WBII-I-O Rev I
Installation & Operation Manual
Models: 51 - 211
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the Knight
Wall Mount Service Manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
ƽ WARNING
Save this manual for future reference.
Installation & Operation Manual
Please read before proceeding
Installer
–
Read all instructions,
When servicing boiler –
ƽ WARNING
including this manual and the Knight
Wall Mount Service Manual, before
installing. Perform steps in the order
given.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
User – This manual is for use only
by
a
qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
• 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.
• 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.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
NOTICE
Consider piping and installation when
determining boiler location.
Boiler water –
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
• 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.
WHAT TO DO IF YOU SMELL GAS
Do not use “homemade cures” or “boiler
patent medicines”. Serious damage to
the boiler, personnel, and/or property
may result.
ƽ CAUTION
• 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.
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.
• 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.
3
Installation & Operation Manual
The Knight Wall Mount Boiler - How it works...
1. Stainless steel heat exchanger
15. Gas connection pipe
Allows system water to flow through specially designed
coils for maximum heat transfer, while providing
Threaded pipe connection of 1/2". This pipe should be
connected to the incoming gas supply for the purpose of
delivering gas to the boiler.
protection against flue gas corrosion.
The coils are
encased in a jacket that contains the combustion process.
16. SMART SYSTEM Control Module
2. Combustion chamber access cover
Allows access to the combustion side of the heat
exchanger coils.
The SMART SYSTEM Control responds to internal and
external signals and controls the blower, gas valve, and pumps
to meet the heating demand.
3. Blower
17. Air intake adapter
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.
Allows for the connection of the PVC air intake pipe to
the boiler.
18. High voltage junction box
4. Gas valve
The junction box contains the connection points for the line
voltage power and all pumps.
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.
19. Manual air vent
Designed to remove trapped air from the heat exchanger
coils.
5. Venturi
The venturi controls air and gas flow into the burner.
20. Low voltage connection board
The connection board is used to connect external low voltage
devices.
6. Flue gas sensor (limit rated)
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
21. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
7. Boiler outlet temperature sensor (housed with high
22. Condensate drain connection
limit sensor)
Connects the condensate drain line to a 1/2" pipe.
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.
23. Access door
Provides access to all internal components.
24. Ignition electrode
8. Boiler inlet temperature sensor
Provides direct spark for igniting the burner.
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.
25. Flame inspection window
The quartz glass window provides a view of the burner
surface and flame.
9. Temperature and pressure gauge (field installed, not
26. Gas shutoff switch
shown)
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
Monitors the outlet temperature of the boiler as well as the
system water pressure.
27. High limit sensor (housed with outlet sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, it will break the control circuit,
shutting the boiler down.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial
and a multiple line liquid crystal display.
11. Flue pipe adapter
28. Relief valve
Allows for the connection of the PVC vent pipe system to the
boiler.
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 30 psi.
12. Burner (not shown)
29. Flame sensor
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
Used by the control module to detect the presence of burner
flame.
30. Line voltage wiring connections (knockouts)
13. Water outlet (system supply)
Conduit connection points for the high voltage junction box.
The water outlet is the water connection for water leaving the
boiler and entering the system. Boiler connection is 1".
31. Air pressure switch
The air pressure switch detects blocked inlet conditions.
14. Water inlet (system return)
The water inlet is the water connection for water entering the
boiler from the system. Boiler connection is 1".
32. Transformer
The transformer provides 24V power to the integrated control.
4
Installation & Operation Manual
The Knight Wall Mount Boiler - How it works...
Models 51 - 211
(continued)
17
11
28
19
22
14
15
23
13
30
21
FRONT
OF UNIT
10
Front View
Bottom View
6
1
32
2
25
24
16
8
5
7
27
20
4
14
29
22
26
18
31
13
3
Left Side (inside unit)
Right Side (inside unit)
5
Installation & Operation Manual
Ratings
Knight Wall Mount Boiler
AHRI Rating
Other Specifications
Net
Input
MBH
AFUE
%
AHRI
Ratings
Water,
MBH
Model Number
Vent/Air Size
Heating
Capacity
MBH
Boiler Water
Content
Gallons
Water
Gas
Note: Change
“N” to “L” for
L.P. gas models.
Connections Connections
(Note 5)
(Note 1, 8)
(Note 4)
2"
(Note 2, 8
45
(Note 3, 8)
Min
10
Max
50
0.6
0.6
0.7
1.3
1.7
1"
1"
1"
1"
1"
1/2"
1/2"
1/2"
1/2"
1/2"
WBN051
WBN081
WBN106
WBN151
WBN211
39
95.3
95.3
95.4
95.5
95.7
2"
2"
3"
3"
16
21
30
42
80
72
94
63
82
105
150
210
135
190
119
165
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
7. The Knight Wall Mount boiler input rate, on some
models, is reduced for vent lengths beyond the minimum.
Models WB(N,L)081 and WB(N,L)106 with 2" vent will
reduce 1% for every 10 feet of vent. Models WB(N,L)151
and WB(N,L)211 with 3" vent will reduce 0.5% for every
10 feet of vent.
1. As an Energy Star Partner, Lochinvar has determined that
Knight wall mount boilers meet the Energy Star guidelines
for energy efficiency.
2. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
8. Ratings have been confirmed by the Hydronics Section of
AHRI.
3. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
9. Knight wall mount boilers comply with the requirements
of CSD-1 Section CW-400 requirements as a temperature
operation control. The manual reset high limit provided
with the Knight wall mount is listed to UL353.
4. Knight wall mount boilers require special gas venting. Use
only the vent materials and methods specified in the Knight
Wall Mount Installation and Operation Manual.
5. Standard Knight wall mount boilers are equipped to operate
from sea level to 4,500 feet only with no adjustments. The
boiler will de-rate by 4% for each 1,000 feet above sea level
up to 4,500 feet.
UNIT EQUIPPED FOR
HIGH ALTITUDE
6. High altitude Knight wall mount boilers are equipped
to operate from 3,000 to 12,000 feet only with no field
adjustments. The boiler will de-rate by 2% for each 1,000
feet above 3,000 feet. High altitude models are manufactured
with a different control module for altitude operation, but
the operation given in this manual remains the same as the
standard boilers. A high altitude label (as shown in FIG. A)
is also affixed to the unit.
3,000 FT. TO 12,000 FT.
6
Figure A High Altitude Label Location
Installation & Operation Manual
1 Determine boiler location
This appliance is certified as an indoor
Installation must comply with:
ƽ WARNING
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.
•
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. The vent connection to the
appliance is made of CPVC. Field supplied
vent fittings must be cemented to the CPVC
fitting on the boiler. Use only the vent
materials, primer, and cement specified in
the manual to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
ƽ WARNING
The Knight wall mount boiler gas
NOTICE
manifold and controls met safe lighting
and other performance criteria when the
boiler underwent tests specified in ANSI
Z21.13 – latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
Closet and alcove installations
A closet is any room the boiler is installed in which is less
than 79 cubic feet for WBN051 through WBN106 models,
104 cubic feet for WBN151 models, and 125 cubic feet for
WBN211 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, 4 feet wide, and
9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be
considered a closet for a Knight wall mount boiler.
For closet and alcove installations as shown
ƽ WARNING
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
in FIG.’s 1-1 and 1-2, CPVC or stainless
steel vent material must be used inside
the structure. The two ventilating air
openings shown in FIG. 1-1 are required
for this arrangement. Failure to follow
this warning could result in fire, personal
injury, or death.
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 wall mount boiler must be installed so
that gas control system components are protected from
dripping or spraying water or rain during operation or
service.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" from combustible materials.
2. Vent pipe – at least 1" from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance
minimums.
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.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 8 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
boiler without removing it from the space.
7
Installation & Operation Manual
1 Determine boiler location
Figure 1-1 Closet Installation - Minimum Required Clearances
TOP
6" MINIMUM
For closet installations, CPVC or
LEFT
24" SERVICE
0" MINIMUM
ƽ WARNING
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.
VENTILATING
*
AIR OPENING
6"
RIGHT
0" MINIMUM
1" MINIMUM CLEARANCE
AROUND VENT PIPE
CLOSED DOOR
6"
VENTILATING
*
AIR OPENING
FRONT
BOTTOM
24" SERVICE
0" MINIMUM
24" SERVICE
6" MINIMUM
1/4" MINIMUM CLEARANCE
AROUND HOT WATER PIPES
*AREA OF EACH OPENING:
Note: Service clearances are recommendations
only.
1 SQ. INCH PER 1000 BTU PER HOUR INPUT
WITH A MINIMUM OF 100 SQ. INCHES.
Figure 1-2 Alcove Installation - Minimum Required Clearances
TOP
6" MINIMUM
LEFT
24" SERVICE
0" MINIMUM
For alcove installations, CPVC or
ƽ WARNING
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.
RIGHT
0" MINIMUM
1" MINIMUM CLEARANCE
AROUND VENT PIPE
OPEN FRONT
FRONT
24" SERVICE
6" MINIMUM
BOTTOM
24" SERVICE
0" MINIMUM
1/4" MINIMUM CLEARANCE
AROUND HOT WATER PIPES
Note: Service clearances are recommendations only.
8
Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
(continued)
Residential garage installation
Precautions
Knight wall mount boiler alone in boiler room
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 wall mount
boiler are at least equal to the SERVICE clearances
shown in FIG.’s 1-1 and 1-2. For spaces that do NOT
supply this clearance, provide two openings as shown
in FIG. 1-1. Each opening must provide one square
inch free area per 1,000 Btu/hr of boiler input.
• 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 wall mount 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 wall mount 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
wall mount 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 wall mount 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 wall mount 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.
Wall mounting location
Prevent combustion air contamination
Ensure the wall for which the boiler is intended to be
mounted is comprised of either, cement, brick, block, or
wooden studs spaced 16" apart from center. Ensure the
wall is capable of supporting at least 200 pounds.
Install air inlet piping for the Knight wall mount boiler as
described in this manual. Do not terminate vent/air in locations
that can allow contamination of combustion air. Refer to
Table 1A, page 10 for products and areas which may cause
contaminated combustion air.
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
Ensure the boiler is installed in a location that minimizes
the risk of water damage due to valves, pumps, etc.
not contain any of the contaminants in Table
1A, page 10. Contaminated combustion air
will damage the boiler, resulting in possible
severe personal injury, death or substantial
property damage. Do not pipe combustion
air near a swimming pool, for example. Also,
avoid areas subject to exhaust fumes from
laundry facilities. These areas will always
contain contaminants.
9
Installation & Operation Manual
1 Determine boiler location
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
emissions, causing severe personal injury
or death.
ƽ WARNING
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Check the following venting components before installing:
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. For polypropylene or
stainless steel venting, an adapter of the same
manufacturer must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3A.
Check to see that this size is used throughout the vent
system.
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
• Manufacturer - For a stainless steel or polypropylene
application, you must use only the listed manufacturers
and their type product listed in Tables 3E and 3G for CAT
IV positive pressure venting with flue producing
condensate.
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
• 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.
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
3H 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 11.
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
With polypropylene and stainless steel vent, seal and connect
all pipe and components as specified by the vent manufacturer
used; with PVC/CPVC vent, see the Installing Vent or Air
Piping Section on page 19.
If any of these conditions are not met,
ƽ WARNING
Garages with workshops
the existing system must be updated or
replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
10
Installation & Operation Manual
1 Determine boiler location
(continued)
When removing a boiler from existing
common vent system:
Do not install the Knight wall mount
boiler into a common vent with any other
appliance. This will cause flue gas spillage or
appliance malfunction, resulting in possible
severe personal injury, death, or substantial
property damage.
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.
ƽ DANGER
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.
11
Installation & Operation Manual
2 Prepare boiler
Table 2A LP Conversion Table
LP Conversion Table
LP Orifice Stamping
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler,
remove the parts box.
Model
51
50
80
2. To remove the boiler from the pallet:
a. Remove the two (2) lag bolts securing the bottom
of the unit to the pallet.
81
106
151
211
105
210 / W150
210 / W150
b. Lift the boiler off the wall bracket mounted to
the pallet.
1. Remove the front access cover from the unit (no tools
required for removal).
3. Remove the two (2) lag bolts securing the wall bracket to
the wood pallet. Be certain not to lose the wall bracket
as it will be needed for securing the boiler to the wall
(FIG. 2-1).
2. Disconnect the ribbon cable from the control board.
Remove the four (4) screws securing the bezel to the front
of the unit and remove the bezel.
Do not drop the boiler or bump the jacket
NOTICE
3. Locate the power switch on the gas valve and turn the power
switch to the “OFF” position (FIG. 2-2).
on the floor or pallet. Damage to the
boiler can result.
4. Disconnect the Molex plug from the wiring connector
located on the gas valve.
Figure 2-1 Boiler Mounted on Shipping Pallet
5. Using a 5/16" nut driver, loosen the band clamp securing the
air intake coupler to the gas valve venturi. Remove the air
intake pipe and coupler from the gas valve venturi.
6. Using a 4mm Allen wrench, remove the two (2) screws
securing the gas valve venturi to the inlet of the combustion
blower (FIG. 2-2). Remove the gas valve venturi assembly
from the unit.
REMOVE SHIPPING
[WALL] BRACKET
Figure 2-2 Gas Valve Power Switch & Venturi Removal
DO NOT DISCARD-
WILL BE NEEDED TO
SECURE THE BOILER
TO THE WALL
REMOVE THE TWO (2) SCREWS
SECURING THE GAS VALVE VENTURI
TO THE INLET OF THE COMBUSTION BLOWER
POWER SWITCH
DETAIL
Gas conversions
7. Using a 4mm Allen wrench, remove the four (4) screws
securing the gas valve to the venturi (FIG. 2-3).
