HomeMy WebLinkAboutM11-0009 NOTE: THIS PERMIT MUST BE POSTED ON JOBS/TE AT ALL T/MES
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Town of Vail, Community Development, 75 South Frontage Road, Vail, Colorado 81657
p. 970-479-2139 f. 970.479.2452 inspections. 970.479.2149
MECHANICAL PERMIT Permit #: M11-0009
AMF Project #: PRJ11-0007
Job Address: 5175 BLACK GORE DR VAIL Status. . . : ISSUED
Location.....: Unit 5 Applied . . : 01/13/2011
Parcel No...: 209918215005 Issued. . : 01/26/2011
Expires. .: 07/25/2011
OWNER MECK,JOHN F.-PINKHAM, SAR 01/13/2011
283 GARFIELD ST
DENVER
CO 80206
APPLICANT EAGLE VALLEY PLUMBING&HEAT 01/13/2011 Phone: 970-949-1926
PO BOX 1772
AVON
CO 81620
License: 361-M
CONTRACTOR EAGLE VALLEY PLUMBING&HEAT 01/13/2011 Phone:970-949-1926
PO BOX 1772
AVON
CO 81620
License: 361-M
Desciption: BOILER REPLACEMENT
Valuation: $4,800.00
�........*............�...»....................���....*.«.�.�....*..�*�<...�.,...FEE SUMMARY..�..��.�..�.»«»...........�........�.....�.....<...........................,....«,,..
Mechanical Permit Fee---> $100.00 Will Call------------> $5.00 Total Calculated Fees---> $130.00
Plan Check-------------------> $25.00 Use Tax Fee------> $0.00 Additional Fees-----------> $0.00
Investigation-----------------> $0.00 TOTAL PERMIT FEE---> $130.00
Total Calculated Fees--> $130.00 Payments----------------> $130.00
BALANCE DUE---------> $0.00
......�..�..............+.....,�,...........�....�.....,......�.».....,..,,.............«...«.........��*,,..*�....��..�.�...,.....«......<.<.<..............................................#
APPROVAIS
Item: 05100 BUILDING DEPARTMENT
01/21/2011 Martin Action:AP
.....*.........�............................�...�.,..�....,,....�.»����........,.��.....<....+....x<,,......��...��..�..�.�..>.».»......�...».».................<.................+......,...
CONDITION OF APPROVAL
Cond: 12
(BLDG.): FIELD INSPECTIONS ARE REQUIRED TO CHECK FOR CODE COMPLIANCE.
Cond:42
(BLDG 2009)CARBON MONOXIDE DETECTORS REQUIRED TO BE INSTALLED PER 2009 IRC R315
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DECLARATIONS
I hereby acknowledge that I have read this application,filled out in full the information required, completed an accurate plot plan, and state that all the information
as required is correct. I agree to comply with the information and plot plan,to comply with all Town ordinances and state laws, and to build this structure
according to the towns zoning and subdivision codes, design review approved, International Building and Residential Codes and other ordinances of the Town
applicable thereto.
REQUESTS FOR INSPECTION SH L B MADE TWENTY-FOUR HOURS IN ADVANCE BY TELEPHONE AT 970.479.2149 OR AT OUR OFFICE FROM 8:0�
AM-4 PM. ' /
�' < �
Sign re o er or Contractor ��� �� D e
J �
Print ame
mechcan ical_permit_041908
**************+***************************************************************************�*
TOWN OF VAIL, COLORADO Statement
***********************+*******+++********************************+*****************+*******
Statement Number: R110000068 Amount: $130 .00 O1/26/201112 :38 PM
Payment Method:Credit Crd Init: LC
Notation: CREDIT CARD
FROM ROGER D VILLEDA, EAGLE VALLEY PLMB & HEAT
-----------------------------------------------------------------------------
Permit No: M11-0009 Type: MECHANICAL PERMIT
Parcel No: 2099-182-1500-5
Site Address: 5175 BLACK GORE DR VAIL
Location: Unit 5
Total Fees: $130. 00
This Payment: $130.00 Total ALL Pmts: $130. 00
Balance: $0. 00
**************�***********************************************�*****************************
ACCOUNT ITEM LIST:
Account Code Description Current Pmts
-------------------- ------------------------------ ------------
MP 00100003111100 MECHANICAL PERMIT FEES 100.00
PF 00100003112300 PLAN CHECK FEES 25.00
WC 00100003112800 WILL CALL INSPECTION FEE 5.00
IW
01 -27 -2011 Inspection Request Reporting Page 5
4:02 pm Vail, CO - City Of
Requested Inspect Date: Friday, January 28, 2011
Site Address: 5175 BLACK GORE DR VAIL
Unit 5
A/P /D Information
Activity: M11 -0009 Type: B -MECH
Const Type: Occuppancy:
Owner: MECK, JOHN F. - PINKHAM, SARAH MECK
Contractor: EAGLE VALLEY PLUMBING & HEATING
Description: BOILER REPLACEMENT
Requested Inspection(s)
Item: 200 MECH -�..
Requestor: EAGLE VALLEYPLUMBING & HEATING
Comments: UNIT 5
Assigned To: JM )' GON
:-'
Action Time Exp: _
Inspection History
Item: 200 MECH -Rough
Item: 315 PLMB -Gas Piping
Item: 390 MECH -Final
REPT131
Sub Type: AMF
Use:
Status: ISSUED
Insp Area:
Phone: 970 - 949 -1926
Requested Time: 08:30 AM
Phone: 970 - 949 -1926 -or- 970 -977-
0567 ROGER
Entered By: DRHOADES K
Run Id: 12514
�
� ,.� , '��� �, ��� Department�f Community Development
� , � � ��'���� , � �,�, 75 South Frontage Road
� � � � ��t , , � Vai1,,Colorado .81-657,
�P� � � � �-,' }� �' 4 �� . .
�`�-.,, �, . � � � �; Te`l: 970=479-2128;
�� �'�� ; � �. �"�!`° s� � � Fax: 970-479-2452
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MECHANICAL PERMIT
Boiler / Furnace & Firealace Applications MUST include�
� Complete Mechanical Room Floor Plan with Dimensions � Boiler size&e�ciency
� Combustion Air Duct Size and Location � Equipment Cut Sheets for Fireplaces/Log Sets
Flue detail or Vent size, location &termination (Manufacturer's info showing make, model &approval listing)
a Gas Piping layout including development length calculations Office Use: ('�
❑ Heat Loss Calculations Project#: f'I� S��— ��d 7
Pro'ect Street Address: Building Permit#: /V�'
�� � �� 1.���� v-r ���� � ��� Mechanical Permit#: �f J'"�Q�q
(Number) (Street) (Suite#) �Ep/}R Po�ay ro�uROasc
Lot#: Block# Subdivision: �t��uC� a
Building/Complex Name:
Define Scope and Location of Work:
Contractor Inform tion:, > ' 1 ���
Company:&� � � /ll - L�II'J/J` �" ,�� �1 � ,,���'�'.��Jv1�� '
CompanyAddr s:�/J. �i�' � (�
City:�/`tl��lV State: �� Zip: ��f�1� � (use additional sheet if necessary)
Contact Name:� � �
o Gas Piping Included
Contact Phone: � "� �r ����r ❑ Gas Piping by Others
E-Mail
❑ Wood to Gas Fireplace Conversion
Town of Vail Contractor Registration No.: �� l^ � Boiler Location:
Interior(�xterior( ) Other( )
X Number of Existing Fireplaces: ,
C e{tet�p"i`red)
:Gas Appliances Gas Logs Wood/Pellet ;
Property Information
Parcel#: o<,[��4- l R a– �S– Q(�S Number of Proposed Fireplaces:
(For parcel#,contact Eagle County Assessors Office at 970-328-8640 or Gas Appliances Gas Logs Wood/Pellet
visitwww.eaglecounty.uslpatie) _ _ _
Type of Building:
Tenant Name: ( p � Single- y Q� �I��( �� ��ilt��a ' ) Commercial O
Commercial Pro erties t,� �
Owner Name: 0�`�Q ��.�� Restaur ) Other( )
Date Re d: �j€���� �
Complete Valu ion for Mechanical Permit: (including fireplaces) 'r�� ' I
Mechanical$: �� ��
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H E A T 1 N G 8 O!L E R
Instailation & Operation Manual °�
Models: 81 - 286
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� i , 1Y� VIlARNING �►"t�is manual must only be used bv a
� � � < / qualified heating installer / service
� c� o � technician. Read all instructians,
���RT i��� `�" � ' iricludizlg this manual and the �-
Kni�ht Boiler Seivice 1�4anual,before :��
installing. Perform steps in ttie order ��
�iven. I'ailure to compl�r could result
�-� in severe personal injury, death, or ,'��
• �� substantial property darnage.
�„ . c . ar R Save this manual for future reference.
' • High Efficienc��Water Heaters,Roilers and Poul Heatcr��
. -
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . .29
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 Vertical Termination-Optionai Concentric Vent . . . . . . . 30-31
THE KNIGHT BOILER--HOW IT WORKS . . . . . . . . . . .4-6 Alternate Vertical Concentric Venting . . . . . . . . . . . . . . . 32-33
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6. HYDRONIC PIPING
1. DETERMINE BOILER LOCATION System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 34
Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 34
Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10 Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Residentiai Garage Installation . . . . . . . . . . . . . . . . . . . . 10 General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 34
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Relief Valve/T&P Installation . . . . . . . . . . . . . . . . . . . . 35
Prevent Combustion Air Contamination. . . . . . . . . . . . . . 10 Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 35-36
Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11 Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 36
Using an Existing Vent System to Install a New Boiler . . 11 Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removing a Boiler from Existing Common Vent . . . . . . . 12 Variable Speed Pump Option . . . . . . . . . . . . . . . . . . . . . 38
2. PREPARE BOILER 7. GAS CONNECTIONS
Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . 13 Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . .46
Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 NaturalGas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Leveling the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . .47
3. GENERAL VENTING Natural Gas Supply Pressure Requirements . . . . . . . 47
Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 16 Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . .47
PVC/CPVC Vent and Air Piping Materials . . . . . . . . . 16 Propane Supply Pressure Requirements . . . . . . . . . .47
Requirements for Instaliation in Canada . . . . . . . . . . . . . 16 Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . .48
Installing Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . 16 Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
PVC/CPVC Air IntakeNent Connections . . . . . . . . . . . . . 17 Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . .49
Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 18 8. FIELD WIRING
Stainless Steel Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Line Voitage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50
Stainless Steel Air IntakeNent Connections . . . . . . . . . . 19 Low Voitage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50
Min./Max. Combustion Air&Vent Piping Lengths . . . . . . 19 Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 9. CONDENSATE DISPOSAL
Optional Room Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4. SIDEWALL DIRECT VENTING 10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-60
VenUAir Termination-Sidewall . . . . . . . . . . . . . . . . . . . .21-24 11. OPERATING INFORMATION
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Prepare Wall Penetrations . . . . .. . . . . . . . . . . . . . . . 23 Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 24 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 65-66
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 24 Knight Boiler Control Module . . . . . . . . . . . . . . . . . . . . . . 67-68
Sidewall Termination-Optional Concentric Vent . . . . . .25-27 Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 69-71
5. VERTICAL DIRECT VENTING 12. MAINTENANCE
VenUAir Termination-Vertical . . . . . . . . . . . . . . . . . . . . . 28-29 Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 72-76
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 28 13. DIAGRAMS
Prepare Roof Penetrations. . . . . . . . . . . .. . . . . . . . .29 Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 29 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Hazard definitions
The following defined terms are used tl�roughout this manual to bring attention to the presence oY hazards oY various risk levels or
�o important information concerning the life of the product.
�� � , DANGER indicates an inmlinently hazardous situation which,if not avoided,will result in death or serious
injury.
�WARNING ���RNING indicates a potentiall}�hazardous situation which,if not avoided,could result in death or serious
injury.
� ���-�-��N ('AUTION indicates a potentially hazardous situation which,if nut avoided,may result in minor or moderate
injury.
�A�T��N CAUTION used without dle safety alert symbol indicates a potentially hazardous situation �vhich, if not
avoided,may resuJt in property damage.
NOTICE NO"I'ICF,indiiates special instructions on installation,operation,or maintenance that are important but not
related to personal injury or propert}'damage.
2
'���M' Instailation & Operation Manual
Please read before proceeding
�WARN6NG Installer — Read all instructions, �(hgn S@1'VlCltlg b01�@C— '
including this manual and the Knight �
Boiler Service Manual, betore installing. • To avoid electric shock, disconnect electrical suppl}�
Perform steps in the ordcr given. before performing maintenance.
User—This manual is for use only by a • To avoid severe burns, allow boiler to cool before
qualified heating installerlservice performing maintenance.
technician. Refer to the Usei's
Information Manual for}�our reference. BOI�@P Op@t"atlOtl —
Have this boiler ser��iced/inspected b)' a • Do not blod: flow of combustion or ventilation air to
qualified service technician, at ]east the boiler.
annually.
Failure to comply with the aUove could 'Should overheating occur or gas supply fail to shut off,
result in severe personal injury, death or do nor turn off or disconnect electrical supply to
substantiai property dainage. circulator. Instead,shut off the�as supply at a location
exCernal to the appliance.
NOTICE �ti'hen calling or�vriting about the boiler— .P�not use this boiler if any part has been under water.
Please have the boiler model and serial The possible damage to a flooded appliauce can be
number from the boiler rating plare. extensive and present numerous safety hazards. Any
Gonsider piping and installation when appliance that has been under water must be replaced.
deternlining boiler location.
Any claims for damage or shortage in Boiler water—
shipment must be filed immediately
againsY the transportation company by 'Thoroughly flush the system (without boiler
the consignee. connected) to remove sedii7ient The high-efficiency
heat exchanger can be damaged by build-up or
Factory �varranty (shipped �vith unit) corrosion due to sediment.
does not apply to units impraperly
installed or improperly operated. • Continual fresh make-up water tivill reduce boiler life.
Nlineral buildup in the heat exchanger reduces heat
�WARNING� Failure to adhere to the guidelines on this transfer> overheats the stainless steel heat exchanger,
� page can result in severe personal injury, and causes failure. Addition of oxygen carried in by�
death,or substantial property damage. makeup water can cause internal corrosion in system
[f the information in this manual is not components. Leaks in boiler or piping must be repaired
B WARNING at once to prevent makeup water.
followed exactly, a fire or ex�losion ma�-°
result causing property dainage,perso��al � CAUTION vO «ot use petroleum-based cleaning or
injury or loss of life. sealing compounds in the boiler system.
This appliance �ti4UtiT NOT be installed Gaskets and seals in the s}'stem may be
in auy location where gasoJine or damaged. This can result in substantial
flammable vapors are likely to be present. property damage.
WHAT TO DO IF YOU SMELL GAS � CAUTION �O I�Ot use"hoinemade cures"or"boiler
• Do not try to Ligl�t anv appliance.
pate�nt medicines" Serious damage to
• Do not touch any electric switch; do tl�e boiler, personnel, and/or property
not use any phone in yotir building. inay result.
• Immediately call your gas supplier
Yrom a near Uy phone. Follow the Freeze protection fluids —
gas supplier's instructions.
• If you cannot reach }�our gas supplier, ' NEl'ER usc automotive antifreeze. Usc only inhibited
call the tlre department. propylene glycol solutions, �vhich are specifically
• Installation and service must be formulated for hydronic systems. Ethylene glycol is
perfonned by a qualified installer, toxic and can attack gaskets and seals used in hydronic
service agency,or the gas supplier. systems.
�, 3 �cr�
�i �.�y�"� Installation & Operation Manual
The Knight Boiler - How it works...
1. Stainless steel heat exchanger 16. SMART SYSTEM Control Module
Allows system water to fto�v through specially designed �he SMART SYSTEM Control responds to internal and
coils for maximum heat transfer, while providing exter��al sig�als and controls the blower, gas valve, and yumps
yrotection against flue gas corrosion. 'I'he coils are to meet the heating demand.
encased in a jacket that contains the combiistion process. 17. Manual air vent
2. Combustion Chamber aCCess Cover Designed to ren�ove trapped air from tl�e heat exchanger
Allows access to the combustion side of the heat coils.
exchai�ger coiis. 18. Air intake adapter
3. Blower Allows for the connection of the PVC; air intake pipe to
'I�he Llower pt�ls in air and gas througl� the venturi (item Yhe boiler.
5). Air and gas mix inside the blower and are pushed into the 19. High voltage jundion box
burner,where they barn inside t'he coinbustion chamber. T'he junction box contains the co�mection points for the line
4. Gas valve voltage power and all punips.
The gas valve senses the negative pressure created by the 20. Boiler drain port
blower, aliowing gas to flow ouly if the gas valve is Lucaiion from which the heat exchanger can be drained.
powered and combustion air is flowing.
21. Low voltage connection boazd
5. Venturi 'l�he connection board is used to connect external low voltage
The venturi controls air and gas flo�v into the burner. �j�`,���5
6. Flue gas sensor(limit rated) 22, I,ow voltage wiring connections(knockouts)
"I'his sensor monitors the flue gas exit ten�perature. The control Conduit connection yoints for the low voltage
�nodule will n�odi�late and shut down the boiler if flue gas ��nnection board.
remperature gets too hot. 'Lhis protects the flue yipe from
overheating. 23. Condensate drain connection
Connects the condensate drain line to a l/Z"P��C union.
7. Boiler outlet temperature sensor (housed with the
high limit sensor) 24. Access cover-front
This sensor�nonitors boiler outlet water temperature (system Provides access to the gas train and the heat exchanger.
supplyj. If selected as the controlling sensor, the control 25. Ignition electrode
module adjusts boiler tiring rate so the outlet te�nperatare is Provides direct syark for igniting the burner.
correct. 26. Flame inspection window
S. Boiler inlet temperature sensor The yuartz glass �vindow provides a view of the burner
This sensor monitors return H�ater temperature (system surface and flan�e.
return). If selected as the controlling sensor, the control 27. Relief valve
n�odule adjusts the boiler firing rate so the inlet temperature is Yrotects the heat exchanger Yroiu an over pressure conditio�.
� correct 'I`he relief��alve provided with the unit is set at 30 psi.
4. Temperature and pressure gauge(field installed,not 2g. Fiame sensor
shown) Used by the control module to detect Yhe presence of burner
A4onitors the outlet temperature of the boiler as �vell as the flame.
system water pressure.
29. Line voltage wiring connections(knockouts)
10. EleCtroniC LCD display Conduit connection points for the high voltage junction box.
The electronic display consists of 4 buttons,a navigation dial
and a rnultiple line liquid crystal display. 30. Top panel
11. Flue pipe adapter RemovaUte panel to gain access to the internal components.
Allu�vs for the connection of ihe I'VC��ent pipe system to the 31. Power switCh
boiler. "l�urns 120 V,AC ON/OFF to the boiler.
12. Burner(not shown) 32. Leveling legs
R�1ade with meTa1 fiber and stainless steel construction, U;ed to allow the heat eschanger to be leveled. This is needed
the burner uses pre-mixed air and gas and provides a for the proper draining of the condensate froin the combustion
�ti�ide range of firing rates. chamUer.
13. Water outlet(system supply) 33. Air pressure switch
NPT water connection that supplies hot water to the �I'he air pressure switcl�detects blocked inlet conditions.
�ystem, either l" or 1-]/4", deyending on the
model. 34. Transformer
14. Water inlet(system return) The transformer provides 24V power to the ii�tegrated control.
NP'1' water connection that returns water from the 35. High limit sensor (housed with the outlet
system to the heat exchanger, either 1" or 1-1/4", temperaiuresensor)
depending on the model. Device that monitors the outlet water temperature. If the
15. Gas connection pipe temperature eYCeeds its setting, the integrated control will
Threaded pipe connection, either 1!2" or 3/4", break the control circuit,shutting the boiler down.
depending on tl�e modeL 'Chis pipe should be counected
to the incoming gas supply for the purpose of delivering 36. Gas shutoff switCh
gas to the boiler. �'1❑ electrical switch designed to cut po�cer to the gas valve to
� prevent releasing any gas.
4
'(���M' Installation & Operation Manual
The Knight Boiler - How it works... (continued)
Models 81 - 211
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Left Side (inside unit) -Models 81 - 211 Right Side(inside unit)-Models 81-211
5
��.��'�'" Installation & Operation Manual
The Knight Boiler - How it works...
Model 286
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Left Side (inside unit) - Model 286 Right Side (inside unit) - Mode1286
6
��r�T' Installatian & Operation Manual
Ratings
�ES1G�-.
� � �� Dt3E � ,��
;
rFR T I F���'% ��
�� Knight Boiler Other Specifications
� 1=B=R Rating
Net
Model Number Input Gross �-B-R Boiler
MBH Out ut Ratings Vent
P Water Water Gas Air
Water, Content Connections Connections
Note:Change"N"to (Note 5) MBH MBH Size Size
"L"for L.P.gas models. Gallons
Min Max (Note 2,�) (Note a,�) �No�e a�
KBN081 16 80 72 63 0.6 1" 1!2" 3" 3"
KBN106 21 105 94 82 0,7 1" 1/2" 3" 3"
KBN151 30 150 135 117 1.3 1" 1!2" 3" 3"
KBN211 42 210 190 165 1.7 1" 1(2" 3" 3"
KBN286 57 285 260 226 2.4 1-1/4" 3!4" 4" 4"
NOTICE n'lazimum allowed workiilg pressurz is loiated on the rating plate.
Notes:
1. As au Energy Star ParUler, Lochinvar has determined that �• Knight boilers comply with the requirements of CSD-1
ICnight boilers meet the Energy Star guidelines for energy Section GW-400 requiremenYs as a temperature operation
effciency. control. The manual reset high limit provided with the
2. The ratings are based on standard test proccdures
�night is listed to UI.353.
prescribed by the United States Deparm�ent of Energy.
3. Net I=B=R ratings are based on net installed radiation of
sufticient quantity for the requirements of tl�e building and
nothing need be added for normal piping and pickup. � ��� ��
Ratings are based on a piping uid pickup allowance of 1.15. ��
4. Knight boilers require special gas venting. Use only the vent � ��,,, � _
materials and meYhods specitied in rhe I�night Installation �°��.�°�,, k •w ,,,�`e. /�� ���\
and Operation Manttal. r���� '� = � uNireouia?e��oR ��
�. Standard Knight boilers are equipped to operate from sea �� �����" �
level to 4,500 feet only with no adjustments. The boiler will HIGH ALTITUDE �
de-rate by 4°'o for each 1,000 feet above sea level up to ��'� ��✓_�� +�°• � �
�a..�N 3a��� � 3.000 FT T012,000 PT
4,500 feet. � j�
�
6. High altitude Knight boilers are equipped ro opeiate from � —`--�-------�"�
3,000 to 12,000 feet only�vith no tield adjustments. The
boiler �vill de-rate by 2°,% for each 1,000 Eeet above 3,000
feet. High altitude models are manufactured with a >����� Y��� ` ��
different control module for altitude operation, but the �� '� `°�'
� � � ��_
operation given in this manual remains the same as the �� � �,,��� �
s[andard boilers. A high altitude label(as shown in FIG.A) �;''�¢' �' � ;� �;�` �.�'
is also affixed to the unit.
7. Ratings have been confirmed by the �-Iydronics Institute,
Section of AHRI. Figure A High Altitude Labe!Location
„H... 7
1�'ti�+��HT Instailation & Operation Manual
7 Determine boiler location
Installation must eomply with: �W����N�, '[�his appliance is certitled as an indoor
appliance. Do not install the appliance
• Local, state, provincial, and national cu�ie;, la��s, outdoors or locate�vhere the appliance will
regulations,and ordirlances. be esposed to freezing temperatures or to
• National Fuel Gas Code,ANSI Z223.1 –latest edition. temperatures that exceed 100°F.
• Standard for Controls and Safetv Devices for
Automatically Fired Boilers, ANSI/ASh�iE CSD-1, when l?ailure to install the appliance indoors
required. could result in severe personal injury,
• National Electrical Gode. death,or substantial property danlage.
• For Canada onl}': B149.1 Installation Code, CSA C;'�.I
Canadian Electrical Code Part 1 and any local codes. �WA���N� 'I'his appliance requires a special venting
system. If using PVC the vent connection
NUTICE The Knight l�oiler gas manifold ai�d to the appliance must be made with the
controls met safe lighting and other starter CPVC pipe section provided with
performance criteria when the boiler the appliance. The field provided vent
underwent tests specified in ANSI Z21.13 fittings must be cemented to the CPVC
–latest edition. pipe section. Use only the vent materials,
primer and cement specifie� in this
Before locating the boiler, ChP.Ck: manual to make the vent connections.
L Check for nearby connection to: Failure to follow this warning could result
•System�kater piping in fire,personal injurj�,or death.
•Venting comlections
•Gas supply pip;�,g Closet and alcove installations
•Electrical power A doset is any room the boiler is installed in which is less than
� 67 cubic feet for KBNO81 and KBN106 models,86 cubic feet
. Locate[he appliance so that if�vater connections should for KBN151 models, 107 cubic Eeet for KBN21] models,
leak,water damage will not ocair. ZVl�en such locations and 120 cubic feet for KBN286 models.
cannot be avoided, it is recoinmended that a suitable
drain pan, adequately drained, be ulstalled under the An alcove is any room whicl� meets the criteria for a closet
appliance. The pan must not restrict combustion air with the exception that it does not have a door.
flow. Under no circumstances is the manufacturer to be
held responsible for wa[er damage in connection with Example: Room dimensions = � feet long, 3 feet wide, and
this appliance,or any of its com�onents. S foot ceiling = 4 x 3 x 8 = 96 cubic feet This would be
considered a closet for•a Knight Boiler.
3. Check area around the boiler. Remove any combustible _
materials,gasoline and other flanlmable liquids. 1�WARNlNG F"�• closet and alcove iustallations as
stiowii iii FIG.'s 1-1 and 1-2, CPVC or
I ailure to keep boiler area clear and free of stainless steel vent material must be used
1�.1 WARNING �.,,i»bustible materials,gasoline,and other inside the structure. The ventilating air
tlammaUle liquids and vapors can result in openings shown in FIC�'s 1-1 and 1-2 are
severe personal injury, death, or required for this arrangement. Failure ro
substantial property damage. follow this ivarning could result in fire,
4. The Knight boiler must be installed so that gas control
personal injury,or death.
system components are protected from dripping or Provide elearances:
spraying water or rain during operation or service.
Clearances from combustible materials
S. If a new boiler will replace an existing boiler, check for 1. Hot water pipes—at least 1"from combustible materials.
� and correct system problems,such as: 2. Vent pipe–at least 1" from combustible materials.
• System leaks causing oxygen corrosion or heat 3. See FIG:s 1-1 and 1-2 on page 9 for other dearance
exc6anger cracks from hard water deposits. minimums.
• [ncorrectly-sized expansion Tank.
• Lack of freeze protection in boiler water causing system Clearanees for serviee aceess
and boiler to freeze and leak. l. Sec FIG:s 1-1 and 1-2 on page 9 for recommended
service clearances. If you do not provide the minimum
dearances shown, it u�ay not be possible to service the
� boiler without removing it from the space.
8
���-Q' Installation & Operation Manual
7 Determine boiler location (continued)
Figure 1-1 Closet Installation -Minimum Required Clearances
�°MINIMUM CLEARANCE CLOSET INSTALLATION
AROUND HOT WATER ,'`�`_,. .. # For Closet installatiOns, CPVC or
PIPES AND VENT PIPE . „r;, � �� �WARNING
T��P
,eaintess steel vent material MUS'C
BE used in a closet structure due to
�"" �! 1 elevaYed temperatures. Pailure to
°°� �' ,.--`�� follow this warning could result in
�
� �� % �� fire,personal injury,or death.
