Lochinvar Wall Mount Boiler Wh 55 399 Users Manual I O Rev H

WH 55-399 to the manual 08959e06-5362-414a-a7e2-1244aa81bc5f

2015-02-09

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WH-I-O Rev H

Installation & Operation Manual

Models: WH 55 - 399

This manual must only be used by

a qualified heating installer / service

technician. Read all instructions,

including this manual and the Knight

Wall Mount Service Manual, before

installing. Perform steps in the order

given. Failure to comply could result

in severe personal injury, death, or

substantial property damage.

 WARNING

Save this manual for future reference.

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.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

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.

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3

THE KNIGHT WALL MOUNT BOILER -- HOW IT WORKS . 4-5

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. DETERMINE BOILER LOCATION

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . . 9

Wall Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Residential Garage Installation . . . . . . . . . . . . . . . . . . . . . 9

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prevent Combustion Air Contamination . . . . . . . . . . . . . . . 9

Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 10

Using an Existing Vent System to Install a New Boiler . . 10

Removing a Boiler from Existing Common Vent . . . . . . . 11

2. PREPARE BOILER

Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . . 12

Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. GENERAL VENTING

Direct Venting Options ..................................................... 14

Install Vent and Combustion Air Piping ........................... 15

Requirements for Installation in Canada .......................... 16

Sizing ............................................................................... 16

Materials ............................................................................ 17

Optional Room Air ............................................................ 18

PVC/CPVC ....................................................................... 19

Polypropylene ................................................................... 20

Stainless Steel Vent ......................................................... 21

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 22-28

Determine Location ................................................ 22-24

Prepare Wall Penetrations .......................................... 24

Multiple Vent/Air Terminations ......................................... 25

Sidewall Termination - Optional Concentric Vent ....... 26-28

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical .................................... 29-30

Determine Location ..................................................... 29

Prepare Roof Penetrations ......................................... 29

Multiple Vent/Air Terminations .................................... 30

Vertical Termination - Optional Concentric Vent ... 30-31

Alternate Vertical Concentric Venting ......................... 32

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . . 33

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 33

Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . . 34

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . . 35

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Variable Speed Pump Option . . . . . . . . . . . . . . . . . . . . . 37

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 48

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 49

Natural Gas Supply Pressure Requirements . . . . . . . 49

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 49

Propane Supply Pressure Requirements . . . . . . . . . . 49

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 51

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 52

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-63

11. OPERATING INFORMATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 68-69

Knight Wall Mount Boiler Control Module . . . . . . . . . . . . 70

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . 71-73

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . 74-77

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

Installation & Operation Manual

Please read before proceeding

Installer – Read all instructions,

including this manual and the Knight

Wall Mount Service Manual, before

installing. Perform steps in the order

given.

User – This manual is for use only

by a qualified heating installer/

service technician. Refer to the User’s

Information Manual for 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.

Failure to adhere to the guidelines on this

page can result in severe personal injury,

death, or substantial property damage.

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 –

• Thoroughly flush the system (without boiler

connected) to remove sediment. The high-efficiency

heat exchanger can be damaged by build-up or

corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life.

Mineral buildup in the heat exchanger reduces heat

transfer, overheats the stainless steel heat exchanger,

and causes failure. Addition of oxygen carried in by

makeup water can cause internal corrosion in system

components. Leaks in boiler or piping must be repaired

at once to prevent makeup water.

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.

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.

If the information in this manual is not

followed exactly, a fire or explosion may

result causing property damage, personal

injury or loss of life.

This appliance MUST NOT be installed

in any location where gasoline or

flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a near by phone. Follow the

gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the fire department.

• Installation and service must be

performed by a qualified installer,

service agency, or the gas supplier.

 WARNING

NOTICE

 WARNING

Do 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.

 CAUTION

 CAUTION Do not use “homemade cures” or “boiler

patent medicines”. Serious damage to

the boiler, personnel, and/or property

may result.

Installation & Operation Manual

The Knight Wall Mount Boiler - How it works...

1. Stainless steel heat exchanger

Allows system water to flow around specially designed

tubes for maximum heat transfer, while providing

protection against flue gas corrosion.

2. Combustion chamber access cover

Allows access to the combustion side of the heat

exchanger.

3. Blower

The blower pulls in air and gas through the venturi (item

5). Air and gas mix inside the blower and are pushed into the

burner, where they burn inside the combustion chamber.

4. 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.

5. Venturi

The venturi controls air and gas flow into the burner.

6. Flue gas sensor (limit rated)

This sensor monitors the flue gas exit temperature. The control

module will modulate and shut down the boiler if flue gas

temperature gets too hot. This protects the flue pipe from

overheating.

7. 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.

8. 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.

9. Temperature and pressure gauge (field installed, not

shown)

Monitors the outlet temperature of the boiler as well as the

system water pressure.

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial

and a multiple line liquid crystal display.

11. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the

boiler.

12. Burner (not shown)

Made with metal fiber and stainless steel construction,

the burner uses pre-mixed air and gas and provides a

wide range of firing rates.

13. Water outlet (system supply)

The water outlet is the water connection for water leaving the

boiler and entering the system.

14. Water inlet (system return)

The water inlet is the water connection for water entering the

boiler from the system.

15. 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.

16. SMART SYSTEM Control Module

The SMART SYSTEM Control responds to internal and

external signals and controls the blower, gas valve, and pumps

to meet the heating demand.

17. Air intake adapter

Allows for the connection of the PVC air intake pipe to

the boiler.

18. High voltage junction box

The junction box contains the connection points for the line

voltage power and all pumps.

19. Low voltage connection board

The connection board is used to connect external low voltage

devices.

20. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage

connection board.

21. Condensate drain connection

Connects the condensate drain line.

22. Access door

Provides access to all internal components.

23. Ignition electrode

Provides direct spark for igniting the burner.

24. Flame inspection window

The quartz glass window provides a view of the burner

surface and flame.

25. Gas shutoff switch

An electrical switch designed to cut power to the gas valve to

prevent releasing any gas.

26. High limit sensor (housed with outlet sensor)

Device that monitors the outlet water temperature. If the

temperature exceeds its setting, it will break the control circuit,

shutting the boiler down.

27. Relief valve

Protects the heat exchanger from an over pressure condition.

The relief valve provided with the unit is set at 30 psi.

28. Flame sensor

Used by the control module to detect the presence of burner

flame.

29. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

30. Transformer

The transformer provides 24V power to the integrated control.

31. ModBus

The optional ModBus option provides intelligent building

system communications.

32. On/Off switch

The On/Off switch is used to turn 120 VAC on and off to the

unit.

33. Manual air vent

Allows for removal of trapped air from the heat exchanger.

Installation & Operation Manual

Front View

IMG00161

Left Side (inside unit)

IMG00162

19 31

Right Side (inside unit)

The Knight Wall Mount Boiler - How it works... (continued)

IMG00117

FRONT OF UNIT

Bottom View

Models 55 - 399

Installation & Operation Manual

Ratings

Notes:

1. As an Energy Star Partner, Lochinvar has determined that

Knight wall mount boilers meet the Energy Star guidelines

for energy efficiency.

2. The ratings are based on standard test procedures prescribed

by the United States Department of Energy.

3. Net AHRI ratings are based on net installed radiation of

sufficient quantity for the requirements of the building

and nothing need be added for normal piping and pickup.

Ratings are based on a piping and pickup allowance of 1.15.

4. Knight wall mount boilers require special gas venting. Use

only the vent materials and methods specified in the Knight

Wall Mount Installation and Operation Manual.

5. Standard Knight wall mount boilers are equipped to operate

from sea level to 4,500 feet only with no adjustments. The

boiler will de-rate by 4% for each 1,000 feet above sea level

up to 4,500 feet.

6. High altitude Knight wall mount boilers are equipped

to operate from 3,000 to 12,000 feet only with no field

adjustments. The boiler will de-rate by 2% for each 1,000

feet above 3,000 feet. High altitude models are manufactured

with a different control module for altitude operation, but

the operation given in this manual remains the same as the

standard boilers. A high altitude label (as shown in FIG. A)

is also affixed to the unit.

Maximum allowed working pressure is located on the rating plate.

NOTICE

Knight Wall Mount Boiler

AHRI Rating

Model Number

Note: Change

“N” to “L” for

L.P. gas models.

Input

MBH

(Note 5)

Min Max

Heating

Capacity

MBH

(Note 2, 8)

Net

AHRI

Ratings

Water,

MBH

(Note 3, 8)

AFUE

(Note 1, 8)

WHN055 11 55 51 44 96

WHN085 17 85 79 69 96

WHN110 22 110 102 89 96

WHN155 31 155 144 125 96

WHN199 40 199 186 162 96

WHN285 57 285 265 230 96

WHN399 80 399 379 330 95

7. The Knight Wall Mount boiler input rate, on some models,

is reduced for vent lengths beyond the minimum. Two inch

vent will reduce Models WH(N,L) 055, WH(N,L) 085 and

WH(N,L)110 by 0.6%, 0.94%, and 1.2% for every 10 feet

of vent. Three inch vent will reduce Models WH(N,L)155,

WH(N,L)199 and WH(N,L) 285 by 0.3%, 0.5%, and 0.6%

for every 10 feet of vent. Four inch vent will reduce Model

WH(N,L) 399 by 0.4% for every 10 feet of vent.

8. Ratings have been confirmed by the Hydronics Section of

AHRI. Model 399 has a thermal efficiency rating.

9. Knight wall mount boilers comply with the requirements

of CSD-1 Section CW-400 requirements as a temperature

operation control. The manual reset high limit provided

with the Knight wall mount boiler is listed to UL353.

Other Specifications

Boiler Water

Content

Gallons

Water

Connections

Gas

Connections

Vent/Air

Size

(Note 4)

2.5 1" 1/2" 2"

3.5 1" 1/2" 3"

5.0 1 1/4" 1/2" 3"

6.5 1 1/2" 3/4" 4"

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000FT TO 12,000FT

ASME

Installation & Operation Manual

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.

Failure to keep boiler area clear and free

of combustible materials, gasoline, and

other flammable liquids and vapors can

result in severe personal injury, death, or

substantial property damage.

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.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations

cannot be avoided, it is recommended that a suitable

drain pan, adequately drained, be installed under the

appliance. The pan must not restrict combustion air

flow. Under no circumstances is the manufacturer to be

held responsible for water damage in connection with

this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

4. The Knight wall mount boiler must be installed so

that gas control system components are protected from

dripping or spraying water or rain during operation or

service.

5. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger

cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system

and boiler to freeze and leak.

 WARNING

NOTICE

1 Determine boiler location

 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 93%. Do not

install the appliance where condensation

may form on the inside or outside of the

appliance, or where condensation may fall

onto the appliance.

Failure to install the appliance indoors

could result in severe personal injury,

death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance

minimums.

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.

Closet and alcove installations

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.

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.

 WARNING

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.

Model Room Volume

(in cubic feet)

55 - 85 90

110 - 285 108

399 178

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.

1/4" MINIMUM CLEARANCE

AROUND HOT WATER PIPES

1" MINIMUM CLEARANCE

ROUND VENT PIPE

OPEN FRONT

LEFT

0" MINIMUM

RIGHT

0" MINIMUM

FRONT

6" MINIMUM

BOTTOM

0" MINIMUM

TOP

6" MINIMUM

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24”

BOTTOM: 24”

LEFT SIDE: 12”

Figure 1-2 Alcove Installation - Minimum Required Clearances

1/4" MINIMUM CLEARANCE

AROUND HOT WATER PIPES

1" MINIMUM CLEARANCE

AROUND VENT PIPE

CLOSED DOOR

VENTILATING

AIR OPENING*

*AREA OF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT

WITH A MINIMUM OF 100 SQ. INCHES.

VENTILATING

AIR OPENING*

TOP

6" MINIMUM

LEFT

0" MINIMUM

BOTTOM

0" MINIMUM

RIGHT

0" MINIMUM

FRONT

6" MINIMUM

RECOMMENDED SERVICE CLEARANCES:

FRONT: 24”

BOTTOM: 24”

LEFT SIDE: 12”

Figure 1-1 Closet Installation - Minimum Required Clearances

 WARNING

Note: Service clearances are recommendations only.

 WARNING

1 Determine boiler location

Installation & Operation Manual

For closet installations, CPVC,

polypropylene or stainless steel

vent material MUST BE used in

a closet structure due to elevated

temperatures. Failure to follow

this warning could result in fire,

personal injury, or death.

For alcove installations, CPVC,

polypropylene or stainless steel

vent material MUST BE used in

an alcove structure due to elevated

temperatures. Failure to follow

this warning could result in fire,

personal injury, or death.

Installation & Operation Manual

Provide air openings to room:

Knight wall mount boiler alone in boiler room

1. No air ventilation openings into the boiler room are

needed when clearances around the Knight wall mount

boiler are at least equal to the SERVICE clearances

shown in FIG.’s 1-1 and 1-2. For spaces that do NOT

supply this clearance, provide two openings as shown

in FIG. 1-1. Each opening must provide one square

inch free area per 1,000 Btu/hr of boiler input.

Knight wall mount boiler in same space with other

gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA

B149.1 (Canada) to size/verify size of the combustion/

ventilation air openings into the space.

The space must be provided with

combustion/ventilation air openings

correctly sized for all other appliances

located in the same space as the Knight

wall mount boiler.

Do not install the boiler in an attic.

Failure to 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 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 is

considered, see Section 3, General Venting. Note prevention of

combustion air contamination below when considering vent/

air termination.

Vent and air must terminate near one another and 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 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.

 WARNING

1 Determine boiler location (continued)

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other

similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

1 Determine boiler location

Installation & Operation Manual

Failure to follow all instructions can result

in flue gas spillage and carbon monoxide

emissions, causing severe personal injury

or death.

 WARNING

When using an existing vent system to

install a new boiler:

 WARNING 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.

Check the following venting components before installing:

• Material - For materials listed for use with this appliance,

see Section 3 - General Venting. For polypropylene or

stainless steel venting, an adapter of the same

manufacturer must be used at the flue collar connection.

• Size - To ensure proper pipe size is in place, see Table 3A.

Check to see that this size is used throughout the vent

system.

• Manufacturer - For a stainless steel or polypropylene

application, you must use only the listed manufacturers

and their type product listed in Tables 3E and 3G for CAT

IV positive pressure venting with flue producing

condensate.

• Supports - Non-combustible supports must be in place

allowing a minimum 1/4" rise per foot. The supports

should adequately prevent sagging and vertical slippage,

by distributing the vent system weight. For additional

information, consult the vent manufacturer’s

instructions for installation.