The gas conversion procedure should
ƽ WARNING
be accomplished BEFORE the boiler is
8. Locate the propane orifice disk from the conversion kit bag.
Verify that the stamping on the orifice disk matches the
boiler size (51 - 211, see Table 2A).
installed. For a boiler already installed,
you must turn off gas supply, turn off
power, and allow the boiler to cool before
proceeding. You must also completely
test the boiler after conversion to verify
performance as described under Start-up,
Section 10 of this manual.
9. Place the orifice into the black rubber grommet in the side of
the gas valve and secure inside the gas valve (see FIG. 2-3).
10. Reposition the gas valve against the venturi and replace the
four (4) screws removed in Step 7, securing the valve to the
venturi (FIG. 2-3).
You must install the propane orifice to fire
the Knight wall mount boiler on propane.
Verify when installing that the orifice size
marking matches boiler size (Table 2A).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
11. Reposition the gas valve venturi assembly inside the unit.
Secure the gas valve venturi to the combustion blower by
replacing the two (2) screws removed in Step 6 (FIG. 2-2).
12. Reattach the air intake pipe and coupler to the gas valve
venturi. Tighten the band clamp to secure.
12
Installation & Operation Manual
2 Prepare boiler
(continued)
The boiler is too heavy for a single person
to lift. A minimum of two people is needed
for mounting the boiler onto the bracket.
13. Reattach the wiring connector to the gas valve. Tighten
the screw on the wiring connector to secure to the gas
valve.
ƽ WARNING
Mounting to a concrete wall:
14. Turn the gas valve power switch to the “ON” position.
1. Mount the wall bracket using the two (2) wedge anchor
bolts provided with the bracket. To mount the wedge
anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and
insert anchor. Hang the bracket from the anchor and secure
with the two nuts provided. Make sure the top edge of the
bracket is away from the wall. Ensure bracket is level when
mounted. Extreme care is needed to ensure the bolts are
secured in the center of the studs.
15. Reattach the bezel to the unit. Reconnect the ribbon cable
to the control board.
16. After installation is complete, fill out the gas conversion
label (in the conversion kit bag) and affix it to the unit
under the boiler rating plate inside the unit. Attach the
LP caution label (in the conversion kit bag) to the left side
of the unit in the lower left corner.
17. Replace the front access cover.
Note: If wall thickness does not allow a 1 1/8" deep hole,
field supplied hardware suitable for the application should be
provided.
After converting to LP, check combustion
ƽ WARNING
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.
2. Hang the boiler on the bracket and secure the bottom of the
boiler with two (2) remaining anchors, following the
instructions above.
The boiler is too heavy for a single person
to lift. A minimum of two people is needed
ƽ WARNING
Figure 2-3 Installing Propane Orifice
for mounting the boiler onto the bracket.
Mounting to a metal studded wall:
1. The wall mount bracket is designed for a stud spacing of
16 inches from center. For other stud spacing a solid
mounting surface must be provided by the installer.
Do not mount the boiler to a hollow wall. Be
ƽ WARNING
sure to mount the boiler to the studs only.
2. Mount the wall bracket using two (2) field supplied toggle
bolts capable of supporting 100 pounds each. Ensure the
top edge of the bracket is away from the wall. Ensure the
bracket is level when mounted. Extreme care is needed to
ensure the bolts are secured in the center of the studs.
3. Hang the boiler on the bracket and secure the bottom of the
boiler with two (2) field supplied toggle bolts.
Mounting the boiler
The boiler is too heavy for a single person
to lift. A minimum of two people is needed
for mounting the boiler onto the bracket.
See page 9 of this manual for boiler mounting location
instructions.
ƽ WARNING
The Knight Wall Mount boiler is not
NOTICE
intended for floor installation.
Figure 2-4 Mounting the Boiler
WALL:
Mounting to a wood studded wall:
WOOD OR METAL STUDS ON
16" CENTERS
-OR-
1. The wall mount bracket is designed for a stud spacing of
16 inches from center. For other stud spacing a solid
mounting surface must be provided by the installer.
MASONRY / POURED CONCRETE
MOUNTING BRACKET
(FACTORY SUPPLIED)
Do not mount the boiler to a hollow wall.
Be sure to mount the boiler to the studs
only.
ƽ WARNING
2. Mount the wall bracket using the 2 1/4" lag bolts
provided. Make sure the top edge of the bracket is away
from the wall. Ensure the bracket is level when mounted.
Extreme care is needed to ensure the bolts are secured in
the center of the studs.
FASTENERS
APPROPRIATE
FOR WALL TYPE
QTY: 4
3. Hang the boiler on the bracket and secure the bottom of
the boiler with two (2) additional lag bolts provided.
13
Installation & Operation Manual
3 General venting
Direct venting options - Sidewall Vent
Figure 3-2 PVC/CPVC Concentric Sidewall
Termination - See page 26 for more details
Figure 3-1 Two-Pipe Sidewall Termination - See
page 22 for more details
Direct venting options - Vertical Vent
Figure 3-3 Two-Pipe Vertical Figure 3-4 PVC/CPVC Concentric
Figure 3-5 Vertical Vent, Sidewall
Termination - See page 29 for more Vertical Termination - See page 31
Air
details
for more details
14
Installation & Operation Manual
3 General venting
(continued)
Install vent and combustion air piping
The Knight wall mount boiler must be
vented and supplied with combustion and
ventilation air as described in this section.
Ensure the vent and air piping and the
combustion air supply comply with these
instructions regarding vent system, air
system, and combustion air quality. See
also Section 1 of this manual.
The Knight wall mount boiler vent and air piping can be
installed through the roof or through a sidewall. Follow the
procedures in this manual for the method chosen. Refer to the
information in this manual to determine acceptable vent and
air piping length.
ƽ DANGER
You may use any of the vent/air piping methods covered in this
manual. Do not attempt to install the Knight wall mount boiler
using any other means.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
You must also install air piping from outside to the boiler
air intake adapter unless following the Optional Room Air
instructions on page 18 of this manual. The resultant installation
is direct vent (sealed combustion).
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6) - Used to
provide combustion air directly to the unit from outdoors. A
fitting is provided on the unit for final connection.
Combustion air piping must be supported per guidelines
listed in the National Mechanical Code, Section 305, Table
305.4 or as local codes dictate.
This appliance requires a special venting
system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and
fittings listed in Tables 3D, 3E, and 3G for
vent pipe, and fittings. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
2. Vent Connector (FIG.'s 3-7 thru 3-9) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
DO NOT mix components from different
systems. The vent system could fail,
causing leakage of flue products into the
living space. Mixing of venting materials
will void the warranty and certification of
the appliance.
ƽ WARNING
Figure 3-6 Near Boiler Air Piping
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
AIR
For closet and alcove installations, CPVC,
polypropylene or stainless steel material
MUST BE used in a closet/alcove structure.
Failure to follow this warning could result
in fire, personal injury, or death.
ƽ WARNING
Improper installation of venting systems
may result in injury or death.
ƽ CAUTION
Follow the instructions in Section 1, page
11 of this manual when removing a boiler
from an existing vent system.
NOTICE
Do not connect any other appliance to
the vent pipe or multiple boilers to a
common vent pipe. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
15
Installation & Operation Manual
3 General venting
Minimum
/
Maximum
allowable
Requirements for installation in
Canada
combustion air and vent piping lengths
are as follows:
1. Installations must be made with a vent pipe system
certified to ULC-S636.
Combustion Air = 12 equivalent feet minimum / 100
equivalent feet maximum
IPEX is an approved vent manufacturer in Canada
supplying vent material listed to ULC-S636.
Vent = 12 equivalent feet minimum / 100 equivalent feet
maximum
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
When determining equivalent combustion air and vent
length, add 5 feet for each 90° elbow and 3 feet for each
45° elbow.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2)
45° elbows + (1) concentric vent kit (CVK3003) = 49
equivalent feet of piping.
4. The 2" and 3" Concentric Vent Kits available from
Lochinvar (see Section 4 – Sidewall Termination – Optional
Concentric Vent) and the 2" and 3" Concentric Vent Kits
available from IPEX are approved for use on the Knight
wall mount boiler. Both kits are listed to the ULC-S636
standard for use in Canada.
The appliance output rating will reduce
NOTICE
by up to 1.5% for each 25 feet of vent
length.
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Sizing
The Knight wall mount boiler uses model specific combustion
air intake and vent piping sizes as detailed in Table 3A below.
Equivalent Vent
Model Kit Number
Length
51 - 106
51 - 211
CVK3008
CVK3003
3 feet
3 feet
Table 3A Maximum Combustion Air and Vent Piping
Lengths
Model 2" Max Vent/Air 3" Max Vent/Air
51
81
40 feet
40 feet
40 feet
N/A
100 feet
100 feet
100 feet
100 feet
100 feet
106
151
211
N/A
Increasing or decreasing combustion air or
vent piping sizes is not authorized.
NOTICE
16
Installation & Operation Manual
3 General venting
(continued)
Materials
Air inlet pipe materials:
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.
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
PVC, CPVC, Polypropylene or ABS
Dryer Vent or Sealed Flexible Duct (not recommended
for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as
specified in this section.
Type “B” double-wall vent with joints and seams sealed as
specified in this section.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
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.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
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.
Using air intake materials other than
those specified can result in personal
injury, death or property damage.
ƽ WARNING
The use of double-wall vent or insulated
NOTICE
material for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized
vent pipe material used for air inlet piping on a sidewall or
vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either
Aluminum Foil Duct Tape meeting UL Standard 723 or
181A-P or a high quality UL Listed silicone sealant such as
those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three (3) sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
17
Installation & Operation Manual
3 General venting
Optional room air
Air contamination
Optional room air is intended for
NOTICE
commercial applications. Combustion air
piping to the outside is recommended for
residential applications.
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.
Commercial applications utilizing the Knight wall mount
boiler may be installed with a single pipe carrying the flue
products to the outside while using combustion air from
the equipment room. In order to use the room air venting
option the following conditions and considerations must be
followed.
Please read the information given in Table 1A, page 10,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
•
The unit MUST be installed with the appropriate
room air kit (Table 3C).
•
The equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
If the boiler combustion air inlet is located
ƽ WARNING
in a laundry room or pool facility, for
example, these areas will always contain
hazardous contaminants.
•
•
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
To prevent the potential of severe personal
injury or death, check for areas and products
ƽ WARNING
building.
Please review Section 1, Prevent
listed in Table 1A, page 10 before installing
the boiler or air inlet piping.
Combustion Air Contamination, to ensure proper
installation.
•
Vent system and terminations must comply with the
standard venting instructions set forth in this
manual.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
When utilizing the single pipe method,
• Relocate air inlet and vent
terminations to other areas.
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.
Table 3C Optional Room Air Kit
Model
51 - 106
151 - 211
Kit Number
KIT30051
KIT30052
18
Installation & Operation Manual
3 General venting
(continued)
PVC/CPVC
Examples: 1. Seven (7) feet vertical
This product has been approved for use with the PVC/CPVC
vent materials listed in Table 3D.
2. Connector + 90° elbow + 2 feet horizontal
3. One (1) foot vertical + 90° elbow + 1 foot
horizontal
Installing vent and air piping
The vent connection to the appliance must
1. Work from the boiler to vent or air termination. Do not
exceedthelengthsgiveninthismanualfortheairorvent
piping.
2. Cut pipe to the required lengths and deburr the inside
and outside of the pipe ends.
ƽ WARNING
be made with the starter piece provided
with the appliance if PVC/CPVC vent is to
be used. The field provided vent fittings
must be cemented to the CPVC pipe section
using an “All Purpose Cement” suitable for
PVC and CPVC pipe. Use only the vent
materials, primer, and cement specified in
Table 3D to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
3. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag.
(Moisturewillretardcuringanddirtorgreasewillprevent
adhesion.)
5. Dry fit vent or air piping to ensure proper fit up before
assembling any joint. The pipe should go a third to
two-thirds into the fitting to ensure proper sealing after
cement is applied.
Use only cleaners, primers, and solvents
NOTICE
that are approved for the materials which
are joined together.
All PVC vent pipes must be glued, properly
NOTICE
6. Priming and Cementing:
supported, and the exhaust must be
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
Insulation should not be used on PVC
ƽ WARNING
c. Apply a second primer coat to the fitting socket.
or CPVC venting materials. The use of
d. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the fitting socket along with an even coat of
approved cement to the fitting socket.
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
Table 3D PVC/CPVC Vent Pipe, and Fittings
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
sufficient cement was not applied and joint could
be defective.
Approved PVC/CPVC Vent Pipe and Fittings
Item
Material
PVC Schedule 40, 80 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
Standard
Vent pipe
g. Wipeexcesscementfromthejointremovingringor
beads as it will needlessly soften the pipe.
PVC Schedule 40
ANSI/ASTM D2466
ANSI/ASTM D2467
ANSI/ASTM F439
ANSI/ASTM D2564
ANSI/ASTM F493
Figure 3-7 Near Boiler PVC/CPVC Venting
Vent fittings PVC Schedule 80
CPVC Schedule 80
Pipe Cement / PVC
Primer
CPVC
CPVC STARTER PIECE
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/
primer must be ULC-S636 certified.
For models 51 - 106 when transitioning from 2
ƽ WARNING
to 3 inch vent diameter, a 2" pipe section and
2"to 3" increaser are required to be CPVC when
PVC/CPVC vent is used.
For installations using 2" vent, the first seven
(7) equivalent feet of vent must be CPVC (field
supplied). See examples on this page.
19
Installation & Operation Manual
3 General venting
This product has been approved for use with polypropylene
vent with the manufacturers listed in Table 3E.
