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Installation & Operation Manual

1

Determine boiler location

DIR #2000543097 00

LEFT
0” MINIMUM

TOP
6” MINIMUM

RIGHT
0” MINIMUM

FRONT
6” MINIMUM

BOTTOM
0” MINIMUM

1” MINIMUM CLEARANCE
AROUND VENT PIPE

1/4” MINIMUM CLEARANCE
AROUND HOT WATER PIPES

OPEN FRONT

Figure 1-2 Alcove Installation - Minimum Required Clearances

DIR #2000543098 00

LEFT
0” MINIMUM

TOP
6” MINIMUM

RIGHT
0” MINIMUM

FRONT
6” MINIMUM

6”

6”

BOTTOM
0” MINIMUM

1” MINIMUM CLEARANCE
AROUND VENT PIPE

1/4” MINIMUM CLEARANCE
AROUND HOT WATER PIPES

CLOSED DOOR

VENTILATING
AIR OPENING*

VENTILATING
AIR OPENING*

* AREA OF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT

WITH A MINIMUM OF 100 SQ. INCHES.

Figure 1-1 Closet Installation - Minimum Required Clearances



WARNING

For closet installations, CPVC,
polypropylene or stainless steel
vent 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.



WARNING

For alcove installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used
in an alcove structure due to
elevated temperatures. Failure to
follow this warning could result
in fire, personal injury, or death.

8

Required Clearances to Combustible Materials

- Front / Top ..................................................................  6"
- Bottom ..........................................................................  0"
- Left / Right Side ..........................................................  0"

Required Clearances to Combustible Materials

- Front / Top ..................................................................  6"
- Bottom ..........................................................................  0"
- Left / Right Side ..........................................................  0"

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Summary of Contents for WH- 286

Page 1: ...ervice technician Read all instructions including this manual and the Knight Wall Hung Fire Tube Boiler Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage WARNING Save this manual for future reference 100287110_2000544742_Rev B ...

Page 2: ...Combustion Air Piping 16 Requirements for Installation in Canada 17 Sizing 17 Materials 18 Optional Room Air 19 PVC CPVC 20 Polypropylene 21 Stainless Steel Vent 22 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 23 26 Determine Location 23 25 Prepare Wall Penetrations 25 26 Multiple Vent Air Terminations 26 Sidewall Termination Optional Concentric Vent 27 29 5 VERTICAL DIRECT VENTING Vent...

Page 3: ...rmed by a qualified installer service agency or the gas supplier WARNING NOTICE WARNING WARNING When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail ...

Page 4: ...ply for the purpose of delivering gas to the boiler 16 SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals to regulate the blower gas valve and pump functions to meet heating demand Optional remote connectivity allows boiler settings to be monitored and modified when connected to the internet 17 Air intake adapter Allows for the connection of the PVC air ...

Page 5: ...8 34 16 19 32 21 35 18 29 Left Side inside unit Front View inside unit_Model 400 The Knight Wall Hung Fire Tube Boiler How it works continued Bottom View DIR 2000543092 00 FRONT OF UNIT 13 14 27 20 30 DIR 2000544038 00 35 17 1 4 5 26 32 18 14 19 16 23 13 25 15 Top View inside unit DIR 2000544036 00 23 26 24 2 3 5 4 ...

Page 6: ...ve been confirmed by the Hydronics Section of AHRI Maximum allowed working pressure is located on the rating plate NOTICE Knight Wall Hung Fire Tube Boiler AHRI Rating Model Number Note Change N to L for L P gas models Input MBH Note 5 Min Max Heating Capacity MBH Note 2 7 Net AHRI Ratings Water MBH Note 3 7 AFUE Note 1 7 WHN056 8 2 55 51 44 95 WHN086 8 5 85 79 69 95 WHN111 11 110 102 89 95 WHN156...

Page 7: ...n air supply see Table 1B on page 10 Prevent combustion air contamination Remove any of these contaminants from the boiler area WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Do not install the appliance where the relative humidity may exceed...

Page 8: ...H OPENING 1 SQ INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC polypropylene or stainless steel vent 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 WARNING For alcove installations CP...

Page 9: ...ages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle Vent and air piping The Knight Wall Hung Fire Tube boiler requi...

Page 10: ...nless steel vent only use terminations listed in Table 3H for the manufacturer of the installed vent 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 polypropylene and stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used with PVC ...

