KBII-I-O Rev D
Installation & Operation Manual
Models: 81 - 286
This manual must only be used by
ƽ WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight Boiler Service Manual,
before installing. Perform steps in
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.
Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
When servicing boiler –
ƽ WARNING
this manual and the Knight Boiler Service
Manual, before installing. Perform steps
in the order given.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
User – This manual is for use only
• To avoid severe burns, allow boiler to cool before
performing maintenance.
by
a
qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Boiler operation –
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
• 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.
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.
NOTICE
• 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.
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.
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.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
• 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.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
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.
ƽ WARNING
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present.
Do not use “homemade cures” or “boiler
patent medicines”. Serious damage to
WHAT TO DO IF YOU SMELL GAS
ƽ CAUTION
the boiler, personnel, and/or property
may result.
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
3
Installation & Operation Manual
The Knight Boiler - How it works...
16. SMART SYSTEM Control Module
1. Stainless steel heat exchanger
The SMART SYSTEM Control responds to internal and
external signals and controls the blower, gas valve, and pumps
to meet the heating demand.
Allows system water to flow through specially designed
coils for maximum heat transfer, while providing
protection against flue gas corrosion.
The coils are
17. Manual air vent
encased in a jacket that contains the combustion process.
Designed to remove trapped air from the heat exchanger
coils.
2. Combustion chamber access cover
Allows access to the combustion side of the heat
exchanger coils.
18. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the boiler.
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.
19. High voltage junction box
The junction box contains the connection points for the line
voltage power and all pumps.
4. Gas valve
20. Boiler drain port
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.
Location from which the heat exchanger can be drained.
21. Low voltage connection board
The connection board is used to connect external low voltage
devices.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated)
22. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
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.
23. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
7. Boiler outlet temperature sensor (housed with the
24. Access cover - front
high limit sensor)
Provides access to the gas train and the heat exchanger.
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.
25. Ignition electrode
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides
surface and flame.
a
view of the burner
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.
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
9. Temperature and pressure gauge (field installed, not
Used by the control module to detect the presence of burner
flame.
shown)
Monitors the outlet temperature of the boiler as well as the
system water pressure.
29. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial
and a multiple line liquid crystal display.
30. Top panel
Removable panel to gain access to the internal components.
11. Flue pipe adapter
31. Power switch
Allows for the connection of the PVC vent pipe system to the
boiler.
Turns 120 VAC ON/OFF to the boiler.
32. Leveling legs
12. Burner (not shown)
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
33. Air pressure switch
13. Water outlet (system supply)
The air pressure switch detects blocked inlet conditions.
NPT water connection that supplies hot water to the
system, either 1" or 1-1/4", depending on the
model.
34. Transformer
The transformer provides 24V power to the integrated control.
35. High limit sensor (housed with the outlet
temperature sensor)
14. Water inlet (system return)
NPT water connection that returns water from the
system to the heat exchanger, either 1" or 1-1/4",
depending on the model.
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will
break the control circuit, shutting the boiler down.
15. Gas connection pipe
Threaded pipe connection, either 1/2" or 3/4",
depending on the model. This pipe should be connected
to the incoming gas supply for the purpose of delivering
gas to the boiler.
36. Gas shutoff switch
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
37. Over-temp switch (Model 286 Only) (located underneath
access cover)
Used to detect excessive temperatures on the upper coil of the heat
exchanger.
4
Installation & Operation Manual
The Knight Boiler - How it works...
(continued)
Models 81 - 211
30
10
22
24
29
31
11
6
Front View - Models 81 - 211
Rear View - Models 81 - 211
10
19
33
21
18
16
34
3
15
4
5
36
8
1
14
25
7
35
27
17
13
20
12
2
28
26
32
23
Left Side (inside unit) - Models 81 - 211
Right Side (inside unit) - Models 81 - 211
5
Installation & Operation Manual
The Knight Boiler - How it works...
Model 286
18
15
10
37
24
Rear View - Model 286
Front View - Model 286
33
34
4
Right Side (inside unit) - Model 286
Left Side (inside unit) - Model 286
6
Installation & Operation Manual
Ratings
Knight Boiler
I=B=R Rating
Other Specifications
Gross
Output
MBH
Input
MBH
Net
Vent
Boiler
Water
Size
I=B=R
Ratings
Water,
MBH
Air
Size
Model Number
Water
Gas
Content Connections Connections
Gallons
(Note 4)
Note: Change “N” to
(Note 5)
“L” for L.P. gas models.
Min
16
Max
80
0.6
0.7
1.3
1.7
2.4
1"
1"
1/2"
1/2"
1/2"
1/2"
3/4"
3"
3"
3"
3"
4"
3"
3"
3"
3"
4"
(Note 2,7)
72
(Note 3,7)
63
KBN081
KBN106
KBN151
KBN211
KBN286
21
30
42
57
105
150
210
285
94
82
1"
135
190
260
117
165
226
1"
1-1/4"
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
8. Knight 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 is listed to UL353.
1. As an Energy Star Partner, Lochinvar has determined that
Knight 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 I=B=R 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.
UNIT EQUIPPED FOR
4. Knight boilers require special gas venting. Use only
the vent materials and methods specified in the Knight
Installation and Operation Manual.
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
5. Standard Knight 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 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.
Figure A High Altitude Label Location
7
7. Ratings have been confirmed by the Hydronics Institute,
Section of AHRI.
Installation & Operation Manual
1 Determine boiler location
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.
Installation must comply with:
ƽ WARNING
•
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.
Failure to install the appliance indoors
could result in severe personal injury,
death, or substantial property damage.
•
•
This appliance requires a special venting
system. If using PVC the vent connection
to the appliance must be made with the
starter CPVC pipe section provided with
the appliance. The field provided vent
fittings must be cemented to the CPVC
pipe section. Use only the vent materials,
primer and cement specified in this manual
to make the vent connections. Failure to
follow this warning could result in fire,
personal injury, or death.
ƽ WARNING
The Knight boiler gas manifold and
NOTICE
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
Closet and alcove installations
A closet is any room the boiler is installed in which is less
than 67 cubic feet for KBN081 and KBN106 models, 86 cubic
feet for KBN151 models, 107 cubic feet for KBN211 models,
and 120 cubic feet for KBN286 models.
• 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.
An alcove is any room which meets the criteria for a closet
with the exception that it does not have a door.
Example: Room dimensions = 4 feet long, 3 feet wide, and
8 foot ceiling = 4 x 3 x 8 = 96 cubic feet. This would be
considered a closet for a Knight Boiler.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
For closet and alcove installations as
ƽ WARNING
shown in FIG.’s 1-1 and 1-2, CPVC or
stainless steel vent material must be used
inside the structure. The ventilating air
openings shown in FIG.’s 1-1 and 1-2 are
required for this arrangement. Failure to
follow this warning could result in fire,
personal injury, or death.
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.
ƽ WARNING
4. The Knight boiler must be installed so that gas control
system components are protected from dripping or
spraying water or rain during operation or service.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6 mm) from combustible
materials.
2. Vent pipe – at least 1" (25 mm) from combustible
materials.
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.
3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance
minimums.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 9 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
boiler without removing it from the space.
8
Installation & Operation Manual
1 Determine boiler location
(continued)
Figure 1-1 Closet Installation - Minimum Required Clearances
CLOSET INSTALLATION
1" MINIMUM CLEARANCE
AROUND HOT WATER
For closet installations, CPVC or
ƽ WARNING
PIPES AND VENT PIPE
13”
TOP
stainless steel vent material MUST
BE used in a closet structure due to
elevated temperatures. Failure to
follow this warning could result in
fire, personal injury, or death.
6"
VENTILATING*
AIR OPENING
CLOSED DOOR
12"
LEFT
VENTILATING*
AIR OPENING
6"
14"
REAR
0"
RIGHT
*AREA OF EACH OPENING:
1 SQ. INCH PER 1000 BTU PER HOUR INPUT
WITH A MINIMUM OF 100 SQ. INCHES.
RECOMMENDED SERVICE CLEARANCES:
6"
FRONT
FRONT
TOP
- 24”
- 24”
LEFT SIDE - 24”
REAR
- 24”
Figure 1-2 Alcove Installation - Minimum Required Clearances
ALCOVE INSTALLATION
1/4" (6 MM) MINIMUM CLEARANCE
For alcove installations, CPVC or
stainless steel vent material MUST
BE used in an alcove structure
due to elevated temperatures.
Failure to follow this warning
could result in fire, personal
injury, or death.
AROUND HOT WATER PIPES
1” (25 MM) MINIMUM CLEARANCE
AROUND VENT PIPE
ƽ WARNING
13”
TOP
OPEN
FRONT
12”
LEFT
14”
REAR
0”
RIGHT
18”
FRONT
RECOMMENDED SERVICE CLEARANCES:
FRONT
TOP
- 24”
- 24”
LEFT SIDE - 24”
REAR
- 24”
9
Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
Residential garage installation
Knight boiler alone in boiler room
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.
1. No air ventilation openings into the boiler room are
needed when clearances around the Knight 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.
• 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.
Knight boiler in same space with other gas or oil-
fired appliances
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
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.
Vent and air piping
The Knight boiler requires a special vent system, designed for
pressurized venting.
The space must be provided with
ƽ WARNING
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the Knight
boiler.
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.
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.
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 boiler using any other means.
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 boiler because it takes its combustion air
from outside (direct vent installation).
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.
Flooring and foundation
Flooring
The Knight boiler is approved for installation on combustible
flooring, but must never be installed on carpeting.
Prevent combustion air contamination
Do not install the boiler on carpeting even
ƽ WARNING
Install air inlet piping for the Knight 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
11 for products and areas which may cause contaminated
combustion air.
if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
You must pipe combustion air to the boiler
ƽ WARNING
air intake. Ensure that the combustion air
will not contain any of the contaminants
in Table 1A, page 11. Contaminated
combustion air will damage the boiler,
resulting in possible severe personal
injury, death or substantial property
damage. Do not pipe combustion air near
a swimming pool, for example. Also,
avoid areas subject to exhaust fumes from
laundry facilities. These areas will always
contain contaminants.
10
Installation & Operation Manual
1 Determine boiler location
(continued)
Table 1A Corrosive Contaminants and Sources
When using an existing vent system to
install a new boiler:
Products to avoid:
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
ƽ WARNING
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
emissions, causing severe personal injury
or death.
Check the following venting components before installing:
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
• Material - For materials listed for use with this appliance,
see Section 3 - General Venting, Table 3A. For stainless
steel venting, an adapter of the same manufacturer
(Table 3B) must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3C.
Check to see that this size is used throughout the vent
system.
Paint or varnish removers
• Manufacturer - For a stainless steel application, you
must use only the listed manufacturers and their type
product listed in Table 3A for CAT IV positive pressure
venting with flue producing condensate.
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
• 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.
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
• 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
3B for the manufacturer of the installed vent.
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 12.
Auto body shops
With 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 16.
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
If any of these conditions are not met,
ƽ WARNING
the existing system must be updated or
replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
Garages with workshops
11
Installation & Operation Manual
1 Determine boiler location
When removing a boiler from existing
common vent system:
Do not install the Knight boiler into a
ƽ DANGER
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.
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
ƽ WARNING
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while
the other appliances remaining connected to the common
venting system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage
or restriction, leakage, corrosion, or other deficiencies,
which could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space
in which the appliances remaining connected to the
common venting system are located and other spaces of
the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined herein, return
doors, windows, exhaust fans, fireplace dampers, and any
other gas-burning appliance to their previous conditions
of use.
12
Installation & Operation Manual
2 Prepare boiler
5. After installation is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit
bag) to the left side of the unit in the lower left corner.
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler,
remove the parts box.
2. Remove the front door to access the lag bolts in front of
the unit (FIG. 2-1).
