electrical power requirements of connected devices. See device manufacturers’ specifications and thermostat instructions for details.

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from direct sunlight or flow of heat or cooling from other sources.

2. Route sensor wires through a knockout in the bottom front right side of the boiler (see FIG. 8-3).

3. Connect outdoor temperature sensor (FIG. 8-4) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight wall mount boiler. If fixed temperature operation is required, do not install outdoor sensor.

DHW thermostat

1. Connect storage indirect water heater (DHW) thermostat

(FIG. 8-4) to the DHW thermostat terminals on the connection board. If a tank sensor is connected (see DHW Tank Sensor below) the tank thermostat is ignored.

DHW tank sensor

1. By installing a tank sensor, the SMART SYSTEM control can perform the tank thermostat function. The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6°F (3°C) below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point.

2. The tank sensor included with the Lochinvar Squire Indirect DHW tank (TST20015) is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals on the Low Voltage Connection Board.

3. If the TST20015 is not compatible with the indirect tank, a tank thermostat can be used to control the boiler. The tank thermostat should be installed per the manufacturers instructions and wired to the DHW Thermostat terminals on the Low Voltage Connection Board.

Louver relay

1. If louvers need to operate when the boiler fires, they can be controlled by this output. Connect these terminals to a 24 vac relay coil, which is wired to operate the louvers (FIG. 8-4).

Louver proving switch

1. When the operation of the louvers needs to be verified before the boiler fires, remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch (FIG. 8-4).

Flow switch

1. A flow switch is used to guarantee flow through the boiler before allowing it to fire. The flow switch must be installed at the boiler outlet.

2. Remove the jumper wire from these terminals and connect these terminals to the normally open contacts on the flow switch (FIG. 8-4).

Variable speed system pump

If a variable speed pump is used in the primary loop, and a 0-10V signal is available from the pump speed control, this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load. By connecting this 0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or cascade) can modulate up and down as the primary flow increases and decreases.

Boiler pump speed output

This 0 - 10V output is available to control the speed of a variable speed boiler pump. The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum T across the heat exchanger, as well as prevent high limit lockouts when the flow in the primary loop is extremely low. Connect this output to the 0 - 10V input on the boiler pump speed control.

Rate output

This output provides a 0 - 10V signal that is proportional to the firing rate of the boiler. This may be used by a BMS system to monitor the actual rate of the boiler.

 WARNING

Failure to use the correct sensor may result in the tank temperature being either above or below the set point.

ModBus

When the optional ModBus interface module is installed, the RS-485 ModBus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module.

Page 54

8 Field wiring

Installation & Operation Manual

System supply sensor

1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected). If it is desired to control the system return temperature, then program the SMART SYSTEM control to use the inlet sensor as the controlling sensor. See the Knight Wall Mount Service Manual for instructions on how to do this. When the inlet sensor is programmed as the controlling sensor, it is strongly recommended that the SYSTEM SUPPLY sensor be installed. DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be used for the system sensor.

3. Connect these terminals to the system supply sensor (FIG. 8-4).

Boiler management system

1. An external control may be connected to control either the firing rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the Heat/Loop Demand 1 terminals. Otherwise, the SMART SYSTEM control will be enabled by the 0-10V signal.

2. Make sure the (-) terminal is connected to the (-) or common output terminal of the external control, and the (+) terminal is connected to the 0 - 10 vdc or (+) terminal of the external control. Make sure the (-) voltage is not below ground.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the boiler is down.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See page 63 “Configuration of the Cascade” for a detailed explanation of this procedure.

Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop (FIG.’s 6-4 and 6-6). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG. 8-4). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 8-4). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters. If the outdoor air sensor is not connected, the Leader control will maintain the fixed water temperature set point that is programmed into the control.

If a Thermostat, Zone Control enable output, or Building Management System enable output is available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the Heat/Loop Demands 1-3 (FIG. 8-4). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the Heat/Loop demand input. This will initiate a call for heat on the Cascade.

Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards (FIG. 8-4). If more than two boilers are on the Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible.

Page 55

8 Field wiring (continued)

Figure 8-4 Low Voltage Field Wiring Connections

SYSTEM SUPPLY SENSOR

OUTDOOR SENSOR

TANK SENSOR

BOILER

SHIELD

Installation & Operation Manual

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

A B

IMG00126

FROM

BOILER

SHIELD

SYSTEM

BUILDING

MANAGEMENT

NEEDED

WIRE AS

SYSTEM PUMP

SPEED CONTROL

CUTOFF

LOW WATER

BOILER PUMP

LOUVER RELAY

LOUVER

COM

DEMAND 2

DEMAND 3

HEAT / LOOP

PROVING SWITCH

FLOW SWITCH

TANK THERMOSTAT

DEMAND 1

HEAT / LOOP

Page 56

9 Condensate disposal

Installation & Operation Manual

Condensate drain

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

2. The bottom of the boiler has a 1 1/4 inch pipe for connection of the condensate trap (FIG. 9-1).

3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Knight wall mount boiler will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.