Page 11: ...f the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuo...

Page 12: ... wall bracket mounted to the pallet 3 Remove the three 3 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 on the floor or pallet Damage to the boiler can result DIR 2000543285 00 REMOVE SHIPPING WALL BRACKET DO NOT DISCARD WILL BE NEEDED TO SECURE...

Page 13: ...ze see Table 2A 3 Place the orifice into the black rubber grommet in the side of the gas valve and secure inside the gas valve FIG 2 3 4 Reattach the venturi to the gas valve and reposition the gas valve venturi assembly inside the unit Reattach the gas pipe to the gas valve Reattach the air intake and coupler and tighten down on the band clamp 5 Reattach the Molex plug to the gas valve Reassemble...

Page 14: ... bottom of the boiler with two 2 field supplied toggle bolts WARNING Do not mount the boiler to a hollow wall Be sure to mount the boiler to the studs only Mounting to a concrete wall 1 Mount the wall bracket using the two 2 wedge anchor bolts provided with the bracket To mount the wedge anchor bolts drill a 1 4 diameter hole 1 1 8 deep and insertanchor Hangthebracketfromtheanchorandsecure withthe...

Page 15: ... Concentric Sidewall Termination See page 27 for more details Direct venting options Sidewall Vent DIR 2000543103 00 Figure 3 3 Two Pipe Vertical Termination See page 30 for more details Direct venting options Vertical Vent DIR 2000543106 00 Figure 3 4 PVC CPVC Concentric Vertical Termination See page 32 for more details DIR 2000543107 00 Figure 3 5 Vertical Vent Sidewall Air ...

Page 16: ...r piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 7 thru 3 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as ...

Page 17: ...B Approved Concentric Vent Systems Sizing The Knight Wall Hung Fire Tube boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below Model Inlet Diameter Vent Diameter Maximum Length 56 2 inches 3 inches 2 inches 3 inches 80 feet 100 feet 86 2 inches 3 inches 2 inches 3 inches 50 feet 100 feet 111 2 inches 3 inches 2 inches 3 inches 40 feet 100 feet 156 3 i...

Page 18: ...ality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported...

Page 19: ... accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Model Vent Diameter Part Number 56 86 2 inch 100157614 111 286 3 inch 100157615 400 4 inch 100157616 Table 3C Optional Roo...

Page 20: ...ent to the pipe f While the cement is still wet insert the pipe into the fitting if possible twist the pipe a 1 4 turn as you insert it NOTE If voids are present sufficient cement was not applied and joint could be defective g Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe PVC CPVC Table 3D PVC CPVC Vent Pipe and Fittings All PVC vent pipes must be g...

Page 21: ... IN A VERTICAL ORIENTATION 2 ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE EQUIVALENT LENGTHS 3 SECTION A IS EQUIVALENT FEET OF RIGID PIPE WHICH MAY INCLUDE 45 AND 90 ELBOWS PLEASE SEE SIZING SECTION FOR DETERMINING EQUIVALENT FEET B DIM 3 RIGID 3 FLEX 4 FLEX Duravent 3 10 FT 20 FT 30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT 60 FT 53 FT 47 FT 40 FT 33 FT 27 FT 20 FT 13 FT 7 FT 90 FT 80 FT 70 FT 6...

Page 22: ...asNSeal Flue CPVC Starter Adapter 3 4 FSA 3 4 PVCO 3 4 FNSF2 DuraVent FasNSeal Flue Flue Collar Adapter 4 FSA KNWH3993 DuraVent FasNSeal Bird Screen Termination 3 4 FSBS3 4 DuraVent FasNSeal Rain Cap Termination 3 4 FSRC3 4 Heat Fab Saf T Vent Flue Coupler Adapter 3 4 93 4 01PVC1 Heat Fab Saf T Vent Flue Collar Adapter 4 WH00043 Heat Fab Saf T Vent Bird Screen Termination 3 4 93 4 92 Heat Fab Saf ...

Page 23: ...t buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas WARNING WARNING WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone f Do not terminate above any door or window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes TO BOILER INTAKE AIR CONNECTION FROM BOIL...

Page 24: ...or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG 4 1B Condensate could freeze and block vent pipe c Do not terminate closer than 4 feet horizontally from any e...