6. Replace the top and front access covers.
Table 2A LP Conversion Table
3. To remove the boiler from the pallet (after removing the
front door):
LP Conversion Table
a. Remove the two lag bolts from the wood pallet
inside the boiler (FIG. 2-1).
b. Detach the boiler from the lag bolts in the rear of the
unit, see FIG. 2-1.
Model
LP Orifice Stamping
81
80
105
150
106
151
211
286
Do not drop the boiler or bump the jacket
NOTICE
210 / W150
285
on the floor or pallet. Damage to the
boiler can result.
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.
ƽ WARNING
Figure 2-1 Boiler Mounted on Shipping Pallet
Figure 2-2 Installing Propane Orifice
. 2
Gas conversions
For a boiler already installed, you must
ƽ WARNING
turn off gas supply, turn off power and
allow boiler to cool before proceeding.
You must also completely test the boiler
after conversion to verify performance
as described under Start-up, Section 10
of this manual. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Leveling the boiler
1. Set the boiler in place and check level.
a) Adjust legs if necessary to level boiler, see FIG. 2-3
below.
You must install a propane orifice to
operate the Knight boiler on propane gas.
Verify when installing that the orifice size
marking matches boiler size (Table 2A).
1. Remove the top and front access covers from the unit (no
tools required for removal).
Figure 2-3 Leveling Legs on the Boiler
2. Remove the three screws securing the gas valve to the
venturi (FIG. 2-2).
3. 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).
Place the orifice into the black rubber grommet in the
side of the gas valve and secure in the valve (FIG. 2-2).
4. Reposition the gas valve against the venturi and replace
the screws (FIG. 2-2) securing the valve to the venturi.
13
Installation & Operation Manual
3 General venting
Direct venting options - Sidewall Vent
Figure 3-1 PVC/CPVC Two-Pipe Sidewall
Termination - See page 21 for more details
Figure 3-2 Stainless Steel Two-Pipe - See page 22
for more details
Figure 3-3 PVC/CPVC Concentric Sidewall
Termination - See page 25 for more details
14
Installation & Operation Manual
3 General venting
(continued)
Direct venting options - Vertical Vent
Figure 3-4 PVC/CPVC Two-Pipe
Vertical Termination - See page
28 for more details
Figure 3-5 Stainless Steel Two-
Pipe Vertical Termination - See
page 28 for more details
Figure 3-6 PVC/CPVC Concentric
Vertical Termination - See page 30
for more details
Direct venting options - Vertical Vent, Sidewall Air
Figure 3-8 Stainless Steel Vertical Vent, Sidewall Air
- See page 20 for more details
Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air -
See page 20 for more details
Stainless steel vent/air design and terminations will vary slightly by manufacturer.
NOTICE
15
Installation & Operation Manual
3 General venting
Install vent and combustion air piping
The Knight boiler must be vented and
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.
ƽ WARNING
ƽ DANGER
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.
Requirements for installation in
Canada
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.
1. Installations must be made with a vent pipe system
certified to ULC-S636.
IPEX is an approved vent manufacturer in Canada
supplying vent material listed to ULC-S636.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
PVC/CPVC vent piping materials
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings. For concentric vent installations, the inner
vent tube must be replaced with field supplied certifiedvent
material to comply with this requirement.
Use only the materials listed in Table
ƽ WARNING
3A for vent pipe, and fittings. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
4. The 3" Concentric Vent Kit available from Lochinvar (see
Section 4 – Sidewall Termination – Optional Concentric
Vent) and the 3" Concentric Vent Kit available from IPEX
are both approved for use on the Knight boiler. Both
kits are listed to the ULC-S636 standard for use in Canada.
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.
NOTICE
For closet and alcove installations, CPVC
or stainless steel material MUST BE used in
a closet/alcove structure. Failure to follow
this warning could result in fire, personal
injury, or death.
Improper installation of PVC or CPVC
ƽ CAUTION
ƽ WARNING
NOTICE
systems may result in injury or death.
Installing vent and air piping
Use only cleaners, primers, and solvents that
NOTICE
All PVC vent pipes must be glued, properly
supported, and the exhaust must be
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
This appliance requires a special venting
system. The vent connection to the
appliance must be made with the starter
CPVC pipe section provided with the
appliance if PVC/CPVC vent is to be used.
For stainless steel venting use an adapter
from Table 3B (page 19) that corresponds
with the intended vent manufacturer to
are approved for the materials which are
joined together.
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.
ƽ WARNING
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.
be used and discard the CPVC starter 4. Clean all pipe ends and fittings using a clean dry rag.
piece. 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
this manual to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
(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.
16
Installation & Operation Manual
3 General venting
(continued)
6. Priming and Cementing:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
f. While primer is still wet, apply an even coat of
approved cement to the fitting socket.
b. Apply a liberal even coat of primer to the fitting
socket.
g. Apply a second coat of cement to the pipe.
h. 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.
c. Apply a liberal even coat of primer to the pipe end to
approximately 1/2" beyond the socket depth.
d. Apply a second primer coat to the fitting socket.
e. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the fitting socket.
i. Wipe excess cement from the joint removing ring or
beads as it will needlessly soften the pipe.
Table 3A Vent Pipe, and Fittings
All vent pipe materials and fittings must comply with the following:
Standards for installation in:
Item
Material
United States
Canada
PVC Plastic Pipe, Schedules 40, 80, & 120
PVC Plastic Pipe Fittings, Schedule 40
PVC Plastic Pipe Fittings, Schedule 80
PVC - DWV Pipe and Fittings
ANSI/ASTM D1785
ANSI/ASTM D2466
ANSI/ASTM D2467
ANSI/ASTM D2665
CPVC and PVC venting must be ULC-S636
Certified. IPEX is an approved manufacturer
in Canada supplying vent material listed to
ULC-S636.
Vent pipe and
fittings
CPVC Plastic Pipe, Schedule 40 & 80
ANSI/ASTM F441
CPVC Plastic Pipe Fittings, Schedule 80
AL29-4C
ANSI/ASTM F439
UL1738
ULC-S636
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
Approved Stainless Steel Vent Manufacturers
Make
Model
FasNSeal Vent / FasNSeal Flex* Vent
Z-Vent
ProTech Systems (Simpson Dura-Vent Co.)
Z-Flex (Nova Flex Group)
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.
PVC/CPVC air intake/vent connections
1. Combustion Air Intake Connector (FIG.’s 3-9 and 3-10) - 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 3-9 and 3-10) - 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 3-9 Near Boiler PVC/CPVC Venting Models
Figure 3-10 Near Boiler PVC/CPVC Venting Model 286
81 - 211
AIR
VENT
3” CPVC PIPE SUPPLIED WITH BOILER
MUST BE USED FOR VENT CONNECTION
4” CPVC PIPE SUPPLIED WITH BOILER
MUST BE USED FOR VENT CONNECTION
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET
AND ALCOVE INSTALLATIONS.
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET
AND ALCOVE INSTALLATIONS.
17
Installation & Operation Manual
3 General venting
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.
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 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.
Failure to properly seal all joints and seams
ƽ DANGER
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.
Stainless steel vent
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3A.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
Use only the materials, vent systems, and
ƽ WARNING
terminations listed in Table 3B. DO
NOT mix vent systems of different types
or manufacturers, unless listed in this
manual. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
Using vent or air intake materials other
ƽ WARNING
than those specified, failure to properly
seal all seams and joints or failure to follow
vent pipe manufacturer’s instructions can
result in personal injury, death or property
damage. Mixing of venting materials will
void the warranty and certification of the
appliance.
Installations must comply with applicable
NOTICE
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
The use of double-wall vent or insulated
NOTICE
material for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.
Installation of a stainless steel vent system
NOTICE
should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
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:
The installer must use a specific vent starter
NOTICE
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.
adapter at the flue collar connection,
supplied by the vent manufacturer to
adapt to its vent system. See Table 3B for
approved vent adapters. Discard CPVC
starter piece.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe
should use a silicone sealant to ensure a proper seal at the
appliance connection and the air inlet cap connection. Dryer
vent or flex duct should use a screw type clamp to seal the vent
to the appliance air inlet and the air inlet cap. Proper sealing
of the air inlet pipe ensures that combustion air will be free of
contaminants and supplied in proper volume.
18
Installation & Operation Manual
3 General venting
(continued)
Stainless steel air intake/vent connections
Figure 3-11 Near Boiler Stainless Steel Venting Model 286
1. Combustion Air Intake Connector (FIG. 3-11) - 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. 3-11) - 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.
3" S.S. ADAPTER
3" S.S. INTERMEDIATE
(FOR SAF-T VENT ONLY)
Table 3B Approved Stainless Steel Terminations and Adapters
ProTech
Heat Fab
Z Flex
FasNSeal
Saf-T Vent
Z-Vent
Model
Intake
Air
Intake
Air
Termination
Boiler
Flue
Boiler Intermediate
Adapter Adapter
Flue
Termination
Boiler
Flue
Intake Air
Adapter Termination
Adapter Termination Termination
Termination
FSBS3
300715
9392
5300CI
2SVSTP03
2SVSRCX03
303889
KB80210 9353BUREZ-1*
KB285600 9454BUREZ-1*
9314TERM 2SVSLA03
9414TERM 2SVSLA04
2SVSTEX0390
2SVSTEX0490
81 - 211
286
FSRC3(R.C)
FSBS4
F303759
FSAIH04
303888
9492
5400CI
2SVSTP04
2SVSRCX04
FSRC4(R.C.)
* = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-11, unless approved vent
other than standard diameter is used. Consult a Heat Fab representative for questions.
The Knight boiler uses model specific combustion air intake
and vent piping sizes as detailed in Table 3C below.
Minimum/Maximumallowablecombustion
air and vent piping lengths are as follows:
Combustion Air = 12 equivalent feet minimum / 100 equivalent
feet maximum
Table 3C Air Intake/Vent Piping Sizes
Model
81 - 211
286
Air Intake
3 inches
Vent
Vent = 12 equivalent feet minimum / 100 equivalent feet
maximum
3 inches
4 inches
4 inches
When determining equivalent combustion air and vent length,
add 5 feet for each 90° elbow and 3 feet for each 45° elbow.
Increasing or decreasing combustion air
or vent piping is not authorized.
NOTICE
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45°
elbows + (1) concentric vent kit (CVK3003) = 49 equivalent
feet of piping.
The appliance output rating will reduce by
NOTICE
up to 1.5% for each 25 feet of vent length.
19
Installation & Operation Manual
3 General venting
•
•
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.
Table 3D Concentric Vent Kit Equivalent Vent Lengths
Equivalent Vent
Model Kit Number
Length
81 - 211
286
CVK3003
CVK3007
3 feet
3 feet
•
Removing from existing vent
When utilizing the single pipe method,
Follow the instructions in Section 1, page 12 of this manual
when removing a boiler from an existing vent system.
ƽ WARNING
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.
Vent and air piping
Vent and air system:
Installation must comply with local
requirements and with the National
NOTICE
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
Table 3E Optional Room Air Kit
You must also install air piping from outside to the boiler air
intake adapter. The resultant installation is direct vent (sealed
combustion).
Model
81 - 211
286
Kit Number
KIT30052
KIT30053
You may use any of the vent/air piping methods covered in
this manual. Do not attempt to install the Knight boiler using
any other means.
Air contamination
DO NOT mix components from different
systems. The vent system could fail,
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.
ƽ WARNING
causing leakage of flue products into the
living space. Use only approved stainless
steel, PVC or CPVC pipe and fittings. For
PVC/CPVC use with primer and cement
specifically designed for the material used.
Vent, air piping and termination:
Please read the information given in Table 1A, page 11,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
The Knight 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.
