Lochinvar KNIGHT 51 Installation And Operation Manual
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Lochinvar KNIGHT 51 Installation And Operation Manual

Lochinvar boiler user manual
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See also: User's Information Manual
WBII-I-O Rev C
Installation & Operation Manual
Models: 51 - 211
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 Lochinvar KNIGHT 51

  • Page 1 WBII-I-O Rev C Installation & Operation Manual Models: 51 - 211 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.

  • Page 2: Table Of Contents

    Gas Conversions ....... 12 Mounting the Boiler ......13 3.

  • Page 3: Please Read Before Proceeding

    Instead, shut off the gas supply at a location external to the appliance. • Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

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

    The venturi controls air and gas flow into the burner. Flue gas sensor (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.
  • Page 5 The Knight Wall Mount Boiler - How it works... Models 51 - 211 Front View Left Side (inside unit) Bottom View Right Side (inside unit) Installation & Operation Manual (continued) FRONT OF UNIT...

  • Page 6: Ratings

    Maximum allowed working pressure is located on the rating plate. NOTICE Notes: 1. As an Energy Star Partner, Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency. 2. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

  • Page 7: Determine Boiler Location

    WARNING WARNING Closet and alcove installations A closet is any room the boiler is installed in which is less than 79 cubic feet for WBN051 through WBN106 models, 104 cubic feet for WBN151 models, and 125 cubic feet for WBN211 models.
  • Page 8 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances LEFT 24" SERVICE 0" MINIMUM 1" MINIMUM CLEARANCE AROUND VENT PIPE BOTTOM 24" SERVICE 0" MINIMUM AREA OF EACH OPENING: 1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ.

  • Page 9: Provide Air Openings To Room

    Do not attempt to install the Knight wall mount boiler using any other means. Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

  • Page 10: Corrosive Contaminants And Sources

    • Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11. With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used;...

  • Page 11: Removing A Boiler From Existing Common Vent

    At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

  • Page 12: Prepare Boiler

    3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-1). Do not drop the boiler or bump the jacket NOTICE on the floor or pallet.

  • Page 13: Mounting The Boiler

    Note: If wall thickness does not allow a 1 1/8" deep hole, field supplied hardware suitable for the application should be provided. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) remaining anchors, following the instructions above.
  • Page 14 General venting Direct venting options - Sidewall Vent Figure PVC/CPVC Two-Pipe Termination - See page 21 for more details Figure Termination - See page 24 for more details Figure 3-2 Stainless Steel Two-Pipe Sidewall Sidewall Termination - See page 22 for more details PVC/CPVC Concentric Installation &...

  • Page 15: General Venting

    General venting Direct venting options - Vertical Vent Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 27 for more details Direct venting options - Vertical Vent, Sidewall Air Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air Stainless steel vent/air design and terminations will vary slightly by manufacturer. NOTICE (continued) Figure 3-5 Stainless Steel Two-Pipe...

  • Page 16: Install Vent And Combustion Air Piping

    The 2" and 3" Concentric Vent Kits available from 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.

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

    ANSI/ASTM D2665 ANSI/ASTM F441 UL1738 ANSI/ASTM D2564 ANSI/ASTM F493 Make Figure 3-9 Near Boiler PVC/CPVC Venting Choose acceptable Installation & Operation Manual Canada CPVC and PVC venting must be ULC- S636 Certified. IPEX is an approved manufacturer in Canada supplying vent material listed to ULC-S636.

  • Page 18: Stainless Steel Vent

    (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 other than standard diameter is used. Consult a Heat Fab representative for questions.

  • Page 19: Max. Allowable Vent Piping Lengths

    Vent and air piping Vent and air system: NOTICE You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion). You may use any of the vent/air piping methods covered in this manual.

  • Page 20: Optional Room Air

    Commercial applications utilizing the Knight wall mount boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

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

    Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown. TO BOILER INTAKE AIR CONNECTION 12”...
  • Page 22 Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION BIRD SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT (IF SPACE PERMITS)

  • Page 23: Prepare Wall Penetrations

    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.

  • Page 24: Sidewall Termination - Optional Concentric Vent

    Sidewall termination – optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 - 3" or #CVK3008 - 2"). Both combustion air and vent pipes must attach to the termination kit.
  • Page 25 Sidewall direct venting Sidewall termination – optional concentric vent models Figure 4-8 Concentric Vent Dimensional Drawing Instead of cementing the smaller pipe to the NOTICE rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG.