• Terminations - Carefully review Sections 3 through 5 to

ensure requirements for the location of the vent and air

terminations are met and orientation of these fit the

appropriate image from the Sidewall or Vertical

options listed in the General Venting Section. For

stainless steel vent, only use terminations listed in Table

3H 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 polypropylene and stainless steel vent, seal and connect

all pipe and components as specified by the vent manufacturer

used; with PVC/CPVC vent, see the Installing Vent or Air

Piping Section on page 19.

When removing a boiler from existing

common vent system:

Do not install the Knight wall mount

boiler into a common vent with any other

appliance. This will cause flue gas spillage or

appliance malfunction, resulting in possible

severe personal injury, death, or substantial

property damage.

Failure to follow all instructions can result

in flue gas spillage and carbon monoxide

emissions, causing severe personal injury or

death.

At the time of removal of an existing boiler, the following steps

shall be followed with each appliance remaining connected

to the common venting system placed in operation, while the

other appliances remaining connected to the common venting

system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion, or other deficiencies, which

could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in

which the appliances remaining connected to the common

venting system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected to

the common venting system. Turn on any exhaust fans,

such as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance

will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance remaining

connected to the common venting system properly vents

when tested as outlined herein, return doors, windows,

exhaust fans, fireplace dampers, and any other gas-burning

appliance to their previous conditions of use.

 DANGER

 WARNING

g. Any improper operation of the common venting system

should be corrected so the installation conforms with

the National Fuel Gas Code, ANSI Z223.1/NFPA 54

and/or CAN/CSA B149.1, Natural Gas and Propane

Installation Code. When resizing any portion of the

common venting system, the common venting system

should be resized to approach the minimum size as

determined using the appropriate tables in Part 11 of

the National Fuel Gas Code, ANSI Z223.1/NFPA and/or

CAN/CSA B149.1, Natural Gas and Propane Installation

Code.

1 Determine boiler location (continued)

Installation & Operation Manual

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).

Do not drop the boiler or bump the jacket

on the floor or pallet. Damage to the

boiler can result.

The gas conversion procedure should

be accomplished BEFORE the boiler is

installed. For a boiler already installed,

you must turn off gas supply, turn off

power, and allow the boiler to cool before

proceeding. You must also completely

test the boiler after conversion to verify

performance as described under Start-up,

Section 10 of this manual.

You must install the propane orifice to fire

the Knight wall mount boiler on propane.

Verify when installing that the orifice size

marking matches boiler size (Table 2A).

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

DO NOT DISCARD-

WILL BE NEEDED TO

SECURE THE BOILER

TO THE WALL

REMOVE SHIPPING

[WALL] BRACKET

Figure 2-1 Boiler Mounted on Shipping Pallet

Gas conversions

LP Conversion Table

Model LP Orifice Stamping

55 055

85 085

110 110

155 155

199 199

285 H285

399 8.0

NOTICE

 WARNING

Table 2A LP Conversion Table

Figure 2-2 Gas Valve Power Switch & Venturi Removal

REMOVE THE SCREWS SECURING

THE GAS VALVE VENTURI TO THE

INLET OF THE COMBUSTION

BLOWER

7. Using an Allen wrench, remove the screws securing the gas

pipe to the gas valve. Remove the gas valve venturi assembly

from the unit (FIG. 2-3).

8. Using an Allen wrench, remove the venturi from the gas

valve.

9. Locate the propane orifice disk from the conversion kit bag.

Verify that the stamping on the orifice disk matches the

boiler size (see Table 2A).

10. Place the orifice into the black rubber grommet in the side of

the gas valve and secure inside the gas valve (see FIG. 2-3).

11. Reattach the venturi to the gas valve and reposition the gas

valve venturi assembly inside the unit. Secure the venturi

back to the gas valve (FIG. 2-3).

12. Reattach the gas pipe to the gas valve. Reattach the air intake

and coupler and tighten down on the band clamp.

1. Remove the front access cover from the unit (no tools

required for removal).

2. Models 55 - 285 only, locate the power switch on the gas

valve and turn the power switch to the “OFF” position

(FIG. 2-2).

3. Model 399 only, shut off power at the source.

4. Disconnect the Molex plug from the gas valve.

5. Using a 5/16" nut driver, loosen the band clamp securing the

air intake coupler to the gas valve venturi. Remove the air

intake pipe and coupler from the gas valve venturi.

6. Using an Allen wrench, remove the screws securing the

gas valve venturi to the inlet of the combustion blower

(FIG. 2-2).

Installation & Operation Manual

2 Prepare boiler (continued)

FASTENERS

APPROPRIATE

FOR WALL TYPE

QTY: 4

MOUNTING BRACKET

(FACTORY SUPPLIED)

WALL:

WOOD OR METAL STUDS ON

16" CENTERS -OR-

MASONRY / POURED CONCRETE

Figure 2-4 Mounting the Boiler

VENTURI

GAS VALVE

GROMMET

BRASS ORIFICE

SCREWS

Figure 2-3 Installing Propane Orifice

13. Reattach the Molex plug to the gas valve.

14. Models 55 - 285 only, turn the gas valve power switch to

the “ON” position.

15. Model 399 only, turn on power at the source.

16. After the installation is complete, fill out the gas conversion

label (in the conversion kit bag) and affix it to the unit

under the boiler rating plate inside the unit. Attach the

LP caution label (in the conversion kit bag) to the left side

of the unit in the lower left corner.

17. Replace the front access cover.

2. Mount the wall bracket using the 2 1/4" lag bolts

provided. Make sure the top edge of the bracket is away

from the wall. Ensure the bracket is level when mounted.

Extreme care is needed to ensure the bolts are secured in

the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of

the boiler with two (2) additional lag bolts provided.

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.

 WARNING The boiler is too heavy for a single person

to lift. A minimum of two people is needed

for mounting the boiler onto the bracket.

2. Mount the wall bracket using two (2) field supplied toggle

bolts capable of supporting 100 pounds each. Ensure the

top edge of the bracket is away from the wall. Ensure the

bracket is level when mounted. Extreme care is needed to

ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the

boiler with two (2) field supplied toggle bolts.

 WARNING Do not mount the boiler to a hollow wall. Be

sure to mount the boiler to the studs only.

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:

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.

 WARNING Do not mount the boiler to a hollow wall.

Be sure to mount the boiler to the studs

only.

Mounting to a concrete wall:

1. Mount the wall bracket using the two (2) wedge anchor

bolts provided with the bracket. To mount the wedge

anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and

insert anchor. Hang the bracket from the anchor and secure

with the two nuts provided. Make sure the top edge of the

bracket is away from the wall. Ensure bracket is level when

mounted. Extreme care is needed to ensure the bolts are

secured in the center of the studs.

Note: If wall thickness does not allow a 1 1/8" deep hole,

field supplied hardware suitable for the application should be

provided.

2. Hang the boiler on the bracket and secure the bottom of the

boiler with two (2) remaining anchors, following the

instructions above.

 WARNING The boiler is too heavy for a single person to

lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

 WARNING After converting to LP, check combustion

per the Start-up procedure in Section 10

of this manual. Failure to check and

verify combustion could result in severe

personal injury, death, or substantial

property damage.

 WARNING The boiler is too heavy for a single person to

lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

3 General venting

Installation & Operation Manual

Figure 3-1 Two-Pipe Sidewall Termination - See page

22 for more details Figure 3-2 PVC/CPVC Concentric Sidewall

Termination - See page 26 for more details

Direct venting options - Sidewall Vent

Figure 3-3 Two-Pipe Vertical

Termination - See page 29 for

more details

Figure 3-4 PVC/CPVC Concentric

Vertical Termination - See page 30

for more details

Figure 3-5 Vertical Vent, Sidewall Air

- See page 18 for more details

Installation & Operation Manual

3 General venting

This appliance requires a special venting

system. Use only approved stainless steel,

PVC, CPVC or polypropylene pipe and

fittings listed in Tables 3D, 3E, and 3G for

vent pipe, and fittings. Failure to comply

could result in severe personal injury,

death, or substantial property damage.

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.

Install vent and combustion air piping

 DANGER The Knight wall mount boiler must be

vented and supplied with combustion and

ventilation air as described in this section.

Ensure the vent and air piping and the

combustion air supply comply with these

instructions regarding vent system, air

system, and combustion air quality. See

also Section 1 of this manual.

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.

 WARNING

NOTICE

 WARNING For closet and alcove installations, CPVC,

polypropylene or stainless steel material

MUST BE used in a closet/alcove structure.

Failure to follow this warning could result

in fire, personal injury, or death.

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-6) - Used to

provide combustion air directly to the unit from outdoors.

A fitting is provided on the unit for final connection.

Combustion air piping must be supported per guidelines

listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

2. Vent Connector (FIG.'s 3-7 thru 3-9) - Used to provide a

passageway for conveying combustion gases to the

outside. A transition fitting is provided on the unit for

final connection. Vent piping must be supported per the

National Building Code, Section 305, Table 305.4 or as

local codes dictate.

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.

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.

You must also install air piping from outside to the boiler

air intake adapter unless following the Optional Room

Air instructions on page 18 of this manual. The resultant

installation is direct vent (sealed combustion).

 WARNING DO NOT mix components from different

systems. The vent system could fail,

causing leakage of flue products into the

living space. Mixing of venting materials

will void the warranty and certification of

the appliance.

 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.

Improper installation of venting systems

may result in injury or death.

 CAUTION

Follow the instructions in Section 1, page

11 of this manual when removing a boiler

from an existing vent system.

NOTICE

AIR

Figure 3-6 Near Boiler Air Piping

3 General venting

Installation & Operation Manual

Model 2" Max Vent/

Air 3" Max Vent/

Air 4" Max Vent/

Air

55 *80 feet 100 feet N/A

85 *50 feet 100 feet N/A

110 *40 feet 100 feet N/A

155 N/A 100 feet N/A

199 N/A 100 feet N/A

285 N/A *50 feet 100 feet

399 N/A N/A 100 feet

Requirements for installation in

Canada

1. Installations must be made with a vent pipe system

certified to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the

appliance flue outlet must be readily accessible for visual

inspection.

3. The components of the certified vent system must not be

interchanged with other vent systems or unlisted

pipe/fittings. For concentric vent installations, the inner

vent tube must be replaced with field supplied certified vent

material to comply with this requirement.

4. The 2" and 3" Concentric Vent Kits available from

Lochinvar (see Section 4 – Sidewall Termination – Optional

Concentric Vent) and the 2" and 3" Concentric Vent Kits

available from IPEX are approved for use on the Knight

wall mount boiler. Both kits are listed to the ULC-S636

standard for use in Canada.

When determining equivalent combustion air and vent

length, add 5 feet for each 90° elbow and 3 feet for each

45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2)

45° elbows + (1) concentric vent kit (CVK3003) = 49

equivalent feet of piping.

The appliance output rating will reduce

by up to 1.5% for each 25 feet of vent

length.

NOTICE

Model Kit Number Equivalent Vent

Length

55 - 110 CVK3008 3 feet

155 - 199 CVK3003 3 feet

285 - 399 CVK3007 3 feet

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Sizing

The Knight boiler uses model specific combustion air intake and

vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

Increasing or decreasing combustion air or

vent piping sizes is not authorized.

NOTICE

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.

* WARNING

Note: The minimum combustion air and vent piping

length is 12 equivalent feet.

Installation & Operation Manual

3 General venting (continued)

Materials

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, Polypropylene or ABS

Dryer Vent or Sealed Flexible Duct (not recommended

for rooftop air inlet)

Galvanized steel vent pipe with joints and seams sealed as

specified in this section.

Type “B” double-wall vent with joints and seams sealed as

specified in this section.

AL29-4C, stainless steel material to be sealed to

specification of its manufacturer.

*Plastic pipe may require an adapter (not provided) to

transition between the air inlet connection on the appliance

and the plastic air inlet pipe.

 WARNING Using air intake materials other than

those specified can result in personal

injury, death or property damage.

NOTICE 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.

Sealing of Type “B” double-wall vent material or galvanized

vent pipe material used for air inlet piping on a sidewall or

vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either

Aluminum Foil Duct Tape meeting UL Standard 723 or

181A-P or a high quality UL Listed silicone sealant such as

those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of

horizontal runs.

c. Secure all joints with a minimum of three (3) sheet metal

screws or pop rivets. Apply Aluminum Foil Duct Tape or

silicone sealant to all screws or rivets installed in the vent

pipe.

d. Ensure that the air inlet pipes are properly supported.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and

sealed with the pipe manufacturer’s recommended solvents

and standard commercial pipe cement for the material used.

The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe

should use a silicone sealant to ensure a proper seal at the

appliance connection and the air inlet cap connection. Dryer

vent or flex duct should use a screw type clamp to seal the vent

to the appliance air inlet and the air inlet cap. Proper sealing

of the air inlet pipe ensures that combustion air will be free of

contaminants and supplied in proper volume.

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.

 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.

3 General venting

Installation & Operation Manual

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.

If the boiler combustion air inlet is located

in a laundry room or pool facility, for

example, these areas will always contain

hazardous contaminants.

To prevent the potential of severe personal

injury or death, check for areas and

products listed in Table 1A, page 10 before

installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently.

—OR—

• Relocate air inlet and vent

terminations to other areas.

 WARNING

Optional room air

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 3C).

• The equipment room MUST be provided with

properly sized openings to assure adequate

combustion air. Please refer to instructions provided

with the room air kit.

• There will be a noticeable increase in the noise level

during normal operation from the inlet air opening.

• Using the room air kit makes the unit vulnerable

to combustion air contamination from within

the building. Please review Section 1, Prevent

Combustion Air Contamination, to ensure proper

installation.

• Vent system and terminations must comply with the

standard venting instructions set forth in this manual.

 WARNING When utilizing the single pipe method,

provisions for combustion and ventilation

air must be in accordance with Air for

Combustion and Ventilation, of the latest

edition of the National Fuel Gas Code,

ANSI Z223.1, in Canada, the latest edition

of CGA Standard B149 Installation Code for

Gas Burning Appliances and Equipment, or

applicable provisions of the local building

codes.

Model Vent Size Kit Number

55 - 110 2" KIT30051

55 - 285 3" KIT30052

199 - 399 4" KIT30053

Table 3C Optional Room Air Kit

NOTICE Optional room air is intended for

commercial applications. Combustion air

piping to the outside is recommended for

residential applications.

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.

3 General venting (continued)

Installation & Operation Manual

Installing vent and air piping

Use only cleaners, primers, and solvents

that are approved for the materials which

are joined together.

NOTICE

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.)

5. Dry fit vent or air piping to ensure proper fit up before

assembling any joint. The pipe should go a third to

two-thirds into the fitting to ensure proper sealing after

cement is applied.