If the boiler combustion air inlet is located in
ƽ WARNING
a laundry room or pool facility, for example,
Optional room air
these areas will always contain hazardous
contaminants.
Optional room air is intended for
commercial applications. Combustion
NOTICE
To prevent the potential of severe personal
ƽ WARNING
air piping to the outside is recommended
for residential applications.
injury or death, check for areas and products
listed in Table 1A, page 11 before installing
the boiler or air inlet piping.
Commercial applications utilizing the Knight 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.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
• Relocate air inlet and vent terminations
to other areas.
•
The unit MUST be installed with the appropriate
room air kit (Table 3E).
•
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.
20
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination – sidewall
Figure 4-1A PVC/CPVC Sidewall Termination of Air
and Vent
Followinstructionsbelowwhendetermining
vent location to avoid possibility of severe
ƽ WARNING
TO BOILER
INTAKE AIR
CONNECTION
personal injury, death, or substantial
property damage.
FROM BOILER
VENT PIPE
CONNECTION
A gas vent extending through an exterior
ƽ WARNING
wall shall not terminate adjacent to a wall
12"
MIN
TO
OVER-
HANG
POSSIBLE ORIENTATIONS
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.
VENT / AIR
TERMINATION
Do not connect any other appliance to the
12"
ƽ WARNING
MIN
vent pipe or multiple boilers to a common
vent pipe. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
GRADE OR
SNOW LINE
Table 4A Sidewall Vent Kits
Installation must comply with local
NOTICE
requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S. installations
or CSA B149.1 for Canadian installations.
Model Kit Number
Vent Size
81 - 211
286
KIT30045
KIT30046
3 inch vent
4 inch vent
Determine location
If using the alternate sidewall termination:
Locate the vent/air terminations using the following guidelines:
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.
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 19
of this manual.
2. You must consider the surroundings when terminating
the vent and air:
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
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.
Do not exceed the maximum lengths of the
ƽ WARNING
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.
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.
Figure 4-1B Alternate PVC/CPVC Sidewall Termination
of Air and Vent w/Field Supplied Fittings
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.
Sidewall vent and air inlet terminations
must terminate in the same pressure zone.
ƽ WARNING
f. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
21
Installation & Operation Manual
4 Sidewall direct venting
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,
pages 21 and 23. Also maintain the following:
a. Vent must terminate:
Vent/air termination – sidewall
Figure 4-1C Alternate PVC/CPVC Venting Arrangement
(if Space Allows) w/Field Supplied Fittings
TO BOILER
• 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.
COUPLING
INTAKE AIR
CONNECTION
12” MIN
15” MAX
FROM BOILER
VENT PIPE
CONNECTION
BIRD SCREEN
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.
12”
MIN
BIRD
SCREEN
GRADE OR
SNOW LINE
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.
6. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
Figure 4-1D Alternate PVC/CPVC/SS Venting
Arrangement - Typical Stainless Steel Sidewall
Termination of Air and Vent w/Field Supplied Fittings,
Utilizing 90° Elbow Intake
Figure 4-2A Clearance to Gravity Air Inlets
TO BOILER
INTAKE AIR
CONNECTION
12" MIN
15" MAX
FROM BOILER
VENT PIPE
CONNECTION
12"
MIN.
12" MIN
BIRD SCREEN
GRADE OR
SNOW LINE
VENT / AIR
TERMINATION
MODELS 80 - 285
12"
MIN.
Figure 4-1E Alternate SS Venting Arrangement -
Typical Stainless Steel Sidewall Termination of Air and
Vent w/Field Supplied Fittings, Utilizing FasNSeal’s
Hood Intake
12"
MIN.
Figure 4-2B Alternate Clearance to Gravity Air Inlets w/
Field Supplied Fittings
BIRD SCREEN
TO BOILER
INTAKE AIR
CONNECTION
12" (305 MM) MIN
15" (381 MM) MAX
FROM BOILER
VENT PIPE
CONNECTION
12”
MIN.
BIRD
SCREEN
(TYPICAL)
12" (305 MM) MIN
GRADE OR
SNOW LINE
12”
MIN.
MODEL 285 WITH FASNSEAL ONLY
12”
MIN.
22
Installation & Operation Manual
4 Sidewall direct venting
(continued)
4. Assemble the vent cap to the vent plate (see FIG. 4-4A).
Insert the stainless steel screws into the vent cap screw
hole openings and securely attach the vent cap to the vent
plate.
Figure 4-3A Clearance to Forced Air Inlets
IF LESS
THAN 10’
VENT / AIR
TERMINATION
36"
MIN.
5. Seal all wall cavities.
Figure 4-4A Sidewall Termination Assembly
FORCED AIR
INLET
AIR PIPING
VENT PIPING
VENT PLATE
7' MIN. ABOVE ANY
PUBLIC WALKWAY
WALL PLATE
VENT CAP
GALVANIZED
THIMBLE
Figure 4-3B Alternate Clearance to Forced Air Inlets w/
Field Supplied Fittings
IF LESS
THAN 10’
Prepare wall penetrations (Alternate -
Field Supplied Option)
36”
MIN.
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.
FORCED AIR
INLET
2. Vent pipe penetration:
BIRD
SCREEN
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:
(TYPICAL)
7’ MIN. ABOVE ANY
PUBLIC WALKWAY
• 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. 4-4B.
Prepare wall penetrations
1. Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
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.
4. Follow all local codes for isolation of vent pipe when
passing through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
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:
Figure 4-4B Alternate Sidewall Termination Assembly w/
Field Supplied Fittings
ELBOW
AIR PIPING
• 4½ inch hole for 3 inch vent pipe
• 5½ inch hole for 4 inch vent pipe
VENT PIPING
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
BIRD SCREEN
2. Install the vent and air intake piping through the wall
into the vent plate openings. Seal all gaps between the
pipes and wall. Use RTV silicone sealant to seal the air
pipe. Use the cement/primer listed in Table 3A on page
17 to seal the vent pipe.
GALVANIZED
THIMBLE
ELBOW
BIRD SCREEN
SIDEWALL
TERMINATION PLATE
3. Mount and secure the vent plate to the wall using
stainless steel screws. Seal around the plate to the wall
assuring no air gaps.
23
Installation & Operation Manual
4 Sidewall direct venting
Termination and fittings
Figure 4-5A Multiple Vent Terminations (must also
comply with Figure 4-1A)
1. The air termination coupling must be oriented at least
12 inches above grade or snow line as shown in FIG. 4-1A,
page 21.
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
2. Maintain the required dimensions of the finished
termination piping as shown in FIG. 4-1A, page 21.
VENT
AIR
3. If using the alternate sidewall termination do not extend
exposed vent pipe outside of the building more than what
is shown in this document. Condensate could freeze and
block vent pipe.
4. PVC/CPVC terminations are designed to accommodate
any wall thickness of standard constructions per the
directions found in this manual.
5. Stainless steel terminations are designed to penetrate
walls with a thickness up to 9.25 inches of standard
construction.
VENT / AIR
TERMINATION
Multiple vent/air terminations
1. When terminating multiple Knight boilers terminate
each vent/air connection as described in this manual
(FIG. 4-5A).
Figure 4-5B Alternate Multiple Vent Terminations w/Field
Supplied Fittings (must also comply with Figure 4-1B)
All vent pipes and air inlets must
ƽ WARNING
terminate at the same height to avoid
possibility of severe personal injury,
death, or substantial property damage.
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 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.
24
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent
Description and usage
e. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
f. Locate or guard vent to prevent condensate damage
to exterior finishes.
Lochinvar offers optional concentric combustion air and vent
pipe termination kits (Factory Kit #CVK3003 for 3" diameter
- Models 81 - 211 and #CVK3007 for 4" diameter - Model
286). Both combustion air and vent pipes must attach to
the termination kit. The termination kits must terminate
outside the structure and must be installed as shown below
4. Cut one (1) hole (5 inch diameter for #CVK3003
installations or 7 inch diameter for #CVK3007 installations)
into the structure to install the termination kit.
in
FIG. 4-6.
The required combustion air and vent pipe materials are
listed in Table 3A, on page 17 of this manual.
5. Partially assemble the concentric vent termination kit.
Clean and cement using the procedures found in these
instructions.
Figure 4-6 Concentric Sidewall Termination
a. Cement the Y concentric fitting to the larger kit pipe
(FIG.’s 4-7 and 4-8).
b. Cement the rain cap to the smaller diameter kit pipe
(FIG.’s 4-7 and 4-8).
Figure 4-7 Kit Contents_CVK3003
RAIN CAP
4" DIA.
SDR-26 PIPE
2 1/2" DIA.
SDR-26 PIPE
Sidewall termination installation
"Y" CONCENTRIC
FITTING
1. Determine the best location for the termination kit (see
FIG. 4-6).
Figure 4-8 Kit Contents_CVK3007
2. The total length of piping for vent or air must not exceed
the limits given in the General Venting section on page 19
of this manual.
RAIN CAP
6" (152 MM) TO 4" (102 MM) REDUCER
6" (152 MM) DIA.
3. 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.
6" (152 MM) DIA.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
4" (102 MM) DIA.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
"Y" CONCENTRIC
FITTING
6" (152 MM) DIA.
d. Avoid possibility of accidental contact of flue
products with people or pets.
"FLEXIBLE" PIPE
COUPLING
25
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Figure 4-9 Concentric Vent Dimensional Drawing -
Figure 4-10 Concentric Vent Dimensional Drawing -
Models 81 - 211
Model 286
"A"
"B" DIA.
"C" DIA.
"D"
3"
(76 MM)
"E"
"G"
"H" DIA.
"B" DIA. PVC
VENT / EXHAUST
"F"
Instead of cementing the smaller pipe
NOTICE
6. Install the Y concentric fitting and pipe assembly through
the structure’s hole from an inside wall.
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).
Do not allow insulation or other materials to
NOTICE
accumulate inside the pipe assembly when
installing through the hole.
When using the alternate screw assembly
method, drill a clearance hole in the rain
7. Install the rain cap and small diameter pipe assembly into
the Y concentric fitting and large pipe assembly from an
outside wall. Ensure small diameter pipe is bottomed
and cemented in the Y concentric fitting for #CVK3003
installations and fastened tightly into the rubber adapter for
#CVK3007 installations.
ƽ WARNING
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.
8. Secure the assembly to the structure as shown in FIG. 4-12
using field-supplied metal strapping or equivalent support
material.
Do not operate the appliance with the rain
ƽ WARNING
Ensure termination location clearance
NOTICE
cap removed or recirculation of combustion
dimensions are as shown in FIG. 4-6.
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.
If assembly needs to be extended to allow
NOTICE
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 standard schedule 40 PVC for CVK3007.
Do not extend dimension D* more than 60
inches (see FIG.’s 4-9 and 4-10).
Figure 4-11 Rain Cap to Vent Pipe Alternate Assembly
If assembly depth needs to be reduced,
NOTICE
dimension D can be as short as possible.
26
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent
Figure 4-12 Concentric Vent Sidewall Attachment
Note: CVK3003 shown for illustration purposes.
Multiventing sidewall terminations
DO NOT use field-supplied couplings
to extend pipes. Airflow restriction
will occur and may cause intermittent
operation.
CAUTION
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.
9. Cement appliance combustion air and vent pipes to
the concentric vent termination assembly. See FIG.
4-12 for proper pipe attachment.
10. Operate the appliance one (1) heat cycle to ensure
combustion air and vent pipes are properly connected
to the concentric vent termination connections.
12"
MINIMUM
VENT
COMBUSTION
AIR
Figure 4-13 Concentric Vent and Combustion Air Termination
27
Installation & Operation Manual
5 Vertical direct venting
Vent/air termination – vertical
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.