A Neutralizer Kit is available from the factory (Kit 3087).

4. Do not expose condensate line to freezing temperatures.

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

NOTICE

6. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage. The switch should be wired in series with the blocked drain switch inside the boiler (see FIG. 10-1 on page 58).

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.

Figure 9-1 Condensate Disposal

CONDENSATE TRAP

REMOVABLE CAP FOR CLEANING TRAP

CONDENSATE DRAIN CONNECTION ROUTE TO FLOOR DRAIN OR NEUTRALIZING FILTER USING 3/4" PVC TUBING

IMG00159

Page 57

10 Start-up

Installation & Operation Manual

Check/control water chemistry

 CAUTION

Hardness less than 7 grains

1. Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not fill boiler or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or spa water.

Test/replace freeze protection fluid

1. For systems using freeze protection fluids, follow fluid manufacturer’s instructions.

2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer’s instructions.

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

Freeze protection (when used)

1. Determine freeze protection fluid quantity using

system water content, following fluid manufacturer’s instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.

2. Local codes may require a backflow preventer or actual

disconnect from city water supply.

3. When using freeze protection fluid with automatic fill,

install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

4. The freeze protection set points may be lowered when

freeze protection fluid is used (see the Knight Wall Mount Service Manual).

4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

 WARNING

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve (see purge/drain

valves, in piping diagrams on pages 38 through 47). Route the hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between

the purge valve and fill connection to the system.

c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open other vents:

a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close boiler drain valve and manual air vent.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water fill pressure for a residential system is 12 psi.

b. Pressure will rise when boiler is turned on and

system water temperature increases.

3. Refill to correct pressure.

Page 58

10 Start-up

Installation & Operation Manual

Check for gas leaks

 WARNING

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate fittings and condensate trap.

2. Fill condensate trap with enough water to make the ball float (FIG. 10-1).

3. Loosen compression fitting (FIG. 10-1).

4. Slide condensate trap onto condensate drain at the bottom of the unit.

5. Tighten compression fitting.

 WARNING

Figure 10-1 Condensate Trap

The condensate trap (FIG. 10-1) must have the float ball in place during all times of boiler operation to avoid flue gas emission from the condensate drain line. Failure to ensure the float ball is in place could result in severe personal injury or death.

COMPRESSION FITTING

Check thermostat circuit(s)

1. Disconnect the two external wires connected to each of the heat/loop demand terminals on the connection board.

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board.

CONDENSATE DRAIN

FLOAT BALL

REMOVABLE CAP TO CLEAN OUT TRAP

IMG00209

Clean/Inspect Trap Assembly

1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

2. Refill the trap according to the instructions above.

Page 59

10 Start-up (continued)

Installation & Operation Manual

Final checks before starting the boiler

 Read the Knight Wall Mount Service Manual to

familiarize yourself with SMART SYSTEM control module operation. Read this manual, pages 60 and 61 for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 57

and 58 have been completed.

 Ensure float ball is inside condensate trap (see FIG. 10-1).

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG.’s 10-2 and 10-3 on pages 60 and 61.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is boiler water temperature above 200°F?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the Troubleshooting Section of the Knight Wall Mount Service Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 57 and 58 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

 Check vent piping and air piping

1. Check for gas tight seal at every connection, seam of air piping, and vent piping.

 WARNING

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 48 of this manual (connecting gas supply piping).

 WARNING

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

 WARNING

Venting system must be sealed gas tight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check flame and combustion

1. Shut off the main power to the boiler by placing the On/Off switch in the OFF position.

2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point.

3. Turn on the main power to the boiler by placing the On/Off switch in the ON position.

Page 60

10 Start-up

Figure 10-2 Operating Instructions - Models 55 - 285

Installation & Operation Manual

Page 61

10 Start-up (continued)

Figure 10-3 Operating Instructions - Model 399

Installation & Operation Manual

Page 62

Installation & Operation Manual

10 Start-up

Check flame and combustion (continued) Set space heating operation

NOTICE

4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 70).

5. Locate the pinhole button below the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.

7. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range,

reference the Troubleshooting Section of the Knight Wall Mount Service Manual for possible causes and corrective actions.

Table 10A Flue Products Chart

Natural Gas Propane

Please note that the brackets ([]) denote screen status.

Determine controlling sensor

For space heating systems, the temperature control can be based on one of three sensors; the inlet, outlet, or system supply sensor. The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor. The control will automatically switch to the system supply sensor once it is connected. If it is desired to base the temperature control on the inlet sensor, the appropriate parameter must be changed in the control. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system pump (if connected), and the boiler pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect DHW (Domestic Hot Water) tank, and the set point is not met, it also turns on the boiler pump. After the space heating call for heat ends, the system pump continues to run for a short period of time. The system pump can be programmed to run continuously, except during outdoor shutdown. If the boiler pump was running, it continues to run for a short period of time as well. These pump delays are factory set to 30 seconds. If different delays are desired, the appropriate parameters in the control must be changed. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Adjust set point temperature(s)

8.0% - 10% 3.0% - 6.5% 10.0% - 11% 4.1% - 5.4%

8. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm. Turn the manual shutoff switch to the ON position and reset the control.