Polypropylene
Use only the adapters and vent system listed
ƽ WARNING
in Tables 3E and 3F. DO NOT mix vent
systems of different types or manufacturers.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
All terminations must comply with listed options in this manual
and be a single-wall vent offering.
For use of flex pipe, it is recommended to have the vent material
in 32°F or higher ambient space before bending at installation.
No bends should be made to greater than 45° and ONLY
installed in vertical or near vertical installations.
Installations must comply with applicable
national, state, and local codes. For
Canadian installation, polypropylene vent
must be listed as a ULC-S636 approved
system.
NOTICE
NOTICE
For support and special connections required, see the
manufacturer's instructions. All vent is to conform to standard
diameter and equivalent length requirements established.
Installation of a polypropylene vent system
should adhere to the vent manufacturer’s
installation instructions supplied with the
vent system.
Table 3E Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make
Model
Centrotherm Eco Systems
InnoFlue SW/Flex
Duravent (M & G Group)
PolyPro Single-Wall / PolyPro Flex
The installer must use a specific vent
Figure 3-8 Near Boiler Polypropylene Venting
NOTICE
starter adapter at the flue collar
connection. The adapter is supplied by
the vent manufacturer to adapt to its vent
system. See Table 3F for approved vent
adapters. Discard CPVC starter piece.
All vent connections MUST be secured by
the vent manufacturer's joint connector
(FIG. 3-8).
NOTICE
Insulation should not be used on
polypropylene venting materials. The use
of insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
ƽ WARNING
JOINT CONNECTOR REQUIRED
AT ALL COMPONENT CONNECTIONS
OF VENT SYSTEM
POLYPROPYLENE ADAPTER
W/FLUE CLAMP
IMG00155
Table 3F Approved PolypropyleneTerminations
Duravent Polypro
Centrotherm InnoFlue SW
Model
Polypropylene Adapter /
Flue Clamp
Joint
Connector
Sidewall Retaining
Bracket*
Sidewall
Adapter*
Joint
Connector
Polypropylene Adapter
Sidewall Kit*
ISAG0202 w/IAFC02
ISAG0303 w/IAFC03
IANS02
IANS03
IATP0202
IATP0303
ISTAGL0202 2PPS-AD w/ PPS-PAC 2PPS-LB 2PPS-HLK
ISTAGL0303 3PPS-AD w/ PPS-PAC 3PPS-LB 3PPS-HLK
51-106
151-211
* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 24).
20
Installation & Operation Manual
3 General venting
(continued)
Installation of a stainless steel vent system
Stainless steel vent
NOTICE
should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3G.
Use only the materials, vent systems, and
ƽ WARNING
Figure 3-9 Near Boiler Stainless Steel Venting
VENT
terminations listed in Tables 3G and 3H.
DO NOT mix vent systems of different
types or manufacturers. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
The installer must use a specific vent starter
NOTICE
adapter at the flue collar connection,
3" S.S. ADAPTER
supplied by the vent manufacturer to
adapt to its vent system. See Table 3H for
approved vent adapters. Discard CPVC
starter piece.
Installations must comply with applicable
NOTICE
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
Table 3G Stainless Steel Vent Pipe and Fittings
Approved Stainless Steel Vent Manufacturers
Make
Model
Dura Vent (M & G Group)
FasNSeal Vent / FasNSeal Flex* Vent
Z-Flex (Nova Flex Group)
Z-Vent
Heat Fab (Selkirk Corporation)
Saf-T Vent
*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure
no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method,
see manufacturer’s instructions.
Table 3H Approved Stainless Steel (S.S.) Terminations and Adapters
ProTech
Heat Fab
Z Flex
FasNSeal
Saf-T Vent
Z-Vent
Model
Intake
Air
Termination
Intake
Air
S.S.
Flue
S.S.
Flue
S.S.
Flue
Intake Air
Adapter Termination
Adapter Termination
Adapter Termination Termination
Termination
WB50210
2SVSLPVC3
300716 (Vent)
(Vent)
(Vent)
FSBS3
300715 (Intake FSRC3(R.C)
Air)
9392
5300CI
2SVSTP03
2SVSTEX0390
2SVSRCX03
2SVSLA03
(Intake Air)
303889
9314TERM
51 - 211
9301PVC
(Intake Air)
21
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination – sidewall
Figure 4-1A PVC/CPVC/Polypropylene Sidewall
Termination of Air and Vent
Follow instructions below when
ƽ WARNING
determining vent location to avoid
TO BOILER
INTAKE AIR
CONNECTION
possibility of severe personal injury,
death, or substantial property damage.
FROM BOILER
VENT PIPE
A gas vent extending through an exterior
ƽ WARNING
CONNECTION
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
12"
MIN
Determine location
GRADE OR
SNOW LINE
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 16
of this manual.
Table 4A Sidewall Vent Kit
Model Kit Number
Vent Size
2. You must consider the surroundings when terminating
the vent and air:
51 - 106
KIT30044
KIT30045
2 inch vent
3 inch vent
a. Position the vent termination where vapors will
not damage nearby shrubs, plants or air
conditioning equipment or be objectionable.
151 - 211
If using the alternate sidewall termination:
b. The flue products will form a noticeable plume as 3. The air piping must terminate in a down-turned elbow
they condense in cold air. Avoid areas where the
plume could obstruct window views.
as shown in FIG. 4-1B. This arrangement avoids
recirculation of flue products into the combustion air
stream.
c. Prevailing winds could cause freezing of
condensate and water/ice buildup where flue
products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
e. Do not locate the terminations where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells,
alcoves, courtyards, or other recessed areas.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
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.
Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall
Termination of Air and Vent w/Field Supplied Fittings
Sidewall vent and air inlet terminations
must terminate in the same pressure zone.
ƽ WARNING
TO BOILER
INTAKE AIR
BIRD SCREEN
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.
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
12” MIN
15” MAX
TERMINATION
PLATE
12”
MIN
BIRD SCREEN
GRADE OR
SNOW LINE
22
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Figure 4-2A Clearance to Gravity Air Inlets
Vent/air termination – sidewall
Figure 4-1C Alternate Venting Arrangement (if Space
Allows) w/Field Supplied Fittings
TO BOILER
INTAKE AIR
CONNECTION
COUPLING
12"
MIN.
12” MIN
15” MAX
FROM BOILER
VENT PIPE
CONNECTION
VENT / AIR
TERMINATION
12"
MIN.
BIRD SCREEN
12"
MIN.
12”
MIN
Figure 4-2B Alternate Clearance to Gravity Air Inlets w/
Field Supplied Fittings
BIRD
SCREEN
GRADE OR
SNOW LINE
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
Figure 4-1D Alternate Venting Arrangement - Typical
Stainless Steel Sidewall Termination of Air and Vent w/
Field Supplied Fittings
12”
MIN
BIRD
SCREEN
(TYPICAL)
TO BOILER
INTAKE AIR
12" MIN
CONNECTION
15" MAX
12”
MIN
FROM
BOILER
VENT PIPE
CONNECTION
12”
MIN
Figure 4-3A Clearance to Forced Air Inlets
IF LESS
THAN 10’
12" MIN
BIRD SCREEN
GRADE OR SNOW LINE
VENT / AIR
TERMINATION
36"
MIN.
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,
pages 22 - 23. Also maintain the following:
a. Vent must terminate:
FORCED AIR
INLET
• 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.
7' MIN. ABOVE ANY
PUBLIC WALKWAY
• No closer than 12 inches below or horizontally
from any door or window or any other gravity air
inlet.
Figure 4-3B Alternate Clearance to Forced Air Inlets w/
Field Supplied Fittings
b. Air inlet must terminate at least 12 inches above
grade or snow line; at least 12 inches below the vent
termination; and the vent pipe must not extend
more than 24 inches vertically outside the building
as shown in FIG. 4-1B. Condensate could freeze and
block vent pipe.
IF LESS
THAN 10’
36”
MIN
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.
FORCED AIR
INLET
BIRD
SCREEN
(TYPICAL)
7’ MIN ABOVE ANY
PUBLIC WALKWAY
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.
23
Installation & Operation Manual
4 Sidewall direct venting
Prepare wall penetrations
Figure 4-4B Polypropylene Sidewall Termination Assembly
1. Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
Air pipe penetration:
SIDEWALL
ADAPTER
(AIR)
WALL
PLATE
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration:
SIDEWALL
RETAINING
PLATE
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:
VENT
PLATE
VENT
CAP
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
SIDEWALL
ADAPTER
(VENT)
2. For Polypropylene Only: Install the vent and air intake
sidewall adapters from Table 3F on page 20 into the vent
plate. Slide the sidewall retaining bracket down the
sidewall adapters flush to the vent plate (FIG. 4-4B).
3. For PVC/CPVC Only: Install the vent and air intake
piping through the wall into the vent plate openings.
Use RTV silicone sealant to seal the air pipe. Use the
cement/primer listed in Table 3D on page 19 to seal the
vent pipe.
IMG00085
GALVANIZED
THIMBLE
Prepare wall penetrations (Alternate -
Field Supplied Option)
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
4. Mount and secure the vent plate to the wall, using stainless
steel screws.
5. Seal all gaps between the pipes and wall. Seal around the
plate to the wall assuring no air gaps.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the vent
pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-4C.
6. Assemble the vent cap to the vent plate (see FIG.'s 4-4A
and 4-4B). Insert the stainless steel screws into the vent
cap screw hole openings and securely attach the vent cap
to the vent plate.
7. Seal all wall cavities.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
8. PVC/CPVC terminations are designed to accommodate
any wall thickness of standard constructions per the
directions found in this manual.
4. Follow all local codes for isolation of vent pipe when
passing through floors or walls.
9. Stainless steel terminations are designed to penetrate
walls with a thickness up to 9.25 inches of standard
construction.
5. Seal exterior openings thoroughly with exterior caulk.
Figure 4-4C Alternate Sidewall Termination Assembly
w/Field Supplied Fittings
Figure 4-4A PVC/CPVC Sidewall Termination Assembly
ELBOW
AIR PIPING
VENT PIPING
VENT
AIR
BIRD SCREEN
CENTERLINE WIDTH
AIR PIPING
VENT PIPING
GALVANIZED
THIMBLE
VENT PLATE
VENT CAP
ELBOW
WALL PLATE
BIRD SCREEN
SIDEWALL
TERMINATION PLATE
GALVANIZED
THIMBLE
24
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Multiple vent/air terminations
Figure 4-5B Alternate Multiple Vent Terminations w/Field
1. When terminating multiple Knight wall mount boilers
terminate each vent/air connection as described in this
manual (FIG. 4-5A).
Supplied Fittings (must also comply with Figure 4-1B)
All vent pipes and air inlets must terminate
ƽ WARNING
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 wall mount boiler is part of a direct
vent connection. It is not classified as a forced air intake
with regard to spacing from adjacent boiler vents.
Figure 4-5A Multiple Vent Terminations (must also
comply with Figure 4-1A)
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
VENT
AIR
VENT / AIR
TERMINATION
25
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Description and usage
Lochinvar offers optional concentric combustion air and vent
pipe termination kits (Factory Kit #CVK3003 - 3" or #CVK3008
- 2"). Both combustion air and vent pipes must attach to the 1. Determine the best location for the termination kit (see
Sidewall termination installation
termination kit. The termination kit must terminate outside
the structure and must be installed as shown below in FIG. 4-6.
FIG. 4-6).
2. Reference the Determine Location Section on page 22 of this
manual for general termination considerations.
The required combustion vent pipe and fittings are listed in
Table 3D, on page 19 of this manual.
3. Cut one (1) hole (5 inch diameter for #CVK3003 installations
or 4 inch diameter for #CVK3008 installations) into the
structure to install the termination kit.
Figure 4-6 Concentric Sidewall Termination
4. Partially assemble the concentric vent termination kit.
Clean and cement using the procedures found in these
instructions.
a. Cement the Y concentric fitting to the larger kit pipe
(FIG. 4-7).
b. Cement the rain cap to the smaller diameter kit pipe
(FIG. 4-7).
Figure 4-7 Kit Contents
26
Installation & Operation Manual
4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent models
Figure 4-8 Concentric Vent Dimensional Drawing
Instead of cementing the smaller pipe to
5. Install the Y concentric fitting and pipe assembly through
the structure’s hole.
NOTICE
the rain cap, a field-supplied stainless steel
screw may be used to secure the two (2)
components together when field disassembly
is desired for cleaning (see FIG. 4-9).
Do not allow insulation or other materials
NOTICE
to accumulate inside the pipe assembly
when installing through the hole.
When using the alternate screw assembly
method, drill a clearance hole in the rain
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
ƽ WARNING
6. Install the rain cap and small diameter pipe assembly into
the Y concentric fitting and large pipe assembly. Ensure
small diameter pipe is bottomed and cemented in the Y
concentric fitting.
7. Secure the assembly to the structure as shown in FIG.
4-10 using field-supplied metal strapping or equivalent
support material.
Ensure termination location clearance
NOTICE
Do not operate the appliance with the rain
cap removed or recirculation of combustion
products may occur. Water may also collect
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to
follow this warning could result in product
damage or improper operation, personal
injury, or death.
dimensions are as shown in FIG. 4-6.
ƽ WARNING
If assembly needs to be extended to
NOTICE
allow sidewall thickness requirement, the
two (2) pipes supplied in the kit may
be replaced by using the same diameter,
field-supplied SDR-26 PVC (D2241) pipe.
Do not extend dimension D more than 60
inches (see FIG. 4-8).
Figure 4-9 Rain Cap to Vent Pipe Alternate Assembly
If assembly needs to be reduced, dimension
NOTICE
D can be as short as possible.
27
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Figure 4-10 Concentric Vent Sidewall Attachment
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.
