WH-I-O Rev H
Installation & Operation Manual
Models: WH 55 - 399
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the Knight
Wall Mount Service Manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
ƽ WARNING
Save this manual for future reference.
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Installation & Operation Manual
Please read before proceeding
Installer
–
Read all instructions,
When servicing boiler –
ƽ WARNING
including this manual and the Knight
Wall Mount Service Manual, before
installing. Perform steps in the order
given.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
User – This manual is for use only
by
a
qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
NOTICE
Consider piping and installation when
determining boiler location.
Boiler water –
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
• Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.
Factory warranty (shipped with unit)
does not apply to units improperly
installed or improperly operated.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure. Addition of oxygen carried in by
makeup water can cause internal corrosion in system
components. Leaks in boiler or piping must be repaired
at once to prevent makeup water.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
ƽ WARNING
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
This appliance MUST NOT be installed
in any location where gasoline or
flammable vapors are likely to be present.
Do not use “homemade cures” or “boiler
patent medicines”. Serious damage to
WHAT TO DO IF YOU SMELL GAS
ƽ CAUTION
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• 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.
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.
3
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Installation & Operation Manual
The Knight Wall Mount Boiler - How it works...
1. Stainless steel heat exchanger
15. Gas connection pipe
Allows system water to flow around specially designed
tubes for maximum heat transfer, while providing
protection against flue gas corrosion.
Threaded pipe connection.
This pipe should be
connected to the incoming gas supply for the purpose of
delivering gas to the boiler.
2. Combustion chamber access cover
Allows access to the combustion side of the heat
exchanger.
16. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and
external signals and controls the blower, gas valve, and pumps
to meet the heating demand.
3. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the
burner, where they burn inside the combustion chamber.
17. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the boiler.
4. Gas valve
18. High voltage junction box
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.
The junction box contains the connection points for the line
voltage power and all pumps.
19. Low voltage connection board
The connection board is used to connect external low voltage
devices.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated)
20. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
21. Condensate drain connection
Connects the condensate drain line.
7. Boiler outlet temperature sensor (housed with high
22. Access door
limit sensor)
Provides access to all internal components.
This sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control
module adjusts boiler firing rate so the outlet temperature is
correct.
23. Ignition electrode
Provides direct spark for igniting the burner.
24. Flame inspection window
8. Boiler inlet temperature sensor
The quartz glass window provides a view of the burner
surface and flame.
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the boiler firing rate so the inlet temperature is
correct.
25. Gas shutoff switch
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
9. Temperature and pressure gauge (field installed, not
shown)
26. High limit sensor (housed with outlet sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, it will break the control circuit,
shutting the boiler down.
Monitors the outlet temperature of the boiler as well as the
system water pressure.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial
and a multiple line liquid crystal display.
27. Relief valve
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 30 psi.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
boiler.
28. Flame sensor
Used by the control module to detect the presence of burner
flame.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
29. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
30. Transformer
13. Water outlet (system supply)
The transformer provides 24V power to the integrated control.
The water outlet is the water connection for water leaving the
boiler and entering the system.
31. ModBus
The optional ModBus option provides intelligent building
system communications.
14. Water inlet (system return)
The water inlet is the water connection for water entering the
boiler from the system.
32. On/Off switch
The On/Off switch is used to turn 120 VAC on and off to the
unit.
33. Manual air vent
Allows for removal of trapped air from the heat exchanger.
4
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Installation & Operation Manual
The Knight Wall Mount Boiler - How it works...
Models 55 - 399
(continued)
17
11
21
15
13
14
22
28
29
20
32
FRONT OF UNIT
IMG00117
10
Front View
Bottom View
33
17
5
27
23
3
25
4
11
28
2
1
16
19
33
24
31
30
18
7
26
6
8
IMG00162
IMG00161
Left Side (inside unit)
Right Side (inside unit)
5
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Installation & Operation Manual
Ratings
A
S
M
E
H
Knight Wall Mount Boiler
AHRI Rating
Other Specifications
Heating
Capacity
MBH
Net
Input
MBH
AHRI
Ratings
Water,
MBH
AFUE
%
Vent/Air
Size
Model Number
Boiler Water
Content
Gallons
Water
Gas
Note: Change
“N” to “L” for
L.P. gas models.
(Note 5)
Connections Connections
(Note 4)
2"
Min
11
Max
55
(Note 1, 8)
96
(Note 3, 8)
44
(Note 2, 8)
51
WHN055
WHN085
WHN110
WHN155
WHN199
WHN285
WHN399
2.5
2.5
3.5
3.5
5.0
5.0
6.5
1"
1"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
3/4"
17
22
31
40
57
85
79
69
89
96
96
96
96
96
2"
110
155
199
285
102
144
186
265
1"
3"
125
162
230
1"
3"
1 1/4"
1 1/4"
1 1/2"
3"
3"
80
399
379
330
95
4"
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
7. The Knight Wall Mount boiler input rate, on some models,
is reduced for vent lengths beyond the minimum. Two inch
vent will reduce Models WH(N,L) 055, WH(N,L) 085 and
WH(N,L)110 by 0.6%, 0.94%, and 1.2% for every 10 feet
of vent. Three inch vent will reduce Models WH(N,L)155,
WH(N,L)199 and WH(N,L) 285 by 0.3%, 0.5%, and 0.6%
for every 10 feet of vent. Four inch vent will reduce Model
WH(N,L) 399 by 0.4% for every 10 feet of vent.
8. Ratings have been confirmed by the Hydronics Section of
AHRI. Model 399 has a thermal efficiency rating.
9. Knight wall mount boilers comply with the requirements
of CSD-1 Section CW-400 requirements as a temperature
operation control. The manual reset high limit provided
with the Knight wall mount boiler is listed to UL353.
1. As an Energy Star Partner, Lochinvar has determined that
Knight wall mount boilers meet the Energy Star guidelines
for energy efficiency.
2. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
3. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
4. Knight wall mount boilers require special gas venting. Use
only the vent materials and methods specified in the Knight
Wall Mount Installation and Operation Manual.
5. Standard Knight wall mount boilers are equipped to operate
from sea level to 4,500 feet only with no adjustments. The
boiler will de-rate by 4% for each 1,000 feet above sea level
up to 4,500 feet.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000FT TO 12,000FT
6. High altitude Knight wall mount boilers are equipped
to operate from 3,000 to 12,000 feet only with no field
adjustments. The boiler will de-rate by 2% for each 1,000
feet above 3,000 feet. High altitude models are manufactured
with a different control module for altitude operation, but
the operation given in this manual remains the same as the
standard boilers. A high altitude label (as shown in FIG. A)
is also affixed to the unit.
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Figure A High Altitude Label Location
6
Installation & Operation Manual
1 Determine boiler location
This appliance is certified as an indoor
appliance. Do not install the appliance
outdoors or locate where the appliance will
be exposed to freezing temperatures or to
temperatures that exceed 100°F.
Installation must comply with:
ƽ WARNING
•
Local, state, provincial, and national codes, laws,
regulations, and ordinances.
•
•
National Fuel Gas Code, ANSI Z223.1 – latest edition.
Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required.
National Electrical Code.
For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
Do not install the appliance where the
relative humidity may exceed 93%. Do not
install the appliance where condensation
may form on the inside or outside of the
appliance, or where condensation may fall
onto the appliance.
•
•
The Knight wall mount boiler gas
NOTICE
Failure to install the appliance indoors
could result in severe personal injury,
death, or substantial property damage.
manifold and controls met safe lighting
and other performance criteria when the
boiler underwent tests specified in ANSI
Z21.13 – latest edition.
This appliance requires a special venting
system. The vent connection to the
appliance is made of CPVC. Field supplied
vent fittings must be cemented to the CPVC
fitting on the boiler. Use only the vent
materials, primer, and cement specified in
the manual to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
ƽ WARNING
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
Closet and alcove installations
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.
A closet is any room the boiler is installed in which the room
volume is less than the room volume listed in the table below.
An alcove is any room which meets the criteria for a closet,
but it does not have a door.
Room Volume
(in cubic feet)
Model
55 - 85
110 - 285
399
90
108
178
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
Example: Room dimensions = 4 feet long, 4 feet wide, and
9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be
considered a closet for the WHN399 model.
Failure to keep boiler area clear and free
of combustible materials, gasoline, and
ƽ WARNING
other flammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
For closet and alcove installations as shown
ƽ WARNING
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.
4. The Knight wall mount boiler must be installed so
that gas control system components are protected from
dripping or spraying water or rain during operation or
service.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" from combustible materials.
2. Vent pipe – at least 1" from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance
minimums.
• System leaks causing oxygen corrosion or heat exchanger
cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system
and boiler to freeze and leak.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 8 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
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7
Installation & Operation Manual
1 Determine boiler location
Figure 1-1 Closet Installation - Minimum Required Clearances
For closet installations, CPVC,
TOP
ƽ WARNING
LEFT
0" MINIMUM
polypropylene or stainless steel
vent material MUST BE used in
a closet structure due to elevated
temperatures. Failure to follow
this warning could result in fire,
personal injury, or death.
6" MINIMUM
VENTILATING
*
AIR OPENING
6"
RIGHT
0" MINIMUM
1" MINIMUM CLEARANCE
AROUND VENT PIPE
CLOSED DOOR
6"
VENTILATING
*
AIR OPENING
FRONT
6" MINIMUM
1/4" MINIMUM CLEARANCE
BOTTOM
0" MINIMUM
*AREA OF EACH OPENING:
1 SQ. INCH PER 1000 BTU PER HOUR INPUT
WITH A MINIMUM OF 100 SQ. INCHES.
AROUND HOT WATER PIPES
RECOMMENDED SERVICE CLEARANCES:
FRONT:
24”
BOTTOM: 24”
LEFT SIDE: 12”
Note: Service clearances are recommendations only.
Figure 1-2 Alcove Installation - Minimum Required Clearances
TOP
6" MINIMUM
LEFT
0" MINIMUM
For alcove installations, CPVC,
ƽ WARNING
polypropylene 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
FRONT
6" MINIMUM
BOTTOM
0" MINIMUM
1/4" MINIMUM CLEARANCE
AROUND HOT WATER PIPES
RECOMMENDED SERVICE CLEARANCES:
FRONT:
24”
BOTTOM: 24”
LEFT SIDE: 12”
Note: Service clearances are recommendations only.
8
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Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
(continued)
Residential garage installation
Knight wall mount boiler alone in boiler room
Precautions
Take the following precautions when installing the appliance in
a residential garage. If the appliance is located in a residential
garage, it should be installed in compliance with the latest
edition of the National Fuel Gas Code, ANSI Z223.1 and/or
CAN/CGA-B149 Installation Code.
1. No air ventilation openings into the boiler room are
needed when clearances around the Knight wall mount
boiler are at least equal to the SERVICE clearances
shown in FIG.’s 1-1 and 1-2. For spaces that do NOT
supply this clearance, provide two openings as shown
in FIG. 1-1. Each opening must provide one square
inch free area per 1,000 Btu/hr of boiler input.
• Appliances located in residential garages and in
adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
all burners and burner ignition devices are located not
less than 18 inches (46 cm) above the floor.
Knight wall mount boiler in same space with other
gas or oil-fired appliances
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.
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
Vent and air piping
The space must be provided with
ƽ WARNING
The Knight wall mount boiler requires a special vent system,
designed for pressurized venting.
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the Knight
wall mount boiler.
The boiler is to be used for either direct vent installation or for
installation using indoor combustion air. When room air is
considered, see Section 3, General Venting. Note prevention of
combustion air contamination below when considering vent/
air termination.
Do not install the boiler in an attic.
Failure to comply with the above
warnings could result in severe personal
injury, death, or substantial property
damage.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. You may use any of the vent/air piping
methods covered in this manual. Do not attempt to install the
Knight wall mount boiler using any other means.
2. Size openings only on the basis of the other appliances
in the space. No additional air opening free area is
needed for the Knight wall mount boiler because it
takes its combustion air from outside (direct vent
installation).
Be sure to locate the boiler such that the vent and air piping can
be routed through the building and properly terminated. The
vent/air piping lengths, routing and termination method must
all comply with the methods and limits given in this manual.
Wall mounting location
Ensure the wall for which the boiler is intended to be
mounted is comprised of either, cement, brick, block, or
wooden studs spaced 16" apart from center. Ensure the
wall is capable of supporting at least 250 pounds for Models
55 - 285 and 300 pounds for the 399 Models.
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.
If flooding is possible, elevate the boiler sufficiently to
prevent water from reaching the boiler.
You must pipe combustion air to the boiler
ƽ WARNING
Ensure the boiler is installed in a location that minimizes
the risk of water damage due to valves, pumps, etc.
air intake. Ensure that the combustion air will
not contain any of the contaminants in Table
1A, page 10. Contaminated combustion air
will damage the boiler, resulting in possible
severe personal injury, death or substantial
property damage. Do not pipe combustion
air near a swimming pool, for example. Also,
avoid areas subject to exhaust fumes from
laundry facilities. These areas will always
contain contaminants.
9
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Installation & Operation Manual
1 Determine boiler location
Table 1A Corrosive Contaminants and Sources
When using an existing vent system to
install a new boiler:
Products to avoid:
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
ƽ WARNING
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
emissions, causing severe personal injury
or death.
Chlorinated waxes/cleaners
Check the following venting components before installing:
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
• Material - For materials listed for use with this appliance,
see Section 3 - General Venting. For polypropylene or
stainless steel venting, an adapter of the same
manufacturer must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3A.
Check to see that this size is used throughout the vent
system.
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
• Manufacturer - For a stainless steel or polypropylene
application, you must use only the listed manufacturers
and their type product listed in Tables 3E and 3G for CAT
IV positive pressure venting with flue producing
condensate.
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
Adhesives used to fasten building products and other
similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
• Terminations - Carefully review Sections 3 through 5 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section. For
stainless steel vent, only use terminations listed in Table
3H for the manufacturer of the installed vent.
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 11.
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
With polypropylene and stainless steel vent, seal and connect
all pipe and components as specified by the vent manufacturer
used; with PVC/CPVC vent, see the Installing Vent or Air
Piping Section on page 19.
If any of these conditions are not met,
ƽ WARNING
the existing system must be updated or
Garages with workshops
replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
10
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Installation & Operation Manual
1 Determine boiler location
(continued)
When removing a boiler from existing
common vent system:
Do not install the Knight wall mount
boiler into a common vent with any other
appliance. This will cause flue gas spillage or
appliance malfunction, resulting in possible
severe personal injury, death, or substantial
property damage.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CAN/CSA B149.1, Natural Gas and Propane
Installation Code. When resizing any portion of the
common venting system, the common venting system
should be resized to approach the minimum size as
determined using the appropriate tables in Part 11 of
the National Fuel Gas Code, ANSI Z223.1/NFPA and/or
CAN/CSA B149.1, Natural Gas and Propane Installation
Code.
ƽ DANGER
Failure to follow all instructions can result
ƽ WARNING
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or
death.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while the
other appliances remaining connected to the common venting
system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies, which
could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space in
which the appliances remaining connected to the common
venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected to
the common venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined herein, return doors, windows,
exhaust fans, fireplace dampers, and any other gas-burning
appliance to their previous conditions of use.
11
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Installation & Operation Manual
2 Prepare boiler
Table 2A LP Conversion Table
LP Conversion Table
LP Orifice Stamping
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler,
remove the parts box.
Model
55
055
085
110
155
199
H285
8.0
2. To remove the boiler from the pallet:
a. Remove the two (2) lag bolts securing the bottom
of the unit to the pallet.
85
110
155
199
285
399
b. Lift the boiler off the wall bracket mounted to
the pallet.
3. Remove the two (2) lag bolts securing the wall bracket to
the wood pallet. Be certain not to lose the wall bracket
as it will be needed for securing the boiler to the wall
(FIG. 2-1).
1. Remove the front access cover from the unit (no tools
required for removal).
2. Models 55 - 285 only, locate the power switch on the gas
valve and turn the power switch to the “OFF” position
(FIG. 2-2).
Do not drop the boiler or bump the jacket
NOTICE
on the floor or pallet. Damage to the
boiler can result.
3. Model 399 only, shut off power at the source.
4. Disconnect the Molex plug from the gas valve.
Figure 2-1 Boiler Mounted on Shipping Pallet
5. Using a 5/16" nut driver, loosen the band clamp securing the
air intake coupler to the gas valve venturi. Remove the air
intake pipe and coupler from the gas valve venturi.
6. Using an Allen wrench, remove the screws securing the
gas valve venturi to the inlet of the combustion blower
(FIG. 2-2).
REMOVE SHIPPING
[WALL] BRACKET
DO NOT DISCARD-
WILL BE NEEDED TO
SECURE THE BOILER
TO THE WALL
Figure 2-2 Gas Valve Power Switch & Venturi Removal
REMOVE THE SCREWS SECURING
THE GAS VALVE VENTURI TO THE
INLET OF THE COMBUSTION
BLOWER
Gas conversions
7. Using an Allen wrench, remove the screws securing the gas
pipe to the gas valve. Remove the gas valve venturi assembly
from the unit (FIG. 2-3).
The gas conversion procedure should
ƽ WARNING
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.
8. Using an Allen wrench, remove the venturi from the gas
valve.
9. Locate the propane orifice disk from the conversion kit bag.
Verify that the stamping on the orifice disk matches the
boiler size (see Table 2A).
10. Place the orifice into the black rubber grommet in the side of
the gas valve and secure inside the gas valve (see FIG. 2-3).
You must install the propane orifice to fire
the Knight wall mount boiler on propane.