Page 25: ...o the vent plate FIG 4 4B 3 For PVC CPVC Only Install the vent and air intake piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3D on page 20 to seal the vent pipe 4 Mount and secure the vent plate to the wall using stainless steel screws 5 Seal all gaps between the pipes and wall Seal around the plate to the wa...

Page 26: ...er vents WARNING Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B 4 Sidewall direct venting Prepare wall penetrations Alternate Field Supplied Option 1 Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For ei...

Page 27: ... to install the termination kit 4 Partially assemble the concentric vent termination kit Clean and cement using the procedures found in these instructions a Cement the Y concentric fitting to the larger kit pipe FIG s 4 7 and 4 8 b Cement the rain cap to the smaller diameter kit pipe FIG s 4 7 and 4 8 Sidewall termination optional concentric vent Description and usage Lochinvar offers optional con...

Page 28: ...e inside the pipe assembly when installing through the hole 6 Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly from an outside wall Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for 100140485 and 100269005 installations and fastened tightly into the rubber adapter for 100140484 installations 7 Secure the a...

Page 29: ...that vent terminations be made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 13 Concentric Vent and Combustion Air Termination Figure 4 12 Concentric Vent Sidewall Attachment DO NOT use field supplied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 8 Cement appliance combustion air and vent pipes to the concentri...

Page 30: ... 5 1B maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet 6 m apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel above the air intake 6 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 7 Do not exte...

Page 31: ...gs and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple Knight Wall Hung Fire Tube boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury death or substantial...

Page 32: ...gether when field disassembly is desired for cleaning see FIG 4 11 page 28 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal in...

Page 33: ...nnected to the concentric vent termination connections Multi venting vertical terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 5 7 It is i...

Page 34: ...with local requirements and with the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existing unused venting system is converted for use with this method of concentric venting the installer must ensure that the existing venting system is clean and free from particulate conta...

Page 35: ...gths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase DIR 2000543111 00 AIR INLET FLUE EXHAUST SEAL EXISTING SEAL CAP FLUE OUTLET For concept illustration only Individual installations may vary due to job site specific equipment 5 Vertical direct venting continued ...

Page 36: ...2 Connect the system supply marked Outlet 3 Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone 4 Install a backflow preventer on the cold feed make up water line 5 Install a pressure reducing valve on the cold feed make up water line 15 psi nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of ...

Page 37: ...on DIR 2000543955 00 T P GAUGE 3 8 BUSHING FIELD PROVIDED TEE FIELD PROVIDED AUTO AIR VENT BUSHING TEE with 3 4 FITTING RELIEF VALVE 3 4 ELBOW Figure 6 2 Bottom Connections Installation Near boiler piping components 1 Boiler system piping Boiler system piping MUST be sized per the pipe requirements listed in Table 6B Reducing the pipe size can restrict the flow rate through the boiler causing inad...

Page 38: ...oil inside the indirect water heater B The indirect water heater is connected to the system supply piping A pump controlled by the Knight Fire Tube boiler s control will regulate the flow of water through the indirect water heater The indirect water heater s temperature will be regulated by the Knight Wall Hung Fire Tube boiler s control The Knight Wall Hung Fire Tube boiler is pre configured to c...

Page 39: ...hd 19 0 gpm 1 1 ft hd 27 0 gpm 2 3 ft hd 7 6 gpm 1 5 gpm 286 1 1 4 UPS 26 99 FC 15 5 gpm 0 8 ft hd 21 7 gpm 1 6 ft hd 27 0 gpm 2 4 ft hd 27 0 gpm 2 4 ft hd 10 8 gpm 1 5 gpm 400 1 1 2 UPS 26 99 FC 21 7 gpm 0 5 ft hd 30 4 gpm 0 9 ft hd 38 0 gpm 1 4 ft hd 38 0 gpm 1 4 ft hd 15 2 gpm 4 5 gpm Reference Table 6B for pump speed selection 6 Hydronic piping continued Pump sizing and flow requirements are b...

Page 40: ... protection Lochinvar offers the Multi Temperature Loop Control Board Kit 100167843 Model Speed TACO Bell Gossett Armstrong UPS 15 58 FC High 005F 007F 008F 0010F 1FC OOR MSF1 IFC 0015 NRF 22 LR 20WR Astro 0 Astro 30 3 Astro 50 3 Astro 230CI Compass Medium 005F IFC 007F IFC 008F IFC 0010F IFC 00R IFC 00R MSF1 IFC NRF9F LW NRF 25 SP 1 2 Astro 25 Astro 30 3 Low 005F IFC 006 IFC 00R MSF1 IFC Astro 20...

