Lochinvar KNIGHT WH 55-399 Installation & Operation Manual Download Page 32 | Manualshive

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Lochinvar KNIGHT WH 55-399 Installation & Operation Manual Download Page 32

Installation & Operation Manual

Figure 5-10 Existing Vent as a Chase

AIR INLET

FLUE EXHAUST

SEAL

CAP

EXISTING

SEAL

FLUE OUTLET

5

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.

32

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

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Summary of Contents for KNIGHT WH 55-399

Page 1: ...ting 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 WARNING Save this manual for future reference ...

Page 2: ... Materials 16 Requirements for Installation in Canada 16 PVC CPVC Air Intake Vent Connections 17 Air Inlet Pipe Materials 18 Stainless Steel Vent 18 19 Max Allowable Vent Piping Lengths 19 Vent and Air Piping 20 Optional Room Air 20 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 21 24 Determine Location 21 22 Prepare Wall Penetrations 23 Termination and Fittings 23 Multiple Vent Air Termi...

Page 3: ... heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can att...

Page 4: ...nd gas and provides a wide range of firing rates 13 Water outlet system supply The water outlet is the water connection for water leaving the boiler and entering the system 14 Water inlet system return The water inlet is the water connection for water entering the boiler from the system 15 Gas connection pipe Threaded pipe connection This pipe should be connected to the incoming gas supply for the...

Page 5: ...11 28 22 10 Front View 11 17 4 3 24 2 6 8 7 26 1 Left Side inside unit 27 23 28 16 19 31 30 18 25 5 Right Side inside unit The Knight Wall Mount Boiler How it works continued 21 13 14 20 15 29 FRONT OF UNIT Bottom View 5 Models 55 399 ...

Page 6: ... affixed to the unit Maximum allowed working pressure is located on the rating plate NOTICE Knight Wall Mount Boiler I B R Rating Model Number Note Change N to L for L P gas models Input MBH Note 5 Min Max Heating Capacity MBH Note 2 8 Net I B R Ratings Water MBH Note 3 8 AFUE Note 1 8 WHN055 11 55 51 44 96 WHN085 17 85 79 69 96 WHN110 22 110 102 89 96 WHN155 31 155 144 125 96 WHN199 40 199 186 16...

Page 7: ...of freeze protection in boiler water causing system and boiler to freeze and leak 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 Failure to install the appliance indoors could result in severe personal injury death or substantial property dam...

Page 8: ...M BOTTOM 0 MINIMUM RIGHT 0 MINIMUM FRONT 6 MINIMUM RECOMMENDED SERVICE CLEARANCES FRONT 24 BOTTOM 24 LEFT SIDE 24 Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC 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 Note Service cl...

Page 9: ... of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages 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...

Page 10: ...er pipe size is in place see Table 3C Check to see that this size is used throughout the vent system Manufacturer For a stainless steel application you must use only the listed manufacturers and their type product listed in Table 3A for CAT IV positive pressure venting with flue producing condensate Supports Non combustible supports must be in place allowing a minimum 1 4 rise per foot The support...

Page 11: ... 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 continuously e Test for spillage at the draft...

Page 12: ... Table Model LP Orifice Stamping 55 055 85 085 110 110 155 155 199 199 285 H285 399 8 0 NOTICE WARNING Table 2A LP Conversion Table Figure 2 2 Gas Valve Power Switch Venturi Removal REMOVE THE SCREWS SECURING THE GAS VALVE VENTURI TO THE INLET OF THE COMBUSTION BLOWER 7 Using an Allen wrench remove the screws securing the gas pipe to the gas valve Remove the gas valve venturi assembly from the uni...

Page 13: ... bolts are secured in the center of the studs 3 Hang the boiler on the bracket and secure the 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 the boiler See page 9 of this manual for boiler mounting location instructions NOTICE The Knight Wall Mount boiler is not intended for floor i...

