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1. 28 Ladder 78 Termination and 28 Wiring 79 Multiple Vent Air 28 Revision Notes Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION NOTICE CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Please read before proceeding ARNING NOTICE A WARNING A WARNING Installer Read all instructions including this manual and the Knight Wall Mount Service Manual before installing Perform steps in
2. SEAL The venting is to be vertical through the roof The annular EI T COMBUSTION AIR space between the O D of the vent pipe and the I D of the E existing unused venting system is utilized for the combustion B AIR INLET air source W SCREEN p The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below SEALED The upper and lower termination as well as any other unsealed CAP __ joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown FLUE OUTLET in FIG s 5 8 and 5 9 Approved venting materials must be used as specified in Table 3A on page 17 Follow all vent air termination and clearance requirements per this section to the appropriate example Installation must comply with local requirements and with the National Fuel For concept illustration only Individual installations may vary due to job site specific equipment Gas Code Figure 5 9 Concentric Vent Example 2 The maximum allowable equivalent vent and air intake SEAL _ FLUE EXHAUST lengths for this venting arrangement are to be determined EM from the General Venting Section Bh x If an existing unused venting system is converted for use B with this method of concentric venting the installer must B O SEAL ensure that the e
3. BACKFLOW 694 PREVENTER 9 i Ii MAKE UP WATER m SEPARATOR SYSTEM SUPPLY SENSOR Fa MAY SUBSTITUTE LOW LOSS HEADER TO Ay pr FROM SYSTEM 3 SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART SYSTEM BALL VALVE CIRCULATOR Y STRAINER TYPICAL RECOMMENDED FLOW CHECK EXPANSION VALVE TANK DOMESTIC ANTI SCALD HOT WATER MIXING VALVE DRAIN POINT CIRCULATOR TYPICAL BOILER E CIRCULATOR E RELIEF VALVE IB H 34 BOILER LH INDIRECT UNION DRAIN DHW TANK TYPICAL TEMPERATURE PRESSURE GAUGE NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 38 WALL MOUNT BOILER Kise Installation amp Operation Manual 6 Hydronic piping continea Figure 6 4 Single Boiler Single Temperature with Zone Valves DHW Priority enuon ASE AUGE bii ZONE 2 ZONE 3 ZONE 4 71r 74 ere BACKFLOW L zum thee ee PREVENTER ZONE VALVES TYPICAL K MAKE UP La Y r5 WATER DIFFERENTIAL n SYSTEM SUPPLY SENSOR BE IUE AIR SEPARATOR RECOMMENDED jc CIEN SYSTEM CIRCULATOR EXPANSION Fa MAY SUBSTITUTE LOW LOSS HEADER NOT 4 PIPE DIA OR MAX OF 12 APART TYPICAL i Y STRAINER TEE RECOMMENDED SUPE DRAIN
4. SCROLL Turning the NAVIGATION dial will move the cursor up or down Turning the NAVIGATION dial will increase or decrease the current g SHDN Press the RIGHT SELECT key to turn the boiler OFF Press the RIGHT SELECT key to turn the boiler ON F RIGHT SELECT NO Press the RIGHT SELECT key to cancel the shutdown operation key function SAVE Press the RIGHT SELECT key to save the current change Press the RIGHT SELECT key to return to the Status Screen and HOME upload parameter changes 73 12 Maintenance Installation amp Operation Manual WALL MOUNT BOILER Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician see the following pages for instructions General e Address reported problems Inspect interior clean and vacuum if necessary Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate Verify flue and air lines in good condition and sealed tight Check system water pressure system piping expansion tank e Check control settings e Check ignition and flame sense electrodes sand off any deposits clean and reposition Check wiring and connections e Perform start up checkout and performance verification per Section 10 of this manual A 2 H lt H o lt lt lt e Flame inspection stable uniform e Flame signal at least 10 microamps at high fire e
5. 17 8 FIELD WIRING Air Inlet Pipe 18 Line Voltage Connections 52 Stainless Steel 18 19 Low Voltage Connections 52 Max Allowable Vent Piping Lengths 19 Wiring of the Cascade 54 Vent and Air Piping 20 9 CONDENSATE DISPOSAL Optional Room 20 Condensate Drain 56 4 SIDEWALL DIRECT VENTING 10 STARTUP 57 63 Vent Air Termination Sidewall 21 24 11 OPERATING INFORMATION Determine 21 22 64 Prepare Wall Penetrations 23 67 Termination and 23 Sequence of Operation 68 69 Multiple Vent Air Terminations 23 24 Knight Wall Mount Boiler Control Module 70 Sidewall Termination Optional Concentric Vent 24 26 Status Display Screens 11 73 5 VERTICAL DIRECT VENTING 12 MAINTENANCE Vent Air Termination Vertical 2 28 Maintenance and Annual Startup 14 77 Determine 27 13 DIAGRAMS Prepare Roof
6. ROUTE TO FLOOR DRAIN OR NEUTRALIZING FILTER USING 3 4 CORRUGATED TUBING 10 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not use the boiler to directly heat swimming pool or spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used l Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 6 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water met
7. 1 Hot water pipes at least 1 4 from combustible materials 2 Vent pipe at least 1 from combustible materials 3 See FIG s 1 1 and 1 2 on page 8 for other clearance minimums Clearances for service access 1 See FIG s 1 1 and 1 2 on page 8 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the boiler without removing it from the space 7 WALL MOUNT BOILER Kiso Installation amp Operation Manual 1 Determine boiler location Figure 1 1 Closet Installation Minimum Required Clearances TOP A WARNINGI E ANIMUM 6 MINIMUM A WARNING stainless steel vent material MUST VENTILATING BE used in a closet structure due to AIR OPENING elevated temperatures Failure to follow this warning could result in p fire personal injury or death b 1 For closet installations CPVC or RIGHT 0 MINIMUM 1 MINIMUM CLEARANCE AROUND VENT PIPE CLOSED DOOR e Ps VENTILATING AIR OPENING FRONT BOTTOM 6 MINIMUM AREA OF EACH OPENING 0 MINIMUM 1 4 MINIMUM CLEARANCE 1 SQ INCH PER 1000 BTU PER HOUR INPUT AROUND HOT WATER PIPES WITH A MINIMUM OF 100 SQ INCHES RECOMMENDED SERVICE CLEARANCES FRONT 24 BOTTOM 24 LEFT SIDE 12 Note Service clearances are recommendations only Figure 1 2 Alcove Installation Minimum Required Clearances TOP 6 MINIMUM LEFT 0 MINIMUM A WARN
8. s recommended solvents and standard commercial pipe cement for the material used The PVC CPVC ABS Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume A DANGER Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death Stainless steel vent This product has been approved for use with stainless steel using the manufacturers listed in Table 3A A WARNING NOTICE NOTICE NOTICE Use only the materials vent systems and terminations listed in Table 3B DO NOT mix vent systems of different types or manufacturers unless listed in this manual Failure to comply could result in severe personal injury death or substantial property damage Installations must comply with applicable national state an
9. shutting the boiler down Relief valve Protects the heat exchanger from an over pressure condition The relief valve provided with the unit is set at 30 psi Flame sensor Used by the control module to detect the presence of burner flame Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box Transformer The transformer provides 24V power to the integrated control ModBus The optional ModBus option provides intelligent building system communications Kise Installation amp Operation Manual WALL MOUNT BOILER The Knight Wall Mount Boiler How it works continue Models 55 399 15 13 14 FRONT OF UNIT Front View Bottom View Left Side inside unit Right Side inside unit WALL MOU Ratings AM Pu CERTIFIED Knight Wall Mount Boiler I B R Rating Heating Net Capacity I B R Ratings Water MBH Note Change N to L for L P gas Uem nf CORAN WHN110 NT BOILER Installation amp Operation Manual DOE ENERGY STAR Other Specifications Vent Air Boiler Water Size Content Gallons NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 As an Energy Star Partner Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency p The ratings are based on standard test procedures prescribed by th
10. 1 hole 5 inch diameter for CVK3003 installations or 4 inch diameter for CVK3008 installations into the structure to install the termination kit 3 Partially assemble the concentric vent termination kit Clean and cement following the cleaning procedures in these instructions a Cement the Y concentric fitting to the larger diameter kit pipe see FIG 4 7 page 24 b Cement rain cap to the smaller diameter kit pipe see FIG 4 7 page 24 Instead of cementing the smaller pipe to the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 9 page 25 A WARNING When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal injury or death 29 D Vertical direct venting NIGH l Installation amp Operation Manual Vertical termination optional concentric vent warning not operate the appliance with the rain cap removed or recirculation of combustion products may occur Water may also collect inside the larger combustion air pipe and flow to the burner enclosure Failure to follow this warning could result in product damage
11. 2 45 elbows 1 concentric vent kit 49 equivalent feet of piping REPLACE APPLIANCE SECURED CPVC ADAPTER WITH APPROPRIATE 7 STAINLESS STEEL ADAPTER FROM TABLE 3B The Knight wall mount boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3C NOTICE Increasing or decreasing the size of the combustion air or vent piping beyond the sizes listed in Table 3C is not authorized 19 General venting Removing from existing vent Follow the instructions in Section 1 page 11 of this manual when removing a boiler from an existing vent system Vent and air piping Vent and air system Installation must comply with local NOTICE requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations You must also install air piping from outside to the boiler air intake adapter The resultant installation is direct vent sealed combustion You may use any of the vent air piping methods covered in this manual Do not attempt to install the Knight wall mount boiler using any other means DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Use only approved stainless steel PVC or CPVC pipe and fittings For PVC CPVC use with primer and cement specifically designed for the material used Vent air piping and terminatio
12. WATER X MIXING VALVE OUT BOILER COLD CIRCULATOR WATER IN PRESSURE RELIEF VALVE S DRAIN INDIRECT UNION TEMPERATURE DHW TANK TYPICAL PRESSURE GAUGE CAUTION Mixing valves are required for the protection of low temperature loops NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone 44 NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes Kuscer Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continea Figure 6 10 Single Boiler Full Flow Single Temperature Zoned with Zone Valves DHW Priority REDUCING VALVE PRESSURE GAUGE ZONE 2 ZONE 3 ZONE 4 D 101 BACKFLOW L A da uec pp qx PREVENTER SA ZONE VALVES MAKE UP TYPICAL WATER il el wi Ii SYSTEM SUPPLY of DIFFERENTIAL SENSOR PRESSURE BYPASS VALVE AIR SEPARATOR RECOMMENDED DOJ AP EXPANSION BALL VALVE TYPICAL DRAIN POINT gt TRIGAL Ly Y STRAINER ee RECOMMENDED DOMESTIC OUT bs HOT WATER FLOW CHECK CIRCULATOR VALVE MIXING VALVE BOILER d x COLD CIRCULATOR L WATER IN PRESSURE A ZA RELIEF VALVE UNION DRAIN TYPICAL TEMPERATURE PRESSURE GAUGE It is the responsibility of the inst
13. X5 10 BLOCKED INLET ek DRAIN JUMPERS C lt lt SENSOR d OPERATING AIR PRESSURE b SENSOR SWITCH O 1 9 lt lt fof HIGH LIMIT 516 SENSOR GAS VALVE FLUE S8a 2 2523 a FLUE SK SENSOR j N BLOWER 1 5 7 13 CONNECTION Sy lt e L BOARD 2 5 16 CN5 1 lt ALARM CONTACTS 5 X4 i4 4 X5 8 4 5 X5 15 CN5 2 X4 6 RUN TIME gt gt lt 7 E CONTACTS CN5 9 X4 13 25 amp TR2 CN6 SYSTEM 2 17 SENSOR w OUTDOOR a lt lt SENSOR 54 SENSoR SHIELD A CASCADE B RU SHIELD S lt lt FLAME ROD CN6 lt lt X6 SPARK ROD T eI HIGH VOLTAGE SPARK LEAD NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may CN3 9 lt lt X4 9 6 09 0000020092090 0 ETE ERU ERU ER BMS IN 0 10V vary from those shown on diagrams depending upon whether utilities M are connected or a fault condition is present SYS PUMP Us IN 00V _ 2 See wiring diagram for additional notes PUMP 9 a BOX DEPICTS mes BB AWARNING OPTIONAL ITEMS 0 10V OUT LOW VOLTAGE SHIELD om DISCONNECT POWER 120 VAC 5 _ BEFORE SERVICING HIGH VOLTAGE M SHIELD G LADDER
14. or greater heat loss from a structure then the GPM should change to match the required BTU hr This is achieved when the variable speed circulators automatically and continually adjust their GPM output by varying speed to match the required BTU hr output of the system no matter the changes in heat load while always maintaining the designed AT between a supply and return sensor Variable speed pump setup Before operation ensure the following Pump is set for an input signal of 0 10Vdc by the dip switches on the pump control Pump is set for external signal control if applicable Pump is set for linear output 1f applicable If pump does not come equipped with a 0 10 Vdc input option an optional module will be required from the vendor Pump sizing and flow requirements are SOTLE based on 20 feet of piping 4 90 elbows and 2 fully ported ball valves NOTICE It is recommended that near boiler piping systems utilize Primary Secondary configurations as shown in FIG s 6 3 through 6 9 only The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance if proper pump sizing and system flow rates are not adhered to 37 WALL MOUNT BOILER Kusi Installation amp Operation Manual 6 Hydronic piping Figure 6 3 Single Boiler Primary Secondary Piping PRESSURE REDUCING VALVE
15. Control enable output or Building Management System enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the Heat Loop Demands 1 3 FIG 8 4 If the boilers are to run continuously connect a jumper wire between the R and W terminals for the Heat Loop demand input This will initiate a call for heat on the Cascade Communication between the Leader boiler and the Member boilers is accomplished by using shielded 2 wire twisted pair communication cable Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards FIG 8 4 If more than two boilers are on the Cascade daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler then from the third to the forth and so on The connections between boilers can be made in any order regardless of the addresses of the boilers Try to keep each cable as short as possible Installation amp Operation Manual BOILER MOUNT NIGHT Field wiring continues Figure 8 4 Low Voltage Field Wiring Connections WALSAS IN3IN3OVNVIN ONIQ II S3SOdifid NOLLVHISIYTIJ Ll 1dS GUVOd NOILLO3NNOO Q1aIHS NO
16. DIAGRAM LBL20170 REV A 78 Kusi Installation amp Operation Manual WALL MOUNT BOILER 13 Dia grams continued Figure 13 2 Wiring Diagram LOW VOLTAGE ue O 120 VAC OPTIONAL ITEMS A WARNING p HIGH VOLTAGE DISCONNECT POWER __ i Iz BEFORE SERVICING INTEGRATED T CONNECTION BOARD Box DEPICTS CONTROL JUNCTION OPTIONAL BOX ITEMS ALARM es d CONTACTS RUN TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH PUMP SYSTEM PUMP _ BELL JUMPER BOILER Z N ALARM BELL e KB ONLY ON OFF SWITCH C o L cup 120V FLOW n SUPPLY SWITCH TANK THERMOSTAT HEAT LOOP 4 DEMAND HEATILOOP 2 DEMAND HEATILOOP 4 DEMAND SILENCING SWITCH c pe OUTDOOR SENSOR gt TANK SENSOR KK SHIELD CN CASCADE SHIELD BMS IN SYS PUMP IN OUT RATE OUT 0 10V SHIELD MC 7 P Ur BUR S NN UM ai BLR PUMP BLOCKED DRAIN JUMPER AIR PRESSURE SWITCH OPERATING SENSOR S1a HIGH LIMIT SENSOR S1b CN7 1 T CN7 2 zc INLET SENSOR S2 CN7 3 FLUE SENSOR S3a FLUE SENSOR S3b GAS VALVE 24VAC WR FLAME
17. E7 PL 55 EH 12 L5 22 31 On Minimum Pipe ae a 1 I ER IARE 3 5 10 55 19 1 1 1 6 22 UPS26 99F 0011 NRF 36 1 NOTICE Pumps listed in bold type are provided by the factory as the boiler circulation pump 36 NOTICE The temperature rise provided by a pump model combination will decrease by 3 per 1000 feet of elevation Kuce Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping continea Variable speed pump option Table 6B Recommended Variable Speed Pumps VFD PUMP 33 00 30 00 4 27 00 24 00 ee aa i155 21 00 LLL 199 285 399 18 00 15 00 4 UPS26 96FC VS 12 00 TACO 0013 IFC VS 9 00 UPS26 96 FC VS 5096 6 00 TACO 0013 IFC VS 5096 3 00 Variable speed pumping to maintain a set differential temperature AT between two 2 sensors allows for the following Automatic adjustment of the pump s performance to match the low of the system or zone Eliminate velocity noise in the zone valve systems Conserve energy Since AT is directly releated to flow rate the pump s speed continually adjusts to the required BTU per hour In almost all applications the design of the system was based on being able to maintain a certain AT and figured by using the universal hydronics equation of BTU hr GPM x 500 x AT Given that any time there is a change to the heat load 1 warmer day
18. Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury death or substantial property damage Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 13 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage 2 warning two wrenches when tightening gas piping at boiler FIG 7 2 using one wrench to prevent the boiler gas line connection from turning Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components Figure 7 2 Inlet Pipe with Backup Wrench USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING NOTICE Maximum inlet gas pressure must not exceed the value specified Minimum value listed 1s for the purposes of input adjustment Installation amp Operation Manual WALL MOUNT BOILER Natural gas Pipe sizing for natural gas 1 Refer to Table 7A for pipe length and diameter Based on rated boiler input divide by 1 000 to obtain cubic feet per hour a Table 7A is only for natural gas with specific gravity 0 60 inches with a pressure drop through the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer
19. For additional information consult the vent manufacturer s instructions for installation Terminations Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section For stainless steel vent only use terminations listed in Table 3B for the manufacturer of the installed vent Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 11 With stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used with PVC CPVC vent see the Installing Vent or Air Piping Section on page 16 If any of these conditions are not met the existing system must be updated or replaced for that concern Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death 10 Installation amp Operation Manual WALL MOUNT BOILER Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish remove
20. Installation amp Operation Manual WALL MOUNT BOILER 7 Gas connections Table 7A Natural Gas Pipe Size Chart Nominal Natural Gas Pipe Capacity Chart Iron Pipe Length of Pipe in Straight Feet for 1 2 PSI Size Inches ola oo s us s o us no are seo o 974 789 677 595 oe oe 2 Ce pen 2260 1950 1720 Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to A WARNING A determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 13 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check inlet gas supply NOTICE CSA or UL listed flexible gas connections 3 Loosen the set screw one 1 full turn from inside the are acceptable but you must exercise pressure tap on top of the gas valve Place the tubing of caution to ensure that the line has the manometer over the tap once the set screw is adequate capacity to allow your boiler loosened asshosm n TiC 7 8 to fire at full rate Consult with local codes for proper installation or service procedures 22 X N NIO NIO sr NA m 2460 4410 9000 Ql O 4 Slowly turn on the gas supply at the field installed manual gas valve 5 Turn on p
21. POINT FLOW CHECK DOMESTIC ANTI SCALD TYPICAL VALVE HOT WATER CIRCULATOR MIXING VALVE COLD BOILER Et WATER CIRCULATOR IN PRESSURE RELIEF VALVE Of UNION TYPICAL DRAIN TEMPERATURE PRESSURE GAUGE NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 39 Installation amp Operation Manual WALL MOUNT BOILER 6 Hydronic piping Figure 6 5 Single Boiler Single Temperature Zoned with Circulators DHW Priority ZONE 2 ZONE 3 ZONE 4 4 PRESSURE PRESSURE REDUCING VALVE GAUGE ee 1 L H E E 1 _ BACKFLOW PREVENTER DA i aan v e TYPICAL UP 1 ud AA SYSTEM SUPPLY SENSOR Ww uu u AIR SEPARATOR J EXPANSION E E LI L pe MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL Y STRAINER RECOMMENDED DRAIN POINT DOMESTIC ANTESCALD TYPICAL HOT WATER NC CIRCULATOR 4 VALVE lt LD BOILER SS WATER CIRCULATOR IN PRESSURE RELIEF VALVE UNION TYPICAL CO un 1 BOILER INDIRECT DRAIN DHW TANK TEMPERATURE PRESSURE GAUGE NOTICE Please note that these illustrations are meant to show system piping concept only the installer is r
22. R04523 V High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 WH I O Rev D www Lochinvar com 11 11
23. SENSOR g m SPARK ROD ene HIGH VOLTAGE SPARK LEAD SHIELD GROUNDING JUMPER Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 Exceptions Replacement high vo Itage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using WIRING DIAGRAM diagrams to troubleshoot unit LBL20169 REV A Revision A ECO C06854 initial release Revision B ECO C08222 reflects the changes to the water pipe clearances from 1 to a 1 4 ECR R04077 pages 7 8 33 and changes made to the service clearances left side from 24 to 12 ECR R04002 Revision C ECO C08645 reflects additional cleaning and inspection instructions for the condensate trap page 75 Revision D ECO 609197 reflects additional information added to the humidity warning 7 along with updates made to the SMART _ o SYSTEM control ECR
24. The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures 1 From the Status Screen press the NAVIGATION dial 2 TurntheNAVIGATION dial counterclockwise to select the appropriate set point 3 Press the NAVIGATION dial to adjust the temperature 4 Once the desired temperature is displayed press the RIGHT SELECT SAVE key 5 If necessary repeat Steps 3 and 4 to make adjustments to additional set points 6 Press the RIGHT SELECT HOME key to upload the changes 7 If the RIGHT SELECT SAVE key is not pressed the new settings will be discarded 1 0 Start u D continued Set domestic hot water DHW operation Verify DHW mode There are two 2 modes of operation for DHW In Normal Mode when a DHW demand begins the control will start the DHW pump turn off the boiler pump if running and modulate to bring the outlet temperature to the DHW boiler set point The maximum firing rate may be limited in this mode if desired In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop When a DHW demand begins the control will turn on the DHW pump output and raise the system temperature set point to the DHW boiler set point if higher The boiler pump will be turned on The system pump may be forced on forced off or not changed depending on the System Pump Mode selected reference the Knight Wall Mount Service Manual for details In
25. YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage After following the warning directions in this manual if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones Replace ignition flame sense electrode making sure gasket is in good condition an
26. and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING Macc noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 3 After the condensate trap is cleaned or serviced it must be checked to ensure that it is installed and draining properly Figure 12 1 Condensate Trap LAC 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight Wall Mount Service Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of FLOAT BALL the boiler CONDENSATE T DRAIN 2 Vacuum any sediment from inside the boiler and components Remove any
27. at ignition speed and will then modulate up to full fire 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 10A below The CO levels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the Troubleshooting Section of the Knight Wall Mount Service Manual for possible causes and corrective actions Table 10A Flue Products Chart 8 0 10 3 0 6 5 9 0 11 4 1 6 9 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm Turn the manual shutoff switch to the ON position and reset the control 9 Turn off power at source and replace the flue temperature sensor into the flue pipe connection 10 Place the boiler back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 62 Kusi Installation amp Operation Manual WALL MOUNT BOILER Set space heating operation Determine controlling sensor For space heating systems the temperature control can be ba
28. at once A WARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage A WARNING Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to each of the heat loop demand terminals on the connection board Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board 58 WALL MOUNT BOILER Insta
29. before proceeding You must also completely test the boiler after conversion to verify performance as described under Start up Section 10 of this manual You must install the propane orifice to fire the Knight wall mount boiler on propane Verify when installing that the orifice size marking matches boiler size Table 2A Failure to comply could result in severe personal injury death or substantial property damage WALL MOUNT BOILER Installation amp Operation Manual Table 2A LP Conversion Table LP Conversion Table LP Orifice Stamping Remove the front access cover from the unit no tools required for removal Models 55 285 only locate the power switch on the gas valve and turn the power switch to the OFF position FIG 2 2 Model 399 only shut off power at the source Disconnect the Molex plug from the gas valve Using a 5 16 nut driver loosen the band clamp securing the air intake coupler to the gas valve venturi Remove the air intake pipe and coupler from the gas valve venturi Using an Allen wrench remove the screws securing the gas valve venturi to the inlet of the combustion blower FIG 242 Figure 2 2 Gas Valve Power Switch amp Venturi Hemoval 8 10 11 12 REMOVE THE SCREWS SECURING THE GAS VALVE VENTURI TO THE gt INLET OF THE COMBUSTION iL BLOWER Using an Allen wrench remove the screws securing the gas pipe to the gas valve Remove the ga
30. install the appliance where condensation may form on the inside or outside of the appliance or where condensation may fall onto the appliance Failure to install the appliance indoors could result in severe personal injury death or substantial property damage This appliance requires a special venting system The vent connection to the appliance is made of CPVC Field supplied vent fittings must be cemented to the CPVC fitting on the boiler Use only the vent materials primer and cement specified in the manual to make the vent connections Failure to follow this warning could result in fire personal injury or death Closet and alcove installations A closet is any room the boiler is installed in which the room volume is less than the room volume listed in the table below An alcove is any room which meets the criteria for a closet but it does not have a door in cubic feet 55 85 O D 110 285 Example Room dimensions 4 feet long 4 feet wide and 9 foot ceiling 4 x 4 x 9 144 cubic feet This would be considered a closet for the WHN399 model For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC or stainless steel vent material must be used inside the structure The two ventilating air openings shown in FIG 1 1 are required for this arrangement Failure to follow this warning could result in fire personal injury or death Provide clearances Clearances from combustible materials
31. obstructions BOTTOM CAP m IMG00046 Inspect condensate trap Monthly inspection A WARNING It is in the best interest of the end user 1 The condensate trap should be inspected monthly to to make sure the ball is present and the ensure the trap is properly installed and connected to the condensate trap is filled with water during condensate pipe under the boiler see FIG 12 1 all times of boiler operation to avoid flue 2 The condensate line should be inspected monthly gas emission from the condensate drain for obstructions making sure it allows free flow for line Failure to have the ball present or to condensate to drain fill the trap could result in severe personal 3 Inspect the neutralizing kit if installed monthly to injury or death ensure the condensate is draining properly and there is still an adequate amount of neutralizing agent available Check all piping for leaks Annual cleaning Eliminate all system or boiler leaks 1 The condensate trap should be cleaned at least once Continual fresh makeup water will reduce annually or at the end of each heating season by removing the bottom cap and cleaning out any sediment that exists 2 The provided condensate trap is equipped with a ball that acts as a seal against harmful flue gases escaping in case there is no condensate in the trap If this ball isnot 1 Inspect all water and gas piping and verify to be leak free present flue gases may be able to pass through the tr
32. of the indirect tank when the Squire is not used may result in decreased performance or the risk of scald injury Installation amp Operation Manual WALL MOUNT BOILER 3 If the TST20015 is not compatible with the indirect tank a tank thermostat can be used to control the boiler The tank thermostat should be installed per the manufacturers instructions and wired to the DHW Thermostat terminals on the Low Voltage Connection Board Louver relay l Iflouvers need to operate when the boiler fires they can be controlled by this output Connect these terminals to a 24 vac relay coil which is wired to operate the louvers FIG 8 4 Louver proving switch 1 When the operation of the louvers needs to be verified before the boiler fires remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 8 4 Flow switch 1 A flow switch is used to guarantee flow through the boiler before allowing it to fire The flow switch must be installed at the boiler outlet 2 Remove the jumper wire from these terminals and connect these terminals to the normally open contacts on the flow switch FIG 8 4 Variable speed system pump If a variable speed pump is used in the primary loop and a 0 10V signal is available from the pump speed control this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load By connecting this 0 10V signal
33. the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA and or CAN CSA B149 1 Natural Gas and Propane Installation Code 11 2 Prepare boiler Remove boiler from wood pallet 1 After removing the outer shipping carton from the boiler remove the parts box 2 To remove the boiler from the pallet a Remove the two 2 lag bolts securing the bottom of the unit to the pallet b Lift the boiler off the wall bracket mounted to the pallet 3 Remove the two 2 lag bolts securing the wall bracket to the wood pallet Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall FIG 2 1 NOTICE Do not drop the boiler or bump the jacket on the floor or pallet Damage to the boiler can result Figure 2 1 Boiler Mounted on Shipping Pallet REMOVE SHIPPING WALL BRACKET DO NOT DISCARD WILL BE NEEDED TO SECURE THE BOILER TO THE WALL Gas conversions A WARNING 12 The gas conversion procedure should be accomplished BEFORE the boiler is installed For a boiler already installed you must turn off gas supply turn off power and allow the boiler to cool
34. the order given User This manual is for use only by a qualified heating installer service technician Refer to the User s Information Manual for your reference Have this boiler serviced inspected by a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If yo
35. the unit runs the fan for an Bar POSTPURGE additional 10 seconds to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position SETPOINT MET The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a condition that has temporarily interrupted the current call for heat Heat Loop Demand 1 has a call for heat Heat Loop Demand 2 has a call for heat Heat Loop Demand 3 has a call for heat B Call for Heat The tank thermostat or sensor has a call for heat Indicators Indicates which heat loop demand shows priority The unit is being controlled by a 0 10V BMS signal The member unit is supplying heat while in Cascade Mode 71 E a gt E S c m gt Kiso Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information Status Display Screens cont d Section Display ___ Description SYSTEM The temperature read the system supply sensor if connected TANK 000000 The temperature read The temperature read by the tank sensor if connected the tank sensor if connected OUTDOOR The temperature read by the outdoor sensor if connected INLET TEMP The temperature read at the inlet to the heat exchanger OUTLET TEMP The temperature read at the outlet of the heat exchanger DELTA The temperature difference between the inlet and the outlet of the heat
36. this mode any low temperature zones such as radiant heating may need additional controls to limit the water temperature sent to those zones Set DHW boiler target temperature When in the DHW Mode the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in the control must be changed See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Set maximum DHW fan speed Ifthe rated input of the indirect tank is less than the maximum output of the boiler change the maximum DHW fan speed setting to limit the boiler output accordingly see the Knight Wall Mount Service Manual for a detailed explanation of this procedure Set clock NOTICE Please note that the brackets denote screen status The SMART SYSTEM control has a built in clock that it uses for its night setback feature and for logging events This clock must be set when the boiler is installed and anytime the boiler has been powered off for more than 4 hours Use the following procedure to set the clock 1 Press and hold the LEFT SELECT MENU key for at least 5 seconds 2 The display changes to with four 4 zeros below it 3 Press the RIGHT SELECT SAVE key 4 The display will then show a menu with the time and date and temperature unit 5 Press the NAVIGATION d
37. through the rain cap a field supplied stainless steel the structure s hole screw may be used to secure the two 2 l Do not allow insulation or other materials components together when field disassembly NOTICE ae to accumulate inside the pipe assembly is desired for cleaning see FIG 4 11 i when installing through the hole A WARNING ae api QD 7 Install the rain cap and small diameter pipe assembly method drill a clearance hole in the rain d dec bois De f into the Y concentric fitting and large pipe assembly Ensure small diameter pipe is bottomed and cemented the screw size being used Failure to drill in the Y concentric fitting for CVK3003 and 3008 adequate NOLES ee cracking oes installations and fastened tightly into the rubber adapter components allowing combustion products for CVK3007 installations to be recirculated Failure to follow this warning could result in personal injury or Secure the assembly to the structure as shown in FIG death 4 12 using field supplied metal strapping or equivalent Do not operate the appliance with the rain support material A WARNING T cap removed or recirculation of combustion NOTICE Ensure termination location clearance products may occur Water may also collect dimensions are as shown in FIG 4 6 pipe ane If assembly needs to be extended to allow flow to the burner enclosure Failure to NOTICE TM d h follow this warning
38. to ANSI Z223 1 or B149 1 for Canadian installations Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on e Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 10096 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane Gas Knight wall mount boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 13 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 8 inches w c with gas flowing verify during boiler startup A WARNING Ensure that the high gas pressure regulator is at least 6 10 feet upstream of the appliance 49 Kuce