Verify when installing that the orifice size
marking matches boiler size (Table 2A).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
11. Reattach the venturi to the gas valve and reposition the gas
valve venturi assembly inside the unit. Secure the venturi
back to the gas valve (FIG. 2-3).
12. Reattach the gas pipe to the gas valve. Reattach the air intake
and coupler and tighten down on the band clamp.
12
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Installation & Operation Manual
2 Prepare boiler
(continued)
The boiler is too heavy for a single person to
lift. A minimum of two people is needed for
mounting the boiler onto the bracket.
13. Reattach the Molex plug to the gas valve.
ƽ WARNING
14. Models 55 - 285 only, turn the gas valve power switch to
the “ON” position.
Mounting to a concrete wall:
15. Model 399 only, turn on power at the source.
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.
16. After the installation is complete, fill out the gas conversion
label (in the conversion kit bag) and affix it to the unit
under the boiler rating plate inside the unit. Attach the
LP caution label (in the conversion kit bag) to the left side
of the unit in the lower left corner.
17. Replace the front access cover.
After converting to LP, check combustion
ƽ WARNING
Note: If wall thickness does not allow a 1 1/8" deep hole,
field supplied hardware suitable for the application should be
provided.
per the Start-up procedure in Section 10
of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
2. Hang the boiler on the bracket and secure the bottom of the
boiler with two (2) remaining anchors, following the
instructions above.
Figure 2-3 Installing Propane Orifice
The boiler is too heavy for a single person to
lift. A minimum of two people is needed for
ƽ WARNING
GAS VALVE
mounting the boiler onto the bracket.
Mounting to a metal studded wall:
GROMMET
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.
BRASS ORIFICE
Do not mount the boiler to a hollow wall. Be
ƽ WARNING
SCREWS
sure to mount the boiler to the studs only.
2. Mount the wall bracket using two (2) field supplied toggle
bolts capable of supporting 100 pounds each. Ensure the
top edge of the bracket is away from the wall. Ensure the
bracket is level when mounted. Extreme care is needed to
ensure the bolts are secured in the center of the studs.
VENTURI
Mounting the boiler
See page 9 of this manual for boiler mounting location
instructions.
3. Hang the boiler on the bracket and secure the bottom of the
boiler with two (2) field supplied toggle bolts.
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.
The Knight Wall Mount boiler is not
NOTICE
ƽ WARNING
intended for floor installation.
Mounting to a wood studded wall:
Figure 2-4 Mounting the Boiler
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.
WALL:
WOOD OR METAL STUDS ON
16" CENTERS -OR-
MASONRY / POURED CONCRETE
MOUNTING BRACKET
(FACTORY SUPPLIED)
Do not mount the boiler to a hollow wall.
Be sure to mount the boiler to the studs
only.
ƽ WARNING
2. Mount the wall bracket using the 2 1/4" lag bolts
provided. Make sure the top edge of the bracket is away
from the wall. Ensure the bracket is level when mounted.
Extreme care is needed to ensure the bolts are secured in
the center of the studs.
FASTENERS
APPROPRIATE
FOR WALL TYPE
QTY: 4
3. Hang the boiler on the bracket and secure the bottom of
the boiler with two (2) additional lag bolts provided.
13
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Installation & Operation Manual
3 General venting
Direct venting options - Sidewall Vent
Figure 3-1 Two-Pipe Sidewall Termination - See page Figure 3-2 PVC/CPVC Concentric Sidewall
22 for more details
Termination - See page 26 for more details
Figure 3-4 PVC/CPVC Concentric Figure 3-5 Vertical Vent, Sidewall Air
Vertical Termination - See page 30 - See page 18 for more details
for more details
Figure 3-3 Two-Pipe Vertical
Termination - See page 29 for
more details
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14
Installation & Operation Manual
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.
The Knight wall mount boiler vent and air piping can be
installed through the roof or through a sidewall. Follow the
procedures in this manual for the method chosen. Refer to the
information in this manual to determine acceptable vent and
air piping length.
ƽ DANGER
You may use any of the vent/air piping methods covered in
this manual. Do not attempt to install the Knight wall mount
boiler using any other means.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
You must also install air piping from outside to the boiler
air intake adapter unless following the Optional Room
Air instructions on page 18 of this manual. The resultant
installation is direct vent (sealed combustion).
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6) - Used to
provide combustion air directly to the unit from outdoors.
A fitting is provided on the unit for final connection.
Combustion air piping must be supported per guidelines
listed in the National Mechanical Code, Section 305, Table
305.4 or as local codes dictate.
This appliance requires a special venting
system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and
fittings listed in Tables 3D, 3E, and 3G for
vent pipe, and fittings. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
2. Vent Connector (FIG.'s 3-7 thru 3-9) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
DO NOT mix components from different
systems. The vent system could fail,
causing leakage of flue products into the
living space. Mixing of venting materials
will void the warranty and certification of
the appliance.
ƽ WARNING
Figure 3-6 Near Boiler Air Piping
Installation must comply with local
requirements and with the National
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
NOTICE
AIR
For closet and alcove installations, CPVC,
polypropylene or stainless steel material
MUST BE used in a closet/alcove structure.
Failure to follow this warning could result
in fire, personal injury, or death.
ƽ WARNING
Improper installation of venting systems
may result in injury or death.
ƽ CAUTION
Follow the instructions in Section 1, page
11 of this manual when removing a boiler
from an existing vent system.
NOTICE
Do not connect any other appliance to
the vent pipe or multiple boilers to a
common vent pipe. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
15
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Installation & Operation Manual
3 General venting
Note: The minimum combustion air and vent piping
length is 12 equivalent feet.
Requirements for installation in
Canada
When determining equivalent combustion air and vent
length, add 5 feet for each 90° elbow and 3 feet for each
45° elbow.
1. Installations must be made with a vent pipe system
certified to ULC-S636.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2)
45° elbows + (1) concentric vent kit (CVK3003) = 49
equivalent feet of piping.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings. For concentric vent installations, the inner
vent tube must be replaced with field supplied certifiedvent
material to comply with this requirement.
The appliance output rating will reduce
by up to 1.5% for each 25 feet of vent
length.
NOTICE
4. The 2" and 3" Concentric Vent Kits available from
Lochinvar (see Section 4 – Sidewall Termination – Optional
Concentric Vent) and the 2" and 3" Concentric Vent Kits
available from IPEX are approved for use on the Knight
wall mount boiler. Both kits are listed to the ULC-S636
standard for use in Canada.
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Equivalent Vent
Model Kit Number
Length
55 - 110
155 - 199
285 - 399
CVK3008
CVK3003
CVK3007
3 feet
3 feet
3 feet
Sizing
The Knight boiler uses model specific combustion air intake and
vent piping sizes as detailed in Table 3A below.
Table 3A Air Intake/Vent Piping Sizes
2" Max Vent/ 3" Max Vent/ 4" Max Vent/
Model
Air
*80 feet
*50 feet
*40 feet
N/A
Air
Air
N/A
55
100 feet
100 feet
100 feet
100 feet
100 feet
*50 feet
N/A
85
N/A
110
155
199
285
399
N/A
N/A
N/A
N/A
N/A
100 feet
100 feet
N/A
For Models 55, 85, and 110 using 2"
venting and Model 285 using 3" venting,
the first seven (7) equivalent feet of vent
must be CPVC (field supplied). This
includes any transition piece used to
increase or decrease the vent diameter.
*ƽ WARNING
Increasing or decreasing combustion air or
vent piping sizes is not authorized.
NOTICE
16
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Installation & Operation Manual
3 General venting
(continued)
Materials
Air inlet pipe materials:
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe
should use a silicone sealant to ensure a proper seal at the
appliance connection and the air inlet cap connection. Dryer
vent or flex duct should use a screw type clamp to seal the vent
to the appliance air inlet and the air inlet cap. Proper sealing
of the air inlet pipe ensures that combustion air will be free of
contaminants and supplied in proper volume.
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
PVC, CPVC, Polypropylene or ABS
Dryer Vent or Sealed Flexible Duct (not recommended
for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as
specified in this section.
Type “B” double-wall vent with joints and seams sealed as
specified in this section.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
When a sidewall or vertical rooftop combustion air supply
system is disconnected for any reason, the air inlet pipe must
be resealed to ensure that combustion air will be free of
contaminants and supplied in proper volume.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
Failure to properly seal all joints and seams
ƽ DANGER
as required in the air inlet piping may
Using air intake materials other than
those specified can result in personal
injury, death or property damage.
result in flue gas recirculation, spillage
of flue products and carbon monoxide
emissions causing severe personal injury
or death.
ƽ WARNING
The use of double-wall vent or insulated
NOTICE
material for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized
vent pipe material used for air inlet piping on a sidewall or
vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either
Aluminum Foil Duct Tape meeting UL Standard 723 or
181A-P or a high quality UL Listed silicone sealant such as
those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three (3) sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
17
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Installation & Operation Manual
3 General venting
Optional room air
Air contamination
Optional room air is intended for
NOTICE
commercial applications. Combustion air
piping to the outside is recommended for
residential applications.
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds.
When these chemicals pass through the boiler, they can form
strong acids. The acid can eat through the boiler wall, causing
serious damage and presenting a possible threat of flue gas
spillage or boiler water leakage into the building.
Commercial applications utilizing the Knight wall mount
boiler may be installed with a single pipe carrying the flue
products to the outside while using combustion air from
the equipment room. In order to use the room air venting
option the following conditions and considerations must be
followed.
Please read the information given in Table 1A, page 10,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of
the boiler combustion air inlet, have your installer pipe the
boiler combustion air and vent to another location, per this
manual.
•
The unit MUST be installed with the appropriate
room air kit (Table 3C).
•
The equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
If the boiler combustion air inlet is located
ƽ WARNING
in a laundry room or pool facility, for
•
•
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.
example, these areas will always contain
hazardous contaminants.
To prevent the potential of severe personal
ƽ WARNING
injury or death, check for areas and
products listed in Table 1A, page 10 before
installing the boiler or air inlet piping.
•
Vent system and terminations must comply with the
standard venting instructions set forth in this manual.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
When utilizing the single pipe method,
ƽ WARNING
provisions for combustion and ventilation
air must be in accordance with Air for
Combustion and Ventilation, of the latest
edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition
of CGA Standard B149 Installation Code for
Gas Burning Appliances and Equipment, or
applicable provisions of the local building
codes.
• Relocate air inlet and vent
terminations to other areas.
Table 3C Optional Room Air Kit
Model
55 - 110
55 - 285
199 - 399
Vent Size
Kit Number
KIT30051
KIT30052
KIT30053
2"
3"
4"
18
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Installation & Operation Manual
3 General venting
(continued)
1. Work from the boiler to vent or air termination. Do not
exceedthelengthsgiveninthismanualfortheairorvent
piping.
PVC/CPVC
This product has been approved for use with the PVC/CPVC
vent materials listed in Table 3D.
2. Cut pipe to the required lengths and deburr the inside
and outside of the pipe ends.
Installing vent and air piping
3. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
The vent connection to the appliance must
ƽ WARNING
be made with the starter piece provided
with the appliance if PVC/CPVC vent is to
be used. The field provided vent fittings
must be cemented to the CPVC pipe section
using an “All Purpose Cement” suitable for
PVC and CPVC pipe. Use only the vent
materials, primer, and cement specified in
Table 3D to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
4. Clean all pipe ends and fittings using a clean dry rag.
(Moisturewillretardcuringanddirtorgreasewillprevent
adhesion.)
5. Dry fit vent or air piping to ensure proper fit up before
assembling any joint. The pipe should go a third to
two-thirds into the fitting to ensure proper sealing after
cement is applied.
6. Priming and Cementing:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
Use only cleaners, primers, and solvents
NOTICE
that are approved for the materials which
b. Apply a liberal even coat of primer to the fitting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
are joined together.
All PVC vent pipes must be glued, properly
NOTICE
supported, and the exhaust must be
c. Apply a second primer coat to the fitting socket.
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
d. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the fitting socket along with an even coat of
approved cement to the fitting socket.
Insulation should not be used on PVC
ƽ WARNING
or CPVC venting materials. The use of
e. Apply a second coat of cement to the pipe.
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
f. While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
sufficient cement was not applied and joint could
be defective.
Table 3D PVC/CPVC Vent Pipe, and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
g. Wipe excess cement from the joint removing ring
or beads as it will needlessly soften the pipe.
Item
Material
PVC Schedule 40, 80 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
Standard
Figure 3-7 Near Boiler PVC/CPVC Venting
Vent pipe
PVC Schedule 40
ANSI/ASTM D2466
ANSI/ASTM D2467
ANSI/ASTM F439
ANSI/ASTM D2564
ANSI/ASTM F493
Vent fittings PVC Schedule 80
CPVC Schedule 80
CPVC STARTER PIECE
Pipe Cement / PVC
Primer
CPVC
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/
primer must be ULC-S636 certified.
19
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Installation & Operation Manual
3 General venting
This product has been approved for use with polypropylene
vent with the manufacturers listed in Table 3E.
Polypropylene
Use only the adapters and vent system listed
in Tables 3E and 3F. DO NOT mix vent
systems of different types or manufacturers.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
ƽ WARNING
All terminations must comply with listed options in this manual
and be a single-wall vent offering.
For use of flex pipe, it is recommended to have the vent material
in 32°F or higher ambient space before bending at installation.
No bends should be made to greater than 45° and ONLY
installed in vertical or near vertical installations.
Installations must comply with applicable
national, state, and local codes. For
Canadian installation, polypropylene vent
must be listed as a ULC-S636 approved
system.
NOTICE
NOTICE
For support and special connections required, see the
manufacturer's instructions. All vent is to conform to standard
diameter and equivalent length requirements established.
Installation of a polypropylene vent system
should adhere to the vent manufacturer’s
installation instructions supplied with the
vent system.
Table 3E Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make
Model
Centrotherm Eco Systems
InnoFlue SW/Flex
Duravent (M & G Group)
PolyPro Single-Wall / PolyPro Flex
Figure 3-8 Near Boiler Polypropylene Venting
The installer must use a specific vent starter
NOTICE
adapter at the flue collar connection.
The adapter is supplied by the vent
manufacturer to adapt to its vent system.
See Table 3F for approved vent adapters.
All vent connections MUST be secured by
the vent manufacturer's joint connector
(FIG. 3-8).
NOTICE
Insulation should not be used on
polypropylene venting materials. The use
of insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
ƽ WARNING
JOINT CONNECTOR REQUIRED
AT ALL COMPONENT CONNECTIONS
OF VENT SYSTEM
POLYPROPYLENE ADAPTER
W/FLUE CLAMP
IMG00130
Table 3F Approved PolypropyleneTerminations
Duravent Polypro
Centrotherm InnoFlue SW
Sidewall
Retaining
Bracket*
Model
Polypropylene
Adapter
Joint
Connector
Joint
Connector
Sidewall Adapter* Polypropylene Adapter
Sidewall Kit*
ISAG0202 w/
IAFC02
ISAG0303 w/
IAFC03
ISAG0404 w/
IAFC04
IANS02
IANS03
IANS04
IATP0202
IATP0303
IATP0404
ISTAGL0202
ISTAGL0303
ISTAGL0404
2PPS-AD w/PPS-PAC 2PPS-LB 2PPS-HLK
3PPS-AD w/PPS-PAC 3PPS-LB 3PPS-HLK
4PPS-AD w/PPS-PAC 4PPS-LB 4PPS-HLK
55 - 85
110 - 285
399
* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 24).
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20
Installation & Operation Manual
3 General venting
(continued)
Installation of a stainless steel vent
system should adhere to the stainless
steel vent manufacturer’s installation
instructions supplied with the vent
system.
Stainless steel vent
NOTICE
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3G.
Use only the materials, vent systems, and
ƽ WARNING
terminations listed in Tables 3G and 3H.
Figure 3-9 Near Boiler Stainless Steel Venting
DO NOT mix vent systems of different
types or manufacturers. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
VENT
The installer must use a specific vent starter
NOTICE
adapter at the flue collar connection,
supplied by the vent manufacturer to
adapt to its vent system. See Table 3H for
approved vent adapters. Discard CPVC
starter piece.
REPLACE APPLIANCE
SECURED CPVC ADAPTER
WITH APPROPRIATE
STAINLESS STEEL ADAPTER
FROM TABLE 3H
Installations must comply with applicable
NOTICE
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
Table 3G Stainless Steel Vent Pipe and Fittings
Approved Stainless Steel Vent Manufacturers
Make
Model
Dura Vent (M & G Group)
FasNSeal Vent / FasNSeal Flex* Vent
Z-Flex (Nova Flex Group)
Z-Vent
Heat Fab (Selkirk Corporation)
Saf-T Vent
*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure
no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method,
see manufacturer’s instructions.
Table 3H Approved Stainless Steel (S.S.) Terminations and Adapters
ProTech
FasNSeal
Heat Fab
Saf-T Vent
Z Flex
Z-Vent
Model
Intake
Air
Termination
Intake
Air
Termination
Boiler
Adapter Termination
Flue
Boiler
Adapter Termination
Flue
Boiler
Flue
Intake Air
Adapter Termination Termination
303005
FSBS3
WH0002
9392
2SVAKA02
2SVSTP03
55 - 85
110 -285
399
303889
9314TERM
2SVSTEX0390
FSRC3(R.C)
5300CI
2SVSRCX03
303006
WH0003
2SVAKA03
FSBS4
303007
FSAIH04
303888
9492
WH0004
2SVSTP04
2SVSRCX04
9414TERM 2SVAKA04
2SVSTEX0490
FSRC4(R.C)
5400CI
21
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Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination – sidewall
Figure 4-1A PVC/CPVC/Polypropylene Sidewall
Termination of Air and Vent
Follow instructions below when
determining vent location to avoid
ƽ WARNING
TO BOILER
INTAKE AIR
CONNECTION
possibility of severe personal injury,
death, or substantial property damage.