Page 14: ...CPVC Two Pipe Sidewall Termination See page 21 for more details Figure 3 3 PVC CPVC Concentric Sidewall Termination See page 24 for more details Direct venting options Sidewall Vent Figure 3 2 Stainless Steel Two Pipe Sidewall Termination See page 22 for more details ...

Page 15: ...tails Figure 3 7 PVC CPVC Vertical Vent Sidewall Air Figure 3 8 Stainless Steel Vertical Vent Sidewall Air Direct venting options Vertical Vent Direct venting options Vertical Vent Sidewall Air Stainless steel vent air design and terminations will vary slightly by manufacturer NOTICE Figure 3 6 PVC CPVC Concentric Vertical Termination See page 29 for more details 3 General venting continued ...

Page 16: ... with other vent systems or unlisted pipe fittings 4 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 Both kits are listed to the ULC S636 standard for use in Canada For Models 55 85 and 110 using 2 venting and Model 285 ...

Page 17: ...mbustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 VentConnector FIG 3 9 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 lo...

Page 18: ...th stainless steel using the manufacturers listed in Table 3A Use only the materials vent systems and terminations listed in Table 3B DO NOT mix vent systems of different types or manufacturers unless listed in this manual Failure to comply could result in severe personal injury death or substantial property damage WARNING Installations must comply with applicable national state and local codes St...

Page 19: ...t length add 5 feet for each 90 elbow 3 feet for each 45 elbow and 3 feet for the concentric vent kit see example below EXAMPLE 20 feet of PVC pipe 4 90 elbows 2 45 elbows 1 concentric vent kit 49 equivalent feet of piping Table 3C Maximum Combustion Air and Vent Piping Lengths Note The minimum combustion air and vent piping length is 12 equivalent feet The Knight wall mount boiler uses model spec...

Page 20: ... 2 KIT30051 55 285 3 KIT30052 199 399 4 KIT30053 Table 3D Optional Room Air Kit NOTICE Optional room air is intended for commercial applications Combustion air piping to the outside is recommended for residential applications Please read the information given in Table 1A page 10 listing contaminants and areas likely to contain them If contaminating chemicals will be present near the location of th...

Page 21: ...ng winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcov...

Page 22: ...ect to buildup of leaves or sediment Vent air termination sidewall ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS BIRD SCREEN 12 MIN 12 MIN 15 MAX COUPLING TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION BIRD SCREEN GRADE OR SNOW LINE Figure 4 1C Alternate Venting Arrangement if Space Allows w Field Supplied Fittings VENT AIR TERMINATION 12 MIN 12 MIN 12 MIN Figure 4 2A Clearance ...

Page 23: ...al property damage Multiple vent air terminations 1 When terminating multiple Knight wall mount boilers terminate each vent air connection as described in this manual FIG 4 5A 2 Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet as shown in FIG 4 5A for U S installations For Canadian installations provide clearances required by CSA B...

Page 24: ...ple or pets 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 4 Cut one 1 hole 5 inch diameter for CVK3003 installations 4 inch diameter for CVK3008 or 7 inch diameter for CVK3007 installations into the structure to install the termination kit 5 Partially assemble the concentric vent ter...

Page 25: ...structure s hole Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for CVK3003 and 3008 installations and fastened tightly into the rubber adapte...

Page 26: ... It is important that vent terminations be made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 11 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 9 Cement appliance combustion air and vent pipes...

Page 27: ...aintain 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 above the air intake ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 OF VENT PIPE BIRD SCREEN TYPICAL COUPLING FIELD SUPPLIED VENT OUTLET 12 MINI...

Page 28: ...t termination uses a rain cap as illustrated in FIG 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 apart and with the vent termination at least 1 foot above the air intake 4 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1A 5 Do ...

Page 29: ...her when field disassembly is desired for cleaning see FIG 4 9 page 25 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 injury...

Page 30: ...connections Multiventing 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 important that vent terminations be made as s...

Page 31: ...example Installation must comply 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 clea...