ƽ WARNING
ƽ WARNING
Do not connect any other appliance to the
ƽ WARNING
vent pipe or multiple boilers to a common
Figure 5-1A PVC/CPVC Vertical Termination of Air and
vent pipe. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” OF VENT
PIPE
Installation must comply with local
NOTICE
requirements and with the National
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
BIRD SCREEN
(TYPICAL)
VENT
Determine location
COUPLING
(FIELD SUPPLIED)
6” MINIMUM
Locate the vent/air terminations using the following
guidelines:
ABOVE ROOF /
SNOW LINE
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page
19 of this manual.
VENT OUTLET
12” MINIMUM
ABOVE AIR INLET
COMBUSTION
AIR
2. 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.
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
3. 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.
BIRD SCREEN
(TYPICAL)
VENT
4. 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 above the air intake.
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
COM,BUSTION
AIR
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
5. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
28
Installation & Operation Manual
5 Vertical direct venting
Vent/air termination – vertical
Prepare roof penetrations
(continued)
Multiple vent/air terminations
1. Air pipe penetration:
1. When terminating multiple Knight boilers, terminate
each vent/air connection as described in this manual
(FIG. 5-2).
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Terminate all vent pipes at the same height
ƽ WARNING
2. Vent pipe penetration:
and all air pipes at the same height to
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.
avoid possibility of severe personal injury,
death, or substantial property damage.
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.
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 5-1A, page 28.
3. The air inlet of a Knight 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.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
Figure 5-2 Vertical Terminations with Multiple Boilers
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Termination and fittings
1. Prepare the vent termination coupling and the air
termination elbow (FIG. 5-1A) by inserting bird screens.
Bird screens should be obtained locally.
2. The air piping must terminate in a down-turned 180°
return bend as shown in FIG. 5-1A. Locate the air
inlet 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.
Figure 5-3 Alternate Vertical Terminations with Multiple
3. 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 apart and with the vent termination at least 1 foot
above the air intake.
Boilers
4. Maintain the required dimensions of the finished
termination piping as shown in FIG. 5-1A.
5. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
29
Installation & Operation Manual
5 Vertical direct venting
Vertical termination – optional concentric vent
Description and usage
2. Cut one (1) hole (5 inch diameter for #CVK3003
installations or inch diameter for #CVK3007
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.
7
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.
Field supplied pipe and fittings are required to complete the
installation.
a. Cement the Y concentric fitting to the larger
diameter kit pipe (see FIG.’s 4-7 and 4-8, page 25).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG.’s 4-7 and 4-8, page 25).
The required combustion vent pipe and fittings are listed in
Table 3A, on page 17 of this manual.
Vertical termination installation
Instead of cementing the smaller pipe
1. See Section 5, Vertical Direct Venting - Determine
Location (where applicable).
NOTICE
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, page 26).
Figure 5-4 Concentric Vertical Termination
When using the alternate screw assembly
ƽ WARNING
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.
Figure 5-5 Do Not Install U-Bend to Rain Cap
30
Installation & Operation Manual
5 Vertical direct venting
(continued)
Vertical termination – optional concentric vent
Do not operate the appliance with
DO NOT use field-supplied couplings
to extend pipes. Airflow restriction will
occur.
ƽ WARNING
CAUTION
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.
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 for #CVK3003 installations and
fastened tightly into the rubber adapter for #CVK3007
installations.
4. Install the Y concentric fitting pipe assembly up through
the structure’s hole and field supplied roof boot/flashing.
7. Cement the appliance combustion air and vent pipes to
the concentric vent termination assembly. See FIG. 5-6
for proper pipe attachment.
Do not allow insulation or other materials
NOTICE
to accumulate inside the pipe assembly
when installing through the hole.
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.
5. Secure the assembly to the roof structure as shown
below in FIG. 5-6 using field supplied metal strapping or
equivalent support material.
Multiventing vertical terminations
Figure 5-6 Concentric Vent Roof Installation
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.
Note: CVK3003 shown for illustration purposes.
Figure 5-7 Concentric Vent and Combustion Air Vertical
Termination
12”
MINIMUM
COMBUSTION
AIR (TYPICAL)
Ensure termination height is above the
NOTICE
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.
If assembly is too short to meet height
NOTICE
requirement, the two (2) pipes supplied
12” (18” FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24” ABOVE ROOF.
in the kit may be replaced by using the
same diameter, field supplied SDR-
26 PVC (D2241) pipe for CVK3003
and standard schedule 40 PVC for
CVK3007. Do not extend dimension
D* more than 60 inches (see FIG.’s 4-9
and 4-10, page 26).
31
Installation & Operation Manual
5 Vertical direct venting
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.
Figure 5-8 Concentric Vent Example 1
FLUE EXHAUST
SEAL
Concentric Venting Arrangement
COMBUSTION AIR
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.
AIR INLET
W/ SCREEN
12"
MIN.
EXISTING
The minimum size of the existing vent system required to
achieve enough annular space for combustion air can be
found in Table 5A below.
SEAL
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.
SEALED
CAP
FLUE OUTLET
Approved venting materials must be used as specified in
Table 3A on page 17.
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
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 5-9 Concentric Vent Example 2
FLUE EXHAUST
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 11 for a list of corrosive contaminants and sources.
COMBUSTION AIR
AIR INLET
W/ SCREEN
Two example scenarios of a concentric venting arrangement
are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
SEAL
EXISTING
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
SEAL
SEALED
CAP
Vent / Air Minimum Existing
Model
Inlet Size
Vent / Chase Size
81 - 211
286
3"
4"
5"
7"
FLUE OUTLET
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
32
Installation & Operation Manual
5 Vertical direct venting
(continued)
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
AIR INLET
FLUE EXHAUST
SEAL
EXISTING
CAP
SEAL
FLUE OUTLET
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
33
Installation & Operation Manual
6 Hydronic piping
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
System water piping methods
The Knight 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.
4. Install a backflow preventer on the cold feed make-up water
line.
5. Install a pressure reducing valve on the cold feed make-
up water line, (15 psi nominal). Check temperature and
pressure gauge (shipped separately), which should read a
minimum pressure of 12 psi.
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.
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.
Observe a minimum of 1/4 inch (6 mm) clearance around all
un-insulated hot water pipes when openings around the
pipes are not protected by non-combustible materials.
8. Install an air elimination device on the system supply.
Low water cutoff device
9. Install a drain valve at the lowest point of the system.
Note: The boiler cannot be drained completely of water
without purging the unit with an air pressure of 15 psi.
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
10. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). 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.
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.
The relief valve, tee and any necessary fittings
are shipped in the install kit with the boiler
ƽ WARNING
Freeze protection
and are to be field installed (FIG. 6-1).
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.
*See the piping illustrations included in this section, FIG.’s 6-4
thru 6-10 for suggested guidelines in piping the Knight boiler
with either zone valves or circulator pumps.
*Please note that these illustrations are
NOTICE
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
The Knight boiler is capable of servicing
multiple temperature loop systems. It is the
responsibility of the installer to protect the
loops with lower temperature requirements
from higher temperatures that may be
required by other loops.
Use only inhibited propylene glycol
ƽ WARNING
CAUTION
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 in this section along with illustrations on
the following pages (FIG.’s 6-4 thru 6-10), which will guide
you through the installation of the Knight boiler (reference
FIG.’s 6-2A and 6-2B).
1. Connect the system return marked “Inlet”.
2. Connect the system supply marked “Outlet”.
34
Installation & Operation Manual
6 Hydronic piping
(continued)
Knight 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. 6-3 on page 37 at full
Relief valve and temperature and
pressure gauge installation
Basic steps are listed below to guide you through the
installation of the relief valve and the temperature and
pressure (T & P) gauge provided with the unit.
speed.
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG. 6-3. Consult the indirect water heater operating
guide to determine flow characteristics for the selected
product used.
1. Install the tee with the 3/4 inch fitting positioned
vertically and on the top as shown in FIG. 6-1.
2. Install the relief valve into the 3/4 inch fitting of the tee
installed in Step 1 (FIG. 6-1).
3. Install a field provided close nipple and tee with the
fitting positioned vertically on the top on the
downstream side of the relief valve (see FIG. 6-1).
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.
4. Install the temperature and pressure gauge provided with
the unit into the top fitting of the tee (a bushing may be
necessary) installed in Step 3 (FIG. 6-1).
5. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 6-4 thru 6-10. Failure to
install check valves could result in a reverse flow
condition during pump(s) off cycle.
Figure 6-1 Relief Valve / T & P Installation
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.
RELIEF VALVE
7. Anti-scald mixing valve:
Field supplied.
recommended when storing domestic hot water above
115°F.
An anti-scald mixing valve is
TEMPERATURE &
PRESSURE GAUGE
8. Unions:
Field supplied. Recommended for unit serviceability.
TEE W/FITTING ON TOP
(FIELD PROVIDED)
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.
CLOSE NIPPLE
(FIELD PROVIDED)
TEE WITH 3/4” FITTING ON TOP
CLOSE NIPPLE
10. Pressure relief valve:
Near boiler piping components
Factory supplied. The pressure relief valve is sized to
ASME specifications.
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe 11. Boiler purge valve:
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.
Field 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.
2. Boiler system pump:
A Grundfos UPS26-99F pump will be provided by the
factory (for standard altitude models) as the boiler
circulation pump based on 20 feet of piping, 4 - 90°
elbows, and 2 - fully ported ball valves.
35
Installation & Operation Manual
6 Hydronic piping
13. Indirect water heaters:
It is up to the installer to ensure the
minimum system flow is not less than the
minimum boiler flow at any time.
CAUTION
The Knight boiler may be piped to an indirect water
heater to heat domestic hot water with the space heat
transfer medium. As depicted on pages 39 through 45
there are two options when utilizing an indirect water
heater.
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.
ƽ WARNING
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
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
boiler’s control.
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 Knight 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.
Circulator sizing
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.
The Knight boiler heat exchanger does have a pressure drop,
which must be considered in your system design. Refer to the
graph in FIG. 6-3 for pressure drop through the Knight boiler
heat exchanger.
Near boiler piping connections
Figure 6-2A Near Boiler Piping w/Y-Strainer
Figure 6-2B Near Boiler Piping w/Low Loss Header
SYSTEM SENSOR
AIR SEPARATOR
AIR VENT VALVE
LOW LOSS HEADER
(TYPICAL)
FILL VALVE
Y-STRAINER
(RECOMMENDED)
SYSTEM SENSOR
AIR SEPARATOR
DOMESTIC HOT
WATER PUMP
DRAIN
EXPANSION TANK
(TYPICAL)
SYSTEM
PUMP
BOILER
PUMP
INDIRECT
DOMESTIC
HOT WATER
TANK
DRAIN VALVE
INDIRECT
DOMESTIC
HOT WATER
Y-STRAINER
(RECOMMENDED)
BOLIER PUMP
DRAIN
(TYPICAL)
TO FLOOR
DRAIN
TO FLOOR
DRAIN
36
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-3 Pressure Drop vs. Flow
Pressure Drop vs. Flow (Includes Secondary Piping)
25
20
15
10
5
81
106
151
211
286
0
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Flow Rate (GPM)
Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°
20°F Temperature Rise Applications
Pump
TACO
0011
0013
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
UPS26-99F
UPS26-99F*
UPS26-99F
UPS32-160
UPS32-80
B & G
NRF-36
NRF-36
NRF-36
PL-55
Armstrong
81
7.5
9.8
24
27
20
29
15
1"
1"
E7
E11
E7
106
151
211
286
14.0
19.6
26.5
1"
0011
1"
1-1/4"
1400-50
1400-20
E9*
E11
PL-36
These pumps are only slightly above 20° rise flows, but are the closest available. To reach a 20° rise or less, an
upsized pump will be required.