6. Priming and Cementing:

a. Handle fittings and pipes carefully to prevent

contamination of surfaces.

b. Apply a liberal even coat of primer to the fitting

socket and to the pipe end to approximately 1/2"

beyond the socket depth.

c. Apply a second primer coat to the fitting socket.

d. While primer is still wet, apply an even coat of

approved cement to the pipe equal to the depth of

the fitting socket along with an even coat of

approved cement to the fitting socket.

e. Apply a second coat of cement to the pipe.

f. While the cement is still wet, insert the pipe into

the fitting, if possible twist the pipe a 1/4 turn as

you insert it. NOTE: If voids are present,

sufficient cement was not applied and joint could

be defective.

g. Wipe excess cement from the joint removing ring

or beads as it will needlessly soften the pipe.

PVC/CPVC

Table 3D PVC/CPVC Vent Pipe, and Fittings

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

 WARNING The vent connection to the appliance must

be made with the starter piece provided

with the appliance if PVC/CPVC vent is to

be used. The field provided vent fittings

must be cemented to the CPVC pipe section

using an “All Purpose Cement” suitable for

PVC and CPVC pipe. Use only the vent

materials, primer, and cement specified in

Table 3D to make the vent connections.

Failure to follow this warning could result

in fire, personal injury, or death.

 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.

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

Vent pipe

PVC Schedule 40, 80 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

Vent fittings

PVC Schedule 40 ANSI/ASTM D2466

PVC Schedule 80 ANSI/ASTM D2467

CPVC Schedule 80 ANSI/ASTM F439

Pipe Cement /

Primer

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Figure 3-7 Near Boiler PVC/CPVC Venting

This product has been approved for use with the PVC/CPVC

vent materials listed in Table 3D.

NOTE: In Canada, CPVC and PVC vent pipe, ﬁ ttings and cement/

primer must be ULC-S636 certiﬁ ed.

CPVC STARTER PIECE

3 General venting

Installation & Operation Manual

The installer must use a specific vent starter

adapter at the flue collar connection.

The adapter is supplied by the vent

manufacturer to adapt to its vent system.

See Table 3F for approved vent adapters.

NOTICE

All vent connections MUST be secured by

the vent manufacturer's joint connector

(FIG. 3-8).

NOTICE

IMG00130

JOINT CONNECTOR REQUIRED

AT ALL COMPONENT CONNECTIONS

OF VENT SYSTEM

POLYPROPYLENE ADAPTER

W/FLUE CLAMP

Figure 3-8 Near Boiler Polypropylene Venting

Model

Centrotherm InnoFlue SW Duravent Polypro

Polypropylene

Adapter Joint

Connector

Sidewall

Retaining

Bracket* Sidewall Adapter* Polypropylene Adapter Joint

Connector Sidewall Kit*

55 - 85 ISAG0202 w/

IAFC02 IANS02 IATP0202 ISTAGL0202 2PPS-AD w/PPS-PAC 2PPS-LB 2PPS-HLK

110 - 285 ISAG0303 w/

IAFC03 IANS03 IATP0303 ISTAGL0303 3PPS-AD w/PPS-PAC 3PPS-LB 3PPS-HLK

399 ISAG0404 w/

IAFC04 IANS04 IATP0404 ISTAGL0404 4PPS-AD w/PPS-PAC 4PPS-LB 4PPS-HLK

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 24).

Table 3F Approved PolypropyleneTerminations

Polypropylene

This product has been approved for use with polypropylene

vent with the manufacturers listed in Table 3E.

All terminations must comply with listed options in this manual

and be a single-wall vent offering.

For use of flex pipe, it is recommended to have the vent material

in 32°F or higher ambient space before bending at installation.

No bends should be made to greater than 45° and ONLY

installed in vertical or near vertical installations.

For support and special connections required, see the

manufacturer's instructions. All vent is to conform to standard

diameter and equivalent length requirements established.

Use only the adapters and vent system listed

in Tables 3E and 3F. DO NOT mix vent

systems of different types or manufacturers.

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

 WARNING

Installations must comply with applicable

national, state, and local codes. For

Canadian installation, polypropylene vent

must be listed as a ULC-S636 approved

system.

NOTICE

Installation of a polypropylene vent system

should adhere to the vent manufacturer’s

installation instructions supplied with the

vent system.

NOTICE

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems InnoFlue SW/Flex

Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex

Table 3E Polypropylene Vent Pipe and Fittings

 WARNING Insulation should not be used on

polypropylene venting materials. The use

of insulation will cause increased vent wall

temperatures, which could result in vent

pipe failure.

3 General venting (continued)

Installation & Operation Manual

Table 3H Approved Stainless Steel (S.S.) Terminations and Adapters

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 3H for

approved vent adapters. Discard CPVC

starter piece.

NOTICE

Approved Stainless Steel Vent Manufacturers

Make Model

Dura Vent (M & G Group) FasNSeal Vent / FasNSeal Flex* Vent

Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

Table 3G Stainless Steel Vent Pipe and Fittings

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure

no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method,

see manufacturer’s instructions.

Stainless steel vent

This product has been approved for use with stainless steel

using the manufacturers listed in Table 3G.

Use only the materials, vent systems, and

terminations listed in Tables 3G and 3H.

DO NOT mix vent systems of different

types or manufacturers. Failure to comply

could result in severe personal injury,

death, or substantial property damage.

 WARNING

Installations must comply with applicable

national, state, and local codes. Stainless

steel vent systems must be listed as a

UL-1738 approved system for the United

States and a ULC-S636 approved system

for Canada.

NOTICE

Installation of a stainless steel vent

system should adhere to the stainless

steel vent manufacturer’s installation

instructions supplied with the vent

system.

NOTICE

VENT

REPLACE APPLIANCE

SECURED CPVC ADAPTER

WITH APPROPRIATE

STAINLESS STEEL ADAPTER

FROM TABLE 3H

Figure 3-9 Near Boiler Stainless Steel Venting

Model

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Boiler

Adapter Flue

Termination

Intake

Air

Termination

Boiler

Adapter Flue

Termination

Intake

Air

Termination

Boiler

Adapter Flue

Termination Intake Air

Termination

55 - 85 303005 FSBS3

FSRC3(R.C) 303889 WH0002 9392

5300CI 9314TERM 2SVAKA02 2SVSTP03

2SVSRCX03 2SVSTEX0390

110 -285 303006 WH0003 2SVAKA03

399 303007 FSBS4

FSRC4(R.C) FSAIH04

303888 WH0004 9492

5400CI 9414TERM 2SVAKA04 2SVSTP04

2SVSRCX04 2SVSTEX0490

4 Sidewall direct venting

Vent/air termination – sidewall

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

TERMINATION

PLATE

BIRD SCREEN

GRADE OR

SNOW LINE

12”

MIN

BIRD SCREEN

12” MIN

15” MAX

Do not exceed the maximum lengths of the

outside vent piping shown in FIG. 4-1B.

Excessive length exposed to the outside

could cause freezing of condensate in the

vent pipe, resulting in potential boiler

shutdown.

Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall

Termination of Air and Vent w/Field Supplied Fittings

 WARNING

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.

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

12"

MIN

OVER

HANG

POSSIBLE ORIENTATIONS

Model Kit Number Vent Size

55 - 110 KIT30044 2 inch vent

110 - 285 KIT30045 3 inch vent

399 KIT30046 4 inch vent

Table 4A Sidewall Vent Kit

Installation & Operation Manual

Follow instructions below when

determining vent location to avoid

possibility of severe personal injury,

death, or substantial property damage.

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.

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 16

of this manual.

2. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air

conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the

plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue

products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation,

such as inside building corners, near adjacent

buildings or surfaces, window wells, stairwells,

alcoves, courtyards, or other recessed areas.

 WARNING

 WARNING Sidewall vent and air inlet terminations

must terminate in the same pressure zone.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

Figure 4-1A PVC/CPVC/Polypropylene Sidewall

Termination of Air and Vent

Vent/air termination – sidewall

Installation & Operation Manual

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

BIRD

SCREEN

12”

MIN

12” MIN

15” MAX

COUPLING

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

GRADE OR

SNOW LINE

Figure 4-1C Alternate PVC/CPVC/SS/ Polypropylene Venting

Arrangement (if Space Allows) w/Field Supplied Fittings

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

12"

MIN.

Figure 4-2A Clearance to Gravity Air Inlets

BIRD

SCREEN

(TYPICAL)

12”

MIN.

12”

MIN.

12”

MIN.

Figure 4-2B Alternate Clearance to Gravity Air Inlets w/

Field Supplied Fittings

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,

pages 22 - 24. 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; and the vent pipe must not extend

more than 24 inches vertically outside the building

as shown in FIG. 4-1B. Condensate could freeze and

block vent pipe.

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.

12" (305 MM) MIN

15" (381 MM) MAX

12" (305 MM) MIN

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER

INTAKE AIR

CONNECTION

BIRD SCREEN

GRADE OR

SNOW LINE

Figure 4-1D Alternate SS Venting Arrangement -

Typical Stainless Steel Sidewall Termination of Air and

Vent w/Field Supplied Fittings, Utilizing a Hood Intake

FORCED AIR

INLET

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

Figure 4-3A Clearance to Forced Air Inlets

6. Locate terminations so they are not likely to be damaged

by foreign objects, such as stones or balls, or subject to

buildup of leaves or sediment.

4 Sidewall direct venting (continued)

4 Sidewall direct venting

Installation & Operation Manual

VENT PIPING

GALVANIZED

THIMBLE

VENT CAP

AIR PIPING

WALL PLATE

VENT PLATE

VENT AIR

CENTERLINE WIDTH

Figure 4-4A PVC/CPVC Sidewall Termination Assembly

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 a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

Vent pipe penetration:

a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe

hole with at least a 1/2 inch clearance around the

vent pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors

into the wall.

2. For Polypropylene Only: Install the vent and air intake

sidewall adapters from Table 3F on page 20 into the vent

plate. Slide the sidewall retaining bracket down the

sidewall adapters flush to the vent plate (FIG. 4-4B).

3. For PVC/CPVC Only: Install the vent and air intake

piping through the wall into the vent plate openings.

Use RTV silicone sealant to seal the air pipe. Use the

cement/primer listed in Table 3D on page 19 to seal the

vent pipe.

4. Mount and secure the vent plate to the wall, using stainless

steel screws.

5. Seal all gaps between the pipes and wall. Seal around the

plate to the wall assuring no air gaps.

6. Assemble the vent cap to the vent plate (see FIG.'s 4-4A

and 4-4B). Insert the stainless steel screws into the vent

cap screw hole openings and securely attach the vent cap

to the vent plate.

7. Seal all wall cavities.

8. PVC/CPVC terminations are designed to accommodate

any wall thickness of standard constructions per the

directions found in this manual.

9. Stainless steel terminations are designed to penetrate

walls with a thickness up to 9.25 inches of standard

construction.

IF LESS

THAN 10’

36”

MIN.

FORCED AIR

INLET

BIRD

SCREEN

(TYPICAL)

7’ MIN. ABOVE ANY

PUBLIC WALKWAY

Figure 4-3B Alternate Clearance to Forced Air Inlets w/

Field Supplied Fittings

SIDEWALL

ADAPTER

(AIR)

SIDEWALL

DAPTER

(VENT)

WALL

PLATE

GALVANIZED

THIMBLE

SIDEWALL

RETAINING

PLATE

VENT

PLATE

VENT

CAP

IMG00085

Figure 4-4B Polypropylene Sidewall Termination Assembly

Model Air Vent Centerline Width

151 - 200 3" 3" 5 5/8"

286 4" 4" 5 5/8"

Table 4B Sidewall Vent Centerline Dimensions

4 Sidewall direct venting (continued)

Installation & Operation Manual

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT / AIR

TERMINATION

VENT

AIR

Figure 4-5A Multiple Vent Terminations (must also

comply with Figure 4-1A)

All vent pipes and air inlets must terminate

at the same height to avoid possibility

of severe personal injury, death, or

substantial property damage.

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).

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.

 WARNING

Figure 4-5B Alternate Multiple Vent Terminations w/Field

Supplied Fittings (must also comply with Figure 4-1B)

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 clearance around the vent

pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole as shown in FIG. 4-4C.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

AIR PIPING

ELBOW

BIRD SCREEN

ELBOW

BIRD SCREEN

SIDEWALL

TERMINATION PLATE

GALVANIZED

THIMBLE

VENT PIPING

Figure 4-4C Alternate Sidewall Termination Assembly

w/Field Supplied Fittings

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent

pipe termination kits (Factory Kit #CVK3003 for 3" diameter

- models 155 - 199, #CVK3008 for 2" diameter - models 55 -

110, or #CVK3007 for 4" diameter - models 285 - 399). Both

combustion air and vent pipes must attach to the termination

kit. The termination kit must terminate outside the structure

and must be installed as shown below in FIG. 4-6.

The required combustion vent pipe and fittings are listed in

Table 3D, on page 19 of this manual.

Figure 4-7 Kit Contents - CVK3008 & CVK3003

(reference Table 3B on page 16)

3. Cut one (1) hole (5 inch diameter for #CVK3003

installations, 4 inch diameter for #CVK3008, or 7 inch

diameter for #CVK3007 installations) into the structure to

install the termination kit.

4. Partially assemble the concentric vent termination kit.

Clean and cement using the procedures found in these

instructions.

a. Cement the Y concentric fitting to the larger kit pipe

(FIG. 4-7).

b. Cement the rain cap to the smaller diameter kit pipe

(FIG. 4-7).

Figure 4-6 Concentric Sidewall Termination

Installation & Operation Manual

4" (102 MM) DIA.

6" (152 MM) DIA.

RAIN CAP

"Y" CONCENTRIC

FITTING

"FLEXIBLE" PIPE

COUPLING

6" (152 MM) DIA.

6" (152 MM) TO 4" (102 MM) REDUCER

4" CONCENTRIC

VENT KIT

Figure 4-8 Kit Contents - CVK3007 (reference Table

3B on page 16)

Sidewall termination installation

1. Determine the best location for the termination kit (see

FIG. 4-6).

2. Reference the Determine Location Section on page 22 of this

manual for general termination considerations.

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent models

Figure 4-9 2" and 3" Concentric Vent Dimensional

Drawing (reference Table 3D on page 19)

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. 4-11).

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.

Do not operate the appliance with the rain

cap removed or recirculation of combustion

products may occur. Water may also collect

inside the larger combustion air pipe and

flow to the burner enclosure. Failure to

follow this warning could result in product

damage or improper operation, personal

injury, or death.

Figure 4-11 Rain Cap to Vent Pipe Alternate Assembly

5. Install the Y concentric fitting and pipe assembly through

the structure’s hole.

Do not allow insulation or other materials

to accumulate inside the pipe assembly

when installing through the hole.