� �'
� ' �
� �` �—VENTILATING'
���'-, " � �: - - AIR OPENING
z, � �,n «
i �� s
��,� �,, �CLOSED DOOR
� ��
„� a
12"��� ` � �' ���
LEFT � "° �VENTILATING'
~'',,� �-, � AIROPENING
\ ����� �� i
� � .�::= l
. ��
b��
� �' ¢ ,��:w°��`S� ,�(
�14 �ti�_ � ���
REAR �'; RIGHT
�/, , �\�� s .
����_...,
t��
�..
*
AREA OF EACH OPENING:
RECOMMENDED SERVICE CLEARANCES: 1 SQ.INCH PER 1000 BTU PER HOUR INPUT
FRONT -24" 6�� WITH A MINIMUM OF 100 SQ.INCHES.
TOP -24" FRONT
LEFT SIDE -24"
REAR -24"
Figure 1-2 Aicove lnstallation - Minimum Required Clearances
ALCOVE INSTALLATION
r�MiNiMUM c�EnRANCE //(( ���n�alcove installations,CPVC or
AROUND HOT WATER ^` / j Lr�WARNII�IG
PIPESANDVENTPIPE i� ��; � z � �; f,titl�eSS Steel vent mdteCld�
�', `'�.� � Tor �1UST BE used in an alcove
` �' � � � �� � structure due to elevated
� � � �
� � , � � temperatures. Failure to follow
�
�� � ,���� � this warning could result in fire,
��; >
� personal injucy,or deaTh.
�
�, � ��� ����`
�
� ''.-,
� ,� �
� �u �
� ��� OPEN
12„ � � , �� � � FRONT
IEFT � � �
� ��x" � �'� ;
'^'., �,� �.n ;�' � I
f�
� 3
ya� �� '��'�
Q
_ , ,
t > ,
i a., .�° � �,_,...
REAR�" �
/� Q..
% �,' �m: �,
RIGHT
��.' �� � �
RECOMMENDED SERVICE CLEARANCES: �18 �'`'�< -
FRONT -24" FRONT � '�
TOP -24" ��
LEFT SIDE -24"
REAR -24"
` 9
��' Installation & Operation Manual
7 Determine boiler location
Provide air openings to room: Residential garage installation
Knight boiler alone in boiler room Precautions
l. No air ventilation openings into the boiler room are Take the following precautions when installing the appliance
needed when clearances around the I�night boiler are at in a residential gara�e. If the appliance is located in a
least equal to the SERVICE clearances shown in residential garage, it should be installed in <ompliance �vith
FIG's 1-1 and 1-2. Por spaces that do NOT supply this the latest edition of the National Fuel Gas Code,ANSI Z223.1
dearanie, provide twv openings as shown in FIG. l-1. and/or CAN/CGA-B149 Installation Code.
Each operling must provide one square inch free area per • Appliances located in residential garages and in
1,000 Btu/hr of boiler input. adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
Knight boiler in same spaee with other gas or oil- all burners and burner ignition devices are located not
fired applianees less than 18 inches (46 cm) above the floor.
1. I=ollo�v the National t'uel Gas Code(U.S.) or CSA B149.1 •The appliance shall be located ar protected so that it is
(Ca�lada)to size/verify size of the combustionlventilation not subject to physical damage bv a moving��ehicle.
air openings into the space. Veht and alt' p1p117�
��WARNING ���e space must be provided with The I�night boiler requires a speeial��ent systern,designed for
<umbustion/ventilaCion air openings pCessurized ve»ting.
�oerectly sized for all other appliances
located in the same space as tl�e Knight The boiler is to be used for either direct vent installation or
boiler. for installation using indoor combustion air. When room air
is considered, see Secrion 3, General Venting. Note
Do not install the boiler in an attic. prevention of combustion air contamuiation below when
Failure to comply with the abo��e warnings considering vent/air termination.
could result in severe personal injury, Vent and air must tenninate near one another and may be
deatll,or substantial property damage. vented vertically through the roof or out a side �vall, unless
otherwise specified. You may use any of the ti�ent/air piping
2. Size openings�nly on the basis of the other appliances in methods covered in this manual. Do not attempt to install the
t6e space. No additiona] air opening free area is needed w�ight boiler using any�other means.
for the Knight boiler because it takes its combustion air
from outside (direct vent installation). Be sure to locate the boiler such that the vent and air piping
Flooring and foundation �an be routed thraugh the building and properly terminated.
The vent/air piping lengths,rouTing and termination method
Flooring must all comply witli the methods and limits given in this
manual.
The Knight boiler is approved for installation on combustible
flooring>bu� must never be insralled on carpeting. Prevent combustion air eontamination
�� Do not install the boiler on carpeting even Install air inlet piping for the Knight boiler as described in
�� 191�WAR1'dIMG this manual. Do not terminate vent/air in l�cations that can
if foundation is used. Fire can result,
causing severe personal injury, death, or �llow contamination of combustion air. Refer to Table lA,
substantial property damage. page l 1 for products and areas which may cause
contaminated combustion air.
If tlooding is possible,elevate the boiler sufficientty to prevent
avater from reaching the boiler. ������N� You must pipe combustion air ro the
boiler air intake. Ensure that the
combustion air will not contain any of the
contaminants in Table lA, page I1.
Contaminated combustion air will
dama�e the boiler, resulting in possible
severe personal injury,dcath or substantial
property damage. Do not pipe
coinbustion air ncar a s�viinming pool,for
example. Also, avoid areas subject to
' exhaust fumes from laundry facilities.
;
These areas will always contain
` 10 - contaminants.
����'� Installation & Operation Manual
7 Determine boiler Iocation (continuedJ
When using an existing vent system to Table 1A Corrosive Contaminants and Sources
install a new boiler:
-� Products to avoid:
�,WARNIN J �`i'�ure to follo�v all instructions can resutt
in flue gas spillage and carbon monoxide Sp��ay cans courainin�,chloro/tluorocarbons
emissions, causing severc personal injury
or death. Permanent wave solutions
Check the foilowing venting components before installing: Chlorinated waxes/deaners
• Material-For materials listed for use with this appliance, Chlorine-based swimming poo]chemicals
see Section 3 - General Venting,Table 3A. For stainless
steel �entu�g, an adapter of the sanie manufacturer Calcium chloride used for thawing
('['able 3B) must be used at the flue coIlar coimection. Sodiui�chloride iised for water softening
• Size-To ensure proper pipe size is in place>see Table 3C.
Check to see that this size is used throughout the vent Refrigerant leaks
system. Paint or varnish removers
• Manufacturer - For a stainless steel application, you
must use only the listed manufacturers and their rype Hydrochloric acidhnuriatic acid
product listed in Table 3A for CAT IV positive pressure (;ements and glues
venting with flue producing condensatc.
• Supports - Non-combustible supports must be in place Antistatic fabric softeners used in clothes dryers
allowing a minimum 1/4" rise per foot. The supports (,hlorine-type bleaches,detergeiits,and cleaning solvents
should adequately prevent sagging and vertical slippage, found in household laundrv rooms
by distributing the vent system weight. For additional ,�dhesives used to fasten building products and orher
information, consult the �ent manufacture�'s Similarproducts
instructions Por installation.
Areas likely to have contaminants
• Terminations-Carefully re��ie�v Sections� throu��h � to
ensure requirements for the location of the ven[and air Dry�cleaning/Iaundr��areas and e.stablishments
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical Swimming poc�ls
options listed in the General Venting Section. For �1eta1 fabrication plants
stainless steel vent,onl}�use terminations listed in Table
3B for the manufacturer of the installed vent. Beauty shops
• Seal-Z�Vith prior requirements met,the system sllould be Refrigeratio�i repair shops
tested to the pirocedure listed in parts (c) through (f} of
the Removal of an Existing Boiler Section on page 12. Photo processing plants
�ti'ith stainless steel vent, seal and connect all pipe and Auto body shops
components as specified by the vent manufacturer used;with
PIrGCPVC vent,see the Installing Vent or Air Piping Section Plastic manufacturing pla�its
O° �a�� ��'• Furniture refinishing areas and establishments
""""""""°"""""""' If any of these conditions are not met,the
81 WARNING New building construction
e�cisting system must be updated or
replaced for that concero. Failure to Remodeling areas
follow all instructic�ns can result in flue gas
spillage and carbon monoxide emissions, ��arages with workshops
causing severe personal injury or death.
11
���H�' Installation & Operation Manual
7 Determine boiler location
When removing a boiler from existing
common vent system:
�� � , Do not install the I�night boiler into a g. Any iniproper operation of the common venting system
�ommon vent with any other appliance. should be corrected so the insrallation conforms with the
I"his will cause flue gas spillage or I�'ational Fuel Gas Code, ANSI Z223.1lNFPA 54 and/or
appliance malfimction, resulting in CAN/CSA B149.1, ;A'atural Gas and Propane Installation
possible severe personal injury, death, or �-ode. When resizing any portion of the ci�mmon venting
substantial property damage. system, the cominon venting system should be resized to
approach the minimum sire as determined using the
appropriate tables in Part 11 of the National Fuel Gas Code>
E'ailure to follow all instructions can result
� t�i WARI�1lNG' ANSI Z223.1/NPPA and/or CAN/CSA B149.1, NaYural Gas
in flue gas spillage and carbon monoxide and Propane Installation Code.
e�nissions, causing severe personal injury
or death.
At the time of removal of an existing boiler, the followiiig
steps shall be follo�ved �vith each appliance remaining
connected to the comma�i ��enting system placed in
operation,�vhile the other appliances rcmaining connected to
the common venting system�re not in operation.
a. Seal any unused openings in the common venting system.
b. `'isually inspect the venting system for pro�er size and
horizontal pitch aud determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies,
�vhich could cause an unsafe condition.
c. TesT vent system—Insofar as is practical,close all building
doors and tivindows and all doors benveen the space in
which the appliances remaining connected to the
common venting system are located and other spaces of
the building. Turn on cluthes dryers and anr appliance
not connected to the common venting system. Turn on
anj� exhaust fans, such as range hoods and bathroom
exhausts,so they will operate at maximum speed. Do not
operate a summer eshaust fan. Close tireplace 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
� minutes of main burner operation. Use the tlame of a
match or candle,or smoke from a cigarette,cigar,or pipe.
E After it l�as been determined that each appliance
remaining connected to the cominon venting system
properly vents �vhen tested as outlined herein, reCurn
doors,windows,exhaust fans,fireplace danlpers,and any
other gas-burning appliance to their previous conditions
of use.
�2 �
���HT Installation & Operation Manual
2 Prepare boiler
RemOVe boller ft'om wOOd pallet �. After installation is coinplete,attach the pro}�ane com�ersion
1. Afrer removing the outer shipping carto�l from tlle boiler, 1abe1 (in the conversion kit bag) next to the boiler rating
remove the parts box. plate. Attach the LP caution label(in the conversion kit bag)
to the left side of the unit in [he lower left corner.
2. Remove the front door to aaess the]ag bolts in front of
the unit (FIG.2-1). 6. Replace the top and front access covers.
3. To remove the boiler from the pallet (after removing the Table 2A LP Converslon Tab(e
fro�it door):
a. Remove the t�vo lag bolts froro the wood pa(let LP Con��ersion Table
inside the boiler(FIG.?-1). Model LP Orifice Sta�nping
b. Detach the boiler from the lag bolts in the rear of the g� 80
unit,see FIG.�-1, Ip(, 105
151 150
NOTICE Do not drop the boiler or bump the jacket 211 210/W150
on the tloor or pailet. Damage to the ,g�, 2�5
boiler can result.
8 WARNING ��fter converting to LP,d�eck combustion per
Figure 2-1 Boiler Mounted on Shipping Pallet clle 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
�,�,�;� '3 '� � damage.
.-��,�.. � �� r i,�� �
' Figure 2-2 Installing Propane Orifice
� ,�;_ \ v ? �� ,�;
� �'' =� �t� -a;J
y
_nc t,i n '�� ;�� � r�� _ �`�
;�iv��} �'� '�`i �p�`� S
._�c�r. r.J' �"`-�R.�-r �
FRONT '''`2 REA.�t GROMMET-,� `•-t��.,�� . --
� �ff i ,..
FRr1�S ORIFI{�E � y, )
Gas conversions � �� �-����
� z��� -����_, �_
$WARNING For a boiler already installed, you must �k` ��� ?� � ��;�
turn off gas supply, turn off power aud i� s° �- " '�
�: _ ,
allow boiler to cool before proceeding. scREV�s, '� `�
You must also coinpletely test tl�e boiler oTV s � � �
atter conversion to verify performance as r� � � �`�
described under Start-up, Section 10 of �- �f
this manual. Faiture to comply could ��. ���a
result in severe personal injury, death, or ��' �
substantial property damage. '.1crvTU���
You must install a propane orifice to Leveling the boiler
operate the Kuight boiler on propane gas. L Set the boiler in place and check level.
Verify when installi�ig that the orifice size a) Adjust legs if ne�cessary to level boiler, see FIG. 2-3
marking matches boiler size(Table 2A). belo�v.
l. Remove the top and front access covers from the unit(no Figure 2-3 Leveling Legs on the Boiler
tools required for removal). ///���schewaHivE�z
�SLOT
Z. Remove the three screws securing the gas valve to the
venturi(FIG.2-2).
3. Locate the propane orifice disk from the conversion kit ��
'F�4
bag. Verify that the stamping on the orifice disk matches _- � - -�
the boiler sire(see Table 2A). "`, �
Flace the orifice into the black rubber grommet in the ����� ��a�s��
side of the gas valve and secure in the valve(FIG.2-2). �``�F '�� �
4. Reposition the gas valve against the venturi and replace �_ ' �
___ _
the screws(FIG.2-2) securing the valve ro the venturi. �...4 �nwER
i�aisE ✓
�3 ;;.
I
���NT Installation & Operation Manual '
3 General venting
Direct venting options - Sidewall Vent
� �
.�\ \�
�
� �\ ��
' � �
� , �
� � , : � ;
� ,
! `� �(/J� I �\ F
I ! I I
� ' ' �
, , �
,, ��� � , � ; , �
.�� �� I -�
, �:� (
� � � � � �
. , �
��� �
� ��� ��
�;; i� ���__
,_ � - /
�_- __
_� �_
Figure 3-1 PVC/CPVC Two-Pipe Sidewall �
Figure 3-2 Stainless Stee! Two-Pipe - See page 22
Termination - See page 21 for more details for more detarls
'�
.\\
� \\ .
1 �
I � ,
1 � ,
/ '
� , (
� I
r ��. , , ,
.
� ��� ; , , �
,�;
�
, �� �
\:g� \� �`:
�� �� `\ I I
� I 1
��. /i
i�/
/
�_' � /
y
Figure 3-3 PVC/CPVC Concentric Sidewall
Termination - See page 25 for more defails
14
�G� Installation & Operation Manual
3 General venting (continued}
Direct venting options - Vertical Vent
�__
�,, ;: ��� ``--\��
� _�_ _�_
__ �,� ,_ �
V \: �-
� ` \
�\\�1.. \�. �\
--��\ \ .���\ '�.T ___
���T�� -_\ ��� �� _
�— _— \ —'='�
1 `' � `• \�-- _
� i ,� � �
__
, -��� � ---� �
,
� £� ' (
� y �
``�� ; `�
�
� �
� � ,
i �; _, � ����.
,-� i '- � , —� � a \
4^, , � ��� , �,,.
� ��� � �
� ; ,� ; ��
.,. l,�v ;;, �� ��,
`� ;�.,� �\i �� �; �// '`�=1 �:
i� �, �, /;.
��
Figure 3-4 PVC/CPVC Two-Pipe Figure 3-5 Stainless Steel Two- Figure 3-6 PVC/CPVC Concentric
Vertical Termination - See page Pipe Vertrcal Termination - See Vertica/ Termination - See page 30
28 for more details page 28 for more detai(s for more details
Direct venting options - Vertical Vent, Sidewall Air
�_
� �_„ --�_
,__\ � �_\
��. ��
�_�� `��-
,�-_ --� =_
J �—__�� . _
� � � ,
� ,
� �� �
,
�i : ; ; i
� � ; , �
� �
, �
�-
' _ ' ��,, (�, , �` � �
�� � � �
� � �y, � � I�'
: ;�� ;- ; � �J
�� �. ., .��� �.
�� �, i
�::� ./� ��_;��=i
�;.
Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air - Figure 3-8 Stainless Steel Vertical Vent, Sidewal!Air
See page 20 for more details - See page 20 for more details
NOTICE Staiuless stzel vent/air design and terminations will tian�,lightly by manutacturer.
15
��M' Installation & Operation Manual
3 General venting
Install vent and combustion air piping
,. � •
The I�night builer must be vented an�i �WA���NG Insulation should not be used on PVC or
supplied with combustion and ventilation CPVC venting materials. The use of
air as described in this section. Ensure the insulation will cause increased vent wall
vent and air piping and the combustion air temperatures, which could result in vent
supplv coroply with these instructions pipe failw-e.
regarding vent systeiYl, air system, and
combustion air quality. Sce also Section � Requirements for installation in
of this manual. Cahada
Inspect finished vent and air piping 1. Installations must be made with a vent pipe system
thoroughly to ensiire all are airtight and �ertified to UI.(_;-S636.
comPly�vith the instructions provided and
with all requirements of applicable codes. IPEY is an approved vent manufacturer in Canada
supplying vent material listed to ULGS636.
Failure to provide a properly instalied vent
and air system will cause severe personal �• '1'he first three (3) feet of plastic vent �ipe from the
injury or death. appliance flue outlet must be readily accessible for visual
inspection.
PVC/CPVC vent piping materials 3. The components of the certified vent system must not be
�WAi�NING� Use only the materials listed in Table 3A fr�r interchanged with other vent systeiZ�s or unlisted
�� vent pipe,and fittings. Failure to compl}� pipe/tittings. For coiicentric vent installations, the inner
could result in severe personal injury, vent tube must be replaced with field supplied certifie�3vent
death,or substantial property damage. material to comply w�ith this requirement.
NOTICE l���tallation must comply with local 4. The 3" Concentric Vent Kit available from Lochinvar (see
requirements and with the National Fuel Section 4 — Sidex�all Terrni��tation — Optior�al Conceniric
Gas Code, ANSI Z223.1 for U.S. [�ent) and the 3° Concentric Vent Kit available from IPEX
installations or CSA B149.1 for Canadian are both approved for use on tfle I�night boiler. Both
installations. kits are listed to the UI..GS636 standard for use in Canada.
m WARNING }�°r closet and alcove installations, CPVC Improper installation of PVC or CP�'C
or stainle�s steel roaterial��it1ST BE used in m CAUTION
systems may result in injury or death.
a doset/alcove structure. Failure to follow
this �varning could result in tire, personal �nstalling vent and air piping
injury,or death.
All PVC vent pipes must be glued,properly NOTICE Use only cieaners,primers,and solvents that
NOTICE are a roved for the materials which are
supported,and the exhaust must be pitched pF
a minimum of a 1/4 inch per foot back to joined together.
the boiler (to allow drainage of
condensate). L �Vork from the boiler to vent or air termination. Do not
exceed the lengths given in this manual for the air or vent
�WARNING i'his appliance requires a special venting �iping.
system. The vent connection to the
appliance must be made with the starter �• Gut pipe to the required lengths and deburr the inside and
GPVC pipe section provided with the outside of the pipe ends.
appliancc if PVGCPVC;vent is to be used. � �,hamfer outside of each pipe end to ensure even cement
For stainless steel venting use an adapter �istribution when joining.
from Table 3B (page 19) that corresponds
with the int�ended vent manufacturer to be 4. Clean all pipe ends and fittings using a clean dry rag.
used and discard the CPVC starter piece. (I�4oisture will retai•d curing and dirt or grease will prevent
The field provided vent iittings must be adhesion.)
ceinented to the CPVC pipe section using
an"All Purpose Cement"suitable for PVC 5. Dr}� fit vent or air piping to ensure proper fit up before
and CPVC pipe. Use only the vent assembling any joint. T'he pipe should go a third to
materials, primer, aud cement specified in two-thirds into the fitting tv ensure proper sealing after
this manual to make the vent connections. cement is applied.
E'ailure to follow this �varning could result
� �6 in tlre,peisoiial injury,or death.
'����T� installation & Operation Manual
3 General venting (continued)
6. Priming and CemenCing:
a. F�iandle fittings and pipes carefully to prevent £ N'hile primer is still wet, apply an even coat of
contamination of surfaces. approved cement to the fitting socket.
b. Apply a liberal even coat of primer to the fittiilg g. Apply a second coat of cement to the pipe.
socket. h. While the cement is still wet, insert the pipe into the
c. Apply a liberal even coat of primer ro the pipe end to fitting,if possible twist the pipe a 1/4 turn as you insert
approximatel}�]/2"beyond the socket depth. it NOTE: If voids are present,sufficient cement was
d. Apply a second primer coat to the fitting socket. not applied and joint could be defective.
e. While primer is still wet, apply an even coat of i, y�]pe excess cement from the joint removing ring or
approved cement to the pipe equal to the depth of beads as it�vill needlesslr soften the pipe.
the fitting sockeT.
Table 3A Vent Pipe; and Fitfings
All vent pipe materials and fittings must comply with the following:
Item Material Standards for installation in:
United States Canada
PVC schedule 40 ANSI/ASTM D1785 CPVC and PVC venting must be ULC-
PVC-DWV ANSI/ASTM D2665 S636 Certified. IPEX is an approved
Vent pipe and fittings manufacturer in Canada supplying vent
CPVC schedule 40/80 ANSI/ASTM F441 material listed to ULGS636.
AL29-4C UL1738 ULGS636
PVC ANSI/ASTM D2564 IPEX S stem 636
Pipe cemenUprimer y
CPVC ANSI(ASTM F493 Cements&Primers
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
Approved Stainless Steel Vent Manufacturers
Make Model
ProTech Systems(Simpson Dura-Vent Co.) FasNSeal Vent/ FasNSeal Flex'Vent
Z-Flex(Nova Flex Group) Z-Vent
Heat Fab(Selkirk Corporation) Saf-T Vent
"Use of FasN5ea1 Flex smooth inner wall vent is to be used in vertical or near vertical sections only,taking precaution to ensure
no sagging occuis of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method,
see manufacturer's instructions.
PVCICPVC air intake/vent connections
1. Combustion Air Intake Connector (FIG:s 3-9 and 3-10) - Used to provide combustion air directly to the unit froni
ouTdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines
listed in the I�?ational�techa�lical Code,Section 3U5,Table 305.4 or as local codes dictate.
2. Vent Connector (PIG'S 3-9 and 3-10) - Used to provide a passageway for conveying combustion gases to the outside. A
transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code,
SecTion 305,'Iable 305.4 or as local codes dictaTe.
Figure 3-9 Near Boiler PVC/CPVC Venfing Models Figure 3-10 Near Boiler PVC/CPVC Venting Mode!286
89 -211
AIR AIR
.� �� r-�
VENT I�
��' �
VENT I, .� _ ,� —� �,
u'� } � ti � �; � ���� �,;`t°°,, (
� � � �� �� i
i � �
t �
a �� v� �
�.J �' � �� �� ;
��ri,, �
.�-J ���_��_ ��g �, �, I ' *� � �' �
° ' �C e,,���y:� k°`� '� __.
� � r"ti — :,'� '
�"'; �.� � s
-�� �, � �� � ���C��-� � � �
�. � �
, �: _ � , G �,
, Fv
� , ,
3"CPVC PIPE SUPPUED WITH BOILER => � 4"CPVC PIPE SUPPLIED WITH BOILER\,
MUST BE USED FOR VENT CONNECTION
MUST BE USED FOR VENT CONNECTION
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET
ANDALCOVEINSTALLATIONS. ANDALCOVEINSTALLATIONS. : �� . ,
�
���t+T Installation & Operation Manual
3 Generai venting
AIC 1111@t pip@ Illat@t'IaIS: When a sidervall or vertical rooftop combustion air supply
system is disconnected for any reason,the air inlet pipe must
The air inlet pipe(s) must be sealed. Choose ac<epTable be resealed to ensure that combustion air �vill be free of
combustion air inlet pipe materials from the following list:
cvntamii�ant:and supplied in proper volume.
PVC,CPVC or ABS �� � Failure to properly seal all joints and
Dryer Vent or Sealed Flexible Duct (not recommended seams as required in the air inlet piping
for rooftop air inlet) may result in flue gas recirculation,
Gabanized steel vent pipe with joints and seams sealed as s}�illage of flue products and carbon
specifed in this sedion. monoxide emissions causing severe
Type`B"double-wall vent�vith joints and seams sealed as personal injury or death.
specified in this section.
AL29-4C, stainless steel material to be sealed to Stainless steel vent
specification of its manufacturer. This prod�ct has been approved for use �vith stainless steel
*Plasric pipe may require an adapter (not provided) ro <<>in�z the�n�anufacturers listed in Table 3A.
transition beriveen the air inlet connection on the appliance °°-�°�°°— ��� oiily the materials,vent systems,and
and the plastic air inlet pipe. �WARNIN�
terminations listed in Table 3B. DO NOT
�WA����� Using vent or air intake maTerials otber �1�ia vent sj�sTems of different types or
than those specified,failure to piroperly seal inanufacturers, unless listed in this
a11 seams and joints or failure to follow vent manual. Failure to comply couid result in
pipe manufacturer's instructions can result severe personal injury, death, or
in personal injury, death or property substantial property dainage.
damage. Mixing of venting materials will Iustallations must comply with applicable
NOTICE
void the warranty�and certification of the nation3L, state, and local codes. Stainless
appliance. steel vent systems must be listed as a
The use of double-wall vent or i�isulated C'L-1738 approved system for the United
NOTIGE 17�aterial for the combustion air inlet pipe is States and a ULC-S636 approved system
reeommended in cold climates to prevent for Canada.
the condensation of airborne moisture in NOTICE Installation of a stainless steel vent system
the incoming combustion air. shotild adhere to the stainless steel vent
Sealing of Type "B" double-wall vent material or galvanized manufacturer's installation instructions
vent pipe material used for air inlet piping on a sidewall or supplied with the vent system.
vertica] rooftop Combustion Air Suppiv System: _
NOTICE The installer must use a specific vent
a. Seal all joints and seams of the air inlet pipe using either starter adapter at the flue collar
Alumiuum Foi] Duct Tape meeting lJL Standard 723 or connection, supplied by the vent
181A-P ar a l�igh quality UL Listed silicone sealant such as manufacturer to adapt to its vent system.
those inanufactured by I)ow Coi�ning or General Flecrric. See Table 3B for approved vent adapters.
b. Do not install seams of vent pipe on the bottom of Discard CPVC starter piece.
horizontal runs.
c. Secure all joints with a minimum of three sheet metal
screws or pop rivets. Apply Aluminum Foil Ducx Tape or
silicone sealant to all scrc:ws or ricets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC,CP�'G or ABS air inlet pipe should be cleaned aiid
sealed with the pipe manufacturer's recommended solvents
and standard commercial pipe cement for the materisl used.
The PVG CPVC,ABS,Dryer Vent or Ple�Dud air inlet pipe
shouid use a silicone sealant to ensure a proper seal at the
appliance connectiou and the air inlet cap connectioo. 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 t�he air inlet pipe ensures that combustion air will be free of
contaminants and supplied in proper volume.
18
���+T Installation & Operation Manual
3 General venting (continued)
Stainless steel air intake/vent connections Figure 3-11 Near eoiler Stainless Steel Venting Model286
I. Combustion Air Intake Connector(PIG.3-11)- Used to
provide combustion air directly to the unit from
outdoors. A fitting is providcd on the unit for final
connection. Combustion air piping must be supported ' �
per guidelines listed in tl�e National I�'[echanical Code,
Section 305,Table 305.�or as local codes dictate.
