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Installation & Operation Manual

Models: 80 - 500

This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight 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.

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Содержание 500

Страница 1: ...nstaller service technician Read all instructions including this manual and the Knight 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 ...

Страница 2: ...ous risk levels or to important information concerning the life of the product DANGER WARNING CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which i...

Страница 3: ...s can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause int...

Страница 4: ...nding on the model 14 Water inlet system return NPT water connection that returns water from the system to the heat exchanger either 1 1 1 4 or 1 1 2 depending on the model 15 Gas connection pipe Threaded pipe connection either 1 2 3 4 or 1 depending on the model This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler 16 SMART Control Module The SMA...

Страница 5: ...n Manual Figure 1 Front View Models 80 210 Figure 3 Left Side inside unit Models 80 210 Figure 4 Right Side inside unit Models 80 210 The Knight Boiler How it works continued Figure 2 Rear View Models 80 210 5 Models 80 210 ...

Страница 6: ...tion Manual 6 The Knight Boiler How it works Figure 5 Rear View Models 285 399 Figure 7 Rear View Model 500 Figure 8 Left Side inside unit Model 500 Figure 6 Left Side inside unit Models 285 399 Models 285 399 Model 500 ...

Страница 7: ...to L for L P gas models CSA Input Modulation Btu hr DOE Heating Capacity Btu hr Net I B R Ratings Btu hr DOE AFUE Lochinvar Low Temperature Application Annual Efficiency Boiler Water Content Gallons Water Connections Gas Connections Vent Air Size Note 6 Note 2 9 Note 3 9 Note 1 9 Note 5 Note 4 KBN080 16 000 80 000 73 000 63 000 93 0 98 0 0 6 1 1 2 3 KBN105 21 000 105 000 95 000 83 000 93 0 98 0 0 ...

Страница 8: ...d correct system problems such as System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits Incorrectly sized expansion tank Lack 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 tem...

Страница 9: ...igure 10 Alcove Installation Minimum Required Clearances Figure 9 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC material MUST BE used in a closet structure Failure to follow this warning could result in fire personal injury or death ...

Страница 10: ...e If the boiler is located in a residential garage per ANSI Z223 1 paragraph 5 1 9 Mount the boiler with a minimum of 18 inches above the floor of the garage to the bottom of the boiler to ensure the burner and ignition devices will be no less than 18 inches above the floor Locate or protect the boiler so it cannot be damaged by a moving vehicle Vent and air piping The Knight boiler requires a spe...

Страница 11: ...n operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all doors between the space in which the appl...

Страница 12: ...ing matches boiler size Models 80 399 Table 2 Failure to comply could result in severe personal injury death or substantial property damage Models 80 285 1 Remove the top and front access covers from the unit no tools required for removal 2 Remove the three star drive screws securing the gas valve to the venturi FIG 12 3 Locate the propane orifice disk from the conversion kit bag Verify that the s...

Страница 13: ...nside the blower Handle the O ring with care do not damage Reposition the venturi against the blower and replace the screws securing the venturi to the blower FIG 13 8 After installation is complete attach the propane conversion label in the conversion kit bag next to the boiler rating plate Attach the LP caution label in the conversion kit bag to the left side of the unit in the lower left corner...

Страница 14: ...al Termination See page 24 for more details Figure 17 Two Pipe Sidewall Termination See page 18 for more details Figure 18 Concentric Vertical Termination See page 26 for more details Figure 19 Concentric Sidewall Termination See page 21 for more details Direct venting options ...

Страница 15: ... Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system air system and combustion air quality See also Section 1 of this manual Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and a...

Страница 16: ...ing to the outside MUST BE used Use of combustion air from the room via louvers plenums or any other device is not authorized NOTICE Figure 20 Near Boiler Venting Models 80 210 Figure 21 Near Boiler Venting Models 285 500 Maximum allowable combustion air and vent piping lengths are as follows Combustion Air 100 equivalent feet Vent 100 equivalent feet When determining equivalent combustion air and...

Страница 17: ...or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal injury or death check for areas and products listed in Table 1 page 11 before installing the boiler or air inlet piping If contaminants are found you MUST Remove products permanently OR Relocate air inlet and vent terminations to other areas Removing from existing vent Fo...