39. to the 0 10V SYS PUMP IN terminals the boiler or cascade can modulate up and down as the primary flow increases and decreases Boiler pump speed output This 0 10V output is available to control the speed of a variable speed boiler pump The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum AT across the heat exchanger as well as prevent high limit lockouts when the flow in the primary loop is extremely low Connect this output to the 0 10V input on the boiler pump speed control Rate output This output provides a 0 10V signal that is proportional to the firing rate of the boiler This may be used by a BMS system to monitor the actual rate of the boiler ModBus When the optional ModBus interface module is installed the RS 485 ModBus cable is connected to these terminals Use shielded 2 wire twisted pair cable If desired the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module 53 Field wiring System supply sensor By installing the system supply sensor into the supply of the primary loop the temperature of the primary supply can be controlled The SMART SYSTEM control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point if the outlet sensor control is currently selected If it is desir
40. 28 OUTDOOR ae F HEHU q SLEEEHM SHOH PUST PURGE SYSTEM THHE OUTDOOR HEHU q SLEEEHM SHOH 1167F 129 1252 26 F a C1162 C1382 OUTDOOR oa SCEEEH SHDH Kise Installation amp Operation Manual WALL MOUNT BOILER If the space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump will aa turn off 2 seconds later This will divert the boiler s outlet water DLIITDOOR from the heating system and send it to the tank coil instead The gt gt control will then modulate to maintain the outlet temperature to ae SCREEN SHEH the DHW boiler set point If the boiler is not part of a Cascade and both the space heating and DHW calls for heat remain active long enough the boiler will SYSTEM switch back and forth between the two heating modes until one of them is satisfied g ScCREEM SHDH P ST PURGE 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during 10 second 1225 postpurge OUTDOOR g1 SCREEH SHOH 11 Any pumps that are running will continue to run for their respective B L D pump delay times before turni
41. 4 inches w c natural 8 inches w c LP minimum and 14 inches w c natural and LP maximum during stand by static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the Knight wall mount boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature this gas valve has a flanged connection to the venturi and blower Failure to follow all precautions could result in fire explosion or death DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage DETAIL Field wiring A WARNING ELECTRICAL SHOCK HAZARD For your safety turn offelectrical p
42. 9 that corresponds with the intended vent manufacturer to be used The field provided vent fittings must be cemented to the CPVC pipe section using an All Purpose Cement suitable for PVC and CPVC pipe Use only the vent materials primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death A WARNING 16 Installation amp Operation Manual WALL MOUNT BOILER A WARNING Insulation should not be used on PVC or CPVC venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure For Models 55 85 and 110 using 2 venting and Model 285 using 3 venting the first seven 7 equivalent feet of vent must be CPVC field supplied This includes any transition piece used to increase or decrease the vent diameter See examples below Examples 1 Seven 7 feet vertical 2 Connector 90 elbow 2 feet horizontal 3 One 1 foot vertical 90 elbow 1 foot horizontal Requirements for installation in Canada 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 2 The first three 3 feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system mus
43. Clean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need e Clean heat exchanger e Remove and clean burner using compressed air only Clean the blower wheel Owner maintenance see the Knight Wall Mount User s Information Manual for instructions e Check boiler area e Check pressure temperature gauge Check vent piping Check air piping Monthly Check air and vent termination screens e Check relief valve Inspect condensate drain system Test low water cutoff if used Periodically e Reset button low water cutoff e Check boiler piping gas and water for leaks Every 6 months Operate relief valve End of season months e Shut boiler down unless boiler used for domestic hot water Kusi Installation amp Operation Manual WALL MOUNT BOILER 1 2 Maintenance continued Follow the Service and maintenance procedures given throughout this manual and in component literature A WARNING i shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The boiler should be inspected annually only by a qualified service technician In addition the maintenance A WARNING i i
44. ILdO 9 SNEGOW v Q1aIHS LAO 31VM NI dNfid SAS 01 0 13 5 g 3Qvosvo y QTSIHS Q3Sfn LON aasn LON YOSNAS YOOaLNO HOSN3S WALSAS ad BERI EJ UU M dOO1 1V3H M aNviN3a M dOO1 1V3H 1 JlOHLINOO Q3ads WALSAS HOLIMS H3AnO1 iim impri SIOVINOO INIL J Cu J J n E OG 3540112 HOSN3S YaLVM MOT HOSN3S a C q 3lHS 0 IQ q 3lHS j yog Ra mg di db oOo snoinaud V WOU ii s HONVIN3G dOO1 1Vv3H sooo B c INvIN3a LVSH ANYWA LV3H LIVLSOWYSHL E E ON HOLIMS MO 1A HOLIMS AJNON AV 138 55 Q Condensate disposal Condensate drain 1 This boiler is a high efficiency appliance that produces condensate The bottom of the boiler has a 1 1 4 inch pipe for connection of the condensate trap FIG 9 1 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the Knight wall mount boiler will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes A Neutralizer Kit is available from the factory Kit 3087 Do not expose condensate line to free
45. ING For alcove installations CPVC Or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result RIGHT in fire personal injury or death 0 MINIMUM 1 MINIMUM CLEARANCE AROUND VENT PIPE OPEN FRONT FRONT 6 MINIMUM BOTTOM 0 MINIMUM 1 4 MINIMUM CLEARANCE AROUND HOT WATER PIPES RECOMMENDED SERVICE CLEARANCES FRONT 24 BOTTOM 24 LEFT SIDE 12 Note Service clearances are recommendations only Lu 8 Installation amp Operation Manual WALL MOUNT BOILER 1 Determine boiler location continued Provide air openings to room Knight wall mount boiler alone in boiler room l No air ventilation openings into the boiler room are needed when clearances around the Knight wall mount boiler are at least equal to the SERVICE clearances shown in FIG s 1 1 and 1 2 For spaces that do NOT supply this clearance provide two openings as shown in FIG 1 1 Each opening must provide one square inch free area per 1 000 Btu hr of boiler input Knight wall mount boiler in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation air openings into the space A WARNING The space must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the Knight wall m
46. ION MAY SUBSTITUTE LOW LOSS HEADER T NOT TO EXCEED 4 PIPE DIA BALL VALVE ri OR MAX OF 12 APART TYPICAL Y STRAINER I RECOMMENDED DRAIN POINT DOMESTIC TYPICAL BOILER HOT WATER CIRCULATOR CIRCULATOR HOT FLOW CHECK WATER OUT ANTI SCALD MIXING VALVE COLD WATER E I IN PRESSURE RELIEF AN VALVE 1 0 BOILER UNION TYPICAL BN TEMPERATURE PRESSURE GAUGE CAUTION Mixing valves are required for the protection of low temperature loops NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 43 WALL MOUNT BOILER Kuce Installation amp Operation Manual 6 Hydronic piping Figure 6 9 Multiple Boilers Multiple Temperature DHW Piped as a Zone Number of Units Model 2 3 415 6 7 8 Req Pipe EE EE EE ae PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW RED ou LOOP 1 LOOP 2 LOOP 3 PREVENTER p rim PRESSURE am gt lt GAUGE MAKE M UP inl NN i 1 i i MIXING VALVES WATER SYSTEM SUPPLY TYPICAL SENSOR AIR SEPARATOR Ay EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BALL VALVE OTTO C M TYPICAL DRAIN POINT TYPICAL DOMESTIC HOT WATER Y STRAINER FLOW CHECK RECOMMENDED VALVE tH ANTI SCALD 74
47. Inspect air separators Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping for suggested best location of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 Hydronic Piping before proceeding further Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed 76 KNiGHI Installation amp Operation Manual WALL MOUNT BOILER Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE
48. Low Voltage Connection Board on the Leader boiler The set point will be calculated based on the programmed reset curve parameters See the Knight Wall Mount Service Manual to program the reset curve If outdoor air reset is not desired do not connect the outdoor air sensor A fixed temperature set point can be programmed into the control See page 62 of this manual to program the set point If the water temperature at the system supply sensor is less than the set point the turn off offset the off on differential then the control will initiate a call for heat on the Cascade see the Knight Wall Mount Service Manual for an explanation of the offset and differential The Leader will energize the lead boiler on the Cascade For a new startup this will be the Leader boiler Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically be changed at set intervals The sequence will be changed once every 24 hours The switching on off sequence will be as follows DAY SWITCHING ON SEQUENCE L M1 M2 M3 M4 M5 M6 M7 M1 M2 M3 M4 M5 M6 M7 L If a boiler is used to heat an indirect DHW tank or locks out it will automatically be given the lowest priority for the rest of that 24 hour period DHW Night Setback and Ramp Delay operation with cascade For Normal Mode DHW operation any boiler s in the Cascade can be selected to provide heat for a DHW call Select a boiler to be de
49. ON 16 CENTERS OR MASONRY POURED CONCRETE MOUNTING BRACKET FACTORY SUPPLIED FASTENERS APPROPRIATE FOR WALL TYPE QTY 4 13 Kaisa Installation amp Operation Manual WALL MOUNT BOILER General venting Direct venting options Sidewall Vent N 2 o Tm 2 S ee c Figure 3 1 PVC CPVC Two Pipe Sidewall Termination Figure 3 2 Stainless Steel Two Pipe Sidewall See page 21 for more details Termination See page 22 for more details de S Figure 3 3 PVC CPVC Concentric Sidewall Termination See page 24 for more details 14 WALL MOUNT BOILER Kuce Installation amp Operation Manual 3 General venting continea Direct venting options Vertical Vent w s M rd ee Figure 3 4 PVC CPVC Two Pipe Figure 3 5 Stainless Steel Two Figure 3 6 PVC CPVC Concentric Vertical Termination See page 27 Pipe Vertical Termination See Vertical Termination See page 29 for more details page 27 for more details for more details Direct venting options Vertical Vent Sidewall Air RO S ie 1 Figure 3 7 PVC CPVC Vertical Vent Sidewall Air Figure 3 8 Stainless Steel Vertical Vent Sidewall Air NOTICE Stainless steel vent air design and terminations will vary slightly by manufacturer 15 Install vent and combustion air piping The Knight wall mount boiler must b
50. PE Y CONCENTRIC 2 DIA FITTING SDR 26 PIPE 2 CONCENTRIC VENT KIT Figure 4 8 Kit Contents CVK3007 reference Table 3C on page 19 RAIN CAP GRADE SNOW LINE Sidewall termination installation 6 152 MM TO 4 102 MM REDUCER 6 152 MM DIA 1 Determine the best location for the termination kit see FIG 4 6 2 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 19 of this manual 4 102 MM DIA Y CONCENTRIC FITTING 6 152 MM DIA 4 CONCENTRIC VENT KIT 3 You must consider the surroundings when terminating the vent and air 24 ss FLEXIBLE PIPE COUPLING Kuscer Installation amp Operation Manual WALL MOUNT BOILER 4 Sidewall direct venting continued Sidewall termination optional concentric vent models Figure 4 9 2 and 3 Concentric Vent Dimensional Figure 4 10 4 Concentric Vent Dimensional Drawing Drawing reference Table 3C on page 19 reference Table 3C on page 19 NOMINAL PVC AIR B DIA NOMINAL PVC VENT B DIA PVC VENT EXHAUST LA B C D E F j G j H Jj A B C D E PF 1524 MM 102 MM 152 MM 537 MM 254 MM 194 MM 76 MM 168 MM NOTICE Instead of cementing the smaller pipe to 6 Install the Y concentric fitting and pipe assembly
51. RATION DISPLAY Upon a call for heat the gas pressure switch es must be closed Once the gas pressure switch es are closed the control turns on the appropriate pumps system and boiler pumps for space heating DHW pump for DHW The flow switch and or LWCO must close The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch must close The control starts a 15 second prepurge cycle by initiating the blower The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve If flame is not detected within 1 second after the sparking ends the control will perform a 10 second post purge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts before locking out Ifflame is detected it holds the firing rate steady for 5 seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal PRE PURGE SYSTEM OUTDOOR MEHO et SCREEH SHDH PRE PURGE 0 SYSTEM 115 TAHE 125 Fet OUTDOOR S MEHU ISCREEH SHDH PRE PURGE ti SYSTEM Lib F 1291252 OUTDOOR 26 F et SCEEEHM SHDH PRE PURGE SYSTEM 11 IZS OUTDOOR ae MEHO aI SCEEEH SHOH IGNITION S1 STEM 1
52. W LINE AIR VENT OUTLET 36 914 MM MINIMUM ABOVE AIR INLET 5 Locate terminations so they are not likely to be damaged by foreign objects or subject to buildup of leaves or sediment 27 D Vertical direct venting Vent air termination vertical Prepare roof penetrations 1 Air pipe penetration a Cuta hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cuta hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 315 inch hole for 2 inch vent pipe 414 inch hole for 3 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole 3 Space the air and vent holes to provide the minimum spacing shown in FIG 5 1A page 27 4 Follow all local codes for isolation of vent pipe when passing through floors ceilings and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Termination and fittings l Prepare the vent termination coupling and the air termination elbow FIG 5 1A by inserting bird screens Bird screens should be obtained locally 2 The air piping must terminate in a down turned 180 return bend as shown in FIG 5 1A Locate the air inlet pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculatio
53. WH I O Rev D KNIGHT WALL MOUNT BOILER Installation amp Operation Manual Models WH 55 399 A WARNING This manual must only be used by a qualified heating installer service 2 77d 2 technician Read all instructions including this manual and the Knight ENERGY STAR installing Perform steps in the order Wall Mount Service Manual before given Failure to comply could result in severe personal injury death or High Efficiency Water Heaters Boilers and Pool Heaters CERTIFIED substantial property damage Save this manual for future reference Contents HAZARD DEFINITIONS 2 Vertical Termination Optional Concentric Vent 29 30 PLEASE READ BEFORE PROCEEDING 3 Optional Vertical Concentric Venting 31 32 THE KNIGHT WALL MOUNT BOILER HOW IT WORKS 4 5 6 HYDRONIC PIPING RATINGS e xu ES es 6 System Water Piping Methods 33 1 DETERMINE BOILER LOCATION Low Water Cutoff 33 Provide Clearances T Chilled Water 33 Provide Air Openings to Room 9 Freeze 33 Wall Mounting Location 9 General Piping Information 33 Residential Garage Installation 9 Near Boiler Piping Compo
54. a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 315 inch hole for 2 inch vent pipe 415 inch hole for 3 inch vent pipe Drill 3 16 diameter holes for inserting the plastic anchors into the wall 2 Install the vent and air intake piping through the wall into the vent plate openings Seal all gaps between the pipes and wall Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3A on page 17 to seal the vent pipe 3 Mount and secure the vent plate to the wall using stainless steel screws Seal around the plate to the wall assuring no air gaps 4 Assemble the vent cap to the vent plate see FIG 4 4A Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate 5 Seal all wall cavities Figure 4 4A Sidewall Termination Assembly is VENT PIPING Pe fi VENT PLATE WALL PLATE OI E VENT CAP GALVANIZED po PA THIMBLE SMA Prepare wall penetrations Alternate Field Supplied Option 1 Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch c
55. aller to ensure that the minimum flow requirements of the boiler are met at NOTICE all times during boiler operation If the minimum flow requirements cannot be met at any time the boiler must be hydraulically separated from the system Please note that these illustrations are meant to show system piping concept only the installer is responsible NOTICE 2 for all equipment and detailing required by local codes 45 WALL MOUNT BOILER deor Installation amp Operation Manual 6 Hydronic piping Figure 6 11 Single Boiler Full Flow Single Temperature Zoned with Valves DHW Piped as a Zone 7 PRESSURE REDUCING VALVE PRESSURE GAUGE ZONE 2 ZONE S ZONE 4 BACKFLOW L pue cq PREVENTER La K ZONE VALVES TYPICAL MAKE UP f 3 RIS Lh LI WATER SYSTEM SUPPLY DIFFERENTIAL SENSOR d PRESSURE BYPASS VALVE AIR SEPARATOR Q RECOMMENDED DR AP EXPANSION BALL VALVE TYPICAL HOT WATER OUT DRAIN POINT Y STRAINER TYPICAL RECOMMENDED ANTI SCALD MIXING VALVE COLD BOILER WATER CIRCULATOR PRESSURE IN RELIEF VALVE P UNION TYPICAL DRAIN TEMPERATURE PRESSURE GAUGE It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at NOTICE all times during boiler operation If the minimum flow requirements cannot met at time the boiler must be hydra
56. ap when there is no condensate present resulting in an unsafe environment It is important to check and make sure the ball is still located in the trap acting as a seal against flue gases at least once annually and after every cleaning 75 boilerlife Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections 12 Maintenance Flue vent system and air piping 1 Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 3 Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem 4
57. as tight A WARNING for proper steps to start boiler to prevent flue gas spillage and carbon monoxide emissions which will result in LI Verify the boiler and system are full of water and all severe personal injury or death system components are correctly set for operation Check gas piping LI Verify the preparation procedures of Section 10 pages 57 and 58 have been completed 1 Check around the boiler for gas odor following the Ensure float ball is inside condensate trap see FIG 10 1 procedure on page 48 of this manual connecting gas supply piping LI Verify electrical connections are correct and securely Fannie If you discover evidence of any gas leak attached shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage LI Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler Propane boilers verify conversion 1 Read and follow the Operating instructions in FIG s 10 2 1 Verify propane conversion has been completed per the and 10 3 on pages 60 and 61 Propane Conversion instructions DO NOT adjust or attempt to measure lf boiler does not start correctly eee gas valve
