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Installation & Operation Manual
Models: 50 - 210
This manual must only be used by a
WARNING
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.
Save this manual for future reference.
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Table of Contents
Related Manuals for Knight 210
Summarization of Contents
1 Determine boiler location
Closet and alcove installations
Guidelines for installing the boiler in confined spaces like closets or alcoves.
Provide clearances
Required clearances around the boiler for service and combustible materials.
1 Determine boiler location (continued)
Provide air openings to room
Requirements for ventilation air openings based on installation scenarios.
Wall mounting location
Considerations for selecting a suitable wall for mounting the boiler.
Residential garage installation
Precautions and requirements for installing the boiler in a garage.
Prevent combustion air contamination
Ensuring clean combustion air to prevent damage and safety hazards.
1 Determine boiler location (continued)
When removing a boiler from existing common vent system
Procedure for safely removing an old boiler from a shared venting system.
2 Prepare boiler
Remove boiler from wood pallet
Instructions for safely removing the boiler unit from its shipping pallet.
Gas conversions
Procedure for converting the boiler from natural gas to propane.
2 Prepare boiler (continued)
Mounting the boiler
Instructions and safety precautions for mounting the boiler to various wall types.
3 General venting
Direct venting options
Overview of different direct venting configurations for combustion air and exhaust.
3 General venting (continued)
Install vent and combustion air piping
Guidelines for installing the vent and combustion air piping systems.
Vent piping materials
Approved materials and standards for vent piping and fittings.
Requirements for installation in Canada
Specific installation requirements for vent systems in Canada.
3 General venting (continued)
Air intake/vent connections
How to connect the combustion air intake and vent piping to the boiler.
Maximum allowable combustion air and vent piping lengths
Limits on the length of vent and combustion air piping for optimal performance.
3 General venting (continued)
Removing from existing vent
Instructions for removing the boiler from an existing vent system.
Air contamination
Preventing contamination of combustion air from household chemicals.
4 Sidewall direct venting
Vent/air termination – sidewall
Determining the correct location and clearances for sidewall vent/air terminations.
4 Sidewall direct venting (continued)
Prepare wall penetrations
Steps for creating wall openings for vent and air intake piping.
Termination and fittings
Details on assembling and installing vent and air termination components.
Multiple vent/air terminations
Guidelines for terminating multiple boilers' vent and air connections.
4 Sidewall direct venting (continued)
Sidewall termination – optional concentric vent
Installation instructions for optional concentric sidewall vent termination kits.
5 Vertical direct venting
Vent/air termination – vertical
Determining the location and clearances for vertical roof vent/air terminations.
5 Vertical direct venting (continued)
Prepare roof penetrations
Steps for preparing roof openings for vent and air intake piping.
Termination and fittings
Details on assembling and installing vertical vent and air termination components.
Multiple vent/air terminations
Guidelines for terminating multiple boilers' vertical vent and air connections.
5 Vertical direct venting (continued)
Vertical termination – optional concentric vent
Installation instructions for optional concentric vertical vent termination kits.
6 Hydronic piping
System water piping methods
Overview of system water piping methods and requirements.
Freeze protection
Proper use of glycol solutions for freeze protection in hydronic systems.
General piping information
Basic steps and considerations for installing hydronic piping.
6 Hydronic piping (continued)
Circulator sizing
Guidance on selecting and sizing circulators for the heating system.
Near boiler piping connections
Diagrams and explanations for piping connections near the boiler.
6 Hydronic piping (continued)
Near boiler piping components
Detailed list and description of components for near boiler piping.
7 Gas connections
Connecting gas supply piping
Step-by-step guide for connecting the natural gas or propane supply.
7 Gas connections (continued)
Natural gas
Requirements for natural gas supply, including pipe sizing and pressure.
Propane Gas
Requirements for propane gas supply, including pipe sizing and pressure.
7 Gas connections (continued)
Check inlet gas supply
Procedures for verifying the gas supply pressure and quality.
7 Gas connections (continued)
Gas Pressure
Specifications for natural gas and LP gas pressure requirements.
Gas valve replacement
Information regarding the replacement of the gas valve.
8 Field wiring
Line voltage connections
Instructions for making 120VAC power connections to the boiler.
8 Field wiring (continued)
Low voltage connections
Instructions for making low voltage wiring connections for controls and sensors.
Thermostat and Sensor Connections
Wiring for thermostats, outdoor, and DHW sensors.
Auxiliary and Flow Control Connections
Connecting auxiliary devices, proving switches, and flow switches.
