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Installation & Operation Manual

X1-7

ON/OFF

SWITCH

1 2 3 4 5

G

R

R W

R

T

W

BK

Y

BL

BLOWER

-T

HIGH LIMIT SENSOR S1b

OPERATING SENSOR S1a

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

INTEGRATED

CONTROL

BK

Y

GAS VALVE
@24VAC

SPARK

ROD

TRANSFORMER

TR2

G

HIGH VOLTAGE SPARK LEAD

CAUTION

FLAME SENSOR

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

ROOM TSTAT

ZONE CONTROL 3

ROOM TSTAT

ZONE CONTROL 2

ROOM TSTAT

ZONE CONTROL 1

11
12
13
14
15
16
17
18
19
20

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

CASCADE

A

B

SHIELD

SHIELD

0-10V

+

-

BMS

IN

0-10V

+

-

SYS PUMP

IN

0-10V

+

-

BLR PUMP

OUT

0-10V

+

-

RATE

OUT

MODBUS

OPTION

A

B

SHIELD

SHIELD

LOW

WATER

CUT-OFF

24 VAC

COM

P/BK

Y

W/R

1
2
3
4
5
6
7
8
9

10

21
22
23
24
25
26
27
28
29
30
31
32

33
34
35
36
37
38
39
40
41
42
43
44

CN7-1
CN7-2
CN7-3
CN7-4

CN5-1
CN5-8
CN5-2
CN5-9
CN5-3

CN5-10
CN5-11

CN5-4
CN5-5

CN5-14
CN5-12

CN5-6

CN5-13

CN5-7

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

BK

Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with the appliance must be replaced, 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 locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.

WIRING DIAGRAM

LBL20127 REV B

BOX DEPICTS

OPTIONAL ITEMS

X4-7

X4-14

X4-6

X4-13

X4-5

X4-12
X4-11

X4-4
X4-3
X4-8

X4-10

X4-2
X4-9
X4-1

BK
BK
BK
BK

BK
BK
BK
BK
BK

BK
BK
BK
BK

CONNECTION BOARD

CN6

X6

HIGH VOLTAGE

LOW VOLTAGE

120 VAC

X-7

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

MODBUS BOARD

MTR-01

CN8

-1

CN8

-2

CN8

-3

X6

-3

X6

-2

X6

-1

X6

-4

X9-1
X9-2
X9-3
X9-4

X4-1
X4-2
X4-3
X4-4

X5-1
X5-2

X1-1
X1-2
X1-3

BK

W

G

R BL G

-T

-T

-T

-T

SHIELD

GROUNDING

JUMPER

O

GY

G

R/BK

W/BK

GY

PR

1 2

G

3

BEL

L

J

U

M

P

E

R

AL

AR

M

BEL

L

SI

L

E

N

C

IN

G

SW

IT

C

H

JUNCTION

BOX

DHW
PUMP

BOILER
PUMP

SYSTEM
PUMP

BOX DEPICTS

OPTIONAL

ITEMS

G

G

G

L

GND

N

120V
SUPPLY

X1-3

X1-4

X1-2

X1-5

X1-6

X1-8

X1-1

BK

OR

W

W

W

BR

PR

W

L

N
L

N
L

N

L
N

KB ONLY

AIR PRESSURE
SWITCH

BLOCKED DRAIN
SWITCH

O

P

O/BK

Figure 13-2

Wiring Diagram

13

Diagrams

76

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...
74
75
76
77
78
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Содержание KNIGHT 51

Страница 1: ...ing 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...

Страница 2: ...g Materials 16 Requirements for Installation in Canada 16 PVC CPVC Air Intake Vent Connections 17 Air Inlet Pipe Materials 17 Stainless Steel Vent 18 Max Allowable Vent Piping Lengths 19 Vent and Air...

Страница 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 w...

Страница 4: ...e of firing rates 13 Water outlet system supply The water outlet is the water connection for water leaving the boiler and entering the system Boiler connection is 1 14 Water inlet system return The wa...

Страница 5: ...19 23 10 28 Front View 16 32 20 29 31 3 13 14 7 27 8 6 Left Side inside unit 2 25 24 5 4 26 22 18 1 Right Side inside unit The Knight Wall Mount Boiler How it works continued FRONT OF UNIT 14 13 30 2...

Страница 6: ...eration but the operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit Maximum allowed working pressure is located...

Страница 7: ...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 temperat...

Страница 8: ...HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES VENTILATING AIR OPENING RIGHT 0 MINIMUM Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC or stainless steel v...

Страница 9: ...149 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...

Страница 10: ...r 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...

Страница 11: ...yers 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 exhau...

Страница 12: ...tch to the OFF position FIG 2 2 4 Disconnect the Molex plug from the wiring connector located on the gas valve 5 Using a 5 16 nut driver loosen the band clamp securing the air intake coupler to the ga...

Страница 13: ...are is needed to ensure the 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 moun...

Страница 14: ...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 Termina...

Страница 15: ...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 term...

Страница 16: ...ar 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...

Страница 17: ...piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate VENT AIR Figure 3 9 Near Boiler PVC CPVC Venting Air inlet pipe materials The air inlet pipe s...

Страница 18: ...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 s...