Страница 18: ...o not exceed the maximum lengths of the outside vent piping shown in FIG 22 Excessive length exposed to the outside could cause freezing of condensate in the vent pipe resulting in potential boiler shutdown 4 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be obje...

Страница 19: ...ief valve or other equipment Never terminate above or below any of these within 4 feet horizontally 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment Vent air termination sidewall Figure 24 Clearance to Gravity Air Inlets Figure 25 Clearance to Forced Air Inlets Prepare wall penetrations 1 Air pipe pene...

Страница 20: ...exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury death or substantial property damage Multiple vent air terminations 1 When terminating multiple Knight boilers terminate each vent air connection as described in this manual ...

Страница 21: ...nating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on bui...

Страница 22: ... pipe and flow to the burner enclosure Failure to follow this warning could result in product damage or improper operation personal injury or death Figure 31 Rain Cap to Vent Pipe Alternate Assembly 6 Install the Y concentric fitting and pipe assembly through the structure s hole Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 In...

Страница 23: ...t that vent terminations be made as shown to avoid recirculation of flue gases Dimension A in FIG 33 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation Figure 33 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation Models 80 210 Only Figure 32 Concentric Vent Sidewall Attachment DO NOT use field supplied...

Страница 24: ...vailing 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 Figure 34 Vertical Termination of Air and Vent 5 Maintain clearances to vent termination as given in FIG 34 a Vent must terminate At least 6 feet from adjacent walls No closer than 5 feet bel...

Страница 25: ... of flue products into the combustion air stream 3 The vent piping must terminate in an up turned coupling as shown in FIG 34 The top of the coupling must be at least 1 foot above the air intake 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 Main...

Страница 26: ...cts to be recirculated Failure to follow this warning could result in personal injury or death 3 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the pl...

Страница 27: ...t appliances are vented near each other each appliance must be individually vented see FIG 39 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 39 but next to the vent terminations must be at least 36 inches away from the first two 2 terminations It is important that vent ter...

Страница 28: ...ough the installation of the Knight boiler reference FIG 40 1 Connect the system return marked Inlet make sure to install with pipe sealant compound 2 Connect the system supply marked Outlet make sure to install with pipe sealant compound 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 ...

Страница 29: ...r sizing The Knight boiler heat exchanger does have a pressure drop which must be considered in your system design Refer to the graphs in FIG s 41 and 42 for pressure drop through the Knight boiler heat exchanger Near boiler piping connections Figure 40 Near Boiler Piping ...

Страница 30: ...FT HD 80 5 9 15 0 4 9 11 5 4 2 7 3 3 7 6 0 3 3 5 7 105 7 7 17 5 6 4 12 1 5 5 9 3 4 8 7 8 4 3 6 0 150 11 0 12 8 9 2 11 0 7 9 9 5 6 9 8 5 6 1 7 1 210 15 5 19 0 12 9 13 0 11 0 9 1 9 7 8 0 8 6 7 1 285 21 0 11 5 17 5 9 1 15 0 7 3 13 1 6 1 11 7 5 0 399 29 4 14 1 24 5 10 3 21 0 7 5 18 4 6 5 16 3 5 5 500 36 8 15 5 30 7 12 5 26 3 9 4 23 0 7 3 20 5 6 3 Boiler secondary system piping based on 20 feet of pipi...

Страница 31: ...k valves could result in a reverse flow condition during pump s off cycle 6 Domestic indirect hot water isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 7 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above 115 F 8 Union...

Страница 32: ...Installation Operation Manual 32 6 Hydronic piping Figure 43 Single Boiler Zoned with Circulators ...

Страница 33: ... 44 Multiple Boilers Zoned with Circulators Model Number of Units 2 3 4 5 6 Required Pipe Sizes 80 1 1 4 1 1 2 2 2 1 2 2 1 2 105 1 1 2 2 2 2 1 2 2 1 2 150 2 2 2 1 2 2 1 2 2 1 2 210 2 2 1 2 2 1 2 3 3 285 2 1 2 2 1 2 3 3 3 1 2 399 2 1 2 3 3 1 2 4 4 500 2 1 2 3 3 1 2 4 5 ...

Страница 34: ...Installation Operation Manual 34 6 Hydronic piping Figure 45 Single Boiler Zoned with Valves ...

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