9. Turn off power at source and replace the flue temperature

sensor into the flue pipe connection.

10. Place the boiler back into normal operation.

 WARNING

You must replace the flue gas temperature sensor to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures.

1. From the Status Screen press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select the appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to additional set points.

6. Press the RIGHT SELECT [HOME] key to upload the changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the new settings will be discarded.

Please note that the brackets ([]) denote screen status.

Page 63

10 Start-up (continued)

Set domestic hot water (DHW) operation

Verify DHW mode

Installation & Operation Manual

There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum firing rate may be limited in this mode if desired.

In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop. When a DHW demand begins, the control will turn on the DHW pump output, and raise the system temperature set point to the DHW boiler set point (if higher). The boiler pump will be turned on. The system pump may be forced on, forced off, or not changed, depending on the System Pump Mode selected (reference the Knight Wall Mount Service Manual for details). In this mode, any low temperature zones (such as radiant heating) may need additional controls to limit the water temperature sent to those zones.

Set DHW boiler target temperature

When in the DHW Mode, the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point. This set point is set at the factory to 180°F. If a different set point is desired, the appropriate parameter in the control must be changed. See the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Set maximum DHW fan speed

If the rated input of the indirect tank is less than the maximum output of the boiler, change the maximum DHW fan speed setting to limit the boiler output accordingly, see the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

Set clock

NOTICE

The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 4 hours. Use the following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

2. The display changes to read [PASSWORD], with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

Please note that the brackets ([]) denote screen status.

7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial.

9. Turn the NAVIGATION dial to adjust the date. Press the NAVIGATION dial.

10. Turn the NAVIGATION dial to adjust the year. Press the RIGHT SELECT [SAVE] key.

11. Press the RIGHT SELECT [HOME] key.

NOTICE

The clock is automatically updated whenever a PC is connected and the Win_Pro-Installer program is started.

Configuration of the cascade

NOTICE

When installed in a Cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters.

Press the [MENU] key for at least five (5) seconds. Input the Installer code as described in the Knight Wall Mount Service Manual. Once the control parameters have been accessed, use the NAVIGATION dial to select the Control Mode parameters. Press the NAVIGATION dial to access these parameters.

Rotate the NAVIGATION dial to select the parameter Cascade Address. Press the NAVIGATION dial to access this parameter. Each appliance in the Cascade system must be programmed with its own address. The boiler designated as the Leader will have an address of 0. The remaining boilers in the Cascade will be Members and have addresses from 1 - 7. Rotate the NAVIGATION dial to select the appropriate address. Press the RIGHT SELECT [SAVE] key.

Press the RIGHT SELECT [HOME] key to upload the address into the control. Repeat this procedure for all boilers in the Cascade, designating the Leader control and the Member controls.

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Please note that the brackets ([]) denote screen status.

Page 64

11 Operating information

General

How the boiler operates

The Knight wall mount boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate. The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow.

How the control module operates

The SMART SYSTEM control module receives inputs from boiler sensors and external devices. The control module activates and controls the blower and gas valve to regulate heat input and switches the boiler, Domestic Hot Water (DHW), and system pumps on and off as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature, boiler inlet water temperature, system temperature, a 0 - 10V signal, or Modbus, depending on the parameter settings.

Control inputs and outputs

Space heating demands

There are three (3) heat/loop demand connections available on this control. These inputs tell the boiler to provide water for space heating. Each demand connection has its own set point and outdoor air reset curve. When multiple demands have a call for heat the control will give priority to the demand with the highest set point.

Example: Assume that both Heat/Loop Demand 1 and Heat/ Loop Demand 2 have a call for heat. Heat/Loop Demand 1 has a set point of 110°F. Heat/Loop Demand 2 has a set point of 140°F. The boiler will regulate the system temperature to 140°F until Heat/Loop Demand 2 has been satisfied. Once Heat/Loop Demand 2 has been satisfied the boiler will provide 110°F water to the system.

 CAUTION

0 - 10V input (set point or power)

The Knight wall mount boiler can be controlled by a Building Management System (BMS) using a 0 - 10 vdc signal. The control can be configured by the installer to use this signal to either control set point or firing rate.

SMART SYSTEM Multi-temp loop control

The Knight wall mount boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. This device controls the temperatures of up to three (3) separate loops, based on the settings for the three (3) heat/loop demands (reference Lochinvar kit RLY30086).

When multiple temperature loops are used, thermostatic mixing valves are required for the protection of any low temperature loops.