� ���� �. .
2. Vent Connector (FIG. 3-]i) - Used to provide a �� �� �� � . �� ��, �;
passageway for conveying combustion gases to the q
outside. A transition fitting is provided on the unit for � ����` '
final connection. Vent piping inust be supported per the � .�.�;a �� "���
National Building Code, Section 305, Table 305.� or as � � <:�f ;
local codes dictate. �� � „�;
I'�Ilp � ',
41 I g � �i�,:.
�i�ill{!i�
I� �
3"
S.S.ADAPTER
3"S.S.INTERMEDIATE
(FOR SAF-T VENT ONLY)
Table 3B Approved Stainiess Stee/ Terminations and Adapters
ProTech Heat Fab Z Flex
FasNSeal Saf-T Vent Z-Vent
Model Intake Intake
"Boiler Flue `*Boiler Intermediate Flue **Boiler Flue Intake Air
Adapter Termination TermAnation Adapter Adapter Termination Termination Adapter Termination Termination
81 -211 300715 FSBS3 303889 KB80211 9353BUREZ-1' g392 9314TERM 2SVSLA03 ZSVSTP03 2SVSTEX0390
FSRC3(R.C) 5300CI 2SVSRCX03
286 F303759 FSBS4 FSAIH04 K6286600 9454BUREZ-1' 9492 9414TERM 2SVSLA04 2SVSTP04 ZSVSTEX0490
FSRC4(R.C.) 303888 5400CI 2SVSRCX04
=This adapter must be used in additioi� to the boiler adapter for Saf-T vent pipe as shown in FIG.3-11,unless approa•ed vent
other than standard diameter is used. Consult a Heat Fab representative for questions.
`*The stainless steel venting optiou is only available in 3"vent diameters. �
The Knight boiler uses model specific combustion air intake Minimum / Maximum allowable
and vent piping sizes as detailed in'I'able 3C belo4v. COmbuStiOn ail' and V@nt plping I@ngths
are as follows:
Table 3C Arr lntakeNent Piping Sizes Combustion Air -= 12 equivalent feet minimum / 100
Model Air Intake V@tlt equivalent feet masimum
' 81 - 211 3 inches 3 inches Vent = 12 eyuivalent feet minimum / 100 equivalent feet
maximum
286 4 inches 4 inches
�Vhen determining equivalent combustion air and vent length,
NOTICE
Increasing or dea•easing combustion air add 5 feet for each 90°elbow and 3 feet for each 45°elbow.
or vent piping is not authorired. EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45°
elbows + (1l concentric vent kit (CVK3003) = 49 equivalent
feet of pipiiig.
NOTICE 11ie appliance output rating �vill reduce by
up to 1.5°io for each 25 feet of vent length.
: 19
��HT Installation & Operation Manual
3 General venting
Table 3D Concentric Vent Kit Equiva(ent Venf Lengths ' There will be a noticeable increase in the noise level
during normal operation from the inlet air opening.
Equivalent Vent • Using the room air kit makes the unit vulnerable to
Model Kit Number Length ��tnbustion air contamination from �vithin the
81 -211 CVK3003 3 feet building. Please review Section 1,Prevent Combustion
Air Contamination,to cnsure proper installation.
286 CVK3007 3 feet • Vent system and terminations must comply with the
RetttOVing fYOrfl @XiSting V@nt standard venting instructions set forth in this manual.
Follow the instructions in Section I, page 12 of this manual When utilizing the single pipe method,
when removin a boiler from an esistin vent s�stem. ��ARNING
� � } proaisions for combustion and ventilation
V@nt and ail' plping air must be in accordance with rtir for
Coinbustion and Ventilation, of the latest
Vent and air System: edition of the Na[ional Fuel Gas Code,ANSI
Z223.1,in Canada,the latest edition of CGA
NOTICE tustallatio❑ must comply with local Standard B149 Installation Code for Gas
requirements and with the National Fuel Buriling Appliances and Equipment, or
Gas Code, ANSI Z223.1 for U.S. applicable provisions of the local building
installations or CSA B149.1 for Ganadian codes.
installations.
You must also instail air piping froni outside to the boiler air Table 3E Optional Room Air Kit
intake adapter. The resultant installation is direct vent(sealed Model Kit Numbel'
combustion). 81 - 211 KIT30052
You may use any of the vent/air piping methods covered in 286 KIT30053
rhis manu<zl. Do not attempt to install the Knight boiler using
anti��,rher mcans. Air contamination
��A����� DO NOT mu components from different p�ol and laundry products and common household and hobby
�� sysrems. 'The venT system could fail,causing products often cont�in fluorine ar chlorine compounds. 4Vhen
leakage of flue products into the living these chemicals pass through the boiler, they can form strong
syace. Use onlr approved stainless steel, �lcids. The acid can eat through the boiler wall,causing serious
PVC or CPVC pipe and fittings. For
PVC/CPVC use with primer and cement dainage and presenting a possible threat of flue gas spillage or
specifically designed for the material used. boiter water Jeakage into the building.
Vent, air piping and termination: Please read the information given in 'Table lA, page 11,listing
The I<night boiler vent and air piping can be installed through contaminants and areas likely to contain thein. If
the roof or through a sidewall. Follow the procedures in this contaminating chemicals will be present near the location of the
manual for the method chosen. Refer to the information in �1Oiler combustion air inlet, have your installer pipe the boiler
uimbustion air and vent to another location,per this manual.
this manual to determine acceptable vent and air piping
length. lt the boiler combustion air inlet is located
1�WARNtNG .
Optional room air an a launciry room or pool facility, for
<�xample, these areas will al�vays contain
NOTICE UPtional room air is intended for harardous contaminants.
commercial applications. Combustion air
piping to the outside is recommended for �w�����G To prevent the potential of severe personal
residential applications. �njury or death,check for areas and products
Commercial applications utilizing [he Knight boiler may be listed iil Table lA, page ll before installing
installed�vith a single pipe carrying the flue products to the the boiler or air inlet piping.
outside while using combustion air from the equipment If contaminants are found,y�ou b4UST:
room, In c�rder to use the room air venting option the • Remove contaminants permanently.
following ccmditions and considerations must be tollowed. —OR—
• The unit I�1UST be installed with the appropriate •Relocate air inlet and vent t�erminations
room air kit(Table 3E). to othei•areas.
• Tl�e eyuipment room MUST be provided with
properly sired openings to assure adeyuate
combustion air. Please refer t�instructions provided
with the room air kit.
2�
(���H'�" Installation & Operation Manual
4 Sidewall direct venting
Ventlair termination - sidewall Figure 4-1A PVC/CPVC Sidewall Termination ofAir
�WARNING
Follow instrttctions below �vheu and Vent
determining vent location to avoid roeo��eR
possibility of severe personal injury, death, �NECrior,
or substantial property damage.
FROtd BOILE� ��_
p �A�A A gas vent extending through an exterior vENra�aE : �
lEl �YMRNING , CONNECTION -
wall shall not term�nate adjacent to a wall or _ _ _ '� �� �
tz„
POSSIBLE ORIENTATIONS I ���- . ��AIN
below buil��ing extensions such as eaves, � � � �"�� ��
parapets, balconies, or decks. Failure to i ��'—' '—�� i ��r� � ,� -�Nc
comply could result in severe personal i , — - - i � ��, �,
injury, death, or substantial property i i �eNrrA�R �� ,1/" '�
T�RMINATION t
damage. � i i j� •
� Do not connect any other appliance to the i �'�` - � � � ,�.,
1�WARNiNG ���i�� � �;-
� � vent pipe or multiple boilers to a common i i i � ",'"
� �
vent pipe. Failure to comply could result in i i e�aoEOR—%� �y
severe personal injury,death,or substantial i_ _ _ _ _ _ _ _ _ _ � SNO"'""E
property damage.
NOTICE Installation must comply with local
Table 4A Srdewafl Vent Kits
requirements and wiTh the Nationa] Fuzl
�a5 coae, a�si z�23.i tor u.s. Model Kit Number Vent S�ze
installations or CSA B149.1 for Canadian
installations. 81 - 211 KIT30045 3 inch vent
Determine location 286 KIT30046 4 inch vent
I.ocarc the vent/air terminations using the follo�eing �f using the alternate sidewall termination:
guidelines: 3. The aii• piping must termviate in a dorvn-turned elbo�v as
shown in FIG.4-1B. This arrangement avoids recirculation
1. The total length of piping for vent ar air must not exceed of flue products into the combustion:�ir stre;�m.
the limits gi��en in the General Venting Section on page 19
of this manual. �. T1�e vent piping must terminate in an elbow pointed
3. You must consider the surroundings when Cerminating the �?ut�,-ard��r a�*ay from the air inlet,as shown in I��IG.4-1 B.
vent and air: 1�WARNING Do not exceed the maximum lengths of the
a. Position t6e vent termination where vapors �vill outside vent piping shown in I'1G. 4-1B.
not damage nearb}' shrubs> plants or air Excessive length exposed to the outside
conditioning equipment or be objectionable. could cause freezing of condensate in the
b. The flue products will fornl a noticeable plume as vent pipe, resulting in potential boiler
they condense in cold air. Avoid areas where the shutdown.
plume could obstruct windoH->>iews. Figure 4-16 Alternate PVC/CPVC SidewaN Termination
c. Prevailing winds could cause freezing of ofAir and Vent w/Field Supplied Fittings
condensate and water(ice buildup where flue
TO BOILER
product�impinge on building surfaces or plants. iNTnKe nik BIRD SCREEN
d. Avoid possibility of accidental contact of flue cor,NECrioN
�v v
products with people or pets. �� � �� ��_ �
FROM BOILER � t a & �
e. Do not locate the terminations where wind eddies veNTaiPe �'\ � �7� ` iz°nniN
could affect performance or cause recirculativn, CONNECTION ` ;,��r��`_:� �s Mnx
such as inside building corners, near adjacent '
buildings or surfaces, window wells, stairwells, r ��� �`��
alcoves,courtyards,or other recessed areas. ,� ��°3��
TERMINATION � `��' �\^
li1 WARNtNG
�� Side�vall vent and air inlet terminations P,�,TF f�� '� �
must terminate in the same pressure rone.
f�. Do not tern�inate above an}� door or window. ,,, � �' � MiN
Condensate can freeze,causing ice formations. � B�RO-�
SCREEN
g. Locate �r guard vent to prevent condensate damage
, , GRAC]E OR
YO eRYC'�C10C fllllStleS. SNOW LINE
21 _
'���� Installation & Operation Manual
4 Sidewall direct venting
V@I1t�11C t@i'1'11111atlOfl — Sla@Wa�� �• A�[aintain clearances as shown in FIG:s 4-1A thru 4-3B,
pages 21 and 23. Also maintain the following:
Figure 4-1C Alternate PVC/CPVC Venting Arrangement a. Vent�nust ter�ninate:
(if Space Allows) w/Field Supplied Fitfings •�t least 6 feet from adjacent walls.
ro aoi�eR -���„—•-^�,,� couP�wc •No closer than 12 ulches below roof overhang.
INTAKE AIR
.�on,NecnoN ��� •At least 7 feet above any public�valkway.
� ' % • At least 3 feet above any forced air intake witllin
� � 12"MIN
�+ r) '�� 15" AX l�ffet.
FROM BOIL\ y
VENTPIPE •No doser than 12 inches below or horizontally
CONNECTION j, , '^� .,
, , from any door or window or an}�other gravity air
�, '.
� \ inlet.
�f i ' �BIRD 9CREEN
��� � � b. Air inlet must terminate aT least 12 inches above
�� � �"� � grade or snow line; at least 12 inches below the vent
�
`�"� � 'iN terminatiou; and Che vent pipe must not extend
B�RO�� more than 24 inches vertically outside the building
SCREEN
GRADEOR 15 SIlOWI] 11]FIG.�-IB.
sNOw�we c. Do not terminate doser than � feet horizontallv
ALTERNATE VENTING ARRANGEMENT
��FSPOCEPeRM�TS� from am electric ineter, gas meter, regulator, relief
Figure 4-1D Alternate PVC/CPVC/SS Venting valve, or other equipment. Never terminate above or
Arrangement - Typical Staintess Stee! SidewaN below any of these within 4 feet horizontally.
Termination of Air and Vent w/Field Supplied Fittings, 6. Locate terminations so they are not likely to be damaged by
Utilizing 90° Elbow Intake foreign objects,such as stones or balls,or subject to buildup
of leaves or sediment.
Figure 4-2A Clearance to Gravity Air Inlets
TO BOILER � �
INTAKEAIR . 72"MIN � �
CONNECTION\ 15"MAX t �-� = �
fROM BOILER \ � � .r �:� ..
VENT PIPE `g
CONNECTION� `'�g� � ,
� ��A��
�� � �r�
,
z
.. ��tfN '�.
i
�'� � . ,. ��j� 1 � �'.
... 12"��'.IN �) -1 �'� 4 `
BIRD SCREEN�J J � � j' �,, ` �A� ��'
GRADE OR J �' � vj" `\``�. � �
1
SNOW LWE � � � ' �' �
, � j ����--VENTIAIR
MODELS 80-285 J.=�� �' TERMINATION
12"
Figure 4-1E Alfernate SS Venting Arrangement - "'� �""""
Typica! Sfain/ess Steel Sidewall Termination of Air and ������ �-M;N
Vent w/Field Supplied Fittings, Utilizing FaslVSeal's
Hood intake Figure 4-26 Alternate Clearance to Gravity Air Inlets
�a�ROSCReeN w/Field Supplied Fittings
TO BOILER
INTAKEAIR �"�"�-� � �
�CONNECTION ^'`�` � �
� � "(�SMM)MIN �'�� � ���� '.
. �i'1381 MM)MAX (`�� � (`� ��A i.i,
I
��
��.l�rt ��,� ., . ` ��`�/ �' i' �� �i
�
FROMBOILER � �� �~\ v �����'�r� � L�
VENTPIPE � �� i2 . I
CONNEGTION y ��K�+ ' � RAfN � �
�� : -'''`�i, ,.� � �
i
��� � •� � � � "'�_.,'BIRD
� 12 (305�MM)MIN "��' �� '� ;"`% SGREEN
� y 1"�, _t
�� � - � ITVPICAL)
J ! �
r\
GRADE OR 1 \, �
SNOW LME "� � 12
I /MIN.
�f'
. �� MODEL 285 WITH FASNSEAL ONLY � �����° �y-
MIN.
�C ���T� Installation & Operation Manual
4 Sidewall direct venting (confinued)
Figure 4-3A Clearance to Forced Air Inlets `�• Asse,nble the vent cap to the vent plate (see FIG. �-4A).
Insert the stainless steel screws into the vent cap screw
.�THAN;o hole openings and securely attach the vent cap to the vent
�� plate.
veHr�A�R _ i��� ��,T �e. 5. Seal all wall cavities.
TERMINATION � . ' �
. '� '-t.1.:N.
� `� �; i Figure 4-4A Sidewall Termination Assembly
�����
� �- " �
,� r.� . � �-FORC�FDAIR \ /-:.
;.;�� :N�ei \\ �-AIR PIPING �� .
{ . �' �v �. �>. �. I
� v
�V �
� � �� '� I
°� VENT PIPING -����� j', ' .�.
� �`�" \ V,
��Mw qaove nNr �-� . A � � � , /-VENT PIATE
i
aueuc wa�Kwa� � -�-."` WALL PLATE !�-�-� �
i �..' � � �VENT CAP
� \y,�.;� � / v�
�� .. . � -- ( - �'� /
GALVAh '��. :; ' I... ��� ,��j> ,�`-. :
''�� THIME] -.. � �1 � -°�
$ �,,,
w�
',`�i .
Figure 4-36 Alternate Clearance to Forced Air lnlets �
w/Fiefd Supplied Fittings
,IF LESS
� THAN 10
�� Prepare wall penetrations (Alternate -
. -"36 Field Supplied Option)
� �r� '�.MIN.
�;-°`� '��'`''� 1. Air pipe pe.iletration:
��j��� ����� a. Cut a hole for the air pipe. Si�e the air pipe hole as
.�`` � �'��FoRCeoniR close as desired to rhe air i e outside diaineter.
INLET �p
��, ?. Vent pipe penetration:
1� ��, �_BIRD
scReeN a. Cut a hole for the vent pipe. I�or either combustible
��MiN.neovenr,v, \\� �'�P'c"�� or noncombustible construction, size the veiit pipe
PUBLIC WALKWAY -, � \ �,j
� � hole with at least a 1/2 inch clearance around the vent
�,/��'��`"�� pipe outer diameter:
����'`� •4'/z inch l�ole for 3 inch vent pipe
•5'/z inch hole for 4 inch vent pipe
Prepare wall penetrations b. Insert a galvanized metal thimble in the vent pipe
l. Use the factory supplied wall plate as a template to locate hole as shown in FIG.4-4B.
the vent and air intake holes and mounting holes. 3. Use a sidewall termination plate as a template for correit
Air pipe penetration: location of hole centers.
a. Cut a hole for the air pipe. Size the aii•pipe hole as 4. Fotlow all local codes for isolation of vent pipe when
close as desired to the air pipe outside diameter. passing through floors or walls.
Vent pipe penetration: 5. Seal exterior openings thoroughly with exterior caulk.
a. Cut a hole for the vent pipe. For either combustible
or noncombustible constn�ccion, size che vent pipe Figure 4-46 Alternate Sidewall Termination Assembly
hole with at least a 1/2 inch clearance around the w�Field Supplied Fittings
vent pipe outer diameter: e�aow
•4!/z inch hole for 3 inch vent pipe AiR PiPiNc
•5?/z inch hole for 4 inch vent pipe vENrPiPiNC „�.��� �����
Drill 3/16" diameter holes for inserting tl�e plastic ���'��� �' : .
anehors into the wall. � aiR�seReerv
.� '
2. Install the vent and air intake piping through the �vall � ���
into the vent plate openi�lgs. Seal all gaps between the '�� ���
pipes and wall. Use RTV silicone sealant to seal the air � '�
pipe. Use the cement/primer listed in Table 3A on page �
I%t0 Sed�tlle Vellt��I��Et. GALVANIZED ELBOW
THIMBLE
3. 1�IOUIlt 8]]({ S2CllCe tll2 V2llt p�dte t0 t�]2 Wall US111�T SIDEWALL �BIRD SCREEN
St3lrileSS SCee� SCt"e�NS. Sed� c1t'OUI7C{ t}le �fj8te t0 t�le W81� TERMINATION PLATE
assuring no air gaps. 23 ���
��� Installation & Operation Manual
4 Sidewall direct venting
Termination and fittings Figure 4-5A Multiple Vent Terminations (must also I
1. 1 he air termmanon couphng must be onented at least Comply with Figufe 4-9A)
12 inches above grade or snow line as shown in FIG.4-lA,
page 21. 12"MIN.BETWEEN EDGE OFAIR
�INLET AND ADJACENT VENT OUTLET
2. Maintain the required dimensions of the finished
terinination piping as sho�vn in FIG.4-lA,page 21. VENT—•
..._.1 _�.,__""'� .__-- . ..
3. If usin�the alternate sidewall terniination do not extend '1,
esposed vent pipe outside of the building more than what �� ;?'�A�R
is shown in this document. Condensate could freezc and � �, '
block vent pipe. l r r-�'�
ti�%``�
4. PVC/CPVC terminations are designed to accommodate r"� .��
anti �vall thickness of standard constructions per the �' ��
directions tound in this manuaL i
5. Stainless steel terminations are designed to penetrate � �.
walls with a thickness up to 9.25 inches of standard
Constnidion. � � �VENTIAIR
TERMINATION
Multiple vent/air terminations
1. 1ti'hen terminating multiple I�night boilers terininate
each vent/air connection as described in this manual
(FIC�.�}-5�},
Figure 4-5B Alfernate Multipte Vent Terminations w/Field
Supplied Fittings (must also comply with Figure 4-16)
�WARNING '��1 vent pipes and air inlets must
terminate at the same height to avoid VENT
possibility of severe personal injury,
death,or substantial property damage. {
2. Place wall penetrations to obtain minimum clearance of _ ����"�1 MIN.
12 inches between edge of air inlet and adjacent vent 15"MAX.
outlet,as shown in FIG.4-5A for U.S. inst�illations. For � �, ,�
Canadian instal(ations> provide clearances required by� � ����-'�', ��� ��
CSA B149.1 Installation Code. � �'`�--�'�I��
(H/
3. The air inlet of a I�night boiler is part of a direct vent J � `
connection. It is not dassified as a forced air intake��ith � �
, �f��'.
regard[o spacing from adjacent boiler vents. � 12"MIN.BETWEEN EDGE OF AIR
I �PIPE AND ADJACENT VENT PIPE
fl
AIR
` 24
��rE-�T Installation & Operation Manual
4 Sidewall direct venting (confinued)
Sidewall termination - optional concentric vent
Description and usage
Lochinvar offers optional conceutric combustion air and vent e. Do not� terminate above any door vr window.
pipe termination kits(Factory Kit#CVK30�3 for 3"diaineter Condensate can freeze,causing ice forniations.
- ,�9odels 8l - 211 and #CVI�3007 for 4" diaineter - n4odel f. Locate or guard ven[ to prevent condensate damage
286). Botll colnbustion air and ve�it pipes must attach to the to exterior finishes.
termination kit. The termination kits must terminate outside �, Cut one (1) hole (5 inch diameter for #CVK3003
the structure and must be installed as sho�vn belorv in installations or 7 inch diameter for �Cl'K3007
FIG.4-6. installatioris) into the structure to install the termination
The required combustion air and vent pipe materials are kit.
listed in 1�able 3A,on page l7 uf this man�ial. ti. Partially assemble the concentric ��ent termination kit.
Clean and cement using the procedures found in these
Figure 4-6 Concentric Sidewall Termination instructi�ns.
OvERHANG a. Cement the Y concentric htting to the larger kit pipe
oR RooF (FIG:s 4-7 and 4-8).
b. Cemenr the rain cap to the smaller diameter kit pipe
�• (FIG:s 4-7 and 4-8).
�
� •� Figure 4-7 Kit Contents CVK3003
� ��. —
�° �
� 12" RAIN CAP
�/J-�'` �°�� <`� MIN
e�
' '1'� p�
,�'
i'�
��� � 4"DIA.
� SDR-26PIPE i�
� �� �, 2 1/2"DIA.
r� �i �.! SDR-26 PIPE
� S-
�,.' /� ��;,,
„K 12n / J l.:
MIN �r�
'��
I GRADEISNOWLWE
@
Sidewall termination installation "Y"CONCENTRIC
FITTING
1. Determine the best location for [he termination l:it (see
FIG.4-6).
Figure 4-8 Kit Contents CVK3007
2. The total length of piping for vent or air must not eaceed —
the limits given in the General Venting section on page 19 RAIN CAP
of this manual.
3. You must consider the surroundings when terminating 6"(152 MM)TO 4"(102 MM)REDUCER
the vent and air:
a. Position the venl termination where vapors will not s°�is2 MM�oin.
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. The flue products tivill form a noticeable plume as s•�iez Mnn�oin.
they condense in cold air. Avoid areas where the
plume could obstruct windo�v V12W5. 4"(102 MM)DIA.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where tlue products impinge °rcoNCeNrRic
FITTING
on building surfaces or plants.
d. Avoid gossibility of accidental contact of flue s•�iezMM�oin.
products�+=ith people or pets. ��F�Exie�e°PiPe
COUPLING
25 .
�� Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination - optional concentric vent
Figure 4-9 Concentric Vent Dimensional Drawing - Figure 4-10 Concentric Vent Dimensiona! Drawing -
Models 81 -211 Model 286
INTAKE/COMBUSTION AIR .A,
.A.�
�"B"DIA.PVC 'C DIA. "B'DIA.
��"�13/16'
�D �
_ ��^ �- :, 3 ,�D� �.
.:;.._ _ _�____________ (76MM I
` _- _- -' _'_ -_ � - ��.,-__ _ __--
_-__-__
•E• --_ E
- .,<.-'I.. � ,.
� . . ... __ �,
�,:. .i i� �, , �, � ',," . •
-'� �'---1 1/2" "C'DIA. � I 7..
"B..DIA.PVC �"F" "G' "H"DIA.
VENT i EXHAUST "8"DIA.PVC ,F,
VENT/EXHAUST
A B C D• E F A B C D E F G H
38 7/S" 3" 4 1/2" 21 1/8" 7 3/8" 6 1/2" 60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"
NOTICE Instead of cementing dle smaller pipe to �, Install the Y concentric ftting and pipe assembly through
the rain cap,a field-supplied stainless steel the structure's hole from an inside�vall.
screw may be used to secure tlle hvo (2)
coi��ponents together when field NOTICE D�iiot allow insulation or other materials to
disassembly is desired for cleaning (see accumulate inside the pipe assembly� when
��'1�'•�-�1�• installing through the hole.
�'"�A".�",���� 1�Vhen using the alternate screw assembl�' -�
�. Install the rain cap and small diameter pipe assembly into
method, drill a clearance hole in the rain the Y concentric fitTing and large pipe assembly from an
�ap and a pilot hole in the vent pipe far the outside wall. E�isure siiiall diameter pipe is bottomed and
screw size being used. Failure to drill cemented in the Y concentric titting for #CVK3003
adequate holes may cause cracking of PVC installations and fastened tightly into the rubber adapter for
components, allowing combustion �C��h3007 installations.
products to be recirculated. Failure to
follow this warning could result in personal 8• �ecure the assembly to the structure as shown in FIG.4-12
injury or death. using field-supplied metal strapping or equivalent support
material.
lsl WARNING ��O not operate the appliance with the rain
� �.�ap removecl or recirculation of combustion NOTICE F..nsure termination location dearance
products�nav occur. �h'ater may also collect dimensions are as shown in FIG.4-6.
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to NOTICE If assembly needs to be extended to allow
follo�v this warning could result in product sidewall thickness requirement, the two (?)
damage or improper operation, personal pipes supplied in the kit may be replaced by
injury,or death. using the same diameter, field-supplied
SDR-26 PVC (D2241) pipe for CVI�3003
Figure 4-1� Rain Cap to Vent Pipe A/ternate Assembly and standard scheciule�u PVC for CVK3007.
Do not extend dimension D* more than 60
STAWLESS STEEL SCREW 1RCIleS�Sez FIG�S�-�8I]d 4-lO).
(FIELD SUPPLIED)
DRILL CLEARANCE HOLE IN NOTICE If aSSElTlli]}' dfpt}I IlezdS t0 �e te(jLlCec�,
RAIN CAP 8 PILOT HOLE (�1ri121lSlOri I)C8Il be 1S 51'101't aS OSSIb1E.
IN VENT PIPE P
I �
�— I �
� i � I
�
i
26
L�
���!�ff' Instailation & Operation Manual
4 Sidewall direct venting (continued)
Sidewall termination - optional concentric vent
Figure 4-12 Concentric Vent Sidewall Attachment
ELBOW
(FIELD
SUPPLIED) STRAP
(FIELD
SUPPLIED)
COMBUSTION
AIR = COMBUSTION
�__ AI R
�
VENT � '' � A'
--� �,,� ` I_ -�►
VENT
r.r.
.,�:
Note: CVK3003 shown for illustration purposes.
CAUTION ��� �'UT use field-supplied couplings Multiventing sidewall terminations
to eYtend pipes. Airflow restriction�k�ill
occur and may cause intermittent bVhen two (2) or more direct vent appliances are vented near
operation. each other, each appliance must be individually vented (see
FIG.4-13). NEVER common vent or breach vent this appliance.