*NOTICE
25°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
TACO
B & G
Armstrong
81
5.9
7.7
15.0
17.5
12.8
19.0
11.5
1"
1"
UPS15-58FC
UPS26-99F
UPS26-99F
UPS26-99F
UPS26-99F
0014
0014
0014
0013
0011
NRF-36
NRF-36
NRF-36
NRF-36
NRF-36
E7
E7
E7
E7
E7
106
151
211
286
11.0
15.5
21.0
1"
1"
1-1/4"
35°F Temperature Rise Applications
Pump
TACO
007
007
Minimum Pipe
Model
GPM
FT/HD
Size
Grundfos
UPS15-58FC
UPS15-58FC
UPS15-58FC
UPS15-58FC
UP26-64F
B & G
NRF-22
NRF-22
NRF-36
NRF-36
NRF-36
Armstrong
Astro-30
Astro-30
Astro-30
Astro-50
E7
81
4.2
5.5
7.3
9.3
9.5
9.1
7.3
1"
1"
106
151
211
286
7.9
1"
008/0010
0010
008/0010
11.0
15.0
1"
1-1/4"
Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude
models.
NOTICE
NOTICE
NOTICE
Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude
models.
The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.
37
Installation & Operation Manual
6 Hydronic piping
Variable speed pump option
Table 6B Recommended Variable Speed Pumps
Minimum Temperature Rise*
Pump
Model
Grundfos
TACO
Wilo
UP26-96 FC/VS
0013 IFC VS
Stratos 1.25 3 x 30
81
20.3
22.3
21.2
26.8
26.7
20.3
21.0
19.8
25.1
24.3
21.7
21.5
19.1
23.6
21.9
106
151
211
286
*The minimum temperature rise is derived from the chart in FIG. 6-3 with the firing rate and pump speed at 100% as shown in
the table above.
The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are
to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 6B to the boiler
high voltage terminal strip.)
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
Pump sizing and flow requirements are
NOTICE
based on 20 feet of piping, 4 - 90°
elbows, and 2 - fully ported ball valves.
It is required that near boiler piping
NOTICE
systems utilize the Primary/Secondary
configuration shown in FIG. 6-10 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.
38
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-4 Single Boiler - Single Temperature Zoned with Circulators
ZONE #1
PRESSURE
GAUGE
PRESSURE
REDUCING VALVE
ZONE #2 ZONE #3
ZONE #4
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
(TYPICAL)
MAKE UP WATER
SYSTEM SUPPLY
SENSOR
ZONE CIRCULATORS
(TYPICAL)
(WHEN USED)
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
BALL VALVE
(TYPICAL)
Y-STRAINER
DRAIN POINT
(TYPICAL)
(RECOMMENDED)
BOILER
HOT
WATER
OUT
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
INDIRECT
DHW TANK
BOILER
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.
NOTICE
39
Installation & Operation Manual
6 Hydronic piping
Figure 6-5 Multiple Boilers - Single Temperature Zoned with Circulators
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
81
1-1/4" 1-1/2"
2"
2"
2"
2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
151
211
2-1/2" 2-1/2" 2-1/2"
3"
3-1/2"
4"
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
2" 2-1/2"
3"
3"
3"
3-1/2"
ZONE #1
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
5"
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
ZONE #2 ZONE #3
ZONE #4
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
SYSTEM SUPPLY
SENSOR
MAKE UP WATER
(TYPICAL)
AIR SEPARATOR
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
HOT
WATER
OUT
ANTI-SCALD
MIXING VALVE
BOILER
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
COLD
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
WATER
IN
UNION
TEMPERATURE /
(TYPICAL)
PRESSURE
GAUGE
DRAIN
BOILER 1
BOILER 2
INDIRECT
DHW TANK
(LEADER)
(MEMBER 1)
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.
NOTICE
40
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-6 Single Boiler - Multiple Temperatures
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
SYSTEM
WATER
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA
OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
DRAIN POINT
(TYPICAL)
BOILER
DOMESTIC
CIRCULATOR
HOT
HOT WATER
CIRCULATOR
WATER
ANTI-SCALD
OUT
FLOW CHECK
VALVE
MIXING VALVE
COLD
WATER
IN
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE DRAIN
GAUGE
Mixing valves are required for the protection of low temperature loops.
CAUTION
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.
41
Installation & Operation Manual
6 Hydronic piping
Figure 6-7 Multiple Boilers - Multiple Temperatures
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
81
1-1/4" 1-1/2"
2"
2"
2"
2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
151
211
2-1/2" 2-1/2" 2-1/2"
3"
3-1/2"
4"
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
2" 2-1/2"
3"
3"
3"
3-1/2"
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
5"
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
SYSTEM
WATER
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
BALL VALVE
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
DRAIN POINT
(TYPICAL)
BOILER
DOMESTIC
CIRCULATOR
HOT WATER
CIRCULATOR
HOT
WATER
OUT
FLOW CHECK
VALVE
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
Y-STRAINER
(RECOMMENDED)
TEMPERATURE /
PRESSURE
GAUGE
UNION
(TYPICAL)
DRAIN
INDIRECT
DHW TANK
BOILER
BOILER
Mixing valves are required for the protection of low temperature loops.
CAUTION
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.
42
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-8 Single Boiler - Multiple Temperatures with DHW Piped as a Zone
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
SYSTEM
WATER
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
DOMESTIC
MAY SUBSTITUTE
HOT WATER
CIRCULATOR
LOW LOSS HEADER
FLOW CHECK
VALVE
BALL VALVE
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA
OR MAX. OF 12" APART
HOT
WATER
ANTI-SCALD
OUT
DRAIN POINT
(TYPICAL)
Y-STRAINER
MIXING VALVE
(RECOMMENDED)
COLD
WATER
IN
BOILER
CIRCULATOR
UNION
(TYPICAL)
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
INDIRECT
DHW TANK
BOILER
Mixing valves are required for the protection of low temperature loops.
CAUTION
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.
NOTICE
NOTICE
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
43
Installation & Operation Manual
6 Hydronic piping
Figure 6-9 Multiple Boilers - Single Temperature Zoned with Valves
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
81
1-1/4" 1-1/2"
2"
2"
2"
2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
151
211
2-1/2" 2-1/2" 2-1/2"
3"
3-1/2"
4"
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
2" 2-1/2"
3"
3"
3"
3-1/2"
ZONE #1
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
5"
PRESSURE
REDUCING VALVE
ZONE #2 ZONE #3 ZONE #4
BACKFLOW
PREVENTER
PRESSURE
GAUGE
BALL VALVE
(TYPICAL)
ZONE VALVES
(TYPICAL)
SYSTEM SUPPLY
MAKE UP WATER
DIFFERENTIAL
SENSOR
PRESSURE BYPASS
VALVE (IF USED)
(WHEN USED)
AIR SEPARATOR
SYSTEM
CIRCULATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
DRAIN POINT
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
ANTI-SCALD
HOT
WATER
OUT
MIXING VALVE
BOILER
CIRCULATOR
DOMESTIC
FLOW CHECK
HOT WATER
VALVE
CIRCULATOR
COLD
WATER
IN
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
UNION
TEMPERATURE /
PRESSURE
GAUGE
(TYPICAL)
DRAIN
BOILER 2
BOILER 1
(LEADER)
INDIRECT
(MEMBER 1)
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.
NOTICE
44
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-10 Multiple Boilers - Non-Zoned Primary/Secondary Piping
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
81
1-1/4" 1-1/2"
2"
2"
2"
2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
151
211
2-1/2" 2-1/2" 2-1/2"
3"
3-1/2"
4"
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
2" 2-1/2"
3"
3"
3"
3-1/2"
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
5"
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
BACKFLOW
PREVENTER
MAKE UP WATER
SYSTEM SUPPLY
SENSOR
SYSTEM
AIR SEPARATOR
MAY SUBSTITUTE LOW LOSS HEADER
CIRCULATOR
TO
FROM
SYSTEM
SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
EXPANSION
TANK
DRAIN POINT
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
HOT
ANTI-SCALD
WATER
MIXING VALVE
OUT
FLOW CHECK
DOMESTIC
VALVE
HOT WATER
COLD WATER
IN
CIRCULATOR
BOILER
CIRCULATOR
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
UNION
(TYPICAL)
BOILER 4
BOILER 3
BOILER 1
(LEADER)
BOILER 2
(MEMBER 1)
INDIRECT
(MEMBER 3)
(MEMBER 2)
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.
NOTICE
45
Installation & Operation Manual
7 Gas connections
3. Support piping with hangers, not by the boiler or its
accessories.
Connecting gas supply piping
1. Remove the top access panel and refer to FIG.’s 7-1 and
7-2 to pipe gas to the boiler.
The gas valve and blower will not support
the weight of the piping. Do not attempt
ƽ WARNING
a. Install ground joint union for servicing, when
required.
b. Install a manual shutoff valve in the gas supply
piping outside boiler jacket when required by local
codes or utility requirements.
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.
c. In Canada – When using manual main shutoff
valves, it must be identified by the installer.
4. Purge all air from the gas supply piping.
2. Install sediment trap / drip leg.
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
Figure 7-1 Gas Supply Piping - Models 81 - 211
a. The appliance must be disconnected from the gas
supply piping system during any pressure testing of
that system at a test pressure in excess of 1/2 PSIG
(3.5 kPa).
UNION
GAS SUPPLY
b. The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
(3.5 kPa).
DRIP
LEG
c. The appliance and its gas connection must be leak
tested before placing it in operation.
MANUAL
SHUTOFF
VALVE
Do not check for gas leaks with an open
ƽ WARNING
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.
6. 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.
Figure 7-2 Gas Supply Piping - Model 286
Failure to apply pipe sealing compound as
ƽ WARNING
detailed in this manual can result in severe
personal injury, death, or substantial
property damage.
Knight boilers are typically shipped ready
ƽ WARNING
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.
SEDIMENT TRAP / DRIP LEG
46
Installation & Operation Manual
7 Gas connections
(continued)
Use two wrenches when tightening gas
piping at boiler (FIG. 7-3), 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:
ƽ WARNING
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.
Figure 7-3 Inlet Pipe with Backup Wrench
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:
Knight boilers are typically shipped ready to
fire on natural gas. Check boiler rating plate
ƽ WARNING
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.
Maximum inlet gas pressure must not
NOTICE
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
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).
Ensure that the high gas pressure regulator
is at least 6 - 10 feet upstream of the
appliance.
ƽ WARNING
47
Installation & Operation Manual
7 Gas connections
Table 7A Natural Gas Pipe Size Chart
Single Unit
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet for 1/2 PSI
Nominal
Iron Pipe
Size (Inches)
10
20
30
97
40
50
60
70
80
90
100
125
150
N/A
175 200
N/A N/A
175
120
82
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1/2
3/4
1
369
697
256
477
974
205
384
789
174
328
677
155
292
595
923
141
267
543
830
128
246
502
769
121
236
472
707
113
210
441
666
106
200
410
636
95
86
79
74
179
369
564
164
333
513
974
149 138
308 287
472 441
871 820
1400
1-1/4
1-1/2
2
2150 1500 1210 1020
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100
6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340
23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720
Knight boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which
2-1/2
3
4
ƽ WARNING
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.
Check inlet gas supply
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. 7-4.
CSA or UL listed flexible gas connections
NOTICE
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.
4. Slowly turn on the gas supply at the field installed
manual gas valve.
5. Turn the power switch to the “ON” position.
DO NOT adjust or attempt to measure
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 or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
ƽ WARNING
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.
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.
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.
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:
11. Turn the power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
1. Turn the main power switch to the “OFF” position.
13. Remove the manometer from the pressure tap on top of
the gas valve. Re-tighten the set screw inside the pressure
tap.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
48
Installation & Operation Manual
7 Gas connections
(continued)
When re-tightening the set screw, be sure
to tighten securely to prevent gas leaks.
