Knight 80 Installation & Operation Manual
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Knight 80 Installation & Operation Manual

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See also: Service Manual
Installation & Operation Manual
Models: 80 - 285
Starting Serial #H07H10040039
This manual must only be used by a
WARNING
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight Boiler 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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  • Page 1 Installation & Operation Manual Models: 80 - 285 Starting Serial #H07H10040039 This manual must only be used by a WARNING qualified heating installer / service technician. Read all instructions, including this manual and the Knight Boiler Service Manual, before installing. Perform steps in the order given.

  • Page 2: Table Of Contents

    Sidewall Termination - Optional Concentric Vent ..21-23 Knight Boiler Control Module ..... . 59-60 5.

  • Page 3: Please Read Before Proceeding

    Please read before proceeding Installer – Read instructions, When servicing boiler – WARNING including this manual and the Knight • To avoid electric shock, disconnect electrical supply Boiler Service Manual, before installing. before performing maintenance. Perform steps in the order given.

  • Page 4: The Knight Boiler - How It Works

    Installation & Operation Manual The Knight Boiler - How it works... Stainless steel heat exchanger 16. SMART Control Module Allows system water to flow through specially designed The SMART Control responds to internal and external signals coils maximum heat transfer, while...
  • Page 5 The Knight Boiler - How it works... (continued) Models 80 - 210 Front View - Models 80 - 210 Rear View - Models 80 - 210 Left Side (inside unit) - Models 80 - 210 Right Side (inside unit) - Models 80 - 210...
  • Page 6 Installation & Operation Manual The Knight Boiler - How it works... Model 285 Rear View - Model 285 Front View - Model 285 Right Side (inside unit) - Model 285 Left Side (inside unit) - Model 285...

  • Page 7: Ratings

    HIGH ALTITUDE Ratings are based on a piping and pickup allowance of 1.15. 4. Knight boilers require special gas venting. Use only the vent 4,501 FT. TO 12,000 FT. materials and methods specified in the Knight Installation and Operation Manual.

  • Page 8: Determine Boiler Location

    4. The Knight boiler must be installed so that gas control Provide clearances: system components are protected from dripping or spraying water or rain during operation or service.
  • Page 9 Installation & Operation Manual Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC WARNING material MUST BE used in a closet structure elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

  • Page 10: Provide Air Openings To Room

    Do not attempt to install the Knight boiler using any 2. Size openings only on the basis of the other appliances in other means.

  • Page 11: Corrosive Contaminants And Sources

    Table 1A Corrosive Contaminants and Sources When removing a boiler from existing common vent system: Products to avoid: Do not install the Knight boiler into a DANGER Spray cans containing chloro/fluorocarbons common vent with any other appliance. This will cause flue gas spillage or...

  • Page 12: Prepare Boiler

    You must install a propane orifice to operate Set the boiler in place and check level. the Knight boiler on propane gas. Verify when installing that the orifice size marking a) Adjust legs if necessary to level boiler, see FIG. 2-3 matches boiler size (Table 2A).

  • Page 13: General Venting Direct Venting Options

    Installation & Operation Manual General venting Direct venting options Figure 3-1 Two-Pipe Vertical Termination - See page Figure 3-2 Two-Pipe Sidewall Termination - See 24 for more details page 17 for more details Figure 3-4 Concentric Sidewall Termination - See Figure 3-3 Concentric Vertical Termination - See page 21 for more details page 26 for more details...

  • Page 14: Install Vent And Combustion Air Piping

    Section 4 – Sidewall Termination – Optional Concentric Vent) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Knight boiler. Both Table 3A Vent Pipe, and Fittings kits are listed to the ULC-S636 standard for use in Canada.

  • Page 15: Air Intake/Vent Connections

    National Building Code, Section 305, Table 305.4 or as local codes dictate. Table 3B Air Intake/Vent Piping Sizes Model Air Intake Vent Figure 3-5 Near Boiler Venting Models 80 - 210 80 - 210 3 inches 3 inches 4 inches 4 inches...

  • Page 16: Removing From Existing Vent

    Removing from existing vent Vent, air piping and termination: The Knight boiler vent and air piping can be installed through Follow the instructions in Section 1, page 11 of this manual the roof or through a sidewall. Follow the procedures in this when removing a boiler from an existing vent system.