Page 32: ...5 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 32 For concept illustration only Individual installations may vary due to job site specific equipment ...

Page 33: ...g with illustrations on the following pages FIG s 6 3 through 6 12 which will guide you through the installation of the Knight wall mount boiler reference FIG s 6 1A and 6 1B 1 Connect the system return marked Inlet 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 ...

Page 34: ... 10 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 11 Boiler purge valve Field supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up 12 System temperature sensor Lochinvar supplies a system temperature sensor The sensor is to be installed in the heating loop downstream from the boiler hot water pipi...

Page 35: ... SYSTEM PUMP LOW LOSS HEADER TYPICAL CONDENSATE DRAIN INDIRECT DOMESTIC HOT WATER TANK Y STRAINER RECOMMENDED DRAIN VALVE BOILER PUMP FILL VALVE EXPANSION TANK TO SYSTEM FROM SYSTEM FROM TO DOMESTIC HOT WATER PUMP VENT AIR TO FLOOR DRAIN CHECK VALVE OUTLET INLET Figure 6 1B Near Boiler Piping w Low Loss Header 6 Hydronic piping continued Circulator sizing The Knight wall mount boiler heat exchange...

Page 36: ...ator Recommendations for Temperature Rise Applications_20 25 and 35 25 F Temperature Rise Applications Model GPM FT HD Minimum Pipe Size Pump Grundfos TACO B G Armstrong 55 4 0 17 1 UPS 15 58FC 1 007 NRF 22 E7 85 7 0 72 1 UPS 15 58FC 1 007 NRF 22 E7 110 8 0 98 1 UPS 15 58FC 2 007 NRF 22 E7 155 12 3 13 1 UPS 15 58FC 3 007 NRF 36 1 E7 199 15 0 71 1 25 UPS26 99F 0011 NRF 36 1 E7 285 22 1 61 1 25 UPS2...

Page 37: ...f the system was based on being able to maintain a certain ΔT and figured by using the universal hydronics equation of BTU hr GPM x 500 x ΔT Given that any time there is a change to the heat load i e warmer day or greater heat loss from a structure then the GPM should change to match the required BTU hr This is achieved when the variable speed circulators automatically and continually adjust their...

Page 38: ...LVE DRAIN POINT TYPICAL MAKE UP WATER FROM SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BOILER CIRCULATOR SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR DRAIN MAY SUBSTITUTE LOW LOSS HEADER Y STRAINER RECOMMENDED HOT WATER OUT FLOW CHECK VALVE Figure 6 3 Single Boiler Primary Secondary Piping Please note that these illustrations are meant to show system piping concept only the installer is...

Page 39: ... EXPANSION TANK ZONE VALVES TYPICAL FLOW CHECK VALVE DIFFERENTIAL PRESSURE BYPASS VALVE RECOMMENDED SYSTEM CIRCULATOR SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 4 Single Boiler Single Temperature with Zone Valves DHW Priority Please note that these illustrations are meant to show ...

Page 40: ...MAKE UP WATER HOT WATER OUT ZONE CIRCULATORS TYPICAL FLOW CHECK VALVE TYPICAL BOILER CIRCULATOR SYSTEM SUPPLY SENSOR PRESSURE RELIEF VALVE Y STRAINER RECOMMENDED MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 5 Single Boiler Single Temperature Zoned with Circulators DHW Priority Please note that these illustrations are meant to show ...

Page 41: ...ULATOR DRAIN Y STRAINER RECOMMENDED TYPICAL MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 6 Multiple Boilers Single Temperature Zoned with Zone Valves 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 NOT...

Page 42: ...IN BOILER 1 LEADER SYSTEM SUPPLY SENSOR TEMPERATURE PRESSURE GAUGE DRAIN Y STRAINER RECOMMENDED TYPICAL MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART ZONE 1 ZONE 2 ZONE 3 ZONE 4 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 42 Installation Ope...