6. Install the rain cap and small diameter pipe assembly

into the Y concentric fitting and large pipe assembly.

Ensure small diameter pipe is bottomed and cemented

in the Y concentric fitting for #CVK3003 and 3008

installations and fastened tightly into the rubber adapter

for #CVK3007 installations.

7. Secure the assembly to the structure as shown in FIG.

4-12 using field-supplied metal strapping or equivalent

support material.

Ensure termination location clearance

dimensions are as shown in FIG. 4-6.

If assembly needs to be extended to allow

sidewall thickness requirement, the two (2)

pipes supplied in the kit may be replaced

by using the same diameter, field-supplied

SDR-26 PVC (D2241) pipe for CVK3003

and 3008, and standard schedule 40 PVC

for CVK3007. Do not extend dimension

D more than 60 inches (see FIG. 4-9 and

FIG. 4-10).

NOTICE

 WARNING

NOTICE

If assembly needs to be reduced, dimension

D can be as short as possible.

NOTICE

Installation & Operation Manual

"B" DIA. PVC

VENT / EXHAUST

"H" DIA.

"D"

"E"

"F"

"G"

(76 MM)

ABCD E F GH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

"C" DIA. "B" DIA.

(1524 MM) (102 MM)

(152 MM) (537 MM) (254 MM) (194 MM) (76 MM) (168 MM)

Figure 4-10 4" Concentric Vent Dimensional Drawing

(reference Table 3D on page 19)

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near

each other, each appliance must be individually vented (see

FIG. 4-13). NEVER common vent or breach vent this appliance.

When two (2) or more direct vent appliances are vented near

each other, two (2) vent terminations may be installed as shown

in FIG. 4-13. It is important that vent terminations be made as

shown to avoid recirculation of flue gases.

VENT

COMBUSTION

AIR

12"

MINIMUM

Figure 4-13 Concentric Vent and Combustion Air Termination

Figure 4-12 Concentric Vent Sidewall Attachment

DO NOT use field-supplied couplings to

extend pipes. Airflow restriction will occur

and may cause intermittent operation.

8. Cement appliance combustion air and vent pipes to the

concentric vent termination assembly. See FIG. 4-12 for

proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure

combustion air and vent pipes are properly connected to

the concentric vent termination connections.

CAUTION

5 Vertical direct venting

Vent/air termination – vertical

ALTERNATE INTAKE LOCATIONS:

INTAKE PIPES MAY BE LOCATED

ANYWHERE WITHIN 24” OF VENT

PIPE

BIRD SCREEN

(TYPICAL)

COUPLING

(FIELD SUPPLIED)

VENT OUTLET

12” MINIMUM

ABOVE AIR INLET

6” MINIMUM

ABOVE ROOF

SNOW LINE

VENT

COMBUSTION

AIR

8. Locate terminations so they are not likely to be damaged by

foreign objects or subject to buildup of leaves or sediment.

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT

COM,BUSTION

AIR

ALTERNATE INTAKE LOCATIONS:

INTAKE PIPES MAY BE LOCATED

ANYWHERE WITHIN 24” (610 MM)

OF VENT PIPE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

BIRD SCREEN

(TYPICAL)

Figure 5-1B Stainless Steel Vertical Termination of Air

and Vent

Installation & Operation Manual

Follow instructions below when

determining vent location to avoid

possibility of severe personal injury, death

or substantial property damage.

Determine location

Locate the vent/air terminations using the following

guidelines:

1. The total length of piping for vent or air must not exceed

the limits given in the General Venting Section on page

16 of this manual.

2. Prepare the vent termination and the air termination

elbow (FIG. 5-1A) by inserting bird screens. Bird screens

should be obtained locally.

3. The vent must terminate at least 3 feet above the highest

place in which the vent penetrates the roof and at least

2 feet above any part of a building within 10 horizontal

feet.

4. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet from the center of the

vent pipe. This placement avoids recirculation of flue

products into the combustion air stream.

5. The vent piping must terminate in an up-turned coupling

as shown in FIG. 5-1A. The top of the coupling must

be at least 1 foot above the air intake. When the vent

termination uses a rain cap as illustrated in FIG. 5-1B

maintain at least 36" (914 mm) above the air inlet. The

air inlet pipe and vent pipe can be located in any desired

position on the roof, but must always be no further than

2 feet (.6 m) apart and with the vent termination at least

1 foot for PVC and 3 feet for stainless steel, above the air

intake.

6. Maintain the required dimensions of the finished

termination piping as shown in FIG. 5-1A.

7. Do not extend exposed vent pipe outside of building

more than shown in this document. Condensate could

freeze and block vent pipe.

Figure 5-1A PVC/CPVC/Polypropylene Vertical

Termination of Air and Vent

 WARNING

 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.

Prepare roof penetrations

1. Air pipe penetration:

a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration:

a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe

hole with at least a 1/2 inch clearance around the

vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole.

5 Vertical direct venting

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 5-1A, page 29.

4. Follow all local codes for isolation of vent pipe when

passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent pipe

and air pipe.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers,

terminate each vent/air connection as described in this

manual (FIG. 5-2).

Terminate all vent pipes at the same height

and all air pipes at the same height to

avoid possibility of severe personal injury,

death, or substantial property damage.

2. Place roof penetrations to obtain minimum clearance of

12 inches between edge of air intake elbow and adjacent

vent pipe of another boiler for U.S. installations (see

FIG. 5-2). For Canadian installations, provide clearances

required by CSA B149.1 Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a

direct vent connection. It is not classified as a forced air

intake with regard to spacing from adjacent boiler vents.

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 5-2 Vertical Terminations with Multiple Boilers

Figure 5-3 Alternate Vertical Terminations with Multiple

Boilers

 WARNING

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 3D, on page 19 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine

Location (where applicable).

2. Cut one (1) hole (5 inch diameter for #CVK3003

installations or 4 inch diameter for #CVK3008 installations)

into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit.

Clean and cement following the cleaning procedures in

these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG. 4-7, page 26).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-7, page 26).

Figure 5-4 Concentric Vertical Termination

Figure 5-5 Do Not Install U-Bend to Rain Cap

Installation & Operation Manual

Prepare roof penetrations (continued)

5 Vertical direct venting (continued)

Instead of cementing the smaller pipe to

the rain cap, a field supplied stainless steel

screw may be used to secure the two (2)

components together when field disassembly

is desired for cleaning (see FIG. 4-9, page

27).

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.

NOTICE

 WARNING

Installation & Operation Manual

Figure 5-6 Concentric Vent Roof Installation

Do not operate the appliance with

the rain cap removed or recirculation

of combustion products may occur.

Water may also collect inside the larger

combustion air pipe and flow to the

burner enclosure. Failure to follow this

warning could result in product damage

or improper operation, personal injury,

or death.

4. Install the Y concentric fitting pipe assembly through the

structure’s hole and field supplied roof boot/flashing.

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.

 WARNING

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 30.

If assembly is too short to meet height

requirement, the two (2) pipes supplied

in the kit may be replaced by using the

same diameter, field supplied SDR-26 PVC

(D2241) pipe. Add standard schedule 40

PVC pipe for #CVK3007 Do not extend

dimension D more than 60 inches (see FIG.

4-9 and FIG. 4-10, page 27).

NOTICE

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. Cement the appliance combustion air and vent pipes to

the concentric vent termination assembly. See FIG. 5-6

for proper pipe attachment.

8. Operate the appliance through one (1) heat cycle to ensure

combustion air and vent pipes are properly connected to

the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or 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.

12”

MINIMUM

12” (18” FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24” ABOVE ROOF.

COMBUSTION

AIR (TYPICAL)

Figure 5-7 Concentric Vent and Combustion Air Vertical

Termination

Installation & Operation Manual

Alternate vertical concentric

venting

Vent / Air Inlet Size Minimum Existing

Vent / Chase Size

2" 4"

3" 5"

4" 7"

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Figure 5-8 Concentric Vent Example 1

12”

MIN.

FLUE EXHAUST

SEAL

COMBUSTION AIR

FLUE OUTLET

SEALED

CAP

EXISTING

SEAL

AIR INLET

W/ SCREEN

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Figure 5-9 Concentric Vent Example 2

SEAL

COMBUSTION AIR

SEAL

FLUE OUTLET

SEALED

CAP

SEAL

EXISTING

FLUE EXHAUST

5 Vertical direct venting

Figure 5-10 Existing Vent as a Chase

AIR INLET

FLUE EXHAUST

SEAL

CAP

EXISTING

SEAL

FLUE OUTLET

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.

*For concept illustration only. Individual installations may

vary due to job site specific equipment.

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

This appliance may be installed with a concentric vent

arrangement where the vent pipe is routed through an

existing unused venting system; or by using the existing

unused venting system as a chase for vent and combustion

air routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular

space between the O.D. of the vent pipe and the I.D. of the

existing unused venting system is utilized for the combustion

air source.

The minimum size of the existing vent system required to

achieve enough annular space for combustion air can be found

in Table 5A.

The upper and lower termination as well as any other unsealed

joints in the existing vent system must be sealed to ensure that

all combustion air is drawn from under the vent cap as shown

in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as specified in Table

3D on page 19.

Follow all vent / air termination and clearance requirements

per this section to the appropriate example. Installation must

comply with local requirements and with the National Fuel

Gas Code.

The maximum allowable equivalent vent and air intake

lengths for this venting arrangement are to be determined

from the General Venting Section.

If an existing unused venting system is converted for use

with this method of concentric venting, the installer must

ensure that the existing venting system is clean and free from

particulate contamination that will harm this appliance and

cause increased nuisance calls or maintenance. See Table 1A

on page 10 for a list of corrosive contaminants and sources.

Two example scenarios of a concentric venting arrangement

are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Installation & Operation Manual

6 Hydronic piping

System water piping methods

The Knight wall mount is designed to function in a closed

loop pressurized system not less than 12 psi. A temperature

and pressure gauge is included to monitor system pressure

and outlet temperature and should be located on the boiler

outlet.

It is important to note that the boiler has a minimal

amount of pressure drop and must be figured in when

sizing the circulators. Each boiler installation must have

an air elimination device, which will remove air from

the system. Install the boiler so the gas ignition system

components are protected from water (dripping, spraying,

etc.) during appliance operation for basic service of circulator

replacement, valves, and others.

Observe a minimum of 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 system should be tested at least once

a year and as recommended by the producer of the glycol

solution. Allowance should be made for the expansion of the

glycol solution in the system piping.

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).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain

on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water

line.

5. Install a pressure reducing valve on the cold feed make-

up water line, (15 psi nominal). Check temperature and

pressure gauge (shipped separately), which should read a

minimum pressure of 12 psi.

6. Install a circulator as shown on the piping diagrams in this

section. Make sure the circulator is properly sized for the

system and friction loss.

7. Install an expansion tank on the system supply. Consult the

tank manufacturer’s instruction for specific information

relating to tank installation. Size the expansion tank for the

required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system.

10. This appliance is supplied with a relief valve sized in

accordance with ASME Boiler and Pressure Vessel Code,

Section IV (“Heating Boilers”). The safety relief valve is

installed at the factory located on the left-hand side of the

boiler. Pipe the discharge of the safety relief valve to prevent

injury in the event of pressure relief. Pipe the discharge to a

drain. Provide piping that is the same size as the safety relief

valve outlet. Never block the outlet of the safety relief valve.

See the *piping illustrations included in this section, FIG.’s 6-3

through 6-10 for suggested guidelines in piping the Knight wall

mount boiler with either zone valves or circulator pumps.

*Please note that these illustrations are

meant to show system piping concept only,

the installer is responsible for all equipment

and detailing required by local codes.

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.

 WARNING

NOTICE

Installation & Operation Manual

6 Hydronic piping

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe

requirements listed in Table 6A. Reducing the pipe size

can restrict the flow rate through the boiler, causing

inadvertent high limit shutdowns and poor system

performance. Flow rates are based on 20 feet of piping,

4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler circulating pump:

A Grundfos UPS15-58FC pump for Models 55 - 155

and a Grundfos UPS26-99FC pump for Models 199 -

399 will be provided by the factory as the boiler circulation

pump based on 20 feet of piping, 4 - 90° elbows, and 2 - fully

ported ball valves.

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.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet

the specified minimum flow requirements listed in

FIG. 6-2. Consult the indirect water heater operating

guide to determine flow characteristics for the selected

product used.

4. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure

to use full port ball valves could result in a restricted flow

rate through the boiler.

5. Check valves:

Field supplied. Check valves are recommended for

installation as shown in FIG.’s 6-3 through 6-10. Failure

to install check valves could result in a reverse flow

condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are

required. Failure to use full port ball valves could

result in a restricted flow rate through the boiler.

7. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is

recommended when storing domestic hot water above

115°F.

8. Unions:

Field supplied. Recommended for unit serviceability.

9. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is

shipped loose. It is the responsibility of the contractor to

install the temperature and pressure gauge on the boiler

water outlet.

10. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to

ASME specifications.

11. Boiler purge valve:

Factory supplied. The boiler purge valve is used to

remove entrapped air from the heat exchanger during

start-up.

12. System temperature sensor:

Lochinvar supplies a system temperature sensor.

The sensor is to be installed in the heating loop

downstream from the boiler hot water piping and

heating loop junction. Typically the sensor will be

located far enough downstream to sense system diluted

water temperature.

13. Indirect water heaters:

The Knight wall mount boiler may be piped to an indirect

water heater to heat domestic hot water with the space heat

transfer medium. As depicted in the piping diagrams on

page 38 thru 47, there are two options when utilizing an

indirect water heater.

A. The space heating piping will branch off to flow the

space heat transfer medium through a single wall

heat exchanger coil inside the indirect water heater.

B. The indirect water heater is connected to the system

supply piping. A pump controlled by the Knight

(wall mount) boiler’s control will regulate the flow of

water through the indirect water heater. The indirect

water 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.

 WARNING The National Standard Plumbing Code, the

National Plumbing Code of Canada and the

Uniform Plumbing Code limit the pressure

of the heat transfer fluid to less than the

minimum working pressure of the potable

water system up to 30 psi maximum. Also,

the heat transfer fluid must be water or

other non-toxic fluid having a toxicity of

Class 1, as listed in Clinical Toxicology of

Commercial Products, 5th Edition.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose

strainer is recommended at the inlet of the heat exchanger

to remove system particles from older hydronic systems and

protect newer systems.