FROM BOILER
VENT PIPE
CONNECTION
12"
A gas vent extending through an exterior
ƽ WARNING
wall shall not terminate adjacent to a wall
MIN
TO
POSSIBLE ORIENTATIONS
or below building extensions such as eaves,
parapets, balconies, or decks. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
OVER-
HANG
VENT / AIR
TERMINATION
12"
MIN
Determine location
GRADE OR
SNOW LINE
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 16
of this manual.
Table 4A Sidewall Vent Kit
Model Kit Number
Vent Size
55 - 110
110 - 285
399
KIT30044
KIT30045
KIT30046
2 inch vent
3 inch vent
4 inch vent
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.
If using the alternate sidewall termination:
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.
3. The air piping must terminate in a down-turned elbow
as shown in FIG. 4-1B. This arrangement avoids
recirculation of flue products into the combustion air
stream.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
Do not exceed the maximum lengths of the
ƽ WARNING
outside vent piping shown in FIG. 4-1B.
Excessive length exposed to the outside
could cause freezing of condensate in the
vent pipe, resulting in potential boiler
shutdown.
Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall
Termination of Air and Vent w/Field Supplied Fittings
Sidewall vent and air inlet terminations
must terminate in the same pressure zone.
ƽ WARNING
TO BOILER
INTAKE AIR
BIRD SCREEN
f. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
12” MIN
15” MAX
TERMINATION
PLATE
12”
MIN
BIRD SCREEN
GRADE OR
SNOW LINE
22
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Installation & Operation Manual
4 Sidewall direct venting
(continued)
Vent/air termination – sidewall
6. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
Figure 4-1C Alternate PVC/CPVC/SS/ Polypropylene Venting
Arrangement (if Space Allows) w/Field Supplied Fittings
TO BOILER
COUPLING
INTAKE AIR
CONNECTION
Figure 4-2A Clearance to Gravity Air Inlets
12” MIN
15” MAX
FROM BOILER
VENT PIPE
CONNECTION
BIRD SCREEN
12"
MIN.
12”
MIN
BIRD
SCREEN
GRADE OR
SNOW LINE
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
VENT / AIR
TERMINATION
Figure 4-1D Alternate SS Venting Arrangement -
Typical Stainless Steel Sidewall Termination of Air and
Vent w/Field Supplied Fittings, Utilizing a Hood Intake
12"
MIN.
12"
MIN.
BIRD SCREEN
Figure 4-2B Alternate Clearance to Gravity Air Inlets w/
Field Supplied Fittings
TO BOILER
INTAKE AIR
CONNECTION
12" (305 MM) MIN
15" (381 MM) MAX
FROM BOILER
VENT PIPE
CONNECTION
12”
MIN.
12" (305 MM) MIN
BIRD
SCREEN
(TYPICAL)
GRADE OR
SNOW LINE
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,
pages 22 - 24. Also maintain the following:
a. Vent must terminate:
12”
MIN.
12”
MIN.
• At least 6 feet from adjacent walls.
• No closer than 12 inches below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within
10 feet.
• No closer than 12 inches below or horizontally
from any door or window or any other gravity air
inlet.
Figure 4-3A Clearance to Forced Air Inlets
IF LESS
THAN 10’
VENT / AIR
TERMINATION
36"
MIN.
b. Air inlet must terminate at least 12 inches above
grade or snow line; at least 12 inches below the vent
termination; and the vent pipe must not extend
more than 24 inches vertically outside the building
as shown in FIG. 4-1B. Condensate could freeze and
block vent pipe.
FORCED AIR
INLET
7' MIN. ABOVE ANY
PUBLIC WALKWAY
c. Do not terminate closer than 4 feet horizontally
from any electric meter, gas meter, regulator, relief
valve, or other equipment. Never terminate above or
below any of these within 4 feet horizontally.
23
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4 Sidewall direct venting
Figure 4-3B Alternate Clearance to Forced Air Inlets w/
Field Supplied Fittings
Figure 4-4A PVC/CPVC Sidewall Termination Assembly
IF LESS
THAN 10’
36”
MIN.
VENT
AIR
FORCED AIR
INLET
CENTERLINE WIDTH
AIR PIPING
BIRD
VENT PIPING
SCREEN
VENT PLATE
VENT CAP
(TYPICAL)
7’ MIN. ABOVE ANY
PUBLIC WALKWAY
WALL PLATE
GALVANIZED
THIMBLE
Prepare wall penetrations
1. Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
Air pipe penetration:
Table 4B Sidewall Vent Centerline Dimensions
Model
Air
Vent Centerline Width
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the
vent pipe outer diameter:
• 4½ inch hole for 3 inch vent pipe
• 5½ inch hole for 4 inch vent pipe
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
151 - 200
286
3"
4"
3"
4"
5 5/8"
5 5/8"
Figure 4-4B Polypropylene Sidewall Termination Assembly
SIDEWALL
ADAPTER
(AIR)
WALL
PLATE
SIDEWALL
RETAINING
PLATE
2. For Polypropylene Only: Install the vent and air intake
sidewall adapters from Table 3F on page 20 into the vent
plate. Slide the sidewall retaining bracket down the
sidewall adapters flush to the vent plate (FIG. 4-4B).
3. For PVC/CPVC Only: Install the vent and air intake
piping through the wall into the vent plate openings.
Use RTV silicone sealant to seal the air pipe. Use the
cement/primer listed in Table 3D on page 19 to seal the
vent pipe.
VENT
PLATE
VENT
CAP
SIDEWALL
ADAPTER
(VENT)
4. Mount and secure the vent plate to the wall, using stainless
steel screws.
5. Seal all gaps between the pipes and wall. Seal around the
plate to the wall assuring no air gaps.
IMG00085
GALVANIZED
THIMBLE
6. Assemble the vent cap to the vent plate (see FIG.'s 4-4A
and 4-4B). Insert the stainless steel screws into the vent
cap screw hole openings and securely attach the vent cap
to the vent plate.
7. Seal all wall cavities.
8. PVC/CPVC terminations are designed to accommodate
any wall thickness of standard constructions per the
directions found in this manual.
9. Stainless steel terminations are designed to penetrate
walls with a thickness up to 9.25 inches of standard
construction.
24
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Installation & Operation Manual
4 Sidewall direct venting
(continued)
Prepare wall penetrations (Alternate -
Field Supplied Option)
Figure 4-5A Multiple Vent Terminations (must also
comply with Figure 4-1A)
1. Air pipe penetration:
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
VENT
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the vent
pipe outer diameter:
AIR
• 4½ inch hole for 3 inch vent pipe
• 5½ inch hole for 4 inch vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-4C.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
VENT / AIR
TERMINATION
4. Follow all local codes for isolation of vent pipe when
passing through floors or walls.
Figure 4-5B Alternate Multiple Vent Terminations w/Field
Supplied Fittings (must also comply with Figure 4-1B)
5. Seal exterior openings thoroughly with exterior caulk.
Figure 4-4C Alternate Sidewall Termination Assembly
w/Field Supplied Fittings
ELBOW
AIR PIPING
VENT PIPING
BIRD SCREEN
GALVANIZED
THIMBLE
ELBOW
BIRD SCREEN
SIDEWALL
TERMINATION PLATE
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).
All vent pipes and air inlets must terminate
ƽ WARNING
at the same height to avoid possibility
of severe personal injury, death, or
substantial property damage.
2. Place wall penetrations to obtain minimum clearance
of 12 inches between edge of air inlet and adjacent vent
outlet, as shown in FIG. 4-5A for U.S. installations. For
Canadian installations, provide clearances required by
CSA B149.1 Installation Code.
3. The air inlet of a Knight wall mount boiler is part of a
direct vent connection. It is not classified as a forced air
intake with regard to spacing from adjacent boiler vents.
25
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4 Sidewall direct venting
Sidewall termination – optional concentric vent
Description and usage
Lochinvar offers optional concentric combustion air and vent
pipe termination kits (Factory Kit #CVK3003 for 3" diameter
- models 155 - 199, #CVK3008 for 2" diameter - models 55 -
110, or #CVK3007 for 4" diameter - models 285 - 399). Both
combustion air and vent pipes must attach to the termination
kit. The termination kit must terminate outside the structure
and must be installed as shown below in FIG. 4-6.
3. Cut one (1) hole (5 inch diameter for #CVK3003
installations, 4 inch diameter for #CVK3008, or 7 inch
diameter for #CVK3007 installations) into the structure to
install the termination kit.
4. Partially assemble the concentric vent termination kit.
Clean and cement using the procedures found in these
instructions.
a. Cement the Y concentric fitting to the larger kit pipe
(FIG. 4-7).
b. Cement the rain cap to the smaller diameter kit pipe
(FIG. 4-7).
The required combustion vent pipe and fittings are listed in
Table 3D, on page 19 of this manual.
Figure 4-6 Concentric Sidewall Termination
Figure 4-7 Kit Contents - CVK3008 & CVK3003
(reference Table 3B on page 16)
Figure 4-8 Kit Contents - CVK3007 (reference Table
3B on page 16)
RAIN CAP
Sidewall termination installation
1. Determine the best location for the termination kit (see
FIG. 4-6).
6" (152 MM) TO 4" (102 MM) REDUCER
6" (152 MM) DIA.
2. Reference the Determine Location Section on page 22 of this
manual for general termination considerations.
6" (152 MM) DIA.
4" (102 MM) DIA.
"Y" CONCENTRIC
FITTING
6" (152 MM) DIA.
4" CONCENTRIC
VENT KIT
"FLEXIBLE" PIPE
COUPLING
26
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4 Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent models
Figure 4-9 2" and 3" Concentric Vent Dimensional
Figure 4-10 4" Concentric Vent Dimensional Drawing
Drawing (reference Table 3D on page 19)
(reference Table 3D on page 19)
"B" DIA.
"C" DIA.
"D"
3"
(76 MM)
"E"
"G"
"H" DIA.
"B" DIA. PVC
VENT / EXHAUST
"F"
A
B
C
D
E
F
G
H
60"
4"
6"
(152 MM)
21 1/8"
10"
7 5/8"
3"
(76 MM)
6 5/8"
(168 MM)
(537 MM) (254 MM) (194 MM)
(1524 MM) (102 MM)
5. Install the Y concentric fitting and pipe assembly through
the structure’s hole.
Instead of cementing the smaller pipe to
NOTICE
the rain cap, a field-supplied stainless steel
screw may be used to secure the two (2)
components together when field disassembly
is desired for cleaning (see FIG. 4-11).
Do not allow insulation or other materials
to accumulate inside the pipe assembly
when installing through the hole.
NOTICE
When using the alternate screw assembly
method, drill a clearance hole in the rain
6. Install the rain cap and small diameter pipe assembly
into the Y concentric fitting and large pipe assembly.
Ensure small diameter pipe is bottomed and cemented
in the Y concentric fitting for #CVK3003 and 3008
installations and fastened tightly into the rubber adapter
for #CVK3007 installations.
ƽ WARNING
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
7. Secure the assembly to the structure as shown in FIG.
4-12 using field-supplied metal strapping or equivalent
support material.
Do not operate the appliance with the rain
ƽ WARNING
Ensure termination location clearance
NOTICE
cap removed or recirculation of combustion
dimensions are as shown in FIG. 4-6.
products may occur. Water may also collect
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to
follow this warning could result in product
damage or improper operation, personal
injury, or death.
If assembly needs to be extended to allow
NOTICE
sidewall thickness requirement, the two (2)
pipes supplied in the kit may be replaced
by using the same diameter, field-supplied
SDR-26 PVC (D2241) pipe for CVK3003
and 3008, and standard schedule 40 PVC
for CVK3007. Do not extend dimension
D more than 60 inches (see FIG. 4-9 and
FIG. 4-10).
Figure 4-11 Rain Cap to Vent Pipe Alternate Assembly
If assembly needs to be reduced, dimension
NOTICE
D can be as short as possible.
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27
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Figure 4-12 Concentric Vent Sidewall Attachment
Multiventing sidewall terminations
DO NOT use field-supplied couplings to
extend pipes. Airflow restriction will occur
and may cause intermittent operation.
CAUTION
When two (2) or more direct vent appliances are vented near
each other, each appliance must be individually vented (see
FIG. 4-13). NEVER common vent or breach vent this appliance.
When two (2) or more direct vent appliances are vented near
each other, two (2) vent terminations may be installed as shown
in FIG. 4-13. It is important that vent terminations be made as
shown to avoid recirculation of flue gases.
8. Cement appliance combustion air and vent pipes to the
concentric vent termination assembly. See FIG. 4-12 for
proper pipe attachment.
9. Operate the appliance one (1) heat cycle to ensure
combustion air and vent pipes are properly connected to
the concentric vent termination connections.
12"
MINIMUM
VENT
COMBUSTION
AIR
Figure 4-13 Concentric Vent and Combustion Air Termination
28
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5 Vertical direct venting
Figure 5-1A PVC/CPVC/Polypropylene Vertical
Termination of Air and Vent
Vent/air termination – vertical
Follow instructions below when
ƽ WARNING
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” OF VENT
PIPE
determining vent location to avoid
possibility of severe personal injury, death
or substantial property damage.
Determine location
Locate the vent/air terminations using the following
BIRD SCREEN
(TYPICAL)
guidelines:
VENT
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page
16 of this manual.
COUPLING
(FIELD SUPPLIED)
6” MINIMUM
ABOVE ROOF /
SNOW LINE
2. Prepare the vent termination and the air termination
elbow (FIG. 5-1A) by inserting bird screens. Bird screens
should be obtained locally.
VENT OUTLET
3. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least
2 feet above any part of a building within 10 horizontal
feet.
12” MINIMUM
ABOVE AIR INLET
COMBUSTION
AIR
Figure 5-1B Stainless Steel Vertical Termination of Air
and Vent
4. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet from the center of the
vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” (610 MM)
OF VENT PIPE
5. The vent piping must terminate in an up-turned coupling
as shown in FIG. 5-1A. The top of the coupling must
be at least 1 foot above the air intake. When the vent
termination uses a rain cap as illustrated in FIG. 5-1B
maintain at least 36" (914 mm) above the air inlet. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than
2 feet (.6 m) apart and with the vent termination at least
1 foot for PVC and 3 feet for stainless steel, above the air
intake.
BIRD SCREEN
VENT
(TYPICAL)
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
COM,BUSTION
AIR
6. Maintain the required dimensions of the finished
termination piping as shown in FIG. 5-1A.
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
7. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
8. Locate terminations so they are not likely to be damaged by
foreign objects or subject to buildup of leaves or sediment.
Rooftop vent and air inlet terminations
must terminate in the same pressure
ƽ WARNING
Prepare roof penetrations
zone, unless vertical vent sidewall air is 1. Air pipe penetration:
set up as shown in the General Venting -
Vertical Vent, Sidewall Air Section.
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the
vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole.
29
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5 Vertical direct venting
Prepare roof penetrations (continued)
Vertical termination – optional
concentric vent
Description and usage
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 5-1A, page 29.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
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.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Multiple vent/air terminations
1. When terminating multiple Knight wall mount boilers,
terminate each vent/air connection as described in this
manual (FIG. 5-2).
Field supplied pipe and fittings are required to complete
the installation.
The required combustion air and vent pipe fittings are
listed in Table 3D, on page 19 of this manual.
Terminate all vent pipes at the same height
ƽ WARNING
Vertical termination installation
and all air pipes at the same height to
1. See Section 5, Vertical Direct Venting - Determine
Location (where applicable).
avoid possibility of severe personal injury,
death, or substantial property damage.
Figure 5-4 Concentric Vertical Termination
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” MINIMUM FROM EDGE OF AIR
INTAKE PIPE TO ADJACENT VENT
PIPE FROM ANOTHER BOILER
Figure 5-5 Do Not Install U-Bend to Rain Cap
Figure 5-3 Alternate Vertical Terminations with Multiple
Boilers
2. Cut one (1) hole (5 inch diameter for #CVK3003
installations or 4 inch diameter for #CVK3008 installations)
into the structure to install the termination kit.
3. Partially assemble the concentric vent termination kit.
Clean and cement following the cleaning procedures in
these instructions.
a. Cement the Y concentric fitting to the larger
diameter kit pipe (see FIG. 4-7, page 26).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG. 4-7, page 26).
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30
Installation & Operation Manual
5 Vertical direct venting
(continued)
Ensure termination height is above the
roof surface or anticipated snow level (12
inches in U.S.A. or 18 inches in Canada) as
shown in FIG. 5-4, page 30.
Instead of cementing the smaller pipe to
the rain cap, a field supplied stainless steel
screw may be used to secure the two (2)
components together when field disassembly
is desired for cleaning (see FIG. 4-9, page
27).
NOTICE
NOTICE
NOTICE
If assembly is too short to meet height
requirement, the two (2) pipes supplied
in the kit may be replaced by using the
same diameter, field supplied SDR-26 PVC
(D2241) pipe. Add standard schedule 40
PVC pipe for #CVK3007 Do not extend
dimension D more than 60 inches (see FIG.
4-9 and FIG. 4-10, page 27).
When using the alternate screw assembly
method, drill a clearance hole in the rain
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
ƽ WARNING
DO NOT use field-supplied couplings to
extend pipes. Airflow restriction will occur.
CAUTION
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.
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.
ƽ WARNING
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.
4. Install the Y concentric fitting pipe assembly through the
structure’s hole and field supplied roof boot/flashing.
Multiventing vertical terminations
When two (2) or more direct vent appliances are vented near
each other, each appliance must be individually vented (see
FIG. 5-7). NEVER common vent or breach vent this appliance.