58. ation can be based on boiler outlet water temperature boiler inlet water temperature system temperature a 0 10V signal or Modbus depending on the parameter settings Control inputs and outputs Space heating demands There are three 3 heat loop demand connections available on this control These inputs tell the boiler to provide water for space heating Each demand connection has its own set point and outdoor air reset curve When multiple demands have a call for heat the control will give priority to the demand with the highest set point Example Assume that both Heat Loop Demand 1 and Heat Loop Demand 2 have a call for heat Heat Loop Demand 1 has a set point of 110 F Heat Loop Demand 2 has a set point of 140 F The boiler will regulate the system temperature to 140 F until Heat Loop Demand 2 has been satisfied Once Heat Loop Demand 2 has been satisfied the boiler will provide 110 F water to the system h Itipl A CAUTION When multiple used thermostatic mixing valves required for the protection of any low temperature loops 0 10V input set point or power The Knight wall mount boiler can be controlled by a Building Management System BMS using a 0 10 vdc signal The control can be configured by the installer to use this signal to either control set point or firing rate 64 Installation amp Operation Manual WALL MOUNT BOILER The Knight wall mount boiler can also be program
59. boiler from the system 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Gas connection pipe Threaded pipe connection This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals and controls the blower gas valve and pumps to meet the heating demand Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler High voltage junction box The junction box contains the connection points for the line voltage power and all pumps Low voltage connection board The connection board is used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low connection board voltage Condensate drain connection Connects the condensate drain line Access door Provides access to all internal components Ignition electrode Provides direct spark for igniting the burner Flame inspection window The quartz glass window provides a view of the burner surface and flame Gas shutoff switch An electrical switch designed to cut power to the gas valve to prevent releasing any gas High limit sensor housed with outlet sensor Device that monitors the outlet water temperature If the temperature exceeds its setting it will break the control circuit
60. bove L T5 ES Unions Field supplied Recommended for unit serviceability Temperature and pressure gauge Factory supplied The temperature and pressure gauge is shipped loose It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 34 WALL 11 12 13 Installation amp Operation Manual MOUNT BOILER Boiler purge valve Field supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up System temperature sensor Lochinvar supplies a system temperature sensor The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction Typically the sensor will be located far enough downstream to sense system diluted water temperature Indirect water heaters The Knight wall mount boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium As depicted in the piping diagrams on page 38 thru 47 there are two options when utilizing an indirect water heater A The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater B The indirect water heater is connected to the system supply piping A pump controlled by the Kn
61. cade system must be programmed with its own address The boiler designated as the Leader will have an address of 0 The remaining boilers in the Cascade will be Members and have addresses from 1 7 Rotate the NAVIGATION dial to select the appropriate address Press the RIGHT SELECT SAVE key Press the RIGHT SELECT HOME key to upload the address into the control Repeat this procedure for all boilers in the Cascade designating the Leader control and the Member controls 63 11 Operating information General How the boiler operates The Knight wall mount boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping The control module regulates blower speed to control the boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow How the control module operates The SMART SYSTEM control module receives inputs from boiler sensors and external devices The control module activates and controls the blower and gas valve to regulate heat input and switches the boiler Domestic Hot Water DHW and system pumps on and off as needed The user programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler oper
62. could result in product pipes supplied in the kit may be replaced damage or improper operation personal me deat by using the same diameter field supplied SDR 26 02241 pipe for CVK3003 3008 and standard schedule 40 PVC Figure 4 11 Rain Cap to Vent Pipe Alternate Assembly De n STAINLESS STEEL SCREW D more than 60 inches see FIG 4 9 and FIELD SUPPLIED FIG 4 10 DRILL CLEARANCE HOLE IN NOTICE If assembly needs to be reduced dimension RAIN CAP amp PILOT HOLE D can be as short as possible IN VENT PIPE 25 4 Sidewall direct venting WALL MOUNT BOILER Kuscer Installation amp Operation Manual Sidewall termination optional concentric vent Figure 4 12 Concentric Vent Sidewall Attachment ELBOW FIELD SUPPLIED STRAP FIELD COMBUSTION AIR CAUTION PO NOT use field supplied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 9 Cement appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 4 10 for proper pipe attachment 10 Operate the appliance one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections AIR SUPPLIED COMBUSTION COMBUSTION AIR Multiventing sidewall terminations When two 2 or more direct vent appliances are vented near each other each appliance must be in
63. ction on the appliance and the plastic air inlet pipe Using vent or air intake materials other than those specified failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air NOTICE Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported 18 WALL MOUNT BOILER Installation amp Operation Manual The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer
64. cturer s instructions Over oiling will damage the circulator Replace the boiler front access cover 77 Installation amp Operation Manual WALL MOUNT BOILER 13 Diagrams Figure 13 1 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL GROUND TERMINAL SIRE TERMINAL STRIP 62 120V SUPPLY L 120V SUPPLY XO INTEGRATED CONTROL ON OFF GND KB ONLY A SwitcH Q SYSTEM CENE SYSTEM x12 PUMP L I1 PUMP N O9 SYSTEM GND Siei PUMP BOILER i BOILER PUMP L PUMP N 9 BOILER GND PUMP DHW m DHW PUMP L TT PUMP N 62 Y S TERMINAL LL TERMINAL STRIP DHW STRIP 3 5 NA KB 801 ONLY CONNECTION BOARD INTEGRATED CONTROL CN5 14 4 8 CN5 10 4 12 gt SWITCH HEAT LOOP PENO CN5 7 X4 1 HEAT LOOP DEMAND CN5 13 4 9 HEAT LOOP DEMAND TANK THERMOSTAT CN5 12 X4 10 O Q LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH SWITCH CN5 11 4 11 OA CN5 3 4 5 INTEGRATED N CONTROL LOUVER RELAY COIL Q ES 24VAC IN LOUVER S PROVING SWITCH CN54 X44 Q Q Q RIBBON CABLE X5 2
65. d correctly positioned Check ignition ground wiring 1 2 3 4 C 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory heck all boiler wiring Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings 1 Set the SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of the Knight Wall Mount Service Manual Adjust settings if necessary See Section 1 of the Knight Wall Mount Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary 1 2 Maintenance continued Perform start up and checks Is 2 Start boiler and perform checks and tests specified Section 10 Start up Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame 1 2 Inspect flame through observation window If the flame is unsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean burner if performed inside a building Remove the burner reference FIG 12 2 pa
66. d local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer s installation instructions supplied with the vent system The installer must use a specific vent starter adapter at the flue collar connection supplied by the vent manufacturer to adapt to its vent system See Table 3B for approved vent adapters aise Installation amp Operation Manual WALL MOUNT BOILER General venti NQ continued Table 3B Approved Stainless Steel Terminations and Adapters ProTech Heat Fab ZFlex FasNSeal Saf T Vent Boiler Flue P Boiler Intermediate Flue Boiler Flue Intake Air Adapter Termination Adapter Adapter Termination We Adapter Termination Termination Termination Termination 55 85 303005 WHO002 2SVAKA02 95 05 309005 ee 303889 UIN 9392 9314TERM 2SVSTPOS GVSTEXOGO0 FSRC3 R C 5300C 2SVSRCX03 110 285 303006 WH1003 2SVAKA03 FSBS4 FSAIH04 9492 2SVSTP04 303007 sacain c WH8004 S454BUREZ T 9414TERM 2SVAKA04 gt Syspexog PSVSTEX0490 This adapter must be used in addition to the boiler adapter for Saf T vent pipe as shown in FIG 3 10 unless approved vent other than standard diameter is used Consult a Heat Fab representative for questions Stainless steel air intake ve
67. dividually vented see FIG 4 11 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 4 11 It is important that vent terminations be made as shown to avoid recirculation of flue gases 12 MINIMUM Figure 4 11 Concentric Vent and Combustion Air Termination EN 55 um D Vertical direct venting Vent air termination vertical A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage A WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substantial property damage NOTICE Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting section on page 19 of this manual 2 The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 3 The air piping must terminate in a down turn
68. e vented and supplied with combustion and ventilation air as described in this section Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system air system and combustion air quality See also Section 1 of this manual A DANGER Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death PVC CPVC Vent piping materials Use only the materials listed in Table 3A for vent pipe and fittings Failure to comply could result in severe personal injury death or substantial property damage A WARNING Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations NOTICE For closet and alcove installations CPVC or stainless steel material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death A WARNING All PVC vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the boiler to allow drainage of condensate NOTICE This appliance requires a special venting system For stainless steel venting use an adapter from Table 3B page 1
69. e United States Department of Energy p Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building 8 and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 P only the vent materials and methods specified in the Knight Wall Mount Installation and Operation Manual d Standard Knight wall mount boilers are equipped to operate from sea level to 4 500 feet only with no adjustments The boiler will de rate by 496 for each 1 000 feet above sea level up to 4 500 feet p High altitude Knight wall mount boilers are equipped to operate from 3 000 to 12 000 feet only with no field adjustments The boiler will de rate by 296 for each 1 000 feet above 3 000 feet High altitude models are manufactured with a different control module for altitude operation but the operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit s Knight wall mount boilers require special gas venting Use 9 The Knight Wall Mount boiler input rate on some models is reduced for vent lengths beyond the minimum Two inch vent will reduce Models WH N L 055 WH N L 085 and WH N L 110 by 0 6 0 94 and 1 2 for every 10 feet of vent Three inch vent will reduce Models WH N L 155 WH N L 199 and WH N L 285 by 0 3 0 5 and 0 6 for every 10 feet of vent F
70. e boiler or air inlet piping If contaminants are found you MUST e Remove contaminants permanently OR Relocate air inlet and vent terminations to other areas 4 Sidewall direct venting Vent air termination sidewall A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage A WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage A WARNING P9 not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substantial property damage NOTICE Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 19 of this manual 2 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be
71. e formations Locate or guard vent to prevent condensate damage to exterior finishes _ _ 4 Cut one 1 hole 5 inch diameter for CVK3003 installations Sidewall termination optional 4 inch diameter for CVK3008 or 7 inch diameter for concentric vent CVK3007 installations into the structure to install the termination kit VENT 12 MIN BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE Description and usage DEM 5 Partially assemble the concentric vent termination kit Clean Lochinvar offers optional concentric combustion air and vent and cement using the procedures found in these instructions pipe termination kits Factory Kit CVK3003 for 5 diameter a Cement the Y concentric fitting to the larger kit pipe models 155 199 CVK3008 for 2 diameter models 55 FIG 4 7 110 or CVK3007 for 4 diameter models 285 399 Both b Cement the rain cap to the smaller diameter kit pipe combustion air and vent pipes must attach to the termination FIG 4 7 kit The termination kit must terminate outside the structure and must be installed as shown below in FIG 4 6 Figure 4 7 Kit Contents CVK3008 amp CVK3003 reference Table on page 19 The required combustion vent pipe and fittings are listed in 3 CONCENTRIC Table 3A on page 17 of this manual VENT KIT 4 DIA SDR 26 PIPE Figure 4 6 Concentric Sidewall Termination OVERHANG OR ROOF 2 1 2 DIA SDR 26 PIPE 3 DIA SDR 26 PI
72. eal rigid vent using specially designed adapters and sealing method see manufacturer s instructions PVC CPVC air intake vent connections Figure 3 9 Near Boiler PVC CPVC Venting 1 Combustion Air Intake Connector FIG 3 9 Used to UR VENT provide combustion air directly to the unit from outdoors A fitting is provided on the unit for final connection AIR Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 7 305 4 or as local codes dictate 2 Vent Connector FIG 3 9 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate 17 General venting Air inlet pipe materials The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from the following list PVC CPVC or ABS Dryer Vent or Sealed Flexible Duct not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified in this section Type B double wall vent with joints and seams sealed as specified in this section AL29 4C stainless steel material to be sealed to specification of its manufacturer Plastic pipe may require an adapter not provided to transition between the air inlet conne
73. ed 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an up turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake When the vent termination uses a rain cap as illustrated in FIG 5 1B maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet 6 m apart and with the vent termination at least 1 foot above the air intake Installation amp Operation Manual WALL MOUNT BOILER A WARNING Rooftop vent and air inlet terminations must terminate in the same pressure zone unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent Sidewall Air Section Figure 5 1A PVC CPVC Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 OF VENT PIPE BIRD SCREEN TYPICAL COUPLING FIELD SUPPLIED 6 MINIMUM ABOVE ROOF SNOW LINE VENT OUTLET 12 MINIMUM ABOVE AIR INLET Figure 5 1B Stainless Steel Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE BIRD SCREEN TYPICAL 6 152 MM MINIMUM ABOVE ROOF SNO
74. ed to control the system return temperature then program the SMART SYSTEM control to use the inlet sensor as the controlling sensor See the Knight Wall Mount Service Manual for instructions on how to do this When the inlet sensor is programmed as the controlling sensor it is strongly recommended that the SYSTEM SUPPLY sensor be installed DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN The TST2032 sensor provided with the boiler must be used for the system sensor Connect these terminals to the system supply sensor FIG 8 4 Boiler management system 1 An external control may be connected to control either the firing rate or the set point of the boiler If the external control uses a set of contacts to enable the boiler connect the contacts to the Heat Loop Demand 1 terminals Otherwise the SMART SYSTEM control will be enabled by the 0 10V signal Make sure the ground terminal is connected to the ground output terminal of the external control and the 0 10 vdc terminal is connected to the 0 10 vdc terminal of the external control Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off This can be used to tu
75. ent freeze potential for the boiler and system 65 11 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow switch low water cutoff gas pressure switches and a louver proving switch The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The boiler provides dry contacts for indicating when the boiler is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the boiler is firing in the Space Heating Mode The other timer monitors the time the boiler is in the DHW Mode The control uses two 2 ignition counters to monitor the amount of boiler cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed Service reminder The control can be programmed for service reminder notification This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will show a Maintenance Required screen The installer s name and phone number can be programmed into the control This information will appear on the Maintenance Required screen The service reminder notification can be reset o