Installation & Operation Manual

The Knight wall mount boiler can also be programmed to accept a call for heat from a 0 - 10V signal, reference the Knight Wall Mount Service Manual for a detailed explanation of this procedure.

DHW priority

The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the DHW thermostat input is ignored. When a boiler is programmed for DHW Normal Mode, the maximum firing rate can be limited to match the input rating of the indirect tank coil.

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is in progress, and the DHW is in Normal Mode, the control will start the DHW pump and shut the boiler pump off. The system pump will remain on. For stand-alone boilers, if the space heating call is still active while the DHW call is in operation, the control will wait for 30 minutes (time adjustable by installer) then it will switch back to the space heating demand. There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating. The control will switch back and forth until one of the heat demands end.

Programmable controlling sensor

The control module is programmed to use the outlet sensor as the control sensor by default. If a system supply sensor is connected, the control automatically uses it as the control sensor. The control sensor can be changed by the installer to the inlet sensor. If the inlet sensor is chosen as the controlling sensor, it is recommended that the system supply sensor be installed in order to provide the best control of the inlet temperature.

Anti-cycling

After the burner turns off, the control will delay the next burner cycle for a set time period (time is adjustable by the installer). The time delay will be bypassed if the inlet water temperature drops too far during the delay.

Boiler and system pump control

The boiler pump will run whenever the burner is firing, unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank. The boiler pump will run during Freeze Protection Mode as well. It will continue to run for a short time after the burner turns off or the Freeze Protection Mode ends.

The system pump will run whenever there is a space heating call for heat, or the boiler goes into Freeze Protection Mode. It may be programmed to run during a DHW call for heat when the DHW is programmed for Zone Mode. It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode. The system pump can be programmed to run continuously if desired, except during outdoor shutdown and/ or a DHW call for heat.

Temperature control

Modulation

The Knight wall mount boiler is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations.

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11 Operating information (continued)

Installation & Operation Manual

Ramp delay

For systems with lower flow, the SMART SYSTEM can limit the firing rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat to a space heating call for heat. There are six (6) limits that can be programmed, as well as six (6) time intervals corresponding to each limit. The sixth limit will also limit the firing rate for the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the firing rate to its lowest setting.

Outdoor air reset

With the outdoor air sensor connected, the control module will calculate the set points of the three (3) space heating demands based on the programmed reset curves. The installer can change the slope of the reset curves by several adjustable parameters. The user can limit the maximum set point for the system using the space heating set points.

Protection features

Outlet temperature, flue temperature, and temperature rise limiting

The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds 185°F, the unit will reduce the fan speed. If the outlet water temperature exceeds 195°F the control will shut the unit down until it cools off.

The control module monitors the flue temperature by a sensor located in the flue exhaust. If the flue temperature exceeds 215°F the control will reduce the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F and the minimum off time has expired.

Boost function

If outdoor air reset is active, and any space heating demand has been active continuously for a set period of time (time adjustable by installer) and there has been no DHW demands, the control will increase the set point of that demand by a fixed number of degrees (adjustable by installer). This process will continue until the space heating demand ends, the set point reaches the programmed set point or a maximum of 20 increases has occurred. Once the system heat demand is satisfied, the set point will revert to the value determined by the reset curve.

Night setback

The controller may be programmed to reduce the space heating and DHW set points during certain times each week. Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback. Any night setback scheduled within the next seven (7) days can be temporarily bypassed if desired.

Flame current support

To prevent nuisance shutdowns when the boiler is firing at minimum rates, the control will increase the firing rate when the flame signal drops too low.

Freeze protection

DO NOT install the boiler in a room likely to freeze.

The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system.

• The SMART SYSTEM control module provides freeze-up protection as follows when the boiler water temperature drops below 45°F:

• Below 45°F, the boiler and system pumps operate constantly.

• Below 37°F, the boiler turns on and runs at 20% of rate.

• Boiler and pumps turn off if boiler water temperature rises above 45°F.

• Lower temperatures may be programmed for systems with anti-freeze solutions (see the Knight Wall Mount Service Manual.

NOTICE

 CAUTION

When system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust.

This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.

Page 66

11 Operating information

Monitor external limits

Connections are provided on the connection board for external limits such as flow switch, low water cutoff, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the boiler is running, and when it is unable to operate.

Run-time and cycle counting

The control uses two timers to monitor the total hours of burner operation. One timer monitors the time the boiler is firing in the Space Heating Mode. The other timer monitors the time the boiler is in the DHW Mode.

The control uses two (2) ignition counters to monitor the amount of boiler cycles. The first counter counts all ignitions of the control. The second counter counts only ignition attempts that have failed.

Service reminder

The control can be programmed for service reminder notification. This notification will become active when either a set time frame has expired, or a set amount of running hours or cycles has expired (all adjustable by the installer). The display will show a Maintenance Required screen. The installer's name and phone number can be programmed into the control. This information will appear on the Maintenance Required screen. The service reminder notification can be reset or disabled by the installer.