9. Cement applia�ce coinbustion air and vent pipes to the �en two (2) or more direct vent appliances are vented near
concentric vent terinination assembly. See FIG. 4-12 each other,two(2)vent terminations may be installed as sho�vn
for proper pipe attachment. in FIG.4-13. It is important that vent terminations be made as
10. Operate the appliance one (1) heat c}�de to ensure shown to avoid recirculation of flue gases.
comUustion air and vent pipes are properly connected
to the concentric vent termination connections.
�"
� f:;
� a.. ` �~°s.�
� .,���.
� �� � �
t '��� ''�. �' �T
12"
!� � ��`MINIMUM
�
��'� � � VENT
�
.f'>` '
�"'--COMBUSTION
' AIR
Figure 4-13 Concentric Vent and Combustion Air Termination
27
����T Installation & Operation Manual
r'J Vertical direct venting
Vent/air termination - vertical
�WARNING Follo�v instructions belo�v titirhen ��������, Rooftop vziit and air inlet terminations
deternlining vent location to avoid must terminate in the same pressure
possibiliry of severe personal injury,death zone,unless vertical vent sidewall air is set
oi�substantial property damage. up as shown in the General Venting -
�WAFtNING ��"'�ot connect any otl�er appliance to the
Vertical VenC,Sidewall Air Section.
vent pipe or multiple boilers to a common
ven�pipe. Failure to comply could result in Figure 5-1A PVC/CPVC Vertiea! Termrnation ofAir and
severe personal injury,death,or substantial Vent
�7COpeCty'C�1t113g�. ALTERNATE WTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24"OF VENT�
NOTICE Installation must comply with local PiPe
requirements and with the ]Vational Fuel
Gas Code, ANSI Z223.1 for U.S.
BIRD SCREEN
installations or GSA B149.1 for Canadian ' �'� :
(TYPICAL)� e' i
1riSYd1�1C1011S. �"�
;,�"��VENT i I,...
Determine location � ' �
COUPLING
FIELD SUPPLIED � 'w
. ( )
L,OC3Ye ll'le Ve17I�£1LC YeCIT11I13Y1011S USlll� I�lZ fO�ION'lll� � � ' 6"MINIMUM
gllldEllllZS: i� /`�, � SNOW R�OOF/
Y `
l. The total length of piping for vent or air must not exceed
the limits given in the Ueneral Venting Section on page vENrouT�eT �' �� " ��
12"MINIMUM ���' COMBUSTION !
I9 Of Y}11S 7ridT1Ua1. ABOVEAIR INLET � A�R, �'%
2. The vent must terminate at least 3 feet above the highest
place in which the �•ent penetrates the roof and ac least Figure 5-16 Stainless Stee! Vertiea! Termination of Air
2 feet above any part of a building�vithin 10 horizontal and Vent
feet. ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
3. T�12 all" plping n1USt tel'minate ltl a dOWn-tUC71ed 180° ANYWHERE WITHIN 24"(610 MM)
return piye no further than 2 feet from the center of the oF vENT PiPE-
vent pipe. This Placement avoids recirculation of flue
products into the combustion air stream. �
/ BIRD SCREEN
4. The vent piping must terminate in an up-turned coupling � �'`,�--' ��`� ," (TYPieA�)
as shown in FIG.5-lA. The top of the coupling must be f� ,� ` � {
�
at least 1 foot above the air intake. �Nhen tl�e vent �-``� � �
termivation uses a rain cap as illustrated in FIG. 5-18 �.- , s°��52 MM>MiwMUM
maintain at least 3b" (914 mrn) above the air inlet. The r�r� ; neovE RooF�
�[- SNOW LINE
air inlet pipe ancl vent pipe can be located in any desired � �������'
�'" C��«
�G19,BUSTION
position on the roof,but must always be no Yurther than v���o�� � ArF � '
2 feet(.6 m) apart and with the vent termination at least uT�ET — " '
36"(914 MM)MINIP�IUM
1 tOOt aliOV�t}lf 81P IritBke. ABOVEAIR INLET
5. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of lcaves or sediment.
28 _ .,,:
����I' Installation & Operation Manual
5 vertical direct venting (contrnued)
Vent/air termination - vertical
Prepare roof penetrations Multiple vent/air terminations
1. Air pipe penetration: 1. When terminatiiig multiple ICniglit boilers, terminate
a. Cut a hole for the air pipe. Size the air pipe hole as each venr/air connection as described in this manual
close as desired to the air pipe outside diameter. (FIG.�-2).
2. Uent pipe penetration: :��q����� Ieriniriate all vent pipes at the same height
a. Gut a hole for the vent pipe. For either combustible �and all air pipes at the same height to
or noncombustible construction, size the vent pipe avoid possibility of severe personal injury,
hole rvith at least a 1I2 inch clearance around the dearh,or substantial property damage.
vent pipe outer diameter:
•4�/z inch hole for 3 inch vent pipe �• Place roof penetrations to obtain minimiim clearance of
•�'iz inch hoJe for 4 inch vent pipe 12 inches between edge of air intake elbow and adjacent
b. Insert a galvanized meral thimble in the vent pipe vent pipe of another boiler for U.S. installations (see
hole. FIG.5-2). For Canadian installations,provide clearances
required by CSA B149.1 Installation Code.
3. Space the air and vent holes to provide the minimum
spacing shown in FIG.5-lA,page 22�. 3. The air inlet of a Knight boiler is part of a direct vent
connection. It is not classitied as a forced air intake with
4. Follow all local codes for isolation of vent pipe when i'egard to spacin�fi-om adjacent boiler venrs.
passing through floors,ceilings,and roofs.
5. Provide flashing and sealing boots sired for the vent pipe F�gure 5-2 Vertica! Terminations with Multiple Borlers
and air pipe.
, ��
12"MINIMUM VERTICALLY
Termination and fittings �FROMVENTOUTLETTO
vervr\\ / . ANVAIRWLET
1. Prepare the vent termination coupling and the air � °'R
"�/ 12"MINIMUM FROM EDGE OF AIR
1C'CI11111flt101] e1�OW �FIC. rJ-It�� tiV lllSel'(lll�bll'd SCT'el'I15. , �INTAKEPIPETOADJACENTVENT
'"ENT \ � plpE FROM ANOTHER BOILER
Bird screens should be obtained locally. ; ��R �
2. The air piping must te►•minate in a down-turned 180° ,
return bend as showu in FIG. 5-lA. Locate the air inlet
pipe no further thau 2 feet from the cei�ter of the venr �
pipe. This placement avoids recirculation of tlue '
products into the combustion air stream. -�
3. The vent piping must termulate in an up-turned coupling
as shown in FIG.5-IA. The top of the coupling must be Figure 5-3 Alternate Vertical Terminafions with Multiple
at least 1 foot above the air intake. �vhen the vent Boi/ers
termination uses a rain cap as illustrated in F1G. 5-1B
maintain at least 36°(914 mm)above the air inlet. The air ���
inlet pipe aud vent pipe can be located in any desired /' `�
position on the roof,but must ahvays be no fiirther than �� VENT �
L feet apart and with the vent termination at least 1 foot rt �
above the air intake. vENT � ��
\
12"MINIMUM VERTICALLY
4. Ib137T1t3111 Clle recjltl['2CI dttTlzriSlOnS Of t}te f7111SheC� FROM VENT OUTLET TO
termination piping as shown in FIG.5-lA. ANVAiR�N�ET
� ':.���AIR `\
5. Do �lot estend esposed vent pipe outside of building
more than sho4vn in this document. Condensate could A�R
freeze and block vent pipe.
k: 2g
(�iZwcHT Installation & Operation Manual
'J� Vertical direct venting
Vertical termination - optional concentric vent
Description and usage
Lochim-ar offers aii optional concenYric combustion air aild 2. Cut one {]) hole (5 inch diameter tor #CVK3003
vent pipe termination kit. Both combustion air and vent installations ar 7 inch diaineter for #CVK3007
pipes must attach to the termination kit. The termination kit installations)into the struct�ure to install the termination
must tenninate o��tside the structure and must be installed as kit.
shown in F[G.5-9.
3. Partially assemble the concentric vent termination kit.
Field supplied pipe and fittings are required to complete the Clean and cement following the cleaning procedures in
installation, these instructions.
The required combustion vent pipe and fitCings are listed in a. Cement the F concentric titting to the larger
T'able 3A,on page 17 of tl�is rnanual. diameter kit pipe(see PIC's 4-7 and 4-8,page 25).
b. Cement rain cap to the sma]ler diameter kiT pipe(see
Vertical termination installation FIG:s 1-7 and 4-8,page 25).
1. See Section 5, Vertical Direct Venting - Determine NOTICE Instead of eementing the smaller pipe to
I,ocation (where applicable). the rain cap,a field supplied stainless steel
screw may be used to secure the rivo (2)
Figure 5-4 Concentric Vertical Termination components together when tleld
�� �.� disassembly is desired for cleaning (see
` FIG.4-1 l,page 26).
vEN7 � ' ���'������N��, 4Vl�en u.sing the alternate scre�v assernbly
method, drill a clearance hole in the rain
A` ca and;� ilot hole in the vent i e for the
COMBUSTION P P p p
' � A�R screw size being used. Pailure to drill
� � adequ�te holes may cause cracking of PVC
� components, allo�ving combustion
� products to be recirculated. Failure to
follow this warning could resu]Y in
12"f18"FOR CANADA) � �� ersonal i[ijur or death.
MINIMUM CLEARANCE P }'
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24"ABOVE ROOF.
Figure 5-5 Do Not lnstal! U-Bend to Rain Cap
_—�\
_�
30
�+��1" Installation & Operation Manual
'rJ Vertical direct venting (continued)
Vertical termination - optional concentric vent
�WARNING �O nOt operate the app(iance�vith the rain p0 NOT use field-supplied couplings to
cap removed or recirculation of �AUTION
extend pipes. Airflow restriction will
combustion products may� occur. �ti'ater occur.
may also collect inside the ]arger
combustion air pipe and tlo�v ro the 6. Install the rain cap and the small diameter piye assembly
burner endosure. Failure to follow this �pto the roof penetration assembly. Ensure the small
warning could result in product damage diameter pipe is cemented and bottomed in the Y
or improper operation,personal injury,or c�ncentric fitting for #CVK3003 installations and
death. fastened tightl}� into the rubber adapter Yor #CVK3007
installations.
4. Llstall the Y conFei�tric fitting pipe assembly up through
the structure's hble and field supplied roof boot/flashing. �• Cement the appliance co�nbustion air and vent Fipes to
the concentric vent termuiation assembly. See FIG. 5-6
NOTICE �o not allow insulation or other materials for proper pipe attachment.
to accumulate inside the pipe assembly
�vhen installing through the hole. R. Operate the appliance through one (1) heat cy�cle to
ensure combustion air and vent pipes are properly
5. Secure tlie assembly to the roof structure as shown below connected to the concentric vent termination
in FIG. 5-6 using field supplied roetal srrapping or
connections.
zquivalent support material.
Multiventing vertical terminations
Figure 5-6 Concenfric Vent Roof lnstallation
Note: CV1�3003 shown for illustration purposes. When two (2) or inore direct vent appliances are vented near
VEN7 each other, each appliance must be individualt�� vented (see
1 12"(78"FOR CANADA) FIG. S-7), NEVER common vent or breach vent this
MINIMUM CLEARANCE
ABOVE HIGHEST appliance. ��'hen two (2) or more direct vent appliances are
nNTiciParEO sNOw vented near each other tti�o (2) vent terminations may be
LEVEL MAXIMUM OF �
COMBUSTION — z4"ABOVE ROOF. i17Sla��ed 8S sho�vn in FIG. 5-7. It is important that vent
��R � terminations be made as shown to avoid recirculation of tlue
RooF soor r �,�.?�� l gases.
FLASHING�� �'"�---�' �=
(FIELD SUPPLIED) �', '�,,
'` ' � Figure 5-7 Concentric Uent and Combusfion Air Vertica!
� [ �c;;
� Termination
,';°
�. � - SUPPORT
(FIELD SUPPLIED) ,_ �p°
'� ! MINIMUM
� r'''
ELBOW
_ (FIELDSUPPLIED) 4,: � _
I --- � ��� �{,.
� � COMBUSTION � ��'�
VENT� � AIR �� ��4--�.-+� � F��,�� .�� � , COMBUSTION
"�:.%'`�� v�� - _ "�AIR(TYPICAL)
NOTICE E��sure termination height is above the
roof surface or anticipated snow level ���'a ;
(12 inches in U.S.A. or 18 inches in
Canada)as shown in FIG.5-�,page 30. �
NOTICE If assemblv is too short to meet heighC �� � � ��� � � �
requirement,rhe two(2)pipes supplied � �z°�ia�FoR cnrvaon�
in the kit may be replaced by using the MINIMUM CLEARANCE
same diameter, field supplied SDR-�6 ABOVe Hi�HEST
ANTICIPATED SNOW
PVC (D2241) pipe for CVK3003 and �eve�.MaxiMUM oF
standard schedule 40 PVC for 24"ABOVEROOF.
CVI<3007. Do not extend dimension
D" more than 60 inches (see FIG's �-9
and 4-10,page 26).
31
�����if Instailation & Operation Manual
'rJ Vertical direct venting
Alternate vertical concentric venting
Thi� appliance may be installed with a concentric vrnr Figuf@ 5-8 COI1C2ntl"iC V617t EXBmpI@ 1
arrangement where the vent yipe is routed through an
existing unused venting system; or by using the existing � FLUE EXHAUST
unused venting system as a chase for vent and combustion air '
routing. ���_--- __ / ��
�� r ��SEAL
Concentric Venting Arrangement ��..
���COMBUSTION AIR
The venting is to be vertical through tl�e roof. The annular \,
space bettiveen the O.D. of the vent pipe and the I.D. of the aiR iN�Er
eYisting wmsed venting system is utilized for the combustion W�SCREEN �
air saurce. � � �: '
�z' —'� ( �
The minimum size of the zxisting vent system required to MiN_ � `, '
-�a,� . `�.
achieve eiiougli annular space for combustion air can be found T �� , ,� ��-� ExisTiN�
in Table SA belo�v. � , �'
'�,,�� ���_
T7�e upper and lower termination as well as any other unsealed �'�` ��E�� �?
jolltts in the existing vent system must be sealed to ensure that -� � � � sEa�Eo
all combustion air is drawn from under the vent cap as shown � '"�'� ` eAP
�
in FIG:s 5-8 and S-9. �\ ���
Approved venting materials must be used as specified in Table �� �`�F�uE ouT�E7
3A on page 17. y�"''
Follow all vent/ air termination and clearance requirements -',='�
per this section to the appropriate example. Installation must *For concept illustration only. Individual installations
comply with local requirements and with the National Fuel may vary due to job site specific equipment.
Gas Code.
The masimum allo�vable equivalent vent and air intake Figure 5-9 Concentric Vent Example 2
lengths for this venting arrangement are to be determined SEAL \ ��-FLUE EXHAUST
from the General Venting Section. �
�
If an existing unused venting syst�is converted for use wirh ��-� �� '
this method of concentric ventin �,the installer must ensure
� i�
that the existing venting systen� is clean and fi-ee from � ��� CpMBUSliotv A�R
partici�late contamination that will harm this apPliance and '��
cause increased nuisance calls or maintenance. See Table lA AIR�N�ET
__�
on page 11 for a list of corrosive contamina�its and sources. WI SCREE� € ��� ���
� � � � �
Two examPle scenarios of a concentric venting arrangement �`L,. ``�,
�
are shown for illustrative purposes in FIG:s 5-8 and 5-9. a � �`�. �
SEAL_� � " �`�
,� '
� , , ti.
Table 5A Altemate 1/ertica!Concentnc Uent/Chase Sizes ' ,, ExisTiN�
��� �., ����� ��
Model Vent i Air Minimum Existing �� �,- ��� �'�� ��A� ��� , sEA�Eo
Inlet Size Vent / Chase Size �� � ': i cAP
�
� � ,;--.� I
81 - 211 3" 5' % ` � �``�. 1
( -'�,,''
286 4" 7" ��`
��
�'""' �� - FLUE OUTLET
��-'��r,�
`For concept illustration only. Individual installations
may vary due to job site specific equipment.
32
��ri-ir Installation & Operation Manual
'rJ Vertical direct venting (continued)
Existing vent as a chase
Folloti� all existing termination and dearance requiremeilts
and allowable pipe lengths. Use only approved venting
materials listed in the General Venting Section of this manual.
Figure 5-10 Existing Vent as a Chase
AIR INLET �- FLUE EXHAUST
�\y j
I'�'�
\
� '' �SEAL
/—EXISTING
�;. `
�
I �' -�._ _
, :;
i �
,� ,..
CAP_ ' � ; �
i =�� '
,�
� ��''� ��'�--S�AL
� � t
�-� -, ��
�i ''j� :.� �>
/�
3. \
/ "
� FWE OUTLET
�� ;.y�-.
��l�
'For concept illustration only. individual installations
may vary due to job site specific equipment.
" 33 °,
�t��-iT Installation & Operation Manual
6 Hydronic piping
SySt@Itl Wat@I' plpillg Rt@thOdS 3. Install purge and balance valve or shutoff valve and drain
The Knight is designed to function in a closed loop �i�system return to purge air out of each zone.
pressurized system not less than l2 psi. � temperature and 4. Install a backflow preventer on the cold feed make-up���ater
pressure gauge is included to monitor system pressure and line.
outlet tempera[ure and should be located on the boiler outlet S. Install a pressure reducing valve on the cold feed make-up �
It is important to note that rhe boiler has a roinimal amount water line, (15 psi nominal). Gheck temperature and
ot pressure drop and must be figured in when siring the pressure gauge (shipped separately), which should read a
circulators. Each boiler installation must have an air minimum pressure of 12 psi.
elimination device, which will remove air froro the s}�s[em. 6. [nstall a circulator as shown on the piping diagrams in this
Install the boiler so the gas ignition system components are section. Make sure the circulator is properly sized for the
protected from water (dripping, spraying, etc.) during systcm and friction loss.
appliance operation for basic service of circulator ;, Instail a�l expansion tank on the system supply. Consult the
replacement,valves,and others. tank roanufacturer's insYruction for specihc information
Observc a minimum of 1 inch clearance around all relating to tank installation. Size the expansion tank for the
un-ii�sulated hot water pipes when openings around the pipes required system volume and capacity.
ai•e not protected by nou-combustible materials. 8. [nstall an air elimination device on the system supply.
Low water cutoff device 9. Install a drain valve at the lowest point of the system.
On a boiler install�d above radiation level, some states and Note: The boi(er cannot be drained completely of water
local codes require a Iow�vater cutoff device at the time of �'ithout purgin�the unir with an air pressure of 15 psi.
installation. 10. This appliance is supplied with a relief valve sized in
Chilled water system accordance with AS1��tE Boiler and Pressure Uessel Code,
Section IV ("Heating Boilers"). Pipe the discharge of the
If the boiler supplies hot�vater tu heatin�coils in air handler safety relief valve to prevent injury in the event of pressare
units,Ylow control valves or other devices must be iustalled to relief. Pipe the discharge to a drain. Provide piping that is
prevent graviry circulation of heater water in the coils during the same size as the safety relief valve outlet. Never block
the cooling cycle. A chilled water medium must be piped in the ouYlet of the safety relief valve.
parallel witli the heater. "
Freeze proteetion �WARN�NG I he relief valve, tee and an,y necessary
i�ttings are shipped in the install kit with the
Freeze protection for new or esisting systems must use�lycol boiler and are to be field installed(FIG.6-1).
that is specially formulated for this purpose. This indudes *See the piping illustrations included in this section, FIG's 6-�
inhibitors, which prevent the glycol from attacking the thru 6-10 for suggested guidelines in piping the Knight boiler
metallic system components. A7ake certain to check tliat the with either zone valves or circulator pumps.
system fluid is correct for the glycol concentratiou and
inhibitor level. The system should be tested at least once a NOTICE �Please nc�te that these illustrations are
year and as recommended by the producer of the giycol meant to sho�v s}�steil� piping concept only,
solution. Allowance should be made for the expansion of the the installer is responsible for all equipment
�l��col solution in rhe system piping. and detailing required by local codes.
�WARNING Use onl}� inhibited propylene glycol CAUTION �he Knight boiler is capable of servicing
solutions, which are specihcally multiple temperature loop systems. It is the
formulated for hydronic systems. Ethylene responsibilit}� of the installer to protect the
glycol is toxic and can attack gaskets and loops �vitll lower temperature requirements
seals used in hydronic systeins. from higher temperatures that m�v be
required by other loops.
General piping information
Basic steps are listed in this section along with illustraTions on
the follo�ving pages (FIG:s 6-4 thru (-l0), which will guide
you through Tl�e installation of the Knight boiler (reference
FIC;�:s 6-2A and 6-2B).
L Connect the system return marked"Inlet"
�. Comiect the system supply marked"Outlet':
�` 34
��� Installation & Operation Manual
6 Hydronic piping (continued)
Relief valve and temperature and xnighr boilers are capable of controlling a variabte
pressure gauge installation speed boiler circulator. Variable speed circulators
Basic steps are listed below to guide you through the MUST be sized ro meet the specified minimum flow
installation of the relief valve and the temperature and requirements listed in PIG.6-3 on page 37 at full speed.
pressure (T&P)gauge provided with rhe unit. 3. Domestic hot water circulating pump:
l. Install the tee with the 3/4 inch fitting positioned Field supplied. The pump MUST be sized to meet
vertically and on the top as shown in PIG.6-1. the specified minimum flow requirements ]isted in
2. Install the relief valve into the 3/4 inch fitting of the tee FIG. G-3. Consi�ilt the indirect ti�ater heater operating
installed in Step 1 (FIG.6-1). guide to determine flo�v characteristics for the selected
product used.
3. Install a field provided close nipple and tee with the
fitting positioned vertically on the top on the 4. Boiler isolation valves:
do�vnstream side of the relief valve(see FIG.6-1). Pield supplied. Full port ball vatves are required.
4. Install the temperature and pressure gauge provided with Failure to use full port ball valves could result in a
the unit into the top fitting of the tee(a bushing may be i-estricted flow rate through the boiler.
necessaryj installed in Ste}�3 (FIG.6-1). 5. CheCk valves:
Field supplied. Check valves are recommended for
Figure 6-1 Rellef Valve/T& P lrtstallafion installation as sho�vn in FIG:s 6-4 thru 6-10. Failure to
install check valves could result in a reverse flow
,.-. +�.,.:
condition during pump(s) off cyde.
`` � 6. Domestic indirect hot water isolation valves:
Field supplied. Full port ball valves are required. Failure
� ; to use fuli port ball vabes could result in a restricted tlow
�� �. �����.
'- '� ��� rate through the boiler.
� �€� :��� � � �
A m 7. Anti-scald mixing valve:
ReueFVn�ve� � ��$ � Field supplied. An anti-scald rnixing valve is
rennPeRa,ruRes �€ � recommended when storing domestic hot water above
PRESSURE GAUGE� „
�, ' � 115°F.
���� �, c
8. Unions:
e
�°� � � � ` ; icfd supplied. Recommended for unit serviceability.
TEEW/FITfINGONTOP �.�> -. :�� � 9. Temperature and pressure gauge:
(Fie�o PROwoeo�---.� ;� Faitory supplied. The temperature and pressure gauge is
��
�� ,;, shipped loose. It is the responsibility of the contractor to
c�ose Niaa�e / install the tem erature and ressure >au�e on the boiler
(FIELD PROVIDED) / � P � � �
TEE WITH 3/4"FITTING ON TOP—� �tiaY2C 011t�et.
CLOSENIPPLE 10. Pressure relief valve:
Factory supplied. The pressure relief vah�e is sized to
Near boiler piping components �SNtE spectfcatsor,s.
1. Boiler system piping: 11. Boiler purge valve:
Boiler system pi��ing Iv1liS7' be sized per the pipe Field suppJied. T6e boiler pw•ge valve is used to
requirements listed in Table 6A. Reducing the pipe size remove entrapped air from the heat exchanger during
can restrict the flow rate through the boiler, causing start-u�.
inadvertent high limit shutdo�vns and poor system 12. System temperature sensor:
performance. Florv rates are based on 20 feet of piping, I.,ochinvar supplies a system temperature sensor.
4-HO°elbows,and 2 -fully ported ball��alves. The sensor is to be installed in the heating loop
2. Boiler system pump: do�=nstream from the boiler hot water piping and
A Grundfos L'PS2(�-99F pump will be provided by the f�eating loop junction. Typically the sensor will be
factorv (for standard altitude models) as the boiler located far enough downstream to sense system diluted
circulation pump based on 20 feet of piping, 4 - 90° �'ater temperature.
elbows,and 2-fully ported ball valves.
` 35
i
�16�T Installation & Operation Manual
6 Hydronic piping
13. Indirect water heaters: CAUTION It is up ro the installer to ensure the
The Knight boiler may be piped to a�l indirect water minimum sy�stem flow is not less than the
heater to heat domestic hot water with the space heat �ninimain boiler flow at any time.
transfer mediuin. As depicted on pages 39 through 4�
there are two options when utiliring an indirect water �+'�WARNING The National Standard Plumbing Code, the
heater. National Plumbing Code of Canada and the
Uniform Plumbing Code limit the pressure
A. The space heating piping will branc�h otf to flow the of the heat transfer fluid to less tllan the
space heat transfer medium through a single wall roinimum working pressure of the potable
heat exchanger coil inside the indirect water heater. water system up to 30 psi r�iaximum. Also,
B. The indirect water heater is connec[ed to the system the heat transfer fluid must be water or other
supply piping. A puinp controlled by the I�nigl�t non-to�c fluid having a toxicity of Class 1,
boiler's control will regulate the flow of water as listed in Clinical 7:oxicology� of
through the indirect water heater. The indirect water Commercial Products,5"'Editiori.
heater's temperaCure will be regulated by the Knight 14. Y-Strainer.
boiler's control.
Field supplied. A Y-strainer or equivalent multi�urpose
The Knight boiler is pre-conhgured to controi tlle strainer is recommended at the inlet of the heat exchaiiger
operation of the DHW purop with Domestic Hot Niater to remove system particles from older hydronic systems and
Prioritization programrning. The DH4V programming is protect newer systems.
designed to control and balance the space heating
demand by switching beYween DHW and space heating. C11'CUlat01' SlZlflg
Lochinvar offers the Squire which is a series of indirect Tlie I:night boiler heat e�:changer does have a pressure drop,
�vater heaters. The Squire features a stainless steel vessel whiih must be considered iu your s}�stem design. Refer to the
�vith a single�kall stainJess sreel heat eschanger. graph in FIG. 6-3 for pressure drop through the ICnight boiler
heat exchanger.
Near boiler piping connections
Figure 6-2A Near Boi(er Prping w/Y-Strainer Figure 6-26 Near Boiler Piping w/Low Loss Header
SVSTEM SENSOR ��n
_ _ AIR VENT VALVE AIR SEPARA70R �L,S��' �
.�51�
.n;;�: �O�S
sy" LOW LOSS HEADER F
f"j� (TVPICAL)
/
FILL VALVE
V-S7RAINER
(RF..COMMENDF.D)�
�
SYSTEM SENSOR� .-�DO�,AESTIC HOT
AIR SEPARATOR F�TER PUMP �- oN.��N `'
� rvaicn�i EXPANSION TANK
SY'STF..M ��.-S�� I'��R��
PUMP 1 ��� BOILER� INDIRECT
FUMP DOMESTIC ORAIN VALVE
,�A'�''v',;, HOT WATER
+t% � ° . 10,I iANK �RVM
�% � � �INDIRECT
� ���� �O�1ESTIC
`-:,;i;.::.! � HOT WATER
KSTR4INER
(RECOMMENDE6) �
-�O
�'� BOLIER PUMP
�. �.