4-11). 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. 4-11. It is important that vent terminations be made as
shown to avoid recirculation of flue gases.
8. Cement appliance combustion air and vent pipes to the
concentric vent termination assembly. See FIG. 4-10 for
proper pipe attachment.
9. Operate the appliance one (1) heat cycle to ensure
combustion air and vent pipes are properly connected to
the concentric vent termination connections.
12"
MINIMUM
VENT
COMBUSTION
AIR
Figure 4-11 Concentric Vent and Combustion Air Termination
28
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.
ƽ WARNING
Figure 5-1A PVC/CPVC/Polypropylene Vertical
Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” OF VENT
PIPE
Determine location
Locate the vent/air terminations using the following
guidelines:
BIRD SCREEN
(TYPICAL)
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page
16 of this manual.
VENT
COUPLING
(FIELD SUPPLIED)
6” MINIMUM
2. Prepare the vent termination and the air termination
elbow (FIG. 5-1A) by inserting bird screens. Bird screens
should be obtained locally.
ABOVE ROOF /
SNOW LINE
VENT OUTLET
12” MINIMUM
ABOVE AIR INLET
3. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least
2 feet above any part of a building within 10 horizontal
feet.
COMBUSTION
AIR
Figure 5-1B Stainless Steel Vertical Termination of Air
4. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet from the center of the
vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
and Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” (610 MM)
OF VENT PIPE
5. The vent piping must terminate in an up-turned coupling
as shown in FIG. 5-1A. The top of the coupling must
be at least 1 foot above the air intake. When the vent
termination uses a rain cap as illustrated in FIG. 5-1B
maintain at least 36" (914 mm) above the air inlet. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than
2 feet (.6 m) apart and with the vent termination at least
1 foot for PVC and 3 feet for stainless steel, above the air
intake.
BIRD SCREEN
VENT
(TYPICAL)
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
COM,BUSTION
AIR
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
6. Maintain the required dimensions of the finished
termination piping as shown in FIG. 5-1A.
7. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
8. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
Rooftop vent and air inlet terminations
ƽ WARNING
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.
29
Installation & Operation Manual
5 Vertical direct venting
Vent/air termination – vertical
Prepare roof penetrations
Figure 5-2 Vertical Terminations with Multiple Boilers
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the
vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole.
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 5-1A, page 29.
Figure 5-3 Alternate Vertical Terminations with Multiple
Boilers
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Multiple vent/air terminations
1. When terminating multiple Knight wall mount boilers,
terminate each vent/air connection as described in this
manual (FIG. 5-2).
Terminate all vent pipes at the same height
ƽ WARNING
and all air pipes at the same height to
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. The air inlet of a Knight wall mount boiler is part of a
direct vent connection. It is not classified as a forced air
intake with regard to spacing from adjacent boiler vents.
30
Installation & Operation Manual
5 Vertical direct venting
(continued)
Vertical termination – optional concentric vent
Description and usage
2. Cut one (1) hole (5 inch diameter for #CVK3003 installations
or 4 inch diameter for #CVK3008 installations) into the
structure to install the termination kit.
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.
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. 4-7, page 26).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG. 4-7, page 26).
The required combustion air and vent pipe fittings are
listed in Table 3D, on page 19 of this manual.
Vertical termination installation
Instead of cementing the smaller pipe to
NOTICE
the rain cap, a field supplied stainless steel
screw may be used to secure the two (2)
components together when field disassembly
is desired for cleaning (see FIG. 4-9, page
27).
1. See Section 5, Vertical Direct Venting - Determine
Location (where applicable) (FIG. 5-1A).
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
31
Installation & Operation Manual
5 Vertical direct venting
Vertical termination – optional concentric vent
DO NOT use field-supplied couplings to
extend pipes. Airflow restriction will occur.
Do not operate the appliance with
the rain cap removed or recirculation
of combustion products may occur.
CAUTION
ƽ WARNING
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.
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.
7. Cement the appliance combustion air and vent pipes to
the concentric vent termination assembly. See FIG. 5-6 for
proper pipe attachment.
4. Install the Y concentric fitting pipe assembly through the
structure’s hole and field supplied roof boot/flashing.
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.
Do not allow insulation or other materials
NOTICE
to accumulate inside the pipe assembly
when installing through the hole.
Multiventing vertical terminations
5. Secure the assembly to the roof structure as shown
below in FIG. 5-6 using field supplied metal strapping or
equivalent support material.
When two (2) or more direct vent appliances are vented near
each other, each appliance must be individually vented (see
FIG. 5-7). NEVER common vent or breach vent this appliance.
When two (2) or more direct vent appliances are vented near
each other, two (2) vent terminations may be installed as shown
in FIG. 5-7. It is important that vent terminations be made as
shown to avoid recirculation of flue gases.
Figure 5-6 Concentric Vent Roof Installation
Figure 5-7 Concentric Vent and Combustion Air Vertical
Termination
12”
MINIMUM
COMBUSTION
AIR (TYPICAL)
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 31.
12” (18” FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24” ABOVE ROOF.
If assembly is too short to meet height
NOTICE
requirement, the two (2) pipes supplied
in the kit may be replaced by using the
same diameter, field supplied SDR-26 PVC
(D2241) pipe. Do not extend dimension
D more than 60 inches (see FIG. 4-8, page
27).
32
Installation & Operation Manual
5 Vertical direct venting
(continued)
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
Concentric Venting Arrangement
SEAL
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.
The minimum size of the existing vent system required to
achieve enough annular space for combustion air can be
found in Table 5A below.
SEALED
CAP
EXISTING
SEAL
The upper and lower termination as well as any other unsealed
FLUE OUTLET
joints in the existing vent system must be sealed to ensure that
all combustion air is drawn from under the vent cap as shown
in FIG.’s 5-8 and 5-9.
Approved venting materials must be used as specified in
Table 3D on page 19.
*For concept illustration only. Individual installations
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.
may vary due to job site specific equipment.
Figure 5-9 Concentric Vent Example 2
The maximum allowable equivalent vent and air intake
lengths for this venting arrangement are to be determined
from the General Venting Section.
FLUE EXHAUST
SEAL
If an existing unused venting system is converted for use
with this method of concentric venting, the installer must
ensure that the existing venting system is clean and free from
particulate contamination that will harm this appliance and
cause increased nuisance calls or maintenance. See Table 1A
on page 10 for a list of corrosive contaminants and sources.
COMBUSTION AIR
AIR INLET
W/ SCREEN
SEAL
Two example scenarios of a concentric venting arrangement
are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
FLUE OUTLET
SEAL
EXISTING
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
SEALED
CAP
Vent / Air Minimum Existing
Model
Inlet Size
Vent / Chase Size
51 - 106
2"
4"
151 - 211
3"
5"
*For concept illustration only. Individual installations may
vary due to job site specific equipment.
33
Installation & Operation Manual
5 Vertical direct venting
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
CAP
EXISTING
SEAL
FLUE OUTLET
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
34
Installation & Operation Manual
6 Hydronic piping
System water piping methods
General piping information
The Knight wall mount is designed to function in a closed Basic steps are listed below along with illustrations on the
loop pressurized system not less than 12 psi. A temperature following pages (FIG.’s 6-3 through 6-10), which will guide
and pressure gauge is included to monitor system pressure you through the installation of the Knight wall mount boiler
and outlet temperature and should be located on the boiler (reference FIG.’s 6-1A and 6-1B).
outlet.
1. Connect the system return marked “Inlet”.
It is important to note that the boiler has a minimal
2. Connect the system supply marked “Outlet”.
amount of pressure drop and must be figured in when
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
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.
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.
Observe a minimum of a 1/4 inch clearance around all
un-insulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
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.
Low water cutoff device
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
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.
Chilled water system
8. Install an air elimination device on the system supply.
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.
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.
10. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). The safety relief valve is
installed at the factory located on the left-hand side of the
boiler. Pipe the discharge of the safety relief valve to prevent
injury in the event of pressure relief. Pipe the discharge to a
drain. Provide piping that is the same size as the safety relief
valve outlet. Never block the outlet of the safety relief valve.
Freeze protection
Freeze protection for new or existing systems must use glycol
that is specially formulated for this purpose. This includes
inhibitors, which prevent the glycol from attacking the
metallic system components. Make certain to check that
the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once
a year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
See the *piping illustrations included in this section, FIG.’s 6-3
through 6-10 for suggested guidelines in piping the Knight wall
mount boiler with either zone valves or circulator pumps.
*Please note that these illustrations are
NOTICE
Use only inhibited propylene glycol
ƽ WARNING
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
35
Installation & Operation Manual
6 Hydronic piping
11. Boiler purge valve:
Near boiler piping components
Field supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe
requirements listed in Table 6A. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on 20 feet of piping,
4 - 90° elbows, and 2 - fully ported ball valves.
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 circulating 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.
13. Indirect water heaters:
The Knight wall mount boiler may be piped to an indirect
water heater to heat domestic hot water with the space heat
transfer medium. As depicted in the piping diagrams on
page 40 thru 47, there are two options when utilizing an
indirect water heater.
Knight wall mount boilers are capable of controlling a
variable speed boiler circulator.
circulators MUST be sized to meet the specified
minimum flow requirements listed in FIG. 6-2 on page 38
at full speed.
Variable speed
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.
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG. 6-2. Consult the indirect water heater operating
guide to determine flow characteristics for the selected
product used.
B. The indirect water heater is connected to the system
supply piping. A pump controlled by the Knight
(wall mount) boiler’s control will regulate the flow of
water through the indirect water heater. The indirect
water heater’s temperature will be regulated by the
Knight (wall mount) boiler’s control.
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.
The Knight wall mount boiler is pre-configured to control
the operation of the DHW pump with Domestic Hot Water
Prioritization programming. The DHW programming is
designed to control and balance the space heating
demand by switching between DHW and space heating.
5. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 6-3 through 6-10. Failure
to install check valves could result in a reverse flow
condition during pump(s) off cycle.
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.
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.
The National Standard Plumbing Code, the
ƽ WARNING
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.
7. Anti-scald mixing valve:
Field supplied.
An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F.
8. Unions:
Field supplied. Recommended for unit serviceability.
9. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
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.
10. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
36
Installation & Operation Manual
6 Hydronic piping
(continued)
Near boiler piping connections
Figure 6-1A Near Boiler Piping w/Y-Strainer
Figure 6-1B Near Boiler Piping w/Low Loss Header
DOMESTIC HOT
WATER PUMP
CONDENSATE
DRAIN
INDIRECT
DOMESTIC
HOT WATER
TANK
INDIRECT
DOMESTIC
HOT WATER
TANK
CONDENSATE
DRAIN
DOMESTIC
BOILER
PUMP
HOT WATER
PUMP
SYSTEM
PUMP
SYSTEM PUMP
SYSTEM SENSOR
AIR SEPARATOR
BOILER
PUMP
TO FLOOR
DRAIN
SYSTEM
SENSOR
FILL VALVE
AIR
Y-STRAINER
SEPARATOR
Y-STRAINER
(RECOMMENDED)
(RECOMMENDED)
EXPANSION TANK
EXPANSION TANK
DRAIN (TYPICAL)
DRAIN VALVE
LOW LOSS HEADER
(TYPICAL)
Circulator sizing
The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer
to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.
37
Installation & Operation Manual
6 Hydronic piping
Figure 6-2 Pressure Drop vs. Flow - Models 51 - 211
6
Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°
20°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
UPS26-99F
UPS26-99F
UPS26-99F
UPS26-99F
UPS32-160
TACO
B & G
NRF-36
NRF-36
NRF-36
NRF-36
PL-55
Armstrong
51
81
5.1
7.5
11
24
27
20
29
1"
1"
1"
1"
1"
0011
0011
E7
E7
106
151
211
9.8
0013
E11
E7
14.0
19.6
0011
1400-50
E9
25°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model GPM
FT/HD
Grundfos
UPS15-58FC
UPS15-58FC
UPS26-99F
UPS26-99F
UPS26-99F
TACO
B & G
NRF-36
NRF-36
NRF-36
NRF-36
NRF-36
Armstrong
51
81
4.1
5.9
7.3
1"
1"
1"
1"
1"
0014
0014
0014
0014
0013
E7
E7
E7
E7
E7
15.0
17.5
12.8
19.0
106
151
211
7.7
11.0
15.5
35°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model GPM
FT/HD
Grundfos
UPS15-58FC
UPS15-58FC
UPS15-58FC
UPS15-58FC
UPS15-58FC
TACO
B & G
NRF-22
NRF-22
NRF-22
NRF-36
NRF-36
Armstrong
Astro-30
Astro-30
Astro-30
Astro-30
Astro-50
51
81
2.9
4.2
4.1
7.3
9.8
10
1"
1"
1"
1"
1"
007
007
106
151
211
5.5
007
7.9
008/0010
0010
11.0
10.1
Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude
models.
NOTICE
Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude
models.
NOTICE
NOTICE
38
The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.
Installation & Operation Manual
6 Hydronic piping
(continued)
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
51/81
106
20.3
22.3
21.2
26.8
20.3
21.0
19.8
25.1
21.7
21.5
19.1
23.6
151
211
*The minimum temperature rise is derived from the chart in FIG. 6-2 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 systems
NOTICE
utilize Primary/Secondary configurations as
shown in FIG.’s 6-3 through 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.
SMART SYSTEM / Multi-temperature loop
control option
The Knight wall mount boiler is capable of producing up
to three (3) set point temperatures to meet different space
heating demands. When using more than one temperature
demand it is necessary to protect the lower temperature
loop from overheating. To help aid with this protection,
Lochinvar offers the Multi- Temperature Loop Control Board
Kit (RLY30086).