76. er to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 4 The freeze protection set points may be lowered when freeze protection fluid is used see the Knight Wall Mount Service Manual Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close boiler drain valve 3 Fillto correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Installation amp Operation Manual WALL MOUNT BOILER 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system Purge air from system a Connect a hose to the purge valve see purge drain valves in piping diagrams on pages 38 through 47 Route the hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system C
77. es Boiler circulating pump A Grundfos UPS15 58FC pump for Models 55 155 anda Grundfos UPS26 99FC pump for Models 199 399 will be provided by the factory as the boiler circulation pump based on 20 feet of piping 4 90 elbows and 2 fully ported ball valves Knight wall mount boilers are capable of controlling a variable speed boiler circulator Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG 6 2 on page 36 at full speed Domestic hot water circulating pump Field supplied The pump MUST be sized to meet the specified minimum flow requirements listed in FIG 6 2 Consult the indirect water heater operating guide to determine flow characteristics for the selected product used Boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler Check valves Field supplied Check valves are recommended for installation as shown in FIG s 6 3 through 6 10 Failure to install check valves could result in a reverse flow condition during pump s off cycle Domestic indirect hot water isolation valves Field supplied Full port ball valves required Failure to use full port ball valves could result in a restricted flow rate through the boiler Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water a
78. esponsible for all equipment and detailing required by local codes 40 WALL MOUNT BOILER Kuscer Installation amp Operation Manual 6 Hydronic piping continea Figure 6 6 Multiple Boilers Single Temperature Zoned with Zone Valves DHW Priority Number of Units Modell 2 3 415 6 7 8 Required Pipe Sizes 2 2 1 2 2 1 2 oa a 4 5 PRESSURE BACKFLOW REDUCING ZONE Z2 ZONE 3 ZONE 4 PREVENTER VALVE PRESSURE BALL VALVE 924 AAGE ZONE VALVES TYPICAL bud TYPICAL I UP WATER DIFFERENTIAL PRESSURE SYSTEM SUPPLY 7 BYPASS VALVE SENSOR RECOMMENDED AIR SEPARATOR EXPANSION TANK 7 MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL n i 5 ANTI SCALD Y STRAINER MIXING VALVE E RECOMMENDED DOMESTIC WATER i y HOT WATER OUT BOILER CIRCULATOR CIRCULATOR NES PRESSURE RELIEF VALVE 1 BOILER 2 MEMBER 1 BOILER 1 LEADER INDIRECT i Ifi i DHW TANK TEMPERATURE DRAIN PRESSURE UNION GAUGE TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 41 WALL MOUNT BOILER Kuscer Installation amp Operation Manual 6 Hydronic piping Figure 6 7 Multiple Boilers Single Tem
79. exchanger FLUE TEMP The temperature read by the flue sensor FLAME CURRENT The current measured by the flame sense circuit c information SYS PUMP INPUT The speed signal received from a variable speed system pump control RATE OUTPUT A 0 10V signal indicating the firing rate of the boiler 72 Kusi Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information continued Status Display Screens cont d Section Display Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen EXIT Press the LEFT SELECT key to exit the current screen or setting D YES Press the LEFT SELECT key to confirm that the boiler needs to shutdown d he LEFT SELECT h hat all a ress the ey to enter the screen that allows you to key function adjust the limit settings HOME Press the LEFT SELECT key to return to the Status Screen and upload parameter changes SKIP Press the LEFT SELECT key when in the Night Setback Screen to access the Night Setback Skip Screen Turning the NAVIGATION dial will select the next or previous Status 4 GCREEH Nd Pressing the NAVIGATION dial will show the next fault NSB Night HEST Setback trigger or ramp delay setting E SELECT Pressing the NAVIGATION dial will select the setting indicated by the cursor NAVIGATION Dial Function 5ETPOINTS Pressing the NAVIGATION dial will display the Set Points Screen
80. f the switch will not OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Move the switch to the ON position above on this label 9 Install front door 2 Setthe thermostat to lowest setting 10 Turn on all electric power to appliance Eu off all electric power to the 11 Set thermostat to desired setting Me NN 12 If the appliance will not operate follow the 4 This appliance is equipped with an instructions To Turn Off Gas To Appliance and ignition device which automatically lights call your service technician or gas supplier the burner Do not try to light the burner by hand 5 Remove front door 6 Move switch to the OFF position 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE set the thermostat to lowest setting 4 Move the switch to the OFF position Turn off all electric power to the appliance 5 Install front door if service is to be performed Remove front door LBL2339 REV B 60 WALL MOUNT BOILER Installation amp Operation Manual 1 0 Start u D continued Figure 10 3 Operating Instructions Model 399 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Im
81. g load ramp delay if enabled and various other temperature limitations Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information continued Ramp delay For systems with lower flow the SMART SYSTEM can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call for heat to a space heating call for heat There are six 6 limits that can be programmed as well as six 6 time intervals corresponding to each limit The sixth limit will also limit the firing rate for the rest of the call for heat Gradient limiting If during operation of the boiler the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Outdoor air reset With the outdoor air sensor connected the control module will calculate the set points of the three 3 space heating demands based on the programmed reset curves The installer can change the slope of the reset curves by several adjustable parameters The user can limit the maximum set point for the system using the space heating set points Boost function If outdoor air reset is active and any space heating demand has been active continuously for a set period of time time adjustable by installer and there has been no DHW demands the control will increase the set point of that demand by a fixed number of degrees adjustable by installer This process will continue unti
82. ge 77 When replacing the burner ensure gasket is in good condition and positioned correctly FIG 12 2 Figure 12 2 Burner Assembly BURNER PLATE GASKET BURNER PLATE INSULATION BURNER DOOR BURNER GASKET Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting of the Knight Wall Mount Service Manual for other procedures to deal with low flame signal Installation amp Operation Manual WALL MOUNT BOILER Review with owner 1 Review the Knight Wall Mount User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Knight Wall Mount User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger 1 4 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup e Do not drain the bo
83. he inlet sensor is chosen as the controlling sensor it is recommended that the system supply sensor be installed in order to provide the best control of the inlet temperature Anti cycling After the burner turns off the control will delay the next burner cycle for a set time period time is adjustable by the installer The time delay will be bypassed if the inlet water temperature drops too far during the delay Boiler and system pump control The boiler pump will run whenever the burner is firing unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank The boiler pump will run during Freeze Protection Mode as well It will continue to run for a short time after the burner turns off or the Freeze Protection Mode ends The system pump will run whenever there is a space heating call for heat or the boiler goes into Freeze Protection Mode It may be programmed to run during a DHW call for heat when the DHW is programmed for Zone Mode It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode The system pump can be programmed to run continuously if desired except during outdoor shutdown and or a DHW call for heat Temperature control Modulation The Knight wall mount boiler is capable of modulating its firing rate from a minimum of 2096 to a maximum of 10096 The firing rate is dictated by the call for heat i e space heating or domestic hot water the heatin
84. ial twice 6 Turn the NAVIGATION dial to adjust the hours Press the NAVIGATION dial read PASSWORD Y WALL MOUNT BOILER Installation amp Operation Manual 7 Turn the NAVIGATION dial to adjust the minutes Press the NAVIGATION dial 8 Turn the NAVIGATION dial to adjust the month Press the NAVIGATION dial 9 Turn the NAVIGATION dial to adjust the date Press the NAVIGATION dial 10 Turn the NAVIGATION dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment The clock is automatically updated whenever a PC is connected and the Win_Pro Installer program is started Configuration of the cascade NOTICE Please note that the brackets denote screen status When installed in a Cascade system the individual controls must be programmed for cascade operation This is accomplished by accessing the control parameters Press the MENU key for at least five 5 seconds Input the Installer code as described in the Knight Wall Mount Service Manual Once the control parameters have been accessed use the NAVIGATION dial to select the Control Mode parameters Press the NAVIGATION dial to access these parameters Rotate the NAVIGATION dial to select the parameter Cascade Address Press the NAVIGATION dial to access this parameter Each appliance in the Cas
85. ided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free A WARNING of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 4 The Knight wall mount boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 5 Ifa new boiler will replace an existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits ncorrectly sized expansion tank Lack of freeze protection in boiler water causing system and boiler to freeze and leak Y WALL MOUNT BOILER Installation amp Operation Manual A WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Do not install the appliance where the relative humidity may exceed 9396 Do not
86. ight wall mount boiler s control will regulate the flow of water through the indirect water heater The indirect water heater s temperature will be regulated by the Knight wall mount boiler s control The Knight wall mount boiler is pre configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating Lochinvar offers the Squire which is a series of indirect water heaters The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger A WARNING The National Standard Plumbing Code the 14 National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum Also the heat transfer fluid must be water or other non toxic fluid having a toxicity of Class 1 as listed in Clinical Toxicology of Commercial Products 5 Edition Y Strainer Field supplied A Y strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems WALL MOUNT BOILER Kuce Installation amp Operation Manual 6 Hydronic piping continea Near boiler piping connections Figure 6 1A Near Boiler Piping Figure 6 1B Near Bo
87. ight to avoid possibility of severe personal injury death or substantial property damage 2 Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet as shown in FIG 4 5A for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Knight wall mount boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 4 5A Multiple Vent Terminations must also comply with Figure 4 1A 12 MIN BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET 23 VENT AIR TERMINATION Kasay Installation amp Operation Manual 4 Sidewall direct venting Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets f Do not terminate above any door or window Condensate can freeze causing ic
88. iler Piping w Low Loss Header DOMESTIC u INLET DOMESTIC HOT OUTLET WATER PUMP INLET INDIRECT DOMESTIC CONDENSATE 027 WATER DRAIN DOMESTIC CONDENSATE TANK HOT WATER DRAIN a e BOILER o PUMP SYSTEM TO FLOOR TO Bern PUMP DRAIN SYSTEM BOILER PUMP PUMP Y STRAINER 1 m ad 4 Te R a 25 lt FILL VALVE A E P SEPARATOR nl AC Y STRAINER Z om EXPANSION TANK RECOMMENDED bL lt KS lt EXPANSION TANK LOW LOSS HEADER DRAIN TYPICAL TYPICAL DRAIN VALVE Circulator sizing The Knight wall mount boiler heat exchanger does have a pressure drop which must be considered in your system design Refer to the graph in FIG 6 2 for pressure drop through the Knight wall mount boiler heat exchanger E 5 WALL MOUNT BOILER Kise Installation amp Operation Manual 6 Hydronic piping Figure 6 2 Pressure Drop vs Flow Minimum Pipe Fimo Mite arunaas Tao 7 E7 E7 E7 UPS 15 58FC gi v 61a UPS26 99F 0011 NRE 36 1 E7 UPS26 99F 0011 NRE 36 3 E7 UPS26 99F 0012 PL 55 25 F Temperature Rise Applications FT HD Minimum Pipe Sue Grundfos TACO 4 2 2 N CO 3 10 105 19 7 38 QJ g gi 0 55 7 UPS 15 58FC 1 NRF 22 UPS 15 58FC NRF 22 1 07 Ph ft vo oo a 5 E7 T E7 E7 E7
89. iler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside Remove the heat exchanger access cover and burner A WARNING The boiler contains ceramic fiber materials Use care when handling these materials per 10 instructions in the Service Manual Failure to comply could result in severe personal injury Remove the condensate trap from the bottom of the boiler Place a bucket underneath the condensate fitting attached to the heat exchanger Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent Using a clean cloth dampened with warm water wipe out the combustion chamber Rinse out debris with a low pressure water supply Allow the heat exchanger to thoroughly dry Perform start up and check out procedures in the Check Flame and Combustion Section 10 Startup on pages 59 and 62 of this manual Replace the burner access cover and condensate trap Restore boiler to operation A CAUTION Do NOT use a metal brush Oiled bearing circulators The circulator shipped with the Knight wall mount boiler is water lubricated No oiling is required Check other circulators in the system Oil any circulators requiring oil following circulator manufa
90. ilizing the single pipe method provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Table 3D Optional Room Air Kit 95 110 55 285 199 399 KIT30051 KIT30052 KIT30053 Air contamination Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals pass through the boiler they can form strong acids The acid can eat through the boiler wall causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building Please read the information given in Table 1A page 10 listing contaminants and areas likely to contain them If contaminating chemicals will be present near the location of the boiler combustion air inlet have your installer pipe the boiler combustion air and vent to another location per this manual A WARNING If the boiler combustion air inlet is located in a laundry room or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal injury or death check for areas and products listed in Table 1A page 10 before installing th
91. is appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Turn Off Gas To Appliance and the burner Do not try to light the burner call your service technician or gas supplier by hand Gas Valve Gas Valve 5 Remove top cover OPEN CLOSED 6 Turn gas shutoff valve counterclockwise oma to OFF Handle will be perpendicular to pipe Do not force 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve counterclockwise to OFF Handle will be perpendicular to pipe Do not force to CLOSE Turn off all electric power to the appliance if service is to be performed Remove top cover Install top cover LBL2284 REV 61 10 Start up Check flame and combustion continued NOTICE Please note that the brackets denote screen status 4 Place the boiler into the active position by pressing the RIGHT SELECT ON key FIG 11 1 page 70 5 Locate the pinhole button below the RESET button on the display board FIG 11 1 Insert a thin wire such as a paper clip into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire
92. is away from the wall Ensure bracket is level when mounted Extreme care is needed to ensure the bolts are secured in the center of the studs Note If wall thickness does not allow a 1 1 8 deep hole field supplied hardware suitable for the application should be provided 2 Hang the boiler on the bracket and secure the bottom of the boiler with two 2 remaining anchors following the instructions above The boiler is too heavy for a single person to lift A minimum of two people is needed for mounting the boiler onto the bracket A WARNING Mounting to a metal studded wall 1 The wall mount bracket is designed for a stud spacing of 16 inches from center For other stud spacing a solid mounting surface must be provided by the installer Do not mount the boiler to a hollow wall Be sure to mount the boiler to the studs only A WARNING Mount the wall bracket using two 2 field supplied toggle bolts capable of supporting 100 pounds each Ensure the top edge of the bracket is away from the wall Ensure the bracket is level when mounted Extreme care is needed to ensure the bolts are secured in the center of the studs Q3 Hang the boiler on the bracket and secure the bottom of the boiler with two 2 field supplied toggle bolts The boiler is too heavy for a single person to lift A minimum of two people is needed for mounting the boiler onto the bracket Figure 2 4 Mounting the Boiler WALL WOOD OR METAL STUDS
