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This manual must only be used by WARNING 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.
Please read before proceeding When servicing boiler – Installer – Read all instructions, 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.
Installation & Operation Manual The Knight Wall Mount Boiler - How it works... Stainless steel heat exchanger 15. Gas connection pipe Allows system water to flow around specially designed Threaded pipe connection. This pipe should be tubes for maximum heat transfer, while providing connected to the incoming gas supply for the purpose of protection against flue gas corrosion.
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Installation & Operation Manual The Knight Wall Mount Boiler - How it works... (continued) Models 55 - 399 FRONT OF UNIT IMG00117 Front View Bottom View IMG00162 IMG00161 Left Side (inside unit) Right Side (inside unit)
*Note: WHN399 value is thermal efficiency. Maximum allowed working pressure is located on the rating plate. NOTICE 7. The Knight Wall Mount boiler input rate, on some models, Notes: is reduced for vent lengths beyond the minimum. Two inch 1. As an Energy Star Partner, Lochinvar has determined that...
The two ventilating air 4. The Knight wall mount boiler must be installed so openings shown in FIG. 1-1 are required that gas control system components are protected from for this arrangement. Failure to follow...
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Installation & Operation Manual Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, WARNING LEFT polypropylene or stainless steel 6" MINIMUM 0" MINIMUM vent material MUST BE used in VENTILATING a closet structure due to elevated AIR OPENING temperatures.
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 described in this manual.
Installation & Operation Manual Determine boiler location When using an existing vent system to Table 1A Corrosive Contaminants and Sources 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.
Determine boiler location (continued) When removing a boiler from existing common vent system: Do not install the Knight wall mount g. Any improper operation of the common venting system DANGER should be corrected so the installation conforms with boiler into a common vent with any other the National Fuel Gas Code, ANSI Z223.1/NFPA 54...
You must install the propane orifice to fire the gas valve and secure inside the gas valve (see FIG. 2-3). the Knight wall mount boiler on propane. Verify when installing that the orifice size 11. Reattach the venturi to the gas valve and reposition the gas marking matches boiler size (Table 2A).
(2) field supplied toggle bolts. instructions. WARNING The boiler is too heavy for a single person The Knight Wall Mount boiler is not NOTICE to lift. A minimum of two people is needed intended for floor installation.
General venting Install vent and combustion air piping The Knight wall mount boiler must be The Knight wall mount boiler vent and air piping can be DANGER vented and supplied with combustion and installed through the roof or through a sidewall. Follow the ventilation air as described in this section.
Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 2" and 3" Concentric Vent Kits Equivalent Vent available from IPEX are approved for use on the Knight Model Kit Number Length wall mount boiler. Both kits are listed to the ULC-S636 standard for use in Canada.
Installation & Operation Manual General venting (continued) Materials Air inlet pipe materials: The PVC, CPVC, or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used.
When these chemicals pass through the boiler, they can form Commercial applications utilizing the Knight wall mount strong acids. The acid can eat through the boiler wall, causing boiler may be installed with a single pipe carrying the flue...
Installation & Operation Manual General venting (continued) PVC/CPVC Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent This product has been approved for use with the PVC/CPVC piping.
Installation & Operation Manual General venting Polypropylene Use only the adapters and vent system listed WARNING in Tables 3E and 3F. DO NOT mix vent This product has been approved for use with polypropylene systems of different types or manufacturers. vent with the manufacturers listed in Table 3E.
Installation & Operation Manual General venting (continued) Stainless steel vent Installation of a stainless steel vent NOTICE system should adhere to the stainless This product has been approved for use with stainless steel steel vent manufacturer’s installation using the manufacturers listed in Table 3G. instructions supplied with the vent system.
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-1A PVC/CPVC/ Polypropylene Sidewall Follow instructions below when Termination of Air and Vent w/Field Supplied Fittings WARNING determining vent location to avoid FACTORY PROVIDED possibility of severe personal injury, BIRD SCREEN death, or substantial property damage.
Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall 6. Locate terminations so they are not likely to be damaged Figure 4-1C Alternate PVC/CPVC/SS/ Polypropylene Venting by foreign objects, such as stones or balls, or subject to Arrangement (if Space Allows) w/Field Supplied Fittings buildup of leaves or sediment.
Installation & Operation Manual Sidewall direct venting Figure 4-3B Alternate Clearance to Forced Air Inlets w/ Figure 4-4A PVC/CPVC Sidewall Termination Assembly Field Supplied Fittings IF LESS THAN 10’ 36” VENT MIN. FORCED AIR AIR PIPING CENTERLINE WIDTH INLET BIRD VENT PIPING SCREEN VENT PLATE...
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.
Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent 3. Cut one (1) hole (5 inch diameter for #CVK3003 pipe termination kits (Factory Kit #CVK3003 for 3" diameter installations, 4 inch diameter for #CVK3008, or 7 inch - models 155 - 199, #CVK3008 for 2"...
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Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent models Figure 4-9 2" and 3" Concentric Vent Dimensional Figure 4-10 4" Concentric Vent Dimensional Drawing Drawing (reference Table 3D on page 19) (reference Table 3D on page 19) "B"...
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Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-12 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.
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent Follow instructions below when WARNING ALTERNATE INTAKE LOCATIONS: determining vent location to avoid INTAKE PIPES MAY BE LOCATED possibility of severe personal injury, death ANYWHERE WITHIN 24”...
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.
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Installation & Operation Manual Vertical direct venting (continued) Ensure termination height is above the Instead of cementing the smaller pipe to NOTICE NOTICE roof surface or anticipated snow level (12 the rain cap, a field supplied stainless steel inches in U.S.A. or 18 inches in Canada) as screw may be used to secure the two (2) shown in FIG.
Installation & Operation Manual Vertical direct venting Alternate vertical concentric Figure 5-8 Concentric Vent Example 1 venting FLUE EXHAUST This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an SEAL existing unused venting system; or by using the existing COMBUSTION AIR unused venting system as a chase for vent and combustion AIR INLET...
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 through 6-12), which will guide...
20 feet of piping, 4 - 90° elbows, and 2 - fully 13. Indirect water heaters: ported ball valves. The Knight wall mount boiler may be piped to an indirect water heater to heat domestic hot water with the space heat Knight wall mount boilers are capable of controlling a transfer medium.
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.
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Installation & Operation Manual Hydronic piping Figure 6-2 Pressure Drop vs. Flow 3.00 9.00 8.00 2.50 7.00 MODEL MODEL 2.00 6.00 5.00 1.50 4.00 1.00 3.00 2.00 0.50 1.00 0.00 0.00 -0.50 FLOW FLOW 3.50 3.00 2.00 1.80 2.50 1.60 MODEL MODEL 1.40...
20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves. The Knight wall mount boiler is capable of producing up It is recommended that near boiler to three (3) set point temperatures to meet different space...
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Installation & Operation Manual Hydronic piping Figure 6-3 Single Boiler - 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 NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART SYSTEM BALL VALVE CIRCULATOR...
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Installation & Operation Manual Hydronic piping (continued) Figure 6-4 Single Boiler - Single Temperature with Zone Valves - DHW Priority ZONE #1 PRESSURE PRESSURE REDUCING VALVE GAUGE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP WATER DIFFERENTIAL PRESSURE...
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Installation & Operation Manual Hydronic piping Figure 6-5 Single Boiler - Single Temperature Zoned with Circulators - DHW Priority ZONE #1 PRESSURE PRESSURE GAUGE REDUCING VALVE ZONE #2 ZONE #3 ZONE #4 BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR ZONE CIRCULATORS...
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Installation & Operation Manual Hydronic piping (continued) Figure 6-6 Multiple Boilers - Single Temperature Zoned with Zone Valves - DHW Priority Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2" 2-1/2"...
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Installation & Operation Manual Hydronic piping Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 1-1/2"...
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Installation & Operation Manual Hydronic piping (continued) Figure 6-8 Single Boiler - Multiple Temperature - DHW Priority PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE REDUCING VALVE LOOP #1 LOOP #2 LOOP #3 BACKFLOW PREVENTER PRESSURE GAUGE MAKE MIXING VALVES SYSTEM WATER (TYPICAL) SUPPLY SENSOR AIR SEPARATOR EXPANSION...
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Installation & Operation Manual Hydronic piping Figure 6-9 Multiple Boilers - Multiple Temperature - DHW Piped as a Zone Number of Units Model Required Pipe Sizes 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 1-1/2"...
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Installation & Operation Manual Hydronic piping (continued) Figure 6-10 Single Boiler - Full Flow - Single Temperature - Zoned with Zone Valves - DHW Priority ZONE #1 PRESSURE PRESSURE REDUCING VALVE GAUGE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP...
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Installation & Operation Manual Hydronic piping Figure 6-11 Single Boiler - Full Flow - Single Temperature Zoned with Valves - DHW Piped as a Zone ZONE #1 PRESSURE REDUCING VALVE PRESSURE ZONE #2 ZONE #3 ZONE #4 GAUGE BACKFLOW PREVENTER ZONE VALVES (TYPICAL) MAKE UP...
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Installation & Operation Manual Hydronic piping (continued) Figure 6-12 Single Boiler - Full Flow - Single Temperature Zoned with Circulators - DHW Piped as a Zone ZONE #1 PRESSURE PRESSURE GAUGE REDUCING VALVE ZONE #2 ZONE #4 ZONE #3 BACKFLOW FLOW CHECK PREVENTER VALVE...
