55-285 Series Fire Tube Boiler

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Product Information

Specifications:

• Models: 55 – 285
• Series: 100-101, 110-111, & 120-121
• Material: Stainless steel heat exchanger
• Usage: Heating system

Product Usage Instructions

1. Installation

Installation of this product should only be carried out by a
qualified heating installer or service technician. Follow the steps
provided in the manual and the Knight Fire Tube Boiler Service
Manual in the given order to ensure proper installation.

2. Operation

After installation, have the boiler serviced and inspected by a
qualified service technician at least annually. Failure to comply
with this requirement may result in severe personal injury, death,
or substantial property damage.

3. Location

Consider piping and installation when determining the boiler
location. Ensure that the appliance is not installed in areas where
gasoline or flammable vapors are likely to be present to prevent
hazards.

4. Maintenance

Avoid using petroleum-based cleaning or sealing compounds in the
boiler system as they can damage gaskets and seals, leading to
property damage. Do not use homemade remedies or boiler patent
medicines to prevent serious damage to the boiler and property.

FAQ

Q: Can I install the appliance in a room with corrosive

contaminants?

A: No, avoid installing the unit in rooms or
environments that contain corrosive contaminants as it could result
in personal injury, death, or substantial property damage.

Q: What should I do if I smell gas?

A: If you smell gas, do not install units in
the area. Ensure safety protocols are followed and contact a
professional immediately.

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100305277_2000558126_Rev K
Installation & Operation Manual Models: 55 – 285
Series 100-101, 110-111, & 120-121

WARNING

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

Save this manual for future reference.

Contents

HAZARD DEFINITIONS ………………………………………….. 2 PLEASE READ BEFORE PROCEEDING ………………… 3 THE KNIGHT FIRE TUBE BOILER — HOW IT WORKS 4-5 RATINGS ……………………………………………………………….. 6 1. DETERMINE BOILER LOCATION Before Locating the Boiler, Check ……………………………….. 7 Closet and Alcove Installations ……………………………………. 7 Provide Clearances …………………………………………………… 9 Provide Air Openings to Room …………………………………… 9 Flooring and Foundation …………………………………………… 9 Residential Garage Installation …………………………………… 9 Vent and Air Piping …………………………………………………… 9 Prevent Combustion Air Contamination ……………………….. 9 Corrosive Contaminants and Sources ……………………….. 10 Using an Existing Vent System to Install a New Boiler … 10 Removing a Boiler from Existing Common Vent………….. 11 2. PREPARE BOILER Remove Boiler from Wood Pallet ………………………………. 12 Gas Conversions………………………………………………… 12-13
Leveling the Boiler ……………………………………………… 13 3. GENERAL VENTING Direct Venting Options …………………………………………….. 14 Install Vent and Combustion Air Piping ……………………… 15 Air Intake / Vent Location………………………………………….. 16 Optional Room Air……………………………………………………. 16 Requirements for Installation in Canada…………………….. 17 Sizing ……………………………………………………………………. 17 Materials…………………………………………………………………. 18 PVC/CPVC …………………………………………………………….. 19 Polypropylene…………………………………………………………. 20 Stainless Steel Vent ………………………………………………… 21 4. SIDEWALL DIRECT VENTING Vent/Air Termination – Sidewall…………………………….. 22-25
Determine Location………………………………………… 22-24 Multiple Vent/Air Terminations……………………………… 22 Prepare Wall Penetrations…………………………………… 24 Sidewall Termination – Optional Concentric Vent ……. 25-27 5. VERTICAL DIRECT VENTING Vent/Air Termination – Vertical ……………………………… 28-29 Determine Location………………………………………… 28-29 Multiple Vent/Air Terminations…………………………. 28-29 Prepare Roof Penetrations ………………………………….. 29

Existing Vent as a Chase …………………………………….. 29 Vertical Termination – Optional Concentric Vent … 30-31 Alternate Vertical Concentric Venting……………………. 32 6. HYDRONIC PIPING System Water Piping Methods………………………………….. 33 Low Water Cutoff Device …………………………………………. 33 Chilled Water System………………………………………………. 33 Freeze Protection Fluids ………………………………………….. 33 General Piping Information ………………………………………. 33 Smart System / Multi-Temperature Loop …………………….. 33 Near Boiler Piping Components………………………………… 34 Pressure Drop vs. Flow / Boiler Flow Requirements …… 35 Piping Diagrams …………………………………………………. 36-46 7. GAS CONNECTIONS Connecting Gas Supply Piping …………………………….. 47-48 Natural Gas ……………………………………………………………. 48 Pipe Sizing for Natural Gas …………………………………. 48 Natural Gas Supply Pressure Requirements …………. 48 Propane Gas ………………………………………………………….. 48 Pipe Sizing for Propane Gas ……………………………….. 48 Propane Supply Pressure Requirements ………………. 48 Check Inlet Gas Supply ………………………………………. 49-50 Gas Pressure …………………………………………………………. 50 Gas Valve Replacement ………………………………………….. 50 8. FIELD WIRING ……………………………………………….51-55 Line Voltage Connections ………………………………………… 51 Low Voltage Connections ………………………………………… 51 Wiring of the Cascade…………………………………………. 53-54 9. CONDENSATE DISPOSAL Condensate Drain …………………………………………………… 56 10. STARTUP ……………………………………………………. 57-63 11. OPERATING INFORMATION General……………………………………………………………… 64-67 Cascade ………………………………………………………………… 68 Sequence of Operation ……………………………………….. 69-70 Knight Fire Tube Boiler Control Module……………………… 71 Status Display Screens ……………………………………….. 72-74 12. MAINTENANCE Maintenance and Annual Startup………………………….. 75-79 13. DIAGRAMS Ladder Diagram ……………………………………………………… 80 Wiring Diagram……………………………………………………….. 81 Revision Notes ………………………………………….. Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE 2

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Installation & Operation Manual

Please read before proceeding

WARNING

Installer ­ Read all instructions, including this manual and the Knight Fire Tube

Boiler Service Manual, before installing.

Perform steps in the order given.

User ­ This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

NOTICE

When calling or writing about the boiler ­ Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

WARNING

Failure to adhere to the guidelines on this page can result in severe personal injury,

death, or substantial property damage.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may

result causing property damage, personal

injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance. · Do not touch any electric switch; do
not use any phone in your building. · Immediately call your gas supplier
from a near by phone. Follow the gas supplier’s instructions. · If you cannot reach your gas supplier, call the fire department. · Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B). Failure to comply could result in severe personal injury, death, or substantial property damage.

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 to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
· Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.
· The installer must verify that at least one carbon monoxide alarm has been installed within a residential living space or home following the alarm manufacturer’s instructions and applicable local codes before putting the appliance into operation.

Boiler water ­
· Thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

CAUTION

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

CAUTION

Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

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 attack gaskets and seals used in hydronic systems.

3

Installation & Operation Manual

The Knight Fire Tube Boiler – How it works…

1. Stainless steel heat exchanger Allows system water to flow around specially designed tubes for maximum heat transfer, while providing protection against flue gas corrosion.
2. Combustion chamber access cover Allows access to the combustion side of the heat exchanger.
3. Blower The blower pulls in air and gas through the venturi (item 5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.
4. Gas valve The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.
5. Venturi The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.
7. Boiler outlet temperature sensor (housed with the high limit sensor) This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.
8. Boiler inlet temperature sensor This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.
9. Temperature and pressure gauge Monitors the outlet temperature of the boiler as well as the system water pressure.
10. Electronic LCD display The display features a high resolution liquid crystal screen, four (4) buttons, and a navigation dial. A serial and LOCH-N-LINK® USB Programming support additional communication with the control.
11. Flue pipe adapter Universal vent adapter allows connection of PVC/CPVC, polypropylene, or stainless steel venting systems to the boiler.
12. Burner (not shown) Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet (system supply) Copper water connection that supplies hot water to the system, either 1″ or 1-1/4″, depending on the model.
14. Water inlet (system return) Copper water connection that returns water from the system to the heat exchanger, either 1″ or 1-1/4″, depending on the model.
15. Gas connection pipe Threaded pipe connection. This pipe should be connected to the incoming gas supply 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 (Models 110 – 285 only)
Allows for the connection of the PVC air intake pipe to the boiler.
18. High voltage junction box The junction box contains the connection points for the line voltage power and all pumps.
19. Low voltage connection board The connection board is used to connect external low voltage devices.
20. Low voltage wiring connections Conduit connection points for the low voltage connection board.
21. Condensate trap The condensate trap has a 1/2″ PVC outlet connection pipe.
22. Access cover – front Provides access to the gas valve, control panel, and heat exchanger.
23. Ignition electrode Provides direct spark for igniting the burner.
24. Flame inspection window The quartz glass window provides a view of the burner surface and flame.
25. Relief valve Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 30 psi.
26. Flame sensor Used by the control module to detect the presence of burner flame.
27. Line voltage wiring connections Conduit connection points for the high voltage junction box.
28. Top panel Removable panel allows access to the gas train and combustion chamber.
29. Side access panels (not shown) Remove panels to gain access to temperature sensors.
30. Power switch Turns 120 VAC ON/OFF to the boiler.
31. Leveling legs Used to allow the heat exchanger to be leveled. This is needed for the proper draining of the condensate from the combustion chamber.
32. Flue and temperature access door Provides access to the flue and temperature sensor.
33. Transformer The transformer provides 24V power to the integrated control.
34. High limit sensor (housed with the outlet temperature sensor) Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.
35. Stainless steel flue collector (not shown) Flue gas and condensate enter the stainless flue collector through the fire tubes. A 1″ drain connection allows condensate to flow through the collector into a condensate trap for disposal.
36. Line voltage receptacle Equipment outlet for use with a condensate pump or other low power equipment. Do not exceed 7 amp load. Note: The power outlet is on a separate circuit than the boiler ON/ OFF switch, and will remain powered when the boiler is turned off.