Installation & Operation Manual

Near boiler piping connections

AIR

Y-STRAINER

(RECOMMENDED)

DOMESTIC

HOT WATER

PUMP

CONDENSATE

DRAIN

SYSTEM

PUMP

BOILER

PUMP

FROMSYSTEMTOSYSTEM

FROM

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

AIR

SEPARATOR

EXPANSION TANK

VENT

OUTLET

INLET

Figure 6-1A Near Boiler Piping

VENT

AIR VENT

VALVE

AIR

SEPARATOR

SYSTEM

SENSOR

DRAIN (TYPICAL)

SYSTEM

PUMP

LOW LOSS HEADER

(TYPICAL)

CONDENSATE

DRAIN INDIRECT

DOMESTIC

HOT WATER

TANK

Y-STRAINER

(RECOMMENDED)

DRAIN VALVE

BOILER

PUMP

FILL VALVE

EXPANSION TANK

TO SYSTEM

FROM SYSTEM

FROM

DOMESTIC HOT

WATER PUMP

VENT

AIR

TO FLOOR

DRAIN

CHECK VALVE

OUTLET

INLET

Figure 6-1B Near Boiler Piping w/Low Loss Header

6 Hydronic piping (continued)

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.

Installation & Operation Manual

6 Hydronic piping

-0.50

0.00

0.50

1.00

1.50

2.00

2.50

3.00

02468101214

FT/HD

FLOW

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

0 2 4 6 8 101214161820

FT/HD

FLOW

110

155

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

0 5 10 15 20 25 30 35 40 45

FT/HD

FLOW

399

MODEL

199

285

MODEL

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

0 5 10 15 20 25 30 35

FLOW

FT/HD

Figure 6-2 Pressure Drop vs. Flow

20°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

55 5 0.27 1" UPS 15-58FC (1) 007 NRF-22 E7

85 8 0.94 1" UPS 15-58FC (1) 007 NRF-22 E7

110 10 1.53 1" UPS 15-58FC (2) 007 NRF-22 E7

155 15 4.26 1" UPS 15-58FC (3) 007 NRF-22 E7

199 19 1.13 1.25" UPS26-99F 0011 NRF-36 (1) E7

285 27 2.42 1.25" UPS26-99F 0011 NRF-36 (3) E7

399 38 1.42 1.5" UPS26-99F 0012 PL-55 E11

Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°

25°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

55 4 0.17 1" UPS 15-58FC (1) 007 NRF-22 E7

85 7 0.72 1" UPS 15-58FC (1) 007 NRF-22 E7

110 8 0.98 1" UPS 15-58FC (2) 007 NRF-22 E7

155 12 3.13 1" UPS 15-58FC (3) 007 NRF-36 (1) E7

199 15 0.71 1.25" UPS26-99F 0011 NRF-36 (1) E7

285 22 1.61 1.25" UPS26-99F 0011 NRF-36 (3) E7

399 31 0.95 1.5" UPS26-99F 0012 PL-55 E11

35°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size Pump

Grundfos TACO B & G Armstrong

55 3 0.10 1" UPS 15-58FC (1) 007 NRF-22 E7

85 5 0.37 1" UPS 15-58FC (1) 007 NRF-22 E7

110 6 0.55 1" UPS 15-58FC (2) 007 NRF-22 E7

155 9 1.76 1" UPS 15-58FC (3) 007 NRF-36 (1) E7

199 11 0.38 1.25" UPS 15-58FC (3) 0010 NRF-36 (1) E7

285 16 0.85 1.25" UPS 15-58FC (3) 0010 NRF-36 (1) E7

399 22 0.48 1.5" UPS26-99F 0011 NRF-36 (1) E7

Pumps listed in bold type are provided by the factory as the boiler circulation pump.

NOTICE

The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.

NOTICE

6 Hydronic piping (continued)

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.

NOTICE

Pump sizing and flow requirements are

based on 20 feet of piping, 4 - 90° elbows,

and 2 - fully ported ball valves.

NOTICE

Variable speed pump option

Table 6B Recommended Variable Speed Pumps

Variable speed pumping to maintain a set differential temperature (ΔT) between two (2) sensors allows for the following:

- Automatic adjustment of the pump's performance to match the low of the system or zone

- Eliminate velocity noise in the zone valve systems

- Conserve energy

Since ΔT is directly releated to flow rate, the pump's speed continually adjusts to the required BTU per hour. In almost all

applications the design of the system was based on being able to maintain a certain ΔT and figured by using the universal

hydronics equation of BTU/hr = GPM x 500 x ΔT. Given that, any time there is a change to the heat load (i.e., warmer day

or greater heat loss from a structure) then the GPM should change to match the required BTU/hr. This is achieved when the

variable speed circulators automatically and continually adjust their GPM output (by varying speed) to match the required

BTU/hr output of the system, no matter the changes in heat load, while always maintaining the designed ΔT between a supply

and return sensor.

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control

- Pump is set for external signal control (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module

will be required from the vendor

Installation & Operation Manual

0.00

3.00

6.00

9.00

12.00

15.00

18.00

21.00

24.00

27.00

30.00

33.00

36.00

0246810121416182022242628303234363840

FT/HD

FLOW

VFD PUMP

155

199

285

399

UPS26-96FC/VS

TACO 0013 IFC VS

UPS26-96 FC/VS 50%

TACO 0013 IFC VS 50%

SMART SYSTEM / Multi-temperature loop

control option

The Knight wall mount boiler is capable of producing up

to three (3) set point temperatures to meet different space

heating demands. When using more than one temperature

demand it is necessary to protect the lower temperature

loop from overheating. To help aid with this protection,

Lochinvar offers the Multi- Temperature Loop Control Board

Kit (RLY30086).

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR

SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF

VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

FROM

SYSTEM

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

CIRCULATOR

SYSTEM

CIRCULATOR

SYSTEM

SYSTEM SUPPLY

SENSOR

DRAIN

MAY SUBSTITUTE LOW LOSS HEADER

Y-STRAINER

(RECOMMENDED)

HOT

WATER

OUT

FLOW CHECK

VALVE

Figure 6-3 Single Boiler - Primary / Secondary Piping

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

6 Hydronic piping

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

EXPANSION

TANK

ZONE VALVES

(TYPICAL)

FLOW CHECK

VALVE

DIFFERENTIAL

PRESSURE

BYPASS VALVE

(RECOMMENDED)

SYSTEM

CIRCULATOR

SYSTEM SUPPLY SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-4 Single Boiler - Single Temperature with Zone Valves - DHW Priority

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

6 Hydronic piping (continued)

Installation & Operation Manual

6 Hydronic piping

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING

VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

DRAIN

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

HOT

WATER

OUT

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

(TYPICAL)

BOILER

CIRCULATOR

SYSTEM SUPPLY SENSOR

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-5 Single Boiler - Single Temperature Zoned with Circulators - DHW Priority

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

6 Hydronic piping (continued)

INDIRECT

DHW TANK

BACKFLOW

PREVENTER

PRESSURE

REDUCING

VALVE PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE UP WATER

ZONE VALVES

(TYPICAL)

BOILER

CIRCULATOR

BOILER 2

(MEMBER 1)

DOMESTIC

HOT WATER

CIRCULATOR

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

HOT

WATER

OUT

COLD

WATER

BOILER 1

(LEADER)

DIFFERENTIAL PRESSURE

BYPASS VALVE

(RECOMMENDED)

SYSTEM SUPPLY

SENSOR

SYSTEM

CIRCULATOR

DRAIN

Y-STRAINER

(RECOMMENDED)

(TYPICAL)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-6 Multiple Boilers - Single Temperature Zoned with Zone Valves - DHW Priority

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Installation & Operation Manual

Model

Number of Units

234567 8

Required Pipe Sizes

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

85 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2"

110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

155 2" 2" 2-1/2" 2-1/2" 3" 3" 4"

199 2" 2" 2-1/2" 3" 4" 4" 4"

285 2-1/2" 2-1/2" 3" 4" 4" 4" 5"

399 2-1/2" 3" 4" 4" 5" 5" 5"

6 Hydronic piping

Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority

INDIRECT

DHW TANK

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

(TYPICAL)

BOILER

CIRCULATOR

BOILER 2

(MEMBER 1)

DOMESTIC

HOT WATER

CIRCULATOR

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

HOT

WATER

OUT

COLD

WATER

BOILER 1

(LEADER)

SYSTEM SUPPLY

SENSOR

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

Y-STRAINER

(RECOMMENDED)

(TYPICAL)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Installation & Operation Manual

Model

Number of Units

234567 8

Required Pipe Sizes

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

85 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2"

110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

155 2" 2" 2-1/2" 2-1/2" 3" 3" 4"

199 2" 2" 2-1/2" 3" 4" 4" 4"

285 2-1/2" 2-1/2" 3" 4" 4" 4" 5"

399 2-1/2" 3" 4" 4" 5" 5" 5"

Installation & Operation Manual

6 Hydronic piping (continued)

BOILER INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE

WATER

HOT WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

MIXING VALVES

(TYPICAL)

FLOW CHECK

VALVE

SYSTEM

SUPPLY

SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE

LOW LOSS HEADER

TEMPERATURE

LOOP #1

TEMPERATURE

LOOP #2

TEMPERATURE

LOOP #3

NOT TO EXCEED 4 PIPE DIA

OR MAX. OF 12" APART

PRESSURE

RELIEF

VALVE

SHIELDED CABLE TO

BOILER CONTROL

120VAC TO PUMPS

24V SIGNAL TO

MIXING VALVES

WIRES TO

LOOP SENSORS

MULTI-TEMP

LOOP CONTROL

IMG00190

Figure 6-8 Single Boiler - Multiple Temperature - DHW Priority

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

Installation & Operation Manual

6 Hydronic piping

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE

WATER

HOT WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

MIXING VALVES

(TYPICAL)

FLOW

CHECK

VALVE

SYSTEM

SUPPLY

SENSOR

MAY SUBSTITUTE

LOW LOSS HEADER

TEMPERATURE

LOOP #1

TEMPERATURE

LOOP #2

TEMPERATURE

LOOP #3

BOILER

INDIRECT

DHW TANK

UNION

(TYPICAL)

DRAIN

Y-STRAINER

(RECOMMENDED)

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

TEMPERATURE /

PRESSURE GAUGE

PRESSURE

RELIEF

VALVE

SHIELDED CABLE TO

BOILER CONTROL

24V SIGNAL TO

MIXING VALVES

120VAC TO PUMPS

WIRES TO

LOOP

SENSORS

MULTI-TEMP TO

LOOP CONTROL

IMG00191

Figure 6-9 Multiple Boilers - Multiple Temperature - DHW Piped as a Zone

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Model

Number of Units

234567 8

Required Pipe Sizes

55 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2"

85 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2"

110 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

155 2" 2" 2-1/2" 2-1/2" 3" 3" 4"

199 2" 2" 2-1/2" 3" 4" 4" 4"

285 2-1/2" 2-1/2" 3" 4" 4" 4" 5"

399 2-1/2" 3" 4" 4" 5" 5" 5"

CAUTION Mixing valves are required for the protection of low temperature loops.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

NOTICE

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

EXPANSION

TANK

ZONE VALVES

(TYPICAL)

FLOW CHECK

VALVE

DIFFERENTIAL

PRESSURE

BYPASS VALVE

(RECOMMENDED)

SYSTEM SUPPLY

SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-10 Single Boiler - Full Flow - Single Temperature - Zoned with Zone Valves - DHW Priority

6 Hydronic piping (continued)

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

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

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

HOT

WATER

OUT

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

EXPANSION

TANK

ZONE VALVES

(TYPICAL)

DIFFERENTIAL

PRESSURE

BYPASS VALVE

(RECOMMENDED)

SYSTEM SUPPLY

SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

BOILER

CIRCULATOR

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-11 Single Boiler - Full Flow - Single Temperature Zoned with Valves - DHW Piped as a Zone

6 Hydronic piping

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

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

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

UNION

(TYPICAL)

DRAIN

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

HOT

WATER

OUT

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

(TYPICAL)

SYSTEM SUPPLY SENSOR

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

BALL VALVE

(TYPICAL)

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-12 Single Boiler - Full Flow - Single Temperature Zoned with Circulators - DHW Piped as a Zone

6 Hydronic piping (continued)

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

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

Installation & Operation Manual

7 Gas connections

Connecting gas supply piping

1. Remove the front access panel and refer to FIG. 7-1

to pipe gas to the boiler.

a. Install a field supplied sediment trap / drip leg

upstream of the boiler gas controls.

MANUAL SHUTOFF VALVE

(FIELD SUPPLIED) UNION

DRIP LEG

GAS SUPPLY

Figure 7-1 Gas Supply Piping

2. Support piping with hangers, not by the boiler or its

accessories.

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.

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.

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.

 WARNING

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.

Installation & Operation Manual

7 Gas connections (continued)

Failure to apply pipe sealing compound

as detailed in this manual can result

in severe personal injury, death, or

substantial property damage.

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.

Use two wrenches when tightening gas

piping at boiler (FIG. 7-2), using one

wrench to prevent the boiler gas line

connection from turning. Failure to

support the boiler gas connection pipe

to prevent it from turning could damage

gas line components.

USE BACK UP WRENCH

TO PREVENT PIPE FROM

ROTATING

Figure 7-2 Inlet Pipe with Backup Wrench

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on

rated boiler input (divide by 1,000 to obtain cubic feet per

hour).

a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas

piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 4 inches w.c. with gas flowing (verify during

boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if

inlet pressure can exceed 14 inches w.c. at any time. Adjust

lockup regulator for 14 inches w.c. maximum.

Propane Gas:

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).

Maximum inlet gas pressure must not

exceed the value specified. Minimum

value listed is for the purposes of input

adjustment.

 WARNING

 WARNING 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.

NOTICE

 WARNING Ensure that the high gas pressure regulator

is at least 6 - 10 feet upstream of the

appliance.

Installation & Operation Manual

7 Gas connections

Nominal

Iron Pipe

Size (Inches)

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet for 1/2 PSI

100

125

150

175

200

1/2

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4

369

256

205

174

155

141

128

121

113

106

697

477

384

328

292

267

246

236

210

200

179

164

149

138

1-1/4

1400

974

789

677

595

543

502

472

441

410

369

333

308

287

1-1/2

2150

1500

1210

1020

923

830

769

707

666

636

564

513

472

441

4100

2820

2260

1950

1720

1560

1440

1330

1250

1180

1100

974

871

820

2-1/2

6460

4460

3610

3100

2720

2460

2310

2100

2000

1900

1700

1540

1400

1300

11200

7900

6400

5400

4870

4410

4000

3800

3540

3330

3000

2720

2500

2340

23500

16100

13100

11100

10000

9000

8300

7690

7380

6870

6150

5640

5130

4720

Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to

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.

Table 7A Natural Gas Pipe Size Chart

The gas piping must be sized for the proper flow and length

of pipe, to avoid excessive pressure drop. Both the gas

meter and the gas regulator must be properly sized for the

total gas load.