Page 41: ...E GAUGE EXPANSION TANK ZONE VALVES TYPICAL FLOW CHECK VALVE DIFFERENTIAL PRESSURE BYPASS VALVE IF USED SYSTEM CIRCULATOR SYSTEM SUPPLY SENSOR DRAIN Y STRAINER TYPICAL FLOW CHECK VALVE MAY SUBSTITUTE LOW LOSS HEADER BOILER CIRCULATOR NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART ZONE 1 ZONE 2 ZONE 3 ZONE 4 KE UP WATER METER Figure 6 5 Single Boiler Single Temperature with Zone Valves DHW Priority Ple...

Page 42: ...TYPICAL FLOW CHECK VALVE TYPICAL BOILER CIRCULATOR SYSTEM SUPPLY SENSOR Y STRAINER TYPICAL MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART VALVE ZONE 2 ZONE 3 ZONE 4 TEMPERATURE PRESSURE GAUGE UNION TYPICAL PRESSURE RELIEF VALVE DRAIN UP WA W WATER METER Figure 6 6 Single Boiler Single Temperature Zoned with Circulators DHW Priority Please note that these illustrations a...

Page 43: ...ER METER Figure 6 7 Multiple Boilers Single Temperature Zoned with Circulators DHW Priority Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE Required pipe diameter is based on maximum flow 17 gpm for Models 56 156 27 gpm for Models 200 286 and 38 gpm for Model 400 through al...

Page 44: ...MAKE UP WATER HOT WATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK MIXING VALVES TYPICAL FLOW CHECK VALVE SYSTEM SUPPLY SENSOR DRAIN Y STRAINER TYPICAL MAY SUBSTITUTE LOW LOSS HEADER TEMPERATURE LOOP 1 TEMPERATURE LOOP 2 TEMPERATURE LOOP 3 NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART PRESSURE RELIEF VALVE SHIELDED CABLE TO BOILER CONTROL 120VAC TO...

Page 45: ...illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE 6 Hydronic piping continued CAUTION Mixing valves are required for the protection of low temperature loops Required pipe diameter is based on maximum flow 17 gpm for Models 56 156 27 gpm for Models 200 286 and 38 gpm for Model 400 through all units ...

Page 46: ...CT DHW TANK CIRCULATOR BOILER 1 LEADER 1 WATER METER Figure 6 11 Multiple Boilers Single Temperature Zoned with Valves Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE Required pipe diameter is based on maximum flow 17 gpm for Models 56 156 27 gpm for Models 200 286 and 38 g...

Page 47: ...OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK ZONE VALVES TYPICAL FLOW CHECK VALVE DIFFERENTIAL PRESSURE BYPASS VALVE RECOMMENDED SYSTEM SUPPLY SENSOR DRAIN Y STRAINER TYPICAL ZONE 1 ZONE 2 ZONE 3 ZONE 4 UNION DRAIN PRESSURE RELIEF VALVE WATER METER Figure 6 13 Single Boiler Full Flow Single Temperature Zoned with Zone Valves DHW Priority It is the ...

Page 48: ... 4 UNION PRESSURE RELIEF VALVE MAKE UP WATER METER Figure 6 14 Single Boiler Full Flow Single Temperature Zoned with Valves DHW Piped as a Zone Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE It is the responsibility of the installer to ensure that the minimum flow requirem...

Page 49: ...TER IN AIR SEPARATOR EXPANSION TANK DRAIN POINT TYPICAL MAKE UP WATER HOT WATER OUT ZONE CIRCULATORS TYPICAL FLOW CHECK VALVE TYPICAL SYSTEM SUPPLY SENSOR Y STRAINER TYPICAL BALL VALVE TYPICAL ZONE 1 ZONE 2 ZONE 3 ZONE 4 BOILER INDIRECT DHW TANK TEMPERATURE PRESSURE GAUGE UNION TYPICAL PRESSURE RELIEF VALVE DRAIN WATER METER Figure 6 15 Single Boiler Full Flow Single Temperature Zoned with Circula...

Page 50: ...valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation WARNING 5 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow Failure to apply pipe s...

Page 51: ...exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 14 inches w ...