When two (2) or more direct vent appliances are vented near
each other, two (2) vent terminations may be installed as shown
in FIG. 5-7. It is important that vent terminations be made as
shown to avoid recirculation of flue gases.
Do not allow insulation or other materials
NOTICE
to accumulate inside the pipe assembly
when installing through the hole.
5. Secure the assembly to the roof structure as shown
below in FIG. 5-6 using field supplied metal strapping or
equivalent support material.
Figure 5-7 Concentric Vent and Combustion Air Vertical
Termination
Figure 5-6 Concentric Vent Roof Installation
12”
MINIMUM
COMBUSTION
AIR (TYPICAL)
12” (18” FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24” ABOVE ROOF.
31
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5 Vertical direct venting
Alternate vertical concentric
venting
Figure 5-8 Concentric Vent Example 1
FLUE EXHAUST
This appliance may be installed with a concentric vent
arrangement where the vent pipe is routed through an
existing unused venting system; or by using the existing
unused venting system as a chase for vent and combustion
air routing.
SEAL
COMBUSTION AIR
AIR INLET
W/ SCREEN
EXISTING
12”
MIN.
Concentric Venting Arrangement
SEAL
SEALED
CAP
The venting is to be vertical through the roof. The annular
space between the O.D. of the vent pipe and the I.D. of the
existing unused venting system is utilized for the combustion
air source.
FLUE OUTLET
The minimum size of the existing vent system required to
achieve enough annular space for combustion air can be found
in Table 5A.
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
The upper and lower termination as well as any other unsealed
joints in the existing vent system must be sealed to ensure that
all combustion air is drawn from under the vent cap as shown
in FIG.’s 5-8 and 5-9.
Figure 5-9 Concentric Vent Example 2
FLUE EXHAUST
SEAL
COMBUSTION AIR
SEAL
Approved venting materials must be used as specified in Table
3D on page 19.
EXISTING
Follow all vent / air termination and clearance requirements
per this section to the appropriate example. Installation must
comply with local requirements and with the National Fuel
Gas Code.
SEAL
SEALED
CAP
FLUE OUTLET
The maximum allowable equivalent vent and air intake
lengths for this venting arrangement are to be determined
from the General Venting Section.
If an existing unused venting system is converted for use
with this method of concentric venting, the installer must
ensure that the existing venting system is clean and free from
particulate contamination that will harm this appliance and
cause increased nuisance calls or maintenance. See Table 1A
on page 10 for a list of corrosive contaminants and sources.
*For concept illustration only. Individual installations may
vary due to job site specific equipment.
Existing vent as a chase
Follow all existing termination and clearance requirements and
allowable pipe lengths. Use only approved venting materials
listed in the General Venting Section of this manual.
Two example scenarios of a concentric venting arrangement
are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
Figure 5-10 Existing Vent as a Chase
FLUE EXHAUST
AIR INLET
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
Minimum Existing
Vent / Air Inlet Size
SEAL
Vent / Chase Size
2"
3"
4"
4"
5"
7"
EXISTING
CAP
SEAL
FLUE OUTLET
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
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32
Installation & Operation Manual
6 Hydronic piping
System water piping methods
General piping information
The Knight wall mount is designed to function in a closed Basic steps are listed below along with illustrations on the
loop pressurized system not less than 12 psi. A temperature following pages (FIG.’s 6-3 through 6-12), which will guide
and pressure gauge is included to monitor system pressure you through the installation of the Knight wall mount boiler
and outlet temperature and should be located on the boiler (reference FIG.’s 6-1A and 6-1B).
outlet.
1. Connect the system return marked “Inlet”.
It is important to note that the boiler has a minimal
2. Connect the system supply marked “Outlet”.
amount of pressure drop and must be figured in when
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
sizing the circulators. Each boiler installation must have
an air elimination device, which will remove air from
the system. Install the boiler so the gas ignition system
components are protected from water (dripping, spraying,
etc.) during appliance operation for basic service of circulator
replacement, valves, and others.
4. Install a backflow preventer on the cold feed make-up water
line.
5. Install a pressure reducing valve on the cold feed make-
up water line, (15 psi nominal). Check temperature and
pressure gauge (shipped separately), which should read a
minimum pressure of 12 psi.
Observe a minimum of a 1/4 inch clearance around all
un-insulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
6. Install a circulator as shown on the piping diagrams in this
section. Make sure the circulator is properly sized for the
system and friction loss.
Low water cutoff device
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
7. Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
Chilled water system
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the 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.
10. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). The safety relief valve is
installed at the factory located on the left-hand side of the
boiler. Pipe the discharge of the safety relief valve to prevent
injury in the event of pressure relief. Pipe the discharge to a
drain. Provide piping that is the same size as the safety relief
valve outlet. Never block the outlet of the safety relief valve.
Freeze protection
Freeze protection for new or existing systems must use glycol
that is specially formulated for this purpose. This includes
inhibitors, which prevent the glycol from attacking the
metallic system components. Make certain to check that
the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once
a year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
See the *piping illustrations included in this section, FIG.’s 6-3
through 6-10 for suggested guidelines in piping the Knight wall
mount boiler with either zone valves or circulator pumps.
*Please note that these illustrations are
NOTICE
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
Use only inhibited propylene glycol
ƽ WARNING
solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
33
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Installation & Operation Manual
6 Hydronic piping
Near boiler piping components
11. Boiler purge valve:
1. Boiler system piping:
Factory supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
Boiler system piping MUST be sized per the pipe
requirements listed in Table 6A. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on 20 feet of piping,
4 - 90° elbows, and 2 - fully ported ball valves.
12. System temperature sensor:
Lochinvar supplies
a
system temperature sensor.
The sensor is to be installed in the heating loop
downstream from the boiler hot water piping and
heating loop junction. Typically the sensor will be
located far enough downstream to sense system diluted
water temperature.
2. Boiler circulating pump:
A Grundfos UPS15-58FC pump for Models 55 - 155
and a Grundfos UPS26-99FC pump for Models 199 -
399 will be provided by the factory as the boiler circulation
pump based on 20 feet of piping, 4 - 90° elbows, and 2 - fully
ported ball valves.
13. Indirect water heaters:
The Knight wall mount boiler may be piped to an indirect
water heater to heat domestic hot water with the space heat
transfer medium. As depicted in the piping diagrams on
page 38 thru 47, there are two options when utilizing an
indirect water heater.
Knight wall mount boilers are capable of controlling a
variable speed boiler circulator.
Variable speed
circulators MUST be sized to meet the specified
minimum flow requirements listed in FIG. 6-2 on page 36
at full speed.
A. The space heating piping will branch off to flow the
space heat transfer medium through a single wall
heat exchanger coil inside the indirect water heater.
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG. 6-2. Consult the indirect water heater operating
guide to determine flow characteristics for the selected
product used.
B. The indirect water heater is connected to the system
supply piping. A pump controlled by the Knight
(wall mount) boiler’s control will regulate the flow of
water through the indirect water heater. The indirect
water heater’s temperature will be regulated by the
Knight (wall mount) boiler’s control.
4. Boiler isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
The Knight wall mount boiler is pre-configured to control
the operation of the DHW pump with Domestic Hot Water
Prioritization programming. The DHW programming is
designed to control and balance the space heating
demand by switching between DHW and space heating.
5. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 6-3 through 6-10. Failure
to install check valves could result in a reverse flow
condition during pump(s) off cycle.
Lochinvar offers the Squire which is a series of indirect
water heaters. The Squire features a stainless steel vessel
with a single wall stainless steel heat exchanger.
6. Domestic indirect hot water isolation valves:
Field supplied.
Full port ball valves are
The National Standard Plumbing Code, the
required. Failure to use full port ball valves could
result in a restricted flow rate through the boiler.
ƽ WARNING
National Plumbing Code of Canada and the
Uniform Plumbing Code limit the pressure
of the heat transfer fluid to less than the
minimum working pressure of the potable
water system up to 30 psi maximum. Also,
the heat transfer fluid must be water or
other non-toxic fluid having a toxicity of
Class 1, as listed in Clinical Toxicology of
Commercial Products, 5th Edition.
7. Anti-scald mixing valve:
Field supplied.
An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F.
8. Unions:
Field supplied. Recommended for unit serviceability.
9. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
14. Y-Strainer:
Field supplied. A Y-strainer or equivalent multipurpose
strainer is recommended at the inlet of the heat exchanger
to remove system particles from older hydronic systems and
protect newer systems.
10. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
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34
Installation & Operation Manual
6 Hydronic piping
(continued)
Near boiler piping connections
Figure 6-1A Near Boiler Piping
Figure 6-1B Near Boiler Piping w/Low Loss Header
AIR
AIR
VENT
VENT
DOMESTIC
OUTLET
INLET
HOT WATER
DOMESTIC HOT
WATER PUMP
PUMP
OUTLET
INLET
INDIRECT
DOMESTIC
HOT WATER
TANK
M
O
CONDENSATE
DRAIN
R
F
INDIRECT
DOMESTIC
HOT WATER
TANK
CONDENSATE
DRAIN
O
T
BOILER
PUMP
TO SYSTEM
SYSTEM
PUMP
TO FLOOR
DRAIN
TO FLOOR
DRAIN
SYSTEM
PUMP
BOILER
PUMP
Y-STRAINER
(RECOMMENDED)
AIR
FILL VALVE
SEPARATOR
Y-STRAINER
EXPANSION TANK
(RECOMMENDED)
EXPANSION TANK
DRAIN (TYPICAL)
DRAIN VALVE
LOW LOSS HEADER
(TYPICAL)
Circulator sizing
The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer
to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.
35
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Installation & Operation Manual
6 Hydronic piping
Figure 6-2 Pressure Drop vs. Flow
MODEL
MODEL
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
MODEL
MODEL
199
285
0
5
10
15
20
FLOW
25
30
35
Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°
20°F Temperature Rise Applications
Pump
TACO
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
B & G
Armstrong
55
5
0.27
0.94
1.53
4.26
1.13
2.42
1.42
1"
1"
UPS 15-58FC (1)
UPS 15-58FC (1)
UPS 15-58FC (2)
UPS 15-58FC (3)
UPS26-99F
007
007
NRF-22
NRF-22
E7
E7
E7
E7
E7
E7
E11
85
8
110
155
199
285
399
10
15
19
27
38
1"
007
NRF-22
1"
007
NRF-22
1.25"
1.25"
1.5"
0011
0011
0012
NRF-36 (1)
NRF-36 (3)
PL-55
UPS26-99F
UPS26-99F
25°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model GPM
FT/HD
Grundfos
UPS 15-58FC (1)
UPS 15-58FC (1)
UPS 15-58FC (2)
UPS 15-58FC (3)
UPS26-99F
TACO
007
B & G
NRF-22
Armstrong
55
4
7
0.17
0.72
0.98
3.13
0.71
1.61
0.95
1"
1"
E7
E7
E7
E7
E7
E7
E11
85
007
NRF-22
110
155
199
285
399
8
1"
007
NRF-22
12
15
22
31
1"
007
NRF-36 (1)
NRF-36 (1)
NRF-36 (3)
PL-55
1.25"
1.25"
1.5"
0011
0011
0012
UPS26-99F
UPS26-99F
35°F Temperature Rise Applications
Pump
TACO
007
Minimum Pipe
Size
Model GPM
FT/HD
Grundfos
B & G
NRF-22
Armstrong
55
3
5
0.10
0.37
0.55
1.76
0.38
0.85
0.48
1"
1"
UPS 15-58FC (1)
UPS 15-58FC (1)
UPS 15-58FC (2)
UPS 15-58FC (3)
UPS 15-58FC (3)
UPS 15-58FC (3)
UPS26-99F
E7
E7
E7
E7
E7
E7
E7
85
007
NRF-22
110
155
199
285
399
6
1"
007
NRF-22
9
1"
007
NRF-36 (1)
NRF-36 (1)
NRF-36 (1)
NRF-36 (1)
11
16
22
1.25"
1.25"
1.5"
0010
0010
0011
Pumps listed in bold type are provided by the factory as the boiler circulation pump.
NOTICE
The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.
NOTICE
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36
Installation & Operation Manual
6 Hydronic piping
(continued)
Variable speed pump option
Table 6B Recommended Variable Speed Pumps
Variable speed pumping to maintain a set differential temperature (ΔT) between two (2) sensors allows for the following:
-
-
-
Automatic adjustment of the pump's performance to match the low of the system or zone
Eliminate velocity noise in the zone valve systems
Conserve energy
Since ΔT is directly releated to flow rate, the pump's speed continually adjusts to the required BTU per hour. In almost all
applications the design of the system was based on being able to maintain a certain ΔT and figured by using the universal
hydronics equation of BTU/hr = GPM x 500 x ΔT. Given that, any time there is a change to the heat load (i.e., warmer day
or greater heat loss from a structure) then the GPM should change to match the required BTU/hr. This is achieved when the
variable speed circulators automatically and continually adjust their GPM output (by varying speed) to match the required
BTU/hr output of the system, no matter the changes in heat load, while always maintaining the designed ΔT between a supply
and return sensor.
Variable speed pump setup
Before operation, ensure the following:
- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control
- Pump is set for external signal control (if applicable)
- Pump is set for linear output (if applicable)
- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module
will be required from the vendor
SMART SYSTEM / Multi-temperature loop
control option
Pump sizing and flow requirements are
based on 20 feet of piping, 4 - 90° elbows,
and 2 - fully ported ball valves.
NOTICE
The Knight wall mount boiler is capable of producing up
It is recommended that near boiler
to three (3) set point temperatures to meet different space
heating demands. When using more than one temperature
demand it is necessary to protect the lower temperature
loop from overheating. To help aid with this protection,
Lochinvar offers the Multi- Temperature Loop Control Board
Kit (RLY30086).
NOTICE
piping systems utilize Primary/Secondary
configurations as shown in FIG.’s 6-3
through 6-9 only. The use of other near
boiler piping configurations could result in
improper building and system flow rates
leading to inadvertent boiler high limit
shutdowns and poor system performance if
proper pump sizing and system flow rates are
not adhered to.
37
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Installation & Operation Manual
6 Hydronic piping
Figure 6-3 Single Boiler - Primary / Secondary Piping
PRESSURE
REDUCING VALVE
PRESSURE
BACKFLOW
GAUGE
PREVENTER
MAKE UP WATER
AIR
SEPARATOR
SYSTEM SUPPLY
SENSOR
MAY SUBSTITUTE LOW LOSS HEADER
TO
FROM
SYSTEM
SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
SYSTEM
BALL VALVE
(TYPICAL)
CIRCULATOR
Y-STRAINER
(RECOMMENDED)
FLOW CHECK
VALVE
EXPANSION
TANK
ANTI-SCALD
DOMESTIC
HOT WATER
CIRCULATOR
HOT
WATER
OUT
MIXING VALVE
DRAIN POINT
(TYPICAL)
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF
VALVE
BOILER
INDIRECT
DHW TANK
DRAIN
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
38
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Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-4 Single Boiler - Single Temperature with Zone Valves - DHW Priority
ZONE #1
PRESSURE
PRESSURE
GAUGE
REDUCING VALVE
ZONE #2
ZONE #3
ZONE #4
BACKFLOW
PREVENTER
ZONE VALVES
(TYPICAL)
MAKE UP
WATER
DIFFERENTIAL
PRESSURE
SYSTEM SUPPLY SENSOR
BYPASS VALVE
(RECOMMENDED)
AIR SEPARATOR
SYSTEM
CIRCULATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
HOT
Y-STRAINER
WATER
OUT
(RECOMMENDED)
DOMESTIC
HOT WATER
CIRCULATOR
FLOW CHECK
VALVE
DRAIN POINT
ANTI-SCALD
(TYPICAL)
MIXING VALVE
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF VALVE
UNION
(TYPICAL)
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
NOTICE
for all equipment and detailing required by local codes.