Error logging

The control will hold in memory the last 10 lockouts as well as the last 10 blockings. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences of each will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature. The target temperature can be set between 32°F and 190°F.

• Target temperature is fixed when the outdoor sensor is not installed.

Installation & Operation Manual

High limit operations

The Knight wall mount is equipped with adjustable automatic reset and manual reset high limits. The automatic reset high limit has a maximum set point of 200°F and the manual reset high limit has a maximum set point of 210°F.

When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 190°F, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at 210°F.

High limit test procedure

NOTICE

1. Turn ON the main power to the boiler by placing the ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating the NAVIGATION dial counterclockwise, then press the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current outlet temperature (or to its minimum setting, whichever is higher) by turning the NAVIGATION dial counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL set point, the MRHL will function causing boiler lockout. If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL set point, locate the pinhole (SERVICE button) below the RESET button on the display board. Insert a thin probe (such as a paper clip) into the hole and press the button continuously for five (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will fire at ignition speed and will then modulate up to full fire.

10. Once the outlet temperature rises up to the MRHL set point, the MRHL will function, causing the boiler to shut down and lock out.

11. Repeat Steps 2, 3 and 4.

12. Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise.

13. Repeat Steps 6 and 7.

14. Press the RESET button to clear the lockout.

15. If needed, press the RIGHT SELECT [STOP] key to exit Service Mode.

Please note that the brackets ([]) denote screen status.

• Target temperature is calculated as described in this section under “Outdoor Reset Operation” and “Target Temperature Boost” when the outdoor sensor is connected.

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11 Operating information (continued)

Installation & Operation Manual

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available

from the factory (WTR20009).

Outdoor reset operation, if used

Target temperature with outdoor reset

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

See the Knight Wall Mount Service Manual to change the settings.

Reset curve

The reset curve looks at outdoor air temperature and adjusts the set point.

Cascade

When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/Lag or Efficiency Optimization control methods.

Once the Leader boiler receives a call for heat from a room thermostat, BMS, or Modbus, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve parameters. See the Knight Wall Mount Service Manual to program the reset curve. If outdoor air reset is not desired, do not connect the outdoor air sensor. A fixed temperature set point can be programmed into the control. See page 62 of this manual to program the set point.

If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the Knight Wall Mount Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals. The sequence will change every hour during the first 24 hours, after that the sequence will be changed once every 24 hours. The switching on/off sequence will be as follows:

TIME SWITCHING ON SEQUENCE

Start L-M1-M2-M3-M4-M5-M6-M7

1 hour M1-M2-M3-M4-M5-M6-M7-L

2 hours M2-M3-M4-M5-M6-M7-L-M1

If a boiler is used to heat an indirect DHW tank, or locks out, it will automatically be given the lowest priority for the rest of that 24 hour period.

DHW, Night Setback, and Ramp Delay operation with cascade

For Normal Mode DHW operation any boiler(s) in the Cascade can be selected to provide heat for a DHW call. Select a boiler to be designated as the DHW boiler. Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device. When the boiler receives a DHW call, the Leader control will take that boiler out of the Cascade sequence. If another boiler is available, the Leader will start it up to take its place.

The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its firing rate to maintain this. Once the DHW call has been satisfied, the Leader control will place that boiler back into the Cascade sequence.

Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode.

When DHW is programmed for Zone Mode, connect the DHW thermostat or tank sensor to the Leader boiler. When a DHW call is received, the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point.

Night Setback operation of the boilers within the Cascade is available. Programming of the Night Setback will be done through the Leader boiler. Refer to the Knight Wall Mount Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the Knight Wall Mount Service Manual is not active when the boilers are part of a Cascade system.

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11 Operating information

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The flow switch and/or LWCO must close.

Installation & Operation Manual

3. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by firing the spark electrode and opening the gas valve.

6. If flame is not detected after the sparking ends, the control will perform a postpurge, then start another prepurge cycle and try to light the burner again. The control will perform a total of 4 attempts before locking out.

7. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command (such as a 0-10V BMS signal).

Page 69

11 Operating information (continued)

OPERATION DISPLAY

8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on first, then the boiler pump will turn off (boiler and DHW pump operation briefly overlap to ensure flow is maintained through the unit). This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead. The control will then modulate to maintain the outlet temperature to the DHW boiler set point.

9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisfied.

10. Once both calls for heat are satisfied, the control will turn off the burner. The blower will continue to run during the postpurge period.

Installation & Operation Manual

11. Any pumps that are running will continue to run for their respective pump delay times before turning off, unless programmed to remain on continuously. A 60 second anti-cycle period will start, which will delay any new call for heat until it times out.

12. In Standby, ready to start a new cycle.

Access modes

User

The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is flashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 63).