4

Installation & Operation Manual
The Knight Fire Tube Boiler – How it works… (continued)

28 10
22

4 5 3 2
23 26
DIR #2000507762 00

25 24
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Front View

Top View (inside unit)

11
7 34 29
13 15
6
8 14

36 27
30 20
31

17 9
18 19
21

DIR #2000557480 00
Left Side (inside unit)

1 16
33
DIR #2000557480 00
Front View (inside unit)
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Installation & Operation Manual

Ratings

A SME
H

Model Number
KHB(XXX)(N,L) XXX = Input (MBH)
N = Natural Gas L = Propane Gas
KHB055(N,L) KHB085(N,L) KHB110(N,L) KHB155(N,L) KHB199(N,L) KHB285(N,L)

Knight Fire Tube Boiler AHRI Rating

Input MBH

Heating Capacity
MBH

(Note 5)

Net
AHRI Ratings Water,
MBH

AFUE %

Min

Max

(Note 2,7)

(Note 3,7) (Note 1, 7)

8.3

55

51

44

95

8.5

85

79

69

95

11.0

110

102

89

95

15.5

155

144

125

95

19.9

199

183

159

95

28.5

285

264

230

95

Other Specifications

Boiler Water Content

Water

Gas

Connections Connections

Air Size

Gallons

Vent Size

(Note 4,8)

2.3

1″

2.2

1″

2.3

1″

3.2

1″

5.2

1-1/4″

4.9

1-1/4″

1/2″

2″

2″

1/2″

2″

2″

1/2″

3″

3″

1/2″

3″

3″

1/2″

3″

3″

1/2″

3″

3″

NOTICE Maximum allowed working pressure is located on the rating plate.

Notes: 1. As an Energy Star Partner, Lochinvar has determined that
Knight Fire Tube boilers meet the Energy Star guidelines for energy efficiency. 2. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 3. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15. 4. Knight Fire Tube boilers require special gas venting. Use only the vent materials and methods specified in the Knight Fire Tube Installation and Operation Manual. 5. Standard Knight Fire Tube boilers are equipped to operate from sea level to 4,500 feet only. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet. 6. High altitude Knight Fire Tube boilers are equipped to operate from 3,000 to 9,600 feet. The boiler will de-rate 1.7% between 5,000 to 9,600 feet. For any units installed past 9,600 feet there is an additional de-rate of 4% per 1,000 feet beyond 9,600 feet per the National Fuel Gas Code. Boilers configured for high altitude shall not be installed below 3000 feet. 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. De-rate values are based on proper combustion calibration and CO2’s adjusted to the recommended levels. 7. Ratings have been confirmed by the Hydronics Section of AHRI.
6

8. Models 055 – 085 can be alternatively vented using a 3″ vent/ air size, the 110 model can be alternatively vented using a 2″ vent/air size, and the 285 model can be alternatively vented using a 4″ vent/air size. See the General Venting – Sizing Section of this manual for maximum allowable lengths.
9. The manual reset high limit provided with the Knight Fire Tube is listed to UL353.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 9,600 FT.
DIR #2000557484 00
Figure A High Altitude Label Location

Installation & Operation Manual

1 Determine boiler location

Installation must comply with:
· Local, state, provincial, and national codes, laws, regulations, and ordinances.
· National Fuel Gas Code, ANSI Z223.1 ­ latest edition. · Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required. · National Electrical Code. · For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.

NOTICE

The Knight Fire Tube boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 ­ latest edition.

Before locating the boiler, check:

1. Check for nearby connection to:

· System water piping

· Venting connections

· Gas supply piping

· Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations

cannot be avoided, it is recommended that a suitable

drain pan, adequately drained, be installed under the

appliance. The pan must not restrict combustion air

flow. Under no circumstances is the manufacturer to be

held responsible for water damage in connection with

this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

WARNING

Failure to keep boiler area clear and free of combustible materials, gasoline, and

other flammable liquids and vapors can

result in severe personal injury, death, or

substantial property damage.

4. The Knight Fire Tube boiler must be installed so that gas

control system components are protected from dripping

or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for

and 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 fluids in boiler water causing

system and boiler to freeze and leak.

· Debris left from existing piping, if not flushed and

cleaned with an appropriate cleaner.

6. Check around the boiler for any potential air

contaminants that could risk corrosion to the boiler

or the boiler combustion air supply (see Table 1B).

Prevent combustion air contamination. Remove any of

these contaminants from the boiler area.

WARNING

DO NOT install units in rooms or environments that contain corrosive

contaminants (see Table 1B). Failure to

comply could result in severe personal

injury, death, or substantial property

damage.

DO NOT install the boiler in a room likely to freeze.

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 93%. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.
Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

WARNING

This appliance requires a special venting system. Use only the vent materials,

primer and cement specified in this

manual to make the vent connections.

Failure to follow this warning could result

in fire, personal injury, or death.

Closet and alcove installations

A closet is any room the boiler is installed in which the room volume is less than the room volume listed in the table below. An alcove is any room which meets the criteria for a closet, but it does not have a door.

Table 1A Room Volume
Model 55 – 285

Room Volume (in cubic feet) 124

Example: Room dimensions = 4 feet long, 3 feet wide, and 8 foot ceiling = 4 x 3 x 8 = 96 cubic feet. This would be considered a closet for a 285 model.

WARNING

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC, polypropylene

or stainless steel vent material must be used

inside the structure. The ventilating air

openings shown in FIG. 1-1 are required

for closet installations. Failure to follow this

warning could result in fire, personal injury,

or death.

Recommended clearances for service access – Front / Left / Top ……………………………………………….. 24″ – Back / Right ……………………………………………………….. 0″

NOTICE

If you do not provide the recommended service clearances shown, it may not be possible to service the boiler without removing it from the space.

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Installation & Operation Manual

1 Determine boiler location
Figure 1-1 Closet Installation – Minimum Required Clearances

TOP 12:”
6″

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.

Required Clearances to Combustible Materials – Front ……………………………………………………………….6″ – Top / Left Side……………………………………………….. 12″ – Back / Right Side ……………………………………………..0″
VENTILATING* AIR OPENING

*AREA OF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT

12″

LEFT

WITH A MINIMUM OF 100 SQ. INCHES.

6″

0″ REAR

6″ FRONT

0″ RIGHT

VENTILATING* AIR OPENING
DIR #2000507564 00

Figure 1-2 Alcove Installation – Minimum Required Clearances

TOP 12″

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.

Required Clearances to Combustible Materials – Front ……………………………………………………………….6″ – Top / Left Side……………………………………………….. 12″ – Back / Right Side ……………………………………………..0″

0″ REAR
8

6″ FRONT

12″ LEFT

0″ RIGHT
DIR #2000507571 00

Installation & Operation Manual

1 Determine boiler location (continued)

Provide clearances: Clearances from combustible materials 1. Hot water pipes–at least 1/4″ (6 mm) from combustible
materials. 2. Vent pipe ­ at least 1″ (25 mm) from combustible
materials. 3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance
minimums.
Provide air openings to room:
Knight Fire Tube boiler alone in boiler room
1. No air ventilation openings into the boiler room are needed when the total room volume is greater than the value given for closet installations (see Table 1A). For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Residential garage installation
Precautions
Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition 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 is not subject to physical damage by a moving vehicle.
Vent and air piping
The Knight Fire Tube boiler requires a special vent system, designed for pressurized venting.

Knight Fire Tube boiler in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

WARNING

The space must be combustion/ventilation

provided with air openings

correctly sized for all other appliances

located in the same space as the Knight

Fire Tube boiler.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage. 2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Knight Fire Tube boiler because it takes its combustion air from outside (direct vent installation).
Flooring and foundation
Flooring
The Knight Fire Tube boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

WARNING

Do not install the boiler on carpeting even if foundation is used. Fire can result,

causing severe personal injury, death, or

substantial property damage.

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 3, General Venting. Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight Fire Tube boiler using any other means.

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination
Install air inlet piping for the Knight Fire Tube boiler as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1B, for products and areas which may cause contaminated combustion air.

WARNING

You must pipe combustion air to the boiler air intake. Ensure that the combustion air

will not contain any of the contaminants

in Table 1B. Contaminated combustion

air will damage the boiler, resulting in

possible severe personal injury, death

or substantial property damage. Do not

pipe combustion air near a swimming

pool, for example. Also, avoid areas

subject to exhaust fumes from laundry

facilities. These areas will always contain

contaminants.

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Installation & Operation Manual

1 Determine boiler location

Table 1B Corrosive Contaminants and Sources
Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues
Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning/laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops

When using an existing vent system to

install a new boiler:

WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide

emissions, causing severe personal injury

or death.

Check the following venting components before installing:

· Material – For materials listed for use with this appliance, see Section 3 – General Venting.

· Size – To ensure proper pipe size is in place, see the General Venting – Sizing Section of this manual. Check to see that this size is used throughout the vent system.

· Manufacturer – For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in the General Venting Section 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 supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

· Terminations – Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section.

· 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.

With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the General Venting – Install Vent and Combustion Air Piping Section.

WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

10

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

DANGER

Do not install the Knight Fire Tube boiler into a common vent with any other

appliance. This will cause flue gas spillage

or appliance malfunction, resulting in

possible severe personal injury, death, or

substantial property damage.

WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide

emissions, causing severe personal injury

or death.

g. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in 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 appliances remaining connected to the common venting system are located and other spaces of 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 continuously.
e. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

11

Installation & Operation Manual

2 Prepare boiler

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler,

remove the parts box.

2. Remove the front door to access the lag bolts in front of

the unit (FIG. 2-1).

3. To remove the boiler from the pallet (after removing the

front door):

a. Remove the two lag bolts from the wood pallet

inside the boiler (FIG. 2-1).

b. Detach the boiler from the lag bolts in the rear of the

unit, see FIG. 2-1.

NOTICE

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

Figure 2-1 Boiler Mounted on Shipping Pallet

1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow the boiler to cool before proceeding.
2. Remove the top panel front access cover from the unit (no tools required for removal) and remove the bezel.
3. Disconnect the air inlet piping from the venturi by loosening the band clamp around the rubber boot coupling. Slide the rubber boot off of the venturi.
4. Disconnect gas piping from the venturi by loosening the threaded nut on the venturi. Remove the gasket between the gas piping and venturi.
5. Remove the bolts connecting the venturi to the fan and proceed to remove the natural gas venturi from the unit, making sure not to damage the blower O-ring gasket (FIG. 2-2).

6. a. Disconnect the wiring from the fan and

FRONT

REAR

remove the bolts securing the fan to the

combustion chamber access cover.

b. Remove the fan and gasket, and install

the air shutter provided in the kit. NOTE:

On 199 LP models, the air shutter MUST

be installed in the proper direction. Install

LAG BOLTS (QTY. 2)

LAG BOLTS (QTY. 2)
DIR #2000557487 00

the air shutter so that the hole in the corner is oriented towards the back right corner of the unit (opposite the front door and gas

Gas conversions

piping).