Gas Pressure
ƽ WARNING
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 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.
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.
14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
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.
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.
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.
Figure 7-4 Inlet Gas Supply Check
Failure to follow all precautions could
ƽ WARNING
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP.
result in fire, explosion, or death!
DO NOT adjust or attempt to measure
ƽ WARNING
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 or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
DETAIL
49
Installation & Operation Manual
8 Field wiring
ELECTRICAL SHOCK HAZARD – For
Installation must comply with:
ƽ WARNING
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.
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.
Wiring must be N.E.C. Class 1.
NOTICE
Line voltage connections
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
1. Connect 120 vac power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 8-1.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 8-1).
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
3. The boiler pump is shipped loose. Wire the boiler pump
as shown in FIG. 8-1.
ƽ CAUTION
4. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 8-1.
Figure 8-1 Line Voltage Field Wiring Connections
5. To activate a system pump, wire as shown in FIG. 8-1.
If the motor is larger than 1/8 hp or 1.8 amps, you must
isolate with a relay.
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 8-2.
2. Connect low voltage wiring to low voltage connection
board as shown in FIG. 8-3 on page 53 of this manual and
the boiler wiring diagram.
Figure 8-2 Routing Field Wiring
LOW VOLTAGE
CONNECTION BOARD
LOW VOLTAGE
WIRING KNOCKOUTS
LINE VOLTAGE WIRING KNOCKOUTS
50
Installation & Operation Manual
8 Field wiring
1. Connect the room thermostats or end switches (isolated
contact only) to room thermostat 1, 2, or 3, as shown in
FIG. 8-3.
(continued)
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
Thermostat
on the Low Voltage Connection Board.
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
Louver relay
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. 8-3).
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.
Louver proving switch
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. 8-3).
Outdoor temperature sensor
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow of heat or cooling from other
sources.
High gas pressure switch
If a switch is provided to detect excessive gas pressure, remove
2. Route sensor wires through a knockout at the rear of the
boiler (see FIG. 8-2).
the jumper wire from the terminals on the connection board,
3. Connect outdoor temperature sensor (FIG. 8-3) to the
outdoor sensor terminals on the connection board to
enable outdoor reset operation of the Knight boiler. If
fixed temperature operation is required, do not install
outdoor sensor.
and then connect them to its normally closed contacts
8-3).
(FIG.
Low gas pressure switch
1. If a switch is provided to detect low gas pressure, remove the
jumper wire from the terminals on the connection board
and connect them to its normally open contacts (FIG. 8-3).
DHW thermostat
Connect storage indirect water heater (DHW) thermostat
(FIG. 8-3) to the DHW thermostat terminals on the
connection board. If a tank sensor is connected (see DHW
2. If both a high and low gas pressure switch is used, connect
their respective contacts in series, and connect them to the
terminals on the connection board (FIG. 8-3).
Tank Sensor below) the tank thermostat is ignored.
Variable speed system pump
If a variable speed pump is used in the primary loop, and
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.
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.
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 (FIG. 8-3). Consult
the tank manufacturer for application and performance
when used with any other indirect tank.
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.
Failure to use the correct sensor may result
ƽ WARNING
in the tank temperature being either above
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.
or below the set point. Failure to consult
the manufacturer of the indirect tank,
when the Squire is not used, may result in
decreased performance or the risk of scald
injury.
51
Installation & Operation Manual
8 Field wiring
ModBus
Alarm contacts
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.
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
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.
When wiring the boilers for Cascade operation, select one
boiler as the Leader boiler. The remaining boilers will be
designated as Members. See page 60 “Configuration of the
Cascade” for a detailed explanation of this procedure.
2. Remove the jumper wire from these terminals, and
connect these terminals to the normally open contacts on
the flow switch (FIG. 8-3).
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,
6-6, and 6-8). The system supply sensor should be wired to
the Low Voltage Connection Board at the terminals marked
for the system sensor (see FIG. 8-3). The Leader control will
use the water temperature at the system supply sensor to
control the operation of the Cascade.
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
controlstheboilerfiringratetomaintainthesystemsupply
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 Boiler Service Manual for instructions
on how to use the inlet sensor as the controlling sensor.
When the inlet sensor is programmed as the controlling
sensor, it is vital that the SYSTEM SUPPLY sensor be
installed. DO NOT INSTALL THE SYSTEM SUPPLY
SENSOR INTO THE SYSTEM RETURN.
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. 8-3). 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.
2. The TST2032 sensor provided with the boiler must be
used for the system sensor.
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 Room
Thermostats 1-3 (FIG. 8-3). If the boilers are to run
continuously, connect a jumper wire between the R and W
terminals for the Thermostat input. This will initiate a call for
heat on the Cascade.
3. Connect these terminals to the system supply sensor
(FIG. 8-3).
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 Room Thermostat 1 terminals.
Otherwise, the SMART SYSTEM control will be enabled
by the 0-10V signal.
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. 8-3). 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.
2. Make sure the ground terminal is connected to the
ground output terminal of the external control, and the
0 - 10 vdc terminal is connected to the 0 - 10 vdc terminal
of the external control.
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.
52
Installation & Operation Manual
8 Field wiring
(continued)
Figure 8-3 Low Voltage Field Wiring Connections
53
Installation & Operation Manual
9 Condensate disposal
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.
Condensate drain
NOTICE
1. This boiler is a high efficiency appliance that produces
condensate.
2. The side of the boiler has a 1/2 inch PVC union for
connection of a 1/2 inch PVC pipe (FIG. 9-1).
3. Slope condensate tubing down and away from the
boiler into a drain or condensate neutralizing filter.
Condensate from the Knight boiler will be slightly acidic
(typically with a pH from 3 to 5). Install a neutralizing
filter if required by local codes.
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.
NOTICE
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.
A Neutralizer Kit (FIG. 9-1) is available from the factory
(Kit 3087).
4. Install the 1/2 inch PVC tee assembly (shipped with the
unit) as shown in FIG. 9-1.
5. Leave the top of the 1/2 inch tee OPEN. This is needed as
a vacuum break.
8. 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 56).
6. Do not expose condensate line to freezing temperatures.
7. Use only plastic tubing or piping as a condensate drain
line (FIG. 9-1).
Figure 9-1 Condensate Disposal
1/2" PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
1/2" PVC UNION
(FACTORY SUPPLIED)
NEUTRALIZER KIT
FLOOR DRAIN OR
DRAIN PAN
54
Installation & Operation Manual
10 Start-up
3. Fill to correct system pressure. Correct pressure will vary
with each application.
Check/control water chemistry
Do not use petroleum-based cleaning or
ƽ CAUTION
a. The minimum cold water fill pressure for
residential system is 12 psi.
a
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets
in the system could occur, resulting in
substantial property damage.
b. Pressure will rise when boiler is turned on and
system water temperature increases.
Hardness less than 7 grains
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Eliminate all system leaks. Continual
Chlorine concentration less than 200 ppm
ƽ WARNING
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.
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.
Purge air from water system
3. Do not use the boiler to directly heat swimming pool or
spa water.
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valves, in piping diagrams on pages 39 through 45).
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.
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.
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.
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 7.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
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.
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 Service
Manual).
2. Open automatic air vent (diaphragm-type or bladder-type
expansion tank systems only) one turn.
Fill and test water system
3. Open other vents:
1. Fill system only after ensuring the water meets the
requirements of this manual.
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
2. Close manual and automatic air vents and boiler drain
valve.
4. Refill to correct pressure.
55
Installation & Operation Manual
10 Start-up
Propane boilers only – Your propane
suppliermixesanodorantwiththepropane
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.
Check for gas leaks
ƽ WARNING
Before starting the boiler, and during
ƽ WARNING
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the top 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.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to each of
the room thermostat terminals on the connection board.
DO NOT adjust or attempt to measure
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 or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or
substantial property damage.
ƽ WARNING
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.)
Figure 10-1 Condensate Trap
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board.
RETAINING
SCREW
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect/fill condensate system
Inspect/check condensate lines and fittings
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
1. Inspect the condensate drain line, condensate PVC
fittings and condensate trap.
Fill condensate trap with water
1. Remove the PVC cap retaining screw from the PVC cap
(FIG. 10-1).
CONDENSATE FROM
HEAT EXCHANGER
2. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 10-1).
TO FLOOR
DRAIN
3. Fill with fresh water until the water begins to pour out of
the drain.
4. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
5. Replace the retaining screw.
The condensate trap (FIG. 10-1) must be
filled with water during all times of boiler
ƽ WARNING
operation to avoid flue gas emission from
the condensate drain line. Failure to fill
the trap could result in severe personal
injury or death.
56
Installation & Operation Manual
10 Start-up
(continued)
Check vent piping and air piping
Final checks before starting the boiler
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
Read the Knight Boiler Service Manual to familiarize
yourself with SMART SYSTEM control module
operation. Read this manual, page 58 for proper steps to
start boiler.
Venting system must be sealed gastight
ƽ WARNING
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
Verify the boiler and system are full of water and all
system components are correctly set for operation.
Check gas piping
Verify the preparation procedures of Section 10, pages 55
1. Check around the boiler for gas odor following the
procedure on page 46 of this manual (connecting gas supply
piping).
and 56 have been completed.
Fill the vent condensate trap with water (removing the
retaining screw in order to remove the 2 inch PVC cap
with the switch located at the top of the trap). Replace
the cap. Press the cap onto the trap until the cap makes
contact with the drain. Replace the retaining screw.
If you discover evidence of any gas leak,
ƽ WARNING
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.
Verify electrical connections are correct and securely
attached.
Propane boilers – verify conversion
Inspectventpipingandairpipingforsignsofdeterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
DO NOT adjust or attempt to measure
ƽ WARNING
gas valve outlet pressure. The gas valve is
Start the boiler
factory-set for the correct outlet pressure.
This setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter or measure the gas valve
outlet pressure could result in damage to
the valve, causing potential severe personal
injury, death, or substantial property
damage.
1. Read and follow the Operating instructions in FIG. 10-2,
page 58.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
Knight boilers are typically shipped ready
to fire on natural gas. Check boiler rating
ƽ WARNING
2. Is boiler water temperature above 200°F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
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.
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 Boiler Service Manual.
Check flame and combustion
Check system and boiler
1. Turn the main power off to the boiler by placing the “On/
Off” switch in the OFF position.
Check water piping
2. Remove the flue temperature sensor from the flue pipe
connection. NOTE: Combustion measurements will be
made at this point.
1. Check system piping for leaks. If found, shut down
the boiler and repair immediately. (See WARNINGS
on pages 55 and 56 (startup) regarding failure to repair
leaks.)
3. Turn the main power on to the boiler by placing the “On/
Off” switch in the ON position.
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.
57
Installation & Operation Manual
10 Start-up
Figure 10-2 Operating Instructions
58
Installation & Operation Manual
10 Start-up
(continued)
Check flame and combustion (continued)
Set space heating operation
Please note that the brackets ([]) denote
screen status.
Determine controlling sensor
NOTICE
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
Boiler Service Manual for a detailed explanation of this
procedure.
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 11-1, page 67).
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.
Verify space heat circulator mode
The Space Heating Mode controls both the system (primary)
pump (if connected), and the boiler (secondary) 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 Boiler Service Manual for a
detailed explanation of this procedure.
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
Boiler Service Manual for possible causes and corrective
actions.
Table 10A Flue Products Chart
Natural Gas
Propane
CO2 O2
CO2
O2
Adjust set point temperature
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
Please note that the brackets ([]) denote
screen status.
NOTICE
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, reset the control, and return
to Service Mode.
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.
9. Turn the main power off to the boiler and replace the flue
temperature sensor into the flue pipe connection.