93. l the space heating demand ends the set point reaches the programmed set point or a maximum of 20 increases has occurred Once the system heat demand 1s satisfied the set point will revert to the value determined by the reset curve Night setback The controller may be programmed to reduce the space heating and DHW set points during certain times each week Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback Any night setback scheduled within the next seven 7 days can be temporarily bypassed if desired Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low Protection features Outlet temperature flue temperature and temperature rise limiting The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F and the mini
94. learance around the vent pipe outer diameter 315 inch hole for 2 inch vent pipe 415 inch hole for 3 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole as shown in FIG 4 4B 3 Use a sidewall termination plate as a template for correct location of hole centers 4 Follow all local codes for isolation of vent pipe when passing through floors or walls 5 Sealexterior openings thoroughly with exterior caulk Figure 4 4B Alternate Sidewall Termination Assembly w Field Supplied Fittings ELBOW AIR PIPING VENT PIPING BIRD SCREEN GALVANIZED THIMBLE dd SIDEWALL BIRD SCREEN TERMINATION PLATE Termination and fittings 1 The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG 4 1 page 21 2 Maintain the required dimensions of the finished termination piping as shown in FIG 4 1A page 21 3 If using the alternate sidewall termination do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe 4 PVC CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual Multiple vent air terminations 1 When terminating multiple Knight wall mount boilers terminate each vent air connection as described in this manual FIG 4 5A A WARNING All vent pipes and air inlets must terminate at the same he
95. llation amp Operation Manual Inspect fill condensate system Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate fittings and condensate trap 2 Fill condensate trap with enough water to make the ball float FIG 10 1 3 Loosen compression fitting FIG 10 1 4 Slide condensate trap onto condensate drain at the bottom of the unit 5 Tighten compression fitting A WARNING The condensate trap FIG 10 1 must have the float ball in place during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to ensure the float ball is in place could result in severe personal injury or death Figure 10 1 Condensate Trap COMPRESSION FITTING FLOAT BALL CONDENSATE DRAIN REMOVABLE CAP TO CLEAN OUT TRAP Clean Inspect Trap Assembly 1 Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out 2 Refill the trap according to the instructions above WALL MOUNT BOILER Kuce Installation amp Operation Manual 1 0 Start u D continued Final checks before starting the boiler Check vent piping and air piping Read the Knight Wall Mount Service Manual to 1 Check for gas tight seal at every connection seam of air familiarize yourself with SMART SYSTEM control piping and vent piping module operation Read this manual pages 60 and 61 Venting system must be sealed g
96. located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle Vent and air piping The Knight wall mount boiler requires a special vent system designed for pressurized venting The boiler is to be used for either direct vent installation or for installation using indoor combustion air When room air 1s considered see Section 3 General Venting Note prevention of combustion air contamination below when considering vent air termination Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall unless otherwise specified You may use any of the vent air piping methods covered in this manual Do not attempt to install the Knight wall mount boiler using any other means Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated The vent air piping lengths routing and termination method must all comply with the methods and limits given in this manual Prevent combustion air contamination Install air inlet piping for the Knight wall mount boiler as described in this manual Do not terminate vent air in locations that can allow contamination of combustion air Refer to Table 1A page 10 for products and areas which may cause contaminated combustion air You must pipe combustion air to the boiler air intake Ensure
97. lose zone isolation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in the system open the manual air vents in the system one at a time beginning with the lowest floor Close the vent when water squirts out Repeat with remaining vents Eh o 66 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents Refill to correct pressure 57 10 Start up Check for gas leaks A WARNING Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the front access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection solution Repair any leaks
98. m should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping Use only inhibited propylene glycol s persuade solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems WALL MOUNT BOILER Installation amp Operation Manual General piping information Basic steps are listed below along with illustrations on the following pages FIG s 6 3 through 6 12 which will guide you through the installation of the Knight wall mount boiler reference FIG s 6 1A and 6 1B l 25 10 Connect the system return marked Inlet Connect the system supply marked Outlet Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone Install a backflow preventer on the cold feed make up water line Install a pressure reducing valve on the cold feed make up water line 15 psi nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi Install a circulator as shown on the piping diagrams in this section Make sure the circulator is properly sized for the system and friction loss Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank in
99. manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise Remove the flue temperature sensor from the flue pipe connection Note Combustion measurements will be made at this point 3 Turn on power at source 59 Installation amp Operation Manual 10 Start up Figure 10 2 Operating Instructions Models 55 285 This appliance does not have a pilot It is Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the move by hand don t try to repair it call a floor qualified service technician Force or attempted WHAT TO DO IF YOU SMELL GAS repair may result in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building to replace any part of the control system and any gas control which has been under water C Use only your hand to move the gas control switch Never use tools I
100. med to accept a call for heat from a 0 10V signal reference the Knight Wall Mount Service Manual for a detailed explanation of this procedure DHW priority The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the DHW thermostat input is ignored When a stand alone boiler is programmed for DHW Normal Mode the maximum firing rate can be limited to match the input rating of the indirect tank coil DHW space heating SH cycling If a DHW call for heat is received while a space heating call is in progress and the DHW is in Normal Mode the control will start the DHW pump and shut the boiler pump off The system pump will remain on For stand alone boilers if the space heating call is still active while the DHW call is in operation the control will wait for 30 minutes time adjustable by installer then it will switch back to the space heating demand There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating The control will switch back and forth until one of the heat demands end Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default If a system supply sensor is connected the control automatically uses it as the control sensor For stand alone boilers the control sensor can be changed by the installer to the inlet sensor If t
101. mediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand If you cannot reach your gas supplier call the fire department BEFORE OPERATING smell all around C Use only your hand to turn the gas control knob the appliance area for gas Be sure to Never use tools If the handle will not turn by smell next to the floor because some gas hand don t try to repair it call a qualified service is heavier than air and will settle on the technician Force or attempted repair may result floor in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance under water Immediately call a qualified D TS tch d service technician to inspect the appliance and UNE d ia sie s 2 to replace any part of the control system and not use any phone in your building any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe 2 Set the thermostat to lowest setting 9 Install top cover 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 Th
102. mum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 55 F the control will reduce the maximum fan speed If the temperature difference exceeds 60 F the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 55 F and the minimum off time has expired Freeze protection DO NOT install the boiler in a room likely to freeze The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only not for the system The SMART SYSTEM control module provides freeze up protection as follows when the boiler water temperature drops below 45 F Below 45 F the boiler and system pumps operate constantly Below 37 F the boiler turns on and runs at 20 of rate Boiler and pumps turn off if boiler water temperature rises above 45 F e Lower temperatures may be programmed for systems with anti freeze solutions see the Knight Wall Mount Service Manual When system return temperatures NOTICE E are maintained below the dew point condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust A CAUTION This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing The installation must still use recognized design installation and maintenance practice to prev
103. n The Knight wall mount boiler vent and air piping can be installed through the roof or through a sidewall Follow the procedures in this manual for the method chosen Refer to the information in this manual to determine acceptable vent and air piping length Optional room air NOTICE Optional room air is intended for commercial applications Combustion air piping to the outside is recommended for residential applications Commercial applications utilizing the Knight wall mount boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room In order to use the room air venting option the following conditions and considerations must be followed The unit MUST be installed with the appropriate room air kit Table 3D The equipment room MUST be provided with properly sized openings to assure adequate combustion air Please refer to instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening 20 Installation amp Operation Manual WALL MOUNT BOILER Using the room air kit makes the unit vulnerable to combustion air contamination from within the building Please review Section 1 Prevent Combustion Air Contamination to ensure proper installation Vent system and terminations must comply with the standard venting instructions set forth in this manual When ut
104. n of flue products into the combustion air stream 3 Thevent piping must terminate in an up turned coupling as shown in FIG 5 1A The top of the coupling must be at least 1 foot above the air intake When the vent termination uses a rain cap as illustrated in FIG 5 1B maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake 4 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 5 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe 28 Installation amp Operation Manual WALL MOUNT BOILER Multiple vent air terminations 1 When terminating multiple Knight wall mount boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U S installations see FIG 5 2 For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Knight wall m
105. n potential boiler shutdown Figure 4 1B Alternate PVC CPVC Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR BIRD SCREEN CONNECTION FROM NN VENT PIPE ee CONNECTION TERMINATION PLATE GRADE OR SNOW LINE 21 4 Sidewall direct venting Vent air termination sidewall Figure 4 1C Alternate Venting Arrangement if Space Allows w Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION COUPLING FROM BOILER VENT PIPE CONNECTION BIRD SCREEN SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS Figure 4 1D Alternate Venting Arrangement Typical Stainless Steel Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE E CONNECTION BIRD SCREEN GRADE OR SNOW LINE 5 Maintain clearances as shown in FIG s 4 1A thru 4 3B pages 21 and 22 Also maintain the following a Vent must terminate At least 6 feet from adjacent walls No closer than 12 inches below roof overhang At least 7 feet above any public walkway At least 3 feet above any forced air intake within 10 feet No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination FIG 4 1B and the vent pipe must not ex
106. nents 34 Vent and Air PIPING 9 Near Boiler Piping Connections 35 Prevent Combustion Air Contamination 9 Circulator 512 0 35 Corrosive Contaminants and Sources 10 Variable Speed Pump Option Using an Existing Vent System to Install New Boiler 10 7 GAS CONNECTIONS Removing a Boiler from Existing Common Vent 11 Connecting Gas Supply Piping 48 2 PREPARE BOILER Natural Gas 49 Remove Boiler from Wood Pallet 12 Pipe Sizing for Natural Gas 49 Gas 12 Natural Gas Supply Pressure Requirements 49 Mounting the Boiler 242 wea eem re x RR RSS 13 eens cee 49 3 GENERAL VENTING Pipe Sizing for Propane Gas 49 Direct Venting 14 15 Propane Supply Pressure Requirements 49 Install Vent and Combustion Air Piping 16 Check Inlet Gas 50 PVC CPVC Vent Piping Materials 16 Gas lt 51 Requirements for Installation in Canada 16 Gas Valve Replacement 51 PVC CPVC Air Intake Vent Connections
107. ng off unless programmed to remain on continuously 60 second anti cycle period will start OUTDOOR which will delay any new call for heat until it times out aA _ _ _ oe SCREEHM SHEH STANDBY 12 In Standby ready to start a new cycle H E 1383 26 F OUTDOOR SETPOINTS SHOH Access modes Saving parameters reference the Parameter Table in User the Knight Wall Mount Service Manual The user can adjust space heating and tank target temperatures NOTICE Please note that the brackets denote by pressing the NAVIGATION dial when SETPOINTS is screen status flashing at the bottom of the display The date and time and the temperature units can also be changed see page 63 To save parameters and exit programming Press the RIGHT SELECT SAVE key and then press the Installer RIGHT SELECT HOME key Most parameters are available only to the installer accessible To enter a parameter and continue programming by entering the installer password see the Knight Wall Mount Service Manual Press the RIGHT SELECT SAVE key 1 time to return to the parameter listings press again to return to the menu listings Remember to press the RIGHT SELECT HOME key when finished programming in order to save the changes made See the Knight Wall Mount Service Manual for a detailed description of parameters and access modes 69 WALL MOUNT BOILER Kuscer Installation amp O
108. note Screen status 1 Turn ON the main power to the boiler by placing the ON OFF switch in the ON position 2 If boiler status reads SHUTDOWN place the boiler into the active position by pressing the RIGHT SELECT ON key 3 Locate the pinhole SERVICE button below the RESET button on the display board Insert a thin wire such as a paper clip into the hole and press the button once hold for five 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire 4 From the Status Screen press the NAVIGATION dial to access the Set Points Screen Press the LEFT SELECT LIMITS key 6 Select the manual reset high limit MRHL by pressing the NAVIGATION dial 7 Decrease the set point of the MRHL below the outlet temperature by turning the NAVIGATION dial counterclockwise 8 Press the RIGHT SELECT SAVE key 9 Press the RIGHT SELECT HOME key 10 The new parameters will upload to the control and the MRHL will function causing boiler shutdown and LOCKOUT to be displayed 11 Repeat Steps 4 5 and 6 12 Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise 13 Repeat Steps 8 and 9 14 Press the RESET button to clear the lockout Low water cutoff protection 1 The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger If the flow rate is too low or
109. nt Maximum allowable combustion air and connections vent piping lengths are as follows 1 Combustion Air Intake Connector FIG 3 10 jet Maximum Combustion Air and Vent Piping Used to provide combustion air directly to the unit from outdoors A fitting is provided on the unit for final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate Model 2 Max Vent 3 Max Vent 4 Max Vent Air Air 100 fes 2 Vent Connector FIG 23 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or BEEN Figure 3 10 Near Boiler Stainless Steel Venting For Models 55 85 and 110 using 2 venting Models 55 399 VENT and Model 285 using 3 venting the first seven 7 equivalent feet of vent must be CPVC field supplied This includes any transition piece used to increase or decrease the vent diameter 3 S S INTERMEDIATE FOR SAF T VENT ONLY Note The minimum combustion air and vent piping length is 12 equivalent feet When determining equivalent combustion air and vent length add 5 feet for each 90 elbow 3 feet for each 45 elbow and 3 feet for the concentric vent kit see example below EXAMPLE 20 feet of PVC pipe 4 90 elbows
110. nt the appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 5 6 for proper pipe attachment 8 Operate the appliance through one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections Multiventing vertical terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 5 7 It is important that vent terminations be made as shown to avoid recirculation of flue gases Figure 5 7 Concentric Vent and Combustion Air Vertical Termination 1 2 MN COMBUSTION AIR TYPICAL L 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF Installation amp Operation Manual WALL MOUNT BOILER D Vertical direct venting ontinuea Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through Figure 5 8 Concentric Vent Example 1 existing unused venting system or by using the existing unused venting system as a chase for vent and combustion air routing d Concentric Venting Arrangement FLUE EXHAUST
111. objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Kuce Installation amp Operation Manual WALL MOUNT BOILER Figure 4 1A PVC CPVC Sidewall Termination of Air and Vent TO BOILER INTAKE AIR CONNECTION e FROM BOILER VENT PIPE CONNECTION VENT AIR TERMINATION zu SNOW LINE Table 4A Sidewall Vent Kit If using the alternate sidewall termination 3 The air piping must terminate in a down turned elbow as shown in FIG 4 1B This arrangement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown in FIG 4 1B Do not exceed the maximum lengths of the outside vent piping shown in FIG 4 1B Excessive length exposed to the outside could cause freezing of condensate in the vent pipe resulting i
112. or improper operation personal injury or death 4 Install the Y concentric fitting pipe assembly through the structure s hole and field supplied roof boot flashing NOTICE Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 5 Secure the assembly to the roof structure as shown below in FIG 5 6 using field supplied metal strapping or equivalent support material Figure 5 6 Concentric Vent Roof Installation 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROCF COMBUSTION AIR SUPPORT FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR NOTICE Ensure termination height is above the roof surface or anticipated snow level 12 inches in U S A or 18 inches in Canada as shown in FIG 5 4 page 29 If assembly is too short to meet height requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied SDR 26 PVC D2241 pipe Add standard schedule 40 PVC pipe for CVK3007 Do not extend dimension D more than 60 inches see FIG 4 9 and FIG 4 10 page 25 30 CAUTION DO NOT use field supplied couplings to extend pipes Airflow restriction will occur 6 Install the rain cap and the small diameter pipe assembly into the roof penetration assembly Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting 7 Ceme
113. ount boiler Do not install the boiler in an attic Failure to comply with the above warnings could result in severe personal injury death or substantial property damage 2 Size openings only on the basis of the other appliances in the space No additional air opening free area is needed for the Knight wall mount boiler because it takes its combustion air from outside direct vent installation Wall mounting location Ensure the wall for which the boiler is intended to be mounted is comprised of either cement brick block or wooden studs spaced 16 apart from center Ensure the wall is capable of supporting at least 250 pounds for Models 55 285 and 300 pounds for the 399 Models If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves pumps etc Residential garage installation Precautions Take the following precautions when installing the appliance in a residential garage If the appliance is located in a residential garage it should be installed in compliance with the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are
114. ount boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 5 2 Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET 12 MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER Figure 5 3 Alternate Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET Installation amp Operation Manual WALL MOUNT BOILER D Vertical direct venting continea Vertical termination optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit Both combustion air and vent pipes must attach to the termination kit The termination kit must terminate outside the structure and must be installed as shown in FIG 5 4 Field supplied pipe and fittings are required to complete the installation The required combustion air and vent pipe fittings are listed in Table 3A on page 17 of this manual Vertical termination installation 1 See Section 5 Vertical Direct Venting Determine Location where applicable Figure 5 4 Concentric Vertical Termination COMBUSTION AIR 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF Figure 5 5 Do Not Install U Bend to Rain Cap 2 Cutone
115. our inch vent will reduce Model WHU N L 399 by 0 4 for every 10 feet of vent Ratings have been confirmed by the Hydronics Institute Section of AHRI Model 399 has a thermal efficiency rating Knight wall mount boilers comply with the requirements of CSD 1 Section CW 400 requirements as a temperature operation control The manual reset high limit provided with the Knight wall mount boiler is listed to UL353 E m EQUIPPED X HIGH ALTITUDE 1 f Tea poes 6 Figure A High Altitude Label Location 1 Determine boiler location Installation must comply with Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes The Knight wall mount boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition Before locating the boiler check 1 Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power 2 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avo
116. outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to 1 Check for loose connections blown fuse or service switch off 2 Isboiler water temperature above 200 F 3 Isthermostat set below room temperature the valve causing potential severe personal 4 boiler injury death or substantial property 4 Is gas turned on at meter or boiler damage 5 Isincoming gas pressure less than 4 inches w c A WARNING Knight wall mount boilers are typically shipped ready to fire on natural gas Check If none of the above corrects the problem refer to the Troubleshooting Section of the Knight Wall Mount Service Manual boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 13 In order to Check system and boiler operate on LP gas an orifice MUST BE Check water piping installed Failure to comply could result in severe personal injury death or substantial 1 Check system piping for leaks If found shut down property damage the boiler and repair immediately See WARNINGS on pages 57 and 58 startup regarding failure to repair leaks Check flame and combustion 1 Shut off power at source 2 Vent any remaining air from the system using
117. outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators Each boiler installation must have an air elimination device which will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc during appliance operation for basic service of circulator replacement valves and others Observe a minimum of a 1 4 inch clearance around all un insulated hot water pipes when openings around the pipes are not protected by non combustible materials Low water cutoff device On a boiler installed above radiation level some states and local codes require a low water cutoff device at the time of installation Chilled water system If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle A chilled water medium must be piped in parallel with the heater Freeze protection Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose This includes inhibitors which prevent the glycol from attacking the metallic system components Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level The syste
118. ower at source DO NOT adjust or attempt to measure A WARNING gas valve outlet pressure The gas valve 6 Adjust the temperature set point on the control panel of is factory set for the correct outlet the SMART SYSTEM control module to call for heat pressure This setting is suitable for 7 Observe the gas supply pressure as the burner fires at natural gas and propane requiring no 100 of rated input Percent of burner input will be field adjustment Attempting to alter displayed on the control panel or measure the gas valve outlet pressure 8 Ensure inlet pressure is within specified range could result in damage to the valve causing potential severe personal injury death or substantial property damage Minimum and maximum gas supply pressures are specified in this section of the manual 9 If gas supply pressure is within normal range and no The gas piping must be sized for the proper flow and length adjustments are needed proceed on to Step 11 of pipe to avoid excessive pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load 10 If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas If you experience a pressure drop greater than 1 inch w c pressure to the control the meter regulator or gas line is undersized or in need of service Perform the steps below
119. ower supply before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death NOTICE Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Label all wires prior to disconnection when A CAUTION P i servicing controls Wiring errors can cause improper and dangerous operation Figure 8 1 Hemove Bezel REMOVE BEZEL Installation must comply with National Electrical Code and any other national state provincial or local codes or regulations In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections 1 2 Remove bezel as shown in FIG 8 1 Connect 120 vac power wiring to the line voltage terminal strip in the junction box as shown in FIG 8 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 8 2 52 Installation amp Operation Manual 4 Wire the boiler pump as shown in FIG 8 2 5 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 8 2 6 To activate a system pump wire as shown in FIG 8 2 If the motor is larger than 1 8 hp or 1 8 amps yo
120. peration Manual 11 Operating information Knight wall mount boiler control module SYSTEM Use the control panel FIG 11 1 to set temperatures operating conditions and monitor boiler operation Figure 11 1 Control Panel NAVIGATION DIAL RESET KEY PRESS OR TURN LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key EN 7 WALL MOUNT BOILER Kiso Installation amp Operation Manual 11 Operating information continued Figure 11 2 Status Display Screen BOILER CALL FOR STATUS ovo TEM THHE OPERATIONAL E LI T LI LI INFORMATION D LEFT SELECT KEY RIGHT SELECT KEY NAVIGATION DIAL Status Display Screens Section Display Description The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat START The unit has begun a burn cycle and is checking all safety circuits PREPURGE The unit has initiated a 10 second purge period on a call for heat IGNITION The unit has begun a 4 second spark period to ignite the main burner A The unit has fired and is running at the displayed percentage Boiler Status The call for heat has been satisfied and
121. perature Zoned with Circulators DHW Priority Number of Units Model 2 3 4 51 6 7 8 Required Pipe Sizes PRESSURE 1 REDUCING VALVE USE ZONE 42 ZONE 3 ZONE 4 BACKFLOW oor PREVENTER L ee v F F MAKE UP 1r5 RISJ t FLOW CHECK WATER VALVE SYSTEM SUPPLY TYPICAL SENSOR AIR SEPARATOR ZONE CIRCULATORS TYPICAL EXPANSION TANK il BALL VALVE Li MAY SUBSTITUTE LOW LOSS HEADER TYPICAL J C NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL HSA EET STRAINER MIXING VALVE mE RECOMMENDED TYPICAL DOMESTIC HOT WATER CIRCULATOR BOILER CIRCULATOR PRESSURE RELIEF VALVE r E E E T BOILER 2 BOILER 1 MEMBER 1 LEADER N INDIRECT TEMPERATURE DRAN UNION DHW TANK TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 42 Installation amp Operation Manual 6 Hydronic piping continued Figure 6 8 Single Boiler Multiple Temperature DHW Priority PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE REDUCING VALVE LOOP 1 PREVENTER i 2 PRESSURE gt lt GAUGE MAKE II WATER O DA 2 MIXING VALVES SUPPLY TYPICAL SENSOR AIR SEPARATOR Ay EXPANS
122. pply piping 1 Remove the front access panel and refer to FIG 7 1 to pipe gas to the boiler a Install a field supplied sediment trap drip leg upstream of the boiler gas controls Figure 7 1 Gas Supply Piping MANUAL SHUTOFF VALVE FIELD SUPPLIED UNION GAS SUPPLY DRIP LEG EH 45 um Installation amp Operation Manual WALL MOUNT BOILER 2 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support the weight of the piping Do not attempt to support the weight of the piping with the boiler or its accessories Failure to comply could result in severe personal injury death or substantial property damage 3 Purge all air from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at less than 13 inches w c b Disconnect the boiler and gas valve from the gas supply piping during any pressure testing greater than 13 inches w c Do not check for gas leaks with an open J flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 5 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow F Gas connections continued A WARNING
123. r Flue gas sensor limit rated This sensor monitors the flue gas exit temperature The control module will modulate and shut down the boiler if flue gas temperature gets too hot This protects the flue pipe from overheating Boiler outlet temperature sensor housed with high limit sensor This sensor monitors boiler outlet water temperature system supply If selected as the controlling sensor the control module adjusts boiler firing rate so the outlet temperature is correct Boiler inlet temperature sensor This sensor monitors return water temperature system return If selected as the controlling sensor the control module adjusts the boiler firing rate so the inlet temperature is correct Temperature and pressure gauge field installed not shown Monitors the outlet temperature of the boiler as well as the system water pressure Electronic LCD display The electronic display consists of 4 buttons a navigation dial and a multiple line liquid crystal display Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler Burner not shown Made with metal fiber and stainless steel construction the burner uses pre mixed air and gas and provides a wide range of firing rates Water outlet system supply The water outlet is the water connection for water leaving the boiler and entering the system Water inlet system return The water inlet is the water connection for water entering the
124. r disabled by the installer Error logging The control will hold in memory the last 10 lockouts as well as the last 10 blockings The date and time of the occurrence will be recorded as well Only the 10 most current occurrences of each will be held in memory Boiler temperature regulation Operating temperature target The SMART SYSTEM control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature The target temperature can be set between 32 F and 190 F Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described in this section under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected 66 Installation amp Operation Manual WALL MOUNT BOILER High limit operations The Knight wall mount is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has a maximum set point of 200 F and the manual reset high limit has a maximum set point of 210 F When the outlet temperature exceeds 200 F the automatic high limit action occurs The boiler shuts down until the outlet water temperature cools below 190 F and a 60 second timer has expired If the outlet temperature continues to increase the manual reset high limit action will occur at 210 F High limit test procedure NOTICE Please note that the brackets de
125. rn on an alarm or signal a Building Management System that the boiler is down 54 Installation amp Operation Manual WALL MOUNT BOILER Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 63 Configuration of the Cascade for a detailed explanation of this procedure Connect the system supply sensor and outdoor air sensor if used to the Leader boiler For the Cascade system to work properly the system supply sensor must be installed The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 6 4 and 6 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor see FIG 8 4 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor FIG 8 4 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat Zone
126. ropane Orifice GAS VALVE GROMMET BRASS ORIFICE d NS VENTURI Mounting the boiler See page 9 of this manual for boiler mounting location instructions NOTICE The Knight Wall Mount boiler is not intended for floor installation Mounting to a wood studded wall The wall mount bracket is designed for a stud spacing of 16 inches from center For other stud spacing a solid mounting surface must be provided by the installer A WARNING Po not mount the boiler to a hollow wall Oo Be sure to mount the boiler to the studs only Mount the wall bracket using the 2 1 4 lag bolts provided Make sure the top edge of the bracket is away from the wall Ensure the bracket is level when mounted Extreme care is needed to ensure the bolts are secured in the center of the studs Hang the boiler on the bracket and secure the bottom of the boiler with two 2 additional lag bolts provided Installation amp Operation Manual WALL MOUNT BOILER A WARNING Lhe boiler is too heavy for a single person to ift A minimum of two people is needed for mounting the boiler onto the bracket Mounting to a concrete wall E m Mount the wall bracket using the two 2 wedge anchor bolts provided with the bracket To mount the wedge anchor bolts drill a 1 4 diameter hole 1 1 8 deep and insert anchor Hang the bracket from the anchor and secure with the two nuts provided Make sure the top edge of the bracket
127. rs Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops Kuscer Installation amp Operation Manual WALL MOUNT BOILER 1 Determine boiler location continued When removing a boiler from existing common vent system A DANGER Do not install the Knight wall mount boiler into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage Failure to follow all instructions can result A WARNING i in flue gas spillage and carbon monoxide emissions causing severe personal injury or death At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting sys