WARNING

For a boiler already installed, you must turn off gas supply, turn off power and

allow boiler to cool before proceeding.

c. Replace all torn or damaged gaskets. Reassemble the fan.
d. Reconnect the wiring harness before

You must also completely test the boiler

operation.

after conversion to verify performance as described under Start-up, Section 10 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.
You must install a propane venturi and any additional components supplied in the kit to operate the Knight Fire

7. Install the propane venturi and verify the following: a. The UP arrow on the plastic housing is pointing up. b. The threaded connection for the gas piping is facing towards the front of the unit.

Tube boiler on propane gas. Verify when installing that

8. LP models 110 – 199 ONLY require an orifice to

the venturi label and orifice marking matches the boiler

be installed in the threaded venturi connection:

size (see Table 2A).

a. Locate the propane orifice from the

Table 2A LP Conversion Table

conversion kit bag and verify the stamping on the orifice matches the boiler size (see

Model

Kit #

Venturi Ø Orifice Ø (mm) Bottom Top

Air Orifice Shutter Stamping

Table 2A). b. With the stamped side facing inwards,

55 100268040 20 mm 2.45 mm 2.65 mm 100150434 N/A 85 100268104 20 mm 2.45 mm 2.55 mm 100150434 N/A

place the orifice in the cavity provided in the threaded connection.

110 100285815 22 mm 3.00 mm 2.85 mm 100284510 .250 155 100285817 24 mm 3.35 mm 2.95 mm 100284509 .302 199 100285818 24 mm 3.40 mm 3.00 mm 100150947 .302

9. Reassemble the gas pipe to the threaded connection on the venturi. Replace torn or damaged gasket(s) and ensure the venturi gasket

285 100268109 30 mm 4.20 mm 4.00 mm 100150434 N/A

is seated properly before tightening the nut on

*NOTE: The 199 LP air shutter should have the hole oriented towards

the venturi.

the back right corner of the unit.

12

Installation & Operation Manual

2 Prepare boiler (continued)

10. Reconnect the rubber boot on the air inlet to the venturi inlet and tighten the band clamp at this connection.
11. After installation is complete, attach the propane conversion label (inside the conversion kit) next to the boiler rating plate. Attach the LP caution label (inside the conversion kit bag) to the left side of the boiler underneath the gas supply piping.
12. Replace the top bezel and front access cover removed in Step 1 and resume operation.

DANGER

When removing the natural gas venturi, inspect the gasket at the gas connection and the O-ring at the blower. These gaskets must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Leveling the boiler 1. Set the boiler in place and check level.
a) Adjust legs if necessary to level boiler, see FIG. 2-3 below.
Figure 2-3 Leveling Legs on the Boiler

Figure 2-2 Remove Natural Gas Venturi

FAN/BLOWER

BLOWER O-RING GASKET VENTURI ORIFICE
(LP MODELS 110 – 199 ONLY)
VENTURI GASKET

GASKET AIR SHUTTER
GASKET

DIR #2000544505 00

WARNING

After converting to LP, check combustion per the Start-up procedure in Section 10

of this manual. Failure to check and verify

combustion could result in severe personal

injury, death, or substantial property damage.

13

3 General venting
Direct venting options – Sidewall Vent

Installation & Operation Manual

DIR #2000507755 00

DIR #2000507732 00

Figure 3-1 Two-Pipe Sidewall Termination

Figure 3-2 PVC/CPVC Concentric Sidewall Termination

Direct venting options – Vertical Vent

DIR #2000507759 00

DIR #2000507752 00

DIR #2000507739 00

Figure 3-3 Two-Pipe Vertical Figure 3-4 PVC/CPVC Concentric Figure 3-5 Vertical Vent, Sidewall

Termination

Vertical Termination

Air

14

Installation & Operation Manual

3 General venting (continued)

Install vent and combustion air piping

DANGER

The Knight Fire Tube boiler must be vented and supplied with combustion and ventilation air as described in this section. 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 air system will cause severe personal injury or death.

WARNING

This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed for vent pipe, and fittings. Failure to comply could result in severe

personal injury, death, or substantial property damage.

WARNING

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Mixing of venting materials will void the warranty and certification of the appliance.

WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. comply could result in severe personal injury, death, or substantial property damage.

Failure to

WARNING

For closet and alcove installations, CPVC, polypropylene or stainless steel material MUST BE used in a closet/ alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

CAUTION Improper installation of venting systems may result in injury or death.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

You may use any of the vent / air piping methods covered in this manual. Do not attempt to install the Knight Fire Tube boiler using any other means. Follow the procedures in this manual for the method chosen.

Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6) – Used to provide combustion air directly to the unit from outdoors. On Models 110 – 285 a fitting is provided on the unit for final 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 – Used to provide a passageway for conveying combustion gases to the outside. A transition fitting sized for PVC/CPVC, polypropylene, or stainless steel is provided on the unit for final connection. Reference the appropriate venting section to determine if an adapter is needed to connect to the specific manufacturer’s vent. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Approved Air Intake Terminations

Approved Vent Terminations

· Elbow with Screen · Stainless Steel Hood Intake · Room Air Kit (see Table 3?)

· Elbow with Screen · Coupling with Screen
· Rain Cap · Chimney Cover

Approved Vent Kits

· Sidewall Vent Kit (see Table 3A)
· Concentric Vent Kit (see Table 3B) NOTE: When using the Sidewall Vent Kit with polypropylene, an adapter kit must be used.

Figure 3-6 Near Boiler Air Intake / Vent Connections
UNIVERSAL PVC/CPVC POLYPROPYLENE OR STAINLESS STEEL VENT ADAPTER

Air intake / vent terminations
The Knight Fire Tube boiler vent and air piping can be installed through the roof or through a sidewall. Intake air must be supplied from outside to the boiler air intake adapter unless following the Optional Room Air instructions in this manual. The resultant installation is direct vent (sealed combustion). Use only approved stainless steel, PVC, CPVC, or polypropylene vent terminations listed. The location and orientation of vent and air terminations must comply with the requirements given in Section 3 through 5. Vent and air must terminate near one another unless otherwise specified. Ensure the location and orientation of the vent and air terminations are met and comply with the requirements given in the Sidewall Direct Venting or Vertical Direct Venting Section.

AIR INTAKE CONNECTOR

DIR #2000556896 00
15

Installation & Operation Manual

3 General venting

Air intake / vent location
The total length of piping for vent or air must not exceed the limits given in the General Venting – Sizing Section. Follow all instructions given in the specific venting section. Locate the vent / air terminations using the following guidelines: 1. Position the vent termination where vapors will not
damage nearby shrubs, plants, air conditioning equipment, or be objectionable.
2. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.
3. Prevailing winds could cause freezing of condensate and water /ice buildup where flue products impinge on building surfaces or plants.
4. Avoid possibility of accidental contact of flue products with people or pets.
5. 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, alcoves, courtyards, or other recessed areas.
6. Do not terminate above any door or window. Condensate can freeze, causing ice formations.
7. Locate or guard vent to prevent condensate damage to exterior finishes.
8. 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.
9. Vent must terminate: · At least 6 feet from adjacent walls. · No closer than 12 inches below roof overhang. · At least 7 feet above any public walkway. · At least 3 feet above any forced air intake within 10 feet. · No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet.
10. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.
11. Air inlet must terminate at least 12 inches above grade or snow line, and at least 12 inches below the vent.
Optional room air
Commercial applications utilizing the Knight Fire Tube boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room.

Table 3A Optional Room Air Kit

Model 55 – 85 110 – 285

Vent Size 2 inch 3 inch

16

Kit Number 100157614 100157615

NOTICE

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

In order to use the room air venting option the following conditions and considerations must be followed.

· The unit MUST be installed with the appropriate room air kit.
· The equipment room MUST be 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 operation from the inlet air opening.
· Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Take precautions to ensure proper installation.
· Vent system and terminations must comply with the standard venting instructions set forth in this manual.

WARNING

When utilizing the single pipe method, provisions for combustion and ventilation

air must be in 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.

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information given in Table 1B, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

WARNING

If the boiler combustion air inlet is located in a laundry room or pool facility, for example,

these areas will always contain hazardous

contaminants.

WARNING

To prevent the potential of severe personal injury or death, check for areas and products

listed in Table 1B before installing the boiler

or air inlet piping.

If contaminants are found, you MUST: · Remove contaminants permanently. –OR– · Relocate air inlet and vent terminations to other areas.

Installation & Operation Manual

3 General venting (continued)
Requirements for installation in Canada
1. Installations must be made with a vent pipe system certified to ULC S636.
2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.
3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/ fittings. For existing concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.
4. The 2″, 3″ and 4″ Concentric and Sidewall Vent Kits available from Lochinvar, IPEX, and Centrotherm (see Tables 3B and 3C) are approved for use on the Knight Fire Tube boiler. All kits are listed to the ULC S636 standard for use in Canada.

Table 3B Approved Sidewall Vent Kits

Vent Diameter
2 inch 3 inch 4 inch 2 inch 3 inch 4 inch

Vent Supplier
Lochinvar Lochinvar Lochinvar Centrotherm Centrotherm Centrotherm

Part Number
100157609 100157610 100157611 ISLPT0202 ISLPT0303 ISLPT0404

Table 3C Approved Concentric Vent Systems

Vent Diameter Lochinvar PVC

2 inch

100140485

3 inch

100274637

4 inch

100140484

Vent Diameter

Centrotherm Roof Terminations

2 inch 3 inch 4 inch

ICRT2435 ICRT3539 ICRT4679

IPEX PVC

IPEX CPVC

196005

—

196006

197009

196021

197021

Centrotherm Wall Terminations

ICWT242 ICWT352 ICWT462

Sizing
The Knight Fire Tube boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3D. When venting with flexible polypropylene, refer to the General Venting – Polypropylene Section for allowable vent diameters and maximum lengths.
If the specific polypropylene vent manufacturer’s instructions do not list equivalent lengths for standard fittings, reference Table 3E for guidelines.

Table 3D Air Intake/Vent Piping Sizes

Model
55 85 110 155 199 285

Inlet Diameter 2 inches / 3 inches 2 inches / 3 inches 2 inches / 3 inches 3 inches 3 inches 3 inches / 4 inches

Vent Diameter 2 inches / 3 inches 2 inches / 3 inches 2 inches / 3 inches 3 inches 3 inches 3 inches / 4 inches

Maximum Length
80 feet / 100 feet 50 feet / 100 feet 40 feet / 100 feet
100 feet 100 feet 50 feet / 100 feet

Table 3E Equivalent Length Guidelines – Polypropylene

Vent Ø Vent Pipe 45° Elbow 90° Elbow Tee

2 inch

1 ft

3 ft

5 ft

9 ft

3 inch

1 ft

4 ft

7 ft

15 ft

4 inch

1 ft

5 ft

10 ft

20 ft

See the Polypropylene Venting Section for flexible vent installation guidelines and specific manufacturer equivalent lengths.

