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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

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

LBL20169 REV D

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

CN

8-1

CN

8-2

CN

8-3

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 BLG

-T

-T

-T

-T

SHIELD

GROUNDING

JUMPER

O

GY

G

R/BK

W/BK

GY

PR

1 2

G

3

BELL JU

MPE

R

ALAR

M BE

LL

SILEN

C

ING SWITCH

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

O

AIR PRESSURE SWITCH

O/BK

HEAT/LOOP

DEMAND

3

HEAT/LOOP

DEMAND

2

HEAT/LOOP

DEMAND

1

P

Figure 13-2 Wiring Diagram

13

Diagrams

(continued)

79

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Содержание Knight WHN055

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: ...ect Venting Options 14 Install Vent and Combustion Air Piping 15 Requirements for Installation in Canada 16 Sizing 16 Materials 17 Optional Room Air 18 PVC CPVC 19 Polypropylene 20 Stainless Steel Ven...

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: ...he 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...

Страница 5: ...iew IMG00161 11 17 4 3 24 2 6 8 7 26 1 33 Left Side inside unit IMG00162 27 23 28 16 19 31 30 18 25 5 33 Right Side inside unit The Knight Wall Mount Boiler How it works continued IMG00117 21 13 14 20...

Страница 6: ...Maximum allowed working pressure is located on the rating plate NOTICE Knight Wall Mount Boiler AHRI Rating Model Number Note Change N to L for L P gas models Input MBH Note 5 Min Max Heating Capacity...

Страница 7: ...ler location 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...

Страница 8: ...NIMUM RIGHT 0 MINIMUM FRONT 6 MINIMUM RECOMMENDED SERVICE CLEARANCES FRONT 24 BOTTOM 24 LEFT SIDE 12 Figure 1 1 Closet Installation Minimum Required Clearances WARNING Note Service clearances are reco...

Страница 9: ...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 sp...

Страница 10: ...heck the following venting components before installing Material For materials listed for use with this appliance see Section 3 General Venting For polypropylene or stainless steel venting an adapter...

Страница 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 fa...

Страница 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 S...

Страница 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 wal...

Страница 14: ...3 2 PVC CPVC Concentric Sidewall Termination See page 26 for more details Direct venting options Sidewall Vent Figure 3 3 Two Pipe Vertical Termination See page 29 for more details Figure 3 4 PVC CPVC...

Страница 15: ...connection Combustion air 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 9 Used to p...

Страница 16: ...are approved for use on the Knight wall mount boiler Both kits are listed to the ULC S636 standard for use in Canada When determining equivalent combustion air and vent length add 5 feet for each 90 e...

Страница 17: ...e meeting UL Standard 723 or 181A P or a high quality 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 hori...

Страница 18: ...provided with properly sized 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...

Страница 19: ...fficient 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 F...

Страница 20: ...terminations must comply with listed options in this manual and be a single wall vent offering For use of flex pipe it is recommended to have the vent material in 32 F or higher ambient space before b...

Страница 21: ...systems and terminations listed in Tables 3G and 3H DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property d...

Страница 22: ...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 i...

Страница 23: ...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 th...

Страница 24: ...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 19 to seal the vent pipe 4 Mount and secure the ven...

Страница 25: ...regard to spacing from adjacent boiler vents WARNING Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B Prepare wall penetrations Alternate F...

Страница 26: ...installations 4 inch diameter for CVK3008 or 7 inch diameter for CVK3007 installations into the structure to install the termination kit 4 Partially assemble the concentric vent termination kit Clean...

Страница 27: ...tructure s hole Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 6 Install the rain cap and small diameter pipe assembly into the Y co...

Страница 28: ...It is important 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 Conc...

Страница 29: ...return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 5 The vent piping must terminate in an up turned...

Страница 30: ...ENT PIPE FROM ANOTHER BOILER Figure 5 2 Vertical Terminations with Multiple Boilers Figure 5 3 Alternate Vertical Terminations with Multiple Boilers WARNING Vertical termination optional concentric ve...

