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Knight 50 - 210 Installation & Operation Manual

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WB-I-O Rev H
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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Summary of Contents for Knight 50 - 210

  • 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

    Termination and Fittings ..... . . 23 Knight Wall Mount Boiler Control Module ... . 61 Multiple Vent/Air Terminations .

  • 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

    Installation & Operation Manual The Knight Wall Mount 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...
  • 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

    3" Maximum allowed working pressure is located on the rating plate. NOTICE 7. The Knight Wall Mount boiler input rate, on some Notes: models, is reduced for vent lengths beyond the 1. As an Energy Star Partner, Lochinvar has determined that minimum.

  • Page 7: Determine Boiler Location

    4. The Knight wall mount boiler must be installed so that Provide clearances: gas control system components are protected from dripping or spraying water or rain during operation or Clearances from combustible materials service.
  • Page 8 Installation & Operation Manual Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC or WARNING stainless steel 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.

  • Page 9: Provide Air Openings To Room

    Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or Install air inlet piping for the Knight wall mount boiler as wooden studs spaced 16" apart from center. Ensure the wall described in this manual.

  • Page 10: Corrosive Contaminants And Sources

    Installation & Operation Manual Determine boiler location Table 1A Corrosive Contaminants and Sources When using an existing vent system to install a new boiler: Products to avoid: Failure to follow all instructions can result WARNING Spray cans containing chloro/fluorocarbons in flue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions or death.

  • Page 11: Removing A Boiler From Existing Common Vent

    Installation & Operation Manual Determine boiler location When removing a boiler from existing common vent system: Do not install the Knight wall mount boiler g. Any improper operation of the common venting system DANGER should be corrected so the installation conforms with into a common vent with any other the National Fuel Gas Code, ANSI Z223.1/NFPA 54...

  • Page 12: Prepare Boiler

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

  • Page 13: Mounting The Boiler

    WARNING The boiler is too heavy for a single person to instructions. lift. A minimum of two people is needed for mounting the boiler onto the bracket. The Knight Wall Mount boiler is not NOTICE intended for floor installation. Figure 2-4 Mounting the Boiler...
  • Page 14 Installation & Operation Manual General venting Direct venting options - Sidewall Vent Figure Figure 3-2 Stainless Steel Two-Pipe Sidewall PVC/CPVC Two-Pipe Sidewall Termination - See page 21 for more details Termination - See page 22 for more details Figure PVC/CPVC Concentric Sidewall Termination - See page 24 for more details...

  • Page 15: General Venting

    Installation & Operation Manual General venting (continued) Direct venting options - Vertical Vent Figure 3-5 Stainless Steel Two-Pipe Figure 3-6 PVC/CPVC Concentric Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 27 Vertical Termination - See page 27 Vertical Termination - See page 29 for more details for more details for more details...

  • Page 16: Install Vent And Combustion Air Piping

    Concentric Vent) and the 2" and 3" Concentric Vent Kits stainless steel material MUST BE used in a available from IPEX are approved for use on the Knight closet/alcove structure. Failure to follow this wall mount boiler. Both kits are listed to the ULC-S636 warning could result in fire, personal injury, standard for use in Canada.

  • Page 17: Pvc/Cpvc Air Intake/Vent Connections

    Installation & Operation Manual General venting (continued) Priming and Cementing: Handle fittings and pipes carefully to prevent While primer is still wet, apply an even coat of contamination of surfaces. approved cement to the fitting socket. Apply a liberal even coat of primer to the fitting Apply a second coat of cement to the pipe.

  • Page 18: Stainless Steel Vent

    Adapter Termination Termination Termination Termination 300716 WB50210 2SVSLPVC3 (Vent) (Vent) (Vent) FSBS3 9392 2SVSTP03 50 - 210 303889 9353BUREZ-1* 9314TERM 2SVSTEX0390 FSRC3(R.C) 5300CI 2SVSRCX03 300715 KB80210 2SVSLA03 (Intake Air) (Intake Air) (Intake Air) * = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-10, unless approved vent...

  • Page 19: Max. Allowable Vent Piping Lengths

    The resultant installation is direct vent (sealed 3" S.S. ADAPTER combustion). You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight wall mount boiler using any other means. DO NOT mix components from different WARNING systems.

  • Page 20: Optional Room Air

    Commercial applications utilizing the Knight wall mount boiler may be installed with a single pipe carrying the flue If the boiler combustion air inlet is located...

  • Page 21: Sidewall Direct Venting Vent/Air Termination - Sidewall

    Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-1A PVC/CPVC Sidewall Termination of Air and Vent Follow instructions below when WARNING determining vent location to avoid TO BOILER INTAKE AIR possibility of severe personal injury, death, CONNECTION or substantial property damage.
  • Page 22 Installation & Operation Manual Sidewall direct venting Figure 4-2A Clearance to Gravity Air Inlets Vent/air termination – sidewall Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER 12" INTAKE AIR COUPLING MIN. CONNECTION 12” MIN 15” MAX FROM BOILER VENT / AIR VENT PIPE...