' � � `�
QRAIN—� �.... ,���
j7YP1CAl.l ., t••�.: v .
� _
TO FLOOR
DRAIN
%
(�j--�
1
TO FLOOR
DRAIN
" 36
�!�,�T' Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-3 Pressure Drop vs. Flow
Pressure Drop vs. Flow(Includes Secondary Piping) '
� 2s
�
d
2
w 20
O
� "'�-81
v �5 �..,-106
Q- 'f-151
� �� ��211
�
d
-�"286
� 5
N
N
d
a` °
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Flow Rate(GPM}
Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°
20°F Temperature Rise Applications
Minimum Pi e
Model GPM FT/HD p Pump
Size Grundfos TACO B & G Armstrong
�� '.5 '`� I" UPS26-49F 0011 NRF-36 E7
1O6 9.8 2i l,� L7PS26-99F 0013 NRI��-36 E11
151 14.0 20 I" UPS26-99F 0011 NRF-36 E7
2l1 19.6 )9 l" UPS3?-160 1�00-50 PL-�5 E9
286 26.5 15 1-1/4" U PS32-�0 1400-�0 PL-S6 �11
25°F Temperature Rise Applications
Model GPM FT/HD Minimum Pipe Pump
Size Grundfos TACO B & G Armstrong
81 5.9 15.0 1" tIPSI.S-58FC 0014 NRF-36 E7
106 7J li.� 1" UPS26-99F 0014 NRF-36 �i
151 I1.0 12.H 1" UPS26-99F 0014 NRF-36 E7
2 i l 155 19.0 1" UPS26-99F 0013 NRF-36 E7
286 21.0 l 1 S I-1/4° UPS26-99F 0011 NRF-36 E7
35°F Temperature Rise Applications
Model GPM FT/HD Minimum Pipe Pump
Size Grundfos TACO B 8� G Armstrong
�1 �•� %•3 1'� LTPSIS-58FC OOi NRF-Z2 Astro-30
106 5.5 9.3 1° UPS15-58FC 007 NRF-2? Astro-30
1S1 7.9 9S 1" UPS15-S�FC 008/0010 NRF-36 Astro-30
211 11.0 9.l I° UPS15-58FC 0010 NRF-36 Astro-50
286 15.0 7.3 I-1/4" L7P26-6�F 008/�010 NRF-3b E7
NOTICE �'umps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude
models.
NOTICE purops listed in italicized rype are provided by rhe facrory as the boiler circulation pump on high altitude
models.
NOTICE The temperature rise provided by a pump/model combination will decrease by�3%per 1000 feet of elevation.
' 37
�C ���if �nstallation & Operatian Manual
6 Hydronic piping
Variable speed pump op#ion
Table 6B Recommended Variable Speed Pumps
Minimum Temperature Rise*
Pump
Model Grundfos TACO Wilo
UP26-96 FCNS 0013 IFC VS Stratos 1.25 3 x 30
81 20.3 20.3 21.7
106 22.3 21.0 21.5
I S1 21.2 19.8 19.1
21] 26.8 25.1 23.6
286 26J 24.3 21.9
*The minimum temperature rise is derived from the chart in FIG.6-3 with the firiu�;rate ar�d pump speed at 100�'�o as sl�own in
the table above.
The shaded regions of pump coverage are only available for applications�vith 230V(60 F3z) supply voltage,all others are
�� to be t 15V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 6B to the boiler
high voltage terminal strip.)
Variable speed pump setup
Before operation,ensure the following:
-Pump is set for an input signal of Q- 10�'dc by the dip switches on the puinp control
-Pump is set for external signal control (if applicable}
-Pump is set for linear output(iE applicable)
-If pump does not come equipped with a 0- 10 Vdc input option,an optional module
will be required from the vendor
NOTICE �°n1P siring and t7��v requirements are
based on 20 feet of piping, 4 - 90°
elbows,and 2-fully ported ball valves.
NOTICE It is required that near boiler piping
� systems utilize the Primary/Secondary
configuration sho�m in FtG. 6-10 only.
The use of other near boiler piping
configurations could result in improper
building and system flow rates leading
to inadvcrtent boiler high limit
shutdowns and poor system
performance.
38
�i �rM'� Installation & Operation Manual
6 Hydronic piping (contrnued)
Figure 6-4 Single Boiler- Single Temperafure Zoned wifh Circulators
� — — — — — — — — — — — — — — — �
� �
I ZONE#1 I
� - - - - - - - - - - - - � I
PRESSURE PRESSURE I I
REDUCING VALVE GAUGE ZONE#2 ZONE#3 ZONE#4
� � r---� r----� r----�
BACKFLOW L J ' __ __
PREVENTER FLOW CHECK
VALVE
(TYPICAL)
MAKE UP WATER SYSTEM SUPPLY
SENSOR
(WHEN USED) ZONE CIRCULATORS
AIR SEPARATOR f f � } �T�'PICAL)
i I
EXPANSION
TANK � I I I
r r r
BALL VALVE MAY SUBSTITUTE LOW LOSS HEADER
(TYPICAL)
DR,41N POINT Y-STRAINER
(TYPICAL) (RECOMMENDED)
BOILER
CIRCULATOR HOT
WATER
OUT
DOMESTIC �
HOT WATER
CIRCULATOR ANTI-SCALD
MIXING VALVE COLD
�— �WATER
� IN
I 1
1�:
UNION
(TYPICAL)
TEMPERATURE/
PRESSURE DRAIN
' GAUGE
BOILER INDIRECT
DHW TANK
NOTICE pleasz note that these illustrations aee meant to show system piping concept only,the instalier is responsible
for all equipment ai�d detailing required by local codes.
�: ' 39
�1116HT� Installation & Operation Manual
v
6 Hydronic piping
Figure 6-5 Multiple Boilers- Single Temperafure Zoned with Circulators
Nurnber of Units
Model 2 3 4 5 6 7 8
Required Pipe Sizes
81 I-71�" 1-1/2�� ,'� 2^ 2-112" 2-IlZ„ ?-l/?��
106 1-11�" 2" 2" ?-1l?" 2-112" 2-1/2" 3"
� - - - - - - - - - - - - 1 I51 2" ,,� 2-1/2" 2-ll2�� �„ 3„ 3-1/?��
� ZONE#1 � 2ll 2" 2-112° 3" 3" 3-112" 4° �"
�- — — — — — — — — — — 286 2-1/2" 2-12" 3" 3-1/a�� 3-1/?�, �,� 5,�
PRESSURE , I
REDUCING VALVE P GAUGE E I �ZONE#2 ZONE#3 ZONE#4
BACKFLOW -- -- --
PREVENTER L _ J __ _ __
FLOW CHECK
MAKE UP WATER SYSTEM SUPPLY VALVE
SENSOR � (TYPICAL)
AIR SEPARATOR � � � �
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
MAY SUBSTITUTE TANK
LOW LOSS HEADER � � � �
1
BALL VALVE � NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART
(TYPICAL�
DRAIN POINT
(TYPICAL) �
� ANTI-SCALD HOT
BOILER MIXING VALVE WATER
CIRCULATOR OUT
DOMESTIC �
HOT WATER
CIRCULATOR COLD
Y-STRAI N ER �_ f—WATER
(RECOMMENDED) IN
(TYPICAL)
—�
} � f �
I, �
��
�
TEMPERATURE/ UNION
PRESSURE (TYPICAL)
GAUGE DRAIN
BOILER 2 BOILER 1
(MEMBER 1) (LEADER INDIRECT
� DHW TANK
NOTICE Please note that tllese illustrations are meant to show system piping concept only,the installer is responsible
for all equipment and detailing required bj-local codes.
40
���T Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-6 Single Boiler- Mu(tiple Temperatures
PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE
BACKFLOW REDUCING VALVE LOOP#1 LOOP#2 LOOP#3
PREVENTER -- '- --
PRESSURE -- -- --
GAUGE
MAKE
UP
WATER SYSTEM MIXING VALVES
SUPPLY (TYPICAL)
SENSOR
AIR SEPARATOR f f �
EXPANSION
TANK
MAY SUBSTITUTE
�LOW LOSS HEADER � I
r � i
NOT TO EXCEED 4 PIPE DIA
BALL VALVE OR MAX.OF 12"APART
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
DRAIN POINT BOILER
(TYPICAL) CIRCULATOR DOMESTIC
HOT WATER HOT
CIRCULATOR WATER
� FLOW CHECK OUT ANTI-SCALD
VALVE � MIXING VALVE
—� �—COLD
WATER
IN
f �
�:
F
UNION �
(TYPICAL)
TEMPERATURE/
PRESSURE DRAIN
GAUGE
CAUTION �1ixing valves are required tor the protection of low temperature loops.
NOTICE Please uote that these illustrations are meant to show system piping concept only,the installer is responsible
for all equipment and detailing required by local codes.
41
����-+T Installation & Operation Manual
6 Hydronic piping
Figure 6-7 Mulfiple Boi/ers-Multiple Temperatures Number of Units
Model 2 3 4� 5 6 7 g
Required Pipe Sizes
81 1-114" 1-1/�" �" �° �-112" 2-1/2" z-l/?"
106 l-1/2" 2�� 2�, ?-U��� �-1 J?�� �-1/?„ 3.,
151 2�� ?�� 2-i/2" 2-1/2° � 3" � 3" 3-1/2��
211 2' 2-1/2' 3" 3' 3-112' 4" �1"
286 2-1/2" 2-1/2" 3° 3-1/2" 3-1/2" q" �„
PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE
6ACKFLOW REDUCING VALVE LOOP#1 LOOP#2 LOOP#3
PREVENTER !-'--� �--� r----�
PRESSURE -- -- __
GAUGE
MAKE
UP
WATER SYSTEM MIXING VAWES
SUPPLY (TYPICAL)
SENSOR
AIR SEPARATOR f f �f I��
EXPANSION
TANK
r _ 1 1 1
BALL VALVE MAY SUBSTITUTE LOW LOSS HEADER
(TYPICAL) NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART
DRAIN POINT
(TYPICAL)
BOILER DOMESTIC
CIRCULATOR HOT WATER
CIRCULATOR
FLOW CHECK HOT
U VALVE ANTI-SCALD WATER
MIXING VALVE �UT
� f-COLD
� � WATER
� _�
� IN
Y-STRAINER
f 1 (RECOMMENDED) t +
1
�
I
TEMPERATURE/ UNION I
PRESSURE (TYPICAL)
GAUGE DRAIN
BOILER BOILER INDIRECT
DHW TANK
CAUTION �1i�ing valves are required for the protection of low temperature lc�ops.
NOTICE please note that these illustrations are meant to show system pipi�ig concept only,the installer is responsible
fvr a11 equipment and detailing required by]ocal codes.
42
'���'� Installation & Operation Manual
6 Hydronic piping (contrnued)
Figure 6-8 Single Borler- Multiple Temperatures with DHW Piped as a Zone
PRESSURE TEMPERATURE TEMPER,4TURE TEMPERATURE
BACKFLOW REDUCING VALVE LOOP#1 LOOP#2 LOOP#3
PREVENTER � � �--� �--'�
PRESSURE -- -- --
GAUGE
MAKE
UP MIXING VALVES
WATER SYSTEM (TYPICAL
SUPPLY �
SENSOR
AIR SEPARATOR � I �
EXPANSION
TANK
MAY SUBSTITUTE DOMESTIC
�LOW LOSS HEADER 1 1 I I HOT WATER
r � � � � � CIRCULATOR
BALLVALVE FLOW CHECK
(TYPICAL) NOT TO EXCEED 4 PIPE DIA VALVE
OR MAX.OF 12"APART } HOT
� �� � WATER
DR,41N POINT Y-STRAINER pUT ANTI-SCALD
(TYPICAL) (RECOMMENDED) MIXING VALVE
�--COLD
WATER
BOILER IN
CIRCULATOR
f �
UNION
(TYPICAL) DRAI"��
TEMPER,4TURE/
PRESSURE
GAUGE
BOILER INDIRECT
DHW TANK
CAUTION �tising valves are required for the protection of low temperature loops.
NOTICE �'lease note that these illustrations are meant to sho�v system piping concept only,the installer is responsible
for aIl equipment and detailing required by local codes.
NOTICE �'lease note rhat the installer is responsible for ensuring DHW prioritization when piped as a zone.
43 _.
�t�� Installation & Operation Manual
6 Hydronic piping
Figure 6-9 Multiple Boilers- Single Temperature Zoned with Valves
Number of Units
Model 2 3 4 5 6 7 8
Required Pipe Sizes
8] 1-1/4° 1-112,� 2,� 2° 2-1/2° Z-1/�„ �-I/���
106 1-i/�„ 2�� �„ ?-1/?�� �-ll2° 2-1/�,� 3,�
� — — — — — — — — — — — — � 151 2" �,� 2-1/2" 2-112�� �„ 3„ 3-1/�„
� � 211 2" 2-1/2" ��� 3,� 3-1J?" 4" 4„
ZONE#1 286 z-1/�„ 2-UZ„ �„ 3-1/�„ 3-1/�„ �„ �,.
� - - - - - - - - - - � I
PRESSURE I
BACKFLOW REDUCING VALVE I �ZONE#2 ZONE#3 ZONE#4
PREVENTER PRESSURE L _ J r r r -
BALLVALVE GAUGE -- -" --
(TYPICAL) ZONE VALVES
(TYPICAL)
MAKE UP WATER SYSTEM SUPPLY DIFFERENTIAL
SENSOR
(WHEN USED) PRESSURE BYPASS
VALVE(IF USED)
AIR SEPARATOR f t f }
r
SYSTEM I
CIRCULATOR I
EXPANSION
TANK I
r — � J
MAY SUBSTITUTE LOW LOSS HEADER
DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART
(TYPICAL)
f1 ANTI-SCALD HOT
BOILER MIXING VALVE WATER
CIRCULATOR OUT
FLOW CHECK DOMESTIC 1
VALVE HOT WATER T
CI RCULATOR COLD
Y-STRAINER a– f–WATER
(RECOMMENDED) IN
(TYPICAL)
f � t �
� �
TEMPERATURE/ UNION i
PRESSURE ��'PICAL) I
GAUGE DRAIN J
BOILER 2 BOILER 1 INDIRECT
(MEMBER 1) (LEADER) DHW TANK
NOTICE Please note that these illustrations are meant to show system piping concept only,the installer is responsible
� for all equipinent and detailing required by local codes.
44
��GHT Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-10 Multrple Boilers-Non-Zoned Primary/Secondary Piping
Number of Units
Model 2 3 � ; � i g
Required Pipe Sizes
81 1-114° L-I/Z„ �" 2" �-(I2" 2-1/2" 2-t2"
106 1-1/2° 2" 2" 2-112" 2-1/2" Z-U2" 3„
151 �" 3" 2-1/2�� 2-1/2�� 3„ 3�� 3-I/2��
211 Z° 2-1J2„ 3" 3 3-t/2` 4' 4'
286 2-1/2° 2-1/2„ 3" 3-1/2" 3-1/�° 4" 5"
PRESSURE
REDUCING VALVE
PRESSURE
BACKFLOW GAUGE
PREVENTER
MAKE UP WATER SYSTEM SUPPLY
SENSOR
SYSTEM AIR SEPARATOR
CIRCULATOR� MAYSUBSTITUTE LOW LOSS HEADER
TO
SYSTEM f- FROM
SYSTEM
- NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART
BALL VALVE ,��;.__.,;
(TYPICAL) EXPANSION
TANK
DRAIN POINT
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
ANTI-SCALD HOT
MIXING VALVE WATER
OUT
FLOW CHECK DOMESTIC
i VALVE HOT WATER
CIRCULATOR COLD WATER
IN
� � BOI�ER y �-
' � CIRCULATOR
� � �
f �
� �� �:
�
, �
,
TEMPERATURE/
PRESSURE UNION DRAIN
GAUGE (TYPICAL)
BOILER 4 BOILER 3 BOILER 2 BOILER 1
(MEMBER 3) (MEMBER 2) (MEMBER 1) (LEADER INDIRECT
� DHW TANK
NOTICE Please note that thesz illustrations are ineant to show systein piping concept only,the installer is responsible
for all equipment and detaili��g required by local coiles.
45
����-+T Installation & Operation Manual
7 Gas connections
C.011t1@Ct111C� gaS SUpp��/ plpltlg 3. Support piping with hangers, not by the boiler or its
I. Remove the top access panel and refer to FIC;'s 7-1 and `"`�`''�,�ie,.
7-2 to pipe gas to the boiler. �j ydARNlf�lG <<>>e gas valve and blower will not support
a. Install ground joinC union for servicing, when ����weight of thc piping. Do nor aCtempt
required. i�� support the weight of the piping with
b. Install a manual shutoff valve in the gas supply the boiler or its accessories. Failure to
piping outside boiler jacket wheii required by locai «>n�p1y couid result in severe personal
codes or utilir}�requirements. iiljury, death, or substantial property
c. In Canada — �vhen using manual r��ain shutoff damage,
vabes,it must be identified by the insYaller. 4. Pur*e all air from the as su� l � in
� S EPYP� g•
2. Install sediment trap/drip leg. 5. Before placing the boiler ii1 operation, check the boiler
and its gas connection for leaks.
Figu►'e 7-1 Gas Supply Piping -Models 81 - 211 a. The appliance must be disconnected from the gas
supply piping system during an}'pressure testing of
uNiotv -. �`., that s}'stem at a test pressure in excess of 1/2 PSIU
GAS SUPPLY �3.�kPa�.
'�� �` � << �� ��:'; b. The appliance must be isolated from the gas supply
i �\ � ��, piping s}'stem by closing a manual shutoff val��e
�� ��, �`�de � ,,_��:,. `
� 4 �� � during any pressure tesring of rhe gas supply piping
�"� �� system at test pressures equ�al to or less than 1/2 PSIG
� =; (3.5 kPa).
�RiP_� ��= u �� c. The applivlce and its gas connection must be leak
�E� ��'*� � ; tested before placing it in operation.
� �•�
MANUA� _ � lli> not check for gas leaks with an open
SHUTOFF �WAEtNiNG
vn�vE �,:: , llame—use the bubble test. Failure to use
the bubble test or check far gas leaks can
cause severe personal injury, deatli, or
substantial property damage.
(. Use pipe sealing compound compatible with propane
gases. Apply sparingly only to male threads of the pipe
Figure 7-2 Gas Supply Piping -Model 286 ioints so that pipe dope does not block gas flow.
G41 WARNING f'i'�ure To apply pipe sealiug compound as
detailed in this manual can result in severe
E�ersonal injury, death, ar substantial
prc�perty damage.
�" I�ui lit boIlers arz t i�all shi ed read
uNioN� � ' t�WAaNING � �'P " Y PP Y
��� � �,, �� to tire on natura] gas. Check boiler rating
�a;� " ,�� plate to determine which fiiel the boiler is
cns suPP�v_ ° '��� �� } set for. It set to natural gas, it ma}� be
'�`�_����" % ' converted to LP by installing an arifice
����' � ` (see page 13). In order to operate on LP
� � � :�
� ,��_ gas,an orifice MUST BE installed. Failure
SEDIMENTTRAP/DRIPLEG—� �� �� t0 COri1pIy COUId I'tSU�t 1[] 52VECe peYSOtla�
� �ti °'�� � � � � in'ur death or s
MANUA�__r , , ) y, , ,ubstantial propert}�
SHUTOFF VALVE damage.
(FIELD SUPPLIED)
46
�, �G�' Installation & Operation Manual
7 Gas connections (continued)
1'�V1IARNIN� lise two wrenches w�hen tightening gas (1�atu1`a� gaS;
piping at boiler (FIG. 7-3), using one
�vrench to prevent the boiler gas line P�Pe sizing for natural gas
connection from turning. Failure to 1. Refer to Table 7A for pipe length and diaineter. Based on
support the boiler gas connection pipe to rated boiler input(divide by ],000 to obtain cubic feet per
preveiit it from turning could damage gas t�our).
line coiuponents. a. Table 7A is onty for natural gas with specitic gravi�ty
0.60 inches, with a pressure drop through the gas
Figure 7-3 lnlet Pipe with Backup Wrench piping of 0.5 inches w.c.
b. For additional gas pipe sizing inforniation,refer to
� � ANSI 7,223.1 (or B149.1 for Canadian installations).
s� . ��
_ ' Natural gas supply pressure requirements
� �� � �
�� �� �''� l. Pressure required at the gas valve inlet pressure port:
� .-� .,;r�,�« � ����� • M�iinum 14 inches w.c. with no tlow (lotkup) or
- ' � ;�, a� �;' with boiler ou.
� '' �� �' • i�linimuni 4 inches iv.c. with gas flowing (verify during
� � boiler startu )
�:� � p •
���„� �y' � �
� ��� �-, � � 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 inehes w.c.maa�mum.
, �i
�" - Propane Gas:
,
���: � »� ., ,i;
�WARNING �`��ight boilers are typicall,v shipped ready to
. ��. fi re on natural gas. Check boiler rating plate
��� ;u deterniine which fuel the boiler is set for.
_ If set to natural gas,it r�iay be converted to
LP by installing an orifice (see page 13). In
USE BACK UP WRENCH J order to operate on LP gas,an orifice MUST
TO PREVENT PIPE FROM--� BE installed. I=ailure to comply could result
RoTATING in severe personal injury, death, c�r
NOTICE
Maximum inlet gas pressure must not substantial property damage.
esceed the value specified. �linimum Pipe sizing for propane gas
value listed is for the purposes of input
adjustment. 1. Contact gas supplier to size pipes,tanks,and 100%lockup
gas pressure regulator.
Propane Supply Pressure Requirements
L Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c.maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches �v.c. with no flow (lockup) or �vith
boiler on.
• 1�-tinimum 8 inches w.c. rvith gas flowiug (verify durin�;
boiler sTartup).
t�WARN(NG Ensure that the high gas pressure regulator
is at least 6 - 10 feet upstream of the
appl iance.
" 47 �
����+T' Installation & Operation Manual
7 Gas connections
Table 7A Natura! Gas Prpe Srze Chart
Nominal Single Unit
Iron Pipe Natural Gas Pipe Capacity Chart
Size (Inches) Length of Pipe in Straight Feet for 1/2 PSI
10 20 3d 40 5d 60 70 80 90 100 125 150 175 200
1/2 175 120 97 82 N/A N/A N/A N/A N(A N/A N/A N/A N!A N/A
3/4 369 256 205 174 155 141 128 121 113 106 95 86 7g 74
1 697 477 384 328 292 267 246 236 210 200 179 164 149 138
1-1/4 1400 974 789 677 595 543 502 472 441 410 369 333 308 287 �
1-1/2 2150 1500 1210 1020 923 830 769 707 666 636 564 513 472 441
2 4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820
2-1/2 6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
3 11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340
4 23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720
t�1 WARNIIVG 1`night boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine�vhich
fuel the boiler is set for. If set to natural gas,it may be converted to LP by installing an orifice(see page 13).
tn order to operate on LP gas,an orifice MUST BE installed. Failure to comply could result in severe personal
injury,death,or siibstantial property daivage.
C�1@C�C Ifl�@t gaS SUpp��/ 3. Loosen the seY scre�v one (1) full rurn from inside the
NOTICE �1SA or UL listed flexible gas connections pressure tap on top of the gas valve. Place the tubing of
are acceptable, but you must exercise the manometer over the tap once the set scre�v is
caution to ensiu-e that the line 6as adequate loosened as sho�vn in FIG.7-4.
capacity to allow your boiler to fire at full :�. Slowly turn on the gas supply at the tield installed
rate. Consult with local codes for proper manual gas valve.
installation or service procedures. 5. Turn the power switch to the"ON"position.
Ll1 WARN)NG 1}���OT adjust or atteinpt to measure gas 6. Adjust the te�roperature set point on the control panel of
ralve outlet pressure. The gas valve is the SA�[ART SI'STEtV1 control module to call for heat.
factory-set for the correct outlet pressure. �. Observe the gas supply pressure as the burner fires at
This setting is suitable for natural gas and 100% of rated input. Percent of burner input �vill be
propane, requiring no field adjustment.
Att�mpting to alter or measure the gas �isplayed on the control panel.
valve outlet press��re could result in �• Ensure inlet pressure is wi[hin specified range.
damage ro the valve, causing potential ��linimum and maaimum gas supply pressures are
severe personal injury, death, �r �pecified in this section of the manual.
substantial property damage. 9. If gas supply pressure is within nonnal range and no
T'he gas piping must be sized for the proper flow and length adjustments are needed,proceed on to Step I 1.
of pipe,to avoid excessive pressure drop. Both the gas meter 10• If The gas pressure is out of range,contact the gas uTility,
and the gas regulator must be properly sized for the total gas gas supplier> qualifieci installer or service agency to
load. determine the necessary steps to providc proper gas
If you esperience a pressure drop greater than 1 inch w.c.,the Pressure to the control.
meter, regulatoi•, or gas line is undersized or in need of 11. Turn Yhe power switch to The"OFF"position.
service. Perform the steps belo�v �vhen checking inlet gas 12. Shut off the gas supply at the manual gas valve in the gas
supply: piping to the appliance.
� L Turn the main power switch to the"OFF"position. 13. Remove the manometer from the pressure tap on top of
, the gas valve. Re-tighten the set screw inside the pressure
_. Shtrt oti�gas supply at the manual gas valve in the gas
piping to the appliance. tap.
48
�4��� Installation & Operation Manual
� Gas connections (continued)
G�1 WARNING ��.hen re-tightening the set screw,be sure Gas Pressure
to tighten securely to prevent gas leaks. The gas pressure must remain between � inches w.c.
Do not check for gas leaks with an open (natural), 8 inches w.c. (LP} minimum and 14 inches w.c.
flame-- use the bubble test. Failure to use (natural and LP) maximum during stand-by (static) mode
the bubble test or check for gas leaks can and while in operaling (dynamic) mode. If an in-line
cause severe personal injury, death, or regulator is used,it must be a minimum of 10 feet from the
substantial property damage. Knighc boiler. It is very importanc that the gas line is properly
t4. 'I'ui•n on the gas supply at the manual gas valve. purged by the gas supplier or utility company. Failure to
properly purge the]ine�s ar improper line sizing,will result in
15. Ti�rn the power s�vitch to the"ON"position. ignition failure.
16. Adjust the temperature set point on the control panel of
the S�tAR'I' SYST'EN1 control module to the desired The problem is especially noticeable in NEW LP installations
water temperature so the appliance will call for heat. and also in empty tank situations. This can also occur�vhen
a utility coiTipany shuts off service to an area to provide
17. Check burner performance by cydin� the systein �vhile rnaintenance to their lines.
you observe Uurner response. The burner should ignite
promptly. Flame pattern should be stable. Turn system Gas valve replacement
off and allow burner to cool,rheil cycle burner again to
ensure proper ignition and flame charaeteristics. The g�s valve l�fUST NOT be replaced with a conventional
gas valve under any circumstances. As an additional safety
Figure 7-4 lnlet Gas Supp(y Check teature,this gas vah�e has a flanged connection to the venturi
and btow�er.
LOOSEN THE SET SCREW ONE(1)FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP. �':��.�AR�'��,' Fd1Il1Tf: TO tOI�OW al�. �I'eC3UTIOriS COUI(I
-` result in fire,explosion,or death!
� � DO NOT ad'ust or attem t to measure as
�1; . ���i �,,v ,� ',�`�,r,� t�WARNING 1 P g
� i �� � ,s �� � � .� .� � - ��� valve outlet pressure. The gas vabe is
��� '. .�`� � , �':�� '`'� facYory-set fox the coxrect outlet pressure.
I , �
s�'� �° °,�'"� '; � _� 'e '� � This setting is suitable for natural gas�nd
I -�. , ,
I
j' ���'� propane, requiring no field adjustment.
