Knight 50 Installation & Operation Manual
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Knight 50 Installation & Operation Manual

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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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  • Page 1 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.

  • Page 2: Table Of Contents

    Vent/Air Termination - Sidewall ....17-20 10. STARTUP ....... . . 45-50 Determine Location .

  • 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 Wall Mount Service Manual, before before performing maintenance. installing. Perform steps in the order given.

  • Page 4: The Knight Wall Mount Boiler--How It Works

    28. Relief valve Protects the heat exchanger from an over pressure condition. 10. Electronic display The relief valve may be set at 30 psi or 50 psi depending on The electronic display consists of 7 buttons and a dual line 32- model.
  • Page 5 Installation & Operation Manual The Knight Wall Mount Boiler - How it works... (continued) Models 50 - 210 FRONT OF UNIT Front View Bottom View Left Side (inside unit) Right Side (inside unit)

  • Page 6: Ratings

    4,500 feet only. 4,501 FT. TO 12,000 FT. 6. High altitude Knight wall mount boilers will have a high altitude label affixed to the unit (as shown in FIG. A) and are equipped for operation of 4,501 feet to 12,000 feet only with no field adjustments.

  • Page 7: Determine Boiler Location

    Provide clearances: 4. The Knight wall mount boiler must be installed so that gas control system components are protected from Clearances from combustible materials dripping or spraying water or rain during operation or 1.
  • Page 8 Installation & Operation Manual Determine boiler location 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. Note: Service clearances are recommendations only.

  • Page 9: Provide Air Openings To Room

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

  • Page 10: 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 wall mount boiler DANGER Spray cans containing chloro/fluorocarbons into a common vent with any other appliance. This will cause flue gas spillage or...

  • Page 11: Prepare Boiler

    Verify that the stamping on the orifice disk matches the boiler to cool before proceeding. You must boiler size (50 - 210, see Table 2A). also completely test the boiler after conversion to verify performance as 9.

  • Page 12: Mounting The Boiler

    See page 9 of this manual for boiler mounting location WARNING The boiler is too heavy for a single person to instructions. lift. A minimum of two people is needed for The Knight Wall Mount boiler is not mounting the boiler onto the bracket. NOTICE intended for floor installation.

  • Page 13: General Venting Direct Venting Options

    Installation & Operation Manual General venting Direct venting options Figure 3-2 Two-Pipe Sidewall Termination - See Figure 3-1 Two-Pipe Vertical Termination - See page page 17 for more details 23 for more details Figure 3-4 Concentric Sidewall Termination - See Figure 3-3 Concentric Vertical Termination - See page 20 for more details page 25 for more details...

  • Page 14: Install Vent And Combustion Air Piping

    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.

  • Page 15: Air Intake/Vent Connections

    Used to provide a passageway for conveying combustion gases to the The Knight wall mount boiler uses model specific combustion outside. A transition fitting is provided on the unit for air intake and vent piping sizes as detailed in Table 3B below.

  • Page 16: Removing From Existing Vent

    Removing from existing vent Vent, air piping and termination: The Knight wall mount boiler vent and air piping can be Follow the instructions in Section 1, page 10 of this manual installed through the roof or through a sidewall. Follow the when removing a boiler from an existing vent system.

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

    Installation must comply with local NOTICE Model Kit Number Vent Size requirements and with the National Fuel Gas 50 - 105 KIT30044 2 inch vent Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. 150 - 210...
  • 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

    Field Supplied Option) Air pipe penetration: 3. The air inlet of a Knight wall mount boiler is part of a direct Cut a hole for the air pipe. Size the air pipe hole as vent connection. It is not classified as a forced air intake close as desired to the air pipe outside diameter.

  • Page 20: Sidewall Termination - Optional Concentric Vent

    Installation & Operation Manual Sidewall direct venting (continued) Figure 4-5B Alternate Multiple Vent Terminations w/Field Sidewall termination installation Supplied Fittings (must also comply with Figure 4-1B) 1. Determine the best location for the termination kit (see FIG. 4-6). 2. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual.
  • Page 21 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent models Figure 4-8 Concentric Vent Dimensional Drawing Instead of cementing the smaller pipe to the 6. Install the Y concentric fitting and pipe assembly through NOTICE rain cap, a field-supplied stainless steel screw the structure’s hole.
  • Page 22 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-10 Concentric Vent Sidewall Attachment Multiventing sidewall terminations DO NOT use field-supplied couplings to CAUTION extend pipes. Airflow restriction will occur When two (2) or more direct vent appliances are vented near and may cause intermittent operation.