Installer

Most parameters are available only to the installer, accessible by entering the installer password, see the Knight Wall Mount Service Manual.

Saving parameters (reference the Parameter Table in

the Knight Wall Mount Service Manual)

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the parameter listings; press again to return to the menu listings. Remember to press the RIGHT SELECT [HOME] key when finished programming in order to save the changes made.

NOTICE

Please note that the brackets ([]) denote screen status.

See the Knight Wall Mount Service Manual for a detailed description of parameters and access modes.

Page 70

Installation & Operation Manual

11 Operating information

Knight wall mount boiler control module

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

Figure 11-1 Control Panel

NAVIGATION DIAL

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in the center):

MENU = Left SELECT Key SETPOINTS = NAVIGATION Dial - Pressing Down SHDN = Right SELECT Key

Page 71

11 Operating information (continued)

Figure 11-2 Status Display Screen

Installation & Operation Manual

(BOILER STATUS)

(OPERATIONAL INFORMATION)

(LEFT SELECT

KEY)

(NAVIGATION DIAL)

Status Display Screens

Section Display Description

STANDBY

START The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE The unit has initiated a prepurge period on a call for heat.

The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.

(CALL FOR

HEAT)

(RIGHT SELECT KEY)

(Boiler Status

Bar)

(Call for Heat

Indicators)

IGNITION The unit has begun a spark period to ignite the main burner.

The unit has fired and is running at the displayed percentage.

POSTPURGE

SHUTDOWN The unit has been placed in the OFF position.

SETPOINT MET The controlled temperature has exceeded its set point and its offset.

BLOCKED

The call for heat has been satisfied and the unit runs the fan for an additional postpurge period to clear the combustion chamber and vent system of residual flue products.

The unit has detected a condition that has temporarily interrupted the current call for heat.

Heat/Loop Demand 1 has a call for heat.

Heat/Loop Demand 2 has a call for heat.

Heat/Loop Demand 3 has a call for heat.

The tank thermostat or sensor has a call for heat.

Indicates which heat/loop demand shows priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

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11 Operating information

Status Display Screens (cont’d)

Section Display Description

SYSTEM: The temperature read by the system supply sensor (if connected).

TANK: The temperature read by the tank sensor (if connected).

OUTDOOR: The temperature read by the outdoor sensor (if connected).

INLET TEMP: The temperature read at the inlet to the heat exchanger.

OUTLET TEMP: The temperature read at the outlet of the heat exchanger.

Installation & Operation Manual

(Operational

Information)

DELTA T:

FLUE TEMP: The temperature read by the flue sensor.

FLAME CURRENT: The current measured by the flame sense circuit.

FAN SPEED: The speed of the combustion blower.

BOILER PUMP: The status of the boiler pump output.

SYSTEM PUMP: The status of the system pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT: The speed signal received from a variable speed system pump control.

RATE OUTPUT: A 0 - 10V signal indicating the firing rate of the boiler.

SH RUN HOURS: The total hours of operation in the Space Heating Mode.

SH CYCLES: The total burner cycles in the Space Heating Mode.

The temperature difference between the inlet and the outlet of the heat exchanger.

DHW RUN HOURS: The total hours of operation in the DHW Mode.

DHW CYCLES: The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:* The last 10 lockouts.

NIGHT SETBACK Shows the next Night Setback trigger (if active).

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11 Operating information (continued)

Status Display Screens (cont’d)

Section Display Description

EXIT Press the LEFT SELECT key to exit the current screen or setting.

Press and hold the LEFT SELECT key for 5 seconds to enter the Menu Screen.

Installation & Operation Manual

(LEFT SELECT

key function)

(NAVIGATION

Dial Function)

YES

LIMITS

HOME

SKIP

Press the LEFT SELECT key to confirm that the boiler needs to shutdown.

Press the LEFT SELECT key to enter the screen that allows you to adjust the limit settings.

Press the LEFT SELECT key to return to the Status Screen and upload parameter changes.

Press the LEFT SELECT key when in the Night Setback Screen to access the Night Setback Skip Screen.

Turning the NAVIGATION dial will select the next or previous Status Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by the cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current setting.

(RIGHT SELECT

key function)

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME

Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes.

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12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Installation & Operation Manual

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and fill with fresh water

• Check for leaks (water, gas, flue, condensate)

• Verify flue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and flame sense electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and performance verification per Section 10

ANNUAL START-UP

of this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high fire)

Owner maintenance

(see the Knight Wall Mount User’s Information

Manual for instructions)

• Check boiler area

Daily

Monthly

Periodically

• Check pressure/temperature gauge

• Check vent piping

• Check air piping

• Check air and vent termination screens

• Check relief valve

• Inspect condensate drain system

• Check air vents

• Test low water cutoff (if used)

• Reset button (low water cutoff)

• Clean the heat exchanger if flue temperature is more than 54°F above return water temperature.