  • Page 23: 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 24: Sidewall Termination - Optional Concentric Vent

    Installation & Operation Manual Sidewall direct venting 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 19 of this manual.
  • Page 25 Installation & Operation Manual Sidewall direct venting (continued) 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 26 Installation & Operation Manual Sidewall direct venting 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 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 FIG.

  • Page 27: Vertical Direct Venting Vent/Air Termination - Vertical

    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, unless vertical vent sidewall air is set up as death or substantial property damage.

  • Page 28: Prepare Roof Penetrations

    CSA B149.1 Installation Code. 3. Space the air and vent holes to provide the minimum 3. The air inlet of a Knight wall mount boiler is part of a spacing shown in FIG. 5-1A, page 27. direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

  • Page 29: Vertical Termination - Optional Concentric Vent

    Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent Description and usage 2. Cut one (1) hole (5 inch diameter for #CVK3003 Lochinvar offers an optional concentric combustion air and installations or 4 inch diameter for #CVK3008 installations) vent pipe termination kit.
  • Page 30 Installation & Operation Manual Vertical direct venting Vertical termination – optional concentric vent DO NOT use field-supplied couplings to Do not operate the appliance with the rain CAUTION WARNING extend pipes. Airflow restriction will occur. removed recirculation combustion products may occur. Water 6.

  • Page 31: 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 32: 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 33 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 34: Near Boiler Piping Components

    13. Indirect water heaters: 2. Boiler system circulating pump: The Knight wall mount boiler may be piped to an indirect A Grundfos UPS26-99F pump will be provided by the water heater to heat domestic hot water with the space heat factory as the boiler circulation pump based on 20 feet of transfer medium.
  • Page 35 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 ZONE CIRCULATORS SENSOR (TYPICAL) AIR SEPARATOR...
  • Page 36 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" ZONE #1 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"...
  • Page 37 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 38 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 39 Installation & Operation Manual Hydronic piping (continued) Figure 6-7 Single Boiler - Non-Zoned Primary/Secondary Piping PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER MAKE UP WATER SEPARATOR SYSTEM SUPPLY SENSOR MAY SUBSTITUTE LOW LOSS HEADER FROM SYSTEM SYSTEM BALL VALVE SYSTEM (TYPICAL) NOT TO EXCEED 4 PIPE DIA OR MAX.

  • Page 40: Gas Connections

    Installation & Operation Manual Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to 2. Support piping with hangers, not by the boiler or its pipe 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 41: 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 13).

  • Page 42: 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 13).

  • Page 43: 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 44: 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 45: Low Voltage Connections

    Flow switch enable outdoor reset operation of the Knight wall mount boiler. If fixed temperature operation is required, do not 1. A flow switch is used to guarantee flow through the boiler install outdoor sensor.

  • Page 46: Wiring Of The Cascade

    SYSTEM control to use the inlet sensor as the controlling location of the system supply sensor should be downstream of sensor. See the Knight Wall Mount Service Manual for the boiler connections in the main system loop (FIG.’s 6-4 and instructions on how to do this.
  • Page 47 Installation & Operation Manual Field wiring (continued) Figure 8-4 Low Voltage Field Wiring Connections...

  • Page 48: 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 to 1 inch.
  • Page 49 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 50: 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 WARNING thermostat terminals on the connection board. initial operation, smell near the floor and around the boiler for gas odorant or any 2.
  • Page 51 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 52 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions...
  • Page 53 5. Locate the pinhole button in the upper right corner of the factory to control the temperature of the outlet sensor. The “T” in the Knight logo on the display board (FIG. 11-1). control will automatically switch to the system supply sensor Insert a thin wire (such as a paper clip) into the hole and once it is connected.
  • Page 54 Use Input the Installer code as described in the Knight Wall Mount the following procedure to set the clock: Service Manual.

  • Page 55: Operating Information

    0 - 10V input (set point or power) The Knight wall mount boiler can be controlled by a Building When a DHW call for heat starts, the DHW pump is turned on. Management System (BMS) using a 0 - 10 vdc signal. The...
  • Page 56 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 57: Cascade

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

  • Page 58: Cascade

    This will continue until the 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 59: 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 60: 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 61: 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 62: 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 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) 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 65: Status Display Screens

    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 66: 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 67: Address Reported Problems

    If they cannot be removed, reinstall failure. Leaking water may also cause severe the air and vent lines per this manual and the Knight Wall property damage. Mount Service Manual. 1. Inspect all water and gas piping and verify to be leak free.

  • Page 68: Check Expansion Tank

    Knight Wall Mount Service Manual. Adjust settings if Safety relief valves should be re-inspected WARNING necessary. See Section 1 of the Knight Wall Mount Service AT LEAST ONCE EVERY THREE YEARS, Manual for adjustment procedures. by a licensed plumbing contractor or authorized inspection agency, to ensure 2.

  • Page 69: Check Flame Signal

    Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to 3. See Section 3 - Troubleshooting of the Knight Wall Mount allow water to flow through the water make-up line to the Service Manual for other procedures to deal with low boiler.

  • 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 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.

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