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Lochinvar KNIGHT 51 User's Manual

1. Figure 3 4 PVC CPVC Two Pipe Figure 3 5 Stainless Steel Two Pipe Figure 3 6 PVC CPVC Concentric Vertical Termination See page 27 Vertical Termination See page 27 Vertical Termination See page 29 for more details for more details for more details Direct venting options Vertical Vent Sidewall Air Figure 3 7 PVC CPVC Vertical Vent Sidewall Air Figure 3 8 Stainless Steel Vertical Vent Sidewall Air NOTICE Stainless steel vent air design and terminations will vary slightly by manufacturer 15 3 General venting 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 DANGER 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 PVC CPVC Vent piping materials Use only the materials listed in Table 3A for vent pipe and fittings Failure to comply could result in severe personal injury death or substantial property damage A WARNING Installation must comply with local requirements an
2. 49 Gas Valve Replacement 49 8 FIELD WIRING Line Voltage Connections 50 Low Voltage Connections 50 Wiring of the Cascade 52 9 CONDENSATE DISPOSAL Condensate Drain 54 10 STARTUP 55 60 11 OPERATING INFORMATION General 61 Cascade 64 Sequence of Operation 65 66 Knight Wall Mount Boiler Control Module 67 Status Display Screens 68 70 12 MAINTENANCE Maintenance and Annual Startup 71 74 13 DIAGRAMS Ladder Diagram 75 Wiring Diagram 76 Revision Notes Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER Injury A WARNING A CAUTION CAUTION Injury Injury NOTICE DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious CAUTION indicates a potentially hazardous situation which if not
3. VENT AIR TERMINATION Kit Number VenSue If using the alternate sidewall termination 3 The air piping must terminate in a down turned elbow as shown in FIG 4 1B This arrangement avoids recirculation of flue products into the combustion air stream HS The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown in FIG 4 1B A WARNING Do not exceed the maximum lengths of the outside vent piping shown in FIG 4 1B Excessive length exposed to the outside could cause freezing of condensate in the vent pipe resulting in potential boiler shutdown Figure 4 1B Alternate PVC CPVC Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR BIRD SCREEN CONNECTION FROM m VENT PIPE ie CONNECTION TERMINATION PLATE BIRD SCREEN GRADE OR SNOW LINE 21 Kuscer Installation amp Operation Manual Sidewall direct venting Ventlair termination sidewall Figure 4 2A Clearance to Gravity Air Inlets Figure 4 1C Alternate Venting Arrangement if Space Allows w Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION COUPLING 12 MIN AX FROM BOILER VENT PIPE VENT AIR CONNECTION TERMINATION BIRD SCREEN Figure 4 2B Alternate Clearance to Gravity Air Inlets w Field Supplied Fittings BIRD SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT IF SPACE
4. The equipment room MUST be provided with properly sized openings to assure adequate combustion air Please refer to Instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening Using the room air kit makes the unit vulnerable to combustion air contamination from within the building Please review Section 1 Prevent Combustion Air Contamination to ensure proper installation Vent system and terminations must comply with the standard venting instructions set forth in this manual When utilizing the single pipe method provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Table 3D Optional Room Air Kit 51 211 KIT30051 Air contamination Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals pass through the boiler they can form strong acids The acid can eat through the boiler wall causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building 20 Kuce Installation amp Operation Manual WALL MOU
5. CAP The upper and lower termination as well as any other unsealed EXISTING Joints in the existing vent system must be sealed to ensure that ELUE OUTLET SEAL 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 3A on page 17 Follow all vent air termination and clearance requirements per this section to the appropriate example Installation must For concept illustration only Individual installations comply with local requirements and with the National Fuel may vary due to job site specific equipment Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section Figure 5 9 Concentric Vent Example 2 SEAL a FLUE EXHAUST 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 AIR INLET W SCREEN Y Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG s 5 8 and 5 9 SEAL Table 5A Alternate Vertical Concentric Vent Chase Sizes FLUE OUTLET Vent Air Minimum Existing EXISTING Inlet Size
6. m BI IFE H Ras OMAUOEEIE SNS O 33JO1nO YOSN3S YOOGLNO YSaLVM YOSN3IS c qT3IHS qT3IHS X31109 aD 1X3N yt POO CX lt lt I OL E 7 Y WOMJ Figure 8 4 Low Voltage Field Wiring Connections x Z LLI Dn OL D p LLI gt 8 Field wi ring continued 53 Kise Installation amp Operation Manual 9 Condensate disposal Condensate drain NOTICE Use materials approved by the authority having jurisdiction In the absence of other This boiler is a high efficiency appliance that produces authority PVC and CPVC pipe must comply condensate with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or The bottom of the boiler has a 1 2 inch pipe for P495 PorCanada use CSA or UIC connection of a 1 2 inch PVC pipe FIG 9 1 PVC or CPVC pipe fittings and cement Slope condensate tubing down and away from the boiler i gt allow fon proper on faros into a drain or condensate neutralizing filter Condensate NOTICE horizontal runs a second line vent may be 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 1 inch The condensate line must rema A Neutralizer Kit is available from the factory Kit 3087 unobstructed allowing free flow condensate If condensate is allowed to fr
7. IZS Fx OUTDOOR ae F MEHU aI SCEEEH HDH A SYSTEM li 126 OUTDOOR MEHU aI SCEEEH HDH POST PORGE SYSTEM TAHE OUTDOOR MEHU qaSLEEEH HDH 1167F ia e 26 F a 1 5 SYSTEMS TAHE OUTDOOR sa SCREEH SHDH 11 Operating information Sequence of operation continued Kise Installation amp Operation Manual WALL MOUNT BOILER If the space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump will turn off 2 seconds later This will divert the boiler s outlet water from the heating system and send it to the tank coil instead The control will then modulate to maintain the outlet temperature 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 SYSTEM TAHE OUTDOOR 52 SCREEH SHDH SYSTEMS TANE OUTDOOR them is satisfied 3 SCREEH SHDH POST PURGE 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during a 10 second postpurge SYSTEM THHE OUTDOOR MEHLI qAaSLEEEH HDH 11 Anv pu
8. UNION PRESSURE DRAIN TYPICAL GAUGE INDIRECT DHW TANK CAUTION Mixing valves are required for the protection of low temperature loops NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 41 KWEHT Installation amp Operation Manual WALL MOUNT BOILER 6 Hvdronic piping Figure 6 7 Multiple Boilers Multiple Temperatures with DHW Piped as a Zone Number of Units Modell 2 3 4 5 6 7 8 Required Pipe Sizes PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW REDUCING VALVE LOOP 1 LOOP 2 LOOP 3 PREVENTER r 1 fl LT 7777 B4 PRESSURE gt lt GAUGE RC i NN La I I AN 7N NA lt Y MIXING VALVES WATER SYSTEM TYPICAL SUPPLY SENSOR EF AIR SEPARATOR u EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER nie BALL VALVE l NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TVPICAL lu m DRAIN POINT TYPICAL DOMESTIC U HOT WATER Y STRAINER CIRCULATOR FLOW CHECK RECOMMENDED VALVE i I ANTI SCALD WATER lt MIXING VALVE OUT BOILER CIRCULATOR LI BOILER BOILER DRAIN TEMPERATURE i PRESSURE GAUGE INDIRECT DHW TANK UNION TYPICAL CAUTION Mixing valves are required for the protection of low temperature loops NOTI
9. Table 12B Heat Exchanger Cleaning Kits Part Component Number Description CTN20005 Rear Refractory Cover KIT30062 MSC20083 Nylon 4 Wheel Brush MSC20085 1 4 x 12 Drill Extension 50 105 1 4 x 24 Drill Extension CAUTION Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush 150 210 KIT30063 Oiled bearing circulators 1 Thecirculator shipped with the Knight wall mount boiler is water lubricated No oiling is required 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 3 Replace the boiler front access cover KNIGHT Installation amp Operation Manual WALL MOUNT BOILER 13 Diagrams Figure 13 1 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL GROUND SQ TERMINAL STRIP TERMINAL STRIP SA S 120V SUPPLY L 120V SUPPLY N l 1 2 ON OFF INTEGRATED CONTROL BLOWER cA SWITCH GND Q 1 6 SYSTEM S SYSTEM 3 PUMP L IT PUMP N X N 69 U 69 SYSTEM PUMP BOILER BOILER PUMP L U PUMP N N N y BOILER PUMP DHW PUMP L n 8 TERMINAL TERMINAL STRIP STRIP 120 VAC V 5 24 KB 801 ONLY CONNECTION BOARD INTEGRATED N CONTROL CN5 5 FLOW CN5 14 X4 8 L
10. AROUND VENT PIPE CLOSED DOOR 6 41 VENTILATING AIR OPENING BOTTOM 24 SERVICE 24 6 1 MINIMUM CLEARANCE AROUND HOT WATER PIPES AREA OF EACH OPENING 1 SQ INCH PER 1000 BTU PER HOUR INPUT WITH MINIMUM 100 SQ INCHES Note Service clearances are recommendations only Figure 1 2 Alcove Installation Minimum Required Clearances TOP LEFT 6 MINIMUM 24 SERVICE MINIMUM For alcove installations CPVC or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death RIGHT 0 MINIMUM 1 MINIMUM CLEARANCE AROUND VENT PIPE OPEN FRONT D FRONT 24 SERVICE BOTTOM 6 MINIMUM 24 SERVICE 0 MINIMUM 1 MINIMUM CLEARANCE Note Service clearances are recommendations only AROUND HOT WATER PIPES Em Installation amp Operation Manual WALL MOUNT BOILER 1 Determine boiler location continued Provide air openings to room Knight wall mount boiler alone in boiler room l 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
11. o WALL MOUNT BOILER Kiser Installation amp Operation Manual 11 Operating information Status Display Screens cont d Display Turning the NAVIGATION dial will select the next or previous Status GUSCREEN lt Pressing the NAVIGATION dlial will show the next fault NSB Night HET Setback trigger or ramp delay setting E SELECT jiksi the NAVIGATION dial will select the setting indicated bv the NAVIGATION dial function LSETFOIHTSE Pressing the NAVIGATION dial will displav the Set Points Screen a SCROLL Turning the NAVIGATION dial will move the cursor up or down 47 ADILIST Turning the NAVIGATION dial will increase or decrease the current setting SHDN Press the RIGHT SELECT key to turn the boiler OFF Press the RIGHT SELECT kev to turn the boiler ON F RIGHT SELECT Press the RIGHT SELECT kev to cancel the shutdown operation kev function SAVE Press the RIGHT SELECT kev to save the current change Press the RIGHT SELECT kev to return to the Status Screen and HOME upload parameter changes 70 Kuce Installation amp Operation Manual WALL MOUNT BOILER 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 Inspect interior clean and vacuum if Check boil
12. For normal mode DHW operation any boiler s in the Cascade can be selected to provide heat for a DHW call Select a boiler to be designated as the DHW boiler Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The DHW boiler will adjust its set point to the programmed DHW set point and will adjust its firing rate to maintain this Once the DHW call has been satisfied the Leader control will place that boiler back into the Cascade sequence Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode When DHW is programmed for Zone Mode connect the DHW thermostat or tank sensor to the Leader boiler When a DHW call is received the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point if higher Night Setback operation of the boilers within the Cascade is available Programming of the Night Setback will be done through the Leader boiler Refer to the Knight Wall Mount Service manual for information regarding Night Setback Ramp Delay operation of the boilers as described in the Knight Wall Mount Service Manual is not active when the boilers are part of a Cascad
13. Front View Bottom View Left Side inside unit Right Side inside unit Ratings Number Note Change N to L Er gas models Pom s _ e s ERR Crane fame ee me ep E s 19 gt e IERI CERTIFIED Knight Wall Mount Boiler I B R Rating Model Net Input Heating I B R MBH Capacity Ratings Water Note 5 MES S Note 2 8 Note 3 8 Installation amp Operation Manual WALL MOUNT BOILER DOE rft ENERGY STAR Other Specifications Boiler Water Vent Air Size Content Connections Connections Gallons Note 1 8 NOTICE Maximum allowed working pressure is located on the rating plate 1 Notes As an Energy Star Partner Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency The ratings are based on standard test procedures prescribed by the United States Department of Energy Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 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 Standard Knight wall mount boilers are equipped to operate from sea level to 4 5
14. Vent Chase Size gt s For concept illustration only Individual installations may vary due to job site specific equipment 71 mm Installation amp 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 EXISTING SEAL FLUE OUTLET For concept illustration only Individual installations may vary due to job site specific equipment EN 30 EH 6 Hydronic piping System water piping methods The Knight wall mount is designed to function in a closed loop pressurized system not less than 12 psi A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators Each boiler installation must have an air elimination device which will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc during appliance operation for basic service of circulator replacement valves and others Observe a minimum of 1 inch clearance around all un insulated hot water pipe
15. Verify that boiler vent discharge and air intake are clean and free of obstructions 3 Replace the clean out cap and resume operation A WARNING Failure to inspect for the above conditions Figure 12 1 Condensate Trap and have them repaired can result in severe 2 PVC CAP WITH BLOCKED DRAIN SWITCH Check water system b 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 personal injury or death RETAINING SCREW CONDENSATE FROM HEAT EXCHANGER 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 ee performance problem 4 Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace 79 caps Make sure vents do not leak Replace any leaking TO CLEAN OUT TRAP vents 1 2 Maintenance continued Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping for suggested best location of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve a
16. requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 10 1 Condensate Trap 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE FROM HEAT EXCHANGER CONDENSATE p DRAIN REMOVABLE CAP TO CLEAN OUT TRAP Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas 56 Installation amp Operation Manual WALL MOUNT BOILER Check thermostat circuit s 1 Disconnect the two external wires connected to each of the room thermostat terminals on the connection board 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to
