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File Documents.210 S 1st St.0281.2017 (32).ARBK
ES I100287110lifiedheatin g 2000544742installer/service Rev A 31 MD CO \K,, , FIRE TUBE BOILER Installation & Operation Manual Models: 56 - 400 . - -Zoo, #. . _ 111)4, <,40410°. 111411414441S11%t444: DIR#2000543091 00 0 WARNING This manual must only be used by p oN (41iw7/� �� technician. Read all instructions, al _�2N,�./ a quaincluding this manual and the o O Knight Wall Hung Fire Tube Boiler FR T I f\t 0CERTIFIED `, Service Manual, before installing. ENERGY STAR Perform steps in the order given. Failure to comply could result in severe personal in'ury t • substantial propert e D � C vare `` .� . HIGH EFFICIENCY BOILERS &WATER HEATERS Save this manual for future referen L.0/0 9/ ' BUILDING DEPARTMENT Contents HAZARD DEFINITIONS 2 6. HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING 3 System Water Piping Methods 36 THE KNIGHT WALL HUNG FIRE TUBE BOILER--HOW IT Low Water Cutoff Device 36 WORKS 4-5 Chilled Water System 36 RATINGS 6 Freeze Protection 36 1. DETERMINE BOILER LOCATION General Piping Information 36-37 Provide Clearances 9 Near Boiler Piping Components 37-38 Provide Air Openings to Room 9 Circulator Sizing 38 Wall Mounting Location 9 Pressure Drop vs. Flow 39 Residential Garage Installation 9 Variable Speed Pump Option 40 Vent and Air Piping 9 SMART SYSTEM/Multi-Temperature Loop Control Option 40 Prevent Combustion Air Contamination 9 Piping Diagrams 41-49 Corrosive Contaminants and Sources 10 7. GAS CONNECTIONS Using an Existing Vent System to Install a New Boiler 10 Connecting Gas Supply Piping 50-51 Removing a Boiler from Existing Common Vent 11 Natural Gas 51 2. PREPARE BOILER Pipe Sizing for Natural Gas 51 Remove Boiler from Wood Pallet 12 Natural Gas Supply Pressure Requirements 51 Gas Conversions 12-13 Propane Gas 51 Mounting the Boiler 13-14 Pipe Sizing for Propane Gas 51 3. GENERAL VENTING Propane Supply Pressure Requirements 51 Direct Venting Options 15 Check Inlet Gas Supply 52 Install Vent and Combustion Air Piping 16 Gas Pressure 53 Requirements for Installation in Canada 17 Gas Valve Replacement 53 Sizing 17 8. FIELD WIRING Materials 18 Line Voltage Connections 54 Optional Room Air 19 Low Voltage Connections 54 PVC/CPVC 20 Wiring of the Cascade 56-57 Polypropylene 21 9. CONDENSATE DISPOSAL Stainless Steel Vent 22 Condensate Drain 59 4. SIDEWALL DIRECT VENTING 10. STARTUP 60-67 Vent/Air Termination - Sidewall 23-26 11. OPERATING INFORMATION Determine Location 23-25 General 68-71 Prepare Wall Penetrations 25-26 Cascade 72 Multiple Vent/Air Terminations 26 Sequence of Operation 73-74 Sidewall Termination - Optional Concentric Vent 27-29 Knight Wall Hung Fire Tube Boiler Control Module 75 5. VERTICAL DIRECT VENTING Status Display Screens 76-78 Vent/Air Termination -Vertical 30-31 12. MAINTENANCE Determine Location 30 Maintenance and Annual Startup 79-83 Prepare Roof Penetrations 31 13. DIAGRAMS Multiple Vent/Air Terminations 31 Ladder Diagram 84 Vertical Termination -Optional Concentric Vent... 32-33 Wiring Diagram 85 Alternate Vertical Concentric Venting 34-35 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. 0 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. O 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 situatiopEic iVED avoided,may result in property damage. ����11.•.• NOTICE NOTICE indicates special instructions on installation,operation,or maintenance that are importa .t04t09/18 related to personal injury or property damage. 2 ASPEN BUILDING DEPARTMENT KN!. HT Installation & Operation Manual Please read before proceeding A WARNING Installer-Read all instructions,including A WARNIN(I, DO NOT install units in rooms or this manual and the Knight Wall Hung environments that contain corrosive Fire Tube Boiler Service Manual, before contaminants(see Table 1B on page 10). installing. Perform steps in the order Failure to comply could result in severe given. personal injury, death, or substantial User - This manual is for use only property damage. by a qualified heating installer/ When servicing boiler— service technician. Refer to the User's Information Manual for your reference. • To avoid electric shock, disconnect electrical supply Have this boiler serviced/inspected by before performing maintenance. a qualified service technician, at least • To avoid severe burns, allow boiler to cool before annually. performing maintenance. Failure to comply with the above could Boiler operation — result in severe personal injury, death or substantial property damage. • Do not block flow of combustion or ventilation air to the boiler. NOTICE When calling or writing about the boiler • Should overheating occur or gas supply