Страница 31: ...of surface or anticipated snow level 12 inches in U S A or 18 inches in Canada as shown in FIG 5 4 page 30 If assembly is too short to meet height requirement the two 2 pipes supplied in the kit may b...

Страница 32: ...combustion air routing Concentric Venting Arrangement The venting is to be vertical through the roof The annular space between the O D of the vent pipe and the I D of the existing unused venting syst...

Страница 33: ...ng 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 ret...

Страница 34: ...t 10 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 11 Boiler purge valve Factory supplied The boiler purge valve is used to remove entrapped air from...

Страница 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 HO...

Страница 36: ...tor 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 N...

Страница 37: ...rmer 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 G...

Страница 38: ...VE 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 S...

Страница 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 NO...

Страница 40: ...AKE 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 E...

Страница 41: ...LATOR 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 w...

Страница 42: ...N 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 Z...

Страница 43: ...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 SHIELDED CABLE TO...

Страница 44: ...IELDED CABLE TO BOILER CONTROL 24V SIGNAL TO MIXING VALVES 120VAC TO PUMPS WIRES TO LOOP SENSORS MULTI TEMP TO LOOP CONTROL IMG00191 Figure 6 9 Multiple Boilers Multiple Temperature DHW Piped as a Zon...

Страница 45: ...D 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 P...

Страница 46: ...R 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 illust...

Страница 47: ...ED 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 i...

Страница 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 press...

Страница 49: ...anadian 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...

Страница 50: ...the gas piping 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 i...

Страница 51: ...in line regulator is used it must be a minimum of 10 feet from the Knight wall mount boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to...

Страница 52: ...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 dan...

Страница 53: ...the normally open contacts on the flow switch FIG 8 4 DHW tank sensor 1 By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automati...

Страница 54: ...eration of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor FIG 8 4 If the outd...

Страница 55: ...3 SYSTEM SUPPLY SENSOR BUILDING MANAGEMENT SYSTEM 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 PU...

Страница 56: ...with ASME D2564 or F493 For Canada 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 p...

Страница 57: ...in valve and manual air vent 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 wil...

Страница 58: ...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...

Страница 59: ...ck 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 sev...

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

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

Страница 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 sys...

Страница 63: ...the NAVIGATION dial to adjust the date Press the NAVIGATION dial 10 Turn the NAVIGATION dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key Please note that the...

Страница 64: ...ased on the settings for the three 3 heat loop demands reference Lochinvar kit RLY30086 The Knight wall mount boiler can also be programmed to accept a call for heat from a 0 10V signal reference the...

Страница 65: ...n the next seven 7 days can be temporarily bypassed if desired Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate...

Страница 66: ...re is fixed at SH 1 3 set points For Models 55 285 the Outdoor Sensor Fault will remain on the display screen until the outdoor sensor is reconnected High limit operations The Knight wall mount is equ...

Страница 67: ...riority 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 cont...

Страница 68: ...tch 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 v...

Страница 69: ...e 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...

Страница 70: ...nel 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 e...

Страница 71: ...tional 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 exce...

Страница 72: ...ured by the flame sense circuit FAN SPEED The speed of the combustion blower BOILER PUMP The status of the boiler pump output SYSTEM PUMP The status of the system pump output DHW PUMP The status of th...

Страница 73: ...Setback Skip Screen E NAVIGATION Dial Function Turning the NAVIGATION dial will select the next or previous Status Screen Pressing the NAVIGATION dial will show the next fault NSB Night Setback trigg...

Страница 74: ...anual 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 per...

Страница 75: ...stalled 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...

Страница 76: ...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 p...

Страница 77: ...ver and burner 5 Remove the condensate trap from the bottom of the boiler Place a bucket underneath the condensate fitting attached to the heat exchanger 6 Use a vacuum cleaner to remove any accumulat...

Страница 78: ...3 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 CN6 X6 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to th...

Страница 79: ...st 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 fa...

Страница 80: ...ision E ECO C09803 reflects the addition of the new Polypropylene Vent material section rearranging the venting section and the addition of the AHRI and ASME logos R05009 Revision F ECO C09843 reflect...

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