17. 3 Hang the boiler on the bracket and secure the bottom of the boiler with two 2 additional lag bolts provided Installation amp Operation Manual WALL MOUNT BOILER A WARNINGI Lhe boiler is too heavy for a single person to lift A minimum of two people is needed for mounting the boiler onto the bracket Mounting to a concrete wall 1 Mount the wall bracket using the two 2 wedge anchor bolts provided with the bracket To mount the wedge anchor bolts drill a 1 4 diameter hole 1 1 8 deep and insert anchor Hang the bracket from the anchor and secure with the two nuts provided Make sure the top edge of the bracket is away from the wall Ensure bracket is level when mounted Extreme care is needed to ensure the bolts are secured in the center of the studs Note If wall thickness does not allow a 1 1 8 deep hole field supplied hardware suitable for the application should be provided 2 Hang the boiler on the bracket and secure the bottom of the boiler with two 2 remaining anchors following the instructions above The boiler is too heavy for a single person to lift A minimum of two people is needed for mounting the boiler onto the bracket Mounting to a metal studded wall 1 The wall mount bracket is designed for a stud spacing of 16 inches from center For other stud spacing a solid mounting surface must be provided by the installer Do not mount the boiler to a hollow wall Be sure to mount the boiler to the stud
18. Cap to Vent Pipe Alternate Assembly NOTICE If assembly needs to be reduced STAIN FIELD SUPPLIED dimension D can be as short as possible FIELD SUPPLIED DRILL CLEARANCE HOLE IN RAIN CAP amp PILOT HOLE IN VENT PIPE 25 Sidewall direct venting WALL MOUNT BOILER Kuscer Installation amp Operation Manual Sidewall termination optional concentric vent Figure 4 10 Concentric Vent Sidewall Attachment ELBOW FIELD SUPPLIED STRAP FIELD COMBUSTION AIR CAUTION DO NOT use field supplied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 9 Cement appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 4 10 for proper pipe attachment 10 Operate the appliance one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections AIR SUPPLIED COMBUSTION COMBUSTION AIR Multiventing sidewall terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 4 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 Itis important that vent terminations be made as shown to avoid recirculation of flue gases 12 MINIMUM Figure 4
19. DHW tank is piped as a zone on the primary loop When a DHW demand begins the control will turn on the DHW pump output and raise the system temperature set point to the DHW boiler set point if higher The system pump and the boiler pump will be turned on In this mode any low temperature zones such as radiant heating may need additional controls to limit the water temperature sent to those zones Set DHW target temperature When in the DHW Mode the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in the control must be changed See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Set maximum DHW fan speed If the rated input of the indirect tank is less than the maximum output of the boiler change the maximum DHW fan speed setting to limit the boiler output accordingly see the Knight Wall Mount Service Manual for a detailed explanation of this procedure Set clock NOTICE The SMART SYSTEM control has a built in clock that it uses for its night setback feature and for logging events This clock must be set when the boiler is installed and anytime the boiler has been powered off for more than 4 hours Use the following procedure to set the clock 1 Press and hold the LEFT SELECT MENU key for at least 5 seconds 2 Th
20. If boiler status reads SHUTDOWN place the boiler into the active position by pressing the RIGHT SELECT ON key 3 Locate the pinhole SERVICE button below the RESET button on the display board Insert a thin wire such as a paper clip into the hole and press the button once hold for five 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire 4 From the Status Screen press the NAVIGATION dial to access the Set Points Screen 5 Press the LEFT SELECT LIMITS key 6 Select the manual reset high limit MRHL by pressing the NAVIGATION dial 7 Decrease the set point of the MRHL below the outlet temperature by turning the NAVIGATION dial counterclockwise 8 Press the RIGHT SELECT SAVE key 9 Press the RIGHT SELECT HOME key 10 The new parameters will upload to the control and the MRHL will function causing boiler shutdown and LOCKOUT to be displayed Press the RESET button to clear the lockout Repeat Steps 4 5 and 6 Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise 14 Repeat Steps 8 and 9 n Q b rm Low water cutoff protection 1 The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger If the flow rate is too low or the outlet temperature too high the control module modulates and shuts the boiler down This ensures bo
21. If the boiler pump was running it continues to run for a short period of time as well These pump delays are factory set to 30 seconds If different delays are desired the appropriate parameters in the control must be changed See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Adjust set point temperature NOTICE The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures Please note that the brackets denote screen status 1 From the Status Screen press the NAVIGATION dial Turn the NAVIGATION dial counterclockwise to select the appropriate set point 3 Press the NAVIGATION dial to adjust the temperature 4 Once the desired temperature is displayed press the RIGHT SELECT SAVE key 5 If necessary repeat Steps 3 and 4 to make adjustments to additional set points 6 Press the RIGHT SELECT HOME key to upload the changes 7 If the RIGHT SELECT SAVE key is not pressed the new settings will be discarded 59 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 In Zone Mode it is assumed that the indirect
22. PUMP BOILER PUMP SYSTEM SENSOR AIR SEPARATOR FILL VALVE Y STRAINER RECOMMENDED EXPANSION TANK LOW LOSS HEADER DRAIN TYPICAL TYPICAL DRAIN VALVE 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 35 Kuscer Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping Figure 6 2 Pressure Drop vs Flow Models 50 210 Pressure Drop vs Flow Includes Boiler Secondary Piping 51 81 Model 106 Model i 151 Model 211 Model ur g ai 1 a ea i 3 4 5 6 7 B 9 10 11 12 13 14 15 18 17 18 Flow Rate GPM Table 6A Circulator Recommendations for Temperature Rise Applications 20 25 and 35 Minimum Pipe PL 55 25 F Temperature Rise Applications FT HD Minimum Pipe Size Grundfos TACO s a UPS15 58FC 0014 J UPS15 58FC 0014 _NRF 36 Isi UPS26 99F 0014 NRF 36 211 UPS26 99F 0013 __NRF 36 Grundfos TACO B amp G Armstrong 1 UPS15 58FC 0010 NRF 36 Astro 50 NOTICE 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 The temperature rise provided by
23. Wall Mount Service Manual for a detailed description of parameters and access modes KAGHT Installation 8 Operation Manual 11 Operating information continued Knight wall mount boiler control module SYSTEM Use the control panel FIG 11 1 to set temperatures operating conditions and monitor boiler operation Figure 11 1 Control Panel NAVIGATION DIAL RESET KEY PRESS OR TURN LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY 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 67 a Kiise Installation amp Operation Manual 11 Operating information Figure 11 2 Status Display Screen B BOILER CALL FOR STATUS OPERATIONAL INFORMATION D LEFT SELECT RIGHT SELECT KEY KEY NAVIGATION DIAL Status Display Screens Display STANDBY 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 START The unit has begun a burn cycle and is checking all safety circuits PREPURGE The unit has initiated a 10 second purge period on a call for heat IGNITION The unit has begun a 4 second spark period to ignite the main burner A The unit has fired and is running at the displayed percentage Boiler Status The call for heat has
24. a pump model combination will decrease by 396 per 1000 feet of elevation 36 Installation amp Operation Manual 6 Hydronic piping continued Variable speed pump option Table 6B Recommended Variable Soeed Pumps Minimum Temperature Rise Grundfos TACO Wilo UP26 96 FC VS 0013 IFC VS Stratos 1 25 3 x 30 Usi n7 106 ns isi Ix ni 23 6 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 NOTICE Pump sizing and flow requirements are based on 20 feet of piping 4 90 elbows and 2 fully ported ball valves It is required that near boiler piping systems utilize Primary Secondary configurations as shown in FIGs 6 3 through 6 10 only The use of other near boiler piping co
25. 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 determin
26. 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 Installation amp Operation Manual WALL MOUNT BOILER 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 Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover 2 Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones 3 Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring jie Inspect all boiler wiring mak
27. 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 DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Use only approved stainless steel PVC or CPVC pipe and fittings For PVC CPVC use with primer and cement specifically designed for the material used Vent air piping and termination 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 Table 3C Maximum Combustion Air and Vent Piping Lengths 2 Max Vent Air 3 Max Vent Air 40 feet 100 feet 40 feet 100 feet 40 feet 100 feet 100 feet 100 feet 19 3 General venting Optional room air NOTICE Optional room air is intended for commercial applications Combustion air piping to the outside is recommended for residential applications Commercial applications utilizing the Knight wall mount boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room In order to use the room air venting option the following conditions and considerations must be followed The unit MUST be installed with the appropriate room air kit Table 3D
28. at full speed 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 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 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 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 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above 115 F Unions Field supplied Recommended for unit serviceability 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 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 34 11 12 13 Installation amp Operation Manual WALL MOUNT BOI
29. avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE A WARNING A WARNING Please read before proceeding A WARNING Installer Read all instructions Including this manual and the Knight Wall Mount Service Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the User s Information Manual for vour reference Have this boiler serviced inspected bv a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or su
30. boiler back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage Installation amp Operation Manual WALL MOUNT BOILER Set space heating operation Determine controlling sensor For space heating systems the temperature control can be based on one of three sensors the inlet outlet or system supply sensor The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor The control will automatically switch to the system supply sensor once it is connected If it is desired to base the temperature control on the inlet sensor the appropriate parameter must be changed in the control See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Verify space heat circulator mode The Space Heating Mode controls both the system primary pump if connected and the boiler secondary pump When the SMART SYSTEM control receives a space heating call for heat it turns on the system pump If the boiler is not heating an indirect DHW Domestic Hot Water tank and the set point is not met it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a short period of time The system pump can be programmed to run continuously except during outdoor shutdown
31. by the flame sense circuit C FAN SPEED The speed of the combustion blower l ir The status of the boiler pump output Information POILERPUMP pump outp The status of the system pump output w lt F The status of the DHW pump output The voltage received from a BMS system BLR PUMP OUTPUT The speed signal sent to a variable speed boiler pump in percent The speed signal received from a variable speed system pump control 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 LAST 10 FAULTS NO The last 10 lockouts MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu EXIT g g lew 2 2 6 a E Gl 21015 o lt c e BIG QO z 2 4a H 2185 15 5 c me Y z z WN 4 o Press the LEFT SELECT kev to exit the current screen or setting D LEFT SELECT kev function Press the LEFT SELECT key to confirm that the boiler needs to shutdown es 42 Press the LEFT SELECT key to enter the screen that allows you to adjust the limit settings Press the LEFT SELECT key to return to the Status Screen and upload HOME parameter changes
32. from the boiler to vent or air termination Do not exceed the lengths given in this manual for the air or vent piping 2 Cut pipe to the required lengths and deburr the inside and outside of the pipe ends 3 Chamfer outside of each pipe end to ensure even cement distribution when joining 4 Clean all pipe ends and fittings using a clean dry rag Moisture will retard curing and dirt or grease will prevent adhesion WALL MOUNT BOILER Kuce Installation amp Operation Manual 3 General venting continued 5 Dry fit vent or air piping to ensure proper fit up before T While primer is still wet apply an even coat of assembling any joint The pipe should go a third to approved cement to the pipe equal to the depth of two thirds into the fitting to ensure proper sealing after the fitting socket cement is applied f While primer is still wet apply an even coat of 6 Priming and Cementing approved cement to the fitting socket a Handle fittings and pipes carefully to prevent v Apply a second coat of cement to the pipe contamination of surfaces h While the cement is still wet insert the pipe into the b Apply a liberal even coat of primer to the fitting fitting if possible twist the pipe a 1 4 turn as you insert socket it NOTE If voids are present sufficient cement was c Applyaliberal even coat of primer to the pipe end to not applied and joint could be defective approximately 1 2 beyond the socket depth
33. in a residential garage it should be installed in compliance with the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is not subject to phvsical damage bv a moving vehicle Vent and air piping The Knight wall mount boiler requires a special vent svstem designed for pressurized venting The boiler is to be used for either direct vent installation or for installation using indoor combustion air When room air is considered see Section 3 General Venting Note prevention of combustion air contamination below when considering vent air termination Vent and air must terminate near one another and mav be vented verticallv through the roof or out a side wall unless otherwise specified You may use any of the vent air piping methods covered in this manual Do not attempt to install the Knight wall mount boiler using any other means Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated The vent air piping lengths routing and termination method must all comply with the methods and limits given in thi
34. inspect the appliance and not use any phone in your building to replace any part of the control system and any gas control which has been under water C Use only your hand to move the gas control switch Never use tools If the switch will not OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Move the switch to the ON position above on this label 9 Install front door 2 Set the thermostat to lowest setting 10 Turn on all electric power to appliance 3 m off all electric power to the 11 Set thermostat to desired setting ic NN 12 If the appliance will not operate follow the 4 This appliance is equipped with an instructions To Turn Off Gas To Appliance and ignition device which automatically lights call your service technician or gas supplier the burner Do not try to light the burner by hand 5 5 Remove front door 6 Move switch to the OFF position 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE oet the thermostat to lowest setting 4 Move switch the OFF position Turn off all electric power to the appliance 5 Install front door if service is to be performed Remove front door LBL2339 REV B 98 1 0 Start up continued Check flame and combustion continued NOTICE 4 Place the boiler into the active p