  • Page 17: Sidewall Direct Venting Vent/Air Termination - Sidewall

    National Fuel Gas Model Kit Number Vent Size Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. 80 - 210 KIT30045 3 inch vent Determine location KIT30046 4 inch vent Locate the vent/air terminations using the following guidelines: If using the alternate sidewall termination: 3.
  • Page 18 Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-2B Alternate Clearance to Gravity Air Inlets Figure 4-1C Alternate Venting Arrangement (if Space w/Field Supplied Fittings Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR COUPLING CONNECTION 12” MIN 15”...

  • Page 19: Prepare Wall Penetrations

    Installation & Operation Manual Sidewall direct venting Prepare wall penetrations Prepare wall penetrations (Alternate - Field Supplied Option) Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: Air pipe penetration: Cut a hole for the air pipe.

  • Page 20: Multiple Vent/Air Terminations

    Canadian installations, provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of a Knight 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.

  • Page 21: Sidewall Termination - Optional Concentric Vent

    (Factory Kit #CVK3003 for 3" diameter - Locate or guard vent to prevent condensate damage Models 80 - 210 and #CVK3007 for 4" diameter - Model 285). to exterior finishes. Both combustion air and vent pipes must attach to the termination kit.
  • Page 22 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-9 Concentric Vent Dimensional Drawing - Figure 4-10 Concentric Vent Dimensional Drawing - Models 80 - 210 Model 285 "A" "B" DIA. "C" DIA. "D" 3"...
  • Page 23 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-12 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. Multiventing sidewall terminations DO NOT use field-supplied couplings CAUTION to extend pipes. Airflow restriction will When two (2) or more direct vent appliances are vented near occur and may cause intermittent each other, each appliance must be individually vented (see...

  • Page 24: Determine Location

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when WARNING Rooftop vent and air inlet terminations WARNING determining vent location to avoid must terminate in the same pressure possibility of severe personal injury, death zone.

  • Page 25: Vertical Direct Venting Vent/Air Termination - Vertical

    CSA B149.1 Installation Code. 3. Space the air and vent holes to provide the minimum 3. The air inlet of a Knight boiler is part of a direct vent spacing shown in FIG. 5-1, page 24. connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

  • Page 26: Vertical Termination - Optional Concentric Vent

    Installation & Operation Manual Vertical direct venting Vertical termination – optional concentric vent Description and usage 3. You must consider the surroundings when terminating Lochinvar offers an optional concentric combustion air and the vent and air: vent pipe termination kit. Both combustion air and vent Position the vent termination where vapors will not pipes must attach to the termination kit.

  • Page 27: Vertical Termination - Optional Concentric Vent

    Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent Do not operate the appliance with the rain DO NOT use field-supplied couplings to WARNING CAUTION removed recirculation extend pipes. Airflow restriction will combustion products may occur. Water occur.

  • Page 28: Hydronic Piping

    3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone. The Knight is designed to function in a closed loop 4. Install a backflow preventer on the cold feed make-up water pressurized system not less than 12 psi.

  • Page 29: Relief Valve / T & P Installation

    Figure 6-1 Relief Valve / T & P Installation The Knight boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 6-3 for pressure drop through the Knight boiler heat exchanger. RELIEF VALVE...
  • Page 30 NRF-36 1" UPS26-99F 0013 NRF-36 14.0 1" UPS26-99F 0011 NRF-36 19.6 1" UPS32-160 1400-50 PL-55 26.5 1-1/4" UPS32-80 1400-20 PL-36 25°F Temperature Rise Applications Pump Minimum Pipe Model FT/HD Size Grundfos TACO B & G Armstrong 15.0 1" UPS15-58FC 0014 PL-30/NRF-36 17.5...