128. s valve venturi assembly from the unit FIG 2 3 Using an Allen wrench remove the venturi from the gas valve Locate the propane orifice disk from the conversion kit bag Verify that the stamping on the orifice disk matches the boiler size see Table 2A Place the orifice into the black rubber grommet in the side of the gas valve and secure inside the gas valve see FIG 2 3 Reattach the venturi to the gas valve and reposition the gas valve venturi assembly inside the unit Secure the venturi back to the gas valve FIG 2 3 Reattach the gas pipe to the gas valve Reattach the air intake and coupler and tighten down on the band clamp 2 Prepare boiler 15 14 I5 16 17 A WARNING Reattach the Molex plug to the gas valve Models 55 285 only turn the gas valve power switch to the ON position Model 399 only turn on power at the source After the installation is complete fill out the gas conversion label in the conversion kit bag and affix it to the unit under the boiler rating plate inside the unit Attach the LP caution label in the conversion kit bag to the left side of the unit in the lower left corner Replace the front access cover After converting to LP check combustion per the Start up procedure in Section 10 of this manual Failure to check and verify combustion could result in severe personal injury death or substantial property damage Figure 2 3 Installing P
129. sed on one of three sensors the inlet outlet or system supply sensor The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor The control will automatically switch to the system supply sensor once it is connected If it is desired to base the temperature control on the inlet sensor the appropriate parameter must be changed in the control See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Verify space heat circulator mode The Space Heating Mode controls both the system primary pump if connected and the boiler secondary pump When the SMART SYSTEM control receives a space heating call for heat it turns on the system pump If the boiler is not heating an indirect DHW Domestic Hot Water tank and the set point is not met it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a short period of time The system pump can be programmed to run continuously except during outdoor shutdown If the boiler pump was running it continues to run for a short period of time as well These pump delays are factory set to 30 seconds If different delays are desired the appropriate parameters in the control must be changed See the Knight Wall Mount Service Manual for a detailed explanation of this procedure Adjust set point temperature s NOTICE Please note that the brackets denote screen status
130. signated as the DHW boiler Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its firing rate to maintain this Once the DHW call has been satisfied the Leader control will place that boiler back into the Cascade sequence Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode When DHW is programmed for Zone Mode connect the DHW thermostat or tank sensor to the Leader boiler When a DHW call is received the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point Night Setback operation of the boilers within the Cascade is available Programming of the Night Setback will be done through the Leader boiler Refer to the Knight Wall Mount Service manual for information regarding Night Setback Ramp Delay operation of the boilers as described in the Knight Wall Mount Service Manual is not active when the boilers are part of a Cascade system 67 Kiso Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information Sequence of operation OPE
131. stallation Size the expansion tank for the required system volume and capacity Install an air elimination device on the system supply Install a drain valve at the lowest point of the system This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The safety relief valve is installed at the factory located on the left hand side of the boiler Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve See the piping illustrations included in this section FIG s 6 3 through 6 10 for suggested guidelines in piping the Knight wall mount boiler with either zone valves or circulator pumps NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 33 6 Hydronic piping Near boiler piping components 1 10 Boiler system piping Boiler system piping MUST be sized per the pipe requirements listed in Table 6A Reducing the pipe size can restrict the flow rate through the boiler causing inadvertent high limit shutdowns and poor system performance Flow rates are based on 20 feet of piping 4 90 elbows and 2 fully ported ball valv
132. t is applied f While primer is still wet apply an even coat of 6 Priming and Cementing approved cement to the fitting socket a Handle fittings and pipes carefully to prevent 5 Apply a second coat of cement to the pipe contaminan onol suraces h While the cement is still wet insert the pipe into the b Apply a liberal even coat of primer to the fitting fitting if possible twist the pipe a 1 4 turn as you insert socket it NOTE If voids are present sufficient cement was c Apply a liberal even coat of primer to the pipe end to not applied and joint could be defective approximately 1727 beyond the socket depth 1 Wipe excess cement from the joint removing ring or d Apply second primer coat to the fitting socket beads as it will needlessly soften the pipe Table 3A Vent Pipe and Fittings All vent pipe materials and fittings must comply with the following tem Standards for installation in United States PVC schedule 40 ANSI ASTM D1785 CPVC and PVC venting must be ULC u PVC DWV ANSI ASTM D2665 5636 Certified IPEX is an approved Vent pipe and fittings manufacturer in Canada supplying vent CPVC schedule 40 80 ANSI ASTM F441 material listed to ULC S636 AL29 4C UL1738 ULC S636 Cements amp Primers A E T Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only taking precaution to ensure no sagging occurs of the vent system Connect to the FasNS
133. t not be interchanged with other vent systems or unlisted pipe fittings The 2 and 3 Concentric Vent Kits available from Lochinvar see Section 4 Sidewall Termination Optional Concentric Vent and the 2 and 3 Concentric Vent Kits available from IPEX are approved for use on the Knight wall mount boiler Both kits are listed to the ULC S636 standard for use in Canada A CAUTION Improper installation of PVC or CPVC systems may result in injury or death Installing vent and air piping NOTICE Use only cleaners primers and solvents that are approved for the materials which are gt joined together 1 Work from the boiler to vent or air termination Do not exceed the lengths given in this manual for the air or vent piping 2 Cut pipe to the required lengths and deburr the inside and outside of the pipe ends 3 Chamfer outside of each pipe end to ensure even cement distribution when joining 4 Clean all pipe ends and fittings using a clean dry rag Moisture will retard curing and dirt or grease will prevent adhesion Installation amp Operation Manual WALL MOUNT BOILER General venting continued 5 Dry fit vent or air piping to ensure proper fit up before e While primer is still wet apply an even coat of assembling any joint The pipe should go a third to approved cement to the pipe equal to the depth of two thirds into the fitting to ensure proper sealing after the fitting socket cemen
134. t once to prevent makeup water A CAUTION 0 not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler CAUTION patent medicines Serious damage to the boiler personnel and or property may result Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 3 Y WALL MOUNT BOILER Installation amp Operation Manual The Knight Wall Mount Boiler How it works 1 10 11 12 13 14 Stainless steel heat exchanger Allows system water to flow around specially designed tubes for maximum heat transfer while providing protection against flue gas corrosion Combustion chamber access cover Allows access to the combustion exchanger side of the heat Blower The blower pulls in air and gas through the venturi item 5 Air and gas mix inside the blower and are pushed into the burner where they burn inside the combustion chamber Gas valve The gas valve senses the negative pressure created by the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing Venturi The venturi controls air and gas flow into the burne
135. tem are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so
136. tend more than 24 inches vertically outside the building c Do not terminate closer than 4 feet horizontally from any electric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet horizontally 6 Locate terminations so they are not likely to be damaged by foreign objects or subject to buildup of leaves or sediment EH 22 UG WALL MOUNT BOILER Installation amp Operation Manual Figure 4 2A Clearance to Gravity Air Inlets VENT AIR TERMINATION Figure 4 2B Alternate Clearance to Gravity Air Inlets w Field Supplied Fittings 22 Z BIRD A SCREEN 4 TYPICAL Figure 4 3A Clearance to Forced Air Inlets IF LESS THAN 10 VENT AIR TERMINATION gt MIN FORCED AIR INLET 7 MIN ABOVE ANY iia afar PUBLIC WALKWAY pe mar es Figure 4 3B Alternate Clearance to Forced Air Inlets w Field Supplied Fittings IF LESS THAN 10 FORCED AIR INLET BIRD SCREEN go TYPICAL 7 MIN ABOVE ANY PUBLIC WALKWAY Installation amp Operation Manual WALL MOUNT BOILER 4 Sidewall direct venting continues Prepare wall penetrations 1 Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes Air pipe penetration a Cut hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration
137. that the combustion air will not contain any of the contaminants in Table 1A page 10 Contaminated combustion air will damage the boiler resulting in possible severe personal injury death or substantial property damage Do not pipe combustion air near a swimming pool for example Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants 9 1 Determine boiler location When using an existing vent system to install a new boiler A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Check the following venting components before installing Material For materials listed for use with this appliance see Section 3 General Venting Table 3A For stainless steel venting an adapter of the same manufacturer Table 3B must be used at the flue collar connection Size To ensure proper pipe size is in place see Table 3C Check to see that this size is used throughout the vent system Manufacturer For a stainless steel application you must use only the listed manufacturers and their type product listed in Table 3A for CAT IV positive pressure venting with flue producing condensate Supports Non combustible supports must be in place allowing a minimum 1 4 rise per foot The supports should adequately prevent sagging and vertical slippage by distributing the vent system weight
138. the outlet temperature too high the control module modulates and shuts the boiler down This ensures boiler shutdown in the event of low water or low flow conditions m 2 Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff Consult local jurisdiction to determine A low water cutoff is available from the factory WTR20009 Installation amp Operation Manual WALL MOUNT BOILER 11 Operating information continued Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the Knight Wall Mount Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Cascade When multiple boilers are installed they can be wired together in a cascade sequence A maximum of eight boilers can be controlled from a single control In this application one boiler would be designated as the Leader control and all others would be designated as Member controls The Leader control can be programmed to use Lead Lag or Efficiency Optimization control methods Once the Leader boiler receives a call for heat from a room thermostat BMS or Modbus the control will determine what the set point will be If outdoor air reset is desired connect the outdoor air sensor to the terminals on the
139. u cannot reach your gas supplier call the fire department Installation and service must performed by a qualified installer service agency or the gas supplier Installation amp Operation Manual WALL MOUNT BOILER When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water e Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired a
140. u must isolate with a relay Figure 8 2 Line Voltage Field Wiring Connections BK BK BK G LINE GROUND NEUTRAL DOMESTIC BOILER SYSTEM 120V SUPPLY HOT WATER PUMP PUMP SERVICE SWITCH Low voltage connections 1 Route all low voltage wires through the knockouts in the bottom front right side just under the control panel as shown in FIG 8 3 2 Connect low voltage wiring to low voltage connection board as shown in FIG 8 4 on page 55 of this manual and the boiler wiring diagram Figure 8 3 Routing Field Wiring LINE VOLTAGE JUNCTION BOX LOW VOLTAGE CONNECTION BOARD LINE VOLTAGE KNOCKOUTS LOW VOLTAGE KNOCKOUTS Field wiring continues Thermostat l Connect the room thermostat or end switch isolated contact only to heat loop demand 1 2 or 3 as shown in FIG 8 4 Install the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor l Mount the sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources Route sensor
141. ulically separated from the system Please note that these illustrations are meant to show system piping concept only the installer is responsible NOTICE e for all equipment and detailing required by local codes 46 WALL MOUNT BOILER Installation amp Operation Manual 6 Hydronic piping continea Figure 6 12 Single Boiler Full Flow Single Temperature Zoned with Circulators DHW Piped as a Zone PRESSURE PRESSURE REDUCING VALVE GAUGE BACKFLOW PREVENTER De Pe d 9 TYPICAL MAKE UP r3 fT WATER SYSTEM SUPPLY SENSOR ZONE CIRCULATORS AIR SEPARATOR TYPICAL EXPANSION TANK Y STRAINER DOMESTIC is H HOT WATER WATER z CIRCULATOR OUT DRAIN POINT I TERIGA m BALL VALVE ANTI SCALD TYPICAL MIXING VALVE COLD WATER IN PRESSURE H RELIEF VALVE UNION TYPICAL WB ue 2 BOILER 8 0 INDIRECT TEMPERATURE DRAIN DHW TANK PRESSURE GAUGE NOTICE It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at all times during boiler operation If the minimum flow requirements cannot be met at any time the boiler must be hydraulically separated from the system NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 47 Gas connections Connecting gas su
142. when checking inlet gas supply 12 Shut off the gas supply at the manual gas valve in the gas piping to the appliance 11 Shut off power at source 1 Shut off power at source 13 Remove the manometer from the pressure tap on top of the gas valve Re tighten the set screw inside the pressure tap 2 Shut off gas supply at the manual gas valve in the gas piping to the appliance 50 F Gas connections continued 1 When re tightening the set screw be sure to tighten securely to prevent gas leaks Do not check for gas leaks with an open flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 14 Turn on the gas supply at the manual gas valve 15 Turn on power at source 16 Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat 17 Check burner performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics Figure 7 3 Inlet Gas Supply Check LOOSEN SET SCREW ONE 1 FULL TURN THEN PLACE TUBING OVER PRESSURE TAP Kuscer Installation amp Operation Manual Gas Pressure The gas pressure must remain between
143. wires through a knockout in the bottom front right side of the boiler see FIG 8 3 Connect outdoor temperature sensor FIG 8 4 to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight wall mount boiler If fixed temperature operation is required do not install outdoor sensor DHW thermostat 1 connection board DHW Tank Sensor below the tank thermostat is ignored Connect storage indirect water heater DHW thermostat FIG 8 4 to the DHW thermostat terminals on the If a tank sensor is connected see DHW tank sensor 1 By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6 F 3 C below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point The tank sensor included with the Lochinvar Squire Indirect DHW tank TST20015 is the only sensor suitable for use with the SMART SYSTEM control Connect the sensor leads to the Tank Sensor terminals on the Low Voltage Connection Board Consult the tank manufacturer for application and performance when used with any other indirect tank Failure to use the correct sensor ma A WARNING iade d result in the tank temperature being either above or below the set point Failure to consult the manufacturer
144. xisting venting system is clean and free from bw particulate contamination that will harm this appliance and Xt d cause increased nuisance calls or maintenance See Table 1A EXISTING on page 10 for a list of corrosive contaminants and sources y SEAL A Two example scenarios of a concentric venting arrangement shown for illustrative purposes in FIG s 5 8 5 9 CAP FLUE OUTLET Table 5A Alternate Vertical Concentric Vent Chase Sizes Minimum Existing Vent Air Inlet Size Vent Chase Size el Et 7 For concept illustration only Individual installations may vary due to job site specific equipment 31 WALL MOUNT BOILER Kuce Installation amp Operation Manual 5 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase FLUE EXHAUST AIR INLET SEAL SEAL FLUE OUTLET For concept illustration only Individual installations may vary due to job site specific equipment 32 6 Hydronic piping System water piping methods The Knight wall mount is designed to function in a closed loop pressurized system not less than 12 psi A temperature and pressure gauge is included to monitor system pressure and
145. zing temperatures Use only plastic tubing or piping as a condensate drain line FIG 9 1 Installation amp Operation Manual Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement NOTICE To allow for proper drainage on large horizontal runs a second line vent may be required and tubing size may need to increase to 1 inch The condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manner condensate can exit from the boiler tee resulting in potential water damage to property 6 A condensate removal pump is required if the boiler is below the drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired in series with the blocked drain switch inside the boiler see FIG 10 1 on page 58 Figure 9 1 Condensate Disposal 3 8 CONDENSATE _ REMOVABLE FOR CLEANING TRAP SECURE INTO CONDENSATE DRAIN STAND PIPE CONDENSATE DRAIN STAND PIPE CONDENSATE DRAIN CONNECTION

continued - Lochinvar

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