35. 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 NOTICE CSA or UL listed flexible gas 3 Loosen the set screw one 1 full turn from inside the connections are acceptable but you pressure tap on top of the gas valve Place tubing of must exercise caution to ensure that the the manometer over the tap once the set screw is line has adequate capacity to allow your loosened as shown in LIC vs boiler to fire at full rate Consult with local codes for proper installation or service procedures N N 1560 E pum E 4 Slowly turn on the gas supply at the field installed manual gas valve Turn the power switch to the ON position DO NOT adjust attempt to measure A WARNING gas valve MN pressure he gas valve is 6 Adjust the temperature set point on the control panel of factory set for the correct outlet the SMART SYSTEM control module to call for heat pressure This setting is suitable for 7 Observe the gas supply pressure as the burner fires at natural gas and propane requiring no 100 of rated input Percent of burner input will be field adjustment Attempting to alter or displayed on the control panel measure the gas valve outlet pressure 8 Ensure inlet pressure i
36. lt FLAME ROD SPARK ROD 2 HIGH VOLTAGE SPARK LEAD TANK L 4 SENSOR lt X4 6 SHIELD 29 A 30 CASCADE B Su NOTES SHIELD 32 1 Where possible switches are shown without utilities gas water or BMS 4 33 electricity connected to the unit As such actual switch states may IN 0 10V 34 vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present BUS iei 940V 3 2 See wiring diagram for additional notes 36 PUMP TL 37 5 our TA 38 BOX DEPICTS RATE aa 39 WARNING OPTIONAL ITEMS OUT i ee 10 LOW VOLTAGE SHIELD 41 DISCONNECT POWER 120 VAC A 2 BEFORE SERVICING MODBUS 43 1 xs ve HIGH VOLTAGE SHIELD 44 CN amp 3y5 63 LADDER DIAGRAM LBL20148 REV B EH 75 Em Kuce Installation amp Operation Manual WALL MOUNT BOILER 13 Diagrams Figure 13 2 Wiring Diagram LOW VOLTAGE NW UE T 120 VAC OPTIONAL ITEMS A WARNING HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING INTEGRATED CTION BOARD CONTROL box DEPICTS ITEMS HS ALARM Y CONTACTS DHW a g RUN TIME PUMP dj 3 CONTACTS m 3 24 VAC LOUVER BOILER 2 RELAY C
37. 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 Installation amp Operation Manual L MOUN Kise WALSAS LNAWASVNVIA ONIQ UNG SISOdANd NOILVHLSATII HO4 111dS GHVOA NOILOANNOO ALON M IVISOWYSAHL NOO4 E Q3Q33N gt SV 3dlAA L q13IHS es J d Ecc NOILdO 8 bo m 8 Z IVLSOWYSHL WOOW d NNd 41108 1 SIJA k Z IVISOWN3HL M lll qT3lHS LNO 31V M L L lll IVLSOINH3H L WOOY NI diNNd SAS TOYLNOD Q33dS dWNd WALSAS qT3IHS 3GVOSVO is qT3IHS aasn LON ON WOO HOLIMS MO 14 HOLIMS DNIAOHd H3An O01 HOLIMS ONIAOYd H3Ano Q3SN LON HOSNAS HOOQLNO HOSN3S WALSAS SLOVLNOSD NOG AV 138 YSANO 1 IB p EN pep Im ad J E
38. tank sensor is connected see DHW Tank Sensor below the tank thermostat is ignored DHW tank sensor l 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 The tank sensor included with the Lochinvar Squire Indirect DHW tank TST20015 is the only sensor suitable for use with the SMART SYSTEM control Connect the sensor leads to the Tank Sensor terminals on the Low Voltage Connection Board Consult the tank manufacturer for application and performance when used with any other indirect tank Failure to use the correct sensor ma A WARNING SS i result in the tank temperature being either above or below the set point Failure to consult the manufacturer of the indirect tank when the Squire is not used may result in decreased performance or the risk of scald injury Installation amp Operation Manual WALL MOUNT BOILER 3 If the TST20015 is not compatible with the indirect tank a tank thermostat can be used to control the boiler The tank thermostat should be installed per the manufacturers instructions and wired to the DHW Thermostat terminals on the Low Voltage Connection Board Louver relay 1 If louvers need to op
39. to the inlet sensor If the inlet sensor is chosen as the controlling sensor it is recommended that the svstem supplv sensor be installed in order to provide the best control of the inlet temperature Anti cvcling After the burner turns off the control will delav the next burner cycle for a set time period time is adjustable by the installer The time delav will be bvpassed if the inlet water temperature drops too far during the delav Boiler and svstem pump control The boiler pump will run whenever the burner is firing unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank The boiler pump will run during Freeze Protection Mode as well It will continue to run for a short time after the burner turns off or the Freeze Protection Mode ends The svstem pump will run whenever there is a space heating call for heat or the boiler goes into Freeze Protection Mode It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode The svstem pump can be programmed to run continuously if desired In either case it will not run during outdoor shutdown Temperature control Modulation The Knight wall mount boiler is capable of modulating its firing rate from a minimum of 20 to a maximum of 100 The firing rate is dictated bv the call for heat i e space heating or domestic hot water the heating load ramp delav if enabled and various other temperature limitatio
40. vent adapters Discard CPVC starter piece Table 3B Approved Stainless Steel Terminations and Adapters Intake Air Boiler Intermediate Adapter ProTech Heat Fab Adapter Termination Termination 300716 Vent 91 211 300715 Intake Air Adapter WB50210 FSBS3 Vent 303889 9353BUREZ 1 FSRC3 R C KB80210 Intake Air Flue Intake ae Air Termination ha Termination 9392 5300C 9314TERM Intake Air This adapter must be used in addition to the boiler adapter for Saf T vent pipe as shown in FIG 3 10 unless approved vent other than standard diameter is used Consult a Heat Fab representative for questions The stainless steel venting option is only available in 3 vent diameters 18 3 General venting continued Stainless steel air intake vent connections 1 Combustion Air Intake Connector FIG 3 10 Used to provide combustion air directly to the unit from outdoors A fitting is provided on the unit for final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate Vent Connector FIG 3 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate Figure 3 10 Near Boiler Stainless S
41. 00 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 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 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 8 Ratings have been confirmed by the Hydronics Institute Section of AHRI 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 is listed to UL353 HIGH ALTITUDE 3 000 FT TO 12 000 FT 4 RN a Figure A High Altitude Label Location N WALL MOUNT BOILER Installation amp Operation Manual 1 Determine boiler location Installation must comply with Local state provincial and national codes laws regulations and ordinances National Fuel Gas Co
42. 11 Concentric Vent and Combustion Air Termination EN 26 mmm 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 A WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substantial property damage NOTICE Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA 149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 19 of this manual 2 The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 3 The air piping must terminate in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an up turned coupling as shown in FIG 5 1A The top of the coupling must be at least 1 foot above the air intake When the vent termination uses a rain c
43. 6 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake 4 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 5 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe 28 N WALL MOUNT BOILER Installation amp Operation Manual 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 U 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 Figure 5 2 Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET 12 MIN
44. CE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 42 NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone Kuscer Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continued Figure 6 8 Single Boiler Zoned with Valves E xl sn ine PRESSURE PRESSURE issa GAUGE ZONE 2 ZONE 3 ZONE 4 deca BACKFLOW L d ise beset Ee PREVENTER SA 9 ZONE VALVES TYPICAL 11 NN I TI MAKE UP WATER I BI DIFFERENTIAL SYSTEM SUPPLY D T PRESSURE BYPASS SENSOR SYSTEM VALVE IF USED re CIRCULATOR AIR SEPARATOR E A EXPANSION TANK T Wa MAV SUBSTITUTE LOW LOSS HEADER BALL VALVE TVPICAL IP Y STRAINER T RECOMMENDED DRAIN POINT HOT TYPICAL DOMESTIC WATER ANTI SCALD 4 FLOW CHECK WATER OUT MIXING VALVE VALVE CIRCULATOR COLD WATER L IN PRESSURE I I in RELIEF VALVE m BOILER CIRCULATOR Aud 1 I UNION TYPICAL DRAIN TEMPERATURE PRESSURE GAUGE 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 Kise Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping
45. EN EDGE OF AIR PIPE AND ADJACENT VENT PIPE Sidewall termination concentric vent Description and usage optional 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 termination kit The termination kit must terminate outside the structure and must be installed as shown below in FIG 4 6 The required combustion vent pipe and fittings are listed in Table 3A on page 17 of this manual Figure 4 6 Concentric Sidewall Termination OVERHANG OR ROOF GRADE SNOW LINE 24 m N i y WALL MOUNT BOILER Installation amp Operation Manual Sidewall termination installation 1 CONCENTRIC FITTING Determine the best location for the termination kit see FIG 4 6 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 19 of this manual You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid p
46. Figure 6 9 Multiple Boilers Zoned with Valves Number of Units Modell 2 T 3 4 5 6 7 8 Required Pipe Sizes r TIT aI 7 PRESSURE BACKFLOW REDUCING VALVE PREVENTER PRESSURE BALL VALVE Q GAUGE ZONE VALVES gt lt TYPICAL in lt TYPICAL I NN i I Ii MAKE UP WATER SYSTEM SUPPLY SENSOR DIFFERENTIAL PRESSURE BYPASS VALVE IF USED AIR SEPARATOR SYSTEM CIRCULATOR EXPANSION TANK I z E MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL I il 5 TEQ ANTI SCALD MIXING VALVE 1 Y STRAINER 4 RECOMMENDED HOT TYPICAL DOMESTIC i WATER LB QQ FLowcHeck WATER OUT BOILER VALVE CIRCULATOR CIRCULATOR PRESSURE RELIEF VALVE o m UrnLe E BOILER 1 LEADER BOILER 2 MEMBER 1 INDIRECT TEMPERATURE UNI DHW TANK PRESSURE GAUGE DRAIN TYPICAL 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 44 Kise Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continued Figure 6 10 Single Boiler Non Zoned Primary Secondary Piping PRESSURE REDUCING VALVE BACKFLOW Ra iE PREVENTER E TT NN 1 I TT MAKE UP WATER MIB SEPARATOR SYSTEM SUPPLY SENSOR MAY SUBSTITU
47. IMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER Figure 5 3 Alternate Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET Installation amp Operation Manual WALL MOUNT BOILER O Vertical direct venting continued Vertical termination optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit Both combustion air and vent pipes must attach to the termination kit The termination kit must terminate outside the structure and must be installed as shown in FIG 5 4 Field supplied pipe and fittings are required to complete the installation The required combustion air and vent pipe fittings are listed in Table 3A on page 17 of this manual Vertical termination installation 1 See Section 5 Vertical Direct Venting Determine Location where applicable Figure 5 4 Concentric Vertical Termination COMBUSTION AIR 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF Figure 5 5 Do Not Install U Bend to Rain Cap 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 Partially assemble the concentric vent termination kit Clean and cement following the cleaning procedures in these inst
48. LER Boiler purge valve Field supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up 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 Indirect water heaters The Knight wall mount boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium As depicted in the piping diagrams on page 38 thru 45 there are two options when utilizing an indirect water heater A The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater B The indirect water heater is connected to the system supply piping A pump controlled by the Knight wall mount boiler s control will regulate the flow of water through the indirect water heater The indirect water heaters temperature will be regulated by the Knight wall mount boiler s control The Knight wall mount boiler is pre configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating Lochinvar offe
49. NT BOILER Please read the information given in Table 1A page 10 listing contaminants and areas likely to contain them 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 A WARNING If the boiler combustion air inlet is located in a laundry room or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal injury or death check for areas and products listed in Table 1A page 10 before installing the boiler or air inlet piping If contaminants are found you MUST Remove contaminants permanently OR Relocate air inlet and vent terminations to other areas Sidewall direct venting Vent air termination sidewall Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage A WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage A WARNING Po 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 substantia
50. OIL PUMP 5 LOUVER PROVING SWITCH SYSTEM aj GAS PRESSURE PUMP SWITCH SN 50 ai KB ONLY ON OFF E Bk Ha I oP BK cup 120V FLOW ay BK ny SUPPLY 2 SWITCH ER BK z TANK BK THERMOSTAT BK L I ROOM TSTAT BK ZONE CONTROL 3 BK ROOM TSTAT ZONE CONTROL 2 ROOM TSTAT O ZONE CONTROL 1 SYSTEM sensor OUTDOOR no i SA I TANK SENSOR px O 1 SHIELD CASCADE L SHIELD El BLOWER a 000000000000 Se 1a z o _ BMS av 2a p SYS PUMP 35 IN 0 10V PUMP 3 e 0 10V OUT 38 9 RATE 39 amp GUT Ey 40 8 BLOCKED DRAIN WITCH 0 MS AIR PRESSURE MODBUS A 1 22 SWITCH OPTION 43 1S a ji a OPERATING SENSOR 81 HIGH LIMIT SENSOR 16 LOW WATER INLET SENSOR S2 CUT OFF FLUE SENSOR S3a FLUE SENSOR S3b GAS VALVE 24VAC W R lt FLAME SENSOR TOI G SHIELD a E GROUNDING ene HIGH VOLTAGE SPARK LEAD JUMPER 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 Excepti
51. PERMITS Figure 4 1D Alternate Venting Arrangement Typical Stainless Steel Sidewall Termination of Air and Vent w Field Supplied Fittings Z BIRD SCREEN TYPICAL TO BOILER INTAKE AIR 12 MIN CONNECTION m MAX FROM BOILER VENT PIPE CONNECTION Figure 4 3A Clearance to Forced Air Inlets IF LESS THAN 10 BIRD SCREEN VENT AIR GRADE OR SNOW LINE TERMINATION Ha 5 Maintain clearances as shown in FIG s 4 1A thru 4 3B pages 21 and 22 Also maintain the following a Vent must terminate At least 6 feet from adjacent walls No closer than 12 inches below roof overhang At least 7 feet above any public walkway S MIN AS VE ANV iR At least 3 feet above any forced air intake within PUBLIC WALKWAY Lm 10 feet No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination FIG 4 1B and the vent pipe must not extend more than 24 inches vertically outside the building c Do not terminate closer than 4 feet horizontally from any electric meter gas meter regulator relief FORCED AIR INLET Figure 4 3B Alternate Clearance to Forced Air Inlets w Field Supplied Fittings IF LESS THAN 10 FORCED AIR valve or other equipment Never terminate above or below any of these within 4 feet horizontally BIRD SCREEN 6 Locate termination