If you experience a pressure drop greater than 1 inch w.c.,

the meter, regulator, or gas line is undersized or in need of

service. Perform the steps below when checking inlet gas

supply:

1. Shut off power at source.

2. Shut off gas supply at the manual gas valve in the gas

piping to the appliance.

 WARNING

3. Loosen the set screw one (1) full turn from inside the

pressure tap on top of the gas valve. Place the tubing of

the manometer over the tap once the set screw is

loosened as shown in FIG. 7-3.

4. Slowly turn on the gas supply at the field installed

manual gas valve.

5. Turn on power at source..

6. Adjust the temperature set point on the control panel of

the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner fires at

100% of rated input. Percent of burner input will be

displayed on the control panel.

8. Ensure inlet pressure is within specified range.

Minimum and maximum gas supply pressures are

specified in this section of the manual.

9. If gas supply pressure is within normal range and no

adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility,

gas supplier, qualified installer or service agency to

determine the necessary steps to provide proper gas

pressure to the control.

11. Shut off power at source.

12. Shut off the gas supply at the manual gas valve in the gas

piping to the appliance.

13. Remove the manometer from the pressure tap on top of

the gas valve. Re-tighten the set screw inside the pressure

tap.

Check inlet gas supply

NOTICE CSA or UL listed flexible gas connections

are acceptable, but you must exercise

caution to ensure that the line has

adequate capacity to allow your boiler

to fire at full rate. Consult with local

codes for proper installation or service

procedures.

DO NOT adjust gas valve outlet

pressure. The gas valve is factory-set

for the correct outlet pressure. This

setting is suitable for natural gas and

propane, requiring no field adjustment.

Attempting to alter the gas valve outlet

pressure could result in damage to the

valve, causing potential severe personal

injury, death, or substantial property

damage.

 WARNING

Installation & Operation Manual

7 Gas connections (continued)

 WARNING 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.

Gas Pressure

The gas pressure must remain between 4 inches w.c. (natural),

8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP)

maximum during stand-by (static) mode and while in operating

(dynamic) mode. If an in-line regulator is used, it must be a

minimum of 10 feet from the Knight wall mount boiler. It is

very important that the gas line is properly purged by the gas

supplier or utility company. Failure to properly purge the

lines or improper line sizing, will result in ignition failure. The

problem is especially noticeable in NEW LP installations and

also in empty tank 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.

DETAIL A

LOOSEN SET SCREW [1] FULL TURN

THEN PLACE TUBING OVER PRESSURE TAP

IMG00163

Figure 7-3 Inlet Gas Supply Check

DO NOT adjust gas valve outlet pressure.

The gas valve is factory-set for the correct

outlet pressure. This setting is suitable

for natural gas and propane, requiring

no field adjustment. Attempting to

alter the gas valve outlet pressure could

result in damage to the valve, causing

potential severe personal injury, death, or

substantial property damage.

Failure to follow all precautions could

result in fire, explosion, or death!

 WARNING

Installation & Operation Manual

8 Field wiring

ELECTRICAL SHOCK HAZARD – For

your safety, turn off electrical power supply

before making any electrical connections

to avoid possible electric shock hazard.

Failure to do so can cause severe personal

injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler

must be replaced, use only type 105°C

wire or equivalent.

Boiler must be electrically grounded as

required by National Electrical Code

ANSI/NFPA 70 – latest edition.

Installation must comply with:

1. National Electrical Code and any other national, state,

provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,

and any local codes.

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, you must isolate

with a relay.

Figure 8-2 Line Voltage Field Wiring Connections

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation.

 WARNING

NOTICE

 CAUTION

REMOVE BEZEL

Figure 8-1 Remove Bezel

Low voltage connections

1. Route all low voltage wires through the knockouts in the

bottom front right side, just under the control panel, as

shown in FIG. 8-3.

2. Connect low voltage wiring to low voltage connection board

as shown in FIG. 8-4 on page 55 of this manual and the

boiler wiring diagram.

LOW VOLTAGE

CONNECTION

BOARD

LINE VOLTAGE

JUNCTION BOX

LINE VOLTAGE

KNOCKOUTS

LOW VOLTAGE

KNOCKOUTS IMG00164

Figure 8-3 Routing Field Wiring

Line voltage connections

1. Remove bezel as shown in FIG. 8-1.

2. Connect 120 vac power wiring to the line voltage terminal

strip in the junction box, as shown in FIG. 8-2.

3. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code (see

FIG. 8-2).

Installation & Operation Manual

8 Field wiring (continued)

Thermostat

1. Connect the room thermostat or end switch (isolated

contact only) to heat/loop demand 1, 2, or 3, as shown

in FIG. 8-4.

2. Install the thermostat on the inside wall away from

influences of drafts, hot or cold water pipes, lighting

fixtures, television, sunlight, or fireplaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps.

b. If connected to relays or other devices, set to

match total electrical power requirements of

connected devices. See device manufacturers’

specifications and thermostat instructions for

details.

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from

direct sunlight or flow of heat or cooling from other

sources.

2. Route sensor wires through a knockout in the bottom

front right side of the boiler (see FIG. 8-3).

3. Connect outdoor temperature sensor (FIG. 8-4) to the

outdoor sensor terminals on the connection board to

enable outdoor reset operation of the Knight wall mount

boiler. If fixed temperature operation is required, do not

install outdoor sensor.

DHW thermostat

1. Connect storage indirect water heater (DHW) thermostat

(FIG. 8-4) to the DHW thermostat terminals on the

connection board. If a tank sensor is connected (see

DHW Tank Sensor below) the tank thermostat is ignored.

Louver relay

1. If louvers need to operate when the boiler fires, they can

be controlled by this output. Connect these terminals to

a 24 vac relay coil, which is wired to operate the louvers

(FIG. 8-4).

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).

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.

2. The tank sensor included with the Lochinvar Squire

Indirect DHW tank (TST20015) is the only sensor

suitable for use with the SMART SYSTEM control.

Connect the sensor leads to the Tank Sensor terminals

on the Low Voltage Connection Board.

Failure to use the correct sensor may

result in the tank temperature being either

above or below the set point.

 WARNING

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.

Variable speed system pump

If a variable speed pump is used in the primary loop, and a

0-10V signal is available from the pump speed control, this

signal can be used by the SMART SYSTEM control to anticipate

changes in the building heat load. By connecting this 0 - 10V

signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or

cascade) can modulate up and down as the primary flow

increases and decreases.

Boiler pump speed output

This 0 - 10V output is available to control the speed of a variable

speed boiler pump. The SMART SYSTEM control will vary the

speed of this pump in order to maintain a minimum T across

the heat exchanger, as well as prevent high limit lockouts when

the flow in the primary loop is extremely low. Connect this

output to the 0 - 10V input on the boiler pump speed control.

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.

Installation & Operation Manual

8 Field wiring

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.

2. Make sure the (-) terminal is connected to the (-) or

common output terminal of the external control, and

the (+) terminal is connected to the 0 - 10 vdc or (+)

terminal of the external control. Make sure the (-)

voltage is not below ground.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts

whenever the burner is running. This is typically used by

Building Management Systems to verify that the boiler is

responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts

whenever the boiler is locked out or the power is turned off.

This can be used to turn on an alarm, or signal a Building

Management System that the boiler is down.

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 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.

System supply sensor

1. By installing the system supply sensor into the supply

of the primary loop, the temperature of the primary

supply can be controlled. The SMART SYSTEM control

automatically detects the presence of this sensor, and

controls the boiler firing rate to maintain the system

supply temperature to the set point (if the outlet sensor

control is currently selected). If it is desired to control

the system return temperature, then program the SMART

SYSTEM control to use the inlet sensor as the controlling

sensor. See the Knight Wall Mount Service Manual for

instructions on how to do this. When the inlet sensor

is programmed as the controlling sensor, it is strongly

recommended that the SYSTEM SUPPLY sensor be

installed. DO NOT INSTALL THE SYSTEM SUPPLY

SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be

used for the system sensor.

3. Connect these terminals to the system supply sensor

(FIG. 8-4).

Installation & Operation Manual

8 Field wiring (continued)

Figure 8-4 Low Voltage Field Wiring Connections

LOUVER RELAY

TANK THERMOSTAT

HEAT / LOOP

DEMAND 3

SYSTEM SUPPLY SENSOR

BUILDING

MANAGEMENT

SYSTEM

LOW WATER

CUTOFF

OUTDOOR SENSOR

TANK SENSOR

SHIELD SHIELD

BOILER

FROM

BOILER

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

WIRE AS

NEEDED

SYSTEM PUMP

SPEED CONTROL

BOILER PUMP

A B

HEAT / LOOP

DEMAND 2

HEAT / LOOP

DEMAND 1

FLOW SWITCH

LOUVER

PROVING SWITCH

COM

IMG00126

Installation & Operation Manual

9 Condensate disposal

Condensate drain

1. This boiler is a high efficiency appliance that produces

condensate.

2. The bottom of the boiler has a 1 1/4 inch pipe for

connection of the condensate trap (FIG. 9-1).

3. Slope condensate tubing down and away from the boiler

into a drain or condensate neutralizing filter. Condensate

from the Knight wall mount boiler will be slightly acidic

(typically with a pH from 3 to 5). Install a neutralizing

filter if required by local codes.

A Neutralizer Kit is available from the factory (Kit 3087).

4. Do not expose condensate line to freezing temperatures.

5. Use only plastic tubing or piping as a condensate drain

line (FIG. 9-1).

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.

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).

NOTICE

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.

CONDENSATE

TRAP

REMOVABLE CAP

FOR CLEANING

TRAP

CONDENSATE DRAIN CONNECTION -

ROUTE TO FLOOR DRAIN OR

NEUTRALIZING FILTER USING

3/4" PVC TUBING

IMG00159

Figure 9-1 Condensate Disposal

Installation & Operation Manual

10 Start-up

Check/control water chemistry

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)

1. Determine freeze protection fluid quantity using

system water content, following fluid manufacturer’s

instructions. Boiler water content is listed on page 6.

Remember to include expansion tank water content.

2. Local codes may require a backflow preventer or actual

disconnect from city water supply.

3. When using freeze protection fluid with automatic fill,

install a water meter to monitor water makeup. Freeze

protection fluid may leak before the water begins to

leak, causing concentration to drop, reducing the freeze

protection level.

4. The freeze protection set points may be lowered when

freeze protection fluid is used (see the Knight Wall

Mount Service Manual).

Fill and test water system

1. Fill system only after ensuring the water meets the

requirements of this manual.

2. Close boiler drain valve and manual air vent.

3. Fill to correct system pressure. Correct pressure will vary

with each application.

a. The minimum cold water fill pressure for a

residential system is 12 psi.

b. Pressure will rise when boiler is turned on and

system water temperature increases.

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

1. Purge air from system:

a. Connect a hose to the purge valve (see purge/drain

valves, in piping diagrams on pages 38 through 47).

Route the hose to an area where water can drain and

be seen.

b. Close the boiler or system isolation valve between

the purge valve and fill connection to the system.

c. Close zone isolation valves.

d. Open quick-fill valve on cold water makeup line.

e. Open purge valve.

f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air.

Run until no noticeable air flow is present. Close the

zone isolation valves and proceed with the next zone.

Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch

that system pressure rises to correct cold-fill

pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located

throughout the system.

i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time,

beginning with the lowest floor. Close the vent when

water squirts out. Repeat with remaining vents.

2. 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.

3. Refill to correct pressure.

4. At initial fill and during boiler startup and testing, check

system thoroughly for any leaks. Repair all leaks before

proceeding further.

 WARNING

 CAUTION

Installation & Operation Manual

10 Start-up

Check for gas leaks

Before starting the boiler, and during

initial operation, smell near the floor and

around the boiler for gas odorant or any

unusual odor. Remove the front access

panel and smell the interior of the boiler

enclosure. Do not proceed with startup

if there is any indication of a gas leak.

Use an approved leak detection solution.

Repair any leaks at once.

DO NOT adjust gas valve outlet pressure.

The gas valve is factory set for the correct

outlet pressure. This setting is suitable

for natural gas and propane, requiring

no field adjustment. Attempting to

alter the gas valve outlet pressure could

result in damage to the valve, causing

potential severe personal injury, death, or

substantial property damage.

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.

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.

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.

CONDENSATE

DRAIN

REMOVABLE CAP TO

CLEAN OUT TRAP

COMPRESSION

FITTING

FLOAT BALL

IMG00209

Figure 10-1 Condensate Trap

 WARNING

Clean/Inspect Trap Assembly

1. Remove the clean out cap on the bottom of the trap. Let the

condensate and any debris drain out.

2. Refill the trap according to the instructions above.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to each

of the heat/loop demand terminals on the connection

board.

2. Connect a voltmeter across these two incoming wires.

Close each thermostat, zone valve, and relay in the

external circuit one at a time and check the voltmeter

reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and

correct the external wiring. (This is a common problem

when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and

corrected if necessary, reconnect the external thermostat

circuit wires to the connection board.

Installation & Operation Manual

10 Start-up (continued)

Final checks before starting the boiler

 Read the Knight Wall Mount Service Manual to

familiarize yourself with SMART SYSTEM control

module operation. Read this manual, pages 60 and 61

for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 57

and 58 have been completed.

 Ensure float ball is inside condensate trap (see FIG. 10-1).

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air

piping and vent piping are intact and correctly installed

per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG.’s 10-2

and 10-3 on pages 60 and 61.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch

off?

2. Is boiler water temperature above 200°F?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the

Troubleshooting Section of the Knight Wall Mount Service

Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down

the boiler and repair immediately. (See WARNINGS

on pages 57 and 58 (startup) regarding failure to repair

leaks.)

2. Vent any remaining air from the system using manual

vents. Air in the system will interfere with circulation

and cause heat distribution problems and noise.

 Check vent piping and air piping

1. Check for gas tight seal at every connection, seam of air

piping, and vent piping.

Venting system must be sealed gas tight

to prevent flue gas spillage and carbon

monoxide emissions, which will result in

severe personal injury or death.

 Check gas piping

1. Check around the boiler for gas odor following the

procedure on page 48 of this manual (connecting gas supply

piping).

If you discover evidence of any gas leak,

shut down the boiler at once. Find the

leak source with a bubble test and repair

immediately. Do not start the boiler again

until corrected. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the

Propane Conversion instructions.

DO NOT adjust gas valve outlet pressure.

The gas valve is factory-set for the correct

outlet pressure. This setting is suitable

for natural gas and propane, requiring

no field adjustment. Attempting to alter

the gas valve outlet pressure could result

in damage to the valve, causing potential

severe personal injury, death, or substantial

property damage.

Check flame and combustion

1. Shut off the main power to the boiler by placing the On/Off

switch in the OFF position.