39
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Installation & Operation Manual
6 Hydronic piping
Figure 6-5 Single Boiler - Single Temperature Zoned with Circulators - DHW Priority
ZONE #1
PRESSURE
GAUGE
PRESSURE
REDUCING VALVE
ZONE #2
ZONE #3
ZONE #4
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
(TYPICAL)
MAKE UP
WATER
SYSTEM SUPPLY SENSOR
AIR SEPARATOR
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
HOT
WATER
OUT
Y-STRAINER
(RECOMMENDED)
DOMESTIC
DRAIN POINT
(TYPICAL)
ANTI-SCALD
HOT WATER
CIRCULATOR
MIXING
VALVE
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF VALVE
UNION
(TYPICAL)
BOILER
INDIRECT
DHW TANK
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
40
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Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-6 Multiple Boilers - Single Temperature Zoned with Zone Valves - DHW Priority
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
55 1-1/4" 1-1/2" 1-1/2" 2"
85 1-1/4" 1-1/2" 2" 2"
110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"
2"
2"
2"
2" 2-1/2" 2-1/2"
155
199
2"
2"
2" 2-1/2" 2-1/2" 3"
3"
4"
4"
5"
4"
4"
5"
5"
2" 2-1/2" 3"
4"
4"
5"
285 2-1/2" 2-1/2" 3"
399 2-1/2" 3" 4"
4"
4"
ZONE #1
PRESSURE
REDUCING
VALVE
BACKFLOW
PREVENTER
ZONE #2 ZONE #3
ZONE #4
PRESSURE
GAUGE
BALL VALVE
(TYPICAL)
ZONE VALVES
(TYPICAL)
MAKE UP WATER
DIFFERENTIAL PRESSURE
BYPASS VALVE
SYSTEM SUPPLY
SENSOR
AIR SEPARATOR
(RECOMMENDED)
SYSTEM
CIRCULATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
DRAIN POINT
(TYPICAL)
ANTI-SCALD
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
MIXING VALVE
HOT
WATER
OUT
DOMESTIC
HOT WATER
CIRCULATOR
BOILER
CIRCULATOR
COLD
WATER
IN
PRESSURE
RELIEF VALVE
BOILER 1
(LEADER)
BOILER 2
(MEMBER 1)
INDIRECT
DHW TANK
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
UNION
(TYPICAL)
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
41
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Installation & Operation Manual
6 Hydronic piping
Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
55 1-1/4" 1-1/2" 1-1/2" 2"
85 1-1/4" 1-1/2" 2" 2"
110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"
2"
2"
2"
2" 2-1/2" 2-1/2"
155
199
2"
2"
2" 2-1/2" 2-1/2" 3"
3"
4"
4"
5"
4"
4"
5"
5"
2" 2-1/2" 3"
4"
4"
5"
285 2-1/2" 2-1/2" 3"
399 2-1/2" 3"
4"
4"
4"
ZONE #1
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
ZONE #2 ZONE #3 ZONE #4
BACKFLOW
PREVENTER
MAKE UP
WATER
FLOW CHECK
VALVE
SYSTEM SUPPLY
(TYPICAL)
SENSOR
AIR SEPARATOR
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
TANK
BALL VALVE
(TYPICAL)
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
DRAIN POINT
(TYPICAL)
ANTI-SCALD
HOT
MIXING VALVE
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
WATER
OUT
DOMESTIC
HOT WATER
CIRCULATOR
BOILER
COLD
WATER
IN
CIRCULATOR
PRESSURE
RELIEF VALVE
BOILER 2
BOILER 1
(LEADER)
(MEMBER 1)
INDIRECT
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
DHW TANK
UNION
(TYPICAL)
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
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42
Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-8 Single Boiler - Multiple Temperature - DHW Priority
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
SYSTEM
WATER
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
WIRES TO
MAY SUBSTITUTE
LOOP SENSORS
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA
OR MAX. OF 12" APART
Y-STRAINER
120VAC TO PUMPS
MULTI-TEMP
BALL VALVE
(TYPICAL)
24V SIGNAL TO
MIXING VALVES
LOOP CONTROL
(RECOMMENDED)
SHIELDED CABLE TO
BOILER CONTROL
BOILER
DRAIN POINT
(TYPICAL)
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
HOT WATER
OUT
FLOW CHECK
VALVE
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
PRESSURE
RELIEF
VALVE
BOILER
UNION
DRAIN
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
IMG00190
Mixing valves are required for the protection of low temperature loops.
CAUTION
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
43
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Installation & Operation Manual
6 Hydronic piping
Figure 6-9 Multiple Boilers - Multiple Temperature - DHW Piped as a Zone
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
55 1-1/4" 1-1/2" 1-1/2" 2"
85 1-1/4" 1-1/2" 2" 2"
110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"
2"
2"
2"
2" 2-1/2" 2-1/2"
155
199
2"
2"
2" 2-1/2" 2-1/2" 3"
3"
4"
4"
5"
4"
4"
5"
5"
2" 2-1/2" 3"
4"
4"
5"
285 2-1/2" 2-1/2" 3"
399 2-1/2" 3" 4"
4"
4"
PRESSURE
WIRES TO
LOOP
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
SENSORS
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
WATER
SYSTEM
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
24V SIGNAL TO
MIXING VALVES
120VAC TO PUMPS
DRAIN POINT
(TYPICAL)
MULTI-TEMP TO
DOMESTIC
LOOP CONTROL
HOT WATER
CIRCULATOR
Y-STRAINER
(RECOMMENDED)
SHIELDED CABLE TO
BOILER CONTROL
FLOW
CHECK
VALVE
ANTI-SCALD
HOT WATER
MIXING VALVE
OUT
BOILER
COLD
WATER
IN
CIRCULATOR
PRESSURE
RELIEF
VALVE
BOILER
DRAIN
BOILER
INDIRECT
DHW TANK
TEMPERATURE /
PRESSURE GAUGE
UNION
(TYPICAL)
IMG00191
Mixing valves are required for the protection of low temperature loops.
CAUTION
NOTICE
NOTICE
44
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
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Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-10 Single Boiler - Full Flow - Single Temperature - Zoned with Zone Valves - DHW Priority
ZONE #1
PRESSURE
PRESSURE
GAUGE
REDUCING VALVE
ZONE #2
ZONE #3
ZONE #4
BACKFLOW
PREVENTER
ZONE VALVES
(TYPICAL)
MAKE UP
WATER
SYSTEM SUPPLY
SENSOR
DIFFERENTIAL
PRESSURE
BYPASS VALVE
(RECOMMENDED)
AIR SEPARATOR
EXPANSION
TANK
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
HOT
WATER
OUT
Y-STRAINER
(RECOMMENDED)
DOMESTIC
HOT WATER
CIRCULATOR
FLOW CHECK
VALVE
ANTI-SCALD
MIXING VALVE
BOILER
CIRCULATOR
COLD
WATER
IN
PRESSURE
RELIEF VALVE
DRAIN
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at
all times during boiler operation. If the minimum flow requirements cannot be met at any time the boiler
must be hydraulically separated from the system.
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.
NOTICE
45
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6 Hydronic piping
Figure 6-11 Single Boiler - Full Flow - Single Temperature Zoned with Valves - DHW Piped as a Zone
ZONE #1
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
ZONE #2
ZONE #3
ZONE #4
BACKFLOW
PREVENTER
ZONE VALVES
(TYPICAL)
MAKE UP
WATER
SYSTEM SUPPLY
SENSOR
DIFFERENTIAL
PRESSURE
BYPASS VALVE
(RECOMMENDED)
AIR SEPARATOR
EXPANSION
TANK
BALL VALVE
(TYPICAL)
HOT
WATER
OUT
Y-STRAINER
DRAIN POINT
(TYPICAL)
(RECOMMENDED)
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
BOILER
CIRCULATOR
PRESSURE
RELIEF VALVE
UNION
(TYPICAL)
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at
all times during boiler operation. If the minimum flow requirements cannot be met at any time the boiler
must be hydraulically separated from the system.
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.
NOTICE
46
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Installation & Operation Manual
6 Hydronic piping
(continued)
Figure 6-12 Single Boiler - Full Flow - Single Temperature Zoned with Circulators - DHW Piped as a Zone
ZONE #1
PRESSURE
GAUGE
PRESSURE
REDUCING VALVE
ZONE #2
ZONE #4
ZONE #3
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
(TYPICAL)
MAKE UP
WATER
SYSTEM SUPPLY SENSOR
ZONE CIRCULATORS
(TYPICAL)
AIR SEPARATOR
EXPANSION
TANK
Y-STRAINER
HOT
WATER
OUT
DOMESTIC
(RECOMMENDED)
HOT WATER
CIRCULATOR
DRAIN POINT
(TYPICAL)
ANTI-SCALD
BALL VALVE
(TYPICAL)
MIXING VALVE
COLD
WATER
IN
PRESSURE
RELIEF VALVE
UNION
(TYPICAL)
BOILER
INDIRECT
DHW TANK
DRAIN
TEMPERATURE /
PRESSURE
GAUGE
It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at
all times during boiler operation. If the minimum flow requirements cannot be met at any time the boiler
must be hydraulically separated from the system.
NOTICE
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.
47
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Installation & Operation Manual
7 Gas connections
Connecting gas supply piping
1. Remove the front access panel and refer to FIG. 7-1
to pipe gas to the boiler.
2. Support piping with hangers, not by the boiler or its
accessories.
a. Install a field supplied sediment trap / drip leg
upstream of the boiler gas controls.
The gas valve and blower will not support
ƽ WARNING
the weight of the piping. Do not attempt
to support the weight of the piping with the
boiler or its accessories. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
Figure 7-1 Gas Supply Piping
3. Purge all air from the gas supply piping.
4. Before placing the boiler in operation, check the boiler and
its gas connection for leaks.
a. Close manual main shutoff valve during any
pressure testing at less than 13 inches w.c.
b. Disconnect the boiler and gas valve from the gas
supply piping during any pressure testing greater
than 13 inches w.c.
Do not check for gas leaks with an open
ƽ WARNING
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.
MANUAL SHUTOFF VALVE
(FIELD SUPPLIED)
UNION
5. Use pipe sealing compound compatible with propane gases.
Apply sparingly only to male threads of the pipe joints so
that pipe dope does not block gas flow.
GAS SUPPLY
DRIP LEG
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7 Gas connections
(continued)
Failure to apply pipe sealing compound
as detailed in this manual can result
in severe personal injury, death, or
substantial property damage.
Natural gas:
ƽ WARNING
Pipe sizing for natural gas
1. Refer to Table 7A for pipe length and diameter. Based on
rated boiler input (divide by 1,000 to obtain cubic feet per
hour).
Knight wall mount boilers are typically
shipped ready to fire on natural gas.
Check boiler rating plate to determine
which fuel the boiler is set for. If set to
natural gas, it may be converted to LP
by installing an orifice (see page 13).
In order to operate on LP gas, an orifice
MUST BE installed. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
a. Table 7A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.5 inches w.c.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with
boiler on.
Use two wrenches when tightening gas
piping at boiler (FIG. 7-2), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
ƽ WARNING
• Minimum 4 inches w.c. with gas flowing (verify during
boiler startup).
2. Install 100% lockup gas pressure regulator in supply line if
inlet pressure can exceed 14 inches w.c. at any time. Adjust
lockup regulator for 14 inches w.c. maximum.
Figure 7-2 Inlet Pipe with Backup Wrench
Propane Gas:
Knight wall mount boilers are typically
ƽ WARNING
shipped ready to fire on natural gas. Check
boiler rating plate to determine which fuel the
boiler is set for. If set to natural gas, it may be
converted to LP by installing an orifice (see
page 13). In order to operate on LP gas, an
orifice MUST BE installed. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100%
lockup gas pressure regulator.
USE BACK UP WRENCH
TO PREVENT PIPE FROM
ROTATING
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. maximum pressure.
Maximum inlet gas pressure must not
NOTICE
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with
boiler on.
• Minimum 8 inches w.c. with gas flowing (verify during
boiler startup).
Ensure that the high gas pressure regulator
is at least 6 - 10 feet upstream of the
appliance.
ƽ WARNING
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7 Gas connections
Table 7A Natural Gas Pipe Size Chart
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet for 1/2 PSI
Nominal
Iron Pipe
Size (Inches)
10
175
369
697
1400
20
30
97
40
82
50
60
70
80
90
100
N/A
106
200
410
636
125
N/A
95
150
N/A
86
175 200
N/A N/A
120
256
477
974
N/A
155
292
595
923
N/A
141
267
543
830
N/A
128
246
502
769
N/A
121
236
472
707
N/A
113
210
441
666
1/2
3/4
1
205
384
789
174
328
677
79
74
179
369
564
164
333
513
974
149 138
308 287
472 441
871 820
1-1/4
1-1/2
2
2150 1500 1210 1020
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100
6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340
23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720
2-1/2
3
4
Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to
ƽ WARNING
determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an
orifice (see page 13). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could
result in severe personal injury, death, or substantial property damage.
Check inlet gas supply
CSA or UL listed flexible gas connections
3. Loosen the set screw one (1) full turn from inside the
pressure tap on top of the gas valve. Place the tubing of
the manometer over the tap once the set screw is
loosened as shown in FIG. 7-3.
NOTICE
are acceptable, but you must exercise
caution to ensure that the line has
adequate capacity to allow your boiler
to fire at full rate. Consult with local
codes for proper installation or service
procedures.
4. Slowly turn on the gas supply at the field installed
manual gas valve.
5. Turn on power at source..
DO NOT adjust gas valve outlet
pressure. The gas valve is factory-set
for the correct outlet pressure. This
setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death, or substantial property
damage.
ƽ WARNING
6. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to call for heat.
7. Observe the gas supply pressure as the burner fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
The gas piping must be sized for the proper flow and length
of pipe, to avoid excessive pressure drop. Both the gas
meter and the gas regulator must be properly sized for the
total gas load.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
If you experience a pressure drop greater than 1 inch w.c.,
the meter, regulator, or gas line is undersized or in need of
service. Perform the steps below when checking inlet gas
supply:
11. Shut off power at source.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
1. Shut off power at source.
13. Remove the manometer from the pressure tap on top of
the gas valve. Re-tighten the set screw inside the pressure
tap.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
50
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7 Gas connections
(continued)
When re-tightening the set screw, be
sure to tighten securely to prevent gas
leaks.
Gas Pressure
ƽ WARNING
The gas pressure must remain between 4 inches w.c. (natural),
8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP)
maximum during stand-by (static) mode and while in operating
(dynamic) mode. If an in-line regulator is used, it must be a
minimum of 10 feet from the Knight wall mount boiler. It is
very important that the gas line is properly purged by the gas
supplier or utility company. Failure to properly purge the
lines or improper line sizing, will result in ignition failure. The
problem is especially noticeable in NEW LP installations and
also in empty tank situations. This can also occur when a utility
company shuts off service to an area to provide maintenance to
their lines.
Do not check for gas leaks with an open
flame -- use the bubble test. Failure to
use the bubble test or check for gas leaks
can cause severe personal injury, death,
or substantial property damage.
14. Turn on the gas supply at the manual gas valve.
15. Turn on power at source.
16. Adjust the temperature set point on the control panel
of the SMART SYSTEM control module to the desired
water temperature so the appliance will call for heat.
Gas valve replacement
17. Check burner performance by cycling the system while
you observe burner response. The burner should
ignite promptly. Flame pattern should be stable. Turn
system off and allow burner to cool, then cycle burner
again to ensure proper ignition and flame
characteristics.
The gas valve MUST NOT be replaced with a conventional gas
valve under any circumstances. As an additional safety feature,
this gas valve has a flanged connection to the venturi and blower.
Failure to follow all precautions could
ƽ WARNING
result in fire, explosion, or death!
Figure 7-3 Inlet Gas Supply Check
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
A
LOOSEN SET SCREW [1] FULL TURN
THEN PLACE TUBING OVER PRESSURE TAP
IMG00163
DETAIL A
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8 Field wiring
ELECTRICAL SHOCK HAZARD – For 4. Wire the boiler pump as shown in FIG. 8-2.
ƽ WARNING
your safety, turn off electrical power supply
before making any electrical connections
to avoid possible electric shock hazard.
Failure to do so can cause severe personal
injury or death.
5. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 8-2.
6. To activate a system pump, wire as shown in FIG. 8-2. If
the motor is larger than 1/8 hp or 1.8 amps, you must isolate
with a relay.
Wiring must be N.E.C. Class 1.
NOTICE
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
Figure 8-2 Line Voltage Field Wiring Connections
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
ƽ CAUTION
Figure 8-1 Remove Bezel
Low voltage connections
1. Route all low voltage wires through the knockouts in the
bottom front right side, just under the control panel, as
shown in FIG. 8-3.
2. Connect low voltage wiring to low voltage connection board
as shown in FIG. 8-4 on page 55 of this manual and the
boiler wiring diagram.
REMOVE BEZEL
Figure 8-3 Routing Field Wiring
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.
LINE VOLTAGE
JUNCTION BOX
2. Connect 120 vac power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 8-2.
3. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 8-2).
LINE VOLTAGE
LOW VOLTAGE
KNOCKOUTS
CONNECTION
BOARD
LOW VOLTAGE
KNOCKOUTS
IMG00164
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52
Installation & Operation Manual
8 Field wiring
(continued)
3. If the TST20015 is not compatible with the indirect tank,
a tank thermostat can be used to control the boiler. The
tank thermostat should be installed per the manufacturers
instructions and wired to the DHW Thermostat terminals
on the Low Voltage Connection Board.
Thermostat
1. Connect the room thermostat or end switch (isolated
contact only) to heat/loop demand 1, 2, or 3, as shown
in FIG. 8-4.
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
Louver relay
1. If louvers need to operate when the boiler fires, they can
be controlled by this output. Connect these terminals to
a 24 vac relay coil, which is wired to operate the louvers
(FIG. 8-4).
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to
match total electrical power requirements of
connected devices. See device manufacturers’
specifications and thermostat instructions for
details.
Louver proving switch
1. When the operation of the louvers needs to be verified
before the boiler fires, remove the jumper wire from these
terminals and connect them to the normally open contacts
on its proving switch (FIG. 8-4).
Outdoor temperature sensor
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow of heat or cooling from other
sources.
Flow switch
1. A flow switch is used to guarantee flow through the boiler
before allowing it to fire. The flow switch must be installed
at the boiler outlet.
2. Route sensor wires through a knockout in the bottom
front right side of the boiler (see FIG. 8-3).
3. Connect outdoor temperature sensor (FIG. 8-4) to the
outdoor sensor terminals on the connection board to
enable outdoor reset operation of the Knight wall mount
boiler. If fixed temperature operation is required, do not
install outdoor sensor.
2. Remove the jumper wire from these terminals and connect
these terminals to the normally open contacts on the flow
switch (FIG. 8-4).
Variable speed system pump
If a variable speed pump is used in the primary loop, and a
0-10V signal is available from the pump speed control, this
signal can be used by the SMART SYSTEM control to anticipate
changes in the building heat load. By connecting this 0 - 10V
signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or
cascade) can modulate up and down as the primary flow
increases and decreases.
DHW thermostat
1. Connect storage indirect water heater (DHW) thermostat
(FIG. 8-4) to the DHW thermostat terminals on the
connection board. If a tank sensor is connected (see
DHW Tank Sensor below) the tank thermostat is ignored.
DHW tank sensor
1. By installing a tank sensor, the SMART SYSTEM control
can perform the tank thermostat function. The SMART
SYSTEM control automatically detects the presence of
this sensor and generates a DHW call for heat when
the tank temperature drops 6°F (3°C) below the tank
set point and finishes the call for heat when the tank
temperature reaches the tank set point.