Page 43: ...N TANK MIXING VALVES TYPICAL FLOW CHECK VALVE SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED 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 Figure 6 8 Single Boiler Multiple Temperature DHW Priority Please note that these illustrations are meant to show system piping concept only the insta...

Page 44: ...F 12 APART BOILER TEMPERATURE PRESSURE GAUGE PRESSURE RELIEF VALVE Figure 6 9 Multiple Boilers Multiple Temperature 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 Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes 55 1 1 4 1 1 2 1 1 2 2 2 2 2 85 1 ...

Page 45: ...ED SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 10 Single Boiler Full Flow Single Temperature Zoned with Zone Valves DHW Priority 6 Hydronic piping continued 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 o...

Page 46: ...ER RECOMMENDED BOILER CIRCULATOR ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 11 Single Boiler Full Flow Single Temperature Zoned with Valves DHW Piped as a Zone 6 Hydronic piping 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 th...

Page 47: ...DED BALL VALVE TYPICAL ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 12 Single Boiler Full Flow Single Temperature Zoned with Circulators DHW Piped as a Zone 6 Hydronic piping continued 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 ensu...

Page 48: ... property damage 3 Purge all air from the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at less than 13 inches w c b Disconnect the boiler and gas valve from the gas supply piping during any pressure testing greater than 13 inches w c The gas valve and blower will not suppor...

Page 49: ...Canadian installations Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches ...

Page 50: ...to the appliance WARNING 3 Loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG 7 3 4 Slowly turn on the gas supply at the field installed manual gas valve 5 Turn on power at source 6 Adjust the temperature set point on the control panel of the SMART SYSTEM control mod...

Page 51: ...gulator 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 Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility...

Page 52: ...o activate a system pump wire as shown in FIG 8 2 If the motor is larger than 1 8 hp or 1 8 amps you must isolate with a relay Figure 8 2 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 REMOVE BEZEL Figure 8 1 Remove Bezel Low voltage connections 1 Route all low volt...

Page 53: ...ally detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6 F 3 C below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point 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 Connect the sensor leads to th...

Page 54: ...urve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat Zone Control enable output or Building Management System enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the Heat Loop Demands 1...

Page 55: ...G MANAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO LOW WATER CUTOFF OUTDOOR SENSOR TANK SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER NOTE CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES WIRE AS NEEDED SYSTEM PUMP SPEED CONTROL BOILER PUMP A B HEAT LOOP DEMAND 2 HEAT LOOP DEMAND 1 Figure 8 4 Low Voltage Field Wiring Connections ...

Page 56: ...da use CSA or ULC certified PVC or CPVC pipe fittings and cement 6 A condensate removal pump is required if the boiler is below the 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 blocked drain switch insi...

Page 57: ... boiler drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Eliminate all system leaks Continual fresh makeupwaterwillreduceboilerlife Minerals can build up in the heat exchanger reducing heat trans...

Page 58: ...condensate trap with enough water to make the ball float FIG 10 1 3 Loosen compression fitting FIG 10 1 4 Slide condensate trap onto condensate drain at the bottom of the unit 5 Tighten compression fitting The condensate trap FIG 10 1 must have the float ball in place during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to ensure the float ball is ...

Page 59: ...d noise Check vent piping and air piping 1 Check for gas tight seal at every connection seam of air piping and vent piping Venting system must be sealed gas tight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the procedure on page 48 of this manual connecting gas supp...

Page 60: ...60 Installation Operation Manual 10 Start up o Figure 10 2 Operating Instructions Models 55 285 ...

Page 61: ...Installation Operation Manual 61 10 Start up continued Figure 10 3 Operating Instructions Model 399 ...

Page 62: ...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 After the space heating call for heat ends the system pump continues to run for a short period of time The system pump can be programmed to run continuously except during outdoor shutdown If the boiler pump was running it continues to run for a short...