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

Every

6 months

End

of season

months

• Check boiler piping (gas and water) for leaks

• Operate relief valve

• Shut boiler down (unless boiler used for domestic hot water)

Page 75

12 Maintenance (continued)

Installation & Operation Manual

 WARNING

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual and the Knight Wall Mount Service Manual.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of the boiler.

2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.

3. After the condensate trap is cleaned or serviced, it must be checked to ensure that it is installed and draining properly.

Figure 12-1 Condensate Trap

FLOAT BALL

CONDENSATE DRAIN

Inspect condensate trap

Monthly inspection:

1. The condensate trap should be inspected monthly to ensure the trap is properly installed and connected to the condensate pipe under the boiler, see FIG. 12-1.

2. The condensate line should be inspected monthly for obstructions, making sure it allows free flow for condensate to drain.

3. Inspect the neutralizing kit (if installed) monthly to ensure the condensate is draining properly, and there is still an adequate amount of neutralizing agent available.

Annual cleaning:

1. The condensate trap should be cleaned at least once annually, or at the end of each heating season, by removing the bottom cap and cleaning out any sediment that exists.

2. The provided condensate trap is equipped with a ball that acts as a seal against harmful flue gases escaping in case there is no condensate in the trap. If this ball is not present, flue gases may be able to pass through the trap when there is no condensate present, resulting in an unsafe environment. It is important to check and make sure the ball is still located in the trap, acting as a seal against flue gases at least once annually and after every cleaning.

BOTTOM CAP

 WARNING

It is in the best interest of the end user to make sure the ball is present and the condensate trap is filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line. Failure to have the ball present or to fill the trap could result in severe personal injury or death.

IMG00046

Check all piping for leaks

 WARNING

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

Page 76

12 Maintenance

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

 WARNING

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold fill pressure for the system. Verify it is

correct (must be a minimum of 12 psi).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect air separators.

Check expansion tank

1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks and air eliminators.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - Hydronic Piping before proceeding further.

 WARNING

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

Installation & Operation Manual

 WARNING

2. After following the warning directions in this manual, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

Inspect ignition and flame sense electrodes

1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of the Knight Wall Mount Service Manual. Adjust settings if necessary. See Section 1 of the Knight Wall Mount Service Manual for adjustment procedures.

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

Page 77

12 Maintenance (continued)

Installation & Operation Manual

Perform start-up and checks

1. Start boiler and perform checks and tests specified in Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 (page 77).

4. When replacing the burner, ensure gasket is in good condition and positioned correctly (FIG. 12-2).

Figure 12-2 Burner Assembly

BURNER PLATE

GASKET, BURNER PLATE

INSULATION, BURNER DOOR

BURNER GASKET

BURNER

Check flame signal

1. At high fire the flame signal shown on the display should be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode.

3. See Section 3 - Troubleshooting of the Knight Wall Mount Service Manual for other procedures to deal with low flame signal.

Review with owner

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

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

3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Cleaning boiler heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup.

• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it has been firing.

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

4. Remove the heat exchanger access cover and burner.

 WARNING

5. Remove the condensate trap from the bottom of the boiler. Place a bucket underneath the condensate fitting attached to the heat exchanger.

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

7. Using a clean cloth dampened with warm water, wipe out the combustion chamber. Rinse out debris with a low pressure water supply.

8. Allow the heat exchanger to thoroughly dry.

9. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 - Startup on pages 59 and 62 of this manual.

10. Replace the burner, access cover and condensate trap. Restore boiler to operation.

 CAUTION

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

* Do NOT use a metal brush.

Oiled bearing circulators

1. The circulator shipped with the Knight wall mount boiler is water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

3. Replace the boiler front access cover.

Page 78

13 Diagrams

Figure 13-1 Ladder Diagram

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF SWITCH

PC INTERFACE

ALARM

BELL

SWITCH

SILENCING

CONTACTS

RUN-TIME

CONTACTS

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

SYS PUMP

BLR PUMP

OUT

RATE

OUT

SHIELD

MODBUS

SHIELD

ALARM

X4-3

CN5-5

X1-6

0-10V

X5-9

CONNECTION

JUNCTION BOX

INTEGRATED CONTROL

3.15A

SYSTEM PUMP

BOILER PUMP

.8A

120 VAC

24 VAC

CN7-3

CN7-1

15 15

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

BOARD

CN8-1

CN8-2

CN8-3 X6-3

RELAY

DHW PUMP

RELAY

24V DC

SUPPLY

HEAT/LOOP

THERMOSTAT

LOW GAS

PRESSURE

SWITCH

RIBBON CABLE

CN5-1

CN5-8

CN5-2

CN5-9

CN6

X6-1

X6-2

LWCO

24 VAC

DEMAND

TANK

M O

D B U S

X1-1

X5-1

HIGH GAS

PRESSURE

SWITCH

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X4-1

X4-2

X4-3

SYSTEM PUMP "L"

X1-2

BOILER

PUMP "L"

X1-4

DHW

PUMP "L"

X1-3

TERMINAL

STRIP

CONNECTION BOARD

CN7-4

CN7-2

INTEGRATED

CONTROL

X9-2

X9-1

X9-3

Installation & Operation Manual

TERMINAL STRIP 120V SUPPLY "N"

GND

SYSTEM

PUMP "N"

GND

SYSTEM

PUMP

BOILER

PUMP "N"

GND

BOILER

PUMP

DHW

PUMP "N"

TERMINAL

STRIP

DHW PUMP

FLOW

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possib le, switches are shown without utiliti es (gas, water or electricity) connected to the unit. As such, actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present.