Table 3F Equivalent Length – Concentric Vent Kits

Vent Diameter

Kit Number Equivalent Length

2 inch

100140485

30 ft

3 inch

100269005

30 ft

4 inch

100140484

30 ft

EXAMPLE: 20 feet of 2″ polypropylene pipe + (4) 90° elbows + (2) 45° elbows = 20 + 4(5) + 2(3) = 46 equivalent feet

NOTICE NOTICE
NOTICE

Increasing or decreasing combustion air or vent piping sizes is not authorized, unless referenced in manual.
For Models 55 – 110 using 2″ venting and Model 285 using 3″ venting, the first seven (7) equivalent feet of vent must be CPVC polypropylene, or stainless steel (field supplied). This includes any transition piece used to increase or decrease the vent diameter.
The minimum combustion air length is 12 equivalent feet, and the minimum vent piping length is 12 equivalent feet.

NOTICE

The appliance output rating will reduce by up to 2.3% for each 25 feet of vent length. Consult factory to determine de-rate values.

Unless otherwise stated by the vent manufacturer, add 5 feet for each 90° elbow and 3 feet for each 45° elbow of PVC/CPVC or stainless steel venting material.

17

Installation & Operation Manual

3 General venting

Materials

Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer. An adapter may be required to transition between the air inlet connection on the appliance and the air inlet pipe.

WARNING

Using air intake materials other than those specified can result in personal injury,

death or property damage.

NOTICE

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape 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 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.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

DANGER

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

Vent pipe materials:

The Knight Fire Tube boiler requires a special vent system, designed for pressurized venting. Use only approved manufacturers and materials for vent pipe and fittings.

Refer to the appropriate PVC/CPVC, Polypropylene, or Stainless Steel Vent Section of this manual for approved manufacturers and additional information.

Approved materials certified for Category IV and Direct Vent appliance venting:

PVC – Schedule 40, Schedule 80, DWV

CPVC – Schedule 40, Schedule 80

AL29-4C Stainless Steel – UL-1738 and ULC S636

Listed from approved manufacturers

Polypropylene – ULC S636 Listed from approved

manufacturers

Follow the polypropylene manufacturer’s instructions when using polypropylene material as an inlet pipe.

18

Installation & Operation Manual

3 General venting (continued)

PVC/CPVC

This product has been approved for use with the PVC/CPVC

vent materials listed in Table 3G. 2.

NOTE: Closet and alcove installations require CPVC vent

pipe be used.

Installing vent and air piping

NOTICE

Use only cleaners, primers, and solvents that are approved for the materials which

are joined together.

NOTICE

All PVC vent pipes must be glued, properly supported, and the exhaust must be

pitched a minimum of a 1/4 inch per foot

back to the boiler (to allow drainage of

condensate).

CAUTION

Allow for all primers, glues, and cements to fully cure before start-up. Failure to

follow this warning could result in property

damage and/or personal injury.

WARNING

Insulation should or CPVC venting

not be used on PVC materials. The use of

insulation will cause increased vent wall

temperatures, which could result in vent

pipe failure.

Table 3G PVC/CPVC Vent Pipe, and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

Item

Material

Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe PVC – DWV

ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

PVC Schedule 40 ANSI/ASTM D2466

PVC Schedule 80 ANSI/ASTM D2467

Vent fittings CPVC Schedule 40 ANSI/ASTM F438

CPVC Schedule 80 ANSI/ASTM F439

PVC – DWV

ANSI/ASTM D2665

Pipe Cement / PVC

Primer

CPVC

ANSI/ASTM D2564 ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.
Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
Chamfer outside of each pipe end to ensure even cement distribution when joining.
Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)
Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
Priming and Cementing: a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2″ beyond the socket depth.
c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.
e. Apply a second coat of cement 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.

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/ primer must be ULC S636 certified.

19

Installation & Operation Manual

3 General venting

Polypropylene This product has been approved for use with polypropylene venting from the manufacturers listed in Table 3H.
All terminations must comply with listed options in this manual and be a single-wall vent offering.
For support and special connections required, see the manufacturer’s instructions. All vent is to conform to standard diameter and equivalent length requirements established in the General Venting – Sizing Section.

Table 3H Approved Polypropylene Vent Manufacturers

Manufacturers DuraVent
Centrotherm Heat Fab Z-Vent

Model PolyPro InnoFlue PolyFlue Z-Dens

Type Single Wall / Flex Single Wall / Flex Single Wall / Flex Single Wall / Flex

Table 3I Flexible Polypropylene Maximum Vent Lengths

The vent connector provided with the unit is sized for PVC/ CPVC, polypropylene, or stainless steel venting. No adapter is required to connect to listed venting options.

Flexible polypropylene
For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations.

When venting with flexible polypropylene it is acceptable to increase piping sizes by one vent diameter. Up-sized flexible polypropylene may be considered as equivalent to one (1) foot of smaller diameter rigid pipe. Do not exceed the maximum flexible vent lengths given in Table 3I. When venting with same diameter flexible and rigid pipe refer to Table 3J for manufacturer equivalent vent lengths.

Sidewall vent kits
When using the Sidewall Vent Kit (see Table 3B), an adapter kit provided by the vent manufacturer must be used to make the final connection. Reference Table 3K for specific manufacturer’s part numbers.

WARNING

Use only the manufacturers and vent adapters listed. DO NOT mix vent systems

of different types or manufacturers. Failure

to comply could result in severe personal

injury, death, or substantial property

damage.

Model

Maximum Flexible Vent Length (Rigid Equivalent)

2 inch Flex 3 inch Flex

4 inch Flex

55

40 ft

50 ft

(80 ft 2 inch) (100 ft 3 inch)

100 ft (100 ft 3 inch)*

85

25 ft

50 ft

(50 ft 2 inch) (100 ft 3 inch)

100 ft (100 ft 3 inch)*

110

20 ft

50 ft

(40 ft 2 inch) (100 ft 3 inch)

100 ft (100 ft 3 inch)*

155

—

50 ft (100 ft 3 inch)*

100 ft (100 ft 3 inch)*

199

—

50 ft (100 ft 3 inch)*

100 ft (100 ft 3 inch)*

285

—

25 ft (50 ft 3 inch)*

50 ft (100 ft 3 inch)*

*Length shown in parentheses reflects the maximum rigid pipe vent length.

NOTE: Maximum vent lengths are based on 2 foot rigid equivalent. Reference Table 3J for specific manufacturer equivalent lengths.

Table 3J Flexible Polypropylene Equivalent Length

Manufacturer
DuraVent Centrotherm
Heat Fab Z-Flex

Flexible Vent Diameter

2 inch

3 inch

4 inch

2 ft

2 ft

2 ft

2 ft

2 ft

2.7 ft

2.5 ft

2.3 ft

2.7 ft

3.2 ft

2 ft

2 ft

WARNING

Insulation should not be used on polypropylene venting materials. The use

of insulation will cause increased vent wall

temperatures, which could result in vent

pipe failure.

NOTICE NOTICE

All vent connections MUST be secured by the vent manufacturer’s joint connector. Installation of a polypropylene system should adhere to the manufacturer’s installation instructions supplied with the vent system.
Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC S636 approved system.

Table 3K Sidewall Vent Kit Adapters

Manufacturer DuraVent
Centrotherm Z-Flex

Vent Diameter (2″, 3″, 4″) (2″, 3″, 4″) (2″, 3″, 4″)

Sidewall Adapter (2,3,4)PPS-HLKL
ISLTK0(2,3,4) 2ZDHKLPA(2,3,4)

20

Installation & Operation Manual

3 General venting (continued)

Stainless steel vent
This product has been approved for use with stainless steel venting from the manufacturers listed in Table 3L. The vent connector provided with the unit is sized for stainless steel venting. No additional vent adapter is needed to connect to the unit.
All terminations must comply with listed options in this manual and be a single-wall vent offering. See Table 3M for specific manufacturer terminations.
For support and special connections required, see the manufacturer’s instructions. All vent is to conform to standard diameter and equivalent length requirements established.

WARNING

Use only the materials, vent systems, and terminations from listed manufacturers. DO NOT mix vent

systems of different types or manufacturers. Failure

to comply could result in severe personal injury,

death, or substantial property damage.

NOTICE

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC S636 approved system for Canada.

NOTICE

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

FasNSeal Flex
Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections ONLY. Taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method. See manufacturer’s instructions.

Table 3M Stainless Steel Vent Terminations

Manufacturer

Vent Diameter

Screen Termination*

DuraVent

(3″, 4″)

FSBS(3,4)

Elbow with Screen*
FSELB900(3,4) with FSBS(3,4)

Heat Fab

(3″, 4″)

9(3,4)90

9(3,4)14TERM

Rain Cap* FSRC(3,4) 5(3,4)00CI

Table 3L Approved Stainless Steel Vent

Manufacturer

Model

DuraVent

FasNSeal / FasNSeal Flex

Heat Fab

Saf-T Vent EZ Seal

Z-Flex

(3″, 4″) 2SVSTPF0(3,4) 2SVSTEX0(3,4)90 2SVSRCF0(3,4)

*To the best of our knowledge, manufacturer part numbers are accurate as of the date of publication, but may be subject to change. Contact the manufacturer to verify specific terminations.

Z-Flex

Z-Vent

NOTE: DuraVent FasNSeal Flex stainless steel vent may be used as an equivalent substitute for rigid pipe.

21

Installation & Operation Manual

4 Sidewall direct venting
Vent/air termination ­ sidewall

WARNING

Follow instructions below determining vent location to

when avoid

possibility of severe personal injury,

death, or substantial property damage.

WARNING

A gas vent extending through an exterior wall shall not terminate adjacent to a wall

or below building extensions such as eaves,

parapets, balconies, or decks. Failure to

comply could result in severe personal

injury, death, or substantial property

damage.

WARNING

Sidewall vent and air intake terminations must terminate in the same pressure zone.

Determine location

Reference the General Venting – Air Intake / Vent Location Section of this manual for required clearances and guidelines on locating vent and air intake terminations.

When using a sidewall termination, follow installation instructions and maintain clearances as shown in this section:
1. Air inlet must terminate at least 12 inches above grade or snow line, and at least 12 inches below the vent termination.

WARNING

All vent pipes and air inlets must terminate at the same height to avoid recirculation

of flue products and the possibility of

severe personal injury, death, or substantial

property damage.