39
Installation & Operation Manual
6 Hydronic piping
Figure 6-3 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)
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
BALL VALVE
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
HOT
WATER
OUT
Y-STRAINER
ANTI-SCALD
MIXING VALVE
(RECOMMENDED)
DRAIN POINT
(TYPICAL)
DOMESTIC
HOT WATER
CIRCULATOR
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF VALVE
UNION
(TYPICAL)
BOILER
TEMPERATURE /
INDIRECT
DRAIN
PRESSURE
GAUGE
DHW TANK
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
40
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-4 Multiple Boilers - Single Temperature Zoned with Circulators
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
51
1" 1-1/4" 1-1/2" 2"
2"
2"
2"
81 1-1/4" 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2" 3"
ZONE #1
151
211
2"
2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"
4"
2" 2-1/2" 3" 3-1/2" 3-1/2" 4"
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
ZONE #2 ZONE #3 ZONE #4
BACKFLOW
PREVENTER
MAKE UP
WATER
FLOW CHECK
VALVE
SYSTEM SUPPLY
(TYPICAL)
SENSOR
AIR SEPARATOR
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
TANK
BALL VALVE
(TYPICAL)
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
DRAIN POINT
(TYPICAL)
ANTI-SCALD
HOT
WATER
OUT
MIXING VALVE
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
DOMESTIC
HOT WATER
CIRCULATOR
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF VALVE
BOILER 2
BOILER 1
(LEADER)
(MEMBER 1)
INDIRECT
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
DHW TANK
UNION
(TYPICAL)
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
41
Installation & Operation Manual
6 Hydronic piping
Figure 6-5 Single Boiler - Multiple Temperatures
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
MIXING VALVES
(TYPICAL)
PRESSURE
GAUGE
MAKE
UP
WATER
SYSTEM
SUPPLY
SENSOR
AIR SEPARATOR
WIRES
EXPANSION
TANK
TO LOOP
SENSORS
MAY SUBSTITUTE
LOW LOSS HEADER
24V SIGNAL TO
MIXING VALVES
NOT TO EXCEED 4 PIPE DIA
OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
MULTI-TEMP
LOOP CONTROL
(OPTIONAL)
BOILER
DRAIN POINT
120VAC TO PUMPS
CIRCULATOR
(TYPICAL)
DOMESTIC
HOT WATER
CIRCULATOR
FLOW CHECK
VALVE
HOT WATER
Y-STRAINER
OUT
(RECOMMENDED)
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
SHIELDED CABLE TO
BOILER CONTROL
UNION
(TYPICAL)
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
IMG00187
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
42
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-6 Multiple Boilers - Multiple Temperatures
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
51
1" 1-1/4" 1-1/2" 2"
2"
2"
2"
81 1-1/4" 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2" 3"
151
211
2"
2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"
2" 2-1/2" 3" 3-1/2" 3-1/2" 4"
4"
WIRES TO
LOOP
SENSORS
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
REDUCING VALVE
LOOP #3
BACKFLOW
PREVENTER
MIXING VALVES
(TYPICAL)
PRESSURE
GAUGE
SYSTEM
MAKE
UP
SUPPLY
SENSOR
WATER
AIR SEPARATOR
EXPANSION
TANK
24V
SIGNAL
TO MIXING
VALVES
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
120VAC TO PUMPS
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
MULTI-TEMP
LOOP CONTROL
(OPTIONAL)
BOILER
CIRCULATOR
SHIELDED CABLE TO
BOILER CONTROL
DOMESTIC
HOT WATER
CIRCULATOR
FLOW CHECK
VALVE
HOT
ANTI-SCALD
WATER
OUT
MIXING
VALVE
Y-STRAINER
COLD
WATER
IN
(RECOMMENDED)
BOILER
BOILER
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
UNION
INDIRECT
DHW TANK
(TYPICAL)
IMG00188
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.
43
Installation & Operation Manual
6 Hydronic piping
Figure 6-7 Multiple Boilers - Multiple Temperatures with DHW Piped as a Zone
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
51
1" 1-1/4" 1-1/2" 2"
2"
2"
2"
81 1-1/4" 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2" 3"
151
211
2"
2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"
4"
2" 2-1/2" 3" 3-1/2" 3-1/2" 4"
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
SYSTEM
WATER
SUPPLY
SENSOR
MIXING VALVES
(TYPICAL)
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
120VAC TO PUMPS
BALL VALVE
(TYPICAL)
24V SIGNAL TO MIXING VALVES
WIRES TO LOOP SENSORS
DRAIN POINT
(TYPICAL)
MULTI-TEMP LOOP CONTROL
(OPTIONAL)
SHIELDED CABLE TO
BOILER CONTROL
Y-STRAINER
DOMESTIC HOT WATER
CIRCULATOR
(RECOMMENDED)
FLOW CHECK
VALVE
ANTI-SCALD
HOT WATER
OUT
MIXING VALVE
BOILER
CIRCULATOR
COLD
WATER
IN
PRESSURE
RELIEF
VALVE
BOILER
BOILER
INDIRECT
DHW TANK
DRAIN
TEMPERATURE /
PRESSURE GAUGE
UNION
(TYPICAL)
IMG00189
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.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
NOTICE
44
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-8 Single Boiler Zoned with Valves
ZONE #1
PRESSURE
PRESSURE
GAUGE
REDUCING VALVE
ZONE #2
ZONE #3 ZONE #4
BACKFLOW
PREVENTER
ZONE VALVES
(TYPICAL)
MAKE UP WATER
DIFFERENTIAL
SYSTEM SUPPLY
SENSOR
PRESSURE BYPASS
VALVE (IF USED)
SYSTEM
CIRCULATOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
BALL VALVE
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
DRAIN POINT
(TYPICAL)
HOT
WATER
OUT
DOMESTIC
HOT WATER
CIRCULATOR
ANTI-SCALD
FLOW CHECK
VALVE
MIXING VALVE
COLD
WATER
IN
PRESSURE
RELIEF VALVE
BOILER
CIRCULATOR
UNION
(TYPICAL)
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
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
6 Hydronic piping
Figure 6-9 Multiple Boilers Zoned with Valves
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
51
1" 1-1/4" 1-1/2" 2"
2"
2"
2"
81 1-1/4" 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2"
106 1-1/2" 2"
2" 2-1/2" 2-1/2" 2-1/2" 3"
ZONE #1
151
211
2"
2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"
2" 2-1/2" 3" 3-1/2" 3-1/2" 4"
4"
PRESSURE
REDUCING VALVE
BACKFLOW
ZONE #2
ZONE #3 ZONE #4
PREVENTER
PRESSURE
GAUGE
BALL VALVE
(TYPICAL)
ZONE VALVES
(TYPICAL)
MAKE UP WATER
DIFFERENTIAL
SYSTEM SUPPLY
PRESSURE BYPASS
SENSOR
VALVE (IF 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
MIXING VALVE
Y-STRAINER
(RECOMMENDED)
HOT
WATER
OUT
DOMESTIC
HOT WATER
CIRCULATOR
(TYPICAL)
FLOW CHECK
BOILER
CIRCULATOR
VALVE
COLD
WATER
IN
PRESSURE
RELIEF VALVE
BOILER 1
(LEADER)
BOILER 2
(MEMBER 1)
INDIRECT
DHW TANK
TEMPERATURE /
PRESSURE
GAUGE
UNION
DRAIN
(TYPICAL)
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
46
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-10 Single Boiler - Non-Zoned Primary/Secondary Piping
PRESSURE
REDUCING VALVE
PRESSURE
BACKFLOW
GAUGE
PREVENTER
MAKE UP WATER
AIR
SEPARATOR
SYSTEM SUPPLY
SENSOR
MAY SUBSTITUTE LOW LOSS HEADER
TO
FROM
SYSTEM
SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
SYSTEM
BALL VALVE
(TYPICAL)
CIRCULATOR
Y-STRAINER
FLOW CHECK VALVE
(RECOMMENDED)
EXPANSION
TANK
DOMESTIC
HOT WATER
CIRCULATOR
ANTI-SCALD
MIXING VALVE
HOT
WATER
OUT
BOILER
CIRCULATOR
DRAIN POINT
(TYPICAL)
COLD
WATER
IN
PRESSURE
RELIEF VALVE
BOILER
INDIRECT
DHW TANK
UNION
DRAIN
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
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
47
Installation & Operation Manual
7 Gas connections
Connecting gas supply piping
1. Remove the front access panel and refer to FIG. 7-1
to pipe gas to the boiler.
2. Support piping with hangers, not by the boiler or its
accessories.
a. Install a field supplied sediment trap / drip leg
upstream of the boiler gas controls.
The gas valve and blower will not support
ƽ WARNING
the weight of the piping. Do not attempt
to support the weight of the piping with the
boiler or its accessories. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
Figure 7-1 Gas Supply Piping
3. Purge all air from the gas supply piping.
4. Before placing the boiler in operation, check the boiler and
its gas connection for leaks.
a. Close manual main shutoff valve during any
pressure testing at less than 13 inches w.c.
b. Disconnect the boiler and gas valve from the gas
supply piping during any pressure testing greater
than 13 inches w.c.
Do not check for gas leaks with an open
ƽ WARNING
UNION
flame – use the bubble test. Failure to
MANUAL SHUTOFF VALVE
(FIELD SUPPLIED)
use the bubble test or check for gas leaks
can cause severe personal injury, death, or
substantial property damage.
DRIP LEG
5. Use pipe sealing compound compatible with propane gases.
Apply sparingly only to male threads of the pipe joints so
that pipe dope does not block gas flow.
GAS SUPPLY
48
Installation & Operation Manual
7 Gas connections
(continued)
Failure to apply pipe sealing compound
as detailed in this manual can result
in severe personal injury, death, or
substantial property damage.
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).
Knight wall mount boilers are typically
shipped ready to fire on natural gas.
Check boiler rating plate to determine
which fuel the boiler is set for. If set to
natural gas, it may be converted to LP
by installing an orifice (see page 13).
In order to operate on LP gas, an orifice
MUST BE installed. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
a. Table 7A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.5 inches w.c.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with
boiler on.
Use two wrenches when tightening gas
piping at boiler (FIG. 7-2), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
ƽ WARNING
• 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.
Figure 7-2 Inlet Pipe with Backup Wrench
Propane Gas:
Knight wall mount boilers are typically
ƽ WARNING
shipped ready to fire on natural gas. Check
boiler rating plate to determine which fuel the
boiler is set for. If set to natural gas, it may be
converted to LP by installing an orifice (see
page 13). In order to operate on LP gas, an
orifice MUST BE installed. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100%
lockup gas pressure regulator.
USE BACKUP WRENCH
TO PREVENT PIPE FROM
ROTATING
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. maximum pressure.
Maximum inlet gas pressure must not
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
NOTICE
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
49
Installation & Operation Manual
7 Gas connections
Table 7A Natural Gas Pipe Size Chart
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet for 1/2 PSI
Nominal
Iron Pipe
Size (Inches)
10
175
369
697
1400
20
30
97
40
82
50
60
70
80
90
100
N/A
106
200
410
636
125
N/A
95
150
N/A
86
175 200
N/A N/A
120
256
477
974
N/A
155
292
595
923
N/A
141
267
543
830
N/A
128
246
502
769
N/A
121
236
472
707
N/A
113
210
441
666
1/2
3/4
1
205
384
789
174
328
677
79
74
179
369
564
164
333
513
974
149 138
308 287
472 441
871 820
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
2-1/2
3
4
Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to
ƽ WARNING
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.
Check inlet gas supply
CSA or UL listed flexible gas connections
3. Loosen the set screw one (1) full turn from inside the
pressure tap on top of the gas valve. Place the tubing of
the manometer over the tap once the set screw is
loosened as shown in FIG. 7-3.
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 gas valve outlet
pressure. The gas valve is factory-set
for the correct outlet pressure. This
setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death, or substantial property
damage.
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.
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.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
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.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
13. Remove the manometer from the pressure tap on top of
the gas valve. Re-tighten the set screw inside the pressure
tap.
50
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 wall mount boiler. It is
very important that the gas line is properly purged by the gas
supplier or utility company. Failure to properly purge the lines
or improper line sizing, will result in ignition failure.
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.
Failure to follow all precautions could
ƽ WARNING
result in fire, explosion, or death!
Figure 7-3 Inlet Gas Supply Check
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
DETAIL
LOOSEN SET SCREW ONE (1)
FULL TURN THEN PLACE
TUBING OVER PRESSURE TAP
51
Installation & Operation Manual
8 Field wiring
ELECTRICAL SHOCK HAZARD – For 3. Wire the boiler pump as shown in FIG. 8-2.
your safety, turn off electrical power supply
ƽ WARNING
4. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 8-2.
before making any electrical connections
to avoid possible electric shock hazard.
Failure to do so can cause severe personal
injury or death.
5. To activate a system pump, wire as shown in FIG. 8-2. If
the motor is larger than 1/8 hp or 1.8 amps, you must isolate
with a relay.
Wiring must be N.E.C. Class 1.
NOTICE
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
Figure 8-2 Line Voltage Field Wiring Connections
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.
ƽ CAUTION
Figure 8-1 Remove Bezel
Low voltage connections
1. Route all low voltage wires through the knockouts in the
bottom front right side, just under the control panel, as
shown in FIG. 8-3.
2. Connect low voltage wiring to low voltage connection board
as shown in FIG. 8-4 on page 55 of this manual and the
boiler wiring diagram.
REMOVE BEZEL
Installation must comply with:
Figure 8-3 Routing Field Wiring
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,
and any local codes.
Line voltage connections
LOW VOLTAGE
CONNECTION BOARD
1. Remove bezel as shown in FIG. 8-1.
LOW VOLTAGE
WIRING KNOCKOUTS
2. Connect 120 vac power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 8-2.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 8-2).