  • Page 26: Sidewall Termination - Optional Concentric Vent

    Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-10 Concentric Vent Sidewall Attachment DO NOT use field-supplied couplings to CAUTION extend pipes. Airflow restriction will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly.

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

    Vertical direct venting Vent/air termination – vertical Follow instructions WARNING determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to WARNING the vent pipe or multiple boilers to a common vent pipe.

  • Page 28: Prepare Roof Penetrations

    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.

  • Page 29: Vertical Termination - Optional Concentric Vent

    Vertical direct venting Vertical termination – optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG.
  • Page 30 Vertical direct venting Vertical termination – optional concentric vent Do not operate the appliance with the rain WARNING removed combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

  • Page 31: Optional Vertical Concentric Venting

    Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.
  • Page 32 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase AIR INLET FLUE EXHAUST SEAL...

  • Page 33: Hydronic Piping

    It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators.

  • Page 34: Near Boiler Piping Components

    DHW and space heating. Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.

  • Page 35: Near Boiler Piping Connections

    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 36 FT/HD 11.0 10.1 Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude NOTICE models. Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude NOTICE models.

  • Page 37: Variable Speed Pump Option

    The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 6B to the boiler high voltage terminal strip.)
  • Page 38 Hydronic piping Figure 6-3 Single Boiler - Single Temperature Zoned with Circulators PRESSURE PRESSURE GAUGE REDUCING VALVE BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) BOILER CIRCULATOR Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 39 BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) BOILER CIRCULATOR PRESSURE RELIEF VALVE BOILER 2 (MEMBER 1) TEMPERATURE / DRAIN PRESSURE GAUGE Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 40 Hydronic piping Figure 6-5 Single Boiler - Multiple Temperatures PRESSURE REDUCING VALVE BACKFLOW PREVENTER MAKE WATER AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 41 PRESSURE GAUGE SYSTEM SUPPLY SENSOR EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART BOILER CIRCULATOR FLOW CHECK VALVE BOILER TEMPERATURE / PRESSURE DRAIN GAUGE Installation & Operation Manual Number of Units Required Pipe Sizes 1"...
  • Page 42 AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) Y-STRAINER (RECOMMENDED) BOILER CIRCULATOR DRAIN UNION (TYPICAL) Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 43 Hydronic piping Figure 6-8 Single Boiler Zoned with Valves PRESSURE PRESSURE REDUCING VALVE GAUGE BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 44 TANK MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART Y-STRAINER (RECOMMENDED) (TYPICAL) FLOW CHECK VALVE BOILER 2 (MEMBER 1) UNION DRAIN (TYPICAL) Installation & Operation Manual Number of Units Required Pipe Sizes 1"...
  • Page 45 Hydronic piping Figure 6-10 Single Boiler - Non-Zoned Primary/Secondary Piping PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SYSTEM SYSTEM BALL VALVE CIRCULATOR (TYPICAL) EXPANSION TANK DRAIN POINT (TYPICAL) RELIEF VALVE Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 46: Gas Connections

    MANUAL SHUTOFF VALVE (FIELD SUPPLIED) GAS SUPPLY Installation & Operation Manual 2. Support piping with hangers, not by the boiler or its accessories. The gas valve and blower will not support WARNING the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories.

  • Page 47: Natural Gas

    Natural gas: Pipe sizing for natural gas 1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas...

  • Page 48: Check Inlet Gas Supply

    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). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

  • Page 49: Gas Pressure

    (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Knight wall mount boiler. It is very important that the gas line is properly purged by the gas supplier or utility company.

  • Page 50: Field Wiring

    (15 amp recommended) as required by the code (see FIG. 8-2). 3. Wire the boiler pump as shown in FIG. 8-2. 4. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG.

  • Page 51: Outdoor Temperature Sensor

    2. The tank sensor included with the Lochinvar Squire Indirect DHW tank (TST20015) is the only sensor suitable for use with the SMART SYSTEM control.

  • Page 52: Wiring Of The Cascade

    Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers.
  • Page 53 Installation & Operation Manual Field wiring (continued) Figure 8-4 Low Voltage Field Wiring Connections...

  • Page 54: Condensate Disposal Condensate Drain

    1. This boiler is a high efficiency appliance that produces condensate. 2. The bottom of the boiler has a 1/2 inch pipe for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter.
  • Page 55 200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the boiler to directly heat swimming pool or spa water. Test/replace freeze protection fluid 1.