2. Remove the flue temperature sensor from the flue pipe

connection. Note: Combustion measurements will be

made at this point.

3. Turn on the main power to the boiler by placing the On/Off

switch in the ON position.

 WARNING

 WARNING 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.

Installation & Operation Manual

10 Start-up

Figure 10-2 Operating Instructions - Models 55 - 285

Installation & Operation Manual

10 Start-up (continued)

Figure 10-3 Operating Instructions - Model 399

Installation & Operation Manual

10 Start-up

Please note that the brackets ([]) denote

screen status.

NOTICE

4. Place the boiler into the active position by pressing the

RIGHT SELECT [ON] key (FIG. 11-1, page 70).

5. Locate the pinhole button below the RESET button on

the display board (FIG. 11-1). Insert a thin wire (such as

a paper clip) into the hole and press the button once and

hold for 5 seconds to place the boiler into Service Mode.

In Service Mode the boiler will fire at ignition speed and

will then modulate up to full fire.

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.

Check flame and combustion (continued) Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be

based on one of three sensors; the inlet, outlet, or system

supply sensor. The SMART SYSTEM control is programmed at

the factory to control the temperature of the outlet sensor. The

control will automatically switch to the system supply sensor

once it is connected. If it is desired to base the temperature

control on the inlet sensor, the appropriate parameter must

be changed in the control. See the Knight Wall Mount Service

Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system pump (if

connected), and the boiler pump. When the SMART SYSTEM

control receives a space heating call for heat, it turns on the

system pump. If the boiler is not heating an indirect DHW

(Domestic Hot Water) tank, and the set point is not met, it

also turns on the boiler pump. After the space heating call

for heat ends, the system pump continues to run for a short

period of time. The system pump can be programmed to run

continuously, except during outdoor shutdown. If the boiler

pump was running, it continues to run for a short period of

time as well. These pump delays are factory set to 30 seconds.

If different delays are desired, the appropriate parameters in

the control must be changed. See the Knight Wall Mount

Service Manual for a detailed explanation of this procedure.

Adjust set point temperature(s)

Table 10A Flue Products Chart

8. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff

switch to the OFF position and ensuring that the boiler

shuts down and registers an alarm. Turn the manual

shutoff switch to the ON position and reset the control.

9. Turn off power at source and replace the flue temperature

sensor into the flue pipe connection.

10. Place the boiler back into normal operation.

You must replace the flue gas temperature

sensor to prevent flue gas spillage into

the room. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

 WARNING

Please note that the brackets ([]) denote

screen status.

NOTICE

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. Turn the NAVIGATION dial counterclockwise to select the

appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the

RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to

additional set points.

6. Press the RIGHT SELECT [HOME] key to upload the

changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the

new settings will be discarded.

Natural Gas Propane

CO2O2CO2O2

8.0% - 10% 3.0% - 6.5% 10.0% - 11% 4.1% - 5.4%

Installation & Operation Manual

10 Start-up (continued)

Set domestic hot water (DHW) operation

Verify DHW mode

There are two (2) modes of operation for DHW. In Normal

Mode, when a DHW demand begins, the control will start

the DHW pump, turn off the boiler pump (if running), and

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 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

If the rated input of the indirect tank is less than the maximum

output of the boiler, change the maximum DHW fan speed

setting to limit the boiler output accordingly, see the Knight

Wall Mount Service Manual for a detailed explanation of this

procedure.

NOTICE The internal clock does not adjust for

Daylight Savings Time and therefore, will

require a manual adjustment.

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.

Please note that the brackets ([]) denote

screen status.

NOTICE

Configuration of the cascade

Please note that the brackets ([]) denote

screen status.

NOTICE

When installed in a Cascade system, the individual controls must

be programmed for cascade operation. This is accomplished by

accessing the control parameters.

Press the [MENU] key for at least five (5) seconds. Input the

Installer code as described in the Knight Wall Mount Service

Manual. Once the control parameters have been accessed, use

the NAVIGATION dial to select the Control Mode parameters.

Press the NAVIGATION dial to access these parameters.

Rotate the NAVIGATION dial to select the parameter Cascade

Address. Press the NAVIGATION dial to access this parameter.

Each appliance in the Cascade system must be programmed

with its own address. The boiler designated as the Leader will

have an address of 0. The remaining boilers in the Cascade

will be Members and have addresses from 1 - 7. Rotate the

NAVIGATION dial to select the appropriate address. Press the

RIGHT SELECT [SAVE] key.

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.

Set clock

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 read [PASSWORD],

with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and

date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press

the NAVIGATION dial.

The clock is automatically updated whenever a PC is connected

and the Win_Pro-Installer program is started.

Installation & Operation Manual

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 operation

can be based on boiler outlet water temperature, boiler inlet

water temperature, system temperature, a 0 - 10V signal, or

Modbus, depending on the parameter settings.

Control inputs and outputs

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.

0 - 10V input (set point or power)

The Knight wall mount boiler can be controlled by a Building

Management System (BMS) using a 0 - 10 vdc signal. The

control can be configured by the installer to use this signal to

either control set point or firing rate.

SMART SYSTEM Multi-temp loop control

The Knight wall mount boiler is capable of producing up

to three (3) set point temperatures to meet different space

heating demands. This device controls the temperatures

of up to three (3) separate loops, based on the settings for

the three (3) heat/loop demands (reference Lochinvar kit

RLY30086).

The Knight wall mount boiler can also be programmed to

accept a call for heat from a 0 - 10V signal, reference the Knight

Wall Mount Service Manual for a detailed explanation of this

procedure.

DHW priority

The SMART SYSTEM control allows the connection of a DHW

thermostat or tank sensor to the low voltage connection board.

When a tank sensor is connected, the DHW thermostat input

is ignored. When a boiler is programmed for DHW Normal

Mode, the maximum firing rate can be limited to match the

input rating of the indirect tank coil.

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. The control sensor can be changed by the installer to

the inlet sensor. If the inlet sensor is chosen as the controlling

sensor, it is recommended that the system supply sensor

be installed in order to provide the best control of the inlet

temperature.

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 20% to a maximum of 100%. The

firing rate is dictated by the call for heat (i.e., space heating or

domestic hot water), the heating load, ramp delay (if enabled),

and various other temperature limitations.

 CAUTION When multiple temperature loops are

used, thermostatic mixing valves are

required for the protection of any low

temperature loops.

Installation & Operation Manual

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 until the space heating demand ends, the set

point reaches the programmed set point or a maximum of

20 increases has occurred. Once the system heat demand is

satisfied, the set point will revert to the value determined by

the reset curve.

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°F the control will reduce the maximum fan speed. If

the flue temperature exceeds 240°F the control will shut the

unit down. The unit will restart automatically once the flue

temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the

inlet and the outlet sensor. If this difference exceeds 55°F the

control will reduce the maximum fan speed. If the temperature

difference exceeds 60°F the control will shut the unit down. The

unit will restart automatically once the temperature difference

has dropped below 55°F and the minimum off time has expired.

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.

• Lower temperatures may be programmed for

systems with anti-freeze solutions (see the Knight Wall

Mount Service Manual.

This feature of the SMART SYSTEM control

module does not eliminate the possibility

of freezing. The installation must still

use recognized design, installation and

maintenance practice to prevent freeze

potential for the boiler and system.

 CAUTION

NOTICE When system return temperatures

are maintained below the dew point,

condensation will form on the inside of the

boiler jacket causing some internal sheet

metal components to rust.

Installation & Operation Manual

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 or 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.

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

1. Turn ON the main power to the boiler by placing the

ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to

access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating

the NAVIGATION dial counterclockwise, then press

the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current

outlet temperature (or to its minimum setting, whichever

is higher) by turning the NAVIGATION dial

counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new

parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL

set point, the MRHL will function causing boiler lockout.

If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL

set point, locate the pinhole (SERVICE button) below the

RESET button on the display board. Insert a thin probe

(such as a paper clip) into the hole and press the button

continuously for five (5) seconds to place the boiler into

Service Mode. In Service Mode, the boiler will fire at

ignition speed and will then modulate up to full fire.

10. Once the outlet temperature rises up to the MRHL set

point, the MRHL will function, causing the boiler to shut

down and lock out.

11. Repeat Steps 2, 3 and 4.

12. Set the MRHL to the appropriate set point by turning the

NAVIGATION dial clockwise.

13. Repeat Steps 6 and 7.

14. Press the RESET button to clear the lockout.

15. If needed, press the RIGHT SELECT [STOP] key to exit

Service Mode.

Please note that the brackets ([]) denote

screen status.

NOTICE

Installation & Operation Manual

11 Operating information (continued)

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 designated as the DHW boiler. Connect the DHW

thermostat or sensor to the terminals on the Low Voltage

Connection Board marked for the corresponding device. When

the boiler receives a DHW call, the Leader control will take that

boiler out of the Cascade sequence. If another boiler is available,

the Leader will start it up to take its place.

The DHW boiler will adjust its set point to the programmed

DHW 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.

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 change every hour during the first 24 hours, after

that the sequence will be changed once every 24 hours. The

switching on/off sequence will be as follows:

TIME SWITCHING ON SEQUENCE

Start L-M1-M2-M3-M4-M5-M6-M7

1 hour M1-M2-M3-M4-M5-M6-M7-L

2 hours M2-M3-M4-M5-M6-M7-L-M1

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.

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 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.

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature

sensing of both supply and return areas of the heat

exchanger. If the flow rate is too low or the outlet

temperature too high, the control module modulates and

shuts the boiler down. This ensures boiler shutdown in

the event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral

features of the control in lieu of requiring an additional

limit control or low water cutoff. Consult local

jurisdiction to determine. A low water cutoff is available

from the factory (WTR20009).

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.

Installation & Operation Manual

11 Operating information

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns

on the appropriate pumps (system and boiler pumps for space

heating, DHW pump for DHW). The flow switch and/or LWCO

must close.

3. The control turns on power to the louver relay. The louver

proving switch, air pressure switch, and blocked drain switch

must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by firing the spark

electrode and opening the gas valve.

6. If flame is not detected after the sparking ends, the control will

perform a postpurge, then start another prepurge cycle and try to

light the burner again. The control will perform a total of 4

attempts before locking out.

7. If flame is detected, it holds the firing rate steady for a few

seconds to let the flame stabilize, then it begins to modulate the

firing rate based on a set point or some other command (such

as a 0-10V BMS signal).

Installation & Operation Manual

11 Operating information (continued)

Access modes

User

The user can adjust space heating and tank target temperatures

by pressing the NAVIGATION dial when “SETPOINTS” is

flashing at the bottom of the display. The date and time, and

the temperature units can also be changed (see page 63).

Installer

Most parameters are available only to the installer, accessible

by entering the installer password, see the Knight Wall Mount

Service Manual.

Saving parameters (reference the Parameter Table in

the Knight Wall Mount Service Manual)

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the

RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the

parameter listings; press again to return to the menu listings.

Remember to press the RIGHT SELECT [HOME] key when

finished programming in order to save the changes made.

See the Knight Wall Mount Service Manual for a detailed

description of parameters and access modes.

OPERATION DISPLAY

8. If the space heating call for heat is active, and the tank thermostat

or sensor starts a DHW call for heat, the boiler will switch to the

DHW mode. If programmed for normal DHW operation (not as a

zone), the DHW pump will turn on first, then the boiler pump will

turn off (boiler and DHW pump operation briefly overlap to ensure

flow is maintained through the unit). This will divert the boiler’s

outlet water from the heating system and send it to the tank coil

instead. The control will then modulate to maintain the outlet

temperature to the DHW boiler set point.

9. If the boiler is not part of a Cascade, and both the space heating

and DHW calls for heat remain active long enough, the boiler will

switch back and forth between the two heating modes until one of

them is satisfied.

10. Once both calls for heat are satisfied, the control will turn off

the burner. The blower will continue to run during the postpurge

period.

11. Any pumps that are running will continue to run for their respective

pump delay times before turning off, unless programmed to

remain on continuously. A 60 second anti-cycle period will start,

which will delay any new call for heat until it times out.

12. In Standby, ready to start a new cycle.

Please note that the brackets ([]) denote

screen status.

NOTICE

Installation & Operation Manual

Knight wall mount boiler control module

NAVIGATION DIAL

Figure 11-1 Control Panel

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

11 Operating information

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

Installation & Operation Manual

11 Operating information (continued)

Status Display Screens

Section Display Description

(Boiler Status

Bar)

STANDBY The unit has not received a call for heat from a remote thermostat nor

has it received a call for heat from a DHW thermostat.

START The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE The unit has initiated a prepurge period on a call for heat.

IGNITION The unit has begun a spark period to ignite the main burner.

The unit has fired and is running at the displayed percentage.

POSTPURGE

The call for heat has been satisfied and the unit runs the fan for an

additional postpurge period to clear the combustion chamber and

vent system of residual flue products.

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.

(Call for Heat

Indicators)

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.

The tank thermostat or sensor has a call for heat.

Indicates which heat/loop demand shows priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

(BOILER

STATUS)

(OPERATIONAL

INFORMATION)

(LEFT SELECT

KEY)

(RIGHT SELECT KEY)

(NAVIGATION DIAL)

(CALL FOR

HEAT)

Figure 11-2 Status Display Screen

Installation & Operation Manual

11 Operating information

Status Display Screens (cont’d)

Section Display Description

(Operational

Information)

SYSTEM: The temperature read by the system supply sensor (if connected).

TANK: The temperature read by the tank sensor (if connected).

OUTDOOR: The temperature read by the outdoor sensor (if connected).

INLET TEMP: The temperature read at the inlet to the heat exchanger.

OUTLET TEMP: The temperature read at the outlet of the heat exchanger.

DELTA T: The temperature difference between the inlet and the outlet of the

heat exchanger.

FLUE TEMP: The temperature read by the flue sensor.

FLAME CURRENT: The current measured by the flame sense circuit.

FAN SPEED: The speed of the combustion blower.

BOILER PUMP: The status of the boiler pump output.

SYSTEM PUMP: The status of the system pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT: The speed signal received from a variable speed system pump control.

RATE OUTPUT: A 0 - 10V signal indicating the firing rate of the boiler.

SH RUN HOURS: The total hours of operation in the Space Heating Mode.

SH CYCLES: The total burner cycles in the Space Heating Mode.

DHW RUN HOURS: The total hours of operation in the DHW Mode.

DHW CYCLES: The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:* The last 10 lockouts.

NIGHT SETBACK Shows the next Night Setback trigger (if active).

Installation & Operation Manual

11 Operating information (continued)

Status Display Screens (cont’d)

Section Display Description

(LEFT SELECT

key function)

MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu

Screen.

EXIT Press the LEFT SELECT key to exit the current screen or setting.