Boiler pump speed output
This 0 - 10V output is available to control the speed of a variable
speed boiler pump. The SMART SYSTEM control will vary the
speed of this pump in order to maintain a minimum T across
the heat exchanger, as well as prevent high limit lockouts when
the flow in the primary loop is extremely low. Connect this
output to the 0 - 10V input on the boiler pump speed control.
2. The tank sensor included with the Lochinvar Squire
Indirect DHW tank (TST20015) is the only sensor
suitable for use with the SMART SYSTEM control.
Connect the sensor leads to the Tank Sensor terminals
on the Low Voltage Connection Board.
Rate output
This output provides a 0 - 10V signal that is proportional to the
firing rate of the boiler. This may be used by a BMS system to
monitor the actual rate of the boiler.
ModBus
Failure to use the correct sensor may
ƽ WARNING
result in the tank temperature being either
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
above or below the set point.
interface module.
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8 Field wiring
System supply sensor
Wiring of the cascade
1. By installing the system supply sensor into the supply
of the primary loop, the temperature of the primary
supply can be controlled. The SMART SYSTEM control
automatically detects the presence of this sensor, and
controls the boiler firing rate to maintain the system
supply temperature to the set point (if the outlet sensor
control is currently selected). If it is desired to control
the system return temperature, then program the SMART
SYSTEM control to use the inlet sensor as the controlling
sensor. See the Knight Wall Mount Service Manual for
instructions on how to do this. When the inlet sensor
is programmed as the controlling sensor, it is strongly
recommended that the SYSTEM SUPPLY sensor be
installed. DO NOT INSTALL THE SYSTEM SUPPLY
SENSOR INTO THE SYSTEM RETURN.
When wiring the boilers for Cascade operation, select one boiler
as the Leader boiler. The remaining boilers will be designated
as Members. See page 63 “Configuration of the Cascade” for a
detailed explanation of this procedure.
Connect the system supply sensor and outdoor air sensor (if
used) to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
location of the system supply sensor should be downstream
of the boiler connections in the main system loop (FIG.’s 6-4
and 6-6). The system supply sensor should be wired to the Low
Voltage Connection Board at the terminals marked for the
system sensor (see FIG. 8-4). The Leader control will use the
water temperature at the system supply sensor to control the
operation of the Cascade.
2. The TST2032 sensor provided with the boiler must be
used for the system sensor.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 8-4). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature set
point that is programmed into the control.
3. Connect these terminals to the system supply sensor
(FIG. 8-4).
Boiler management system
1. An external control may be connected to control either
the firing rate or the set point of the boiler. If the external
control uses a set of contacts to enable the boiler, connect
the contacts to the Heat/Loop Demand 1 terminals.
Otherwise, the SMART SYSTEM control will be enabled
by the 0-10V signal.
If a Thermostat, Zone Control enable output, or Building
Management System enable output is available, it should be
wired to the Low Voltage Connection Board on the Leader
boiler at the terminals marked for one of the Heat/Loop
Demands 1-3 (FIG. 8-4). If the boilers are to run continuously,
connect a jumper wire between the R and W terminals for the
Heat/Loop demand input. This will initiate a call for heat on
the Cascade.
2. Make sure the (-) terminal is connected to the (-) or
common output terminal of the external control, and
the (+) terminal is connected to the 0 - 10 vdc or (+)
terminal of the external control. Make sure the (-)
voltage is not below ground.
Communication between the Leader boiler and the Member
boilers is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to Cascade terminal A on each of the Low Voltage Connection
boards, and the other wire of the twisted pair to Cascade
terminal B on each of the Low Voltage Connection Boards.
Connect the shield wires to one of the shield terminals on the
Low Voltage Connection Boards (FIG. 8-4). If more than two
boilers are on the Cascade, daisy chain the wiring from the
Cascade terminals on the second boiler to the Cascade terminals
on the third boiler, then from the third to the forth, and so on.
The connections between boilers can be made in any order,
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 regardless of the addresses of the boilers. Try to keep each cable
whenever the boiler is locked out or the power is turned off. as short as possible.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down.
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8 Field wiring
(continued)
Figure 8-4 Low Voltage Field Wiring Connections
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Installation & Operation Manual
9 Condensate disposal
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493. For Canada use CSA or ULC certified
PVC or CPVC pipe, fittings, and cement.
Condensate drain
NOTICE
NOTICE
1. This boiler is a high efficiency appliance that produces
condensate.
2. The bottom of the boiler has a 1 1/4 inch pipe for
connection of the condensate trap (FIG. 9-1).
3. Slope condensate tubing down and away from the boiler
into a drain or condensate neutralizing filter. Condensate
from the Knight wall mount boiler will be slightly acidic
(typically with a pH from 3 to 5). Install a neutralizing
filter if required by local codes.
To allow for proper drainage on large
horizontal runs, a second line vent may be
required and tubing size may need to increase
to 1 inch.
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in
any other manner, condensate can exit from
the boiler tee, resulting in potential water
damage to property.
A Neutralizer Kit is available from the factory (Kit 3087).
4. Do not expose condensate line to freezing temperatures.
5. Use only plastic tubing or piping as a condensate drain
line (FIG. 9-1).
6. A condensate removal pump is required if the boiler is
below the drain. When installing a condensate pump, select
one approved for use with condensing boilers and furnaces.
The pump should have an overflow switch to prevent
property damage from condensate spillage. The switch
should be wired in series with the blocked drain switch
inside the boiler (see FIG. 10-1 on page 58).
Figure 9-1 Condensate Disposal
CONDENSATE DRAIN CONNECTION -
ROUTE TO FLOOR DRAIN OR
NEUTRALIZING FILTER USING
3/4" PVC TUBING
CONDENSATE
TRAP
REMOVABLE CAP
FOR CLEANING
TRAP
IMG00159
56
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Installation & Operation Manual
10 Start-up
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Check/control water chemistry
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets
in the system could occur, resulting in
substantial property damage.
Eliminate all system leaks. Continual fresh
ƽ WARNING
makeup water will reduce boiler life. Minerals
can build up in the heat exchanger, reducing
heat transfer, overheating the heat exchanger,
and causing heat exchanger failure.
Hardness less than 7 grains
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Purge air from water system
Chlorine concentration less than 200 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valves, in piping diagrams on pages 38 through 47).
Route the hose to an area where water can drain and
be seen.
b. Close the boiler or system isolation valve between
the purge valve and fill connection to the system.
c. Close zone isolation valves.
2. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are much lower.
3. Do not use the boiler to directly heat swimming pool or
spa water.
Test/replace freeze protection fluid
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
1. For systems using freeze protection fluids, follow fluid
manufacturer’s instructions.
f. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close the
zone isolation valves and proceed with the next zone.
Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch
that system pressure rises to correct cold-fill
pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open
the manual air vents in the system one at a time,
beginning with the lowest floor. Close the vent when
water squirts out. Repeat with remaining vents.
2. Freeze protection fluid must be replaced periodically due
to degradation of inhibitors over time. Follow all fluid
manufacturer’s instructions.
Freeze protection (when used)
1. Determine freeze protection fluid quantity using
system water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
3. When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid may leak before the water begins to
leak, causing concentration to drop, reducing the freeze
protection level.
2. Open 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. The freeze protection set points may be lowered when
freeze protection fluid is used (see the Knight Wall
Mount Service Manual).
Fill and test water system
3. Refill to correct pressure.
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close boiler drain valve and manual air vent.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a
residential system is 12 psi.
b. Pressure will rise when boiler is turned on and
system water temperature increases.
57
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Installation & Operation Manual
10 Start-up
Check for gas leaks
Inspect/fill condensate system
Before starting the boiler, and during
Inspect/check condensate lines and fittings
ƽ WARNING
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the front access
panel and smell the interior of the boiler
enclosure. Do not proceed with startup
if there is any indication of a gas leak.
Use an approved leak detection solution.
Repair any leaks at once.
1. Inspect the condensate drain line, condensate fittings and
condensate trap.
2. Fill condensate trap with enough water to make the ball
float (FIG. 10-1).
3. Loosen compression fitting (FIG. 10-1).
4. Slide condensate trap onto condensate drain at the bottom
of the unit.
DO NOT adjust gas valve outlet pressure.
The gas valve is factory set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
ƽ WARNING
5. Tighten compression fitting.
The condensate trap (FIG. 10-1) must have
the float ball in place during all times of
ƽ WARNING
boiler operation to avoid flue gas emission
from the condensate drain line. Failure to
ensure the float ball is in place could result in
severe personal injury or death.
Propane boilers only – Your propane
suppliermixesanodorantwiththepropane
to make its presence detectable. In some
instances, the odorant can fade, and the
gas may no longer have an odor. Before
startup (and periodically thereafter), have
the propane supplier verify the correct
odorant level in the gas.
ƽ WARNING
Figure 10-1 Condensate Trap
COMPRESSION
FITTING
Check thermostat circuit(s)
1. Disconnect the two external wires connected to each
of the heat/loop demand terminals on the connection
board.
CONDENSATE
DRAIN
FLOAT BALL
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.)
REMOVABLE CAP TO
CLEAN OUT TRAP
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board.
IMG00209
Clean/Inspect Trap Assembly
1. Remove the clean out cap on the bottom of the trap. Let the
condensate and any debris drain out.
2. Refill the trap according to the instructions above.
58
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Installation & Operation Manual
10 Start-up
(continued)
Check vent piping and air piping
Final checks before starting the boiler
1. Check for gas tight seal at every connection, seam of air
piping, and vent piping.
Read the Knight Wall Mount Service Manual to
familiarize yourself with SMART SYSTEM control
module operation. Read this manual, pages 60 and 61
for proper steps to start boiler.
Venting system must be sealed gas tight
ƽ WARNING
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
Verify the boiler and system are full of water and all
system components are correctly set for operation.
Check gas piping
Verify the preparation procedures of Section 10, pages 57
and 58 have been completed.
1. Check around the boiler for gas odor following the
procedure on page 48 of this manual (connecting gas supply
piping).
Ensure float ball is inside condensate trap (see FIG. 10-1).
Verify electrical connections are correct and securely
If you discover evidence of any gas leak,
ƽ WARNING
attached.
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.
Inspectventpipingandairpipingforsignsofdeterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
Start the boiler
Propane boilers – verify conversion
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
1. Read and follow the Operating instructions in FIG.’s 10-2
and 10-3 on pages 60 and 61.
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
If boiler does not start correctly
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to alter
the gas valve outlet pressure could result
in damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
1. Check for loose connections, blown fuse or service switch
off?
2. Is boiler water temperature above 200°F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
Knight wall mount boilers are typically
ƽ WARNING
5. Is incoming gas pressure less than 4 inches w.c.?
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.
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Knight Wall Mount Service
Manual.
Check system and boiler
Check water piping
1. Check system piping for leaks. If found, shut down
the boiler and repair immediately. (See WARNINGS
on pages 57 and 58 (startup) regarding failure to repair
leaks.)
Check flame and combustion
1. Shut off the main power to the boiler by placing the On/Off
switch in the OFF position.
2. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation
and cause heat distribution problems and noise.
2. Remove the flue temperature sensor from the flue pipe
connection. Note: Combustion measurements will be
made at this point.
3. Turn on the main power to the boiler by placing the On/Off
switch in the ON position.
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10 Start-up
Figure 10-2 Operating Instructions - Models 55 - 285
o
60
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Installation & Operation Manual
10 Start-up
(continued)
Figure 10-3 Operating Instructions - Model 399
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Installation & Operation Manual
10 Start-up
Check flame and combustion (continued)
Set space heating operation
Please note that the brackets ([]) denote
screen status.
NOTICE
Determine controlling sensor
For space heating systems, the temperature control can be
based on one of three sensors; the inlet, outlet, or system
supply sensor. The SMART SYSTEM control is programmed at
the factory to control the temperature of the outlet sensor. The
control will automatically switch to the system supply sensor
once it is connected. If it is desired to base the temperature
control on the inlet sensor, the appropriate parameter must
be changed in the control. See the Knight Wall Mount Service
Manual for a detailed explanation of this procedure.
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 11-1, page 70).
5. Locate the pinhole button below the RESET button on
the display board (FIG. 11-1). Insert a thin wire (such as
a paper clip) into the hole and press the button once and
hold for 5 seconds to place the boiler into Service Mode.
In Service Mode the boiler will fire at ignition speed and
will then modulate up to full fire.
Verify space heat circulator mode
6. Insert the probe from a combustion analyzer into the hole
left by the removal of the flue temperature sensor.
The Space Heating Mode controls both the system pump (if
connected), and the boiler pump. When the SMART SYSTEM
control receives a space heating call for heat, it turns on the
system pump. If the boiler is not heating an indirect DHW
(Domestic Hot Water) tank, and the set point is not met, it
also turns on the boiler pump. After the space heating call
for heat ends, the system pump continues to run for a short
period of time. The system pump can be programmed to run
continuously, except during outdoor shutdown. If the boiler
pump was running, it continues to run for a short period of
time as well. These pump delays are factory set to 30 seconds.
If different delays are desired, the appropriate parameters in
the control must be changed. See the Knight Wall Mount
Service Manual for a detailed explanation of this procedure.
7. Once the boiler has modulated up to full fire, measure
the combustion. The values should be in the range listed
in Table 10A below. The CO levels should be less than
150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference the Troubleshooting Section of the Knight Wall
Mount Service Manual for possible causes and corrective
actions.
Table 10A Flue Products Chart
Natural Gas
Propane
Adjust set point temperature(s)
CO2
O2
CO2
O2
Please note that the brackets ([]) denote
screen status.
8.0% - 10%
3.0% - 6.5% 10.0% - 11% 4.1% - 5.4%
NOTICE
8. Once the combustion analysis is complete, test the
safety shutoff device by turning the manual shutoff
switch to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Turn the manual
shutoff switch to the ON position and reset the control.
The NAVIGATION dial may be used during normal operation
to adjust the space heating and tank set point temperatures.
1. From the Status Screen press the NAVIGATION dial.
2. TurntheNAVIGATIONdialcounterclockwisetoselectthe
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.
9. Turn off power at source and replace the flue temperature
sensor into the flue pipe connection.
10. Place the boiler back into normal operation.
You must replace the flue gas temperature
ƽ WARNING
sensor to prevent flue gas spillage into
the room. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
7. If the RIGHT SELECT [SAVE] key is not pressed, the
new settings will be discarded.
62
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Installation & Operation Manual
10 Start-up
(continued)
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
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
modulate to bring the outlet temperature to the DHW boiler 8. Turn the NAVIGATION dial to adjust the month. Press the
set point. The maximum firing rate may be limited in this
mode if desired.
NAVIGATION dial.
9. Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
In Zone Mode it is assumed that the indirect DHW tank is
piped as a zone on the primary loop. When a DHW demand
begins, the control will turn on the DHW pump output, and
raise the system temperature set point to the DHW boiler set
point (if higher). The boiler pump will be turned on. The
system pump may be forced on, forced off, or not changed,
depending on the System Pump Mode selected (reference
the Knight Wall Mount Service Manual for details). In this
mode, any low temperature zones (such as radiant heating)
may need additional controls to limit the water temperature
sent to those zones.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
11. Press the RIGHT SELECT [HOME] key.
The internal clock does not adjust for
Daylight Savings Time and therefore, will
NOTICE
require a manual adjustment.
The clock is automatically updated whenever a PC is connected
and the Win_Pro-Installer program is started.
Set DHW boiler target temperature
Configuration of the cascade
When in the DHW Mode, the control will modulate to
maintain the boiler outlet temperature or system supply
temperature to a set point. This set point is set at the factory
to 180°F. If a different set point is desired, the appropriate
parameter in the control must be changed. See the Knight
Wall Mount Service Manual for a detailed explanation of this
procedure.
Please note that the brackets ([]) denote
screen status.
NOTICE
When installed in a Cascade system, the individual controls must
be programmed for cascade operation. This is accomplished by
accessing the control parameters.
Press the [MENU] key for at least five (5) seconds. Input the
Installer code as described in the Knight Wall Mount Service
Manual. Once the control parameters have been accessed, use
the NAVIGATION dial to select the Control Mode parameters.
Press the NAVIGATION dial to access these parameters.
Set maximum DHW fan speed
If the rated input of the indirect tank is less than the maximum
output of the boiler, change the maximum DHW fan speed
setting to limit the boiler output accordingly, see the Knight
Wall Mount Service Manual for a detailed explanation of this
procedure.
Rotate the NAVIGATION dial to select the parameter Cascade
Address. Press the NAVIGATION dial to access this parameter.
Each appliance in the Cascade system must be programmed
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.
Set clock
Please note that the brackets ([]) denote
screen status.
NOTICE
The SMART SYSTEM control has a built-in clock that it
uses for its night setback feature and for logging events. This
clock must be set when the boiler is installed, and anytime the
boiler has been powered off for more than 4 hours. Use the
following procedure to set the clock:
Press the RIGHT SELECT [HOME] key to upload the address
into the control. Repeat this procedure for all boilers in the
Cascade, designating the Leader control and the Member
controls.
1. Press and hold the LEFT SELECT [MENU] key for at
least 5 seconds.
2. The display changes to read [PASSWORD],
with four (4) zeros below it.
3. Press the RIGHT SELECT [SAVE] key.
4. The display will then show a menu with the time and
date and temperature unit.
5. Press the NAVIGATION dial twice.
6. Turn the NAVIGATION dial to adjust the hours. Press
the NAVIGATION dial.
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11 Operating information
General
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.