8 Field wiring (continued)
System supply sensor
Connecting the system supply sensor for temperature control.
Boiler management system
Connecting external controls for boiler firing rate or set point.
Wiring of the cascade
Instructions for wiring multiple boilers in a cascade system.
9 Condensate disposal
Condensate drain
Proper installation and maintenance of the condensate drain system.
10 Start-up
Check/control water chemistry
Ensuring proper water chemistry, hardness, and chlorine levels.
Fill and test water system
Steps for filling the system with water and checking for leaks.
Purge air from water system
Procedure for removing air from the hydronic system.
10 Start-up (continued)
Check for gas leaks
Performing checks for gas leaks before and during boiler operation.
Inspect/fill condensate system
Inspecting and filling the condensate trap and drain system.
10 Start-up (continued)
Final checks before starting the boiler
Final inspection steps before initiating boiler operation.
Check system and boiler
Verifying water, vent, gas piping, and conversion status.
Check flame and combustion
Procedures for checking the burner flame and combustion analysis.
10 Start-up (continued)
Set space heating operation
Configuring settings for space heating, including sensors and set points.
10 Start-up (continued)
Set domestic hot water (DHW) operation
Configuring settings for domestic hot water heating operation.
Set clock
Procedure for setting the internal clock for the control module.
Configuration of the cascade
Programming individual controls for cascade boiler system operation.
11 Operating information
General
Overview of the boiler's operation and control module functionality.
Control inputs and outputs
Description of inputs like thermostats and outputs for pumps.
DHW priority
How the system prioritizes domestic hot water heating calls.
DHW / space heating (SH) cycling
How the system manages simultaneous DHW and space heating demands.
11 Operating information (continued)
Ramp delay
Control feature to manage firing rate during system demand changes.
Protection features
Boiler safety features like temperature and flue limits.
Freeze protection
Information on the built-in freeze protection feature of the control module.
11 Operating information (continued)
Monitor external limits
Connecting and using external safety and control limits.
Boiler temperature regulation
How the control module manages target water temperatures.
High limit operations
Boiler response to high outlet temperatures and safety shutdowns.
Low water cutoff protection
How the control module prevents operation in low water or flow conditions.
11 Operating information (continued)
Cascade
Information on configuring and operating multiple boilers in a cascade system.
Sequence of the cascade
How boiler firing sequences are managed in a cascade system.
DHW, Night Setback, and Ramp Delay operation with cascade
Operating modes like DHW, Night Setback, and Ramp Delay in cascade systems.
11 Operating information (continued)
Sequence of operation
Detailed step-by-step description of the boiler's operational sequence.
11 Operating information (continued)
Access modes
Information on accessing user and installer settings for the control module.
Saving parameters
How to save parameter changes made to the control module.
11 Operating information (continued)
SMART Knight wall mount boiler control module
Overview of the control panel interface and its functions.
11 Operating information (continued)
Status Display Screens
Description of the various display screens on the control panel.
11 Operating information (continued)
Operation of the cascade
Detailed display information for boilers operating in a cascade system.
12 Maintenance
Maintenance and annual startup
Schedules and procedures for routine maintenance and annual startup.
12 Maintenance (continued)
Address reported problems
Procedure for inspecting and correcting reported issues with the boiler.
Inspect boiler area
Checking the area around the boiler for safety and air quality.
Inspect boiler interior
Inspecting and cleaning the internal components of the boiler.
Clean condensate trap
Instructions for cleaning and maintaining the condensate trap.
Check all piping for leaks
Procedure for checking all water, gas, and vent piping for leaks.
12 Maintenance (continued)
Flue vent system and air piping
Inspecting the flue vent system and air piping for damage or leaks.
Check water system
Verifying the installation and operation of the water system components.
Check expansion tank
Inspecting the expansion tank's role in managing system water volume.
Check boiler relief valve
Procedures for inspecting and testing the safety relief valve.
Inspect ignition and flame sense electrodes
Cleaning and inspecting the ignition and flame sense electrodes.
12 Maintenance (continued)
Perform start-up and checks
Performing essential checks and tests as part of the maintenance routine.
Check burner flame
Inspecting the burner flame for proper operation and appearance.
Cleaning boiler heat exchanger
Procedure for cleaning the boiler's heat exchanger for optimal performance.
13 Diagrams
Ladder Diagram
Schematic diagram illustrating the boiler's control logic and wiring.
13 Diagrams (continued)
Wiring Diagram
Detailed wiring diagram showing electrical connections for the boiler.
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