Page 63: ... dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key Please note that the brackets denote screen status NOTICE Configuration of the cascade Please note that the brackets denote screen status NOTICE When installed in a Cascade system the individual controls must be programmed for cascade operation This is accomplished by accessing the control parameters Press ...

Page 64: ... thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the DHW thermostat input is ignored DHW space heating SH cycling If a DHW call for heat is received while a space heating call is in progress and the DHW is in Normal Mode the control will start the DHW pump and shut the boiler pump off The system pump will remain on If the space heating call is still ac...

Page 65: ...es the control will increase the firing rate when the flame signal drops too low Protection features Outlet temperature flue temperature and temperature rise limiting The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F the control will shut the unit dow...

Page 66: ...set high limits The automatic reset high limit has a maximum set point of 200 F and the manual reset high limit has a maximum set point of 210 F When the outlet temperature exceeds 200 F the automatic high limit action occurs The boiler shuts down until the outlet water temperature cools below 190 F and a 60 second timer has expired If the outlet temperature continues to increase the manual reset ...

Page 67: ... M4 M5 M6 M7 Day 1 1 hour M1 M2 M3 M4 M5 M6 M7 L Day 1 2 hours M2 M3 M4 M5 M6 M7 L M1 If a boiler is used to heat an indirect DHW tank or locks out it will automatically be given the lowest priority for the rest of that 24 hour period Cascade When multiple boilers are installed they can be wired together in a cascade sequence A maximum of eight boilers can be controlled from a single control In th...

Page 68: ...ain switch must close 4 The control starts a 15 second prepurge cycle by initiating the blower 5 The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected within 1 second after the sparking ends the control will perform a 10 second post purge then start another prepurge cycle and try to light the burner again The control wil...

Page 69: ... access modes OPERATION DISPLAY 8 If the space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump will turn off 2 seconds later This will divert the boiler s outlet water from the heating system and send it to the...

Page 70: ...anel FIG 11 1 to set temperatures operating conditions and monitor boiler operation 11 Operating information The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key ...

Page 71: ... for an additional 10 seconds 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 for heat B Call for Heat Indicators Heat Loop Demand 1 has a call fo...

Page 72: ...tput BMS VOLTAGE The voltage received from a BMS system BLR PUMP OUTPUT The speed signal sent to a variable speed boiler pump in percent SYS PUMP INPUT The speed signal received from a variable speed system pump control RATE OUTPUT A 0 10V signal indicating the firing rate of the boiler SH RUN HOURS The total hours of operation in the Space Heating Mode SH CYCLES The total burner cycles in the Spa...

Page 73: ...etting indicated by the cursor Pressing the NAVIGATION dial will display the Set Points Screen Turning the NAVIGATION dial will move the cursor up or down Turning the NAVIGATION dial will increase or decrease the current setting 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 can...

Page 74: ... 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 ANNUAL START UP Owner maintenance see the Knight Wall Mount User s Inform...

Page 75: ...lean condensate trap 1 Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out 2 Replace the clean out cap 3 Fill condensate trap with enough water to make the ball float FIG 12 1 Resume operation Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat ...

Page 76: ...lve is inoperative Shut down the boiler until a new relief valve has been installed 2 After following the warning directions in this manual if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing WARNING WARNING 12 Maintenance...

Page 77: ...irculators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 3 Replace the boiler front access cover The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the Service Manual Failure to comply could result in severe personal injury WARNING Cleaning boiler heat exchanger 1 Shut down boiler Follow the...

Page 78: ...ELD CN6 X6 CN6 X6 CN6 X6 CN6 X6 CN6 X6 CN8 1 X6 1 CN8 2 X6 2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 21 22 26 27 23 24 30 31 32 33 35 36 37 38 39 40 41 42 43 44 3 4 1 2 ALARM CONTACTS M O D B U S 29 34 10 16 14 9 5 6 7 8 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 v...

Page 79: ... it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement 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 locatio...

Page 80: ...Revision A ECO C06854 initial release WH I O Rev A 11 10 ...

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