10. Place the boiler back into normal operation.
You must replace the flue gas temperature
ƽ WARNING
5. If necessary repeat Steps 3 and 4 to make adjustments to
additional set points.
sensor to prevent flue gas spillage into
the room. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
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.
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Installation & Operation Manual
10 Start-up
Set domestic hot water (DHW) operation
Verify DHW mode
8. Turn the NAVIGATION dial to adjust the month. Press the
NAVIGATION dial.
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.
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.
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 system pump and the boiler pump will
be turned on. In this mode, any low temperature zones (such
as radiant heating) may need additional controls to limit the
water temperature sent to those zones.
The internal clock does not adjust for
NOTICE
Daylight Savings Time and therefore, will
require a manual adjustment.
Configuration of the cascade
Please note that the brackets ([]) denote
screen status.
NOTICE
When installed in a Cascade system, the individual controls
must be programmed for cascade operation. This is
accomplished by accessing the control parameters.
Set DHW 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
Boiler Service Manual for a detailed explanation of this
procedure.
Press the [MENU] key for at least five (5) seconds. Input
the Installer code as described in the Knight Boiler 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.
Set maximum DHW fan speed
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. If installing
the boilers in an existing system, the new boilers should
be programmed as the Leader and/or the higher number
addresses.
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 Boiler Service Manual for a detailed explanation
of this procedure.
Set clock
Please note that the brackets ([]) denote
screen status.
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:
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.
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.
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
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Installation & Operation Manual
11 Operating information
DHW priority
General
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.
How the boiler operates
The Knight 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.
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. 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.
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.
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 the system supply in order to provide the best
control of the inlet temperature.
Control inputs and outputs
Room thermostat
Anti-cycling
There are three (3) thermostat connections available on this
control. These inputs tell the boiler to provide water for space
heating. Each thermostat connection has its own set point
and outdoor air reset curve. When multiple thermostats have
a call for heat the control will give priority to the demand with
the highest set point.
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
Example: Assume that both Room Thermostat 1 and Room
Thermostat 2 have a call for heat. RoomThermostat 1 has
a set point of 110°F. Room Thermostat 2 has a set point of
140°F. The boiler will regulate the system temperature to
140°F until Room Thermostat 2 has been satisfied. Once
Room Thermostat 2 has been satisified the boiler will provide
110°F water to the system.
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, a DHW call for heat when the DHW is programmed
for Zone Mode, or the boiler goes into Freeze Protection 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.
When multiple temperature loops are
ƽ CAUTION
used, thermostatic mixing valves are
required for the protection of any low
temperature loops.
0 - 10V input (set point or power)
Temperature control
Modulation
TheKnightboilercanbecontrolledbyaBuildingManagement
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.
The Knight 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
The Knight boiler can also be programmed to accept a call for
heat from a 0 - 10V signal, reference the Knight Boiler Service
Manual for a detailed explanation of this procedure.
other temperature limitations.
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Installation & Operation Manual
11 Operating information
Ramp delay
Protection features
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.
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.
Gradient limiting
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.
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.
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.
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.
•
Night setback
•
•
Below 37°F, the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F.
Lower temperatures may be programmed for
systems with anti-freeze solutions.
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 event scheduled
within the next seven (7) days can be temporarily bypassed
if desired.
•
When system return temperatures
NOTICE
are maintained below the dew point,
condensation will form on the inside of
the boiler jacket causing some internal
sheet metal components to rust.
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.
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.
ƽ CAUTION
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Installation & Operation Manual
11 Operating information
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.
(continued)
Monitor external limits
High limit operations
The Knight boiler 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.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
High limit test procedure
Run-time and cycle counting
Please note that the brackets ([]) denote
screen status.
NOTICE
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 firing in the DHW Mode.
1. Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
2. If boiler status reads [SHUTDOWN] place the boiler into
the active position by pressing the RIGHT SELECT [ON]
key.
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.
3. Locate the pinhole (SERVICE button) below the RESET
button on the display board. Insert a thin wire (such as a
paper clip) into the hole and press the button once, hold
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.
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
service reminder notification can be reset or disabled by the
installer.
4. From the Status Screen, press the NAVIGATION dial to
access the Set Points Screen.
5. Press the LEFT SELECT [LIMITS] key.
6. Select the manual reset high limit (MRHL) by pressing the
NAVIGATION dial.
7. Decrease the set point of the MRHL below the outlet
temperature by turning the NAVIGATION dial
counterclockwise.
The time dependent feature has been disabled by the
manufacturer. To enable this feature change parameter K1 to
the desired time range, reference the Knight Service Manual
for details regarding parameters.
8. Press the RIGHT SELECT [SAVE] key.
9. Press the RIGHT SELECT [HOME] key.
Error logging
10. The new parameters will upload to the control and the
MRHL will function causing boiler shutdown and
[LOCKOUT] to be displayed.
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.
11. Press the RESET button to clear the lockout.
12. Repeat Steps 4, 5 and 6.
13. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
Boiler temperature regulation
14. Repeat Steps 8 and 9.
Operating temperature (target)
Low water cutoff protection
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.
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
•
•
Target temperature is fixed when the outdoor sensor
is not installed.
Target temperature is calculated as described below
under “Outdoor Reset Operation” and “Target
Temperature Boost” when the outdoor sensor is
connected.
factory (WTR20009).
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Installation & Operation Manual
11 Operating information
Outdoor reset operation, if used
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.
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
The sequence will be changed once every 24 hours. The
switching on/off sequence will be as follows:
See the Knight Boiler Service Manual to change the settings.
Reset curve
DAY
Day 1
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
The reset curve looks at outdoor air temperature and adjusts
the set point.
Day 1 + 1 hour
Cascade
Day 1 + 2 hours
M2-M3-M4-M5-M6-M7-L-M1
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. If installing the boilers in
an existing system, the new boilers should be programmed as
the Leader and/or the higher number addresses. The Leader
control can be programmed to use Lead/Lag or Efficiency
Optimization control methods.
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.
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 Boiler 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 59 of this manual to
program the set point.
The DHW boiler will adjust its set point to the programmed
DHW 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.
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 Boiler 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.
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 Boiler Service
Manual for information regarding Night Setback.
Ramp Delay operation of the boilers as described in the
Knight Boiler Service Manual is available when the boilers are
part of a Cascade system.
64
Installation & Operation Manual
11 Operating information
(continued)
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.
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 a 15 second prepurge cycle by initiating the
blower.
5. The control starts a 4 second trial for ignition by firing the spark
electrode and opening the gas valve.
6. If flame is not detected within 1 second after the sparking ends,
the control will perform a 10 second post-purge, 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 5 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).
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Installation & Operation Manual
11 Operating information
Sequence of operation (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 2 seconds later. 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 a 10 second
postpurge.
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.
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Installation & Operation Manual
11 Operating information
(continued)
Knight 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
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Installation & Operation Manual
11 Operating information
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 60).
Installer
Most parameters are available only to the installer, accessible
by entering the installer password, see the Knight Boiler Service
Manual.
Saving parameters (reference the Parameter Table in the
Knight Boiler Service Manual)
Please note that the brackets ([]) denote
screen status.
NOTICE
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.
See the Knight Boiler Service Manual for a detailed description of
parameters and access modes.
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Installation & Operation Manual
11 Operating information
(continued)
Figure 11-2 Status Display Screen
B
A
(CALL FOR
HEAT)
(BOILER
STATUS)
C
(OPERATIONAL
INFORMATION)
F
D
(LEFT SELECT
KEY)
(RIGHT SELECT KEY)
E
(NAVIGATION DIAL)
Status Display Screens
Section
Display
Description
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.
STANDBY
START
The unit has begun a burn cycle and is checking all safety circuits.
The unit has initiated a 10 second purge period on a call for heat.
PREPURGE
IGNITION
The unit has begun a 4 second spark period to ignite the main burner.
The unit has fired and is running at the displayed percentage.
A
%
(Boiler Status
Bar)
The call for heat has been satisfied and the unit runs the fan for an
additional 10 seconds to clear the combustion chamber and vent
system of residual flue products.
POSTPURGE
SHUTDOWN
The unit has been placed in the OFF position.
The controlled temperature has exceeded its set point and its offset.
The unit has detected a condition that has temporarily interrupted
the current call for heat.
BLOCKED
Room Thermostat 1 has a call for heat.
Room Thermostat 2 has a call for heat.
Room Thermostat 3 has a call for heat.
B
The tank thermostat or sensor has a call for heat.
(Call for Heat
Indicators)
Indicates which room thermostat 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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Installation & Operation Manual
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).
The temperature read by the outdoor sensor (if connected).
OUTDOOR:
INLET TEMP:
OUTLET TEMP:
DELTA T:
The temperature read at the inlet to the heat exchanger.
The temperature read at the outlet of the heat exchanger.
The temperature difference between the inlet and the outlet of the
heat exchanger.
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.
C
BOILER PUMP:
SYSTEM PUMP:
DHW PUMP:
The status of the boiler pump output.
The status of the system pump output.
The status of the DHW pump output.
(Operational
Information)
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:
SH RUN HOURS:
SH CYCLES:
A 0 - 10V signal indicating the firing rate of the boiler.
The total hours of operation in the Space Heating Mode.
The total burner cycles in the Space Heating Mode.
The total hours of operation in the DHW Mode.
The total burner cycles in the DHW Mode.
The last 10 lockouts.
DHW RUN HOURS:
DHW CYCLES:
LAST 10 FAULTS NO:*
Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
MENU
EXIT
YES
Press the LEFT SELECT key to exit the current screen or setting.
D
Press the LEFT SELECT key to confirm that the boiler needs to
shutdown.
(LEFT SELECT
key function)
Press the LEFT SELECT key to enter the screen that allows you to
adjust the limit settings.
LIMITS
HOME
Press the LEFT SELECT key to return to the Status Screen and upload
parameter changes.
70
Installation & Operation Manual
11 Operating information
(continued)
Status Display Screens (cont’d)
Section
Display
Description
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.
E
(NAVIGATION
Dial Function)
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.
SHDN
ON
Press the RIGHT SELECT key to turn the boiler OFF.
Press the RIGHT SELECT key to turn the boiler ON.
F
NO
Press the RIGHT SELECT key to cancel the shutdown operation.
Press the RIGHT SELECT key to save the current change.
(RIGHT SELECT
key function)
SAVE
HOME
Press the RIGHT SELECT key to return to the Status Screen and
upload parameter changes.
71
Installation & Operation Manual
12 Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Owner maintenance
(see the Knight User’s Information Manual for
instructions)
Service technician
(see the following pages for instructions)
• Check boiler area
General:
• Address reported problems
• Check pressure / temperature
gauge
• Inspect interior; clean and vacuum if
necessary;
Daily
• 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 vent piping
• Check air piping
• Check system water pressure/system
piping/expansion tank
Monthly
• Check air and vent termination
screens
• Check control settings
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check relief valve
• Check condensate drain system
• Check air vents
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 10
of this manual.
Periodically
•Test low water cutoff (if used)
• Reset button (low water cutoff)
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Check boiler piping (gas and
water) for leaks
Every
6 months
• Operate relief valve
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
End
of season
months
•Shut boiler down (unless boiler
used for domestic hot water)
• Clean the blower wheel
72
Installation & Operation Manual
12 Maintenance
(continued)
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.
Flue vent system and air piping
ƽ WARNING
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.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
ƽ 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.
Following installation, the valve lever
must be operated AT LEAST ONCE
A YEAR to ensure that waterways are
ƽ WARNING
clear.
Certain naturally occurring
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
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.
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.
2. After following the above warning directions, 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.
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.
73
Installation & Operation Manual
12 Maintenance
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.
ƽ WARNING
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.
ƽ WARNING
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.
ƽ WARNING
Address reported problems
Figure 12-1 Condensate Trap
RETAINING
SCREW
1. Inspect any problems reported by the owner and correct
before proceeding.