LINE VOLTAGE
JUNCTION BOX
LINE VOLTAGE
WIRING KNOCKOUTS
52
Installation & Operation Manual
8 Field wiring
(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
on the Low Voltage Connection Board.
Thermostat
1. Connect the room thermostat or end switch (isolated
contact only) to heat/loop demand 1, 2, or 3, as shown
in FIG. 8-4.
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
Louver relay
1. If louvers need to operate when the boiler fires, they can
be controlled by this output. Connect these terminals to
a 24 vac relay coil, which is wired to operate the louvers
(FIG. 8-4).
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
1. When the operation of the louvers needs to be verified
before the boiler fires, remove the jumper wire from these
terminals and connect them to the normally open contacts
on its proving switch (FIG. 8-4).
Outdoor temperature sensor
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow of heat or cooling from other
sources.
Flow switch
1. A flow switch is used to guarantee flow through the boiler
before allowing it to fire. The flow switch must be installed
at the boiler outlet.
2. Route sensor wires through a knockout in the bottom
front right side of the boiler (see FIG. 8-3).
3. Connect outdoor temperature sensor (FIG. 8-4) to the
outdoor sensor terminals on the connection board to
enable outdoor reset operation of the Knight wall mount
boiler. If fixed temperature operation is required, do not
install outdoor sensor.
2. Connect these terminals to the normally open contacts on
the flow switch (FIG. 8-4).
Variable speed system pump
If a variable speed pump is used in the primary loop, and a
0-10V signal is available from the pump speed control, this
signal can be used by the SMART SYSTEM control to anticipate
changes in the building heat load. By connecting this 0 - 10V
signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or
cascade) can modulate up and down as the primary flow
increases and decreases.
DHW thermostat
1. Connect storage indirect water heater (DHW) thermostat
(FIG. 8-4) to the DHW thermostat terminals on the
connection board. If a tank sensor is connected (see
DHW Tank Sensor below) the tank thermostat is ignored.
DHW tank sensor
Boiler pump speed output
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.
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.
2. The tank sensor included with the Lochinvar Squire
Indirect DHW tank (TST20015) is the only sensor
Rate output
suitable for use with the SMART SYSTEM control. This output provides a 0 - 10V signal that is proportional to the
Connect the sensor leads to the Tank Sensor terminals firing rate of the boiler. This may be used by a BMS system to
on the Low Voltage Connection Board.
monitor the actual rate of the boiler.
Failure to use the correct sensor may
result in the tank temperature being either
above or below the set point.
Modbus
ƽ WARNING
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.
53
Installation & Operation Manual
8 Field wiring
System supply sensor
Wiring of the cascade
1. By installing the system supply sensor into the supply
of the primary loop, the temperature of the primary
supply can be controlled. The SMART SYSTEM control
automatically detects the presence of this sensor, and
controls the boiler firing rate to maintain the system
supply temperature to the set point (if the outlet sensor
control is currently selected). If it is desired to control
the system return temperature, then program the SMART
SYSTEM control to use the inlet sensor as the controlling
sensor. See the Knight Wall Mount Service Manual for
instructions on how to do this. When the inlet sensor
is programmed as the controlling sensor, it is strongly
recommended that the SYSTEM SUPPLY sensor be
installed. DO NOT INSTALL THE SYSTEM SUPPLY
SENSOR INTO THE SYSTEM RETURN.
When wiring the boilers for Cascade operation, select one boiler
as the Leader boiler. The remaining boilers will be designated
as Members. See page 62 “Configuration of the Cascade” for a
detailed explanation of this procedure.
Connect the system supply sensor and outdoor air sensor (if
used) to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
location of the system supply sensor should be downstream
of the boiler connections in the main system loop (FIG.’s 6-4
and 6-6). The system supply sensor should be wired to the Low
Voltage Connection Board at the terminals marked for the
system sensor (see FIG. 8-4). The Leader control will use the
water temperature at the system supply sensor to control the
operation of the Cascade.
2. The TST2032 sensor provided with the boiler must be
used for the system sensor.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 8-4). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature set
point that is programmed into the control.
3. Connect these terminals to the system supply sensor
(FIG. 8-4).
Boiler management system
1. An external control may be connected to control either
the firing rate or the set point of the boiler. If the external
control uses a set of contacts to enable the boiler, connect
the contacts to the Room Thermostat 1 terminals.
Otherwise, the SMART SYSTEM control will be enabled
by the 0-10V signal.
If a Thermostat, Zone Control enable output, or Building
Management System enable output is available, it should be
wired to the Low Voltage Connection Board on the Leader
boiler at the terminals marked for one of the Heat/Loop
Demands 1-3 (FIG. 8-4). If the boilers are to run continuously,
connect a jumper wire between the R and W terminals for the
Heat/Loop Demand input. This will initiate a call for heat on
the Cascade.
2. Make sure the (-) terminal is connected to the (-) output
terminal of the external control, and the (+) or common
terminal is connected to the 0 - 10 vdc or (+) terminal of
the external control. Make sure that the (-) voltage is not
below ground.
Communication between the Leader boiler and the Member
boilers is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to Cascade terminal A on each of the Low Voltage Connection
boards, and the other wire of the twisted pair to Cascade
terminal B on each of the Low Voltage Connection Boards.
Connect the shield wires to one of the shield terminals on the
Low Voltage Connection Boards (FIG. 8-4). If more than two
boilers are on the Cascade, daisy chain the wiring from the
Cascade terminals on the second boiler to the Cascade terminals
on the third boiler, then from the third to the forth, and so on.
The connections between boilers can be made in any order,
regardless of the addresses of the boilers. Try to keep each cable
as short as possible.
Runtime contacts
The SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
The SMART SYSTEM control closes another set of contacts
whenever the boiler is locked out or the power is turned off.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down.
54
Installation & Operation Manual
8 Field wiring
(continued)
Figure 8-4 Low Voltage Field Wiring Connections
55
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
NOTICE
1. This boiler is a high efficiency appliance that produces
condensate.
2. The bottom of the boiler has a 1/2 inch pipe 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 wall mount 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.
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 is available from the factory (Kit 3087).
4. Do not expose condensate line to freezing temperatures.
5. Use only plastic tubing or piping as a condensate drain
line (FIG. 9-1).
7. A condensate removal pump is required if the boiler is
below the drain. When installing a condensate pump, select
one approved for use with condensing boilers and furnaces.
The pump should have an overflow switch to prevent
property damage from condensate spillage. The switch
should be wired in series with the blocked drain switch
inside the boiler (see FIG. 10-1 on page 58).
6. Leave the top of the tee assembly installed in the unit
open, this is needed as a vacuum break. The blocked drain
switch will shut the boiler down before any condensate
can flow out of the tee.
Figure 9-1 Condensate Disposal
CONDENSATE DRAIN CONNECTION -
ROUTE TO FLOOR DRAIN OR
NEUTRALIZING FILTER USING:
1/2" PVC PIPE & FITTINGS or
1/2" CPVC PIPE & FITTINGS or
5/8" I.D. PLASTIC TUBING
CONDENSATE TRAP
REMOVABLE CAP
FOR CLEANING TRAP
(FIELD SUPPLIED)
56
Installation & Operation Manual
10 Start-up
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Check/control water chemistry
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets
in the system could occur, resulting in
substantial property damage.
Eliminate all system leaks. Continual fresh
ƽ WARNING
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.
Hardness less than 7 grains
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Purge air from water system
Chlorine concentration less than 200 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valves, in piping diagrams on pages 40 through 47).
Route the hose to an area where water can drain and
be seen.
b. Close the boiler or system isolation valve between
the purge valve and fill connection to the system.
c. Close zone isolation valves.
2. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are much lower.
3. Do not use the boiler to directly heat swimming pool or
spa water.
Test/replace freeze protection fluid
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
1. For systems using freeze protection fluids, follow fluid
manufacturer’s instructions.
f. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close the
zone isolation valves and proceed with the next zone.
Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch
that system pressure rises to correct cold-fill
pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open
the manual air vents in the system one at a time,
beginning with the lowest floor. Close the vent when
water squirts out. Repeat with remaining vents.
2. Freeze protection fluid must be replaced periodically due
to degradation of inhibitors over time. Follow all fluid
manufacturer’s instructions.
Freeze protection (when used)
1. Determine freeze protection fluid quantity using
system water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
3. When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid may leak before the water begins to
leak, causing concentration to drop, reducing the freeze
protection level.
2. Open automatic air vent (diaphragm-type or bladder-type
expansion tank systems only) one turn.
4. The freeze protection set points may be lowered when
freeze protection fluid is used (see the Knight Wall
Mount Service Manual).
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
4. Refill to correct pressure.
2. Close manual and automatic air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a
residential system is 12 psi.
b. Pressure will rise when boiler is turned on and
system water temperature increases.
57
Installation & Operation Manual
10 Start-up
Check for gas leaks
Check thermostat circuit(s)
Before starting the boiler, and during
1. Disconnect the two external wires connected to each of the
heat/loop demand terminals on the connection board.
ƽ WARNING
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the front access
panel and smell the interior of the boiler
enclosure. Do not proceed with startup
if there is any indication of a gas leak.
Use an approved leak detection solution.
Repair any leaks at once.
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.)
DO NOT adjust gas valve outlet pressure.
The gas valve is factory set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
ƽ WARNING
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings
and condensate trap.
Figure 10-1 Condensate Trap
Fill condensate trap with water
1. Remove the bezel as depicted in FIG. 8-1 on page 52 of this
manual.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 10-1).
3. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 10-1).
4. Fill with fresh water until the water begins to pour out of the
drain.
5. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
6. Replace the retaining screw.
7. Reinstall bezel.
Propane boilers only – Your propane
ƽ WARNING
The condensate trap (FIG. 10-1) 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.
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.
ƽ WARNING
Clean/Inspect Trap Assembly
1. Remove the clean out cap on the bottom of the trap. Let the
condensate and any debris drain out.
2. Refill the trap according to the instructions above.
58
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 Wall Mount Service Manual to
familiarize yourself with SMART SYSTEM control
module operation. Read this manual, page 60 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 57
and 58 have been completed.
1. Check around the boiler for gas odor following the
procedure on page 48 of this manual (connecting gas supply
piping).
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.
Inspectventpipingandairpipingforsignsofdeterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
Propane boilers – verify conversion
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
Start the boiler
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
The gas valve is factory-set for the correct
1. Read and follow the Operating instructions in FIG. 10-2,
page 60.
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to alter
the gas valve outlet pressure could result
in damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is boiler water temperature above 200°F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
Knight wall mount boilers are typically
ƽ WARNING
shipped ready to fire on natural gas. Check
boiler rating plate to determine which fuel
the boiler is set for. If set to natural gas,
it may be converted to LP by installing
an orifice (see page 13). In order to
operate on LP gas, an orifice MUST BE
installed. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
5. Is incoming gas pressure less than 4 inches w.c.?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Knight Wall Mount Service
Manual.
Check system and boiler
Check flame and combustion
Check water piping
1. Turn the main power off to the boiler.
1. Check system piping for leaks. If found, shut down
the boiler and repair immediately. (See WARNINGS
on pages 57 and 58 (startup) regarding failure to repair
leaks.)
2. Remove the flue temperature sensor from the flue pipe
connection. Note: Combustion measurements will be
made at this point.
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.
3. Turn the main power on to the boiler.
59
Installation & Operation Manual
10 Start-up
Figure 10-2 Operating Instructions
60
Installation & Operation Manual
10 Start-up
(continued)
Check flame and combustion (continued)
Set space heating operation
Please note that the brackets ([]) denote
screen status.
NOTICE
Determine controlling sensor
For space heating systems, the temperature control can be based
on one of three sensors; the inlet, outlet, or system supply
sensor. The SMART SYSTEM control is programmed at the
factory to control the temperature of the outlet sensor. The
control will automatically switch to the system supply sensor
once it is connected. If it is desired to base the temperature
control on the inlet sensor, the appropriate parameter must
be changed in the control. See the Knight Wall Mount Service
Manual for a detailed explanation of this procedure.
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 11-1, page 69).
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.
Verify space heat circulator mode
6. Insert the probe from a combustion analyzer into the hole
left by the removal of the flue temperature sensor.
The Space Heating Mode controls both the system pump (if
connected), and the boiler pump. When the SMART SYSTEM
control receives a space heating call for heat, it turns on the
system pump. If the boiler is not heating an indirect DHW
(Domestic Hot Water) tank, and the set point is not met, it
also turns on the boiler pump. After the space heating call
for heat ends, the system pump continues to run for a short
period of time. The system pump can be programmed to run
continuously, except during outdoor shutdown. If the boiler
pump was running, it continues to run for a short period of
time as well. These pump delays are factory set to 30 seconds.
If different delays are desired, the appropriate parameters in the
control must be changed. See the Knight Wall Mount Service
Manual for a detailed explanation of this procedure.
7. Once the boiler has modulated up to full fire, measure
the combustion. The values should be in the range listed
in Table 10A below. The CO levels should be less than
150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference the Troubleshooting Section of the Knight Wall
Mount Service Manual for possible causes and corrective
actions.
Table 10A Flue Products Chart
Natural Gas
Propane
Adjust set point temperature(s)
CO2 O2
CO2
O2
Please note that the brackets ([]) denote
screen status.
NOTICE
8.0% - 10% 3.0% - 6.5% 10.0% - 11% 4.1% - 5.4%
The NAVIGATION dial may be used during normal operation
to adjust the space heating and tank set point temperatures.
8. Once the combustion analysis is complete, test the
safety shutoff device by turning the manual shutoff
switch to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Turn the manual
shutoff switch to the ON position and reset the control.
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.
5. If necessary repeat Steps 3 and 4 to make adjustments to
additional set points.