52. T TYPICAL Y STRAINER RECOMMENDED DRAIN POINT DOMESTIC TYPICAL BOILER HOT WATER CIRCULATOR CIRCULATOR HOT FLOW CHECK WATER VALVE OUT ANTI SCALD MIXING VALVE Da 4 COLD WATER IN L UNION lt TYPICAL DRAIN TEMPERATURE PRESSURE GAUGE CAUTION Mixing valves are required for the protection of low temperature loops 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 40 Kusi Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continued Figure 6 6 Multiple Boilers Multiple Temperatures Number of Units Modell 273 4 5 6 7 8 Required Pipe Sizes PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW REDUCING VALVE LOOP 1 LOOP 2 LOOP 3 PREVENTER L PRESSURE pk GAUGE 9 rte LI NN LI ON A A UP Bh SS ETA MIXING VALVES WATER SYSTEM TYPICAL iso x EP 01224 JH H al AIR SEPARATOR EXPANSION TANK Jj MAY SUBSTITUTE gt cow LOSS HEADER H l NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BALL VALVE TYPICAL DRAIN POINT I TYPICAL TT NS d BOILER 4 CIRCULATOR Wess Lam E pw CIRCULATOR R 1 FLOW CHECK lt A U ve ANTI SCALD MIXING VALVE 2 Y STRAINER N 4 RECOMMENDED BOILER BOILER U l Q TEMPERATURE
53. TE LOW LOSS HEADER TO Se k FROM SYSTEM LI 4 SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART SYSTEM BALL VALVE CIRCULATOR TYPICAL Y STRAINER FLOW CHECK VALVE RECOMMENDED EXPANSION DOMESTIC ANTI SCALD TANK BOILER HOT WATER MIXING VALVE DRAIN POINT eran CIRCULATOR TYPICAL PRESSURE RELIEF VALVE INDIRECT DHW TANK UNION TVPICAL DRAIN TEMPERATURE PRESSURE GAUGE NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required bv local codes 7 Gas connections Connecting gas supply piping l Remove the front access panel and refer to FIG 7 1 to pipe gas to the boiler Install a field supplied sediment trap drip leg a upstream of the boiler gas controls Figure 7 1 Gas Supply Piping MANUAL SHUTOFF VALVE FIELD SUPPLIED GAS SUPPLY UNION DRIP LEG Kiso Installation amp Operation Manual WALL MOUNT BOILER 2 Support piping with hangers not by the boiler or its accessories WARNING The gas valve and blower will not support S 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 3 Purge all air from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas conn
54. WBII I O Rev C Kcd WALL MOUNT BOILER Installation amp Operation Manual Models 51 211 A WARNING This manual must only be used by a nerf qualified heating installer service technician Read all instructions including this manual and the Knight ENERGY STAR Wall Mount Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Save this manual for future reference Y High Efficiency Water Heaters Boilers and Pool Heaters HAZARD DEFINITIONS PLEASE READ BEFORE PROCEEDING THE KNIGHT WALL MOUNT BOILER HOW IT WORKS 1 DETERMINE BOILER LOCATION Provide Clearances Provide Air Openings to Room Wall Mounting Location Residential Garage Installation Vent and Air Piping Prevent Combustion Air Contamination Corrosive Contaminants and Sources Using an Existing Vent System to Install a New Boiler Removing a Boiler from Existing Common Vent 2 PREPARE BOILER Remove Boiler from Wood Pallet Gas Conversions Mounting the Boiler 3 GENERAL VENTING Direct Venting Options Install Vent and Combustion Air Piping PVC CPVC Vent Piping Materials Requirements for Installation in Canada PVC CPVC Air Intake Vent Connections Air Inlet Pipe Materials Stainless Steel Vent Max Allowable Vent Piping Lengths Vent and Air Piping Optio
55. WCO lt gt lt lt CN7 1 CN7 4 SWITCH CN5 10 4 12 O O CN7 3 CN7 2 CONNECTION BOARD ROOM THERMOSTAT 1 CN5 7 X4 1 ROOM THERMOSTAT 2 CN5 13 X4 9 ROOM THERMOSTAT 3 CN5 6 4 2 TANK THERMOSTAT o o LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH SWITCH CN5 12 X4 10 CN5 11 X4 11 O e OA CN5 3 4 5 INTEGRATED eM CONTROL LOUVER RELAY COIL Q 24VAC IN LOUVER S PROVING SWITCH CN5 4 4 4 Lo S gt lt RIBBON CABLE PC INTERFACE BLOCKED X5 10 pep z X85 DRAIN SWITCH _ XS AIR PRESSURE lt oc OPERATING S1a lt SWITCH B SN sensor KK VT HIGH LIMIT Sib Qe GAS VALVE T HS SENSOR X2 2 2 S3a lt lt X5 5 O lt R 6 X2 1 S3b Q9 lt E 30 a e BLOWER 1 X5 7 13 fsf CONNECTION L BOARD 2 5 16 CN5 1 X4 7 ALARM SH gt gt lt 4 X5 8 CONTACTS E 2 CN5 8 X4 14 BOJ gt gt 5 5 15 CN5 2 X4 6 RUN TIME 3 22 lt CONTACTS 4 HSH TR2 SVSTEM 21 HOH gt gt lt lt xe X1 7 SENSOR S6 CS EN ON6 lt X6 OUTDOOR S5 23 OH 6 SENSOR NN 54 lt
56. a stainless steel application you must use only the listed manufacturers and their type product listed in Table 3A for CAT IV positive pressure venting with flue producing condensate Supports Non combustible supports must be in place allowing a minimum 1 4 rise per foot The supports should adequately prevent sagging and vertical slippage by distributing the vent system weight For additional information consult the vent manufacturer s instructions for installation Terminations Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section For stainless steel vent only use terminations listed in Table 3B for the manufacturer of the installed vent Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 11 With stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used with PVC CPVC vent see the Installing Vent or Air Piping Section on page 16 If any of these conditions are not met the A WARNING 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 persona
57. ap as illustrated in FIG 5 1B maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet 6 m apart and with the vent termination at least 1 foot above the air intake Installation amp Operation Manual WALL MOUNT BOILER Rooftop vent and air inlet terminations must terminate in the same pressure zone unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent Sidewall Air Section A WARNING Figure 5 1A PVC CPVC Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 OF VENT PIPE BIRD SCREEN TYPICAL COUPLING FIELD SUPPLIED 6 MINIMUM ABOVE ROOF SNOW LINE VENT OUTLET 12 MINIMUM ABOVE AIR INLET Figure 5 1B Stainless Steel Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE BIRD SCREEN A TVPICAL 6 152 MM MINIMUM ABOVE ROOF SNOW LINE Se COM BUSTION AIR VENT OUTLET gt 36 914 MM MINIMUM ABOVE AIR INLET 5 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 27 D Vertical direct venting Ventlair termination vertical Pre
58. area per 1 000 Btu hr of boiler input Knight wall mount boiler in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation air openings into the space A WARNING The space must be provided with combustion ventilation air openings correctiv sized for all other appliances located in the same space as the Knight wall mount boiler Do not install the boiler in an attic Failure to complv with the above warnings could result in severe personal injurv death or substantial propertv damage 2 Size openings only on the basis of the other appliances in the space No additional air opening free area is needed for the Knight wall mount boiler because it takes its combustion air from outside direct vent installation Wall mounting location Ensure the wall for which the boiler is intended to be mounted is comprised of either cement brick block or wooden studs spaced 16 apart from center Ensure the wall is capable of supporting at least 200 pounds If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves pumps etc Residential garage installation Precautions Take the following precautions when installing the appliance in a residential garage If the appliance is located
59. as 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 Turn on the gas supply at the manual gas valve Turn the power switch to the ON position 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 Check burner performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics Figure 7 3 Inlet Gas Supply Check LOOSEN SET SCREW ONE 1 FULL TURN THEN PLACE TUBING OVER PRESSURE TAP Kuscer Installation amp Operation Manual Gas Pressure The gas pressure must remain between 4 inches w c natural 8 inches w c LP minimum and 14 inches w c natural and LP maximum during stand by static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the Knight wall mount boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank situati
60. asoline and other flammable vapors and c Eliminate all system or boiler leaks liquids Continual fresh makeup water will reduce 2 Verify that air intake area is free of any of the boiler life Minerals can build up in contaminants listed in Section 1 of this manual If any of sections reducing heat transfer overheating these are present in the boiler intake air vicinity they heat exchanger and causing heat exchanger must be removed If they cannot be removed reinstall failure Leaking water may also cause severe the air and vent lines per this manual and the Knight Wall property damage 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 1 Remove the front access cover and inspect the interior of found the boiler 3 Check gas line using the procedure found in Section 7 2 Vacuum any sediment from inside the boiler and Gas Connections components Remove any obstructions Flue vent system and air piping Clean condensate trap 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 1 Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out 2 Fill with fresh water until the water begins to pour out of the drain 2
61. ater system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 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 Installation amp Operation Manual WALL MOUNT BOILER 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system l Purge air from system a Connect a hose to the purge valve see purge drain valves in piping diagrams on pages 38 through 45 Route the hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve 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 isol
62. ation 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 T moan Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 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 4 Refill to correct pressure 55 10 Start up Check for gas leaks Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the front access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection solution Repair any leaks at once DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane
63. been satisfied and the unit runs the fan for an Bar POSTPURGE additional 10 seconds to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position CE TPL HT MET The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a condition that has temporarily interrupted the current call for heat Room Thermostat 1 has a call for heat Room Thermostat 2 has a call for heat B Room Thermostat 3 has a call for heat Indicators 2 Indicates which room thermostat demand shows priority The unit is being controlled by a 0 10V BMS signal The member unit is supplying heat while in Cascade Mode Call for Heat h The tank thermostat or sensor has a call for heat 68 Kuce Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information continued Status Display Screens cont d Display SYSTEM The temperature read by the system supply sensor if connected The temperature read by the tank sensor if connected OUTDOOR The temperature read by the outdoor sensor if connected INLET TEMP The temperature read at the inlet to the heat exchanger OUTLET TEMP The temperature read at the outlet of the heat exchanger TANK 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
64. bstantial property damage If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Installation amp Operation Manual WALL MOUNT BOILER When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler e Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been
65. d with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations NOTICE For closet and alcove installations CPVC or stainless steel material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death A WARNING All PVC vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the boiler to allow drainage of condensate NOTICE This appliance requires a special venting system The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC CPVC vent is to be used For stainless steel venting use an adapter from Table 3B page 18 that corresponds with the intended vent manufacturer to be used and discard the CPVC starter piece The field provided vent fittings must be cemented to the CPVC pipe section using an All Purpose Cement suitable for PVC and CPVC pipe Use only the vent materials primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death A WARNING Installation amp Operation Manual WALL MOUNT BOILER A WARNING Insulation should not be used on PVC or CPVC venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure Fo
66. de 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 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 Electrical power 2 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free of A WARNING combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 4 The Knight wall mount boiler must be installed so that gas control system co
67. e display changes to with four 4 zeros below it 3 Press the RIGHT SELECT SAVE key The display will then show a menu with the time and date and temperature unit Press the NAVIGATION dial twice Turn the NAVIGATION dial to adjust the hours Press the NAVIGATION dial 60 Please note that the brackets denote screen status read PASSWORD Installation amp Operation Manual WALL MOUNT BOILER 7 Turn the NAVIGATION dial to adjust the minutes Press the NAVIGATION dial 8 Turn the NAVIGATION dial to adjust the month Press the NAVIGATION dial 9 Turn the NAVIGATION dial to adjust the date Press the NAVIGATION dial 10 Turn the NAVIGATION dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Configuration of the cascade NOTICE Please note that the brackets denote screen status 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 Ro
68. e system Kiso Installation amp Operation Manual 11 Operating information continued Sequence of operation OPERATION DISPLAY Upon a call for heat the gas pressure switch es must be closed 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 The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch must close The control starts a 15 second prepurge cycle by initiating the blower The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve If flame is not detected within 1 second after the sparking ends the control will perform a 10 second post purge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts before locking out If flame is detected it holds the firing rate steady for 5 seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal START SYSTEM OUTDOOR MEHO et SCEEEHM SHDH START f SYSTEM 115 TANK 128 Fr1 OUTDOOR S MEHU ASCREEH SHDH START SYSTEM Lib F 1291252 OUTDOOR 26 F et SCEEEHM SHDH PRE PURGE SYSTEM 11
69. eader boiler The set point will be calculated based on the programmed reset curve parameters See the Knight Wall Mount Service Manual to program the reset curve If outdoor air reset is not desired do not connect the outdoor air sensor A fixed temperature set point can be programmed into the control See page 59 of this manual to program the set point If the water temperature at the system supply sensor is less than the set point the turn off offset the off on differential then the control will initiate a call for heat on the Cascade see the Knight Wall Mount Service Manual for an explanation of the offset and differential The Leader will energize the lead boiler on the Cascade For a new startup this will be the Leader boiler 64 Installation amp Operation Manual Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically be changed at set intervals 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 DAY SWITCHING ON SEQUENCE L M1 M2 M3 M4 M5 M6 M7 Day 1 1 hour M1 M2 M3 M4 M5 M6 M7 L Day 1 2 hours M2 M3 M4 M5 M6 M7 L M1 If a boiler is used to heat an indirect DHW tank it will automatically be given the lowest priority DHW Night Setback and Ramp Delay operation with cascade