I � Attempting to alter or measure the gas
� � ���, valve outlet pressure could result in
i ' �
� � dama�e to the valve, causing potential
� DETAIL severe personal injury, death, or
substantia]propertp danl�ge.
� : 4g
��HT Installation & Operation Manual
8 Field wiring
�wa��virvG ELEC,TRic.aL sxoc�: HAZARL� - For Installation must comply with�
your safety, turn off electr.ical power �
supply before making any electricai 1. National Electrical Code and any other national, state,
conuections to avoid possible electric provincial,or local codes,or re�,ulations.
�.. , i.,,.,..i r � �
I
�c�c�cyc�euiiaiin)un orcleatn. , _ __ .. . .,, . � _. . . ,
ar,�l��.nv local codes.
NOTICE �viring must be N.E.C.C;lass l.
Line voltage connections
If origina] wiring as supplied �vith boilei
must be replaced, use only tj�pe 10�°C 1• Connect 1?0 vac powerwiring to the line voltage termival
wire or equivalent. strip in the junctio�i box,as shown in FIG.8-1.
Boiler musT be electrically grounded as 2• Provide and install a fused disconnect or service switch
required by National Electrical Code (15 amp recommended) as required b}' the code (see
ANSIlNFPA 70—latest edition. FIG.8-I).
I.abel all wires prior to disconnection 3. The boiler pump is shipped loose. Wire the boiler pump
� CAI,�TION as shown in FIG.8-l.
�vhen servicing controls. Wiring errors
c<u� cause improper and dangerous 4. GVhen connecting a domestic hot water (DH�•'V) pump,
operation. connect the wiring To the line voltage terminal strip as
shown it�FIf;.8-1.
Figure 8-1 Line Voltage Field Wiring Connections ;, To activate a systein puinp,tivire as shown in FIG.8-1. If
the motor is larger than 1/8 hp or 1.8 amps, you must i
isolate with a relav. ��
Low voltage connections
SERVICE
oonnESric swireH 1. Route all lo�e voltage�vires through the knockouts in the
HoT vvnrER eoi�ER svsrEn,� 120V SUPPLY rear of the boiler, as shown in FIG.8-?.
PUMP PUMP PU�-tP
��NE �RO�NO NE�rRA� Z_ Co�mect low voltage wiring to iow ��oltage coimection
��' .Y Ni
sK H �K BK `" board as shown in FIG.8-3 on page�3 of this manual and
the boiler wiring diagram.
Figure 8-2 Routing Field Wiring
LOW VOLTAGE `��\"
�� CONNECTION BOARD
i
ii� � � i`t;
;y � �.� �;
�
a, -`^� 3 $w
+ �° °��
� — ,
� �_._� -- _ _� '� € ,�' .�:
� ,- 3� • ��_3i
�,.�r�,
o �� `.����,,�
�
LOW VOLTAGE _ � '
WIRING KNOCKOUTS ''
_ ,� � ���
I
LINE VOLTAGE WIRING KNOCKOUTS
50
'���HT" Installa#ion & Operation Manual
H Field wiring (continued)
Tf1@I't110StFlt 3. If the TST20015 is not compatible with the indirect tank,a
L Connect the room thermostats or end s��itches (isolated tank thermosYat can be used to control the boiler. The tailk
contact only) to room thermostat 1,2,or 3,as shotirn in thermostat should be inst�lled per the manufacturers
FIG.8-3. instructions and wired to the DH��V Therinostat terminals
on the Low Voltage t;onnection Board.
2. Install the thermostat on tl�e inside wall away from
influences of drafts, hat or cold water pipes, lighting Louver relay
fixtures,televisia�,sunlight,or fireplaces.
If louvers need to operate when the boiler fires, they can be
3. Thermostat anticipator(if applicable): controlled by this output. Connect these terminals to a 24 vac
� a. If connected directlr to boiler,set for 0.1 amps. relay coil,whicl� is wired to operate the louvers (FIG.8-3).
b. If connected to relays or other devices,set to match
total electrical power requirements of connected Louver proving switeh
devices. See device manufacturers' specifications �tihen the operation of the louvers needs to be verified before
and thermostat instructions for details, the boiler fires, remove the jumper wire from these terminals
011td001' t@I11p@I'atUP@ S@I1S01' and connect them to the normally open contacts on its proving
swi[ch(F[G.8-3).
l. Mount the sensor on an eYterior wall, shielded froro
direct sunlight or flow of heat or cooling from other High gas pressure switeh
sources. If a s�vitch is provided to detect e�cessive gas pressure, remove
l. Route sensor wires through a I:nockout at the rear of the the jumper wire from the terminals on the connection board,
boiler(see FIG.S-2). and then connect them to its normally closed contacts
3. Connect outdoor tempera[ure sensor (FIG. 8-3) to the (FIG.8-3).
outdoor sensor terniinals on the connection board to
enable outdoor reset operation of tbe Knight boiler. If LOW ga5 pP@SSlll'@ SWItC�'t
fixed temperature operation is required, do not install 1. If a s�vitdi is provided to detect low gas pressure,remove the
outdoor sensor. jumper wire from the terminals on the connection board
DHW thermostat and connect them to its normally open contacts(FIG.8-3).
Connect storage indirect water heater (DNW) thermostat �• If both a high and low gas pressure switch is used,connect
(f�IG. �-3) to the DHW thermostat terminals on the their respective contacts in series,and connect them to tl�e
connection bo.�rd. If a tank sensor is connected (see DH�V termivals on the connection board(FtG.8-3).
Tailk Sensor below) thz tank thernlostat is ignored. Varlab�@ Sp@@t� S�/St@117 pUl't7p
DHW tank sensor If a variable speed pump is used in the pri�nary loop, and a
1. By installing a tank sensor,the SMART S�'STE�1 controt 0-lOV signal is available from the pun�p speed control, this
can perform the tank thermostat function. The SMART 'ignal can be used by the SMART SI'STEM control to anticipate
SYSTEM control automatically detects the presence of changes in tl�e building heat load. By connecting this 0 - lOV
this sensor and generates a DF��'call for heat when the signal to the 0 - 10�' SYS PliMP IN terminals, the boiler (or
tank temperature drops 6°F (3°C) below the tank set cascade) can modulate up and down as the primar�� flow
point and tlnishes the call for heat when the tank �n�reases and decreases.
temperature reaches the tank set point. Boiler pump speed output
2. The tank sensor induded with the Loehinvar Squire This 0- 10�'output is available to control the speed of a variable
Indirect DHW tank (TST20015) is the only sensor speed boiler pump. The SMART SYSTEM control will vary the
suitable for use with the SMART SYSTEM control. speed of this pump in order to maintain a minimum 4T aaoss
Connect the sensor leads to the Tank Sensor terminals on the heat exchanger,as well as prevent high limit lockouts when
the Low Voltage Connection Board (FIC�. 8-3). Consult the flow in the primary loop is extremely low. Gonnect this
the tank manufacturer for application and performance output to the 0- LOV input on the bviler pump speed control.
���hen used�vith any other indirect tank.
1 ailure to use the correct sensor may result Rate output
d WARNING �p the tank temperature being either above �is output provides a 0- lOV signal that is proportional to tt�e
or below the set point. Failure to consult firing rate of the boiler. This may be used by a BMS system to
the manufacturer of the indirect tank, monitor the actual rate of the boiler.
when the Squire is not used,ma}'result in
decreased performance or the risk of scald
injury. ' S1
16N I
�._ T Installation & Operatian Manuai
8 Field wiring
ModBus Alarm contacts
When the optional NlodBus interface modulr is installed,the The SMAR"I' SYSTF.:�•[ control closes another set of contacts
RS-485 ModBus cable is connected to these terminals. Use whenever the boiler is locked out or the power is turned off.
shielded,2-wire twisted pair cable. [f desired,the shield can "This can bc used to turn on an alarm, or signal a Building
be connected to ground by installing a jumper wire between Management System that the boiler is down.
tetminals 1 and 3 on connector 7�5 on the optional ModBus
interface module. wll'lltg Of t�'1@ CaSCade '
F�OW SWItC�1 �1/hen wiring the boilers for Cascade operation, selcct o�1e ��
1. A Ylow switch is used to guarantee flow through the boiler boiler as the Leader boiler. The remaining boilers will be
before allowing it to fre. The flow swiCch must be designated as I�lembers. See page 60 "Configuration of the
installe�l at the boiler outlet Cascade"for a detailed explanation of this procedw-e.
2. Connect these terminals to the normally open contacts on Connect the system supply sensor and outdoor air sensor (if
the t]ow switch (I�'IG.8-3), used} to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
System supply sensor location of the system supply sensor should be downstream of
1. By installing the system supply sensor into tl�e supplv of the boiler connections in the roain system loop (FIG:s 6-4,
the primary loop,the temperature of the primary supply 6-6,and 6-t�).The system supply sensor should be wired to the
can be controlled. The S�1ART SYSTEM control ����w'Voltage Connection Board at the terminals mar]<ed for
automatically� detects the presence of this sensor, and the system sensor (see FIG. 8-3).The Leader control will use
controls the boiler firing rate to niaintain the system the water temperature at the system supply sensor to control
supply temperature to the set point (if the outtet sensor the operation of the Cascade.
control is currently selected). It it is desired to control the If outdoar air reset is desired,the outdoor air sensor should be
system return temperature, then program the S�1ART wired to the Low Voltage Conilection Board at the terminals
SYSTEM control to use the inlet sensor as the controlling marked for the outdoor air sensor (FIG.8-3). If the outdoor
sensor. See the Knight Boiler Service 1�lanual for air sensor is connected, the Leader control will calculate the
instructions on hotiv to use the inlet sensor as tkie water temperature set �oint based on the programmed reset
controlling sensor. 4'Vhen the inlet sensor is programmed curve parameters.If the outdoor air sensor is not coniiected,
as the controlling sensor, it is vital that the SI'STENI the Leader control �vill maintain the fixed water temperature
SUPPLY sensor be installed. DO NOT INSTALL T'HF, set point that is programmed into the control.
SYSTEM SUPPLY SENSOR INTO THE SYSTEn4 If a Thermostat, Zone Control enable output, or Building
RETURN. Management System enable output is available,it should be
2. The TST2032 sensor provided with the boiler must be wired to the Low Voltage Connection Board on the Leader
used for the system sensor. boiler at the tenninals marked for one of the Room
3. Connect these terminals To the system supply sensor Thermostats 1-3 (FIG. 8-3). If the boilers are to run
(FIG.8-3). continuously, connect a jumper wire between the R and W
Boiler management system terminals for the Thermostat input.This will initiate a call for
heat on the Cascade.
1. An esternal control may be connected Co coutrol either �;��mmimication beriveen the Leader boiler and the i�lember
the firing rate or the set point oE the boiler. If the external boilers is accomp]ished by using shielded,2-wire twisted pair
control uses a set of contacts to enable the boiler,connect
communication cable.Connect one of the twisted pair wires
the contacts to the Room Thermostat 1 ternlinals. to Cascade terminal A on each of the I,ow Voltagc Connection
Otherwise,the SMART SYSTEM control will be enabled �oards, and the other wire of the twisted pair to Cascade
by the 0-10�'signal. terminal B on each of the I.,o�v Voltage Connection Boards.
2. Make sure the ground terminal is connected to the Connect the shield wires to one of the shield terminals on the
groiuld output terniinal of the external control, and 2he Low Voltage Connection Boards (FIG.8-3).If more than two
0- 10 vdc terminal is connected to tlle 0- 10 vdc terininal ���ilers are on the Cascade, daisy ihain the wiring from the
of the external cuntrol. Cascade terminals on the second boiler to the Cascade
RU11�Ifl1@ COt1taC�5 terminals<m the third boiler,then from the third to the forth,
and so on. The connections between boilers can be made in
The S1��IART SYSTEI�1 control doses a set of dry contacts any order, regardless of the addresses of the boilers. Try to
�vhenever the burner is running. This is typically used by keep each cable as short as possible.
Building Management Systems to verify that the boiler is
responding to a ca]1 for heat.
� 52 ��
��' Instailation & Operation Manual
8 Field wiring (contrnued)
Figure 8-3 Low Voltage Field Wrring Connections
�
0
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z
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cn � i � z � _ �
z � � � a a � � �
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(� O � s er G C� i'.'i � � U � �: L�-, m O , �z m �m
�. � F w O G t; �'r`' b � o�,�, tn a >?',,>2 >a:�;,;a c� � �- p: d O
Z � � h-en drr =''�tua � � � � �u� ouy o�€o. [i � Q � 4 ��
Q � } >w w 0��� O 2 z c,9�c� �� ,U� � .:i Q�
� r O
� � O (n rr,u��O+n z��,t-m z uy a m in, , + t , '�� + r� � m c,�, - m z
W
Z
F-J u c�r: � p O
p z m t � �::. � : '�.���.. w�
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am �Z�
Q � s ^ =r ��: - oo�
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mzu�i
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n
- �� --- — ' J ---�1 —
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� ........ / _ . _l,_ � v ,� -
W �i n''I v .- :�
f.�I F F-� 1-� (- .�'�' .
_ ¢.` �.�� � � 4 Q d 6 u �.
(n � � 2'�,� , LiJ � � h � ��
v'7 tF} � cn�� � , � �' Ci O �.
Qm �� -.�;. U �U �b ��I�,-' � �cc �� ��
� ��_�,° �¢ �¢ v> �'j;aU� � �w Oiu Ou� Ow °� �
g r�� �� t cr E' ¢¢ r; >'r- ¢r Q= o� �_ �—�
O=-� ..�_. '�',¢� �?!:��' �2'�.Q�',, , '.�� �� �F' �•`y �~ "'_�
�O— '�`�3 '. 7 �.�z,. C � .- . _ . ��
LL�Q .....� t.r.
�m `��a....��..., ;;�'��^�'7v - K�!�'�'�?,� `'x"� �,y' �
a J� ���_�"� '����"�. :_r
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w� � ; ;� � `-
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Q �~ = Q � � �
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Z (n 2 � r �
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� a " � � � �
53 �
��f+T Installation & Operation Manual
9 Condensate disposal
C.011C�@flSat@ dl'altl NOTICE Use materials approved by the authority
having jurisdiction. In rhe absence of
1. This boiler is a high efficiency �pplianee that produces other authority,PVC and CPVC pipe must
condensate. comply with ASTM D 1785 or D2845.
Cement and primer must comply with
2. The side of the boiler has a 1/? inch PVC union tor AS�4E D?�64 or F493. For Canada use
connection of a 1/2 inch PVC pipe(FIG.9-1).
CSA or ULC certified PVC or CPVC pipe,
3. Slope condensate tubing down and away frcml the boiler fittings,and cement.
into a cirain or condensate neutralizing filter. Condensate NOTICE To allow for proper drainage on large
from the I�night boiler will be slightly acidic (typically horiiontal runs,a second line vent mav be
tivith a pH from 3 to 5). Install a neutralizing filter if required and tubing size may need to
required by local codes. increase Yo 1 inch.
A Neutralizer Kit (FIG.9-1) is available from the factorv The condensate line must remain
(Kit 3087 j.
' unobstructed, allowing free flow of
condensate. If condensate is allowed to
4. Install the I I3 inch PVC tee asse�Y�bl}� (sllipped with the freeze in the line or if the line is obseructed
in any other inanner, condensate can exit
unit)as shown in FIG.9-]. from the boiler tee, resulting in potential
� water damage to property.
5. I_eave the top of the 1/�inch tee OPEN. 'I'his is needed as
a vacuum break. 8. A condensate renioval pump is required if the boiler is
below the drain. VVhen installing a condensate pump,
6. Do not expose condensate line to freezing temperatures. select one approved for use with condensing boilers and
furnaces. The pump should have an overflow switch to
7. Use only plastic tubing or piping as a condensate drain prevent property damage from condensate spillage. The
line(FIG.9-1). switch should be wired in series with the blocked drain
switch inside the boiler(see FIG. 10-1 on page 56).
Figure 9-1 Condensate Disposal
�'�',`\
_� ��
� � �
�"�� �, .
i � . �'-
.� �
�� ��_.�� �
� �
� ��� �
, I
1/2"PVC TEE ASSEMBLY- `s� ' �
(FACTORYSUPPLIED) �,,,•- �
i-;
�--1/2"PVC UNION
(FACTORY SUPPIIED)
NEUTRALIZER KIT
FLOOR DRAIN OR
DRAIN PAN
54
BORING 1
ELEV.=1009.5'
1010 1010
oo.:
1005 0" 33/i 2 1005
WC=8.5
:Q; +4=24
-200=30
�°• LL=21
PROPOSED GARAGE FFE PI=6
w �aoo 1� �
'� W
� �
� z
0 0
�
> ;
� 995 995 �
w
990 990
98� 985
Note:Explanation of symbols is shown on Figure 3.
.��H�
110191A C�C7t@CI'1 LOG OF DCPLORATORY BORING FIGURE 2
HEPWORTH-PAWLAK GEOTECHNICAL
7 � Start-up
CheCk/eontrol water ehemistry 3. Fill to correct system pressure. Correct pressure will vary
with each applicaTion.
� CAUTION I?o not use petroleum-based cleaning or
sealing compouuds in the boiler system. a. The rninimum cold water fill pressure for a
Damage to elastomer seals and gaskets in residential system is 12 psi.
the systent cotild occur, resulting in h, Pressure will rise �vhen boiler is turned on and
substantial property dainage. system water temperature increases.
Hardness less than 7 grains
4. At initial fill and during boiler startup and testing, check
L Consult local water treatment companies fur tlard water sy�stem thoroughly for any� teaks. Repair all ]eaks before
areas(above 7 grains hardness). E�r�ccedin� further.
Chlorine concentration less than 200 ppm �{NARNING �'liminate all system leaks. Concinual fresh
l. Do not fill boiler or operate ��ith water cru��aii�iu� makeup water will reduce boiler liEe.
cl�lorine in excess of 200 ppm. ��Iinerals can build up in the heat exchanger,
reducin�; heat transfer, overheating the heat
2. Filling with chlorinated fresh water should be acceptable eschanger, and causing heat exchanger
since drinking water chlorine levels are much lower, failure.
3. Do not use the boiler to directly heat swimming pool or purge air from water system
spa water.
1. Purge air from system:
Test/replace freeze proteCtion fluid a. Connect a hose to the purge valve (see purge/drain
l. For svstems using freeze protection fluids, follow fluid valves, in piping diagrams on pages 39 through 45).
ma�iufacturei's instructions. Route The hose to an area where water can drain and
2. Freeze protection fluici must be replaced periodiially due �e seen,
b. Close tl�e boiler or system isolation valve between
to degradation of inhibitors over time. Tollow all fluid the purge valve and fill connection to the system.
manufacturer's instructions. c. Close zone isolation valves.
Freeze protection (when used) �• Open yuick-fill valve on cold water makeup line.
e. Opev purge valve.
1. Determine freeze protection fluid quantity using system r. One zone at a tiine, open the isolation valves. Allow
water content, follo���ing fluid manufacturer's water to run through the zone, pushing out the air.
instructions. Boiler water conteut is listed on page 7. Run until ❑o noticeable air flow is present Close the
Remember to include expansion tank�vater content. zone isolation valves and proceed with the next zone.
2. l.,ocal codes ma,r-require a bad:flow preventer or actual Pollow this procedure until all zones are purged.
disconnect from city water supply. g. Close the quick-fill water valve and purge valve anci
remove the hose. Open all isolation ��alves. 4��atch
3. When using freeze protection fluid with automatic fill, that system pressure rises to correct cold-fill
install a water meter to monitor water makeup. Freeze
pressurc.
protection tluid may leak before the�vater begins to leak, h. After the system has operated for a while, eliminate
causing concentration to di•op, reducing the freeze aily residual air by using the inanual air vents located
protection level. throughout the system.
4. The freere prorection set points may> be lowered when i. If purge valves are not installed in the s}�stem, open
freere pmtection tluid is used (see the I�night Service the manual air vents in the system one at a time,
�tanual). beginning with the lowest tloor. Close the vent when
�vater squirts out Repeat with remaining vents.
Fill and test water system
2. Open automatic air vent (diaphragm-type or bladder-type
L Pill system only afrer ensuring Che water meets the �xpansion tank systems onl}�)one turn.
requirements of this manual.
2. Close manual and automatic air vents and boiler drain 3. Open other vents:
valve. a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refi11 to correct pressure.
55
�,�.�r�i�' Installation & Operation Manuai
7 � Start-up
CheCk fQ1' gaS IeakS ��A����� Propane boilers only — Your propane
supplier mixes an odorant with the
!�1 WARF�IING �efore starting the boiler, and �luring propane to make its presence detedable.
� �nitial operat�ion,smell near the tloor and ln some instances, the odorant can fade,
around the boiler for gas odorant or any and the gas may no longer have an odor.
unusual odor. Remove the top access Before startup (and periodically
panel and smell tl�e interior of the boiler thereafter}, have the propane supplier
enclosure. Do not proceed with startup if verif}-the correct odorant level in the gas.
there is any indication of a gas leak. Use an
approved leak detection solution. Repair �+heck thermostat eireuit(s)
any leal:s at once.
L Discormect the t�vo e�rternal �tiires connected to each of
�WA����� DO NOT adjust or attempt to measure gas the room thermostat ternlinals on the connection board.
vabe outlet pressure. The gas valve is
factory set for the correct outlet pressure. 2• Connect a voltmeter across tl�ese rwo incoming wires.
"I'his setting is suitable for natural gas and Close each thermostat, zone valve, aiid relay vi the
propane, requiring no field adjustment. external circuit one at a time and check the voltmeter
Attempting to alter or measure the gas readin�across the incoming lvires.
valve outlet pressure could result in 3. These should 1V'EVER be a voltage reading.
damage to the vabe, causing potential
severe personal iniur}', death, or '�• If a voltage does oaur under any condition, check and
substanTial property damage. correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
Figur'e 10-1 Condensate Trap 5. Once the external thern�ostat circuit wiring is checked
and corrected if necessary, reconnect rhe externai
RETAINING
seRew� thermostat circuit�wires to the connection 1>oard.
� 2"PVCCAPWITH Inspectlfill condensate system
� �BLOCKED DRAIN SWITCH �nspecticheck condensate lines and fittings
�.� �1 PvcTeensseMe�v 1. Inspect the condensate drain line, condensate PVC
t � ���, (FACTORY SUPPLIED)
I fittings and condensate trap.
��� l� Fill condensate trap with water
' 1. Reinove the PVC cap retaining screw from the PVC cap
I (FIG. 10-1).
, I
� � �� 2. Remove the 2 inch PVC cap with the switch located at the
' top af the trap (FIG. 10-1).
CONDENSATE PROM / �`���� /
HEATEXCHANGER'� T DRAIN R �. F'll�.Wltt]tl'eS}l W2te1'lllltl�YI'1P.WateT bCg,ICiS t0 p011l'011t Of
t�l�(jr31I1.
4. Replace the cap. Press the cap onto the trap until the cap
makes contact with the�rain.
5. Replace the retaining screw.
Lf1 WARNING T'he condensate trap (FIG. 10-I) must be
tllled with water during all times of boiler �
�,peration to avoid flue gas emission Yrom
the condensate drain line. Failure to fill
the trap could result iv severe personal
injury ar death.
56 _.��
I
���+T Installation & Operation Manual
1 � Start�l,lp (continued)
Final checks before starting the 6oiler ❑ Check vent piping and air piping
]. Check for gastight seal at every connection, seam of air
❑ Read the Knight Boiler Service Manual to familiarize p�pin�,and vent piping.
vourself with S1�1ART SI'STEM control modiile
operation. Read this manual,page�t�for proper steps to �yu�q���j� ��enting system must be sealed gastight to
� revent tlue as s illa e and carbon
start boiler. P � � g
monoaide emissions, which will result in
❑ Verify the boiler and system are full of water and all severe personal injury or death.
system components are correctly set for operation. ❑ Cheek gas piping
❑ Verify the preparation procedures of Section l0,pages 55 l. Cl�eck around the boiler Eor gas odor following the
and 56 have been completed. procedure o�i page 46 of this manual(connecting gas supply
��ipin��).
❑ Fill the vent condensate trap with water (removing thr
retaining screrv in arder to remove the 2 inch PVC cap �,j WARNING' If you discover evidence of any gas leak,shut
witl� the switch located at the top of the trap). Replace � � � down the boiler at once. Find the leak source
the cap. Press the cap onYo the trap until the cap makes �+�ith a bubble test and repair immedia[ely.
contact�vith the drain. Replace the retaining screw. Do not start the boiler again until corrected.
Failure to comply could result in severe
❑ Verify electrical corinections are correct uid securely personal injury, death, or substantial
attached. property damage.
❑ Inspect vent piping and air piping for signs of ❑ Propane boilers—verify conversion
deterioration from corrosion, physical damage or 1. �Terify propane conversion lias been completed per the
sagging. Verify air piping and vent piping arc inract and pi-t��1i1E Com�ersion instructions.
correctly installed per this nlanual.
�WARNING �� NOT adjust or attempt to measure gas
Start the boileY ��alve outlet pressure. The gas valve is
1. Read and follo�,-tl�e Operating in;tructir�ns in I�IG. 1(l-?, factory-set far the correct outlet pressure.
This setting is suitable ti�r natural gas and
p���'���� propane, requiring no field adjustment.
If boiler does not start eorrectly Attempting ta alter or mcasure the gas valve
outlet pressure could result in damage to the
1. Check for]oc�se connections,blown fuse or service switch ealve, causing potential severe personal
°f� injur}�, death, or substantial property
2. Is boiler water tempeiature above 200°F? damage. �,
3. Is thermostat set below room temperature? �Vfi��RNING �i�ight boilers are typically�shipped ready to ��
hre on natural gas. Check boiler ratin�plate
4. Is gas turned on at meter or boiler? to determine which fuel the boiler is set for.
If set to natural gas,it may be converted to LP
5. Is incoming gas pressure less than 4 inches w.c.? by installing an orifice(see page 13). In order
If none of the above corrects the problem, refer to the to operate ou LP gas, an orifice MUST BE
Troubleshooting Section of the Knight Boiler Service Manual. installed. Failure to comply could result in
severe persona] injur}�, death, or subsTantial
Check system and boiler propertv dam�tge.
❑ Check water piping Check flame and combustion
1. Check s�stem piping for leaks. If found, shut down the 1. Turn the main power off ro the boiler by placing the
boiler and repair immediately. (See ��VARNINGS on On/Off"switch in The OFF positiou.
pages 55 and 56 (startup) regarding failure to repair �. Remove the flue temperature sensor from the flue pipe '
leaks.) connection. NOTE: Combustion measurements will be '
made at this point �
2. Ven[ any remaining air from the system using manual
vents. Air in the svstem tivill interfere with circulation and 3. Turn the main power on to the boiler by placing the
cause heat distribution probleros and noise. "On10ff"switch in the ON position.
; 57
���HT Installation & Operatian Manual
7 � Start-up
Figure 10-2 Operating Instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or expiosion
may result causing property damage, personal injury, or loss of life.
A. This appliance does not have a pilot. It is Immediately call your gas supplier from a
equipped with an ignition device which neighbor's phone. Follow the gas supplier's
automatically lights the burner. Do not try instructions.
to light the burner by hand. If you cannot reach your gas supplier, call
B. BEFORE OPERATING smell all around the fire department.
the appliance area for gas. Be sure to C. Use only your hand to move the gas control
smell next to the floor because some gas switch. Never use tools. If the switch will not
is heavier than air and will settle on the move by hand, don't try to repair it, cali a
floor. qualified service technician. Force or attempted
WHAT TO DO IF YOU SMELL GAS repair may result in a fire or explosion.