YES Press the LEFT SELECT key to confirm that the boiler needs to

shutdown.

LIMITS Press the LEFT SELECT key to enter the screen that allows you to

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.

(NAVIGATION

Dial Function)

Turning the NAVIGATION dial will select the next or previous Status

Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night

Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by

the cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current

setting.

(RIGHT SELECT

key function)

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME Press the RIGHT SELECT key to return to the Status Screen and

upload parameter changes.

Installation & Operation Manual

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if

necessary;

• Clean condensate trap and fill with fresh

water

• Check for leaks (water, gas, flue,

condensate)

• Verify flue and air lines in good condition

and sealed tight

• Check system water pressure/system

piping/expansion tank

• Check control settings

• Check ignition and flame sense

electrodes (sand off any deposits; clean

and reposition)

• Check wiring and connections

• Perform start-up checkout and

performance verification per Section 10

of this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at

high fire)

• Clean the heat exchanger if flue

temperature is more than 54°F above

return water temperature.

If combustion or performance

indicate need:

• Clean heat exchanger

• Remove and clean burner using

compressed air only

• Clean the blower wheel

ANNUAL START-UP

Owner maintenance

(see the Knight Wall Mount User’s Information

Manual for instructions)

Daily

• Check boiler area

• Check pressure/temperature

gauge

Monthly

• Check vent piping

• Check air piping

• Check air and vent termination

screens

• Check relief valve

• Inspect condensate drain system

• Check air vents

Periodically • Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check boiler piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

• Shut boiler down (unless boiler

used for domestic hot water)

12 Maintenance

Installation & Operation Manual

12 Maintenance (continued)

Follow the Service and maintenance procedures given throughout this manual and in component literature

shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler

or system. Failure to follow the directions in this manual and component literature could result in severe

personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance

and care of the boiler designated in Table 12A and explained on the following pages must be performed to

assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could

result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as

noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,

causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct

before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials,

gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants

listed in Section 1 of this manual. If any of these are

present in the boiler intake air vicinity, they must be

removed. If they cannot be removed, reinstall the air and

vent lines per this manual and the Knight Wall Mount

Service Manual.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of

the boiler.

2. Vacuum any sediment from inside the boiler and

components. Remove any obstructions.

Inspect condensate trap

Monthly inspection:

1. The condensate trap should be inspected monthly to

ensure the trap is properly installed and connected to the

condensate pipe under the boiler, see FIG. 12-1.

2. The condensate line should be inspected monthly

for obstructions, making sure it allows free flow for

condensate to drain.

3. Inspect the neutralizing kit (if installed) monthly to

ensure the condensate is draining properly, and there is

still an adequate amount of neutralizing agent available.

Annual cleaning:

1. The condensate trap should be cleaned at least once

annually, or at the end of each heating season, by

removing the bottom cap and cleaning out any sediment

that exists.

2. The provided condensate trap is equipped with a ball

that acts as a seal against harmful flue gases escaping in

case there is no condensate in the trap. If this ball is not

present, flue gases may be able to pass through the trap

when there is no condensate present, resulting in an

unsafe environment. It is important to check and make

sure the ball is still located in the trap, acting as a seal

against flue gases at least once annually and after every

cleaning.

Eliminate all system or boiler leaks.

Continual fresh makeup water will reduce

boiler life. Minerals can build up in sections,

reducing heat transfer, overheating heat

exchanger, and causing heat exchanger

failure. Leaking water may also cause severe

property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems

found.

3. Check gas line using the procedure found in Section 7 -

Gas Connections.

Check all piping for leaks

It is in the best interest of the end user

to make sure the ball is present and the

condensate trap is filled with water during

all times of boiler operation to avoid flue

gas emission from the condensate drain

line. Failure to have the ball present or to

fill the trap could result in severe personal

injury or death.

 WARNING

IMG00046

CONDENSATE DRAIN

FLOAT BALL

BOTTOM CAP

Figure 12-1 Condensate Trap

3. After the condensate trap is cleaned or serviced, it must be

checked to ensure that it is installed and draining properly.

Installation & Operation Manual

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.

Safety relief valves should be re-inspected

AT LEAST ONCE EVERY THREE YEARS,

by a licensed plumbing contractor or

authorized inspection agency, to ensure

that the product has not been affected by

corrosive water conditions and to ensure

that the valve and discharge line have not

been altered or tampered with illegally.

Certain naturally occurring conditions may

corrode the valve or its components over

time, rendering the valve inoperative. Such

conditions are not detectable unless the

valve and its components are physically

removed and inspected. This inspection

must only be conducted by a plumbing

contractor or authorized inspection agency

– not by the owner. Failure to re-inspect the

boiler relief valve as directed could result in

unsafe pressure buildup, which can result in

severe personal injury, death, or substantial

property damage.

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.

2. After following the warning directions in this manual, if

the relief valve weeps or will not seat properly, replace the

relief valve. Ensure that the reason for relief valve weeping

is the valve and not over-pressurization of the system due to

expansion tank waterlogging or undersizing.

 WARNING

12 Maintenance

Inspect ignition and flame sense

electrodes

1. Remove the ignition and flame sense electrodes from the

boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame

sense electrode using sandpaper. If the electrodes cannot be

cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket

is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access

cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good

condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to

Parameter Mode and check all settings. See Section 1 of

the Knight Wall Mount Service Manual. Adjust settings if

necessary. See Section 1 of the Knight Wall Mount Service

Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust

if necessary.

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air

piping for blockage, deterioration or leakage. Repair any

joints that show signs of leakage. Verify that air inlet pipe

is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean

and free of obstructions.

Failure to inspect for the above conditions

and have them repaired can result in severe

personal injury or death.

 WARNING

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold fill pressure for the system. Verify it is

correct (must be a minimum of 12 psi).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high.

Excessive pressure rise indicates expansion tank sizing or

performance problem.

4. Inspect air separators.

Installation & Operation Manual

12 Maintenance (continued)

BURNER

GASKET

INSULATION,

BURNER DOOR

GASKET,

BURNER PLATE

Figure 12-2 Burner Assembly

Check flame signal

1. At high fire the flame signal shown on the display should

be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged

flame sense electrode. If cleaning the flame sense electrode

does not improve, ground wiring is in good condition,

and ground continuity is satisfactory, replace the flame

sense electrode.

3. See Section 3 - Troubleshooting of the Knight Wall

Mount Service Manual for other procedures to deal with

low flame signal.

Oiled bearing circulators

1. The circulator shipped with the Knight wall mount boiler is

water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators

requiring oil, following circulator manufacturer’s

instructions. Over-oiling will damage the circulator.

3. Replace the boiler front access cover.

The boiler contains ceramic fiber materials.

Use care when handling these materials per

instructions in the Service Manual. Failure

to comply could result in severe personal

injury.

 WARNING

Cleaning boiler heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions

for the boiler in Section 10 - Startup.

• Do not drain the boiler unless it will be exposed to

freezing temperatures. If using freeze prevention fluid

in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it

has been firing.

3. Remove the nuts securing the heat exchanger access cover

to the heat exchanger and set aside.

4. Remove the heat exchanger access cover and burner.

5. Remove the condensate trap from the bottom of the boiler.

Place a bucket underneath the condensate fitting attached

to the heat exchanger.

6. Use a vacuum cleaner to remove any accumulation on the

boiler heating surfaces. Do not use any solvent.

7. Using a clean cloth dampened with warm water, wipe out

the combustion chamber. Rinse out debris with a low

pressure water supply.

8. Allow the heat exchanger to thoroughly dry.

9. Perform start-up and check-out procedures in the Check

Flame and Combustion - Section 10 - Startup on pages 59

and 62 of this manual.

10. Replace the burner, access cover and condensate trap.

Restore boiler to operation.

* Do NOT use a metal brush.

 CAUTION

Review with owner

1. Review the Knight Wall Mount User’s Information Manual

with the owner.

2. Emphasize the need to perform the maintenance schedule

specified in the Knight Wall Mount User’s Information

Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor

should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure

and to schedule an annual start-up at the beginning of the

next heating season.

Perform start-up and checks

1. Start boiler and perform checks and tests specified in

Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating

pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire,

turn off boiler and allow boiler to cool down. Remove the

burner and clean it thoroughly using a vacuum cleaner

or compressed air. Do not use compressed air to clean

burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 (page 77).

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG. 12-2).

Installation & Operation Manual

13 Diagrams

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM

LBL20170 REV D

120 VAC

24 VAC

120VAC

TERMINAL STRIP

120V SUPPLY "L"

ON / OFF

SWITCH

X1-6 F2

NEUTRAL

INTEGRATED

CONTROL

X2-1

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

3.15A

TR2

X1-7

FLAME ROD

SPARK

ROD

INTEGRATED CONTROL

GROUND

JUNCTION BOX

CAUTION HIGH VOLTAGE SPARK LEAD

BLOWER

CONNECTION

BOARD

INLET

SENSOR

OPERATI NG

SENSOR

FLUE

SENSOR

INTEGRATED

CONTROL

RUN-TIME

CONTACTS

RIBBON CABLE

SYSTEM

SENSOR

TANK

SENSOR

OUTDOOR

SENSOR

0-10V

CASCADE A

SHIELD

SILENCING

SWITCH

ALARM

BELL

BMS

CN6 X6

CN5-2 X4-6

CN5-9 X4-13

CN5-1 X4-7

CN5-8 X4-14

CN6 X6

HIGH LIMIT

SENSOR

FLUE

SENSOR

X5-4

X5-12

X5-5

X5-13

X5-14

X5-6

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS A

SHIELD

CN6 X6

CN8-1 X6-1

CN8-2 X6-2

CN8-3 X 6-3

X4-1 X9-2

X4-2 X9-1

X4-3 X9-3

PC INTERFACE

S1a

S1b

S3a

S3b

ALARM

CONTACTS

CN6 X6

X2-2

NOTES:

1. Where possible, switches are shown without utilities (gas, water or

electricity) connected to the unit. As such, actual switch states may

vary from those shown on diagrams depending upon whether utilities

are connected or a fault condition is present.

2. See wiring diagram for additional notes.

X1-1

BLOWER

SYSTEM PUMP

RELAY

DHW PUMP

RELAY

BOILER PUMP

RELAY

24V DC

SUPPLY

.8A

X5-1

X5-9

CN5-5

X4-3

X1-4

X1-3

X1-2

BOILER

PUMP "L"

DHW

PUMP "L"

SYSTEM

PUMP "L"

BOILER

PUMP

DHW

PUMP

SYSTEM

PUMP

BOILER

PUMP "N"

DHW

PUMP "N"

SYSTEM

PUMP "N"

TERMINAL

STRIP

TERMINAL

STRIP

GND

TERMINAL STRIP

120V SUPPLY "N"

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

X5-2

X5-11

AIR PRESSURE

SWITCH

CN5-6

CN5-12

CN5-11

X4-2

X4-10

X4-11

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH CN5-4 X4-4

CN5-3 X4-5

CN5-13 X4-9

CN5-7 X4-1

CN5-10 X4-12

CN5-14 X4-8

CONNECTION BOARD

CN7-3

CN7-2

CN7-4

CN7-1

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOW GAS

PRESSURE

SWITCH

FLOW

SWITCH

11 12

24 VAC

LWCO

X5-11

X5-10

Figure 13-1 Ladder Diagram

Installation & Operation Manual

X1-7

ON/OFF

SWITCH

1 2 3 45

BLOWER

-T

HIGH LIMIT SENSOR S1b

OPERATING SENSOR S1a

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

INTEGRATED

CONTROL

GAS VALVE

@24VAC

SPARK

ROD

TRANSFORMER

TR2

HIGH VOLTAGE SPARK LEAD

CAUTION

FLAME SENSOR

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

CASCADE

SHIELD

0-10V

BMS

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS

OPTION

SHIELD

LOW

WATER

CUT-OFF

24 VAC

COM

P/BK

W/R

CN7-1

CN7-2

CN7-3

CN7-4

CN5-1

CN5-8

CN5-2

CN5-9

CN5-3

CN5-10

CN5-11

CN5-4

CN5-5

CN5-14

CN5-12

CN5-6

CN5-13

CN5-7

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a

minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead

or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using

diagrams to troubleshoot unit.

WIRING DIAGRAM

LBL20169 REV D

BOX DEPICTS

OPTIONAL ITEMS

X4-7

X4-14

X4-6

X4-13

X4-5

X4-12

X4-11

X4-4

X4-3

X4-8

X4-10

X4-2

X4-9

X4-1

CONNECTION BOARD

CN6 X6

HIGH VOLTAGE

LOW VOLTAGE

120 VAC

X-7

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

MODBUS BOARD

MTR-01

CN8-1

CN8-2

CN8-3

X6-3

X6-2

X6-1

X6-4

X9-1

X9-2

X9-3

X9-4

X4-1

X4-2

X4-3

X4-4

X5-1

X5-2

X1-1

X1-2

X1-3

RBLG

-T

SHIELD

GROUNDING

JUMPER

R/BK

W/BK

BELL JUMPER

ALARM BELL

SILENCING SWITCH

JUNCTION

BOX

DHW

PUMP

BOILER

PUMP

SYSTEM

PUMP

BOX DEPICTS

OPTIONAL

ITEMS

GND

120V

SUPPLY

X1-3

X1-4

X1-2

X1-5

X1-6

X1-8

X1-1

AIR PRESSURE SWITCH

O/BK

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

Figure 13-2 Wiring Diagram

13 Diagrams (continued)

Revision A (ECO #C06854) initial release.

Revision B (ECO #C08222) reflects the changes to the water pipe

clearances from 1" to a 1/4" (ECR #R04077), pages 7, 8, and 33 and

changes made to the service clearances (left side) from 24" to 12" (ECR

R04002).

Revision C (ECO #C08645) reflects additional cleaning and inspection

instructions for the condensate trap (page 75).

Revision D (ECO #C09197) reflects additional information added to the

humidity warning on page 7, along with updates made to the SMART

SYSTEM control (ECR #R04523).

Revision E (ECO #C09803) reflects the addition of the new Polypropylene

Vent material section, rearranging the venting section, and the addition

of the AHRI and ASME logos (R05009).

Revision F (ECO #C09843) reflects the addition of the manual air vent in

the outlet tubing and the new condensate trap pipe (R04984).

Revision G (ECO C10297) reflects the addition of the venting notice on

page 16 and updates made to the ignition timing information.

Revision H (ECO C10450) reflects changes made to Table 10A on

page 62.

WH-I-O Rev H

05/12

Lochinvar Wall Mount Boiler Wh 55 399 Users Manual I O Rev H

WH 55-399 to the manual 08959e06-5362-414a-a7e2-1244aa81bc5f

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