Page 52: ...d input Percent of burner input will be displayed on the control panel 8 Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in this section of the manual 9 If gas supply pressure is within normal range and no adjustments are needed proceed on to Step 11 10 If the gas pressure is out of range contact the gas utility gas supplier qualified installe...

Page 53: ...emain between 4 inches w c natural 8 inches w c LP minimum and 14 inches w c natural and LP maximum during stand by 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 Hung Fire Tube boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the li...

Page 54: ...er than 1 8 hp or 1 8 amps you must isolate with a relay Figure 8 1 Line Voltage Field Wiring Connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation WARNING NOTICE CAUTION Low voltage connections 1 Route all low voltage wires through the openings on the bottom as shown in FIG 8 2 2 Connect low voltage wiring to low voltag...

Page 55: ...nect storage indirect water heater DHW thermostat FIG 8 3 to the DHW thermostat terminals on the connection board If a tank sensor is connected see DHW Tank Sensor below the tank thermostat is ignored DHW tank sensor 1 By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generate...

Page 56: ...connected to the 0 10 Vdc terminal of the external control Make sure the voltage is not below ground Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the ...

Page 57: ...er wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards FIG 8 3 If more than two boilers are on the 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 T...

Page 58: ...GEMENT SYSTEM LOUVER PROVING SWITCH TO NEXT BOILER FROM PREVIOUS BOILER NOTE CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES WIRE AS NEEDED SYSTEM PUMP SPEED CONTROL LOUVER RELAY FLOW SWITCH TANK THERMOSTAT ROOM THERMOSTAT 1 SYSTEM SUPPLY SENSOR COM NO OUTDOOR SENSOR DHW RECICULATION SENSOR A B A B ROOM THERMOSTAT 3 ROOM THERMOSTAT 2 TANK SENSOR DIR 2000507983 00 ...

Page 59: ...e drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired in series with the air pressure switch inside the boiler Figure 9 1 Condensate Disposal DIR 2000543292 00 CONDENSATE DRAIN CONNECTION ROUTE TO FLOOR DRAIN OR NEUTRALIZING FIL...

Page 60: ...rs Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and corrosion in closed loop systems Pre CommissioningCleaning 1 Prior to fill and start up flush the entire heating system 2 Clean the entire heating system with an approved pre commissioning cleaner comparable to Sentinel X300 or X400 and Fernox F3 or DS40 in accordance with the ma...

Page 61: ...re rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in the system open the manual air vents in the system one at a time beginning with the lowest floor Close the vent when water squirts out Repeat with remaining vents 2 Open the automatic air ven...

Page 62: ...o the connection board Inspect condensate system Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate fittings and condensate trap to ensure the trap is properly installed and connected to the condensate pipe under the boiler Reference Section 9 Condensate Disposal for installation instructions WARNING WARNING WARNING Final checks before starting the boiler Re...

Page 63: ...y or by installing a propane orifice Model WH400 only see pages 12 and 13 In order to operate on LP gas these components MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Table 10B Flue Products Chart 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF position and en...

Page 64: ... new settings will be discarded Set domestic hot water DHW operation Verify DHW mode There are two 2 modes of operation for DHW In Normal Mode when a DHW demand begins the control will start the DHW pump turn off the boiler pump if running and modulate to bring the outlet temperature to the DHW boiler set point The maximum firing rate may be limited in this mode if desired In Zone Mode it is assum...

Page 65: ...ess the NAVIGATION dial to access this parameter Each appliance in the Cascade system must be programmed with its own address The boiler designated as the Leader will have an address of 0 The remaining boilers in the Cascade will be Members and have addresses from 1 7 Rotate the NAVIGATION dial to select the appropriate address Press the RIGHT SELECT SAVE key Press the RIGHT SELECT HOME key to upl...

Page 66: ...66 Installation Operation Manual 10 Start up Figure 10 2 Operating Instructions_ Models WH56 WH286 ...

Page 67: ...67 Installation Operation Manual 10 Start up continued Figure 10 3 Operating Instructions_Model WH400 ...

Page 68: ...ratures of up to three 3 separate loops based on the settings for the three 3 heat loop demands reference Lochinvar kit 100167843 0 10V input set point or power The Knight Wall Hung Fire Tube boiler can be controlled by a Building Management System BMS provided that either an external energy management system is installed that reduces the boiler water temperature as the heating load decreases the ...