70. ection 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 ING Do not check for gas leaks with an open LL 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 5 Usepipe 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 7 Gas connections continued A WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury death or substantial property damage Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 13 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage A WARNING 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 Fig
71. ed 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 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer s recommended solvents and standard commercial pipe cement for the material used The PVC CPVC ABS Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume KNIGHT WALL MOUNT BOILER Installation am
72. ed 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 Installation amp Operation Manual g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA and or CAN CSA B149 1 Natural Gas and Propane Installation Code 11 2 Prepare boiler Remove boiler from wood pallet 1 After removing outer shipping carton from boiler remove the parts box To remove the boiler from the pallet a Remove the two 2 lag bolts securing the bottom of the unit to the pallet b Lift the boiler off the wall bracket mounted to the pallet 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 Do not drop the boiler or bump the jacket NOTICE on the floor or pallet Damage to the boiler can result Figure 2 1 Boiler Moun
73. ee Do not expose condensate line to freezing temperatures required and tubing size may need to increase in of Ze in the line or if the line is obstructed in any Use only plastic tubing or piping as a condensate drain other manner condensate can exit from the line FIG 9 1 boiler tee resulting in potential water damage to property Leave the top of the tee assembly installed in the unit open this is needed as a vacuum break The blocked drain 7 A condensate removal pump is required if the boiler IS switch will shut the boiler down before any condensate below the drain When installing a condensate pump select can flow out of the tee one approved for use with condensing boilers and furnaces The pump should have an overflow switch to preve nt property damage from condensate spillage The switch should be wired in series with the blocked drain switch Inside the boiler see FIG 10 1 on page 56 Figure 9 1 Condensate Disposal CONDENSATE DRAIN CONNECTION ROUTE TO FLOOR DRAIN OR NEUTRALIZING FILTER USING 1 2 PVC PIPE amp FITTINGS or 1 2 CPVC PIPE amp FITTINGS or REMOVABLE CAP 5 8 1 0 PLASTIC TUBING FOR CLEANING TRAP FIELD SUPPLIED CONDENSATE TRAP 54 10 Start up Check control water chemistry CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial proper
74. em heat demand is satisfied the set point will revert to the value determined by the reset curve Night setback The controller may be programmed to reduce the space heating and DHW set points during certain times each week Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback 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 62 Installation amp Operation Manual WALL MOUNT BOILER Protection features Outlet temperature flue and temperature rise limiting temperature The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F and the minimum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 55 F the cont
75. ensor FIG 8 4 Boiler management system l 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 Make sure the ground terminal is connected to the ground output terminal of the external control and the 0 10 vdc terminal is connected to the 0 10 vdc terminal of the external control Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat 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 52 Installation amp Operation Manual WALL MOUNT BOILER Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 60 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 syste
76. er area necessary Check pressure temperature Clean condensate trap and fill with fresh gauge water eCheck for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check vent piping eCheck system water pressure system piping expansion tank Check air piping Check control settings Monthly e Check air and vent termination Check ignition and flame sense screens electrodes sand off any deposits clean and reposition Check relief valve e Check wiring and connections e Check condensate drain system lt o lt lt lt lt e Perform start up checkout and performance verification per Section 10 of this manual e Flame inspection stable uniform e Test low water cutoff if used e Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Periodically Reset button low water cutoff e Check boiler piping gas and water for leaks Every If combustion or performance 6 months Operate relief valve indicate need Clean heat exchanger e Remove and clean burner using compressed air only Clean the blower wheel End of season months Shut boiler down unless boiler used for domestic hot water Installation amp Operation Manual 12 Maintenance Follow the Service and maintena
77. erate when the boiler fires they can be controlled by this output Connect these terminals to a 24 vac relay coil which is wired to operate the louvers FIG 8 4 Louver proving switch 1 When the operation of the louvers needs to be verified before the boiler fires remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 8 4 Flow switch 1 A flow switch is used to guarantee flow through the boiler before allowing it to fire The flow switch must be installed at the boiler outlet 2 Connect these terminals to the normally open contacts on the flow switch FIG 8 4 Variable speed system pump If a variable speed pump is used in the primary loop and a 0 10V signal is available from the pump speed control this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load By connecting this 0 10V signal to the 0 10V SYS PUMP IN terminals the boiler or cascade can modulate up and down as the primary flow increases and decreases Boiler pump speed output This 0 10V output is available to control the speed of a variable speed boiler pump The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum AT 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 Ra
78. gas valve power switch to the ON position 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 A WARNING After converting to LP check combustion per the Start up procedure in Section 10 of this manual Failure to check and verify combustion could result in severe personal injury death or substantial property damage BRASS ORIFICE GROMMET GAS VALVE Mounting the boiler See page 9 of this manual for boiler mounting location instructions NOTICE Mounting to a wood studded wall The Knight Wall Mount boiler is not intended for floor installation 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 A WARNING Do not mount the boiler to a hollow wall Be sure to mount the boiler to the studs only 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
79. gh 6 10 which will guide you through the installation of the Knight wall mount boiler reference FIGs 6 1A and 6 1B 1 Connect the system return marked Inlet 2 Connect the system supply marked Outlet 3 Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone 4 Install a backflow preventer on the cold feed make up water line 5 Install a pressure reducing valve on the cold feed make up water line 15 psi nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi 6 Install a circulator as shown on the piping diagrams in this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity 8 Install an air elimination device on the system supply 9 Install a drain valve at the lowest point of the system 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 di
80. i Wipe excess cement from the joint removing ring or d Apply a second primer coat to the fitting socket beads as it will needlessly soften the pipe Table 3A Vent Pipe and Fittings All vent pipe materials and fittings must comply with the following Standards for installation in United States PVC schedule 40 ANSI ASTM D1785 CPVC and PVC venting must be ULC u PVC DWV ANSI ASTM D2665 5636 Certified IPEX is an approved Vent pipe and fittings manufacturer in Canada supplying vent CPVC schedule 40 80 ANSI ASTM F441 material listed to ULC S636 AL29 4C UL1738 ULC S636 FT ANSI ASTM D2564 IPEX System 636 p p CPVC ANSI ASTM F493 Cements amp Primers NOTICE DO NOT USE CELLULAR FOAM CORE PIPE Approved Stainless Steel Vent Manufacturers Protech Systems Simpson Dura Vent Co Heat Fab Selkirk Corporation Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only taking precaution to ensure no sagging occurs of the vent system Connect to the FasNSeal rigid vent using specially designed adapters and sealing method see manufacturer s instructions PVC CPVC air intake vent connections 1 Combustion Air Intake Connector FIG 3 9 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 dic
81. iler 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 63 11 Operating information Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the Knight Wall Mount Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Cascade When multiple boilers are installed they can be wired together in a cascade sequence A maximum of eight boilers can be controlled from a single control In this application one boiler would be designated as the Leader control and all others would be designated as Member controls If installing the boilers in an existing system the new boilers should be programmed as the Leader and or the higher number addresses The Leader control can be programmed to use Lead Lag or Efficiency Optimization control methods 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 L
82. ing sure wires are in good condition and securelv attached Check control settings 1 Set SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of the Knight Wall Mount Service Manual Adjust settings if necessary See Section 1 of the Knight Wall Mount Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks I Start boiler and perform checks and tests specified in Section 10 Start up Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame b 2 Inspect flame through observation window 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 Remove the burner reference FIG 12 2 page 74 When replacing the burner ensure gasket is in good condition and positioned correctly FIG 12 2 73 12 Maintenance Figure 12 2 Burner Assembly AIR GAS ARM SCREWS QTY 5 Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not imp
83. l property damage A WARNING Installation must comply with local requirements and with the National Fuel NOTICE Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 19 of this manual 2 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Installation amp Operation Manual WALL MOUNT BOILER Figure 4 1A PVC CPVC Sidewall Termination of Air and Vent TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION
84. l as the system water pressure Electronic LCD display The electronic display consists of 4 buttons a navigation dial and a multiple line liquid crystal display Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler Burner not shown Made with metal fiber and stainless steel construction the burner uses pre mixed air and gas and provides a wide range of firing rates Water outlet system supply The water outlet is the water connection for water leaving the boiler and entering the system Boiler connection is 1 Water inlet system return The water inlet is the water connection for water entering the boiler from the system Boiler connection is 1 Gas connection pipe 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 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals and controls the blower gas valve and pumps to meet the heating demand Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler High voltage junction box The junction box contains the connection points for the line voltage power and all pumps Manual air vent Designed to remove trapped air from the heat exchanger coils Low voltage con
85. l injury or death 10 Installation amp Operation Manual WALL MOUNT BOILER Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops 1 Determine boiler location 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 Fail A WARNING ilure to follow all instructions can result in flue gas spillage
86. l will hold in memory the last 10 lockouts as well as the last 10 blockings The date and time of the occurrence will be recorded as well Only the 10 most current occurrences of each will be held in memory Boiler temperature regulation Operating temperature target The SMART SYSTEM control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature The target temperature can be set between 32 F and 190 F Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described in this section under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations The Knight wall mount is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has a maximum set point of 200 F and the manual reset high limit has a maximum set point of 210 F When the outlet temperature exceeds 200 F the automatic high limit action occurs The boiler shuts down until the outlet water temperature cools below 190 F and a 60 second timer has expired If the outlet temperature continues to increase the manual reset high limit action will occur at 210 F High limit test procedure NOTICE Please note that the brackets denote screen status 1 Turn ON the main power to the boiler by placing the ON OFF switch in the ON position 2
87. late heat input and switches the boiler Domestic Hot Water DHW and system pumps on and off as needed The user programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation can be based on boiler outlet water temperature boiler inlet water temperature system temperature a 0 10V signal or Modbus depending on the parameter settings Control inputs and outputs Room thermostat There are three 3 thermostat connections available on this control These inputs tell the boiler to provide water for space heating Each thermostat connection has its own set point and outdoor air reset curve When multiple thermostats have a call for heat the control will give priority to the demand with the highest set point Example Assume that both Room Thermostat 1 and Room Thermostat 2 have a call for heat RoomThermostat 1 has a set point of 110 E Room Thermostat 2 has a set point of 140 The boiler will regulate the system temperature to 140 F until Room Thermostat 2 has been satisfied Once Room Thermostat 2 has been satisified the boiler will provide 110 F water to the system A CAUTION When multiple temperature loops are used thermostatic mixing valves are required for the protection of any low temperature loops 0 10V input set point or power The Knight wall mount boiler can be controlled by a Building Management System BMS u
88. m supply sensor must be installed The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 6 4 and 6 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor see FIG 8 4 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor FIG 8 4 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat Zone Control enable output or Building Management System enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the Room Thermostats 1 3 FIG 8 4 If the boilers are to run continuously connect a jumper wire between the R and W terminals for the Thermostat input This will initiate a call for heat on the Cascade Communication between the Leader boiler and the Member boilers is accomplished by using shielded 2 wire twisted pair communication cable Connect