  • Page 31: Near Boiler Piping Components

    13. Indirect water heaters: 3. Domestic hot water circulating pump: The Knight boiler may be piped to an indirect water heater Field supplied. The pump MUST be sized to meet to heat domestic hot water with the space heat transfer the specified minimum flow requirements listed in medium.
  • Page 32 Installation & Operation Manual Hydronic piping Figure 6-4 Single Boiler Zoned with Circulators ZONE #1 PRESSURE PRESSURE GAUGE REDUCING VALVE ZONE #2 ZONE #3 ZONE #4 BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL) SYSTEM SUPPLY MAKE UP WATER SENSOR AIR SEPARATOR ZONE CIRCULATORS (TYPICAL) EXPANSION...
  • Page 33 Installation & Operation Manual Hydronic piping (continued) Figure 6-5 Multiple Boilers Zoned with Circulators Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"...
  • Page 34 Installation & Operation Manual Hydronic piping Figure 6-6 Single Boiler Zoned with Valves ZONE #1 PRESSURE PRESSURE REDUCING VALVE GAUGE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED) AIR SEPARATOR SYSTEM...
  • Page 35 Installation & Operation Manual Hydronic piping (continued) Figure 6-7 Multiple Boilers Zoned with Valves Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"...
  • Page 36 Installation & Operation Manual Hydronic piping Figure 6-8 Single Boiler - Non-Zoned Primary/Secondary Piping PRESSURE REDUCING VALVE BACKFLOW PRESSURE PREVENTER GAUGE MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR AIR SEPARATOR FROM SYSTEM SYSTEM NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART BALL VALVE BOILER ANTI-SCALD...
  • Page 37 Installation & Operation Manual Hydronic piping (continued) Figure 6-9 Multiple Boilers - Non-Zoned Primary/Secondary Piping Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"...

  • Page 38: Gas Connections

    5. Before placing the boiler in operation, check the boiler and its gas connection for leaks. Figure 7-1 Gas Supply Piping - Models 80 - 210 The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

  • Page 39: Natural Gas

    14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum. Propane Gas: Knight boilers are typically shipped ready to WARNING fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for.

  • Page 40: Check Inlet Gas Supply

    5640 5130 4720 Knight boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine WARNING which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 12).

  • Page 41: Gas Pressure

    10 feet from the substantial property damage. Knight boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to 14. Turn on the gas supply at the manual gas valve.

  • Page 42: Field Wiring

    Installation & Operation Manual Field wiring ELECTRICAL SHOCK HAZARD – For Installation must comply with: WARNING your safety, turn off electrical power 1. National Electrical Code and any other national, state, supply before making any electrical provincial, or local codes, or regulations. connections to avoid possible electric shock hazard.

  • Page 43: Low Voltage Connections

    1. When the operation of an auxiliary device needs to be enable outdoor reset operation of the Knight boiler. If verified before the boiler fires, remove the jumper wire from fixed temperature operation is required, do not install these terminals and connect them to the normally open outdoor sensor.

  • Page 44: Wiring Of The Cascade

    SYSTEM control to use the inlet sensor as the controlling marked for the outdoor air sensor (FIG. 8-3). If the outdoor sensor. See the Knight Boiler Service Manual for air sensor is connected, the Leader control will calculate the instructions on how to use the inlet sensor as the water temperature set point based on the programmed reset controlling sensor.
  • Page 45 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections CUTOFF WATER...

  • Page 46: Condensate Disposal Condensate Drain

    Condensate To allow for proper drainage on large NOTICE from the Knight boiler will be slightly acidic (typically horizontal runs, a second line vent may be with a pH from 3 to 5). Install a neutralizing filter if required and tubing size may need to required by local codes.

  • Page 47: Startup

    Installation & Operation Manual Start-up Check/control water chemistry 4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before Do not use petroleum-based cleaning or proceeding further. CAUTION sealing compounds in the boiler system. Eliminate all system leaks.
  • Page 48 Installation & Operation Manual Start-up Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the Before starting the boiler, and during propane to make its presence detectable. WARNING initial operation, smell near the floor and In some instances, the odorant can fade, around the boiler for gas odorant or any and the gas may no longer have an odor.
  • Page 49 Final checks before starting the boiler Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air Read the Knight Boiler Service Manual to familiarize piping, and vent piping. yourself with SMART SYSTEM control module Venting system must be sealed gastight to operation.
  • Page 50 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions...
  • Page 51 The SMART SYSTEM control is programmed 5. Locate the pinhole button above the “T” in the Knight at the factory to control the temperature of the outlet sensor. logo on the display board (FIG. 11-1). Insert a thin wire...
  • Page 52 See the Knight Boiler Service Manual for a detailed explanation of this procedure. If there is an active space Use the UP and DOWN keys to increment or decrement the...