  • Page 56: Startup

    Before starting the boiler, and during WARNING initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak.
  • Page 57 Read this manual, page 58 for proper steps to start boiler. Verify the boiler and system are full of water and all system components are correctly set for operation. Verify the preparation procedures of Section 10, pages 55 and 56 have been completed.
  • Page 58 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions...
  • Page 59 (if connected), and the boiler (secondary) pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect DHW (Domestic Hot Water) tank, and the set point is not met, it also turns on the boiler pump.
  • Page 60 This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 4 hours. Use the following procedure to set the clock: Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

  • Page 61: Operating Information General

    Freeze Protection Mode ends. The system pump will run whenever there is a space heating call for heat, or the boiler goes into Freeze Protection Mode. It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode.

  • Page 62: Protection Features

    55°F and the minimum off time has expired. Freeze protection DO NOT install the boiler in a room likely to freeze. The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system.

  • Page 63: Boiler Temperature Regulation

    Please note that the brackets ([]) denote NOTICE screen status. Turn ON the main power to the boiler by placing the ON/OFF switch in the ON position. If boiler status reads [SHUTDOWN] place the boiler into the active position by pressing the RIGHT SELECT [ON] key.

  • Page 64: Cascade

    For normal mode DHW operation any boiler(s) in the Cascade can be selected to provide heat for a DHW call. Select a boiler to be designated as the DHW boiler. Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device.

  • Page 65: Sequence Of Operation

    OPERATION 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, pump The flow switch and/or LWCO must close.

  • Page 66: Sequence Of Operation

    The control will then modulate to maintain the outlet temperature 9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisfied.

  • Page 67: Knight Wall Mount Boiler Control Module

    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 NAVIGATION DIAL The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the...

  • Page 68: Status Display Screens

    (OPERATIONAL INFORMATION) (LEFT SELECT KEY) Section Display STANDBY START PREPURGE IGNITION (Boiler Status Bar) POSTPURGE SHUTDOWN BLOCKED (Call for Heat Indicators) (NAVIGATION DIAL) Status Display Screens The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.
  • Page 69 The status of the DHW pump output. The voltage received from a BMS system. The speed signal sent to a variable speed boiler pump in percent. The speed signal received from a variable speed system pump control. A 0 - 10V signal indicating the firing rate of the boiler.

  • Page 70: Status Display Screens

    Turning the NAVIGATION dial will increase or decrease the current setting. Press the RIGHT SELECT key to turn the boiler OFF. Press the RIGHT SELECT key to turn the boiler ON. Press the RIGHT SELECT key to cancel the shutdown operation.

  • Page 71: Maintenance

    • Check condensate drain system • Check air vents • Test low water cutoff (if used) • Reset button (low water cutoff) • Check boiler piping (gas and water) for leaks • Operate relief valve • Shut boiler down (unless boiler...

  • Page 72: Inspect Boiler Area

    The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance WARNING and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

  • Page 73: Check Expansion Tank

    4. Replace ground wires if ground continuity is not satisfactory. Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings.

  • Page 74: Check Flame Signal

    • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. 2. Allow time for the boiler to cool to room temperature if it has been firing. 3. Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

  • Page 75: Diagrams

    SYSTEM X1-1 PUMP "L" PUMP "N" X1-2 3.15A SYSTEM PUMP BOILER BOILER SYSTEM PUMP PUMP "L" PUMP "N" X1-4 RELAY BOILER PUMP BOILER RELAY PUMP PUMP "L" PUMP "N" X1-3 DHW PUMP RELAY TERMINAL TERMINAL STRIP STRIP 24V DC PUMP...

  • Page 76: Wiring Diagram

    X1-2 X1-3 Installation & Operation Manual BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING BOX DEPICTS JUNCTION OPTIONAL ITEMS X1-3 PUMP X1-4 BOILER PUMP X1-2 SYSTEM PUMP KB ONLY ON/OFF SWITCH 120V X1-6 SUPPLY X1-5 X1-8 X1-1 TRANSFORMER...
  • Page 77 Installation & Operation Manual Notes...
  • Page 78 Installation & Operation Manual Notes...
  • Page 79 Installation & Operation Manual Notes...
  • Page 80 Revision A (ECO #C05747) initial release. Reflects the new model numbers for the Knight Wall Mount upgrade. Revision B (ECO #C06188) reflects updates made to the ladder and wiring diagrams (ECO #C06158). Revision C (ECO #C06234) reflects changes made to the Service Reminder feature.

This manual is also suitable for:

Knight wbn051Knight wbn081Knight wbn106Knight wbn151Knight wbn211

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