Sidewall vent kit

When venting out a sidewall using PVC, CPVC, or polypropylene vent material, an optional sidewall vent termination kit can be ordered (FIG. 4-5A). See General Venting Section for kit numbers.

Field supplied fittings
The air piping must terminate in a down-turned elbow. This arrangement avoids recirculation of flue products into the combustion air stream. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-5B.

Figure 4-1 Field Supplied Fittings with Vent Termination Elbow

FACTORY PROVIDED BIRD SCREEN

2. For installations where the vent terminates in an elbow

24″ MAX

outside the building, the vent piping must not extend more

than 24 inches vertically (FIG. 4-1). To prevent blockages

due to freezing condensate, the recommended maximum

length of vent piping is 15 inches.

Do not exceed the maximum lengths of the outside vent piping. Excessive length exposed to the low temperatures could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

FACTORY PROVIDED BIRD SCREEN

3. Vent piping must terminate no closer than 12 inches

below a roof overhand, or 12 inches below or horizontally from any door, window, or other gravity air inlet (FIG. 4-2).

Figure 4-2 Clearance to Gravity Air Inlets (Field Supplied Fittings Shown)

4. Vent must terminate at least 3 feet above any forced air intake within 10 feet (FIG. 4-3).

Multiple vent / air terminations

Multiple vent terminations must be placed to maintain a

12″

minimum clearance of 12 inches (U.S. installations) between

MIN.

the edge of the air inlet and adjacent vent outlet (FIG. 4-4).

For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

BIRD SCREEN (TYPICAL)

The air inlet of a Knight Fire Tube boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

12″ MIN.

12″ MIN.

22

Installation & Operation Manual

4 Sidewall direct venting (continued)
Vent/air termination ­ sidewall

Figure 4-3 Clearance to Forced Air Inlets (Sidewall Vent Kit Shown)
IF LESS THAN 10′

VENT / AIR TERMINATION

36″ MIN.

Figure 4-5B Field Supplied Fittings with Vent Termination

Coupling

TO BOILER INTAKE AIR CONNECTION

COUPLING

FROM BOILER VENT PIPE
CONNECTION

12″ MIN

FORCED AIR INLET

BIRD SCREEN

7′ MIN. ABOVE ANY PUBLIC WALKWAY

12″ MIN BIRD SCREEN GRADE OR SNOW LINE
ALTERNATE VENTING ARRANGEMENT (IF SPACE PERMITS)

Figure 4-5C Typical Stainless Steel Sidewall Termination Figure 4-4 Multiple Vent Terminations (Field Supplied with Field Supplied Fittings and Hood Intake Fittings Shown)
BIRD SCREEN TO BOILER INTAKE AIR CONNECTION
12″ MIN.

24″ MAX.

FROM BOILER VENT PIPE
CONNECTION

Figure 4-5A Sidewall Vent Kit
TO BOILER INTAKE AIR CONNECTION
FROM BOILER VENT PIPE
CONNECTION POSSIBLE ORIENTATIONS
VENT / AIR TERMINATION
GRADE OR SNOW LINE

12″ MIN.
GRADE OR SNOW LINE
Figure 4-5D Sidewall Snorkel Vent Installation – Side View

12″ MIN TO OVERHANG
12″ MIN

SUPPORT PIPING
AS NEEDED
60″ MAX

EXHAUST
INTAKE AIR CHASE OPTIONAL

23

Installation & Operation Manual

4 Sidewall direct venting
Vent/air termination ­ sidewall
Prepare wall penetrations – Sidewall vent kit
The PVC/CPVC and polypropylene sidewall vent terminations are designed to accommodate any wall thickness of standard construction.
Install the sidewall vent kit as shown in FIG. 4-6 and per the directions found in this manual.
1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.
2. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
3. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 3½ inch hole for 2 inch vent pipe · 4½ inch hole for 3 inch vent pipe · 5½ inch hole for 4 inch vent pipe
4. Drill 3/16″ diameter holes for inserting the plastic anchors into the wall.
5. Polypropylene Venting: Install the vent and air intake sidewall adapters listed in the General Venting Polypropylene Section into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate.
PVC/CPVC Venting: 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 the General Venting – PVC/ CPVC Section to seal the vent pipe.
6. Mount and secure the vent plate to the wall, using stainless steel screws.
7. Seal all gaps between the pipes and wall. Seal around the plate to the wall assuring no air gaps.
8. Assemble the vent cap to the vent plate. Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.
7. Seal all wall cavities and exterior openings.
Prepare wall penetrations – Field supplied fittings
PVC/CPVC and polypropylene sidewall vent terminations are designed to accommodate any wall thickness of standard construction. Stainless steel terminations are designed to penetrate a wall with a thickness up to 9.25 inches of standard construction.
1. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
24

2. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 3½ inch hole for 2 inch vent pipe · 4½ inch hole for 3 inch vent pipe · 5½ inch hole for 4 inch vent pipe
3. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-7.
4. For installations using a vent elbow termination, use the sidewall termination plate as a template for correct location of hole centers.
5. Follow all local codes for isolation of vent pipe when passing through floors or walls.
6. Seal exterior openings thoroughly with exterior caulk.

Figure 4-6 Sidewall Vent Kit Assembly

PVC/CPVC PIPE OR POLYPROPYLENE ADAPTER (VENT)

PVC/CPVC PIPE OR

POLYPROPYLENE ADAPTER

(AIR)

WALL

PLATE

SIDEWALL RETAINING PLATE

VENT PLATE
VENT CAP

GALVANIZED THIMBLE

IMG00085

Figure 4-7 Field Supplied Termination Assembly

AIR PIPING VENT PIPING

ELBOW

BIRD SCREEN

GALVANIZED THIMBLE

SIDEWALL TERMINATION PLATE

ELBOW BIRD SCREEN

Installation & Operation Manual

4 Sidewall direct venting (continued)
Sidewall termination ­ optional concentric vent

Description and usage
Lochinvar offers optional concentric combustion air and vent pipe termination kits (see the General Venting Section for part numbers). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as described in the General Venting – Air Intake / Vent Location Section, and as shown below in FIG. 4-8.
The required combustion air and vent pipe materials are listed in the General Venting – PVC/CPVC Section of this manual.

Concentric sidewall installation
1. Cut one (1) hole into the structure to install the termination kit. · 5 inch diameter for 2 inch concentric vent kit · 4 inch diameter for 3 inch concentric vent kit · 7 inch diameter for 4 inch concentric vent kit
2. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions (FIG.’s 4-9A and 4-9B). a. Cement the Y concentric fitting to the larger kit pipe. b. Cement the rain cap to the smaller diameter kit pipe.

Figure 4-9A 2 and 3 Inch Concentric Vent Kits (reference the General Venting Section)

Figure 4-8 Concentric Sidewall Termination

Figure 4-9B 4 Inch Concentric Vent Kit (reference the General Venting Section)
RAIN CAP
6″ (152 MM) TO 4″ (102 MM) REDUCER 6″ (152 MM) DIA.
6″ (152 MM) DIA.
4″ (102 MM) DIA. “Y” CONCENTRIC FITTING 6″ (152 MM) DIA. “FLEXIBLE” PIPE COUPLING
25

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination ­ optional concentric vent

Figure 4-10A 2 and 3 Inch Concentric Vent Dimensions Figure 4-10B 4 Inch Concentric Vent Dimensions

(reference the General Venting Section)

(reference the General Venting Section)

“C” DIA.

“B” DIA.

3″

“D”

(76 MM)

“E”

“G”

“H” DIA.

“B” DIA. PVC

“F”

VENT / EXHAUST

A

B

C

D

60″

4″

6″ 21 1/8″

(1524 MM) (102 MM) (152 MM) (537 MM)

E 10″
(254 MM)

F 7 5/8″
(194 MM)

G 3″
(76 MM)

H 6 5/8″
(168 MM)

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-11).

WARNING

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 or death.

WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion

products may occur. Water may also collect

inside the larger combustion air 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 4-11 Rain Cap to Vent Pipe Alternate Assembly

3. Install the Y concentric fitting and pipe assembly through the structure’s hole from an inside wall.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

4. 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 2 and 3 inch installations and fastened tightly into the rubber adapter for 4 inch installations.

5. Secure the assembly to the structure as shown in FIG. 4-12 using field- supplied metal strapping or equivalent support material.

NOTICE NOTICE
NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-8.
If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied SDR-26 PVC (D2241) pipe for 2 and 3 inch kits and standard Schedule 40 PVC for 4 inch. Do not exceed dimension “D” more than 60 inches (see FIG.’s 4-10A and 4-10B).
If assembly depth needs to be reduced, dimension D can be as short as possible.

26

Installation & Operation Manual
4 Sidewall direct venting (continued)
Sidewall termination ­ optional concentric vent
Figure 4-12 Concentric Vent Sidewall Attachment

NOTE: 100140480 shown for illustration purposes.

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

6. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-12 for proper pipe attachment.

7. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multi-venting sidewall terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-13). 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. 4-13. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

VENT

12″ MINIMUM

COMBUSTION AIR Figure 4-13 Concentric Vent and Combustion Air Termination
27

Installation & Operation Manual

5 Vertical direct venting

Vent/air termination ­ vertical

WARNING

Follow instructions below determining vent location to

when avoid

possibility of severe personal injury, death

or substantial property damage.

Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ OF VENT PIPE

Determine location
Reference the General Venting – Air Intake / Vent Location Section of this manual for required clearances and guidelines on locating vent and air intake terminations.
When using vertical termination methods, follow installation instructions and maintain clearances as shown in this section.
1. The air intake must terminate in a down-turned 180° return pipe with a bird screen installed.
2. The vent pipe must terminate in either an up-turned coupling with a bird screen installed or a stainless steel rain cap.
3. The air intake must terminate at least 6 inches above the roof or snow line.
4. The vent must terminate at least 3 feet (36 inches) above the highest place in which the vent penetrates the roof and at least 2 feet (24 inches) above any part of a building within 10 horizontal feet.
5. The top of the PVC/CPVC or polypropylene vent coupling must be at least 1 foot (12 inches) above the air intake.
The discharge opening of a stainless steel coupling or rain cap termination must maintain at least 3 feet (36 inches) above the air inlet.
6. 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 (24 inches) apart. This placement avoids recirculation of flue products into the combustion air stream.
7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent, Sidewall Air Section.