Page 69: ...temperature limitations Ramp delay For systems with lower flow the SMART SYSTEM can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call for heat to a space heating call for heat There are six 6 limits that can be programmed as well as six 6 time intervals corresponding to each limit The sixth limit will also limit the firing rate for the r...

Page 70: ...turn temperatures are maintained below the dew point condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust Low voltage blocking The blower and gas valve require a minimum amount of voltage in order to operate properly If an ignition attempt is made when the line voltage is temporarily low such as during a brownout the control could enter a m...

Page 71: ...new MRHL set point the MRHL will function causing boiler lockout If this occurs skip to Step 11 11 Operating information continued 9 If the current outlet temperature is below the new MRHL set point locate the pinhole SERVICE button above the RESET button on the display board Insert a thin probe such as a paper clip into the hole and press the button continuously for five 5 seconds to place the bo...

Page 72: ...d as the DHW boiler Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The DHW boiler will adjust its set point to the programmed DHW boiler se...

Page 73: ...w switch and or LWCO must close 3 The control turns on power to the louver relay The louver proving switch and blocked drain switch must close 4 The control starts the prepurge cycle by initiating the blower 5 The control starts the trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected after the sparking ends the control will perform a postpurge then...

Page 74: ...d through the unit This will divert the boiler s outlet water from the heating system and send it to the tank coil instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point 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 mode...

Page 75: ...d the temperature units can also be changed see page 64 Installer Most parameters are available only to the installer accessible by entering the installer password see the Knight Wall Hung Fire Tube Boiler Service Manual Saving parameters reference the Parameter Table in the Knight Wall Hung Fire Tube Boiler Service Manual Please note that the brackets denote screen status NOTICE To save parameter...

Page 76: ... The call for heat has been satisfied and the unit runs the fan for an additional postpurge period to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position SETPOINT MET The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a condition that has temporarily interrupted the current call...

Page 77: ...The temperature of Loop 3 reported by the MTLC control I O SCREEN a GAS PRESS SW The state of the gas pressure switch b FLOW SW The state of the flow switch c LOUVER RELAY The state of the louver relay output d LOUVER SW The state of the louver proving switch e BLOCKED DRAIN The state of the blocked drain switch f GAS VALVE The state of the gas valve output BMS SCREEN a 0 10V BMS IN b 0 10V RATE O...

Page 78: ...ext DHW night setback trigger D LEFT SELECT key function USB Press the LEFT SELECT key to access the USB and Installer menu E NAVIGATION dial function MODIFY Pressing the NAVIGATION dial will allow the installer to change the text F RIGHT SELECT key function SHDN Press the RIGHT SELECT key to turn the boiler OFF ON Press the RIGHT SELECT key to turn the boiler ON NO Press the RIGHT SELECT key to c...

Page 79: ...ons Perform start up checkout and performance verification per Section 10 of this manual Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ...

Page 80: ...ings and condensate trap Inspect condensate trap Monthly inspection 1 The condensate trap should be inspected monthly to ensure the trap is properly installed and connected to the condensate pipe under the boiler see FIG 12 1 2 The condensate line should be inspected monthly for obstructions making sure it allows free flow for condensate to drain 3 Inspect the neutralizing kit if installed monthly...

Page 81: ... should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the...

Page 82: ...tment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks 1 Start boiler and perform checks and tests specified in Section 10 Start up 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame 1 Inspect flame through observation window 2 If the flame is unsatisfactory at either high fire ...

Page 83: ...5 16 driver and disconnect the air inlet from the venturi 6 On Models WH56 WH286 loosen the threaded nut on the venturi Remove the gasket between the gas piping and venturi On the WH400 model disconnect the Molex plug from the gas valve Using a 5 mm Allen wrench remove the screws securing the gas pipe to the gas valve 7 Remove the 10 mm nuts securing the heat exchanger top plate to gain access to ...

Page 84: ...5 46 47 19 20 21 22 ALARM CONTACTS M O D B U S 33 38 CN6 X6 DHW RECIRC SENSOR 48 29 30 CN6 X6 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes X1 1 1...

Page 85: ...lacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations ...

Page 86: ...Installation Operation Manual 86 Notes ...

Page 87: ...Installation Operation Manual 87 Notes ...

Page 88: ... Notes Revision A Process 3000008912_Change 500009028 initial release Revision B PCP 3000010423 CN 500010150 reflects an update to the neutralizer information on page 59 MM 100287110_ DIR 2000544742_Rev B 08 17 ...

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