How the boiler operates
The Knight wall mount boiler uses an advanced stainless
steel heat exchanger and electronic control module that
allows fully condensing operation. The blower pulls in air
and pushes flue products out of the boiler through the heat
exchanger and flue piping. The control module regulates
blower speed to control the boiler firing rate. The gas valve
senses the amount of air flowing into the boiler and allows
only the right amount of gas to flow.
DHW priority
The SMART SYSTEM control allows the connection of a DHW
thermostat or tank sensor to the low voltage connection board.
When a tank sensor is connected, the DHW thermostat input
is ignored. When a boiler is programmed for DHW Normal
Mode, the maximum firing rate can be limited to match the
input rating of the indirect tank coil.
How the control module operates
DHW / space heating (SH) cycling
If a DHW call for heat is received while a space heating call is
in progress, and the DHW is in Normal Mode, the control will
start the DHW pump and shut the boiler pump off. The system
pump will remain on. For stand-alone boilers, if the space
heating call is still active while the DHW call is in operation, the
control will wait for 30 minutes (time adjustable by installer)
then it will switch back to the space heating demand. There is
a timer to switch from space heating to DHW and a timer to
switch from DHW to space heating. The control will switch
back and forth until one of the heat demands end.
The SMART SYSTEM control module receives inputs
from boiler sensors and external devices. The control
module activates and controls the blower and gas valve to
regulate heat input and switches the boiler, Domestic Hot
Water (DHW), and system pumps on and off as needed.
The user programs the module to meet system needs by
adjusting control parameters. These parameters set operating
temperatures and boiler operating modes. Boiler operation
can be based on boiler outlet water temperature, boiler inlet
water temperature, system temperature, a 0 - 10V signal, or
Modbus, depending on the parameter settings.
Programmable controlling sensor
The control module is programmed to use the outlet sensor
as the control sensor by default. If a system supply sensor
is connected, the control automatically uses it as the control
sensor. The control sensor can be changed by the installer to
the inlet sensor. If the inlet sensor is chosen as the controlling
sensor, it is recommended that the system supply sensor
be installed in order to provide the best control of the inlet
temperature.
Control inputs and outputs
Space heating demands
There are three (3) heat/loop demand connections available
on this control. These inputs tell the boiler to provide water
for space heating. Each demand connection has its own set
point and outdoor air reset curve. When multiple demands
have a call for heat the control will give priority to the
demand with the highest set point.
Anti-cycling
After the burner turns off, the control will delay the next burner
cycle for a set time period (time is adjustable by the installer).
The time delay will be bypassed if the inlet water temperature
drops too far during the delay.
Example: Assume that both Heat/Loop Demand 1 and Heat/
Loop Demand 2 have a call for heat. Heat/Loop Demand 1
has a set point of 110°F. Heat/Loop Demand 2 has a set point
of 140°F. The boiler will regulate the system temperature to
140°F until Heat/Loop Demand 2 has been satisfied. Once
Heat/Loop Demand 2 has been satisfied the boiler will
provide 110°F water to the system.
Boiler and system pump control
The boiler pump will run whenever the burner is firing, unless
the DHW is programmed for Normal Mode and the boiler is
heating the DHW tank. The boiler pump will run during Freeze
Protection Mode as well. It will continue to run for a short time
after the burner turns off or the Freeze Protection Mode ends.
When multiple temperature loops are
ƽ CAUTION
used, thermostatic mixing valves are
required for the protection of any low
temperature loops.
The system pump will run whenever there is a space heating call
for heat, or the boiler goes into Freeze Protection Mode. It may
be programmed to run during a DHW call for heat when the
DHW is programmed for Zone Mode. It will continue to run
for a short time after the end of the heat demand or the Freeze
Protection Mode. The system pump can be programmed to run
continuously if desired, except during outdoor shutdown and/
or a DHW call for heat.
0 - 10V input (set point or power)
The Knight wall mount boiler can be controlled by a Building
Management System (BMS) using a 0 - 10 vdc signal. The
control can be configured by the installer to use this signal to
either control set point or firing rate.
SMART SYSTEM Multi-temp loop control
The Knight wall mount boiler is capable of producing up Temperature control
to three (3) set point temperatures to meet different space
heating demands. This device controls the temperatures
of up to three (3) separate loops, based on the settings for
the three (3) heat/loop demands (reference Lochinvar kit
RLY30086).
Modulation
The Knight wall mount boiler is capable of modulating its firing
rate from a minimum of 20% to a maximum of 100%. The
firing rate is dictated by the call for heat (i.e., space heating or
domestic hot water), the heating load, ramp delay (if enabled),
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64
Installation & Operation Manual
11 Operating information
(continued)
Ramp delay
Protection features
For systems with lower flow, the SMART SYSTEM can limit
the firing rate (when enabled) when a space heating call for
heat starts, or when switching from a DHW call for heat to a
space heating call for heat. There are six (6) limits that can be
programmed, as well as six (6) time intervals corresponding
to each limit. The sixth limit will also limit the firing rate for
the rest of the call for heat.
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F the control will shut the unit down
until it cools off.
Gradient limiting
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F the control will reduce the maximum fan speed. If
the flue temperature exceeds 240°F the control will shut the
unit down. The unit will restart automatically once the flue
temperature drops 25°F and the minimum off time has expired.
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate to
its lowest setting.
Outdoor air reset
With the outdoor air sensor connected, the control module
will calculate the set points of the three (3) space heating
demands based on the programmed reset curves. The
installer can change the slope of the reset curves by several
adjustable parameters. The user can limit the maximum set
point for the system using the space heating set points.
The control monitors the temperature difference between the
inlet and the outlet sensor. If this difference exceeds 55°F the
control will reduce the maximum fan speed. If the temperature
difference exceeds 60°F the control will shut the unit down. The
unit will restart automatically once the temperature difference
has dropped below 55°F and the minimum off time has expired.
Boost function
Freeze protection
If outdoor air reset is active, and any space heating demand
has been active continuously for a set period of time (time
adjustable by installer) and there has been no DHW demands,
the control will increase the set point of that demand by a
fixed number of degrees (adjustable by installer). This process
will continue until the space heating demand ends, the set
point reaches the programmed set point or a maximum of
20 increases has occurred. Once the system heat demand is
satisfied, the set point will revert to the value determined by
the reset curve.
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the SMART SYSTEM control
module provides some protection for the boiler only -- not for
the system.
•
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F:
Below 45°F, the boiler and system pumps operate
constantly.
•
•
Below 37°F, the boiler turns on and runs at 20% of rate.
Boiler and pumps turn off if boiler water
temperature rises above 45°F.
Lower temperatures may be programmed for
systems with anti-freeze solutions (see the Knight Wall
Mount Service Manual.
Night setback
The controller may be programmed to reduce the space
heating and DHW set points during certain times each week.
Seven different start and stop times may be programmed for
the space heating setback and seven start and stop times for
the DHW setback. Any night setback scheduled within the
next seven (7) days can be temporarily bypassed if desired.
•
When system return temperatures
NOTICE
are maintained below the dew point,
condensation will form on the inside of the
boiler jacket causing some internal sheet
metal components to rust.
Flame current support
To prevent nuisance shutdowns when the boiler is firing at
minimum rates, the control will increase the firing rate when
the flame signal drops too low.
This feature of the SMART SYSTEM control
module does not eliminate the possibility
of freezing. The installation must still
use recognized design, installation and
maintenance practice to prevent freeze
potential for the boiler and system.
ƽ CAUTION
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11 Operating information
Connections are provided on the connection board for
external limits such as flow switch, low water cutoff, gas
pressure switches, and a louver proving switch. The SMART
SYSTEM will shut off the burner and inhibit relighting
whenever any of these external limits open.
Monitor external limits
High limit operations
The Knight wall mount is equipped with adjustable automatic
reset and manual reset high limits. The automatic reset high
limit has a maximum set point of 200°F and the manual reset
high limit has a maximum set point of 210°F.
When the outlet temperature exceeds 200°F, the automatic
high limit action occurs. The boiler shuts down until the outlet
water temperature cools below 190°F, and a 60 second timer
has expired. If the outlet temperature continues to increase, the
manual reset high limit action will occur at 210°F.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
High limit test procedure
Run-time and cycle counting
Please note that the brackets ([]) denote
screen status.
NOTICE
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler is
firing in the Space Heating Mode. The other timer monitors
the time the boiler is in the DHW Mode.
1. Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
2. From the Status Screen, press the NAVIGATION dial to
access the Set Points Screen.
3. Press the LEFT SELECT (LIMITS) key.
4. Select the manual reset high limit (MRHL) by rotating
the NAVIGATION dial counterclockwise, then press
the NAVIGATION dial.
5. Decrease the set point of the MRHL to below the current
outlet temperature (or to its minimum setting, whichever
is higher) by turning the NAVIGATION dial
counterclockwise.
6. Press the RIGHT SELECT [SAVE] key.
7. Press the RIGHT SELECT [HOME] key. The new
parameter will upload to the control.
8. If the current outlet temperature is above the new MRHL
set point, the MRHL will function causing boiler lockout.
If this occurs, skip to Step 11.
The control uses two (2) ignition counters to monitor the
amount of boiler cycles. The first counter counts all ignitions
of the control. The second counter counts only ignition
attempts that have failed.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when either
a set time frame has expired, or a set amount of running
hours or cycles has expired (all adjustable by the installer).
The display will show a Maintenance Required screen. The
installer's name and phone number can be programmed into
the control. This information will appear on the Maintenance
Required screen. The service reminder notification can be
reset or disabled by the installer.
9. If the current outlet temperature is below the new MRHL
set point, locate the pinhole (SERVICE button) below the
RESET button on the display board. Insert a thin probe
(such as a paper clip) into the hole and press the button
continuously for five (5) seconds to place the boiler into
Service Mode. In Service Mode, the boiler will fire at
ignition speed and will then modulate up to full fire.
10. Once the outlet temperature rises up to the MRHL set
point, the MRHL will function, causing the boiler to shut
down and lock out.
Error logging
The control will hold in memory the last 10 lockouts as
well as the last 10 blockings. The date and time of the
occurrence will be recorded as well. Only the 10 most current
occurrences of each will be held in memory.
Boiler temperature regulation
Operating temperature (target)
11. Repeat Steps 2, 3 and 4.
12. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
13. Repeat Steps 6 and 7.
14. Press the RESET button to clear the lockout.
15. If needed, press the RIGHT SELECT [STOP] key to exit
Service Mode.
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.
66
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Installation & Operation Manual
11 Operating information
(continued)
Low water cutoff protection
Sequence of the cascade
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the flow rate is too low or the outlet
temperature too high, the control module modulates and
shuts the boiler down. This ensures boiler shutdown in
the event of low water or low flow conditions.
To equalize the run time of all boilers on the Cascade, the firing
sequence will automatically be changed at set intervals. The
sequence will change every hour during the first 24 hours, after
that the sequence will be changed once every 24 hours. The
switching on/off sequence will be as follows:
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).
TIME
Start
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
1 hour
2 hours
M2-M3-M4-M5-M6-M7-L-M1
Outdoor reset operation, if used
If a boiler is used to heat an indirect DHW tank, or locks out,
it will automatically be given the lowest priority for the rest of
that 24 hour period.
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
DHW, Night Setback, and Ramp Delay operation with
cascade
See the Knight Wall Mount Service Manual to change the
settings.
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.
Reset curve
The reset curve looks at outdoor air temperature and adjusts
the set point.
Cascade
When multiple boilers are installed, they can be wired
together in a cascade sequence. A maximum of eight boilers
can be controlled from a single control. In this application
one boiler would be designated as the Leader control and all
others would be designated as Member controls. The Leader
control can be programmed to use Lead/Lag or Efficiency
Optimization control methods.
The DHW boiler will adjust its set point to the programmed
DHW boiler set point and will adjust its firing rate to maintain
this. Once the DHW call has been satisfied, the Leader control
will place that boiler back into the Cascade sequence.
Switching of the boiler between DHW operation and SH
operation when there is a call for both does not occur in
Cascade Mode.
Once the Leader boiler receives a call for heat from a room
thermostat, BMS, or Modbus, the control will determine what
the set point will be. If outdoor air reset is desired, connect
the outdoor air sensor to the terminals on the Low Voltage
Connection Board on the Leader boiler. The set point will be
calculated based on the programmed reset curve parameters.
See the Knight Wall Mount Service Manual to program the
reset curve. If outdoor air reset is not desired, do not connect
the outdoor air sensor. A fixed temperature set point can be
programmed into the control. See page 62 of this manual to
program the set point.
When DHW is programmed for Zone Mode, connect the DHW
thermostat or tank sensor to the Leader boiler. When a DHW
call is received, the Leader will modulate the entire Cascade to
bring the system supply temperature up to the DHW boiler set
point.
Night Setback operation of the boilers within the Cascade is
available. Programming of the Night Setback will be done
through the Leader boiler. Refer to the Knight Wall Mount
Service manual for information regarding Night Setback.
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.
Ramp Delay operation of the boilers as described in the Knight
Wall Mount Service Manual is not active when the boilers are
part of a Cascade system.
67
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Installation & Operation Manual
11 Operating information
Sequence of operation
OPERATION
DISPLAY
1. Upon a call for heat, the gas pressure switch(es) must be closed.
2. Once the gas pressure switch(es) are closed, the control turns
on the appropriate pumps (system and boiler pumps for space
heating, DHW pump for DHW). The flow switch and/or LWCO
must close.
3. The control turns on power to the louver relay. The louver
proving switch, air pressure switch, and blocked drain switch
must close.
4. The control starts the prepurge cycle by initiating the blower.
5. The control starts the trial for ignition by firing the spark
electrode and opening the gas valve.
6. If flame is not detected after the sparking ends, the control will
perform a postpurge, then start another prepurge cycle and try to
light the burner again. The control will perform a total of 4
attempts before locking out.
7. If flame is detected, it holds the firing rate steady for a few
seconds to let the flame stabilize, then it begins to modulate the
firing rate based on a set point or some other command (such
as a 0-10V BMS signal).
68
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Installation & Operation Manual
11 Operating information
(continued)
OPERATION
DISPLAY
8. If the space heating call for heat is active, and the tank thermostat
or sensor starts a DHW call for heat, the boiler will switch to the
DHW mode. If programmed for normal DHW operation (not as a
zone), the DHW pump will turn on first, then the boiler pump will
turn off (boiler and DHW pump operation briefly overlap to ensure
flow is maintained through the unit). This will divert the boiler’s
outlet water from the heating system and send it to the tank coil
instead. The control will then modulate to maintain the outlet
temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one of
them is satisfied.
10. Once both calls for heat are satisfied, the control will turn off
the burner. The blower will continue to run during the postpurge
period.
11. Any pumps that are running will continue to run for their respective
pump delay times before turning off, unless programmed to
remain on continuously. A 60 second anti-cycle period will start,
which will delay any new call for heat until it times out.
12. In Standby, ready to start a new cycle.
Access modes
Saving parameters (reference the Parameter Table in
the Knight Wall Mount Service Manual)
User
Please note that the brackets ([]) denote
screen status.
NOTICE
The user can adjust space heating and tank target temperatures
by pressing the NAVIGATION dial when “SETPOINTS” is
flashing at the bottom of the display. The date and time, and
the temperature units can also be changed (see page 63).
To save parameters and exit programming:
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
Installer
Most parameters are available only to the installer, accessible
by entering the installer password, see the Knight Wall Mount
Service Manual.
To enter a parameter and continue programming:
Press the RIGHT SELECT [SAVE] key 1 time to return to the
parameter listings; press again to return to the menu listings.
Remember to press the RIGHT SELECT [HOME] key when
finished programming in order to save the changes made.
See the Knight Wall Mount Service Manual for a detailed
description of parameters and access modes.
69
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Installation & Operation Manual
11 Operating information
Knight wall mount boiler control module
Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Figure 11-1 Control Panel
NAVIGATION DIAL
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
70
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Installation & Operation Manual
11 Operating information
(continued)
Figure 11-2 Status Display Screen
B
A
(CALL FOR
HEAT)
(BOILER
STATUS)
C
(OPERATIONAL
INFORMATION)
F
D
(LEFT SELECT
KEY)
(RIGHT SELECT KEY)
E
(NAVIGATION DIAL)
Status Display Screens
Section
Display
Description
The unit has not received a call for heat from a remote thermostat nor
has it received a call for heat from a DHW thermostat.
STANDBY
START
The unit has begun a burn cycle and is checking all safety circuits.
The unit has initiated a prepurge period on a call for heat.
PREPURGE
IGNITION
The unit has begun a spark period to ignite the main burner.
The unit has fired and is running at the displayed percentage.
A
%
(Boiler Status
Bar)
The call for heat has been satisfied and the unit runs the fan for an
additional postpurge period to clear the combustion chamber and
vent system of residual flue products.
POSTPURGE
SHUTDOWN
The unit has been placed in the OFF position.
SETPOINT MET
The controlled temperature has exceeded its set point and its offset.
The unit has detected a condition that has temporarily interrupted
the current call for heat.
BLOCKED
Heat/Loop Demand 1 has a call for heat.
Heat/Loop Demand 2 has a call for heat.
Heat/Loop Demand 3 has a call for heat.
B
The tank thermostat or sensor has a call for heat.
Indicates which heat/loop demand shows priority.
The unit is being controlled by a 0 - 10V BMS signal.
The member unit is supplying heat while in Cascade Mode.
(Call for Heat
Indicators)
71
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Installation & Operation Manual
11 Operating information
Status Display Screens (cont’d)
Section
Display
Description
SYSTEM:
The temperature read by the system supply sensor (if connected).
TANK:
The temperature read by the tank sensor (if connected).
The temperature read by the outdoor sensor (if connected).