BIRD SCREEN (TYPICAL)
COUPLING (FIELD SUPPLIED)

VENT

6″ MINIMUM ABOVE ROOF / SNOW LINE

VENT OUTLET 12″ MINIMUM ABOVE AIR INLET

COMBUSTION AIR

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ (610 MM) OF VENT PIPE

VENT

COMBUSTION AIR

6″ (152 MM) MINIMUM ABOVE ROOF / SNOW LINE

Multiple vent / air terminations
Multiple vent terminations must be placed to maintain a minimum clearance of 12 inches (U.S. installations) between the edge of the air inlet and adjacent vent outlet (FIG. 5-2A).
For Canadian installations, provide clearances required by CSA B149.1 Installation Code.
The air inlet of a Knight Fire Tube boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

28

Installation & Operation Manual

5 Vertical direct venting (continued)

Vent/air termination ­ vertical

Figure 5-2A Vertical Terminations with Multiple Boilers
12″ MINIMUM (STAINLESS STEEL 36″ MINIMUM) VERTICALLY FROM VENT OUTLET TO ANY AIR INLET

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.

Figure 5-3 Existing Vent as a Chase

AIR INLET

FLUE EXHAUST

Figure 5-2A Alternate Vertical Terminations with Multiple Boilers
12″ MINIMUM (STAINLESS STEEL 36″ MINIMUM) VERTICALLY FROM VENT OUTLET TO ANY AIR INLET

WARNING

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 property damage.

Prepare roof penetrations

1. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

2. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 3 1/2 inch hole for 2 inch vent pipe · 4 1/2 inch hole for 3 inch vent pipe · 5 1/2 inch hole for 4 inch vent pipe

3. Insert a galvanized metal thimble in the vent pipe hole.

4. Maintain clearances as described in both the General Venting and the Vertical Direct Venting sections of this manual.

5. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.

6. Provide flashing and sealing boots sized for the vent and air pipe.

CAP

SEAL EXISTING

SEAL

FLUE OUTLET

DIR #2000508018 00
*For concept illustration only. Individual installations may vary due to job site specific equipment.

29

Installation & Operation Manual

5 Vertical direct venting

Vertical termination ­ optional concentric vent

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The kit must terminate outside the structure and must be installed as shown in this section.

Figure 5-4 Concentric Vent Vertical Installation

Field supplied pipe and fittings are required to complete the installation. The required combustion vent pipe and fittings are listed in the General Venting Section of this manual.

Vertical termination installation

Maintain clearances as described in both the General Venting and the Vertical Direct Venting sections of this manual, where applicable.

1. Cut one (1) hole (5 inch diameter for 2 inch installations, 4 inch diameter for 3 inch installations, or 7 inch diameter for 4 inch installations) into the structure to install the termination kit.

2. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions. a. Cement the Y concentric fitting to the larger diameter kit pipe. b. Cement rain cap to the smaller diameter kit pipe.

See the Sidewall Direct Venting – Optional Concentric Vent Section for details.

3. Install the Y concentric fitting pipe assembly up through the structure’s hole and field supplied roof boot/flashing.

4. Secure the assembly to the roof structure as shown in FIG. 5-4 using field supplied metal strapping or equivalent support material.

5. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-4 for proper pipe attachment.

6. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning.

WARNING

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

30

personal injury or death.

WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion

products may occur. Water may also

collect inside the larger combustion air

pipe and flow to the burner enclosure.

Failure to follow this warning could result

in product damage or improper operation,

personal injury, or death.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

NOTICE

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4.

NOTICE CAUTION

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe for 100140480/100140485 and standard schedule 40 PVC for 4 inch. Do not extend dimension “D” more than 60 inches. Refer to the Sidewall Direct Venting – Optional Concentric Vent Section.
DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

5 Vertical direct venting (continued)
Vertical termination ­ Concentric vent kit
Figure 5-5 Do Not Install U-Bend to Rain Cap

Installation & Operation Manual

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. 5-6). 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. 5-6. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
Figure 5-6 Multiple Concentric Vent Terminations
12″ MINIMUM
COMBUSTION AIR (TYPICAL)

12″ (18″ FOR CANADA) MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF
24″ ABOVE ROOF.

31

Installation & Operation Manual

5 Vertical direct venting
Vertical termination – Alternate concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.

Figure 5-7A Concentric Vent Example 1
FLUE EXHAUST SEAL

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 system is utilized for the combustion air source.
The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below.
The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-7A and 5-7B.
Approved venting materials must be used as specified in the General Venting Section of this manual.
Follow all vent / air termination and clearance requirements per this section to the appropriate 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 clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See the Corrosive Contaminants and Sources table in the Determine Boiler Location Section for a list of corrosive contaminants and sources.
Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-7A and 5-7B.

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Vent / Air Inlet Size

Minimum Existing Vent / Chase Size

AIR INLET W/SCREEN
12″ MIN.

COMBUSTION AIR

SEAL

EXISTING SEALED CAP
FLUE OUTLET

DIR #2000508030 00
*For concept illustration only. Individual installations may vary due to job site specific equipment.

Figure 5-7B Concentric Vent Example 2

SEAL
AIR INLET W/SCREEN
SEAL

FLUE EXHAUST COMBUSTION AIR

EXISTING

SEAL

SEALED CAP
FLUE OUTLET

2 inch 3 inch 4 inch

4 inch 5 inch 7 inch

DIR #2000508027 00
*For concept illustration only. Individual installations may vary due to job site specific equipment.

32

Installation & Operation Manual

6 Hydronic piping
System water piping methods

The Knight Fire Tube is designed to function in a closed loop pressurized system not less than 12 psi (Non-metallic system piping must have an oxygen barrier to be considered a closed loop). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.
It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.
Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non- combustible materials.

Low water cutoff device
On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system
If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection fluids

Freeze protection fluids for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

WARNING

Use only inhibited propylene glycol solutions, which are specifically formulated

for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used

in hydronic systems.

General piping information

All boiler piping must contain an
IMPORTANT oxygen barrier. This will help prevent
any excess oxygen from entering the system.
Basic steps are listed in this section along with illustrations on the following pages (FIG.’s 6-2 thru 6-12), which will guide you through the installation of the Knight Fire Tube boiler with either zone valves or circulation pumps.

NOTICE

*These illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

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 the cold feed make-up water line.
5. Install a pressure reducing valve on the cold feed makeup water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.
6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss. Refer to the graph in FIG. 6-1 for pressure drop through the Knight Fire Tube boiler heat exchanger.
7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instructions for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. NOTE: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.
10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve is installed at the factory on the left side of the boiler. Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.
11. Install a field supplied strainer to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre- existing system, a strainer/ filter capable of removing debris left in the system is recommended.

SMART SYSTEM / Multi-temperature loop control option

The Knight Fire Tube boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help aid with this protection, Lochinvar offers the Multi- Temperature Loop Control Board Kit.
It is the responsibility of the installer to CAUTION protect the loops with lower temperature
requirements from higher temperatures that may be required by other loops.

33

Installation & Operation Manual

6 Hydronic piping

Near boiler piping components
1. Boiler system piping: Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance.
2. Boiler circulating pump: A Grundfos UPM series variable speed pump will be provided by the factory as the boiler circulation pump. When connected to the low voltage board, the Knight Fire Tube boiler will control the pump via a 0 – 10 VDC signal. In case the pump does not receive a signal from the control (cable break), it will run at maximum speed. Factory supplied pump wiring – brown (+) blue (-).
3. Domestic hot water circulating pump: Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in Table 6A. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.
4. Boiler 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.
5. Check valves: Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-2 thru 6-12. Failure to install check 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. Unions: Field supplied. Recommended for unit serviceability.
9. Temperature and pressure gauge: Factory installed.
10. Pressure relief valve: Factory installed. The pressure relief valve is sized to ASME specifications.

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 piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.

13. Indirect water heaters: The Knight Fire Tube boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. As depicted in FIG.’s 6-2 thru 6-12 there are two options when utilizing an indirect water heater.

A. The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil 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 Fire Tube boiler’s control.

The Knight Fire Tube boiler is pre-configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming. The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating.

Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.

CAUTION

It is up to the installer to ensure the minimum system flow is not less than the minimum boiler flow at any time.

WARNING

The National Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th Edition.

14. Water Meter: Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.

11. Boiler purge valve: Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.
34

15. Y-Strainer: Field supplied. Install a Y-strainer or equivalent multipurpose strainer just before the boiler pump at the inlet of the heat exchanger. This item is used to remove system debris from older hydronic systems and to protect newer systems.

6 Hydronic piping (continued)
Figure 6-1 Pressure Drop vs. Flow

Installation & Operation Manual

Model
55 85 110 155 199 285

Minimum Pipe Ø
1″ 1″ 1″ 1″ 1-1/4″ 1-1/4″

Table 6A – Boiler Flow Requirements

Temperature Rise and Head Loss Based on Boiler Output in Btu/hr

Factory Provided Circulator

20°F

25°F

35°F

Minimum Flow Maximum Flow
High Fire Low Fire

UPML 5.2 gpm 0.3 ft 4.2 gpm 0.2 ft 3.0 gpm 0.1 ft 17 gpm 3.1 ft 2.1 gpm 1.0 gpm

UPML 8.1 gpm 1.0 ft 6.5 gpm 0.6 ft 4.6 gpm 0.3 ft 17 gpm 4.3 ft 3.2 gpm 1.0 gpm

UPML 10.5 gpm 1.7 ft 8.4 gpm 1.1 ft 6.0 gpm 0.5 ft 17 gpm 4.4 ft 4.2 gpm 1.0 gpm

UPML 14.7 gpm 4.5 ft 11.8 gpm 2.9 ft 8.4 gpm 1.5 ft 17 gpm 6.0 ft 5.9 gpm 1.0 gpm

UPMXL 19.0 gpm 1.1 ft 15.2 gpm 0.7 ft 10.9 gpm 0.4 ft 27 gpm 2.3 ft 7.6 gpm 1.5 gpm

UPMXL 27.0 gpm 2.4 ft 21.7 gpm 1.6 ft 15.5 gpm 0.8 ft 27 gpm 2.4 ft 10.8 gpm 1.5 gpm

35

Installation & Operation Manual
6 Hydronic piping
Figure 6-2 Single Boiler – Single Temperature with Zone Valves – DHW Priority

ZONE #1

WATER METER

PRESSURE REDUCING VALVE
BACKFLOW PREVENTER

PRESSURE GAUGE

MAKE UP WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

ZONE #2 ZONE #3 ZONE #4
ZONE VALVES (TYPICAL)
DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

SYSTEM CIRCULATOR
EXPANSION TANK

BALL VALVE (TYPICAL)
DRAIN POINT (TYPICAL)
BOILER CIRCULATOR
FLOW CHECK VALVE

MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

Y-STRAINER

FLOW CHECK VALVE

DOMESTIC HOT WATER CIRCULATOR

HOT WATER
OUT
ANTI-SCALD MIXING VALVE
COLD WATER IN

PRESSURE RELIEF VALVE

TEMPERATURE / PRESSURE GAUGE

NOTICE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
INDIRECT DHW TANK

DIR #2000507794 00

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.