  • Page 53: Operating Information General

    DHW priority Modulation The Knight boiler is capable of modulating its firing rate from The SMART SYSTEM control module allows connection of a DHW thermostat to the low voltage connection board. When a minimum of 20% to a maximum of 100%. The firing rate the DHW thermostat calls for heat, the module activates the is dictated by the call for heat (i.e., space heating or domestic...
  • Page 54 Installation & Operation Manual Operating information Ramp delay Protection features For systems with lower flow, the SMART SYSTEM can limit Outlet temperature, flue temperature, the firing rate (when enabled) when a space heating call for temperature rise limiting heat starts, or when switching from a DHW call for heat to a space heating call for heat.

  • Page 55: Cascade

    This notification will become active when either a set time frame has expired, or a set amount of running See the Knight Boiler Service Manual to change the settings. hours or cycles has expired (all adjustable by the installer).

  • Page 56: Cascade

    Cascade (see the selected to provide heat for a DHW call. Select a boiler to be Knight Boiler Service Manual for an explanation of the offset designated as the DHW boiler. Connect the DHW and differential).

  • Page 57: Sequence Of Operation

    Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pumps BLR: Standby (system and boiler pumps for space heating call; DHW pump for OUT: 123.8F(129) DHW call).

  • Page 58: Sequence Of Operation

    Installation & Operation Manual Operating information Sequence of operation (continued) OPERATION DISPLAY 8. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 seconds, BLR: SH 41% RATE and resume modulating based on the space heating set point.

  • Page 59: Knight Boiler Control Module

    Installation & Operation Manual Operating information (continued) Knight boiler control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel...
  • Page 60 • Total operating hours • Total cycles Installer Most parameters are available only to the installer, accessible only by entering the installer access code, see the Knight Boiler Service Manual. Saving parameters (reference the Parameter Table in the Knight Boiler Service Manual) To save parameters and exit programming: Press the ENTER/RESET button.

  • Page 61: Status Display Screens

    Installation & Operation Manual Operating information (continued) Status Display Screens By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 62 Installation & Operation Manual Operating information Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 63 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 64 Installation & Operation Manual Operating information Status Display Screens (cont’d) Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...

  • Page 65: Maintenance Maintenance And Annual Startup

    Installation & Operation Manual Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the Knight User’s Information Manual for (see the following pages for instructions) instructions) • Check boiler area General: • Address reported problems •...

  • Page 66: Inspect Boiler Area

    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 Boiler Service Manual. Inspect boiler interior 1.

  • Page 67: Check Expansion Tank

    Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage.

  • Page 68: Check Burner Flame

    Parameter Mode and check all settings. See Section 1 of Knight Boiler Service Manual. Adjust settings if necessary. See Section 1 of the Knight Boiler Service Manual for adjustment procedures. 2. Check settings of external limit controls (if any) and adjust if necessary.

  • Page 69: Check Flame Signal

    Do not use any solvent. 3. See Section 3 - Troubleshooting of the Knight Boiler 7. Finish cleaning using a clean cloth dampened with warm Service Manual for other procedures to deal with low water.

  • Page 70: Diagrams

    Installation & Operation Manual Diagrams Figure 13-1 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" ON / OFF INTEGRATED CONTROL MODELS ONLY SWITCH SYSTEM SYSTEM PUMP "L" PUMP "N" X1-2 SYSTEM PUMP X1-6 RELAY SYSTEM...

  • Page 71: Wiring Diagram

    Installation & Operation Manual Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE WARNING DISPLAY 120 VAC DISCONNECT POWER HIGH VOLTAGE BEFORE SERVICING INTEGRATED CONTROL JUNCTION BOX DEPICTS OPTIONAL ITEMS INTERFACE CONNECTION BOARD X1-3 AUX. PUMP X1-5 DEVICE PILOT CN2-16 SUPPLY X1-4 BOILER CN4-8...

  • Page 72: Revision Notes

    Revision Notes: Revision 7 (KB-I&O-07) reflects the addition of the Dungs information to the manual. Revision 8 (KB-I&O-08) reflects edits made to all the plumbing diagrams. Revision 9 (KB-I&O-09) reflects changes made to the ratings page. Revision 10 (KB-I&O-10) reflects changes made to Model 210 orifice.

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