Do not try to light any appliance. D. Do not use this appliance if any part has been
under water. Immediately call a qualified
Do not touch any electric switch; do service technician to inspect the appliance and
not use any phone in your building. to replace any part of the control system and
any gas control which has been under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information 8. Move the switch to the"ON" position.
above on this label. 9. Install front door.
2. Set the thermostat to lowest setting. 10. Turn on all electric power to appliance.
3. Turn off all electric power to the 11. Set thermostat to desired setting.
appliance. 12. If the appliance will not operate,follow the
4. This appliance is equipped with an instructions"To Turn Off Gas To Appliance"and
ignition device which automatically lights call your service technician or gas supplier.
the burner. Do not try to light the burner
by hand.
5. Remove front door. ' '
6. Move switch to the"OFF" position. -- i `- ,
7. Wait five (5) minutes to clear out any gas. �. � i �
If you then smell gas, STOP! Follow"B" ' � � �; � 4
�
in the safety information above this label. °° ' �
If you don't smell gas, go to next step. i flFF QN
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting. 4. Move switch the"OFF" position.
2. Turn off all electric power to the appliance 5. install front door.
if service is to be performed.
3. Remove front door.
LBL2339 REV B
58
(�I��NT` instaliation & �peration Manual
1 O Start�Up (continued)
Check flame and combustion (continued) Set space heating operation
NOTICE Please ,�ote that the brackets ([]) denote Determine controlling sensor
screen status. For space heating systems, the remperature control can be
4. Place the boiler into the active position by pressing the based on one of three sensors; the inlet, outlet, or system
RIGHT SELECT [ON� key(FIG. 1 I-1, page 67). supply sensor. 'I'he SMART SYSTEA�1 contro]is programmed
at the factory to control the temperatare of the outlet sensor.
5. Locate thc pinhole button below the RESET button on the The control �vill automatically switch to the system supply
display board (FIG. I1-1). Insert a thin �vire (such as a sensor once it is connected. If it is desired to base the
paper dip) into the hole and press the button once and temperature control on tl�e inlet sensor, the appropriate
hold for 5 seconds to place the boiler into Ser��ice l�-fode. pararoeter must be changed in the control. See� the Knight
In Service Mode the boiler�rill fire at ignition speed and Boiler Service Manual for a detailed explanation of this
will then modulate up to full fire. procedure.
6. Insert the probe from a combustion analyzer into the hole Verify Space heat circulator mode
left by the removal of the flue temperature sensor. The Space F-Ieating Mode controls both the svstem (primary)
7. Once the boiler has modulated up to full fire,measure the pump (if connec[ed), and the boiler (secondary) pump.
combustion. The values should be in the range listed in �'hen the Siti1ART SYSTEM control receives a space heating
Table l0A below. The CO levels should be less than call for heat,it turns on the system pump. If the boiler is not
150 ppm for a properly installed unit. heating an indirect DHW (Domestic ���ot Water) tank, and
the set point is not met, it also turns on the boiler pump.
If the combustion is not within the specified range, ��er the syace heating call for heat ends, the system pump
reference the Troubleshooting Section of the Knight continues to run for a short period vf time. The system pump
Boiler Service Manu�l for possible causes and corrective can be programmed to run continuously, excePt during
actions, outdoor shutdown. If the boiler pump was run�ling, it
continues to run for a short period of time as well. These
Table 10A Flue P�oducts Chart pump delays are factory set to 3(?seconds. If different delays
are ciesired,the appropriate parameters in the control must be
Natura) Gas Propane changed. See the Knight Boiler Service Manual for a detailed
explanation of this procedure.
CO2 OZ COZ OZ
8.0%- 10% 3.0%-6.5% 9.0%- 11% 4.1%-6.9% Adjust set point temperature
NOTICE Vlease note that the brackets (()) denote
8. Once the combust�ion analysis is complete,test the safety
screen status.
shutoff device by turning the manual shutoff sti�itch to The NAVIGA'[TON dial may be used during normal
the OFF position and ensuring that the boiler shuts operation to adjust the space heating and tank set point
down and registers an alarm. Turn the manual shutoff temperatures.
switch to t�he ON position, reset the control,and return
to Service Mode. 1. From the Status Screen press the NAVIGATION dial.
2. Turo the NAVIGATION dial counterclockwise to select
9. Turn the main power off to the boiler and replace the flue the appropriate set point.
temperature sensor into the flue pipe connection. 3. Press the NAVIGf1'I'ION dial to adjust the temperature.
4. Once the desired temperature is displayed, press the
t 0. Vlace the boiler back into normal operation. KIGHT SELECT [SAVE] key.
5. If necessary repeat Steps 3 and 4 to make adjustments to
�WARNING ��°u must reylace the flue gas tem�erature additional set points.
,ensor to prevent flue gas spillage into the 6. Press the RIGHT SELECT [HOME[ key ro upload the
room. Failurc to comply could result in changes.
severe personal injury, death, or � If the RIGHT SELECT [SAVE] key is not pressed, the
substantial property damage.
new settings will be discarded.
59 �
���+T Installation & Operation Manual
7 � start-up
Set domestic hot water (DHW) operation
Verify DHW mode 8. Turn tlie NAVIGATION dial to adjust the�nonth. Press the
There are two (2) modes of operation for DHW. In Normal NA`'IUATION dial.
Mode,when a DHW demand begins,the control will start the 9. Turn flle NAVIGATION dial to adjust the date. Press the
DH�1' Pump, turn off the boiler pump (if running), and NAVIGATION dial.
modulate to bring the outlet temperature ro the DHW boiler 7 p, Turn tl�e NAVIGATION diai to adjust the year. Press the
set point. The maaimum firing rate may be limited in this RIGHT SELEC'T [SAVE� key.
mode if desired. ]I. Press the R1GHT SELECT' [HOME] key.
Li Zone Mode it is assumed that the indirect DH�N tank is
piped as a zone on the primary loop. When a DHW demand NOTICE The internal clock does not adjust for
begins,the control will turn on the DF-I1h'pump output,and I�aylight Saviugs Time and therefore, �+-i11
raise the system temperature set point to the DHW boiler set require a manual adjustment.
point(if higherl. The system pump and the boiler pump will Configuration af the cascade
be turned on. In this mode,any lo�v temperature zones(such
as radiant heating) may need additional controls to limit the NOTICE Please note that the brackets ([]) denote
�vater temperature sent to those zones. screen status.
Set DHW target temperature ��'hen installed in a Cascade system, the individual controls
must be programmed tor cascade operation. This is
When in tl�e DHW Mode> the control will modulate to accomplished by accessing the control parameters.
maintain the boiler outlet temperature or system supply
temperature to a set point. This set point is set at the factory Press the [MENU] key for at least five(5)seconds. Input the
to 180°F. lf a different set point is desired, the appropriate Installer code as described in the Knight Boiler Service
parameter in the control must be changed. See the Knigh[ Nlanual.Once the control parameters have been accessed,use
Boiler Service Manual for a detailed expianation of this the NAVIGA"TION dia] to select the Control Mode
procedure. parameters. Press the NAVIGATION dial to access these
paramcters.
Set m8xlmum DHW fan speed Rotate the NAVIGATION dial to select the parameter
If the rated input of the in�irect tank is less than the "Cascade Address':Press the NAVIG�'�TION dial to access this
m�imum output of the boiler,change the maaimum DHW Farameter. Each appliance in the Cascade system must be
fan speed setting to limit the boiler output accordingly, see programmed with its own address. The boiler designated as
tbe Knight Boiler Service Ntanual for a detailed explanation of the Leader will have an address of 0.The remaining boilers in
this procedure. the Cascade will be Membcrs and ha��e addresses from 1 - 7.
Rotate the NAVIGATION dial to selecx the appropriate
Set CIoCk address. Press the RIGH'I' SF.:I.,F..C"I' (SAVF.J key. If installing
NOTICE �'lease note that the brackets ((]) denote the boilers in an existing system, the new boilers should be
screen status. programmed as the Leader and/or the higher number
addresses.
The SMAR1'SYST�EI�T control has a built-in clock that it uses press the RIGHT SELECT[HONIE]key to upload the address
for its night setback feature and for logging events. This into the control. Repeat this procedure for all boilers in the
dock must be set when the boiler is installed, and anytime Cascade, designating the Leader control and the Member
the boiler has been po�vered off for more thaii 4 hours. Use controls.
the following procedure to set the clock:
1. Press and hold the LEFT SELECT [1�4ENUj key for at
least 5 seconds.
?. The display changes to read [YASSt�'OR[:)],
with four(4)zeros below it.
3. Press the RIGHT SELECT (SAVEJ key.
4. The display �vill then show a menu with The time and
date and temperature unit.
�. Press the NAVIGATION dial twice.
6. Turn the NAVIGATION dial to adjust the hours. Press
the NAVIGATION dial.
7. Turn the NAVIGATIOIV'dial to adjust the minutes. Press
the NA�'IGr1TION dia1.
6�
��+T Installation & Operation Manual
7 '� Operating information
General DHW priority
HOW th@ 1�011@P Op@I'a'�@S The SMART SYSTEM control allows the connection uf a DHW
The Knight boiler uses an advanced stainless steel heat thermostat or tank sensor to the l�w voltage connection board.
eachanger and electronic control module that allows fully �''hen a tank seneor is connected,the DHW thermostat input is
condensing operation. The blawer pulls in air and pushes ignored.
flue products out of the boiler through d1e heat exchanger DHW!spaee heating (SH) eyeling
and flue piping. The control module regulates blo�ver speed
to control the boiler firing rate. The gas valve senses the If a DHW call for heat is received while a space heating call is in
amount of air flowing into the boiler and allows only the right progress and the DHW is in I��ormal Mode,the control will start
amount of is to flow. the DHW pump and shut the boiler pump off. The system
�. _
pump will remain on. If the space heating call is still active
How the control module operates while the DHti'call is in operation,the control will wait tor 30
minutes(tiine adjustable by installer)then it will switch back to
The SI�2ART SYSTEVI control inodule receives inputs from the space heating demand. There is a timer to stivitch frc�m space
boiler sensors and external devices. The control module heating to D�IW and a timer to switch from DEIW to space
activates and controls the blower and gas valve to regulat€ heating. The control will switch back and forth until one of the
heat input and switches the boiler, Domestic Hot Water heat demands end.
(DHW),and system Pumps on and off as needed. The user
programs the module co meec system needs by adjusting Programmable controlling sensor
control parameters. These parameters set operating The control module is progranlmed to use the outlet sensor as
temperatures aud boiler operating modes. Boiler operation the control sensor by default If a system supply sensor is
can be based on boiler outlet water temperature,boiler inlet connected, the control automatically uses it as the control
water temperature, s}�stem temperature, a 0-l OV signal or �ensor. The control sensor can be changed by the installer to the
Modbus,depending on the parameter settings. inlet sensor. If the inlet sensor is chosen as the controlling
sensor, it is recommended that the srstem supply sensor be
Control inputs and outputs installed in the system supply in order to provide the best
Room thermostat control of the inlet temperature.
There are three (3) thermostat connections available on this Anti-eyCling
control. These inputs tell the boiler to provide water for space
heating. Each thermostat connection has iCs own set point ���i the burner turns off,the control will delay the next burner
and outdoor air reset curve. LVhen multiple thermostats l�ave cycle for a set time period (time is adjustable by the installer),
a call for heat the control will gi��e priority to the demand with The time delay H�ill be bypassed if the inlet water teiYiperature
the highest set point. drops too far during the delay.
Exam�pte: Assume that both Room Thermostat 1 and Room
Boiler and system pump control
T'hermostat 2 have a call for heat. Room'I'hermostat I has a The boiler pump w�ill rtin�vhenever the burner is tiring,unless
set point of 110°F. Room Therrnostat 2 has a set point of the DH W is programmed for Nortnal Mode and the boi]er is
140°F. The boiler will regulate the s}�stem temperahire to heating the DHW tank. The boiler pump�vill run during Freeze
140°F until Room Thermostat 2 has been satistied. Once Protection���[ode as�vell. It will couCinue to run for a short time
Room"I'hermostat 2 has been satisified the boiler tivill provide afrer the burner turns off or the Preeze Protection Mode ends.
110°F water to the system. The system pump will run whenever there is a space heating call
�tihen mulTiple temperature loops are for heat,or the boiler goes into Freeze Protection Mode. It will
� CAUTION continue ro run for a short time after the end of the heat
used, thermostatic mixing valves are
required for the protection of any low �jemand or the Freeze Protection Mode. The system pump can
temperature loops. be programmed to run continuously if desired. In either case,
it�tiill not run during outdoor shutdown.
0- 10V input(set point or power) Temperature Control
The Knight boiler c�n be controlled by a Buildin� Modulation
Niansgement System (BMS) using a 0 - 10 vdc signal. The
contro]can be configured by the installer to use this signal to The Knight boiler is capable of inodulating its firing rate fro�n a
either control set point or firing rate. minimuin of 20% to a maximum of 100%. "I'he firing rate is
The Knight boiler can also be programmed to accept a call for �ictated by the call for heat(i.e.,space heating or dotnestic hot
heat from a 0-lOV signal,reference the Knight Boiler Service �'`'aTer), the heating load, ramp delay (if enabled), and various
other temperature limitations.
blanual for a detailed explanation of this procedure. ��
«T fnstallation & Operation Manual
11 Operating information
Ramp delay Protection features
For systems wirh lower tlow,the SMART SYSTE�4 can linlit Outlet temperature, flue temperature, and
the tiring rate (when enabled) when a space heating call for temperature rise limiting
heat starts,or when switching from a DH1V call for heat to a
space heating call for heat There are six(6)limits that can be The outlet teroperature is monitored by the boiler outlet
programmed,as well as si.� (6) time intervals corresponding temperature sensor. When the outlet temperature exceeds
to each limir. The sixth limit will also liinit the firing rate for 185°F,the unit wIll reduce the fan speed. If the oudet water
the rest of the call for heat. temperature exceeds 195°F the control �vill shut the unit
down until it cools off.
Gradient limiting
'I'he control module monitors the flue teniperature by a
If during operation of the boiler the outlet water temperature sensor located in the tlue exhaust if the flue temperature
is rising too quickly,the control will reduce the tlring rste to exceeds 215°F the control will reduce the lroaximum fan
its]owest seTting. speed. If the flue temperature exceeds 240°F the control will
shut the unit down. The unit��ill restart automatically once
Outdoor air reset the flue temperature drops 25°F and t}ie minimum off time
With the outdoor air sensor connected> the control i�iodule has expired.
will calculate the set points of the three (3) space heating 'I'he control monitors the temperature difference between the
demands based on the programmed reset curves. The inlet and the outlet sensor. If this difEerence exceeds 55°F the
installer can cl�ange the slope of the reset curves by several control �vill reduce the inaaimum fan speed. If the
adjustable parameters, T'he user can limit the maximum set temperature difference eaceeds 60°F the control will shut the
point for the system using the space heating set points. unit down. The unit will restart automatically once the
temperature difference has dropped below 55°F and the
Boost funetion minimum off time has expired.
If outdoor air reset is aitive,a»d any space heating demand
Freeze protection
has been active continuously for a set period of time (time
adjustable by installer) and there has been no DHW DO NOT install the boiler in a room tikely to freeze.
demands, the control will increase the set point of that
demand by a fixed number of degrees (adjustable by The following integral feature c�f the SNIART SYSTENt
installer). This process will continue until the space heating control module provides soine protection for the boiler only
demand ends,the set point reaches the programmed set point --n��for the system.
or a maximum of 20 increases has occurred. Once the svstem
heat demand is satisfied,the set point will revert to the value ' ����he SMAR7' SYS"1'EM control niodule provides
determined by the reset curve. freeze-up protection as follows �vhen the boiler
water temperature drops below 45°F:
Night SetbaCk • Below 45°F, the boiler and system pumps operate
constantiv.
The controller may be programmed to reduce the space • Below 37°F,the bc�iler turns on.
heating<ind DH�V set points during certain times each week. • Boiler and pumps turn off if boiler water
Seven different start a�ld stop times may be programmed for temperature rises above 45°F.
the space heating setback and seven start and stop times for • Lower temperatures may be programmed for
tl�e DHW setback. svstems with anti-freeze solutions.
Flame current support NOTICE �'�'men system return temperatures are
maintained belo�v the dew point,
To prevent nuisance shutdo�vns �vhen the boiler is firing at condensation �vill form on the inside of
minimum rates,tl�e control will increase the fir•ing rate when the boiler jacket causing some internal
the flame signal drops too low. sheet metal components to rust.
�CAUTION This feature of the S�4ART SYSTEM
control module does not eliminate the
possibility of freezing. The installation
must still use recognized design,
installation and maintenance practice to
prevent freere potential for the boiler and
: 62 ' : system.
���T Installation & Operation Manual
11 Operating information (continued)
Monitor external limits High limit operations
ConnecTions are provided on the connection board for The ICnight boiler is equipped �vith adjustable automatic reset
eaternal limits such as flow switch, low water cutoff, gas and manual reset high limits. The automatic reset high limit
pressure switches,and a louver proving switch. The SMART has a maximum set point of 200°F and the manua] reset high
SYSTEM ���ill shut off the burner and inhibit relighting limit has a masimum set point of 210°F.
wheuever any of these external limits open. �Vhen the outlet temperature exceeds 200°F,the automatic high
limit action occurs. The boiler shuts do�vn until the outlet
Run-time and alarm outputs water temperature cools below 190°F,and a 60 second timer has
The boiler provides dry� contacts for indicating whe❑ the expired. If the outlet temperature continues to increase, the
boiler is running,and�vhen it is unable to operate. manual reset high limit action will occur at 210°F.
High limit test procedure
Run-time and eycle eounting NOTICE �'lease note that the brackets ([J) denote
The control uses two tiroers to i��oilitor the total hours of �� screen status.
burner operation. One timer mo�litors the time the boiler is 1. Turn ON the m�in power to the boiler by placing the
6ring in the Sp3ce Heating Mode. The other timer monitors ON/OFF switch in the ON position.
the time the boiler is firing in the DHW Mode. 2, If boiler status reads [SHUTDOWN) place the boiter inTo
The cozitrol uses two (2) igiiition counters to monitor the the active position by pressiilg the RIGHT SELECT [ON]
amount of boiler cycles. The first counter counts all ignitions ke��.
of the controL The secorid counter counts only ignition 3. Locate the pinhole (SERVICE button) below the RESET
attempts that have failed. button on the display board. Insert a thin wire (such as a
paper dip) into the hole and press the butto�l once,hold
Service reminder for fve (5) seconds to place the boiler into Service Mode.
In Service Mode the boiler will fire at ignition speed and
The control ca�i be programmed for service reminder ��,ill then modulate up to full fre.
notification. This notification will become active when either
a set time frame has espired, or a set amount of running `�' �'rom the Stahis Screen, �ress the NAVIGATION dial to
hours or cydes has expired (all adjustable by the installer). access the Set Points Screen.
The display �vi11 show a Maintenance Required screen. The 5. Press the I.EFT SFL.ECT [LIMITSj key.
service reminder notification can be reset or disabled by the 6. Select the manual reset high limit(MRI��L)by pressing the
it�staller. NAVIGATION dial.
7. Decrease the set point of the i�4RHL below the outlet
Erto� logging temperature by turning the NAVIGATION dial
The control will hold in memory the last 10 lockouts as well counCercloclavise.
as the last 10 blockings. The date and tiine of the occurrence g• Press the RIGHT SELECT [SAVE] kej�.
will be recorded as well. Only the 10 most current y• Press the RIGHT SELECT (HOA�1E] key.
occurrences of each wiIl be held in memory. 10. The neav parameters will upload to the control and the
MRHL rvill function causing boiler shutdown and
Boiler temperature regulation (I,ocKOt7't'] to be displayed.
Operating temperature (target) 11. Press the RESET button to clear the]ockout.
12. Repeat Steps 4,5 and 6.
The SMART SYSTEiV1 control module senses water 13. Set the N1RF-IL to the appropriate set point by turning the
temperature and regulates boiler firing and firing rate to NAVIGATION dial clockwise.
achieve a target temperature. The target temperature can be 14. Repeat Steps 8 and 9.
set between 32°F and 190°F.
�ow water cutoff protection
• Target temperature is fixed when the outdoor sensor 1. The SNL'1RT SYSTEM control module uses temperature
is not insralled, sensing of both supply and return areas of the heat
• Target temperature is calculated as described belo�v excl�anger. Tf the flow rate is too ]ow or the outlet
under "Outdoor Reset Clperation" and "Target temperature too high, the control module modulates and
Temperature Boost" when the outdoor sensor is shuts the boiler down. '['his ensures boiler shutdown in the
connected. event of low�vater or low flow conditions.
2. Some codes and jurisdiction may aicept these integral
features of the control in lieu of requiring an additional
limit control or low water cutoff. Consult]ocal jurisdiction
to determine. A low water cutoff is available from the
facCorr-(VVTR20009). 63
�116HT Installation & Operation Manual
V
11 Operating information
Outdoor reset operation, if used Sequence of the cascade
Target temperature with outdoor reset To equalize the rnn time of all boilers on the Cascade, the
This feature improves the s}�stem's efficiency as the outdoor tiring sequence will automatically be changed at set intervals.
temperacure�,�arnzs up. For the first 24 hours after initializing the Cascade, the
See the Knight Boiler Service Manual to change the settings. sequence will be changed every hour.After that the sequence
will be changed once every 24 hours. The switching on/off
RBSet Curve sequence tivill be as follows:
The reset cur��e looks at outdoor air temperature and adjusts ��Y SWITCHING ON SEQUENCE
the set point.
Da� 1 L-i�'tl-M2-M3-M4-1�15-��16-M7
CaSCad@ Day 1 + 1 hour �II-M2-M3-M�-M5-M6-M7-L
Wlien multiple boilers are installed,they can be ti-ired togerher Day 1 + 2 hours M2-:�t3-M4-M5-N16-M7-L-M 1
in a cascade sequence. A maximum of eight boilers ca�i be
controlled from a single control. [n this application one boiler If a boiler is used to heat an indirect DHW tank, it will
would be designated as the Leader control and all others would automatically be given the lowest priority.
be designated as Member controls. If installing the boilers in an
existing system,the new boilers should be programmed as the DHW, Night Setback, and Ramp Delay operation
Leader ana/or the higher number addresses.The Leader control With cascade
can be programmed to use Lead/Lag or Efficiency Optimization l�or normal mode I:�HVV operation any boiler(s) in the
control methods. Cascade can be selected to provide heat for a DH��V call.Select
Once the Leader boiler receives a call for heat from a room a boiler to be designated as the DHVV boiler. Connect the
thermostat, BMS,or Modbus,the control will determine what DHW thermostat or sensor to the terminals oil the Low
the set point will be.If outdoor air reset is desired,connect the Voltage Connection Board marked far the corresponding
outdoor air sensor to the terminals on the Low Voltage device. When the boiler receives a DHW call, the Leader
Connection Board on the I,eader boiler. The set point will be CO��trol will take that boiler out of the Cascade sequence. If
calculated based on the programmed reser curve parameters. another boiler is available,the Leader will start it up to take its
See the Knight Boiler Service �laiival to program the reset Place.
curve. [f outdoor air reset is not desired, do not connect the The DHW boiler ti-i11 adjust its set point to the programmed
outdoor air sensor. A tixed temperature set point can be DHV4'set point and will adjust its firing rare to maintain this.
programmed inTo the conrrol. See page 59 of this manual to Once the DH�1r call has been satistled,the Leader control will
program the set point. place that boiler back into the Cascade sequencc.
If the water tcmperature at the system supply sensor is less than Switching of the b�iler between DI-IW opzration and SH
the set point+the turn-off offset-the off-on differential,then operation w�hen there is a call for both does not occur in
the control will initiate a call for l�eat on the Cascade {see the Cascade Mode.
K�iight Boiler Service Manual for an esplanation of the offset When DH�N is programmed far Zone Nfode, connect the
and differential).Tl�e Leader will energize the lead boiler on the DHW thermostat or tank sensor to the Leader boiler. �'hen
Cascade.For a new startup this�tiill be the Leader boiler. a DH�V call is received, the Leader will modulate the entire
Cascade to bring the sysrem supply temperature up to the
DHW boiler set point(if higher).
Night Setback operation of the boilers within the Cascade is
available. Programming of the Night Setback will be done
through the Leader boiler.Refer to the Knight Boiler Service
Manual for information regarding Night Setback.
Ranip Delay operation of the boilers as described iu the
Knight Boiler Service Manual is available when the boilers are
part of a Cascade system.
64
��T Installation & Operation Manual
11 Operating information (continued)
Sequence of operat'ran
PE TIO DISPL.AY
��'��� t1
J�ti}I L'ii� � ib'`�r
1. Upon a call for heat,the gas pressure switch(es)must be closed. T����. 1�$°�k12�i
1 ITI��i'�- �vi r{.r
Uu��UUh4� g r
•--------------------------------
�IcrfiU ��;S�hCcL'� �tii fi
����� 'J
2. Once the gas pressure switch(es) are closed, the control turns
on the a ro riate um s s stem and boiler um s for s ace ��'�1��.M: 11�`F
PP P P P � Y p P p �ffaFIIC: ?2�'F�f���
heating, DHW pump for DHW). The flow switch and/or LWCO ����•���}f��. ���F
must ciose.
MF�hIIJ ��'�f,�RF'E.N �Hf�hl
����� L=J
3. The control turns on power to the louver relay. The louver �����M� �±�fi_
proving switch, air pressure switch, and blocked drain switch TO�I�; l�$¢F•:]��`•
must close. �;i iTf��;�1�; �;°=
--------------------------------
���L� �c SC�E�F� firi��
�f��'f��I�L7G 'J
4. �i he control starts a 15 second prepurge cycle by initiating the °�'=T�r•1: :�7¢F{ j�$)
blower. T�'�F:: :28¢F� ]30)
^�Tp::��� ��4 F
���U �?'S;'R=E�C S-��S
����ITI�� �
5. The control starts a 4 second trial for ignition by firing the spark �'•'t r�hl; n 17`�f�1$�
electrode and opening the gas valve. v5H!�! YF��Y: n�$`�C h.�,0)
L't17l�vtiC14': u{�°�
"'.F�l1 �,?'Sv'R�F� �Hp!�
P��T-P���E �
6. If flame is not detected within 1 second after the sparking ends,
the control will perform a 10 second post-purge, then start 4���fE.h1: t��r"�_< 1��7
another prepurge cycle and try to light the burner again. The 1�F�IdIC: 1��"F� l�4�7
controi will perform a total of 4 attempts before locking out. ������������' ��'A�
I�IENU 5��'��REEN SHGh�
��� � ��
7. If flame is detected, it holds the firing rate steady for 5 seconds
to let the flame stabilize,then it begins to modulate the firing rate �'��TEM� 1 1?°F{1 1$f
based on a set point or some other command (such as a 0-10V TFINIk: 12�°F C 1 u0 f
BMS signal). ��T����� ��'4 r
--------------------------------•
MCNU �?'�CF:CEN �EI�N
65
�!,�!H�T" Installation & Operation Manual
11 Operating information ,
Sequence of operation (continued)
a �a►r�ow ��� �
8. If the space heating call for heat is active,and the tank thermostat
or sensor starts a DHW cali for heat, the boiler will switch to the �•J�� � , �
DHW mode. If programmed for normai DHW operation (not as a � ' - ��'�
zone), the DHW pump will turn on first, then the boiler pump wiii ti����.?�,: + i�°�(;io)
turn off 2 seconds later. This will divert the boiler's outlet water Tr+�l�t 12�4°�f:�35
from the heating system and send it to the tank coil instead. The
�JiiTi�:,'u.�': v'o°�
--------------------------------
control will then modulate to maintain the outlet temperature to r'1C;�U �,�v�r����; �;uu►�
the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating ��� � � .�w
and DHW calls for heat remain active long enough,the boiler will ���'fE:M: t]%"FL t]S}
switch back and forth between the two heating modes until one of 1'AIJK: 1't.4"F< i�k]}
them is satisfied. �il��'�)�u]�{: ���,°F
MEIJU ���iskEE:N �HI)IJ
P��T-�U��E
10. Once both calls for heat are satisfied, the control wi�l turn off the
burner. The blower will continue to run during a 10 second SVSTEhI: 11?'Ff 118)
postpurge. TpN�� 128°F(130)
OUTGOQR: 56°F
MF'hll� !,�S�.kE.F'hl SHDhI
11. Any pumps that are running will continue to run for their ����,���
respective pump delay times before turning off, unless
programmed to remain on continuousiy. A 60 second anti-cycie '�''���'�' i��;F C i x 8)
7G�iw: iI4 ��i:i0)
period wi�l start, which will delay any new call for heat until it q;�7p(;p;�; ��4�
times out.
iiEivU �Z'�Ci�E�� SriO�`i
���i����
12. In Standby, ready to start a new cycle. S�'STEhI: 117`F
C�HlJ TANK: 128`F(1,�0?