36

Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-3 Single Boiler – Single Temperature Zoned with Circulators – DHW Priority
ZONE 1

PRESSURE REDUCING VALVE
BACKFLOW WATER PREVENTER METER

PRESSURE GAUGE

MAKE UP WATER
SYSTEM SUPPLY SENSOR
AIR SEPARATOR

ZONE 2 ZONE 3 ZONE 4

FLOW CHECK VALVE (TYPICAL)

ZONE CIRCULATORS (TYPICAL)

BALL VALVE (TYPICAL)
DRAIN POINT (TYPICAL)
BOILER CIRCULATOR
VALVE

EXPANSION TANK

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

HOT

WATER

Y-STRAINER

OUT

DOMESTIC HOT WATER

ANTI-SCALD MIXING VALVE

CIRCULATOR

PRESSURE RELIEF VALVE

COLD WATER
IN

TEMPERATURE / PRESSURE GAUGE

NOTICE

BALL VALVE (TYPICAL) UNION (TYPICAL)

DRAIN POINT (TYPICAL)

INDIRECT DHW TANK

DIR #2000507791 00
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.

37

Installation & Operation Manual

6 Hydronic piping

Figure 6-4 Multiple Boilers – Single Temperature Zoned with Circulators – DHW Priority

ZONE 1

Recommended Water Pipe Diameter – Cascade
Model 2 3 4 5 6 7 8 Units Units Units Units Units Units Units
55 1-1/4” 1-1/2” 1-1/2” 2” 2” 2” 2” 85 1-1/4” 1-1/2” 2” 2” 2” 2-1/2” 2-1/2” 110 1-1/2” 2” 2” 2-1/2” 2-1/2” 2-1/2” 3” 155 2” 2” 2-1/2” 2-1/2” 3” 3” 4” 199 2” 2” 2-1/2” 3” 4” 4” 4” 285 2-1/2” 2-1/2” 3” 4” 4” 4” 5”

WATER METER

PRESSURE REDUCING VALVE
BACKFLOW PREVENTER

PRESSURE GAUGE

MAKE UP WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

ZONE 2 ZONE 3 ZONE 4
FLOW CHECK VALVE
(TYPICAL)
ZONE CIRCULATORS (TYPICAL)

BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL)
BOILER CIRCULATOR

EXPANSION TANK

MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

Y-STRAINER (TYPICAL)

ANTI-SCALD MIXING VALVE
DOMESTIC HOT WATER CIRCULATOR

HOT WATER
OUT

COLD WATER
IN

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK

NOTICE

DIR #2000507798 00
It is the responsibility of the installer to maintain flow rates based on system piping requirements.

NOTICE

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.

38

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-5 Single Boiler – Multiple Temperatures – DHW Priority

WATER METER

BACKFLOW PREVENTER

SYSTEM SUPPLY SENSOR
PRESSURE REDUCING VALVE
PRESSURE GAUGE

TEMPERATURE LOOP #1

TEMPERATURE LOOP #2

TEMPERATURE LOOP #3

MIXING VALVES (TYPICAL)

MAKE UP
WATER
AIR SEPARATOR
BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL)

EXPANSION TANK
MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART
Y-STRAINER
BOILER CIRCULATOR

FLOW CHECK VALVE

DOMESTIC HOT WATER CIRCULATOR

PRESSURE RELIEF VALVE

HOT WATER
OUT

ANTI-SCALD MIXING VALVE
COLD WATER IN

TEMPERATURE / PRESSURE GAUGE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
INDIRECT DHW TANK
DIR #2000507796 00

CAUTION NOTICE

Mixing valves are required for the protection of low temperature loops.
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.

39

Installation & Operation Manual

6 Hydronic piping
Figure 6-6 Multiple Boilers – Multiple Temperatures – DHW Priority
Recommended Water Pipe Diameter – Cascade Model 2 3 4 5 6 7 8
Units Units Units Units Units Units Units 55 1-1/4″ 1-1/2” 1-1/2” 2” 2” 2” 2” 85 1-1/4″ 1-1/2” 2” 2” 2” 2-1/2” 2-1/2” 110 1-1/2” 2” 2” 2-1/2” 2-1/2” 2-1/2” 3” 155 2″ 2” 2-1/2” 2-1/2” 3” 3” 4” 199 2″ 2” 2-1/2” 3” 4” 4” 4” 285 2-1/2″ 2-1/2” 3” 4” 4” 4” 5”

WATER METER

BACKFLOW PREVENTER

PRESSURE REDUCING VALVE
PRESSURE GAUGE

TEMPERATURE LOOP #1

MAKE UP
WATER
AIR SEPARATOR

SYSTEM SUPPLY SENSOR

EXPANSION TANK

MAY SUBSTITUTE LOW LOSS HEADER

TEMPERATURE LOOP #2

TEMPERATURE LOOP #3

MIXING VALVES (TYPICAL)

BALL VALVE (TYPICAL)
BOILER CIRCULATOR

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

Y-STRAINER (TYPICAL)

ANTI-SCALD MIXING VALVE

DOMESTIC HOT WATER CIRCULATOR

HOT WATER
OUT

COLD WATER
IN

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
DIR #2000507797 00

CAUTION Mixing valves are required for the protection of low temperature loops.

NOTICE It is the responsibility of the installer to maintain flow rates based on system piping requirements.

NOTICE
40

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.

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-7 Single Boiler – Multiple Temperatures with DHW Piped as a Zone
SYSTEM SUPPLY SENSOR

WATER METER

BACKFLOW PREVENTER

PRESSURE REDUCING VALVE
PRESSURE GAUGE

TEMPERATURE LOOP #1

TEMPERATURE LOOP #2

TEMPERATURE LOOP #3

MIXING VALVES (TYPICAL)

MAKE UP
WATER AIR SEPARATOR
BALL VALVE (TYPICAL)
DRAIN POINT (TYPICAL)

EXPANSION TANK
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART
Y-STRAINER BOILER CIRCULATOR

PRESSURE RELIEF VALVE

DOMESTIC HOT WATER CIRCULATOR
FLOW CHECK VALVE

HOT WATER OUT

ANTI-SCALD MIXING VALVE
COLD WATER IN

TEMPERATURE / PRESSURE GAUGE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
INDIRECT DHW TANK DIR #2000507803 00

CAUTION Mixing valves are required for the protection of low temperature loops.

NOTICE NOTICE

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.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

41

Installation & Operation Manual

6 Hydronic piping

Figure 6-8 Multiple Boilers – Single Temperature Zoned with Valves

WATER METER

PRESSURE REDUCING VALVE
BACKFLOW PREVENTER

PRESSURE GAUGE

ZONE #1

Recommended Water Pipe Diameter – Cascade
Model 2 3 4 5 6 7 8 Units Units Units Units Units Units Units
55 1-1/4” 1-1/2” 1-1/2” 2” 2” 2” 2” 85 1-1/4” 1-1/2” 2” 2” 2” 2-1/2” 2-1/2” 110 1-1/2” 2” 2” 2-1/2” 2-1/2” 2-1/2” 3” 155 2” 2” 2-1/2” 2-1/2” 3” 3” 4” 199 2” 2” 2-1/2” 3” 4” 4” 4” 285 2-1/2” 2-1/2” 3” 4” 4” 4” 5”
ZONE #2 ZONE #3 ZONE #4

ZONE VALVES (TYPICAL)

MAKE UP WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

SYSTEM CIRCULATOR
EXPANSION TANK

BALL VALVE (TYPICAL)
BOILER CIRCULATOR

MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

Y-STRAINER (TYPICAL)

ANTI-SCALD MIXING VALVE
DOMESTIC HOT WATER CIRCULATOR

HOT WATER
OUT

COLD WATER
IN

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE
BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN POINT (TYPICAL)

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE
BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
DIR #2000507810 00

NOTICE NOTICE

It is the responsibility of the installer to maintain flow rates based on system piping requirements.
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.

42

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-9 Multiple Boilers – Non-Zoned Primary/Secondary Piping

Recommended Water Pipe Diameter – Cascade
Model 2 3 4 5 6 7 8 Units Units Units Units Units Units Units
55 1-1/4” 1-1/2” 1-1/2” 2” 2” 2” 2” 85 1-1/4” 1-1/2” 2” 2” 2” 2-1/2” 2-1/2” 110 1-1/2” 2” 2” 2-1/2” 2-1/2” 2-1/2” 3” 155 2” 2” 2-1/2” 2-1/2” 3” 3” 4” 199 2” 2” 2-1/2” 3” 4” 4” 4” 285 2-1/2” 2-1/2” 3” 4” 4” 4” 5”

WATER METER

BACKFLOW PREVENTER

PRESSURE REDUCING VALVE
PRESSURE GAUGE

MAKE UP
WATER

AIR SEPARATOR

SYSTEM SUPPLY SENSOR

MAY SUBSTITUTE LOW LOSS HEADER

BALL VALVE (TYPICAL)

SYSTEM CIRCULATOR
EXPANSION TANK

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART

BOILER 4 (MEMBER 3)

BOILER CIRCULATOR

Y-STRAINER (TYPICAL)

ANTI-SCALD MIXING VALVE
DOMESTIC HOT WATER CIRCULATOR

HOT WATER
OUT

COLD WATER
IN

PRESSURE RELIEF VALVE

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

BOILER 3 (MEMBER 2)

BALL VALVE (TYPICAL)
BOILER 2 (MEMBER 1)

UNION (TYPICAL)
DRAIN POINT (TYPICAL)

BOILER 1 (LEADER)

INDIRECT DHW TANK
DIR #2000507818 00

NOTICE NOTICE

It is the responsibility of the installer to maintain flow rates based on system piping requirements.
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.

43

Installation & Operation Manual
6 Hydronic piping
Figure 6-10 Single Boiler – Full Flow – Single Temperature – Zoned with Zone Valves – DHW Priority

ZONE #1

WATER METER

PRESSURE REDUCING VALVE
BACKFLOW PREVENTER

PRESSURE GAUGE

MAKE UP WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

SYSTEM CIRCULATOR
EXPANSION TANK

ZONE #2 ZONE #3 ZONE #4
ZONE VALVES (TYPICAL)
DIFFERENTIAL PRESSURE BYPASS VALVE (IF USED)

BALL VALVE (TYPICAL)
DRAIN POINT (TYPICAL)
FLOW CHECK VALVE
BOILER CIRCULATOR

Y-STRAINER

FLOW CHECK VALVE

DOMESTIC HOT WATER CIRCULATOR

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

HOT WATER
OUT
ANTI-SCALD MIXING VALVE
COLD WATER IN

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
INDIRECT DHW TANK DIR #2000507800 00

NOTICE

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.