10. Place the boiler back into normal operation.
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.
You must replace the flue gas temperature
ƽ WARNING
sensor to prevent flue gas spillage into
the room. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
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Installation & Operation Manual
10 Start-up
Set domestic hot water (DHW) operation
Verify DHW mode
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.
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
8. Turn the NAVIGATION dial to adjust the month. Press the
NAVIGATION dial.
9. Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
In Zone Mode it is assumed that the indirect DHW tank is
piped as a zone on the primary loop. When a DHW demand
begins, the control will turn on the DHW pump output, and
raise the system temperature set point to the DHW boiler set
point (if higher). The boiler pump will be turned on. The
system pump may be forced on, forced off, or not changed,
depending on the System Pump Mode selected (reference
the Knight Wall Mount Service Manual for details). In this
mode, any low temperature zones (such as radiant heating)
may need additional controls to limit the water temperature
sent to those zones.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
11. Press the RIGHT SELECT [HOME] key.
The internal clock does not adjust for
NOTICE
Daylight Savings Time and therefore, will
require a manual adjustment.
The clock is automatically updated whenever a PC is connected
and the Win_Pro-Installer program is started.
Set DHW boiler target temperature
Configuration of the cascade
When in the DHW Mode, the control will modulate to
maintain the boiler outlet temperature or system supply
temperature to a set point. This set point is set at the factory
to 180°F. If a different set point is desired, the appropriate
parameter in the control must be changed. See the Knight
Wall Mount Service Manual for a detailed explanation of this
procedure.
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.
Press the [MENU] key for at least five (5) seconds. Input the
Installer code as described in the Knight Wall Mount Service
Manual. Once the control parameters have been accessed, use
the NAVIGATION dial to select the Control Mode parameters.
Press the NAVIGATION dial to access these parameters.
Set maximum DHW fan speed
If the rated input of the indirect tank is less than the maximum
output of the boiler, change the maximum DHW fan speed
setting to limit the boiler output accordingly, see the Knight
Wall Mount Service Manual for a detailed explanation of this
procedure.
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
Set clock
Please note that the brackets ([]) denote with its own address. The boiler designated as the Leader will
NOTICE
screen status.
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.
The SMART SYSTEM control has a built-in clock that it
uses for its night setback feature and for logging events. This
clock must be set when the boiler is installed, and anytime the
boiler has been powered off for more than 4 hours. Use the
following procedure to set the clock:
1. Press and hold the LEFT SELECT [MENU] key for at
least 5 seconds.
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.
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.
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Installation & Operation Manual
11 Operating information
The Knight wall mount boiler can also be programmed to
accept a call for heat from a 0 - 10V signal, reference the Knight
Wall Mount Service Manual for a detailed explanation of this
procedure.
General
How the boiler operates
The Knight wall mount boiler uses an advanced stainless
steel heat exchanger and electronic control module that
allows fully condensing operation. The blower pulls in air
and pushes flue products out of the boiler through the heat
exchanger and flue piping. The control module regulates
blower speed to control the boiler firing rate. The gas valve
senses the amount of air flowing into the boiler and allows
only the right amount of gas to flow.
DHW priority
The SMART SYSTEM control allows the connection of a DHW
thermostat or tank sensor to the low voltage connection board.
When a tank sensor is connected, the DHW thermostat input
is ignored. When a boiler is programmed for DHW Normal
Mode, the maximum firing rate can be limited to match the
input rating of the indirect tank coil.
How the control module operates
DHW / space heating (SH) cycling
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.
If a DHW call for heat is received while a space heating call is
in progress and the DHW is in Normal Mode, the control will
start the DHW pump and shut the boiler pump off. The system
pump will remain on. For stand-alone boilers, if the space
heating call is still active while the DHW call is in operation, the
control will wait for 30 minutes (time adjustable by installer)
then it will switch back to the space heating demand. There is
a timer to switch from space heating to DHW and a timer to
switch from DHW to space heating. The control will switch
back and forth until one of the heat demands end.
Control inputs and outputs
Programmable controlling sensor
Room thermostat
The control module is programmed to use the outlet sensor
as the control sensor by default. If a system supply sensor
is connected, the control automatically uses it as the control
sensor. The control sensor can be changed by the installer to
the inlet sensor. If the inlet sensor is chosen as the controlling
sensor, it is recommended that the system supply sensor
be installed in order to provide the best control of the inlet
temperature.
There are three (3) heat/loop demand 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.
Example:
Assume that both heat/loop demand
have call for heat.
Anti-cycling
1
and heat/loop demand
2
a
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.
Demand 1 has a set point of 110°F. Demand 2 has a set point
of 140°F. The boiler will regulate the system temperature to
140°F until Demand 2 has been satisfied. Once Demand 2
has been satisified the boiler will provide 110°F water to the
system.
Boiler and system pump control
When multiple temperature loops are
ƽ CAUTION
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.
used, mixing valves are required for the
protection of any low temperature loops.
SMART SYSTEM Multi-temp loop control
The Knight wall mount boiler is capable of producing up
to three (3) set point temperatures to meet different space
heating demands. This device controls the temperatures
of up to three (3) separate loops, based on the settings for
the three (3) heat/loop demands (reference Lochinvar kit
RLY30086).
The system pump will run whenever there is a space heating call
for heat, or the boiler goes into Freeze Protection Mode. It may
be programmed to run during a DHW call for heat when the
DHW is programmed for Zone Mode. It will continue to run
for a short time after the end of the heat demand or the Freeze
Protection Mode. The system pump can be programmed to run
continuously if desired, except during outdoor shutdown and/
or a DHW call for heat.
0 - 10V input (set point or power)
The Knight wall mount boiler can be controlled by a Building
Management System (BMS) using a 0 - 10 vdc signal. The
control can be configured by the installer to use this signal to
either control set point or firing rate.
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Installation & Operation Manual
11 Operating information
Temperature control
Protection features
Modulation
Outlet temperature, flue temperature, and temperature
rise limiting
The Knight wall mount boiler is capable of modulating its
firing rate from a minimum of 20% to a maximum of 100%.
The firing rate is dictated by the call for heat (i.e., space
heating or domestic hot water), the heating load, ramp delay
(if enabled), and various other temperature limitations.
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.
Ramp delay
For systems with lower flow, the SMART SYSTEM can limit
the firing rate (when enabled) when a space heating call for
heat starts, or when switching from a DHW call for heat to a
space heating call for heat. There are six (6) limits that can be
programmed, as well as six (6) time intervals corresponding
to each limit. The sixth limit will also limit the firing rate for
the rest of the call for heat.
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F the control will reduce the maximum fan speed. If
the flue temperature exceeds 240°F the control will shut the
unit down. The unit will restart automatically once the flue
temperature drops 25°F and the minimum off time has expired.
The control monitors the temperature difference between the
inlet and the outlet sensor. If this difference exceeds 55°F the
control will reduce the maximum fan speed. If the temperature
difference exceeds 60°F the control will shut the unit down. The
unit will restart automatically once the temperature difference
has dropped below 55°F and the minimum off time has expired.
Gradient limiting
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate to
its lowest setting.
Outdoor air reset
Freeze protection
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.
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.
Boost function
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F:
Below 45°F, the boiler and system pumps operate
constantly.
Below 37°F, the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F.
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.
•
•
•
•
Lower temperatures may be programmed for
systems with anti-freeze solutions.
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.
Night setback
The controller may be programmed to reduce the space
heating and DHW set points during certain times each week.
Seven different start and stop times may be programmed for
the space heating setback and seven start and stop times for
the DHW setback.
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
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.
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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 wall mount is equipped with adjustable automatic
reset and manual reset high limits. The automatic reset high
limit has a maximum set point of 200°F and the manual reset
high limit has a maximum set point of 210°F.
When the outlet temperature exceeds 200°F, the automatic
high limit action occurs. The boiler shuts down until the outlet
water temperature cools below 190°F, and a 60 second timer
has expired. If the outlet temperature continues to increase, the
manual reset high limit action will occur at 210°F.
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.
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler is
firing in the Space Heating Mode. The other timer monitors
the time the boiler is in the DHW Mode.
NOTICE
1. Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
2. From the Status Screen, press the NAVIGATION dial to
access the Set Points Screen.
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. Press the LEFT SELECT (LIMITS) key.
4. Select the manual reset high limit (MRHL) by rotating
the NAVIGATION dial counterclockwise, then press
the NAVIGATION dial.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when either
a set time frame has expired, or a set amount of running
hours or cycles has expired (all adjustable by the installer).
The display will show a Maintenance Required screen. The
installer’s name and phone number can be programmed into
the control. This information will appear on the Maintenance
Required screen. The service reminder notification can be
reset or disabled by the installer.
5. Decrease the set point of the MRHL to below the current
outlet temperature (or to its minimum setting, whichever
is higher) by turning the NAVIGATION dial
counterclockwise.
6. Press the RIGHT SELECT [SAVE] key.
7. Press the RIGHT SELECT [HOME] key. The new
parameter will upload to the control.
8. If the current outlet temperature is above the new MRHL
set point, the MRHL will function causing boiler lockout.
If this occurs, skip to Step 11.
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 Wall Mount
Service Manual for details regarding parameters.
9. If the current outlet temperature is below the new MRHL
set point, locate the pinhole (SERVICE button) below the
RESET button on the display board. Insert a thin probe
(such as a paper clip) into the hole and press the button
continuously for five (5) seconds to place the boiler into
Service Mode. In Service Mode, the boiler will fire at
ignition speed and will then modulate up to full fire.
Error logging
The control will hold in memory the last 10 lockouts as
well as the last 10 blockings. The date and time of the
occurrence will be recorded as well. Only the 10 most current
occurrences of each will be held in memory.
10. Once the outlet temperature rises up to the MRHL set
point, the MRHL will function, causing the boiler to shut
down and lock out.
Boiler temperature regulation
11. Repeat Steps 2, 3 and 4.
Operating temperature (target)
12. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
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.
13. Repeat Steps 6 and 7.
14. Press the RESET button to clear the lockout.
15. If needed, press the RIGHT SELECT [STOP] key to exit
Service Mode.
•
Target temperature is fixed when the outdoor
sensor is not installed.
•
Target temperature is calculated as described in
this section under “Outdoor Reset Operation” and
“Target Temperature Boost” when the outdoor
sensor is connected.
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Installation & Operation Manual
11 Operating information
Low water cutoff protection
Sequence of the cascade
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the flow rate is too low or the outlet
temperature too high, the control module modulates and
shuts the boiler down. This ensures boiler shutdown in
the event of low water or low flow conditions.
2. Some codes and jurisdiction may accept these integral
features of the control in lieu of requiring an additional
limit control or low water cutoff. Consult local
jurisdiction to determine. A low water cutoff is available
from the factory (WTR20009).
To equalize the run time of all boilers on the Cascade, the firing
sequence will automatically be changed at set intervals.
For the first 24 hours after initializing the Cascade, the sequence
will be changed every hour. After that the sequence will be
changed once every 24 hours. The switching on/off sequence
will be as follows:
TIME
Start
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
1 hour
Outdoor reset operation, if used
2 hours
M2-M3-M4-M5-M6-M7-L-M1
Target temperature with outdoor reset
If a boiler locks out or is used to heat an indirect DHW tank,
it will automatically be given the lowest priority for the rest of
that 24 hour period..
This feature improves the system’s efficiency as the outdoor
temperature warms up.
See the Knight Wall Mount Service Manual to change the
settings.
DHW, Night Setback, and Ramp Delay operation with
cascade
Reset curve
For normal mode DHW operation any boiler(s) in the Cascade
can be selected to provide heat for a DHW call. Select a boiler
to be designated as the DHW boiler. Connect the DHW
thermostat or sensor to the terminals on the Low Voltage
Connection Board marked for the corresponding device. When
the boiler receives a DHW call, the Leader control will take that
boiler out of the Cascade sequence. If another boiler is available,
the Leader will start it up to take its place.
The reset curve looks at outdoor air temperature and adjusts
the set point.
Cascade
When multiple boilers are installed, they can be wired
together in a cascade sequence. A maximum of eight boilers
can be controlled from a single control. In this application
one boiler would be designated as the Leader control and all
others would be designated as Member controls. The Leader
control can be programmed to use Lead/Lag or Efficiency
Optimization control methods.
The DHW boiler will adjust its set point to the programmed
DHW boiler set point and will adjust its firing rate to maintain
this. Once the DHW call has been satisfied, the Leader control
will place that boiler back into the Cascade sequence.
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
Switching of the boiler between DHW operation and SH
operation when there is a call for both does not occur in
Cascade Mode.
calculated based on the programmed reset curve parameters. When DHW is programmed for Zone Mode, connect the DHW
See the Knight Wall Mount Service Manual to program the thermostat or tank sensor to the Leader boiler. When a DHW
reset curve. If outdoor air reset is not desired, do not connect call is received, the Leader will modulate the entire Cascade to
the outdoor air sensor. A fixed temperature set point can be bring the system supply temperature up to the DHW boiler set
programmed into the control. See page 61 of this manual to point (if higher).
program the set point.
Night Setback operation of the boilers within the Cascade is
If the water temperature at the system supply sensor is available. Programming of the Night Setback will be done
less than the set point + the turn-off offset - the off-on through the Leader boiler. Refer to the Knight Wall Mount
differential, then the control will initiate a call for heat on Service manual for information regarding Night Setback.
the Cascade (see the Knight Wall Mount Service Manual for
Ramp Delay operation of the boilers as described in the Knight
Wall Mount Service Manual is not active when the boilers are
part of a Cascade system.
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.
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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 the prepurge cycle by initiating the blower.
5. The control starts the trial for ignition by firing the spark
electrode and opening the gas valve.