Installation & Operation Manual Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 2. Support piping with hangers, not by the boiler or its to 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.
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).
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).
(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.
Installation & Operation Manual Field wiring Line voltage connections ELECTRICAL SHOCK HAZARD – For your 1. Remove bezel as shown in FIG. 8-1. WARNING safety, turn off electrical power supply before 2. Connect 120 vac power wiring to the line voltage terminal making any electrical connections to avoid strip in the junction box, as shown in FIG.
2. Remove the jumper wire from these terminals and connect outdoor sensor terminals on the connection board to these terminals to the normally open contacts on the flow enable outdoor reset operation of the Knight wall mount switch (FIG. 8-4). boiler. Residential boilers with inputs less than 300,000...
SYSTEM control to use the inlet sensor as the controlling as the Leader boiler. The remaining boilers will be designated sensor. See the Knight Wall Mount Service Manual for as Members. See page 63 “Configuration of the Cascade” for a instructions on how to do this.
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Installation & Operation Manual Field wiring (continued) Figure 8-4 Low Voltage Field Wiring Connections...
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.
Starting on the lowest floor, open air vents one at a 4. The freeze protection set points may be lowered when time until water squirts out. freeze protection fluid is used (see the Knight Wall Repeat with remaining vents. Mount Service Manual).
Installation & Operation Manual Start-up Check for gas leaks Inspect/fill condensate system Before starting the boiler, and during Inspect/check condensate lines and fittings WARNING initial operation, smell near the floor and 1. Inspect the condensate drain line, condensate fittings and around the boiler for gas odorant or any condensate trap.
Final checks before starting the boiler Check vent piping and air piping 1. Check for gas tight 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.
5 seconds to place the boiler into Service Mode. be changed in the control. See the Knight Wall Mount Service In Service Mode the boiler will fire at ignition speed and Manual for a detailed explanation of this procedure.
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NOTICE depending on the System Pump Mode selected (reference Daylight Savings Time and therefore, will the Knight Wall Mount Service Manual for details). In this require a manual adjustment. mode, any low temperature zones (such as radiant heating) may need additional controls to limit the water temperature The clock is automatically updated whenever a PC is connected sent to those zones.
The Knight wall mount boiler can also be programmed to exchanger and flue piping. The control module regulates accept a call for heat from a 0 - 10V signal, reference the Knight blower speed to control the boiler firing rate. The gas valve...
Protection features Modulation Outlet temperature, flue temperature, and temperature The Knight wall mount boiler is capable of modulating its rise limiting 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...
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Operating information Monitor external limits High limit operations The Knight wall mount is equipped with adjustable automatic Connections are provided on the connection board for reset and manual reset high limits. The automatic reset high external limits such as flow switch, low water cutoff, gas limit has a maximum set point of 200°F and the manual reset...
+ the turn-off offset - the off-on differential, then the control will initiate a call for heat on Ramp Delay operation of the boilers as described in the Knight the Cascade (see the Knight Wall Mount Service Manual for Wall Mount Service Manual is not active when the boilers are an explanation of the offset and differential).
Installation & Operation Manual 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).
Most parameters are available only to the installer, accessible To enter a parameter and continue programming: by entering the installer password, see the Knight Wall Mount Press the RIGHT SELECT [SAVE] key 1 time to return to the Service Manual.
Installation & Operation Manual Operating information 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 NAVIGATION DIAL The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the...
Installation & Operation Manual Operating information (continued) Figure 11-2 Status Display Screen (CALL FOR (BOILER HEAT) STATUS) (OPERATIONAL INFORMATION) (RIGHT SELECT KEY) (LEFT SELECT KEY) (NAVIGATION DIAL) Status Display Screens Section Display Description The unit has not received a call for heat from a remote thermostat nor STANDBY has it received a call for heat from a DHW thermostat.
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Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display Description 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.
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Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) Section Display Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen. EXIT Press the LEFT SELECT key to exit the current screen or setting. Press the LEFT SELECT key to confirm that the boiler needs to shutdown.
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 •...
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.
Knight Wall Mount Service Manual. Adjust settings if water from the valve to a proper place of necessary. See Section 1 of the Knight Wall Mount Service disposal. Otherwise severe personal injury Manual for adjustment procedures.
If cleaning the flame sense electrode does not improve, ground wiring is in good condition, 1. The circulator shipped with the Knight wall mount boiler is and ground continuity is satisfactory, replace the flame water-lubricated. No oiling is required.
Installation & Operation Manual Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED BOX DEPICTS CONNECTION BOARD CONTROL JUNCTION OPTIONAL ITEMS ALARM X1-3 CONTACTS PUMP RUN-TIME CONTACTS X1-4 24 VAC LOUVER...
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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).