  • Page 23: Determine Location

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

  • Page 24: Vertical Direct Venting Vent/Air Termination - Vertical

    Termination and fittings 1. If venting a WB 50 - 105 with 2" vent or a WB 150 - 210 with 3" vent, remove the two bird screens secured inside one of the two elbows and secure it into the vent termination coupling.

  • Page 25: Vertical Termination - Optional Concentric Vent

    Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent Description and usage 3. You must consider the surroundings when terminating the Lochinvar offers an optional concentric combustion air and 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 26: Vertical Termination - Optional Concentric Vent

    Installation & Operation Manual Vertical direct venting 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 27: Hydronic Piping

    Hydronic piping System water piping methods General piping information The Knight wall mount is designed to function in a closed Basic steps are listed below along with illustrations on the loop pressurized system not less than 12 psi. A temperature following pages (FIG.’s 6-3 - 6-7), which will guide you through...

  • Page 28: Circulator Sizing

    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.
  • Page 29 Installation & Operation Manual Hydronic piping (continued) Figure 6-2 Pressure Drop vs. Flow - Models 50 - 210 Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35° 20°F Temperature Rise Applications Pump Minimum Pipe Model FT/HD Size Grundfos TACO B &...

  • Page 30: Near Boiler Piping Components

    13. Indirect water heaters: FIG. 6-2. Consult the indirect water heater operating guide The Knight wall mount boiler may be piped to an indirect to determine flow characteristics for the selected product water heater to heat domestic hot water with the space heat used.
  • Page 31 Installation & Operation Manual Hydronic piping (continued) Figure 6-3 Single Boiler Zoned with Circulators ZONE #1 PRESSURE PRESSURE ZONE #2 ZONE #3 ZONE #4 GAUGE REDUCING VALVE BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR AIR SEPARATOR ZONE CIRCULATORS (TYPICAL) EXPANSION...
  • Page 32 Installation & Operation Manual Hydronic piping Figure 6-4 Multiple Boilers Zoned with Circulators Number of Units Model Required Pipe Sizes 1" 1-1/4" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 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"...
  • Page 33 Installation & Operation Manual Hydronic piping (continued) Figure 6-5 Single Boiler Zoned with Valves ZONE #1 ZONE #1 PRESSURE PRESSURE ZONE #2 ZONE #3 ZONE #4 ZONE #2 ZONE #3 ZONE #4 REDUCING VALVE GAUGE BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP WATER DIFFERENTIAL SYSTEM SUPPLY...
  • Page 34 Installation & Operation Manual Hydronic piping Figure 6-6 Multiple Boilers Zoned with Valves Number of Units Model Required Pipe Sizes 1" 1-1/4" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 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"...
  • Page 35 Installation & Operation Manual Hydronic piping (continued) Figure 6-7 Single Boiler - Non-Zoned Primary/Secondary Piping PRESSURE REDUCING VALVE BACKFLOW PRESSURE PREVENTER GAUGE MAKE UP WATER SEPARATOR SYSTEM SUPPLY SENSOR FROM SYSTEM SYSTEM NOT TO EXCEED 4 PIPE DIA. OR A MAX. OF 12” APART SYSTEM CIRCULATOR BOILER...

  • Page 36: Gas Connections

    Installation & Operation Manual Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to pipe 2. Support piping with hangers, not by the boiler or its gas to the boiler. accessories. Install a field supplied sediment trap / drip leg The gas valve and blower will not support upstream of the boiler gas controls.

  • Page 37: Natural Gas

    14 inches w.c. maximum. Figure 7-2 Inlet Pipe with Backup Wrench Propane Gas: 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 11).

  • Page 38: Check Inlet Gas Supply

    5640 5130 4720 Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to WARNING 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 11).

  • Page 39: Gas Pressure

    (dynamic) mode. If an in-line regulator is used, it must be a use the bubble test or check for gas leaks minimum of 10 feet from the Knight wall mount boiler. It is can cause severe personal injury, death, very important that the gas line is properly purged by the gas or substantial property damage.

  • Page 40: Field Wiring

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

  • Page 41: Low Voltage Connections

    (FIG. 8-4). outdoor sensor terminals on the connection board to Flow switch enable outdoor reset operation of the Knight wall mount boiler. If fixed temperature operation is 1. A flow switch is used to guarantee flow through the boiler required, do not install outdoor sensor.