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
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 Boiler Service
Manual.
CONDENSATE FROM
HEAT EXCHANGER
TO FLOOR
DRAIN
Inspect boiler interior
1. Remove the front access cover and inspect the interior of
the boiler.
The condensate trap must be filled with
water during all times of boiler operation
to avoid flue gas emission from the
condensate drain line. Failure to fill the
trap could result in severe personal injury
or death.
ƽ WARNING
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
Check all piping for leaks
1. Inspect the condensate drain line, condensate PVC
fittings, and condensate trap.
Eliminate all system or boiler leaks.
ƽ WARNING
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.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 12-1).
3. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 12-1).
4. Remove any sediment in the trap.
1. Inspect all water and gas piping and verify to be leak free.
5. Fill with fresh water until the water begins to pour out of
the drain.
2. Look for signs of leaking lines and correct any problems
found.
6. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
3. Check gas line using the procedure found in Section 7
- Gas Connections.
7. Replace the retaining screw.
74
Installation & Operation Manual
12 Maintenance
(continued)
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
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.
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. Remove the burner, reference FIG. 12-2 below.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 12-2).
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
Figure 12-2 Burner Assembly
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 Knight Boiler Service Manual. Adjust settings if
necessary. See Section 1 of the Knight Boiler Service
Manual for adjustment procedures.
Check flame signal
1. At high fire the flame signal shown on the display should be
at least 10 microamps.
2. Check settings of external limit controls (if any) and
adjust if necessary.
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.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 10 - Start-up.
3. See Section 3 - Troubleshooting of the Knight Boiler
Service Manual for other procedures to deal with low flame
signal.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
75
Installation & Operation Manual
12 Maintenance
11. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
Review with owner
1. Review the Knight Boiler User’s Information Manual
with the owner.
2. Emphasize the need to perform the maintenance schedule
specified in the Knight Boiler User’s Information Manual
(and in this manual as well).
12. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 10 - Startup on pages 57
and 59 of this manual.
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
13. Replace the access cover and restore boiler to operation.
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.
Table 12B Heat Exchanger Cleaning Kits
Kit
Part
Component
Description
Model
Cleaning boiler heat exchanger
Number Number
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 12B - Heat Exchanger Cleaning Kits.
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20085 1/4" x 12” Drill Extension
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
81
-
106
KIT30062
KIT30063
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.
151
-
286
MSC20084
3mm Allen Wrench
MSC20086 1/4" x 24" Drill Extension
2. Allow time for the boiler to cool to room temperature if
it has been firing.
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
replacement nylon brush.
ƽ CAUTION
3. Remove the nuts securing the heat exchanger access
cover to the heat exchanger and set aside.
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
Figure 12-3 Rope Gasket - Heat Exchanger Door
ROPE GASKET
The boiler contains ceramic fiber
ƽ WARNING
materials. Use care when handling these
materials per instructions in the Service
Manual. Failure to comply could result in
severe personal injury.
5. Remove the condensate hose from the heat exchanger
end. Connect a field supplied 3/4" diameter hose to
a drain pan. Using field supplied means, cover the
refractory in the back of the combustion chamber of the
heat exchanger.
CAUTION: IF GASKET IS DAMAGED
DO NOT REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
Rope gasket is intended for sealing combustion
(FIG. 12-3). If damaged DO NOT reuse, the
heat exchanger door must be replaced. Consult
factory for replacement heat exchanger door
(kit WTR3080).
NOTICE
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
7. Brush the heat exchanger while dry using a nylon bristle
brush. Caution: DO NOT use a metal brush. Re-vacuum
the heat exchanger.
Oiled bearing circulators
1. The circulator shipped with the Knight boiler is water-
lubricated. No oiling is required.
8. Finish cleaning using a clean cloth dampened with warm
water. Rinse out debris with a low pressure water supply.
9. Allow the heat exchanger to thoroughly dry.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger
and reassemble.
3. Replace the boiler front access cover.
76
Installation & Operation Manual
13 Diagrams
Figure 13-1 Ladder Diagram
JUNCTION BOX
120VAC
NEUTRAL GROUND
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
1
2
INTEGRATED CONTROL
BLOWER
3
ON / OFF
SWITCH
GND
KB ONLY
SYSTEM
PUMP "L"
SYSTEM
PUMP "N"
X1-1
X1-6
F2
X1-2
3.15A
GND
F1
5A
SYSTEM
PUMP
BOILER
BOILER
PUMP "N"
SYSTEM PUMP
RELAY
PUMP "L"
X1-4
X1-3
BOILER PUMP
RELAY
GND
BOILER
PUMP
DHW
PUMP "L"
DHW
PUMP "N"
DHW PUMP
RELAY
F3
TERMINAL
STRIP
TERMINAL
STRIP
DHW
PUMP
.8A
24V DC
SUPPLY
X5-9
X5-1
120 VAC
24 VAC
X4-3
3.5A
KB 801 ONLY
CONNECTION BOARD
FLOW
INTEGRATED
CONTROL
CN5-5
CN5-14 X4-8
CN5-10 X4-12
LWCO
CN7-1
CN7-3
CN7-4
CN7-2
11
SWITCH
12
CONNECTION BOARD
HEAT/LOOP
DEMAND
1
CN5-7
CN5-13
CN5-6
X4-1
X4-9
19
17
20
18
16
14
HEAT/LOOP
DEMAND 2
HEAT/LOOP
DEMAND 3
X4-2
15
13
TANK
THERMOSTAT
CN5-12
X4-10
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
CN5-11
CN5-3
X4-11
X4-5
10
9
5
INTEGRATED
CONTROL
LOUVER
RELAY COIL
6
7
24VAC
LOUVER
PROVING SWITCH
CN5-4
X4-4
X7
8
RIBBON CABLE
X5-2
KB 286 ONLY
PC INTERFACE
BLOCKED
X5-10
X5-11
X2-2
O-TEMP HEX SW
DRAIN SWITCH
X5-6
X5-4
S2
INLET
SENSOR
AIR PRESSURE
SWITCH
S1a
OPERATING
SENSOR
1
X5-12
X5-5
S1b
HIGH LIMIT
SENSOR
GAS VALVE
2
S3a
FLUE
SENSOR
GAS VALVE
RELAY
X2-1
6
X5-13
X5-14
S3b
FLUE
SENSOR
BLOWER
1
2
4
5
X5-7
X5-16
X5-8
13
CONNECTION
BOARD
CN5-1
CN5-8
X4-7
1
2
ALARM
CONTACTS
X4-14
X5-15
CN5-2
CN5-9
X4-6
3
4
RUN-TIME
CONTACTS
X4-13
TR2
CN6
CN6
CN6
X6
X6
X6
S6
21
22
X1-7
SYSTEM
SENSOR
S5
FLAME ROD
23
24
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
OUTDOOR
SENSOR
SPARK
ROD
CN3-9
X4-9
S4
TANK
SENSOR
CN3-6
X4-6
SHIELD
CAUTION HIGH VOLTAGE SPARK LEAD
CN6
X6
A
CASCADE
B
CN6
CN6
X6
X6
NOTES:
1. Where possible, switches are shown without utilities (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.
SHIELD
CN6
CN6
CN6
X6
X6
X6
BMS
+
0-10V
IN
-
+
-
SYS PUMP
IN
2. See wiring diagram for additional notes.
0-10V
0-10V
0-10V
CN6
CN6
X6
X6
+
-
BLR PUMP
OUT
CN6
CN6
X6
X6
BOX DEPICTS
OPTIONAL ITEMS
+
-
RATE
OUT
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
M
O
D
B
U
S
SHIELD
CN8-1
X4-1
X9-2
X9-1
X9-3
X6-1
42
A
MODBUS
CN8-2
43
X6-2
X6-3
X4-2
X4-3
B
CN8-3
44
LADDER DIAGRAM
LBL20148 REV C
SHIELD
77
Installation & Operation Manual
13 Diagrams
Figure 13-2 Wiring Diagram
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
CONTROL
BOX DEPICTS
OPTIONAL
ITEMS
CONNECTION BOARD
JUNCTION
BOX
ALARM
CONTACTS
1
2
X1-3
X1-4
X1-2
X-7
OR
BR
L
DHW
G
G
G
PUMP
RUN-TIME
3
W
W
W
N
L
CONTACTS
4
24 VAC LOUVER
BOILER
PUMP
5
RELAY COIL
6
N
L
LOUVER
PROVING SWITCH
7
PR
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
BK
X4-7
X4-14
X4-6
SYSTEM
PUMP
8
GAS PRESSURE
9
N
SWITCH
10
X4-13
X4-5
KB ONLY
ON/OFF
SWITCH
X4-12
X4-11
X4-4
L
120V
SUPPLY
X1-6
X1-5
L
N
BK
W
GND
N
FLOW
SWITCH
11
12
13
14
15
16
17
18
19
20
X4-3
X4-8
BK
BK
BK
BK
TANK
THERMOSTAT
HEAT/LOOP
X4-10
X4-2
X4-9
X1-8
X1-1
G
R
1
2
3
DEMAND
X4-1
HEAT/LOOP
DEMAND
HEAT/LOOP
TRANSFORMER
DEMAND
RW G
SYSTEM
SENSOR
OUTDOOR
SENSOR
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
BLOWER
TANK
SENSOR
1
2
3
4
5
SHIELD
A
CASCADE
B
SHIELD
X5-7
X5-16
X5-8
R
T
CN6
X6
W
BK
Y
BMS
IN
33
34
35
36
37
38
39
40
41
42
43
44
+
0-10V
X5-15
X5-9
-
SYS PUMP
+
0-10V
IN
-
BLR PUMP
X5-1
BL
O
+
0-10V
OUT
-
KB 286 ONLY
X5-2
RATE
+
O-TEMP HEX SW
0-10V
BLOCKED DRAIN SWITCH
AIR PRESSURE SWITCH
OUT
-
X5-10
X5-11
X5-4
P
SHIELD
A
O/BK
R/BK
GY
MODBUS
-T
-T
OPTION
B
OPERATING SENSOR S1a
SHIELD
X5-12
X5-6
HIGH LIMIT SENSOR S1b
INLET SENSOR S2
-T
-T
-T
24 VAC
LOW
CN7-1
P/BK
W/BK
PR
CN7-2
CN7-3
CN7-4
WATER
CUT-OFF
COM
X5-5
FLUE SENSOR S3a
FLUE SENSOR S3b
X5-13
X5-14
RBLG
Y
X2-2
BK
Y
GAS VALVE
@24VAC
O
GY
G
X4-1
X4-2
X4-3
X4-4
X9-1
X9-2
X9-3
X9-4
X2-1
X1-7
TR2
MODBUS BOARD
MTR-01
W/R
FLAME SENSOR
SPARK
ROD
G
SHIELD
GROUNDING
JUMPER
X5-1
X5-2
CAUTION HIGH VOLTAGE SPARK LEAD
BK
W
G
X1-1
X1-2
X1-3
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a
minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead
or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller 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.
WIRING DIAGRAM
LBL20127 REV C
78
Installation & Operation Manual
Notes
79
Revision Notes: Revision A (ECO C05747) initial release. Reflects the
new model numbers for the Knight upgrade.
Revision B (ECO #C06188) reflects updates made to the ladder and
wiring diagrams (ECO #C06158).
Revision C (ECO #C06234) reflects changes made to the Service
Reminder feature.
Revision D (ECO #C07981) reflects the layout in InDesign, edits made
to Section 11 - Operating Information, ECR04077 - combustible water
pipes change from 1" to a 1/4", changes made to the vent pipe chart on
page 17, ECR03743 - 20° rise notice on page 37, addition of O-temp
switch.
KBII-I-O Rev D
05/11
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RCA CC 285 User Manual
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