89. 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 7 Concentric Vent and Combustion Air Vertical Termination COMBUSTION AIR TYPICAL L 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF Kise Installation amp Operation Manual WALL MOUNT BOILER 5 Vertical direct venting continues Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an Figure 5 8 Concentric Vent Example 1 existing unused venting system or by using the existing unused venting system as a chase for vent and combustion air FLUE EXHAUST routing Concentric Venting Arrangement The venting is to be vertical through the roof The annular space between the O D of the vent pipe and the I D of the existing unused venting system is utilized for the combustion INLET W SCREEN air source The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below SEALED
90. mponents are protected from dripping or spraying water or rain during operation or service 5 Ifa 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 A WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Failure to install the appliance indoors could result in severe personal injury death or substantial property damage This appliance requires a special venting system The vent connection to the appliance is made of CPVC Field supplied vent fittings must be cemented to the CPVC fitting on the boiler Use only the vent materials primer and cement specified in the manual to make the vent connections Failure to follow this warning could result in fire personal injury or death Closet and alcove installations A closet is any room the boiler is installed in which is less than 79 cubic feet for WBNO051 through WBN106 models 104 cubic feet for WBN151 models and 125 cubic feet for WBN211 models An alcove is any room which meets the criteria for a closet with the exception that it does not have a door Example Ro
91. mps that are running will continue to run for their BLOCKED respective pump delay times before turning off unless programmed to remain on continuously SYSTEM TAHKE A 60 second anti cycle period will start which will delay any new OUTDOOR call for heat until it times out 12 In Standby ready to start a new cycle Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when ISETPOINTS is flashing at the bottom of the display The date and time and the temperature units can also be changed see page 60 Installer Most parameters are available only to the installer accessible by entering the installer password see the Knight Wall Mount Service Manual 66 42 SCREEH SHDH STANDBY SYSTEM lirtF 156 F 1383 OUTDOOR a6 F SETPOINTS SHOH Saving parameters reference the Parameter Table in the Knight Wall Mount Service Manual NOTICE Please note that the brackets denote screen status To save parameters and exit programming Press the RIGHT SELECT SAVE key and then press the RIGHT SELECT HOME key To enter a parameter and continue programming Press the RIGHT SELECT SAVE key 1 time to return to the parameter listings press again to return to the menu listings Remember to press the RIGHT SELECT HOME key when finished programming in order to save the changes made See the Knight
92. n FIG 4 1A page 21 If using the alternate sidewall termination do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe PVC CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual Multiple vent air terminations 1 When terminating multiple Knight wall mount boilers terminate each vent air connection as described in this manual FIG 4 5A A WARNING All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury death or substantial property damage 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 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 23 VENT AIR TERMINATION 4 Sidewall direct venting Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B 12 MIN 15 MAX 12 MIN BETWE
93. nal Room Air 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall Determine Location Prepare Wall Penetrations Termination and Fittings Multiple Vent Air Terminations Sidewall Termination Optional Concentric Vent 5 VERTICAL DIRECT VENTING Vent Air Termination Vertical Determine Location Prepare Roof Penetrations Termination and Fittings Multiple Vent Air Terminations Vertical Termination Optional Concentric Vent 29 30 Optional Vertical Concentric Venting 31 32 6 HYDRONIC PIPING System Water Piping Methods 33 Low Water Cutoff Device 33 Chilled Water System 33 Freeze Protection 33 General Piping Information 33 Near Boiler Piping Components 34 Near Boiler Piping Connections 39 Circulator SIZING gia ss Arr 35 Variable Speed Pump Option 37 7 GAS CONNECTIONS Connecting Gas Supply Piping 46 Natural Gas 47 Pipe Sizing for Natural Gas 47 Natural Gas Supply Pressure Requirements 47 Propane GAS 47 Pipe Sizing for Propane Gas 47 Propane Supply Pressure Requirements 47 Check Inlet Gas Supply 48 Gas Pressure
94. nce procedures given throughout this manual and in component literature A WARNING U shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The boiler should be inspected annually only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING l noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems A WARNING The condensate trap must be filled with 1 1 water during all times of boiler operation to Inspect any problems reported by the owner and correct avoid flue gas emission from the condensate before proceeding drain line Failure to fill the trap could Inspect boiler area result in severe personal injury or death 1 Verify that boiler area is free of any combustible Check all piping f r leaks materials g
95. nd 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 A WARNING A WARNING Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed
96. nection board The connection board is used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low connection board voltage Condensate drain connection Connects the condensate drain line to a 1 2 pipe Access door Provides access to all internal components Ignition electrode Provides direct spark for igniting the burner Flame inspection window The quartz glass window provides a view of the burner surface and flame Gas shutoff switch An electrical switch designed to cut power to the gas valve to prevent releasing any gas 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 Relief valve Protects the heat exchanger from an over pressure condition The relief valve provided with the unit is set at 30 psi Flame sensor Used by the control module to detect the presence of burner flame Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box Air pressure switch The air pressure switch detects blocked inlet conditions Transformer The transformer provides 24V power to the integrated control WALL MOUNT BOILER Kise Installation amp Operation Manual The Knight Wall Mount Boiler How it works continued Models 51 211 13 n FRONT OF UNIT
97. nfigurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance 37 Kuscer Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping Figure 6 3 Single Boiler Single Temperature Zoned with Circulators ZONE 2 ZONE 3 ZONE 4 l PRESSURE PRESSURE REDUCING VALVE GAUGE L L BACKFLOW PREVENTER DA a CHECK F id Q TYPICAL ONIN WATER SYSTEM SUPPLY T SENSOR ZONE CIRCULATORS TYPICAL AIR SEPARATOR EXPANSION LI A 1 MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE TYPICAL NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART HOT WATER Y STRAINER OUT DRAIN POINT RECOMMENDED DOMESTIC ANTI SCALD TYPICAL HOT WATER MIXING VALVE CIRCULATOR BOILER CIRCULATOR LI PRESSURE RELIEF VALVE UNION TVPICAL el ka d z m BOILER LIII I TEMPERATURE PRESSURE DRAIN INDIRECT GAUGE DHW TANK 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 38 Kise Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continued Figure 6 4 Multiple Boilers Single Temperature Zoned with Circulators Number of Units Modell 273 7475 1617 8 Requi
98. ns 61 11 Operating information Ramp delay For systems with lower flow the SMART SYSTEM can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call for heat to a space heating call for heat There are six 6 limits that can be programmed as well as six 6 time intervals corresponding to each limit The sixth limit will also limit the firing rate for the rest of the call for heat Gradient limiting If during operation of the boiler the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Outdoor air reset With the outdoor air sensor connected the control module will calculate the set points of the three 3 space heating demands based on the programmed reset curves The installer can change the slope of the reset curves by several adjustable parameters The user can limit the maximum set point for the system using the space heating set points Boost function If outdoor air reset is active and any space heating demand has been active continuously for a set period of time time adjustable by installer and there has been no DHW demands the control will increase the set point of that demand by a fixed number of degrees adjustable by installer This process will continue until the space heating demand ends the set point reaches the programmed set point or a maximum of 20 increases has occurred Once the syst
99. oiler 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 A WARNING Check flame and combustion 1 Turn the main power off to the boiler 2 Remove the flue temperature sensor from the flue pipe connection Note Combustion measurements will be made at this point 3 Turn the main power on to the boiler 57 Kuscer Installation amp Operation Manual 10 Start up Figure 10 2 Operating Instructions This appliance does not have a pilot It is Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the move by hand don t try to repair it call a floor qualified service technician Force or attempted WHAT TO DO IF YOU SMELL GAS repair may result in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to
100. om 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 in FIG s 1 1 and 1 2 CPVC or stainless steel vent material must be used inside the structure The two ventilating air openings shown in FIG 1 1 are required for this arrangement Failure to follow this warning could result in fire personal injury or death Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 from combustible materials 2 Vent pipe at least 1 from combustible materials 3 See FIG s 1 1 and 1 2 on page 8 for other clearance minimums Clearances for service access 1 See FIG s 1 1 and 1 2 on page 8 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the boiler without removing it from the space Kise Installation amp Operation Manual WALL MOUNT BOILER 1 Determine boiler location Figure 1 1 Closet Installation Minimum Required Clearances TOP LEFT 6 MINIMUM 24 SERVICE 0 MINIMUM Zl For closet installations CPVC or stainless steel vent material MUST BE used in a closet structure due to VENTILATING elevated temperatures Failure to AIR OPENING follow this warning could result in fire personal injury or death RIGHT 0 MINIMUM 1 MINIMUM CLEARANCE
101. ons Replacement high vo Itage 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 WIRING DIAGRAM diagrams to troubleshoot unit LBL20127 REV B Kiso Installation amp Operation Manual WALL MOUNT BOILER Notes 77 Installation amp Operation Manual WALL MOUNT BOILER Notes 78 Kuce Installation amp Operation Manual WALL MOUNT BOILER Notes 79 Revision A ECO C05747 initial release Reflects the new model numbers for the Knight Wall Mount upgrade Revision C06188 reflects updates made to the ladder et wiring diagrams ECO C06158 f High Efficiency Water Heaters Boilers and Pool Heaters Revision C ECO C06234 reflects changes made to the Service 300 Maddox Simpson Parkway Lebanon TN 37090 Reminder feature 615 889 8900 Fax 615 547 1000 www Lochinvar com WBII I O Rev C 8 10
102. ons This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature this gas valve has a flanged connection to the venturi and blower Failure to follow all precautions could result in fire explosion death A WARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage 49 A WARNING NOTICE CAUTION Field wiring ELECTRICAL SHOCK HAZARD For your safety turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous opera
103. osition by pressing the RIGHT SELECT ON key FIG 11 1 page 67 Please note that the brackets denote screen status 5 Locate the pinhole button below the RESET button on the display board FIG 11 1 Insert a thin wire such as a paper clip into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 10A below The CO levels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the Troubleshooting Section of the Knight Wall Mount Service Manual for possible causes and corrective actions Table 10A Flue Products Chart 8 0 10 9 0 11 4 1 6 9 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm Turn the manual shutoff switch to the ON position reset the control and return to Service Mode 3 0 6 5 9 Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection 10 Place the
104. ossibility of accidental contact of flue products with people or pets 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 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 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 3 CONCENTRIC VENT KIT 4 DIA SDR 26 PIPE 2 1 2 DIA SDR 26 PIPE 3 DIA SDR 26 PIPE 2 DIA SDR 26 PIPE 2 CONCENTRIC VENT KIT Kuce Installation amp Operation Manual WALL MOUNT BOILER 4 Sidewall direct venting continued Sidewall termination optional concentric vent models Figure 4 8 Concentric Vent Dimensional Drawing B DIA NOMINAL PVC AIR B DIA NOMINAL PVC VENT NOTICE Instead of cementing the smaller pipe tothe 6 Install the Y concentric fitting and pipe assembly through rain cap a field supplied stainless steel screw the structure s hole may be used to secure the two 2 components together when field disassembly Do not allow insulation or other materials is desired for cleaning
105. p Operation Manual A 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 Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death A DANGER Stainless steel vent This product has been approved for use with stainless steel using the manufacturers listed in Table 3A Use only the materials vent systems and terminations listed in Table 3B DO NOT mix vent systems of different types or manufacturers unless listed in this manual Failure to comply could result in severe personal injury death or substantial property damage NOTICE Installations must comply with applicable national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada Installation of a stainless steel vent system NOTICE I should adhere to the stainless steel vent manufacturer s installation instructions supplied with the vent system NOTICE The installer must use a specific vent starter adapter at the flue collar connection supplied by the vent manufacturer to adapt to its vent system See Table 3B for approved
106. pare roof penetrations 1 Air pipe penetration a Cuta 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 Cuta 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 3 inch hole for 2 inch vent pipe 414 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 27 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 Termination and fittings l Prepare the vent termination coupling and the air termination elbow FIG 5 1A by inserting bird screens Bird screens should be obtained locally 2 The air piping must terminate in a down turned 180 return bend as shown in FIG 5 1A Locate the air inlet pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 3 The vent piping must terminate in an up turned coupling as shown in FIG 5 1A The top of the coupling must be at least 1 foot above the air intake When the vent termination uses a rain cap as illustrated in FIG 5 1B maintain at least 3