  • Page 42: Wiring Of The Cascade

    Leader boiler. The remaining boilers will be designated as controlled. The SMART SYSTEM control automatically Members. See page 50 “Configuration of the Cascade” for a detects the presence of this sensor, and controls the boiler detailed explanation of this procedure.
  • Page 43 Installation & Operation Manual Field wiring (continued) Figure 8-4 Low Voltage Field Wiring Connections...

  • Page 44: Condensate Disposal Condensate Drain

    Condensate horizontal runs, a second line vent may be from the Knight wall mount boiler will be slightly acidic required and tubing size may need to increase (typically with a pH from 3 to 5). Install a neutralizing filter to 1 inch.
  • Page 45 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 CAUTION proceeding further. sealing compounds in the boiler system. Damage to elastomer seals and gaskets in Eliminate all system leaks.

  • Page 46: Startup

    Installation & Operation Manual Start-up Check for gas leaks Check thermostat circuit(s) 1. Disconnect the two external wires connected to the room Before starting the boiler, and during initial WARNING thermostat terminals on the connection board. operation, smell near the floor and around the boiler for gas odorant or any unusual 2.
  • Page 47 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 Wall Mount Service Manual to piping, and vent piping. familiarize yourself with SMART SYSTEM control module operation.
  • Page 48 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions...
  • Page 49 5. Locate the pinhole button in the upper right corner of factory to control the temperature of the outlet sensor. The the “T” in the Knight logo on the display board (FIG. control will automatically switch to the system supply sensor 11-1).
  • Page 50 Use the following Input the Installer code as described in the Knight Wall Mount procedure to set the clock: Service Manual. Once the control parameters have been accessed, use the DOWN arrow key to select the H Control Press and hold the MENU key for at least 5 seconds.

  • Page 51: Operating Information

    Modulation The SMART SYSTEM control module allows connection of The Knight wall mount boiler is capable of modulating its firing a DHW thermostat to the low voltage connection board. rate from a minimum of 20% to a maximum of 100%. The When the DHW thermostat calls for heat, the module firing rate is dictated by the call for heat (i.e., space heating or...
  • Page 52 Installation & Operation Manual Operating information Ramp delay Protection features For systems with lower flow, the SMART SYSTEM can limit the Outlet temperature, flue temperature, firing rate (when enabled) when a space heating call for heat temperature rise limiting starts, or when switching from a DHW call for heat to a space heating call for heat.

  • Page 53: Cascade

    One timer monitors the time the boiler event of low water or low flow conditions. is firing under 50% of rate. The other timer monitors the time the boiler is firing over 50% rate. Some codes and jurisdiction may accept these integral...

  • Page 54: Cascade

    Service manual for information regarding Night Setback. demand is satisfied and all boilers are shut off. Ramp Delay operation of the boilers as described in the Knight Wall Mount Service Manual is not active when the boilers are Sequence of the cascade part of a Cascade system.

  • Page 55: 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 56: Sequence Of Operation

    See the Knight Wall Mount Service Manual for a detailed Installer description of parameters and access modes. Most parameters are available only to the installer, accessible only by entering the installer access code, see the Knight Wall Mount Service Manual.

  • Page 57: Knight Wall Mount Boiler Control Module

    Installation & Operation Manual Operating information (continued) Knight wall mount 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 58: Status Display Screens

    Installation & Operation Manual Operating information 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 59 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 60 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 61 Installation & Operation Manual Operating information (continued) 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 62: Maintenance Maintenance And Annual Startup

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

  • Page 63: Address Reported Problems

    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.

  • Page 64: Check Expansion Tank

    Knight Wall Mount Service Manual. Adjust settings if disposal. Otherwise severe personal injury necessary. See Section 1 of the Knight Wall Mount Service may result. If no water flows, valve is Manual for adjustment procedures.

  • Page 65: Cleaning Boiler Heat Exchanger

    Mount Service Manual for other procedures to deal with Oiled bearing circulators low flame signal. 1. The circulator shipped with the Knight wall mount boiler is Review with owner water-lubricated. No oiling is required. 1. Review the Knight Wall Mount User’s Information 2.

  • Page 66: 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 67: 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 68 Revision B (WB-I&O-Rev B) reflects changes made to the ratings page. Revision C (WB-I&O-Rev C) reflects changes made to the orifice on Models 150 and 210. Revision D (ECO #C02407) reflects the addition of air inlet pipe materials, Maintenance Section, high altitude, air pressure switch, new condensate trap image and the addition of the new vent termination.

This manual is also suitable for:

210

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