2. See wiring diagram for additional notes.

BLOWER

CN5-14 X4-8

CN5-10

X4-12

CN5-7 X4-1

X4-9

CN5-13

CN5-6

X4-2

CN5-12

X4-10

CN5-11

X4-11

CN5-3

CN5-4 X4-4

X5-2

X5-10

X5-11

X2-2

X2-1

TR2

X1-7

FLAME ROD

X4-5

X5-16

X5-15

NEUTRAL

INTEGRATED

CONTROL

GAS VALVE

RELAY

X5-7

X5-8

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

LADDER DIAGRAM

LBL20170 REV D

GROUND

Page 79

13 Diagrams (continued)

Figure 13-2 Wiring Diagram

Installation & Operation Manual

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

CONNECTION BOARD

BELL JUMPER

ALARM BELL

SILENCING SWITCH

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK THERMOSTAT HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

3 2 1

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32

CN5-1 CN5-8 CN5-2 CN5-9 CN5-3 CN5-10 CN5-11 CN5-4 CN5-5 CN5-14 CN5-12 CN5-6 CN5-13 CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

BMS

0-10V

OUT

RATE

OUT

OPTION

LOW

WATER

SHIELD

JUMPER

SHIELD

0-10V

24 VAC

COM

SYS PUMP

BLR PUMP

MODBUS

CUT-OFF

GROUNDING

Notes:

1. All wiri ng must be installed in accordan ce with:

2. If any original eq uipment w ire as suppli ed with minimum of 105°C. Exceptions: Replacement high vo or ribbo n cables can l ead to oper ational problems which could result in non-re pairable d amage to t he integrat ed controll er or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

33 34 35 36 37 38 39 40 41 42 43 44

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

X5-1 X5-2

local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada the appliance must be replaced, it must be replaced

ltage spark lead and ribbon cables must be purchase

MTR-01

CN8-1

CN8-2

CN8-3

X6-3

X6-2

X6-1

X6-4

X4-1 X4-2 X4-3 X4-4

X1-1 X1-2 X1-3

INTEGRATED

CONTROL

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

X9-1

X9-2 X9-3

X9-4

with wire having same wire gauge (AWG) and rated for a

d from t he factory. Use of a non- approved spark lead

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HO USING

X1-3

X1-4

X1-2

X1-6

X1-5

X1-8

X1-1

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

O/BK

X5-4

R/BK

X5-12

X5-6

P/BK

X5-5

W/BK

X5-13

X5-14

X2-2

X2-1

X1-7

W/R

TR2

ON/OFF SWITCH

BLOWER

1 2 345

-T

FLAME SENSOR SPARK

ROD

CAUTION

TRANSFORMER

AIR PRESSURE SWITCH

OPERATING SENSOR S1a

HIGH LIMIT SENSOR S1b

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

GAS VALVE @24VAC

HIGH VOLTAGE SPARK LEAD

JUNCTION

BOX

N L

L N

BOX DEPICTS

OPTIONAL

ITEMS

120V

GND

SUPPLY

WIRING DIAGRAM

LBL20169 REV D

DHW PUMP

BOILER PUMP

SYSTEM PUMP

Page 80

Revision A (ECO #C06854) initial release. Revision B (ECO #C08222) reflects the changes to the water pipe

clearances from 1" to a 1/4" (ECR #R04077), pages 7, 8, and 33 and changes made to the service clearances (left side) from 24" to 12" (ECR R04002).

Revision C (ECO #C08645) reflects additional cleaning and inspection instructions for the condensate trap (page 75).

Revision D (ECO #C09197) reflects additional information added to the humidity warning on page 7, along with updates made to the SMART SYSTEM control (ECR #R04523).

Revision E (ECO #C09803) reflects the addition of the new Polypropylene Vent material section, rearranging the venting section, and the addition of the AHRI and ASME logos (R05009).

Revision F (ECO #C09843) reflects the addition of the manual air vent in the outlet tubing and the new condensate trap pipe (R04984).

Revision G (ECO C10297) reflects the addition of the venting notice on page 16 and updates made to the ignition timing information.

Revision H (ECO C10450) reflects changes made to Table 10A on page 62.

WH-I-O Rev H

05/12