107. r models 50 105 when transitioning from 2 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 below Examples 1 Seven 7 feet vertical 2 Connector 90 elbow 2 feet horizontal 3 One 1 foot vertical 90 elbow 1 foot horizontal Requirements for installation in Canada 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 2 The first three 3 feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings 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 CAUTION Improper installation of PVG or CPVC systems may result in injury or death Installing vent and air piping NOTICE Use only cleaners primers and solvents that are approved for the materials which are joined together 1 Work
108. red Pipe Sizes T Walnut E 1 C OT REDUCING VALVE What oA ZONE 2 ZONE 3 ZONE 4 PREVENTER RA L MAKE UP WATER uw FLOW CHECK SYSTEM SUPPLY TYPICAL SENSOR AIR SEPARATOR ZONE CIRCULATORS TYPICAL EXPANSION M TANK r quy BALL VALVE U TYPICAL c MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT I NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART dst 5 ANTI SCALD V STRAINER MIXING VALVE MAS un RECOMMENDED OUT TYPICAL DOMESTIC KA HOT WATER CIRCULATOR CIRCULATOR LI 4 u PRESSURE Xs d VALVE T T BOILER 2 MEMBER 1 SM Ol LEADER INDIRECT TEMPERATURE DRAIN UNION DHW TANK PRESSURE TYPICAL GAUGE 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 39 Kuce Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping Figure 6 5 Single Boiler Multiple Temperatures PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW LOOP 1 LOOP 2 LOOP 3 PREVENTER f 1 fl PRESSURE me PSE GAUGE 9 MAKE mm cha ieli 5 N A MIXING VALVES WATER EDT Pd TYPICAL SENSOR j Si S AIR SEPARATOR Ay EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA BALL VALVE OR MAX OF 12 APAR
109. rol 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 Freeze protection DO NOT install the boiler in a room likely to freeze The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only not for the system The SMART SYSTEM control module provides freeze up protection as follows when the boiler water temperature drops below 45 F Below 45 F the boiler and system pumps operate constantly Below 37 F the boiler turns on Boiler and pumps turn off temperature rises above 45 F Lower temperatures may be programmed for systems with anti freeze solutions When svstem return temperatures are NOTICE Vau P maintained below the dew point condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust A CAUTION 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 if boiler water Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information continued Monitor external limits Connections are provided on
110. rove ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting of the Knight Wall Mount Service Manual for other procedures to deal with low flame signal Review with owner Review the Knight Wall Mount User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Knight Wall Mount User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed instructions see Table 12B Heat Exchanger Cleaning Kits l 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 Allow time for the boiler to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 74 Installation amp Operation Manual WALL MOUNT BOILER 4 Remove the hea
111. roviding protection against flue gas corrosion The coils are encased in a jacket that contains the combustion process Combustion chamber access cover Allows access to the combustion exchanger coils side of the heat Blower The blower pulls in air and gas through the venturi item 5 Air and gas mix inside the blower and are pushed into the burner where they burn inside the combustion chamber Gas valve The gas valve senses the negative pressure created by the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing Venturi The venturi controls air and gas flow into the burner 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 Boiler outlet temperature sensor housed with high limit sensor This sensor monitors boiler outlet water temperature system supply If selected as the controlling sensor the control module adjusts boiler firing rate so the outlet temperature is correct Boiler inlet temperature sensor This sensor monitors return water temperature system return If selected as the controlling sensor the control module adjusts the boiler firing rate so the inlet temperature is correct Temperature and pressure gauge field installed not shown Monitors the outlet temperature of the boiler as wel
112. rs 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 A WARNING The National Standard Plumbing Code the National Plumbing Code of Canada and the 14 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 5 Edition 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 6 Hydronic piping continued Near boiler piping connections Installation amp Operation Manual WALL MOUNT BOILER Figure 6 1A Near Boiler Piping w Y Strainer y QW INDIRECT DOMESTIC HOT WATER TANK DOMESTIC go BOILER HOT WATER X9 PUMP E SYSTEM PUMP SYSTEM 4 CY SENSOR TO FLOOR DRAIN i 22 l AIR JE SEPARATOR EXPANSION TANK V STRAINER RECOMMENDED Circulator sizing 4 a e Figure 6 1B Near Boiler Piping w Low Loss Header DOMESTIC HOT WATER PUMP CONDENSATE n DRAIN CO INDIRECT DOMESTIC E HOT WATER I 4 lt NO NOD lt SYSTEM
113. ructions a Cement the Y concentric fitting to the larger diameter kit pipe see FIG 4 7 page 24 b Cement rain cap to the smaller diameter kit pipe see FIG 4 7 page 24 NOTICE Instead of cementing the smaller pipe to the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 9 page 25 A WARNING When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal injury or death 29 D Vertical direct venting Kuce Installation amp Operation Manual WALL MOUNT BOILER Vertical termination optional concentric vent 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 4 Install the Y concentric fitting pipe assembly through the structure s hole and field supplied roof boot flashing NOTICE Do not allow insulation Or other materials to accumulate inside the pipe assembly when installing
114. s manual Prevent combustion air contamination Install air inlet piping for the Knight wall mount boiler as described in this manual Do not terminate vent air in locations that can allow contamination of combustion air Refer to Table 1A page 10 for products and areas which may cause contaminated combustion air You must pipe combustion air to the boiler air intake Ensure that the combustion air will not contain any of the contaminants in Table 1A page 10 Contaminated combustion air will damage the boiler resulting in possible severe personal injury death or substantial property damage Do not pipe combustion air near a swimming pool for example Also avoid areas subject to exhaust fumes from laundry facilities These areas wil always contain contaminants 9 1 Determine boiler location When using an existing vent system to install a new boiler A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Check the following venting components before installing Material For materials listed for use with this appliance see Section 3 General Venting Table 3A For stainless steel venting an adapter of the same manufacturer Table 3B must be used at the flue collar connection Size To ensure proper pipe size is in place see Table 3C Check to see that this size is used throughout the vent system Manufacturer For
115. s 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 A WARNING The boiler is too heavy for a single person to lift A minimum of two people is needed for mounting the boiler onto the bracket Figure 2 4 Mounting the Boiler LA WALL l WOOD OR METAL STUDS ON 16 CENTERS OR MASONRV POURED CONCRETE MOUNTING BRACKET FACTORV SUPPLIED gi FASTENERS APPROPRIATE FOR WALL TYPE QTY 4 13 Kuce Installation amp Operation Manual WALL MOUNT BOILER 3 General venting Direct venting options Sidewall Vent EN J Figure 3 1 PVC CPVC Two Pipe Sidewall Figure 3 2 Stainless Steel Two Pipe Sidewall Termination See page 21 for more details Termination See page 22 for more details A Lj a Pa 7 Q P d B ie d Figure 3 3 PVC CPVC Concentric Sidewall Termination See page 24 for more details 14 Kuce Installation amp Operation Manual WALL MOUNT BOILER 3 General venting continued Direct venting options Vertical Vent
116. s so they are not likely to be damaged by ARGUE MEN fi ne foreign objects such as stones or balls or subject to buildup ie of leaves sediment MEETS 22 m Installation amp Operation Manual WALL MOUNT BOILER 4 Sidewall direct venting continued Prepare wall penetrations l Use the factory supplied wall plate as template to locate the vent and air intake holes and mounting holes Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 315 inch hole for 2 inch vent pipe 415 inch hole for 3 inch vent pipe Drill 3 16 diameter holes for inserting the plastic anchors into the wall Install the vent and air intake piping through the wall into the vent plate openings Seal all gaps between the pipes and wall Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3A on page 17 to seal the vent pipe Mount and secure the vent plate to the wall using stainless steel screws Seal around the plate to the wall assuring no air gaps Assemble the vent cap to the vent plate see FIG 4 4A Insert the stainless steel screws into the vent cap screw hole openings and securely a
117. s when openings around the pipes are not protected by non combustible materials Low water cutoff device On a boiler installed above radiation level some states and local codes require a low water cutoff device at the time of installation Chilled water system If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle A chilled water medium must be piped in parallel with the heater Freeze protection Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose This includes inhibitors which prevent the glycol from attacking the metallic system components Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level The system should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping A WARNING Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems N T WALL MOUNT BOILER Installation amp Operation Manual General piping information Basic steps are listed below along with illustrations on the following pages FIG s 6 3 throu
118. s within specified range could result in damage to the valve Minimum and maximum gas supply pressures are causing potential severe personal injury specified in this section of the manual death or substantial property damage 9 If gas supply pressure is within normal range and no The gas piping must be sized for the proper flow and length adjustments are needed proceed on to Step 11 of pipe to avoid excessive pressure drop Both the gas meter 10 If the gas pressure is out of range contact the gas utility and the gas regulator must be properly sized for the total gas gas supplier qualified installer or service agency to load determine the necessary steps to provide proper gas If you experience a pressure drop greater than inch w c pressure to the control the meter regulator or gas line is undersized or in need of 11 Turn the power switch to the OFF position pais Perform the steps below when checking inlet gas 12 Shut off the gas supply at the manual gas valve in the gas Supply u piping to the appliance L Turn the main power switch to the OFF 13 Remove the manometer from the pressure tap on top of 2 Shut off gas supply at the manual gas valve in the gas the gas valve Re tighten the set screw inside the pressure piping to the appliance tap 48 7 Gas connections continued A WARNING When re tightening the set screw be sure to tighten securely to prevent gas 14 15 16 17 leaks Do not check for g
119. scharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve See the piping illustrations included in this section FIG s 6 3 through 6 10 for suggested guidelines in piping the Knight wall mount boiler with either zone valves or circulator pumps 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 33 6 Hydronic piping Near boiler piping components 1 10 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 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 Knight wall mount boilers are capable of controlling a variable speed boiler circulator Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG 6 2 on page 36
120. se heat distribution problems and noise Kisa Installation amp Operation Manual Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death U Check gas piping 1 Check around the boiler for gas odor following the procedure on page 46 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage U Propane boilers verify conversion 1 Verify propane conversion has been completed per the Propane Conversion instructions DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the b
121. see FIG 4 9 to accumulate inside the pipe assembly when installing through the hole When using the alternate screw assembly method drill a clearance hole in rain 7 Install the rain cap and small diameter pipe assembly into and a pilot hole in the vent pipe for the screw the Y concentric fitting and large pipe assembly Ensure size being used Failure to drill adequate small diameter pipe is bottomed and cemented in the Y holes may cause cracking of PVC concentric fitting components allowing combustion products to be recirculated Failure to follow this warning could result in personal injury or death Ensure termination location clearance i NOTICE A WARNING Do not operate the appliance with the rain denon areo hoan in E UE de cap removed or recirculation of combustion products may occur Water may also collect NOTICE If assembly needs to be extended to allow inside the larger combustion air pipe and sidewall thickness requirement the two 8 Secure the assembly to the structure as shown in FIG 4 10 using field supplied metal strapping or equivalent support material flow to the burner enclosure Failure to 2 pipes supplied in the kit may be follow this warning could result in product replaced by using the same diameter field damage or improper operation personal supplied SDR 26 PVC D2241 pipe Do injury or death not extend dimension D more than 60 nN inches see FIG 4 8 Figure 4 9 Rain
122. sing a 0 10 vdc signal The control can be configured by the installer to use this signal to either control set point or firing rate The Knight 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 KAGHT Installation 8 Operation Manual DHW prioritv The SMART SVSTEM 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 DHW space heating SH cvcling 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 svstem pump will remain on If the space heating call is still active while the DHW call is in operation the control will wait for 30 minutes time adjustable bv installer then it will switch back to the space heating demand There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating The control will switch back and forth until one of the heat demands end Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sensor bv default If a svstem supplv sensor is connected the control automaticallv uses it as the control sensor The control sensor can be changed by the installer