OUTDOOR:
INLET TEMP:
OUTLET TEMP:
DELTA T:
The temperature read at the inlet to the heat exchanger.
The temperature read at the outlet of the heat exchanger.
The temperature difference between the inlet and the outlet of the
heat exchanger.
FLUE TEMP:
The temperature read by the flue sensor.
FLAME CURRENT:
The current measured by the flame sense circuit.
FAN SPEED:
The speed of the combustion blower.
BOILER PUMP:
SYSTEM PUMP:
DHW PUMP:
The status of the boiler pump output.
The status of the system pump output.
The status of the DHW pump output.
C
(Operational
Information)
BMS VOLTAGE:
The voltage received from a BMS system.
BLR PUMP OUTPUT:
The speed signal sent to a variable speed boiler pump in percent.
SYS PUMP INPUT:
The speed signal received from a variable speed system pump control.
RATE OUTPUT:
SH RUN HOURS:
SH CYCLES:
A 0 - 10V signal indicating the firing rate of the boiler.
The total hours of operation in the Space Heating Mode.
The total burner cycles in the Space Heating Mode.
The total hours of operation in the DHW Mode.
The total burner cycles in the DHW Mode.
The last 10 lockouts.
DHW RUN HOURS:
DHW CYCLES:
LAST 10 FAULTS NO:*
NIGHT SETBACK
Shows the next Night Setback trigger (if active).
72
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Installation & Operation Manual
11 Operating information
(continued)
Status Display Screens (cont’d)
Section
Display
Description
Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
MENU
EXIT
Press the LEFT SELECT key to exit the current screen or setting.
Press the LEFT SELECT key to confirm that the boiler needs to
shutdown.
YES
D
(LEFT SELECT
key function)
Press the LEFT SELECT key to enter the screen that allows you to
adjust the limit settings.
LIMITS
HOME
SKIP
Press the LEFT SELECT key to return to the Status Screen and upload
parameter changes.
Press the LEFT SELECT key when in the Night Setback Screen to
access the Night Setback Skip Screen.
Turning the NAVIGATION dial will select the next or previous Status
Screen.
Pressing the NAVIGATION dial will show the next fault, NSB (Night
Setback) trigger, or ramp delay setting.
Pressing the NAVIGATION dial will select the setting indicated by
the cursor.
E
(NAVIGATION
Dial Function)
Pressing the NAVIGATION dial will display the Set Points Screen.
Turning the NAVIGATION dial will move the cursor up or down.
Turning the NAVIGATION dial will increase or decrease the current
setting.
SHDN
ON
Press the RIGHT SELECT key to turn the boiler OFF.
Press the RIGHT SELECT key to turn the boiler ON.
F
NO
Press the RIGHT SELECT key to cancel the shutdown operation.
Press the RIGHT SELECT key to save the current change.
(RIGHT SELECT
key function)
SAVE
HOME
Press the RIGHT SELECT key to return to the Status Screen and
upload parameter changes.
73
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Installation & Operation Manual
12 Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Owner maintenance
(see the Knight Wall Mount User’s Information
Manual for instructions)
Service technician
(see the following pages for instructions)
General:
• Address reported problems
• Check boiler area
• Inspect interior; clean and vacuum if
necessary;
• Check pressure/temperature
gauge
Daily
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check vent piping
• Check air piping
• Check system water pressure/system
piping/expansion tank
Monthly
• Check air and vent termination
screens
• Check control settings
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check relief valve
• Inspect condensate drain system
• Check air vents
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 10
of this manual.
•Test low water cutoff (if used)
• Reset button (low water cutoff)
Periodically
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Check boiler piping (gas and
water) for leaks
Every
6 months
• Operate relief valve
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
End
•Shut boiler down (unless boiler
used for domestic hot water)
• Clean the blower wheel
of season
months
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Installation & Operation Manual
12 Maintenance
(continued)
Follow the Service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler
or system. Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
ƽ WARNING
ƽ WARNING
ƽ WARNING
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the boiler designated in Table 12A and explained on the following pages must be performed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
Address reported problems
1. Inspect any problems reported by the owner and correct
before proceeding.
3. After the condensate trap is cleaned or serviced, it must be
checked to ensure that it is installed and draining properly.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
Figure 12-1 Condensate Trap
2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of this manual. If any of these are
present in the boiler intake air vicinity, they must be
removed. If they cannot be removed, reinstall the air and
vent lines per this manual and the Knight Wall Mount
Service Manual.
Inspect boiler interior
1. Remove the front access cover and inspect the interior of
the boiler.
FLOAT BALL
CONDENSATE DRAIN
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
BOTTOM CAP
Inspect condensate trap
IMG00046
Monthly inspection:
It is in the best interest of the end user
ƽ WARNING
1. The condensate trap should be inspected monthly to
ensure the trap is properly installed and connected to the
condensate pipe under the boiler, see FIG. 12-1.
2. The condensate line should be inspected monthly
for obstructions, making sure it allows free flow for
condensate to drain.
3. Inspect the neutralizing kit (if installed) monthly to
ensure the condensate is draining properly, and there is
still an adequate amount of neutralizing agent available.
to make sure the ball is present and the
condensate trap is filled with water during
all times of boiler operation to avoid flue
gas emission from the condensate drain
line. Failure to have the ball present or to
fill the trap could result in severe personal
injury or death.
Check all piping for leaks
Eliminate all system or boiler leaks.
ƽ WARNING
Annual cleaning:
Continual fresh makeup water will reduce
1. The condensate trap should be cleaned at least once
annually, or at the end of each heating season, by
removing the bottom cap and cleaning out any sediment
that exists.
2. The provided condensate trap is equipped with a ball
that acts as a seal against harmful flue gases escaping in
case there is no condensate in the trap. If this ball is not
present, flue gases may be able to pass through the trap
when there is no condensate present, resulting in an
unsafe environment. It is important to check and make
sure the ball is still located in the trap, acting as a seal
against flue gases at least once annually and after every
boiler life. Minerals can build up in sections,
reducing heat transfer, overheating heat
exchanger, and causing heat exchanger
failure. Leaking water may also cause severe
property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 7 -
Gas Connections.
cleaning.
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75
Installation & Operation Manual
12 Maintenance
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions may
corrode the valve or its components over
time, rendering the valve inoperative. Such
conditions are not detectable unless the
valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection agency
– not by the owner. Failure to re-inspect the
boiler relief valve as directed could result in
unsafe pressure buildup, which can result in
severe personal injury, death, or substantial
property damage.
ƽ WARNING
Flue vent system and air piping
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe
is connected and properly sealed.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in severe
personal injury or death.
ƽ WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
2. After following the warning directions in this manual, if
the relief valve weeps or will not seat properly, replace the
relief valve. Ensure that the reason for relief valve weeping
is the valve and not over-pressurization of the system due to
expansion tank waterlogging or undersizing.
4. Inspect air separators.
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Inspect ignition and flame sense
Tanks may be open, closed or diaphragm or bladder electrodes
type. See Section 6 - Hydronic Piping for suggested best
location of expansion tanks and air eliminators.
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 boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 6 - Hydronic Piping before
proceeding further.
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger access
cover to ground terminal strip.
Following installation, the valve lever
must be operated AT LEAST ONCE
ƽ WARNING
2. Verify all wiring is in good condition and securely attached.
3. Check ground continuity of wiring using continuity meter.
4. Replace ground wires if ground continuity is not satisfactory.
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.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
Check control settings
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the Knight Wall Mount Service Manual. Adjust settings if
necessary. See Section 1 of the Knight Wall Mount Service
Manual for adjustment procedures.
2. Check settings of external limit controls (if any) and adjust
if necessary.
76
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Installation & Operation Manual
12 Maintenance
(continued)
Review with owner
Perform start-up and checks
1. Review the Knight Wall Mount User’s Information Manual
with the owner.
1. Start boiler and perform checks and tests specified in
Section 10 - Start-up.
2. Emphasize the need to perform the maintenance schedule
specified in the Knight Wall Mount User’s Information
Manual (and in this manual as well).
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
Check burner flame
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
1. Inspect flame through observation window.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove the
burner and clean it thoroughly using a vacuum cleaner
or compressed air. Do not use compressed air to clean
burner if performed inside a building.
4. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.
Cleaning boiler heat exchanger
1. Shut down boiler:
3. Remove the burner, reference FIG. 12-2 (page 77).
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 12-2).
• 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.
Figure 12-2 Burner Assembly
2. Allow time for the boiler to cool to room temperature if it
has been firing.
3. Remove the nuts securing the heat exchanger access cover
to the heat exchanger and set aside.
4. Remove the heat exchanger access cover and burner.
The boiler contains ceramic fiber materials.
ƽ WARNING
BURNER PLATE
Use care when handling these materials per
instructions in the Service Manual. Failure
to comply could result in severe personal
injury.
GASKET,
BURNER PLATE
INSULATION,
BURNER DOOR
5. Remove the condensate trap from the bottom of the boiler.
Place a bucket underneath the condensate fitting attached
to the heat exchanger.
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
7. Using a clean cloth dampened with warm water, wipe out
the combustion chamber. Rinse out debris with a low
pressure water supply.
BURNER
GASKET
BURNER
8. Allow the heat exchanger to thoroughly dry.
9. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 10 - Startup on pages 59
and 62 of this manual.
10. Replace the burner, access cover and condensate trap.
Restore boiler to operation.
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
* Do NOT use a metal brush.
ƽ CAUTION
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the flame
sense electrode.
Oiled bearing circulators
1. The circulator shipped with the Knight wall mount boiler is
water-lubricated. No oiling is required.
3. See Section 3 - Troubleshooting of the Knight Wall
Mount Service Manual for other procedures to deal with
low flame signal.
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.
77
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Installation & Operation Manual
13 Diagrams
Figure 13-1 Ladder Diagram
JUNCTION BOX
GROUND
NEUTRAL
120VAC
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
1
2
INTEGRATED CONTROL
BLOWER
ON / OFF
SWITCH
GND
SYSTEM
PUMP "L"
SYSTEM
PUMP "N"
X1-1
X1-6
F2
3
X1-2
3.15A
GND
SYSTEM
PUMP
F1
5A
BOILER
BOILER
PUMP "N"
SYSTEM PUMP
RELAY
PUMP "L"
X1-4
X1-3
BOILER PUMP
RELAY
GND
BOILER
PUMP
DHW
PUMP "L"
DHW
PUMP "N"
DHW PUMP
RELAY
F3
TERMINAL
STRIP
TERMINAL
STRIP
DHW
PUMP
.8A
24V DC
SUPPLY
X5-9
X5-1
120 VAC
24 VAC
X4-3
CONNECTION BOARD
INTEGRATED
CONTROL
CN5-5
LWCO
FLOW
CN5-14 X4-8
CN7-3
CN7-1
12
11
CN7-4
CN7-2
SWITCH
CN5-10
X4-12
24 VAC
HEAT/LOOP
DEMAND
1
CN5-7
X4-1
20
18
16
14
19
17
HEAT/LOOP
DEMAND 2
CN5-13 X4-9
HEAT/LOOP
DEMAND 3
CN5-6
X4-2
15
TANK
THERMOSTAT
CN5-12
X4-10
13
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
CN5-11
CN5-3
X4-11
X4-5
9
10
INTEGRATED
CONTROL
LOUVER
RELAY COIL
5
6
7
24VAC
LOUVER
PROVING SWITCH
CN5-4
X4-4
X7
RIBBON CABLE
X5-2
PC INTERFACE
X5-10
X5-11
X5-6
X5-4
X5-12
X5-5
S2
INLET
SENSOR
S1a
S1b
S3a
OPERATING
SENSOR
AIR PRESSURE
SWITCH
1
HIGH LIMIT
SENSOR
X2-2
X2-1
GAS VALVE
2
FLUE
SENSOR
GAS VALVE
RELAY
6
X5-13
X5-14
S3b
FLUE
SENSOR
BLOWER
1
2
4
5
X5-7
X5-16
X5-8
13
CONNECTION
BOARD
CN5-1
CN5-8
X4-7
1
2
ALARM
CONTACTS
X4-14
X5-15
CN5-2
CN5-9
X4-6
3
4
RUN-TIME
CONTACTS
X4-13
TR2
CN6
CN6
CN6
X6
X6
X6
S6
S5
S4
21
22
X1-7
SYSTEM
SENSOR
FLAME ROD
23
24
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
OUTDOOR
SENSOR
SPARK
ROD
CN6
X6
TANK
SENSOR
SHIELD
CAUTION HIGH VOLTAGE SPARK LEAD
CN6
X6
A
CASCADE
B
CN6
CN6
X6
X6
NOTES:
1. Where possible, switches are shown without utilities (gas, water or
electricity) connected to the unit. As such, actual switch states may
vary from those shown on diagrams depending upon whether utilities
are connected or a fault condition is present.
SHIELD
CN6
CN6
CN6
X6
X6
X6
BMS
+
0-10V
0-10V
0-10V
0-10V
IN
-
+
-
SYS PUMP
IN
2. See wiring diagram for additional notes.
CN6
CN6
X6
X6
+
-
BLR PUMP
OUT
CN6
CN6
X6
X6
BOX DEPICTS
OPTIONAL ITEMS
+
-
RATE
OUT
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
M
O
D
B
U
S
SHIELD
CN8-1
X4-1
X9-2
X9-1
X9-3
X6-1
A
MODBUS
CN8-2
CN8-3
X6-2
X6-3
X4-2
X4-3
B
LADDER DIAGRAM
LBL20170 REV D
SHIELD
78
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Installation & Operation Manual
13 Diagrams
(continued)
Figure 13-2 Wiring Diagram
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
CONTROL
BOX DEPICTS
OPTIONAL
ITEMS
CONNECTION BOARD
JUNCTION
BOX
ALARM
CONTACTS
1
2
X1-3
X-7
OR
BR
L
DHW
G
G
G
PUMP
RUN-TIME
3
W
W
W
N
L
CONTACTS
4
X1-4
X1-2
24 VAC LOUVER
BOILER
PUMP
5
RELAY COIL
6
N
L
LOUVER
PROVING SWITCH
GAS PRESSURE
SWITCH
7
PR
CN5-1
CN5-8
CN5-2
CN5-9
CN5-3
CN5-10
CN5-11
CN5-4
CN5-5
CN5-14
CN5-12
CN5-6
CN5-13
CN5-7
BK
BK
BK
BK
X4-7
X4-14
X4-6
8
SYSTEM
PUMP
9
N
10
X4-13
X4-5
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
X4-12
X4-11
X4-4
ON/OFF
SWITCH
L
120V
SUPPLY
X1-6
X1-5
L
N
BK
W
GND
FLOW
SWITCH
11
12
13
14
15
16
17
18
19
20
X4-3
N
X4-8
TANK
X4-10
X4-2
THERMOSTAT
HEAT/LOOP
X4-9
X1-8
X1-1
G
R
3
2
1
DEMAND
X4-1
HEAT/LOOP
DEMAND
HEAT/LOOP
TRANSFORMER
DEMAND
RW G
SYSTEM
SENSOR
OUTDOOR
SENSOR
21
22
23
24
25
26
27
28
29
30
31
32
1 2 3
BLOWER
TANK
SENSOR
1 2 3 4 5
SHIELD
A
CASCADE
B
SHIELD
X5-7
X5-16
X5-8
R
T
CN6
X6
W
BK
Y
BMS
IN
33
34
35
36
37
38
39
40
41
42
43
44
+
0-10V
X5-15
X5-9
-
SYS PUMP
+
0-10V
IN
-
BLR PUMP
X5-1
BL
O
+
0-10V
OUT
-
X5-2
RATE
+
0-10V
OUT
-
X5-10
X5-11
X5-4
P
SHIELD
AIR PRESSURE SWITCH
A
O/BK
R/BK
GY
MODBUS
-T
-T
-T
-T
-T
OPTION
B
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
SHIELD
X5-12
X5-6
24 VAC
LOW
WATER
CUT-OFF
CN7-1
CN7-2
CN7-3
CN7-4
COM
P/BK
W/BK
PR
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
X5-5
X5-13
X5-14
RBLG
Y
X2-2
BK
Y
GAS VALVE
@24VAC
O
GY
G
X4-1
X4-2
X4-3
X4-4
X9-1
X9-2
X9-3
X9-4
X2-1
X1-7
TR2
MODBUS BOARD
MTR-01
W/R
FLAME SENSOR
SPARK
ROD
G
SHIELD
GROUNDING
JUMPER
X5-1
X5-2
CAUTION HIGH VOLTAGE SPARK LEAD
BK
W
G
X1-1
X1-2
X1-3
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a
minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead
or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
WIRING DIAGRAM
LBL20169 REV
D
79
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Revision A (ECO #C06854) initial release.
Revision B (ECO #C08222) reflects the changes to the water pipe
clearances from 1" to a 1/4" (ECR #R04077), pages 7, 8, and 33 and
changes made to the service clearances (left side) from 24" to 12" (ECR
R04002).
Revision C (ECO #C08645) reflects additional cleaning and inspection
instructions for the condensate trap (page 75).
Revision D (ECO #C09197) reflects additional information added to the
humidity warning on page 7, along with updates made to the SMART
SYSTEM control (ECR #R04523).
Revision E (ECO #C09803) reflects the addition of the new Polypropylene
Vent material section, rearranging the venting section, and the addition
of the AHRI and ASME logos (R05009).
Revision F (ECO #C09843) reflects the addition of the manual air vent in
the outlet tubing and the new condensate trap pipe (R04984).
Revision G (ECO C10297) reflects the addition of the venting notice on
page 16 and updates made to the ignition timing information.
Revision H (ECO C10450) reflects changes made to Table 10A on
page 62.
WH-I-O Rev H
05/12
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