44

Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-11 Single Boiler – Full Flow – Single Temperature Zoned with Valves – DHW Piped as a Zone

ZONE 1

PRESSURE REDUCING VALVE
BACKFLOW PREVENTER WATER METER

PRESSURE GAUGE

MAKE UP WATER

SYSTEM SUPPLY SENSOR

AIR SEPARATOR

ZONE 2 ZONE 3 ZONE 4
ZONE VALVES (TYPICAL)
DIFFERENTIAL PRESSURE BYPASS VALVE (RECOMMENDED)

EXPANSION TANK
BALL VALVE (TYPICAL)
DRAIN POINT (TYPICAL) BOILER
CIRCULATOR FLOW CHECK
VALVE

Y-STRAINER
PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

HOT WATER
OUT
ANTI-SCALD MIXING VALVE
COLD WATER IN

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK
INDIRECT DHW TANK
DIR #2000507805 00

NOTICE

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.

45

Installation & Operation Manual
6 Hydronic piping
Figure 6-12 Single Boiler – Full Flow – Single Temperature Zoned with Circulators – DHW Piped as a Zone

ZONE 1

PRESSURE REDUCING VALVE

WATER METER

BACKFLOW PREVENTER

PRESSURE GAUGE

MAKE UP WATER

SYSTEM SUPPLY SENSOR AIR SEPARATOR

ZONE 2 ZONE 3 ZONE 4

FLOW CHECK VALVE (TYPICAL)

ZONE CIRCULATORS (TYPICAL)

EXPANSION TANK
Y-STRAINER
DRAIN POINT (TYPICAL)

DOMESTIC HOT WATER CIRCULATOR BALL VALVE (TYPICAL)
PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

ANTI-SCALD MIXING VALVE

HOT WATER
OUT
COLD WATER
IN

NOTICE

BALL VALVE (TYPICAL) UNION (TYPICAL)
DRAIN POINT (TYPICAL)

INDIRECT DHW TANK

DIR #2000507790 00
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.

46

Installation & Operation Manual

7 Gas connections

Connecting gas supply piping
1. Refer to FIG. 7-1 to pipe gas to the boiler. a. Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada ­ When using manual main shutoff valves, it must be identified by the installer.
2. Install sediment trap / drip leg.
Figure 7-1 Gas Supply Piping
GAS SUPPLY
UNION
DRIP LEG MANUAL SHUTOFF VALVE

3. Support piping with hangers, not by the boiler or its accessories.

WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt

to support the weight of the piping with

the boiler or its accessories. Failure to

comply could result in severe personal

injury, death, or substantial property

damage.

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).
b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff 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

Do not check for gas leaks with an open flame ­ use the bubble test. Failure to

use the bubble test or check for gas leaks

can cause severe personal injury, death, or

substantial property damage.

DIR #2000507859 00

6. 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.

WARNING

Failure to apply pipe sealing compound as detailed in this manual can result in severe

personal injury, death, or substantial

property damage.

WARNING

Knight Fire Tube boilers are typically shipped ready to fire on natural gas.

Check boiler rating plate to determine

which fuel the boiler is set for. If set to

natural gas, it may be converted to LP

by installing an LP venturi. In order to

operate on LP gas, an LP venturi MUST

BE installed. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

47

Installation & Operation Manual

7 Gas connections

WARNING

Use two wrenches when tightening gas piping at boiler (FIG. 7-2), using one

wrench to prevent the boiler gas line

connection from turning. Failure to

support the boiler gas connection pipe to

prevent it from turning could damage gas

line components.

Figure 7-2 Inlet Pipe with Backup Wrench

Natural gas:
Pipe sizing for natural gas
1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour). a. Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas piping of 0.3 inches w.c. b. For additional gas pipe sizing information, refer to ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

NOTICE

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).

USE BACKUP WRENCH TO PREVENT PIPE FROM ROTATING

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 w.c. maximum.

DIR #2000507867 00
Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

Propane Gas:

WARNING

Knight Fire Tube boilers are typically shipped ready to fire on natural gas. Check

boiler rating plate to determine which fuel

the boiler is set for. If set to natural gas,

it may be converted to LP by installing an

LP venturi. In order to operate on LP gas,

an LP venturi MUST BE installed. Failure

to comply could result in severe personal

injury, death, or substantial property

damage.

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.c. with no flow (lockup) or with boiler on. · Minimum 8 inches w.c. with gas flowing (verify during boiler startup).

WARNING Ensure that the high gas pressure regulator is at least 6 – 10 feet upstream of the appliance.

48

Installation & Operation Manual

7 Gas connections (continued)

Table 7A Natural Gas Pipe Size Chart

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30″ w.c. pressure drop)

Pipe Size (Inches)
1/2
3/4 1 1 1/4 1 1/2
2 2 1/2
3 4

10 20 30

131 90 273 188 514 353 1,060 726 1,580 1,090 3,050 2,090 4,860 3,340 8,580 5,900 17,500 12,000

72 151 284 583 873 1,680 2,680 4,740 9,660

Length of Pipe in Straight Feet

40 50 60 70 80 90 100

62 129 243 499 747 1,440 2,290 4,050 8,270

55 114 215 442 662 1,280 2,030 3,590 7,330

N/A 104 195 400 600 1,160 1,840 3,260 6,640

N/A 95 179 368 552 1,060 1,690 3,000 6,110

N/A 89 167 343 514 989 1,580 2,790 5,680

N/A 83 157 322 482 928 1,480 2,610 5,330

N/A 79 148 304 455 877 1,400 2,470 5,040

125
N/A 70 131 269 403 777 1,240 2,190 4,460

150
N/A 63 119 244 366 704 1,120 1,980 4,050

175
N/A 58 109 224 336 648 1,030 1,820 3,720

200
N/A N/A 102 209 313 602 960 1,700 3,460

WARNING

Knight Fire Tube boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi. In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check inlet gas supply

NOTICE

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.

WARNING

DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct

outlet pressure. This setting is suitable

for natural gas and propane, requiring

no field adjustment. Attempting to

alter the gas valve outlet pressure could

result in damage to the valve, causing

potential severe personal injury, death, or

substantial property damage.

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

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 the power switch to the “ON” position.
6. Locate the pinhole button above the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire.
7. Observe the gas supply pressure as the burner fires at 100% of rated 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 installer or service agency to determine the necessary steps to provide proper gas pressure to the control.
11. Place the boiler back into normal operation by pressing STOP.
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WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open flame — use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

12. Turn the power switch to the “OFF” position.
13. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.
14. Remove the manometer from the pressure tap on top of the gas valve. Re- tighten the set screw inside the pressure tap.
15. Turn on the gas supply at the manual gas valve.
16. Turn the power switch to the “ON” position.
17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Figure 7-3 Inlet Gas Supply Check

Gas Pressure

The gas pressure must remain 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 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 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 company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the venturi and blower.

WARNING

Failure to follow all precautions result in fire, explosion, or death!

could

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

A
DIR #2000507872 00

DETAIL A

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8 Field wiring
Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations. 2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

WARNING

ELECTRICAL SHOCK HAZARD ­ For your safety, turn off electrical power supply before

making any electrical connections to avoid

possible electric shock hazard. Failure to do

so can cause severe personal injury or death.

NOTICE

Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/ NFPA 70 ­ latest edition.

Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-1.
2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code.
3. Wire the boiler, DHW (if used), and system pump as shown in FIG. 8-1: a. The boiler pump is shipped loose. Wire into the line voltage terminal strip as shown. For variable speed pump operation, connect the 0 – 10 VDC signal cables to the low voltage board.

NOTICE

This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override, which is provided primarily to permit the use of an external energy management system that serves the same function. This override MUST NOT be used unless at least one of the following conditions is true: 1. An external energy management
system is installed that reduces the boiler water temperature as the heating load decreases. 2. This boiler is not used for any space heating. 3. This boiler is part of a modular or multiple boiler system having a total input of 300,000 Btuh/hr or greater. 4. This boiler is equipped with a tankless coil.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause

improper and dangerous operation.

NOTICE NOTICE

If the boiler, DHW, or system pump motor is larger than 1/8 hp or 1.8 amps, it must be isolated with a relay.
The power outlet is on a separate circuit than the boiler ON/OFF switch, and will remain powered when the boiler is turned off.

The line voltage terminals supply power to an equipment outlet, located on the side of the unit. This can be used to supply power to a condensate pump or other low power equipment. Ensure the load does not exceed a maximum of 7 amps.

Low voltage connections

1. Route all low voltage wires through the openings on the left side, as shown in FIG. 8-2.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-3 and the boiler wiring diagram.

Figure 8-2 Routing Field Wiring

Figure 8-1 Line Voltage Field Wiring Connections
NEUTRAL W

GROUND G
120V SUPPLY
LINE BK
SERVICE SWITCH

SYSTEM PUMP

WG BK

HIGH VOLTAGE WIRING OPENINGS
LOW VOLTAGE CONNECTION BOARD
LOW VOLTAGE WIRING OPENINGS

BOILER PUMP

WG BK

DOMESTIC HOT WATER
PUMP

WG BK

DIR #2000507881 00

DIR #2000507882 00
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Installation & Operation Manual

8 Field wiring

Thermostat
1. Connect the room thermostats or end switches (isolated contact only) to Heat/Loop Demand 1, 2, or 3, as shown in FIG. 8-3.
2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunlight, or fireplaces.
3. Thermostat anticipator (if applicable): a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to match total electrical power requirements of connected devices. See device manufacturer’s specifications and thermostat instructions for details.
Outdoor temperature sensor
In the absence of an external energy management system, an outdoor temperature sensor must be used.
1. Mount the sensor on an exterior wall, shielded from direct sunlight or flow of heat or cooling from other sources.
2. Route sensor wires through a knockout at the rear of the boiler (see FIG. 8-2).
3. Connect outdoor temperature sensor (FIG. 8-3) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Knight Fire Tube boiler.
DHW thermostat
Connect 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 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 is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals on the Low Voltage Connection Board (FIG. 8-3).

WARNING

Failure to use the correct sensor may result in the tank temperature being either above

or below the set po

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