123. sult 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 Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 8 inches w c with gas flowing verify during boiler startup A WARNING Ensure that the high gas pressure regulator is at least 6 10 feet upstream of the appliance 47 Kuce Installation amp Operation Manual WALL MOUNT BOILER 7 Gas connections Table 7A Natural Gas Pipe Size Chart Nominal Natural Gas Pipe Capacity Chart Iron Pipe Length of Pipe in Straight Feet for 1 2 PSI Size Inches 9 2 3 N Z nN BB NO N o 1210 1020 923 83 1440 1330 1250 1180 2310 2100 2000 1900 2 4100 2820 2260 1950 1720 2 1 2 6460 4460 3610 3100 2720 2460 3 11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340 23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720 Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to A WARNING an i determine which fuel the boiler
124. t exchanger access cover burner and gas air arm assembly A WARNING The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the Service Manual Failure to comply could result in severe personal injury 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 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 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 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 57 and 59 of this manual 13 Replace the access cover and restore boiler to operation
125. tate 2 Vent Connector FIG 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 Air inlet pipe materials Figure 3 9 Near Boiler PVC CPVC Venting The air inlet pipe s must be sealed Choose acceptable VENT combustion air inlet pipe materials from the following list PVC CPVC or ABS Dryer Vent or Sealed Flexible Duct not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified in this section Type B double wall vent with joints and seams sealed as specified in this section AL29 4C stainless steel material to be sealed to specification of its manufacturer Plastic pipe may require an adapter not provided to transition between the air inlet connection on the appliance and the plastic air inlet pipe 17 3 General venting A WARNING Using vent or air intake materials other than those specified failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance NOTICE The use of double wall vent or insulated material for the combustion air inlet pipe is recommend
126. tate the NAVIGATION dial to select the parameter Cascade Address Press the NAVIGATION dial to access this parameter Each appliance in the Cascade system must be programmed with its own address The boiler designated as the Leader will have an address of 0 The remaining boilers in the Cascade will be Members and have addresses from 1 7 Rotate the NAVIGATION dial to select the appropriate address Press the RIGHT SELECT SAVE key If installing the boilers in an existing system the new boilers should be programmed as the Leader and or the higher number addresses 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 11 Operating information General How the boiler operates The Knight wall mount boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping The control module regulates blower speed to control the boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow How the control module operates The SMART SYSTEM control module receives inputs from boiler sensors and external devices The control module activates and controls the blower and gas valve to regu
127. te output This output provides a 0 10V signal that is proportional to the firing rate of the boiler This may be used by a BMS system to monitor the actual rate of the boiler Modbus When the optional ModBus interface module is installed the RS 485 ModBus cable is connected to these terminals Use shielded 2 wire twisted pair cable If desired the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module 51 8 Field wiring System supply sensor l 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 SUPPIY sensor be installed DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN The TST2032 sensor provided with the boiler must be used for the system sensor Connect these terminals to the system supply s
128. ted on Shipping Pallet REMOVE SHIPPING WALL BRACKET DO NOT DISCARD WILL BE NEEDED TO SECURE THE BOILER TO THE WALL Gas conversions The gas conversion procedure should be accomplished BEFORE the boiler is installed For a boiler already installed you must turn off gas supply turn off power and allow the boiler to cool before proceeding You must also completely test the boiler after conversion to verify performance as described under Start up Section 10 of this manual You must install the propane orifice to fire the Knight wall mount boiler on propane Verify when installing that the orifice size marking matches boiler size Table 2A Failure to comply could result in severe personal injury death or substantial property damage 12 KuusoT Installation amp Operation Manual Table 2A LP Conversion Table LP Conversion Table LP Orifice Stamping ______ 8 210 W150 210 W150 1 Remove the front access cover from the unit no tools required for removal 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 3 Locate the power switch on the gas valve and turn the power switch to the OFF position FIG 2 2 4 Disconnect the Molex plug from the wiring connector located on the gas valve 5 Using a 5 16 nut driver loosen the band clamp securing the air intake coupler to the gas
129. teel Venting VENT 3 S S INTERMEDIATE FOR SAF T VENT ONLY 3 S S ADAPTER The Knight wall mount boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3C below NOTICE Maximum allowable combustion air and vent piping lengths are as follows Increasing or decreasing the size of the combustion air or vent piping beyond the sizes listed in Table 3C is not authorized Installation amp Operation Manual WALL MOUNT BOILER For 2 vent air lengths greater than 40 feet consult the factory NOTICE Note The minimum combustion air and vent piping length is 12 equivalent feet When determining equivalent combustion air and vent length add 5 feet for each 90 elbow 3 feet for each 45 elbow and 3 feet for the concentric vent kit see example below EXAMPLE 20 feet of PVC pipe 4 90 elbows 2 45 elbows 1 concentric vent kit 49 equivalent feet of piping Removing from existing vent Follow the instructions in Section 1 page 11 of this manual when removing a boiler from an existing vent system Vent and air piping Vent and air system NOTICE You must also install air piping from outside to the boiler air intake adapter The resultant installation is direct vent sealed combustion 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 You may use
130. 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 Fill condensate trap with water 1 Remove the bezel as depicted in FIG 8 1 on page 50 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 The condensate trap FIG 10 1 must be SIS 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 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 1 0 Start up continued Final checks before starting the boiler U Read the Knight Wall Mount Service Manual to familiarize yourself with SMART SYSTEM control module operation Read this manual page 58 for proper steps to start boiler U Verify the boiler and system are full of water and all system components are correctly set for operation U Verify
131. the connection board for external limits such as flow switch low water cutoff gas pressure switches and a louver proving switch The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The boiler provides dry contacts for indicating when the boiler is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the boiler is firing in the Space Heating Mode The other timer monitors the time the boiler is in the DHW Mode The control uses two 2 ignition counters to monitor the amount of boiler cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed Service reminder The control can be programmed for service reminder notification This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will show a Maintenance Required screen The service reminder notification can be reset or disabled by the installer 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 Error logging The contro
132. the preparation procedures of Section 10 pages 55 and 56 have been completed U 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 U Verify electrical connections are correct and securely attached U Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler 1 Read and follow the Operating instructions in FIG 10 2 page 58 If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is boiler water temperature above 200 F 3 Is thermostat set below room temperature 4 Is gas turned on at meter or boiler 5 Is incoming gas pressure less than 4 inches w c If none of the above corrects the problem refer to the Troubleshooting Section of the Knight Wall Mount Service Manual Check system and boiler U Check water piping 1 Check system piping for leaks If found shut down the boiler and repair immediately See WARNINGS on pages 55 and 56 startup regarding failure to repair leaks 2 Vent any remaining air from the system using manual vents Air in the system will interfere with circulation and cau
133. through the hole 5 Secure the assembly to the roof structure as shown below in FIG 5 6 using field supplied metal strapping or equivalent support material Figure 5 6 Concentric Vent Roof Installation 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF AIR SUPPORT FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR Ensure termination height is above the roof surface or anticipated snow level 12 inches in U S A or 18 inches in Canada as shown in FIG 5 4 page 29 NOTICE If assembly is too short to meet height requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied SDR 26 PVC D2241 pipe Do not extend dimension D more than 60 inches see FIG 4 8 page 25 30 CAUTION PO NOT use field supplied couplings to extend pipes Airflow restriction will occur 6 Install the rain cap and the small diameter pipe assembly into the roof penetration assembly Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting 7 Cement the appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 5 6 for proper pipe attachment 8 Operate the appliance through one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections Multiventing vertical terminations When two 2 or
134. tion Figure 8 1 Remove Bezel REMOVE BEZEL Installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections 1 Remove bezel as shown in FIG 8 1 2 Connect 120 vac power wiring to the line voltage terminal strip in the junction box as shown in FIG 8 2 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 8 2 50 WALL MOUNT BOILER Installation amp Operation Manual Wire the boiler pump as shown in FIG 8 2 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 8 2 To activate a system pump wire as shown in FIG 8 2 If the motor is larger than 1 8 hp or 1 8 amps you must isolate with a relay Figure 8 2 Line Voltage Field Wiring Connections PUMP OUTPUTS 1 8A MAX 120V BOILER SYSTEM SUPPLY a I BK G W LINE GROUND NEUTRAL DOMESTIC BOILER SYSTEM 120V SUPPLY HOT WATER PUMP PUMP Fel SERVICE SWITCH 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 Connect low voltage wiring to low voltage connection board as shown in FIG 8 4 on page 53 of this manual and the boiler
135. ttach the vent cap to the vent plate Seal all wall cavities Figure 4 4A Sidewall Termination Assembly AIR PIPING gt VENT PIPING VENT PLATE WALL PLATE GALVANIZED THIMBLE Prepare wall penetrations Alternate Field Supplied Option l Air pipe penetration a Cut hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 315 inch hole for 2 inch vent pipe 415 inch hole for 3 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole as shown in FIG 4 4B Use a sidewall termination plate as a template for correct location of hole centers Follow all local codes for isolation of vent pipe when passing through floors or walls Seal exterior openings thoroughly with exterior caulk Figure 4 4B Alternate Sidewall Termination Assembly w Field Supplied Fittings ELBOW AIR PIPING VENT PIPING BIRD SCREEN GALVANIZED THIMBLE ELBOW SIDEWALL BIRD SCREEN TERMINATION PLATE Termination and fittings l The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG 4 1A page 21 Maintain the required dimensions of the finished termination piping as shown i
136. ty damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not use the boiler to directly heat swimming pool or spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used 1 Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 6 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 4 The freeze protection set points may be lowered when freeze protection fluid is used see the Knight Wall Mount Service Manual Fill and test w
137. under water must be replaced Boiler water Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent makeup water A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be property damage Do not use homemade cures or boiler damaged This can result in substantial A CAUTION patent medicines Serious damage to the boiler personnel and or property may result Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems N WALL MOUNT BOILER Installation amp Operation Manual The Knight Wall Mount Boiler How it works 1 10 11 12 13 14 15 Stainless steel heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer while p
138. ure 7 2 Inlet Pipe with Backup Wrench USE BACKUP WRENCH TO PREVENT PIPE FROM ROTATING NOTICE Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment Installation amp Operation Manual WALL MOUNT BOILER Natural gas Pipe sizing for natural gas 1 Refer to Table 7A for pipe length and diameter Based on rated boiler input divide by 1 000 to obtain cubic feet per hour a Table 7A is only for natural gas with specific gravity 0 60 inches with a pressure drop through the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 for Canadian installations Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 10096 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane Gas Knight 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 re
139. 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 Figure 2 2 Gas Valve Power Switch amp Venturi Removal REMOVE THE TWO 2 SCREWS SECURING THE GAS VALVE VENTURI TO THE INLET OF THE COMBUSTION BLOWER POWER SWITCH DETAIL 7 Using a 4mm Allen wrench remove the four 4 screws securing the gas valve to the venturi FIG 2 3 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 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 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 2 Prepare boiler continued 13 Reattach the wiring connector to the gas valve Tighten the screw on the wiring connector to secure to the gas valve 14 Turn the
140. wiring diagram Figure 8 3 Routing Field Wiring LINE VOLTAGE JUNCTION BOX NYA LOW VOLTAGE CONNECTION BOARD LOW VOLTAGE WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS 8 Field wi ring continued Thermostat l Connect the room thermostat or end switch isolated contact only to room thermostat 1 2 or 3 as shown in FIG 8 4 Install the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor 1 Mount the sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources Route sensor wires through a knockout in the bottom front right side of the boiler see FIG 8 3 Connect outdoor temperature sensor FIG 8 4 to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight wall mount boiler If fixed temperature operation is required do not Install outdoor sensor DHW thermostat l Connect storage indirect water heater DHW thermostat FIG 8 4 to the DHW thermostat terminals on the connection board If a

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