QUTDOOR; 5�`F
I'IENU J�SETPO I NTS SHGN
66
���T Installation & Operation Manuai
11 Operating information (continued)
�- Knight boiler control module
SYSTE M
Use the control panel (FIG. l l-1) to sct temperaTures,operating conditions,and monitor boiler operation.
Figure 91-? Confro!Panel
,
� �, ��
,., � . _ � ��� � ,
���� F� ��� �� �� �
�� � � � , � �� ���:.
. � � � ��;
� s :
� �,. �� � � �
� ; �. ;y
; ;
a\ � � " ��� ;�.
�:; �, ,� Q"
° N GA A
���°� �`
, °���� ` 0,." ' � 7�''4��5::t�� 1�.)�t�•�;�
r;��E��,� ,�� - ��\
� ,
�,�
a� � ��, ��," , �
��'' � -_ �
�� �a..d � 1������.! �.�i 7� �AF��� ? d , x;.!. ^_ ,.�P......
�� , T ��� � 1��°'�'���� � `��
�_ �� � � ���� �, � � = `�
� �G � . ;�
�
� ! dA
� Q� ���� ��� ��`��� �
� � � � ���
��
� �
� '
a � _
. �
��. _. � , - r ,. ��;.
� �
� �'� x�� ��� �� ��
�
�° ��� ,
�;a
�.
�;�^ ;,:
l��a��f"r7�E„�C:T tSF1' . t�'.It_�T`;�IHF�T�4�4`
�;��3F�°iC�'�:i {.�t�FT���`;}
The intormation on the bottom of the display sho�vs the functions of the ttivo SELECT keys (on either corner), and the
NAVIGATION dia] (in the center):
A�1ENU- Left SELECT Key
SETPOINTS= NAVIGATION Dial-Pressing Down
SHDN=Right SELECT Ke}'
67 'Y',.
���T lnstallation & Operation Manual
11 Operating information
Access modes
User
The user can adjust space heating and tanl:target temperatures by
pressing Yhe NAVIGATION dial when"1SETYOINTS"is flashiug
aT the bottom of the display. 'I'he date and time, ai�d the
temperature uiuts can also be changed (see page 60).
Installer
i�tost parameters are available only to the installer,accessible by
entering the installer password, see the I�night Boiler Service
Manual.
$aV111g pal'alY1@t@I'S (reference the Pnranreter Table in the
Kr�iglir Boiler Scrvice[�larru�tl)
NOTICE Please note that the brackets ([]) denote
saeen status.
Ta save parameters and exit programming:
Press the RIGHT SELECT [SAVE) key and then press the RIGE�IT
SELECT [H0�1E] key.
To eoter a parameter and continue programming:
Press the RIGH"I' SF.,LF.CT [SAVF.] key 1 time to return to the
parameter listiugs; press again to return to the menu listings.
Remember to press the RIGHT SFI.ECT (HOME] key �vhen
fi�lished programming in order to save the changes made.
See the Knight Boiler Seivice Manual for a detailed description of
parameters and access modes.
� ` 68 �'���
��+�+T Installation & Operation Manual
11 Operating information ��ont;nu���
Figure 19-2 Status Display Screen
A �. � � �: � i � � � B
(BOILER H I,�I
STATUS (CALL FOR
� HEAT)
'��':�TE�1 : 11 r�' F � 11 � �
C Tl�t�ll�: : 1 ��� F � 1 �� �
(OPERATIONAL (�I I�T����ti � ,�Cj�� F
INFORMATION)
p �1Et•a�� �� �' :��f�EEt�I �HC�f�a F
(LEFT SELECT (RIGHT SELECT KEY)
KEY)
E
(NAVIGATION DIAL)
Status Disp ay Screens
Section Display Description
STANDBY The unit tias not received a cafl for heat ii�om a remote thermostat nor
has it received a call for hear from a DHW thermostat.
START The unit has begun a burn cycle ai�d is checking all safety circuits.
PREPURGE The unit has initiated a 10 second purge period on a call for heat.
IGNITION The unit has begun a 4 second spark period to ig�lite the mau�burner.
A o
�o � The unit has fired and is running at the displayed percentage.
�B011er St1tUS The cali for heat has been satisfied and the unit runs the fan for an
B1P� POSTPURGE additional 10 seconds to clear the conibustion chamber and vent
sys[em ot residual t]ue products.
SHUTDOWN The iuiit has been placed in the OI'F position.
�������� ��� The coiitrolled temperature has exceeded its set povit and its offset.
BC,OCKED The unit has deTected a condition that has temporarily inCerrupYed
the current call for heat.
1 Room Therinostat 1 has a call for heat.
� Room Thernlostat 2 has a calt for heat.
B � Room Thermostat 3 has a call for heat.
�C��OT He1� �� "I'he tank thermostat or sensor has a call for hear.
TI1C�1Ca�OPS� � � � Indicates which rooin thermostat demand shows priority.
�y The unit is being controlled by a 0- tOV BMS sign:�l.
� The member unit is supplying heat while in Cascade N1ode.
69
(�+��HT' Installation & Operation Manual
11 �perating information
Status Disp ay Screens (cont'rt)
Section Display Description
SYSTEM: The temperature read by the s��stem supply sensor (if connecteci).
TANK: The temperature read by the tank sensor(if counected).
OUTDOOR: "I`he temperature read by the outdoor sensor(if connected).
INLET TEMP: The temperature read at t��e inlet to the heat exchan};er.
OUTLET TEMP: The temperature read at the outlet of the heat exchanger.
DFLTA T: The temperature difference between the inlet and the outlet of the
heat eachanger.
FLUE TEMP: The temperature read by the flue sensor.
FLAME CURRENT: The current measured by the flame sense circuit.
FAN SPEED: Ttle speed of the combustion blower.
� BOILER PUMP: The status of the boiler pump output.
(Operational
SYSTEM PUMP: The status of the systeni pump output.
Information)
DHW PUMP: The status of the DHW pump output.
BMS VOLTAGE: The voltage received from a BI�4S system.
BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.
SYS PLJMP INPUT: '1'he speed signal received from a variable specd s}�stem pump control.
RATE OUTPUT: A 0- lOV signal indicating the firing rate of rhe boiler. I
SH RLIN HOURS: The total hours of operation in the Spaee I3eating Mode. ��
SH CYCLES: The total burner cycles in the Space I-Ieatuig Mode.
DHW RLIN HOURS: The total hours of operation in the DHW Mode. '
DHW CYCLES: The total burner cycles in the DHW l4ode. �'
LAST 10 FAULTS NO:* The last 101ockouts.
MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
EXIT Press the LEFT SEI,EC"C l:ey to exit the current screen or setting.
� YES Press the LEFT SELECT key to contlrm that the boiler needs to
(LEFT SELECT `hUta°�vt,.
key functian} Press the LEFT SLLECT key to enter the screen that allows you to
I.IMITS .
adjust the limit sett�ngs.
HOME Press the LEFT SELECT key to return to the Status Screen and upload
parameter changes.
70
���-�'�' Installation & Operation Manual
7 7 Operating information (continued)
Status Disp ay Screens (conr'd)
Section Display Description
Turi�ing the NAVIGATION dial wi11 selzct the next or previous Status
����F:EEI'�� Screen.
�4haE�iT Pi-essing the NAVIGATION dial will show the next fault,NSB (Night
Setback) trigger,or ramp delay setting.
E �• ������. Pressing the NA��IGATION diai will select the setting indicated by the
cursor.
(NAVIGATION
�la� FU11Ct10Il� ��ETF'�I f`�Tti� Pressing the NAVIGA'TIO�dial will display the Set PoinCs Screen.
�y?� =tiC f�0 LL Turning the NA�'IGATION di�il will move the cursor up or down.
�� ���U� Turnin�the NAVIGATION dia]will increase or decrease the current
setting.
SHDN Press the RIGHT SEI.ECT key to turn the boiler OFF.
ON Press the RIGH'I'SELEC"['key to turn the boiler ON.
F
�RIGHT SELECT NO Press the RIGHT SELECT key�to cancei the shutdown operation.
key function}
SAVE Press the RIGF-IT SLLECT key to save the current change.
HOME Press the RIGI-IT SELECT key to return to the Status Screen and
upload paranleter changes.
71
�c,� Installation & Operation Manual
'I Z Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Service technician Owner maintenance
(see the follawing pages for instructions) (see the Knight User's Information Manual far
instructions)
General: • Check boiler area
•Address reported problems • Check pressure/temperature
• Inspect interior; clean and vacuum if gauge
necessary; � �
•Clean condensate trap and fill with fresh
water
•Check for leaks (water, gas, flue,
condensate)
•Verify flue and air lines in good condition
and sealed tight • Check vent piping
� •Check system water pressure/system
piping/expansion tank • Check air piping
� • Check control settings . • Check air and vent termination
•Check ignition and flame sense screens
electrodes (sand off any deposits; clean
and reposition} • Check relief valve
• Check wiring and connections
•Perform start-up checkout and
• Check condensate drain system
performance verification per Section 10 •Check air vents
of this manual.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at � � •Test low water cutoff(if used)
high fire)
•Clean the heat exchanger if flue • Reset button (low water cutoff)
temperature is more than 54°F above
return water temperature.
•Check boiler piping (gas and
water)for leaks
If combustion or performance
indicate need: • Operate relief valve
• Clean heat exchanger ' '
• Remove and clean burner using
compressed air only
• Clean the blower wheel
' •Shut boiler down (unless boiler
• • • used for domestic hot water)
.
72
��� Installation & Operation Manual
1 � Maintenance (confinued)
Flue vent system and air piping �WaR�'�� �.�1ety relief valves should be re-inspected
�T 1_EAS7'ONCE EVF..R�'THRF.,E YEARS,
L Visuall�-inspect the entire flue ga�venting system and air by� a licensed plumbing contractor or
piping for blockage,deterioration or leakage. Repair any authorized inspection agency, to ensure
joints that show signs of leakage.Verify that air inlet pipe that the product has not been affected by
is connected and properly sealed. corrosive water conditions and ro ensure
that the valve and discharge line have not
2. Verify that boiler vent discllarge and air vltake are clean been altered or tampered with illegally.
and free of c�bstructions. Certain naturally occurring conditions
may corrode the valve or its components
�WARNING Eailure to inspect for the above conditions over time,rendering the valve inoperative.
and have them repaired can result in Such conditions are not detectable unless
severe personal injury or death. the valve and its components are
physically removed and inspected. This
Check water system inspection must only be conducted by a
1. Verifi�all system components are correctl�installe�{ and plumbing contractc�r or authorized
operational. inspection agencv — not by the o�vner.
Failure to re-inspect the boiler relief valve
2. Check the cold fill pressure for the sysYem. �'erify it is as directed could result in unsafe pressurc
correct(must be a minimum of 12 psij. buildup, which can result in severe
, personal injury, death, or substantial
3. �hatch the system pressure as the boiler heats up (during property damage.
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or B WA��I�G Following installation, the valve lever
performance problem. must be operated AT LEAST ONCE A
1'EAR to ensure that waterways are clear.
4. Ins�ect automatic air vents and air separators. Remove Certain naturally occurring mineral
air vent caps and briefly press push valve to flush vent. deposits may adhere to the valve,
Replace caps. Make sure vents do not leak. Replace any� rendering it inoperative. �'hen manually
leaking vents. operating the lever, water will discharge
and precautions must be taken to avoid
Ci�1@C�C @Xpa1lSlOfl t3t1�( contact with hot water and to avoid water
damage. Before operating lever, check to
l. Expansion Tanks provide space for lvater to move in and see that a discharge line is connected to
out as the heating system water expands due to this valve directiug the flo�v of hot water
temperature increase or contracts as the water cools. from the valve to a proper place of
Tanks may be open,closed or diaphragm or bladder t}'pe. dispvsal. Otherwise severe personal injury
See Section 6 - Hydronic Piping for suggested best may result. If no water flows, valve is
location of expansion tanks ancl air eliminators. inoperative. Shut down the boiler until a
new relief valve has been installed.
Cheek boiler relief valve 2. After following the above warning directions,if the relief
valve weeps or will nor seat properly, replace the relief
1. Inspect the relief valve and lift the lever to verify flow. valve. Ensure that the reason for relief vabe weeping is
Before operating any relief valve,ensure that it is piped the valve and not over-pressurization of the system due to
with its discharge in a safe area to avoid severe scald expansion tank waterlogging or undersizing.
potential. Read SecTion 6 - Hydronic Piping before
proceeding further.
73 _.
�� ��f Installation & Operation Manual
7 2 Maintenance
�WARNING �O�lotiv the seivice and maintenance procedures given throughout this manual and in component literature
shipped v��ith the l�oiler. 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
personai injury,death,or substantial property damage.
���WARNING �he boiler should be inspected annually only by a qualifed service technician. In addition,the maintenance
and care of the boiler designated in Table 12A and esplained on the following pages must be perfarmed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
t�WAR�IING Electrica] shock hazard—Turn off power to tbe boiler before any service operation on the boiler except as
noted otherwise in this instruction mauual. Failure to turn off electrical power could result in electrical shock,
causin�severe personal injury i>r deat�h.
Address reported problems Figure 12-1 Condensate Trap
1. Iiispect any problems reported by the owner and correct RETAiNiNc
before proceeding. scRew�
Inspect boiler area � 2"PVCCAPWITH
� BLOCKED DRAIN SWITCH
1. Verity that boiler area is free of any combustible
materials, gasoline aud other flammable vapors and � �j PvcreensseMe�r
I1CjUIC�S. � �a �(FACTORY SUPPIIED)
2. Verify that air intake area is free of sny of the ,�' •; �
contaminants listed in Section 1 of this manual. If any of � �
these are present in the boiler intake air vici�iit��, they � °
must be removed. If they cannot be removed, reinstall ,�
the air and vent lines per this mauual and the Knight
Boiler Service Manual. i _ �,
i/ ���
Inspect boiler interior CONDENSATEFROM�/ TOFLOOR
HEAT EXCHANGER DRAIN
1. Femove the front access cover and inspect the interiar��f�
the boiler. �WARNING The condensate trap must be tllled with
water during all times of boiler operation
2. Vacuum an�� sediment from inside the boiler and to avoid ftue ��s emission from the
components. Remo��e any obstructions. condensate drain line. Failure to fill the
trap could result in severe personal injury
or death.
Clean condensate trap Check all i �n for leaks
p�P J
1. Inspect the condensate dr,�in linr, a�n�je�3��itr PV"C:
fttings,and condensate trap. 1�.1 WARNENG+ titiminate all system or boiler leaks.
Continual fresh makeup water will reduce
�� 2. Remove the PVC cap retainin�� �cEC4�� I�rum the ('V�C cap boiler life. Minerals can build up in
(FIG. 12-1). sections, reducing heat transfer,
3. Remove the 2 inch PVC cap with the switch located at the overheatiug heat exchanger, and causing
top of the trap (FIG. 12-1). heat exchanger faihu-e. Leaking water may
4. Remove any�sediment in the trap.
also cause scvere property damage.
5. Fill with fresh water until the water begins to pour out oY L Inspect all water and gas piping and verify to be leak free.
the drain. 2. Look for signs of leaking lines and correct any problems
6. Replace the cap. Press the cap onto the trap until the cap Found.
makes contact with the drain. 3. Check gas line usin�the procedure found in Section 7 -
7. Replace the retaining screw. Gas Connections.
74
�i,�" Installation & Operation Manual
7 2 Maintenance (continued)
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect tlame through observation window.
1. Remove the ignition and flame sense electrodes from the.
boiler heat exchanger access cover. 2. If the flame is unsarisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool doti�n. Remove the
2. Remove any deposits accun�ulated on the ignitiou/flame hurner and clean it thoroughly using a vacuum cleaner or
sense electrode using sandpaper. If the electrodes cannot compressed air. Do not use compressed air to clean burner
be cleaned satisfactorily,replace with new ones. if performed inside a building.
3. Replace ignition/flaroe sense electrode, making sure 3. Remove the burner,reference FIG. 12-2 below.
gasket is in good condition and correctly positioned.
�1. When replacing the burner, ensure gasket is in good
C�l@C�( IgflltlOt7 gl'O1111t� WII'Iflg condition and positioned correctl}�(FIG. 12-2).
l. Inspect boiler ground wire from the heat exchanger access Figu►'e 12-2 Bumer Assembly
cover to ground terminal strip.
2. Verify all wiring is in good condition and securely ��� �
a[tached. � \\\�,
��
3. Check ground continuit}' of wiring using continuity �, � :�'�
meter. `�°��
.
4. Replace ground tivii•es if ground continuity is not �° �`'�. AiRr�nsARM�
�
satisfaetory. �,�,�e �
,�`�r �
,
a,z �
Check all boiler wiring �`° � ' �
�� {�
L [uspecT all boiler �viring, making sure wires are in good �
condition and securelyattached. �� „
/
BURNER—�
Check control settings ,' ����, �
GASKET�
1. Set the SA4ART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of seRews
(aTY.3)
Knight Boiler Service �4anual. Adjust settings if
necessary. See Section 1 of the Knight Boiler Service
Manual for adjustmeut procedures.
2. Check settings of exrernal limit controls (if any) and
adjust if necessarv.
Perform start-up and checks
1.' Start boiler and perform cl�ecks and tests specified in
Section 10-Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
75 �
i
�1116HT Installation & Operation Manual
v
72 Maintenance
�'i�1@C�C f�a111@ Slgt7a� 5. Remc�ve the condensate hose from the heat exchanger end.
Connect a field supplied 314"diameter hose to a drain pan.
1. At high fire the flamz signal show�i c�ri the display should Using field supplied means,cover the refractory in the back
be at least 10 microamps. of the combustion chamber of the heat exchanger.
6. Use a vacuum deaner to remove any accumulation on the
2. A lower flame signal may indicate a fouled or damaged boiler heating surfaces. Do not use any solvent.
flame sense electrode. If� deaning the flame sense 7. Brush thc heat exchanger while dry using a nylon bristle
electrode does not improve, ground wiring is in good brush. Caution: DO NOT use a inetal brush. Re-vacuum
condition, and ground continuity is satisfac[ory, replace the heat exchanger.
the fllme sense electrode. 8. Finish cleaning using a clean cloth dampened with warm
water. Rinse out debris w�ith a low pressure�vater supply.
3. See Section 3 - Troubleshooting of the I�night Boiler
Service I�4anual for other procedures to deal with Jo4v �' ��IO��'the heat exchanger to thoroughly dry.
fla�ne signal. 10. Remove the field suppiied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
Review with owner reassemble.
11. Close isolation valves on piping to isolate boiler from
1. Review the Kiiight Boiler Usei's Information b4auual system. Attadl a hose ro the boiler drain and tlush boiler
with the owner. thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
2. Einphasize tl�e need to perform the inaintenance U�iler.
schedule specified in the Knight Boiler User's 12• Perform srart-up and check-out procedures in the Check
Information Manual(and in this manual as�vell). . Flame and Combustion - Section 10 - Startup on pages 57
and 59 of this manual.
3. Remind the owner of th� need to call a licensed 13. Replace the access co��er and restore boiler to operation.
contractor should the boiler or svstem eahibit any
unusual behavior. Table 12B Heat Exchanger Cleaning Kits
�. Remind the owner to follow the proper shutdown Kit Part Component
procedure and to schedule an annual start-u at the Modef
P Number Number Descriptian
beginning of the nest heating season.
CTN20005 Rear Refractory Cover
Cleaning boiler heat exchanger $'
KIT30062 MSG20083' Nylon 4"Wheel Brush�
Far recomitiended materials; induding brush, appropriate 106
esten;ion(s), refractory ci�ver, and detailed instructions see MSC20085 1/4"x 12"Drill Extension
Table 12B- Heat Exchanger Cleaning Kits. CTN20005 Rear Refractory Cover
1. Shut down boiler:
•Follow the"To Turn Off Gas to Appliance"instructions 151 MSC20083' Nylon 4"Wheel Brush*
for Tl�e boiler in Section 10-Startup. - KIT30063
•Do not drain the boiler unless it will be exposed to 286 MSC20084 3mm Allen Wrench
freezing temperatures. If using Ereeze prevention fluid
in system,do not cirain. MSC20086 1/4"x 24"Drill Extension
2. Allow time for the boiler to co<>1 to room temperature if
it has been firing. �CAUTION ' Do NOT' use a metal brush. Only use the
kit provided brush or an equivalent
3. Remove the nuts securing the heat exchanger access cover replacement nylon brush.
to the heat ezchanger and set aside.
�. Remove the heat exchanger access cover, burner, and Oiled bearing eireulators
��a;/air arm a�sembly. l. The circulator shipped with the Knight boiler is water-
�WARNING �he boiler contains cerai7lic fiber lubricated. No oilii�g is required.
m<iterials, LTse care�vhen handling these �. Check other circularors in the s}�srem. Oil any circulators
materials per instructions in rhe Service requirin� oil, following circulator manufacturer's
Manual. Failure to comply could result in instructio��s. Over-oiling will damage the circulator.
severe personal injury. 3. Replace the boiler front access cover.
„ 76
���T installation & Operation Manuai
13 Diagrams
Figure 13-1 Ladder Diagram
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s"t° � ' � • HIGH VOLTAGE SPARK LEAD
��AS..a�"--a�' —..—d�--«
Ia�_' ( -=�>-<f-- � VOTES:
=E o t —���t . t Nncre possible,swilches xe shown withoul utilRes(gas,waler ar
I enis .� ±,; _._ .--��.lt__ elec4'c�ty)<onnectetl to Ihe unit.As sueh aetud aw��eh states may
x __ ,µ ___j��F__ vary fran ihose shown an tliagrams Aepending upon wM�her u�lities
I s��p-�uP� . . . are connecte0 or a(aul�condi[ron is present.
� —��`E- 1.See winng tliag2m for atlAibonal rroles.
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I H� 39 ?'�.-- �.�CE� '� BOXDEPICiS��
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'�- D5f 7NNF.LTFt,� =R — 120VAC
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mooeu I� � �� � E �3'� E' r t�F 6FR t..l tt � HIGH VOLTAGE
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00
LBL'LOI�N NE V:.
/ /
i�'CLi �6�+T Installation & Operation Manual
13 Diagrams
Figure 13-2 Wirrng Diagram
_....--
o - ° LOW VOLTAGE �
+ �aox oePicrs� �
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° _�' . HIGH VOLTAGE — —
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I;UNUFCI IQN 60ARD CONTROL �OX DEPICT�
___
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( -�,
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I ALARM � _ .___- ___............___
I s I CONTACTS �I- X-7 X13 pR �
� a RUN-T�ME- 3 F"j1 C, � DH� I
Iw j I CONTACTS--��- ;y LV N �PUMP
m � I 24 VAC LOUVER �� 5 X1-4 RR � ``"
I � �BOILER
¢ m RELAYCOII � ."' � ...�; � PuMF I
LOWER�:r��-- 7 �--
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Ia �._PROVING_6VJITCIi �. g CNS-1 ��eK— X4-7 Xb2 PR � __ �PuMPEMI
I GASPRESSURE �'� g� CNS-8 BK X4-14 �-G
I I __ __ SWITCH�-�� �p CN5-2 AK X4-6 '�a N
— J
--- CNS-9 ---BK._...-- X4-�3
IFCNS-3 BK X4-5 K�t oNl1�
2 I CNr10 6K X4-12 oNrprF-
m' CNS-11 BK X4-11 �...... �
SWITCF
Z ..... . ..___ CNS-4 BK X4-4 X1�6 gK L � GND 120V
v I ��� PLOW Y�.. 77 CN5-5 �K X4-3 Xb5 �v � N N SUPPLY
Iw I ._SWITCH _ 12--j� CNr14 ett X4-8
� TANK �r?' 13- CNS-1Z BK X4-70
LTHERMOSTAT � ._...--- -14_.- - CNS-6 BK Xq_Z :
ROOAfTSTAT � 15 CNS-t3 BK X4-9 X1-e G _J \
I ZONE CONTROL 3 �ti CNS-7 BK ___,____.._._____
ROOMTSTAT �7- xt-i R
�ZONE CONTROL 2 �g.-.
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ROOMTSTAT --p-��r ig
� ZONECONTROL� � � 20 1'RANSPORMER
... _.... ....._. . �
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I SYSTEM `��, 21--� �.� .. .' RWG
SENSOR __._..,,.._f� 22
r __ _
OUTDOOR 23 - t 2 3
SENSOR 24
r ____. . ..____. _ .
I 25
TANK 26 BLOVYER
I...SENSOR� ' Z7 .
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BMS +0-10V -- 33
IN - - 34 ._.________..._---- 7c5-is BK
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I OUT _0-10V 3�
- _. _.._____
RATE } 39 I Xri-2 JiHK AIR PRESSURE
OUT _0-'IOV �O SW�iCH
� SHiLLD - A1 YS-1U OR
MODBU5 /+ q2 k5_11 �_._.__ BLOCKEDDRAIN
OPTION d --- 43 svvlTCrf
L SMIELU 44 x� -RiBK-----�� OPERATINGSENSORSta
r... _— __- . .., ': :
I__ xs-�z GV ', HIGH LIMIT SENSOR Sib
LOW -at C c��-+
WATER �-.f�l-< <'n XS-6 prgK IYLFT SF.NSOR 52
' CUT-OFF �M1��3 ��
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v�
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r — L C�
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I �,�v ;
X�-2 BK�GAS VALVE
'�. :--0 Xlt . ....- �,24VAC
I -i�Y X3 XZ-7 -Y
MOQBUS BOARD �- -� x�"-� X1-7 �,q,�;H=�.-pLAb1E SENSOR
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SPARF:
GROUNUING RuD -
>`��:' ' • HIGH VOLTAGE SPARK LEAD
JUMPER ...__ ..... ..� I ,
L4K
u � �,y
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Notes L -__. ___. __.-_._ __._. ____ J
1.All wiring must be installed in accordance wlth� Iocal,statE r r�iiiC:ai ,�„n;I cere 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 mus,be re:plac,ea.�.^,m:;s[be replaced with wire having same wire gauge(AWG)and rated for a
minimum of 105`C. Exceptions: Replacement high vo Itage spark lead and riobon cables must be purchased from the factory. Use of a non-approved spark lead
or ribbon cables can lead to operetional problems which could result in non-repairable damage[o the integrated controller or olher componen[s.
3.Actual r,onnector block locations may vary from those shown on diagrams. Refe,r to actual components for proper connector block locations when using WIRING DIAGRAM
diayrems m troubleshoot unit.
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