Страница 19: ...Table 305 4 or as local codes dictate Maximum allowable combustion air and vent piping lengths are as follows Model 2 Max Vent Air 3 Max Vent Air 51 40 feet 100 feet 81 40 feet 100 feet 106 40 feet 10...

Страница 20: ...ed openings to assure adequate combustion air Please refer to instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet...

Страница 21: ...s c Prevailing 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...

Страница 22: ...lls or subject 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 F...

Страница 23: ...l 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...

Страница 24: ...nt 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...

Страница 25: ...result in product damage or improper operation personal injury or death Figure 4 9 Rain Cap to Vent Pipe Alternate Assembly 6 Install the Y concentric fitting and pipe assembly through the structure s...

Страница 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 10 Conce...

Страница 27: ...ast 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...

Страница 28: ...e coupling must be at least 1 foot above the air intake When the vent 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...

Страница 29: ...er 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 sc...

Страница 30: ...cal 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...

Страница 31: ...n 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 Genera...

Страница 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 Ventin...

Страница 33: ...rough 6 10 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 Outle...

Страница 34: ...f 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 d...

Страница 35: ...YSTEM SENSOR DRAIN TYPICAL 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...

Страница 36: ...UPS15 58FC 0014 NRF 36 E7 106 7 7 17 5 1 UPS26 99F 0014 NRF 36 E7 151 11 0 12 8 1 UPS26 99F 0014 NRF 36 E7 211 15 5 19 0 1 UPS26 99F 0013 NRF 36 E7 35 F Temperature Rise Applications Model GPM FT HD M...

Страница 37: ...the table above 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...

Страница 38: ...R 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 PIP...

Страница 39: ...ER 1 LEADER SYSTEM SUPPLY SENSOR TEMPERATURE PRESSURE GAUGE DRAIN Y STRAINER RECOMMENDED TYPICAL MAY SUBSTITUTE LOW LOSS HEADER ZONE 1 ZONE 2 ZONE 3 ZONE 4 Figure 6 4 Multiple Boilers Single Temperatu...

Страница 40: ...GE EXPANSION 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 T...

Страница 41: ...SURE GAUGE UNION TYPICAL DRAIN Y STRAINER RECOMMENDED NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BOILER Figure 6 6 Multiple Boilers Multiple Temperatures Please note that these illustrations are mean...

Страница 42: ...AL DRAIN Y STRAINER RECOMMENDED NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART BOILER TEMPERATURE PRESSURE GAUGE Please note that these illustrations are meant to show system piping concept only the inst...

Страница 43: ...IRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK ZONE VALVES TYPICAL FLOW CHECK VALVE DIFFERENTIAL PRESSURE BYPASS VALVE IF USED SYSTEM CIRCULATOR SYSTEM SUPPLY SENSO...

Страница 44: ...PASS VALVE IF USED SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR DRAIN Y STRAINER RECOMMENDED TYPICAL NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART MAY SUBSTITUTE LOW LOSS HEADER ZONE 1 ZONE 2 ZONE 3 ZONE 4 FL...

Страница 45: ...INT 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 REC...

Страница 46: ...rom 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 inche...

Страница 47: ...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 b...

Страница 48: ...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...

Страница 49: ...ine 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 Failure to prop...

Страница 50: ...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...

Страница 51: ...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...

Страница 52: ...rve 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...

Страница 53: ...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 ROOM THERMOSTAT 1 ROOM THERMOSTAT 2 NOTE CONNECTI...

Страница 54: ...comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 7 A condensate removal pump is required...

Страница 55: ...sure 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 Elim...

Страница 56: ...and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check...

Страница 57: ...the system will interfere with circulation and cause heat distribution problems and noise Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent pi...

Страница 58: ...10 Start up Figure 10 2 Operating Instructions 58 Installation Operation Manual...

Страница 59: ...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 pu...

Страница 60: ...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 bracke...

Страница 61: ...ection of a DHW 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...

Страница 62: ...crease 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 outle...

Страница 63: ...connected High limit operations The Knight wall mount is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has a maximum set point of 200 F and the m...

Страница 64: ...n off sequence will be as follows DAY SWITCHING ON SEQUENCE Day 1 L M1 M2 M3 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 indirec...

Страница 65: ...d drain 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...

Страница 66: ...iption of parameters and 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 mo...

Страница 67: ...IG 11 1 to set temperatures operating conditions and monitor boiler operation 11 Operating information continued The information on the bottom of the display shows the functions of the two SELECT keys...

Страница 68: ...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 The controlled temperature has exceeded its...

Страница 69: ...MS 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...

Страница 70: ...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 decrea...

Страница 71: ...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 pe...

Страница 72: ...out cap on the bottom of the trap Let the condensate and any debris drain out 2 Fill with fresh water until the water begins to pour out of the drain 3 Replace the clean out cap and resume operation E...

Страница 73: ...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 re...

Страница 74: ...iler in Section 10 Startup 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 roo...

Страница 75: ...D SHIELD 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...

Страница 76: ...original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage s...

Страница 77: ...Installation Operation Manual Notes 77...

Страница 78: ...Installation Operation Manual Notes 78...

Страница 79: ...Installation Operation Manual Notes 79...

Страница 80: ...ts 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 S...

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