6. If flame is not detected after the sparking ends, the control will
perform a postpurge, then start another prepurge cycle and try to
light the burner again. The control will perform a total of 4
attempts before locking out.
7. If flame is detected, it holds the firing rate steady for a few
seconds to let the flame stabilize, then it begins to modulate the
firing rate based on a set point or some other command (such
as a 0-10V BMS signal).
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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 (boiler and DHW pump operation briefly overlap to ensure
flow is maintained through the unit). This will divert the boiler’s
outlet water from the heating system and send it to the tank coil
instead. The control will then modulate to maintain the outlet
temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one of
them is satisfied.
10. Once both calls for heat are satisfied, the control will turn off the
burner. The blower will continue to run during the postpurge
period.
11. Any pumps that are running will continue to run for their respective
pump delay times before turning off, unless programmed to
remain on continuously. A 60 second anti-cycle period will start,
which will delay any new call for heat until it times out.
12. In Standby, ready to start a new cycle.
Access modes
Saving parameters (reference the Parameter Table in
the Knight Wall Mount Service Manual)
User
Please note that the brackets ([]) denote
screen status.
NOTICE
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 62).
To save parameters and exit programming:
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
Installer
Most parameters are available only to the installer, accessible
by entering the installer password, see the Knight Wall Mount
Service Manual.
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 Wall Mount Service Manual for a detailed
description of parameters and access modes.
68
Installation & Operation Manual
11 Operating information
(continued)
Knight wall mount boiler control module
Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Figure 11-1 Control Panel
NAVIGATION DIAL
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
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Installation & Operation Manual
11 Operating information
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 prepurge period on a call for heat.
PREPURGE
IGNITION
The unit has begun a 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 postpurge period 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
Heat/Loop Demand 1 has a call for heat.
Heat/Loop Demand 2 has a call for heat.
Heat/Loop Demand 3 has a call for heat.
B
The tank thermostat or sensor has a call for heat.
Indicates which heat/loop demand shows priority.
The unit is being controlled by a 0 - 10V BMS signal.
The member unit is supplying heat while in Cascade Mode.
(Call for Heat
Indicators)
70
Installation & Operation Manual
11 Operating information
(continued)
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.
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.
C
(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:
NIGHT SETBACK
Shows the next Night Setback trigger (if active).
71
Installation & Operation Manual
11 Operating information
Status Display Screens (cont’d)
Section
Display
Description
Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
MENU
EXIT
Press the LEFT SELECT key to exit the current screen or setting.
Press the LEFT SELECT key to confirm that the boiler needs to
shutdown.
YES
D
(LEFT SELECT
key function)
Press the LEFT SELECT key to enter the screen that allows you to
adjust the limit settings.
LIMITS
HOME
SKIP
Press the LEFT SELECT key to return to the Status Screen and upload
parameter changes.
Press the LEFT SELECT key when in the Night Setback Screen to
access the Night Setback Skip Screen.
Turning the NAVIGATION dial will select the next or previous Status
Screen.
Pressing the NAVIGATION dial will show the next fault, NSB (Night
Setback) trigger, or ramp delay setting.
Pressing the NAVIGATION dial will select the setting indicated by
the cursor.
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.
72
Installation & Operation Manual
12 Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Owner maintenance
(see the Knight Wall Mount User’s Information
Manual for instructions)
Service technician
(see the following pages for instructions)
General:
• Address reported problems
• Check boiler area
• Inspect interior; clean and vacuum if
necessary;
• Check pressure/temperature
gauge
Daily
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Check vent piping
• Check air piping
• Verify flue and air lines in good condition
and sealed tight
• 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.
•Test low water cutoff (if used)
Periodically
• Reset button (low water cutoff)
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Check boiler piping (gas and
water) for leaks
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
Every
6 months
• Operate relief valve
If combustion or performance
indicate need:
• Clean heat exchanger
End
of season
months
•Shut boiler down (unless boiler
used for domestic hot water)
• Remove and clean burner using
compressed air only
• Clean the blower wheel
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
ƽ WARNING
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.
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.
The condensate trap must be filled with
Address reported problems
ƽ WARNING
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.
1. Inspect any problems reported by the owner and correct
before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
Check all piping for leaks
gasoline and other flammable vapors and liquids.
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. Verify that air intake area is free of any of the contaminants
listed in Section 1 of this manual. If any of these are
present in the boiler intake air vicinity, they must be
removed. If they cannot be removed, reinstall the air and
vent lines per this manual and the Knight Wall Mount
Service Manual.
1. Inspect all water and gas piping and verify to be leak free.
Inspect boiler interior
2. Look for signs of leaking lines and correct any problems
found.
1. Remove the front access cover and inspect the interior of
the boiler.
3. Check gas line using the procedure found in Section 7 -
Gas Connections.
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Flue vent system and air piping
Clean condensate trap
1. Remove the clean out cap on the bottom of the trap. Let
the condensate and any debris drain out.
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. Fill with fresh water until the water begins to pour out of
the drain.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
3. Replace the clean out cap and resume operation.
Failure to inspect for the above conditions
and have them repaired can result in severe
personal injury or death.
ƽ WARNING
Figure 12-1 Condensate Trap
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
4. Inspect 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.
74
Installation & Operation Manual
12 Maintenance
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.
(continued)
2. After following the warning directions in this manual, if
the relief valve weeps or will not seat properly, replace the
relief valve. Ensure that the reason for relief valve weeping
is the valve and not over-pressurization of the system due to
expansion tank waterlogging or undersizing.
Check expansion tank
Inspect ignition and flame sense
electrodes
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
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.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot be
cleaned satisfactorily, replace with new ones.
3. Replace ignition/flame sense electrode, making sure gasket
is in good condition and correctly positioned.
Following installation, the valve lever
must be operated AT LEAST ONCE
ƽ WARNING
A YEAR to ensure that waterways are Check ignition ground wiring
clear.
Certain naturally occurring
1. Inspect boiler ground wire from the heat exchanger access
cover to ground terminal strip.
mineral deposits may adhere to the valve,
rendering it inoperative. When manually
operating the lever, water will discharge
2. Verify all wiring is in good condition and securely attached.
and precautions must be taken to avoid 3. Check ground continuity of wiring using continuity meter.
contact with hot water and to avoid water
damage. Before operating lever, check
4. Replace ground wires if ground continuity is not satisfactory.
Check all boiler wiring
to see that a discharge line is connected
to this valve directing the flow of hot
1. Inspect all boiler wiring, making sure wires are in good
water from the valve to a proper place of
condition and securely attached.
disposal. Otherwise severe personal injury
Check control settings
may result. If no water flows, valve is
inoperative. Shut down the boiler until a
new relief valve has been installed.
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the Knight Wall Mount Service Manual. Adjust settings if
Safety relief valves should be re-inspected
ƽ WARNING
necessary. See Section 1 of the Knight Wall Mount Service
AT LEAST ONCE EVERY THREE
Manual for adjustment procedures.
YEARS, by a licensed plumbing contractor
2. Check settings of external limit controls (if any) and adjust
if necessary.
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
Perform start-up and checks
have not been altered or tampered with 1. Start boiler and perform checks and tests specified in
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.
Section 10 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
Check burner flame
1. Inspect flame through observation window.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove the
burner and clean it thoroughly using a vacuum cleaner or
compressed air. Do not use compressed air to clean burner
if performed inside a building.
3. Remove the burner, reference FIG. 12-2 (page 76).
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 12-2).
75
Installation & Operation Manual
12 Maintenance
Cleaning boiler heat exchanger
Figure 12-2 Burner Assembly
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 12B - Heat Exchanger Cleaning Kits.
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in Section 10 - Startup.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fluid
in system, do not drain.
2. Allow time for the boiler to cool to room temperature if
it has been firing.
3. Remove the nuts securing the heat exchanger access cover
to the heat exchanger and set aside.
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
Check flame signal
The boiler contains ceramic fiber materials.
ƽ WARNING
Use care when handling these materials per
instructions in the Service Manual. Failure
to comply could result in severe personal
injury.
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the flame
sense electrode.
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.
3. See Section 3 - Troubleshooting of the Knight Wall
Mount Service Manual for other procedures to deal with
low flame signal.
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.
Review with owner
1. Review the Knight Wall Mount User’s Information
Manual with the owner.
8. Finish cleaning using a clean cloth dampened with warm
water. Rinse out debris with a low pressure water supply.
2. Emphasize the need to perform the maintenance schedule
specified in the Knight Wall Mount User’s Information
Manual (and in this manual as well).
9. Allow the heat exchanger to thoroughly dry.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
reassemble.
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual start-up at the
beginning of the next heating season.
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.
12. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 10 - Startup on pages 59
and 61 of this manual.
13. Replace the access cover and restore boiler to operation.
76
Installation & Operation Manual
12 Maintenance
(continued)
Oiled bearing circulators
Table 12B Heat Exchanger Cleaning Kits
1. The circulator shipped with the Knight wall mount
Kit
Part
Component
Description
Model
boiler is water-lubricated. No oiling is required.
Number Number
CTN20005
Rear Refractory Cover
Nylon 4" Wheel Brush*
1/4" x 12" Drill Extension
Rear Refractory Cover
Nylon 4" Wheel Brush*
3mm Allen Wrench
2. Checkothercirculatorsinthesystem. Oilanycirculators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
51 - 106
KIT30062
KIT30063
MSC20083*
MSC20085
CTN20005
MSC20083*
MSC20084
MSC20086
3. Replace the boiler front access cover.
151 - 211
1/4" x 24" Drill Extension
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
replacement nylon brush.
ƽ CAUTION
Figure 12-3 Rope Gasket - Heat Exchanger Door
ROPE GASKET
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
NOTICE
NOT reuse, the heat exchanger door must
be replaced. Consult factory for replacement
heat exchanger door (kit WTR30002).
77
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
INTEGRATED
CONTROL
LWCO
CN5-5
FLOW
CN5-14 X4-8
CN7-3
CN7-4
CN7-2
SWITCH
11
12
CN5-10
X4-12
24 VAC
CN7-1
HEAT/LOOP
DEMAND
1
CN5-7
X4-1
20
18
16
14
19
HEAT/LOOP
DEMAND 2
CN5-13 X4-9
17
HEAT/LOOP
DEMAND 3
CN5-6
X4-2
15
13
TANK
THERMOSTAT
CN5-12
X4-10
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
X4-11
X4-5
CN5-11
CN5-3
9
10
INTEGRATED
CONTROL
LOUVER
RELAY COIL
5
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
S1b
S3a
OPERATING
SENSOR
1
X5-12
X5-5
HIGH LIMIT
SENSOR
GAS VALVE
2
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
42
43
44
OUTDOOR
SENSOR
SPARK
ROD
CN6
CN6
X6
X6
S4
TANK
SENSOR
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
2. See wiring diagram for additional notes.
0-10V
CN6
CN6
X6
X6
IN
+
-
BLR PUMP
0-10V
CN6
CN6
X6
X6
OUT
BOX DEPICTS
OPTIONAL ITEMS
+
RATE
0-10V
OUT
-
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
M
O
D
B
U
S
SHIELD
CN8-1
CN8-2
CN8-3
X6-1
X6-2
X4-1
X9-2
X9-1
X9-3
A
MODBUS
B
X4-2
X4-3
X6-3
LADDER DIAGRAM
LBL20148 REV D
SHIELD
78
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
PR
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
GAS PRESSURE
SWITCH
7
BK
BK
BK
BK
X4-7
X4-14
X4-6
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
SYSTEM
PUMP
8
9
N
10
X4-13
X4-5
BK
KB ONLY
ON/OFF
SWITCH
BK
BK
BK
BK
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
BK
X4-8
BK
BK
BK
BK
X4-10
X4-2
TANK
THERMOSTAT
HEAT/LOOP
X4-9
X1-8
X1-1
G
R
3
2
1
DEMAND
X4-1
HEAT/LOOP
DEMAND
HEAT/LOOP
TRANSFORMER
DEMAND
RW G
2 3
SYSTEM
SENSOR
OUTDOOR
SENSOR
21
22
23
24
25
26
27
28
29
30
31
32
1
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
OUT
-
X5-10
X5-11
X5-4
P
SHIELD
AIR PRESSURE SWITCH
A
O/BK
R/BK
GY
MODBUS
-T
OPTION
B
OPERATING SENSOR S1a
SHIELD
-T
X5-12
X5-6
HIGH LIMIT SENSOR S1b
INLET SENSOR S2
-T
-T
-T
24 VAC
LOW
WATER
CUT-OFF
CN7-1
COM
P/BK
W/BK
PR
CN7-2
CN7-3
CN7-4
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
X9-1
X9-2
X9-3
X9-4
X2-1
X1-7
TR2
X4-2
X4-3
X4-4
MODBUS BOARD
MTR-01
W/R
FLAME SENSOR
G
SPARK
ROD
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 voltage 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
E
79
Revision A (ECO #C05747) initial release. Reflects the new model
numbers for the Knight Wall Mount 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 #C08222) reflects the new layout in InDesign, the
addition of the rope gasket, along with changes to the water pipe
clearances from 1" to a 1/4" (ECR #R04077), pages 7, 8, and 33.
Revision E (ECO #C09161) reflects additional information added to the
humidity warning on page 7, along with updates made to the SMART
SYSTEM control (ECR #R04523).
Revision F (ECO #C09803) reflects the addition of the new Polypropylene
Vent material section, rearranging the venting section, and the addition
of the AHRI and ASME logos (R05009).
Revision G (ECO #C10143) reflects updates made to the ignition timing
information.
Revision H (ECO #C10297) reflects the removal of a venting notice on
page 16.
Revision I (ECO #C10450) reflects changes made to Table 10A on
page 61.
WBII-I-O Rev I
05/12
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