fail to shut off, - Please have the boiler model and serial do not turn off or disconnect electrical supply to number from the boiler rating plate. circulator. Instead,shut off the gas supply at a location Consider piping and installation when external to the appliance. determining boiler location. •Do not use this boiler if any part has been under water. Any claims for damage or shortage in The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any shipment must be filed immediately appliance that has been under water must be replaced. against the transportation company by the consignee. Boiler water— Factory warranty(shipped with unit)does •Thoroughly flush the system to remove debris. Use not apply to units improperly installed or an approved pre-commissioning cleaner (see Start-Up improperly operated. Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat A WARNING! Failure to adhere to the guidelines on this exchanger can be damaged by build-up or corrosion due page can result in severe personal injury, to sediment. death,or substantial property damage. Note: Cleaners are designed for either new systems or A WARNING If the information in this manual is not pre-existing systems. Choose accordingly. followed exactly, a fire or explosion may result causing property damage,personal Do not use petroleum-based cleaning or injury or loss of life. A CAUTION j rY sealing compounds in the boiler system. This appliance MUST NOT be installed in Gaskets and seals in the system may be any location where gasoline or flammable damaged. This can result in substantial vapors are likely to be present. property damage. Do not use"homemade cures"or"boiler WHAT TO DO IF YOU SMELL GAS 0 CAUTIO] patent medicines". Serious damage to • Do not try to light any appliance. the boiler, personnel, and/or property • Do not touch any electric switch; do may result. not use any phone in your building. • Immediately call your gas supplier from a near by phone. Follow the Freeze protection fluids — gas supplier's instructions. •NEVER use automotive antifreeze. Use only inhibited • If you cannot reach your gas supplier, propylene glycol solutions, which are specifically Y call the fire department. hydronic for h dronic systems.R' u i �if L � � • Installation and service must be toxic and can attack gaskets and se 1 -c .iri y ronic performed by a qualified installer, systems. 10/0 9/18 service agency,or the gas supplier. a ASN BUILDING DEPARTMENT RtvGT Installation & Operation Manual The Knight Wall Hung Fire Tube Boiler - How it works... 1. Stainless steel heat exchanger functions to meet heating demand. Optional remote connectivity Allows system water to flow around specially designed tubes allows boiler settings to be monitored and modified when connected for maximum heat transfer,while providing protection against to the internet. flue gas corrosion. 17. Air intake adapter 2. Combustion chamber access cover Allows for the connection of the PVC air intake pipe to Allows access to the combustion side of the heat the boiler. exchanger. 18. High voltage junction box 3. Blower The junction box contains the connection points for the line The blower pulls in air and gas through the venturi (item voltage power and all pumps. 5). Air and gas mix inside the blower and are pushed into the 19. Low voltage connection board burner,where they burn inside the combustion chamber. The connection board is used to connect external low voltage 4. Gas valve devices. The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is 20. Low voltage wiring connections powered and combustion air is flowing. Conduit connection points for the low voltage connection board. 5. Venturi The venturi controls air and gas flow into the burner. 21. Condensate trap(field installed) The condensate trap prevents flue gasses from escaping the 6. Flue gas sensor(limit rated) condensate drain line. This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas 22. Access cover-front temperature gets too hot. This protects the flue pipe from Provides access to the gas valve,control panel,and heat exchanger. overheating. 23. Ignition electrode 7. Boiler outlet temperature sensor (housed with the Provides direct spark for igniting the burner. high limit sensor) 24. Flame inspection window This sensor monitors boiler outlet water temperature (system The quartz glass window provides a view of the burner supply). If selected as the controlling sensor, the control surface and flame. module adjusts boiler firing rate so the outlet temperature is 25. Relief valve(shipped loose-factory installed on Model correct. 400 only) 8. Boiler inlet temperature sensor Protects the heat exchanger from an over pressure condition. This sensor monitors return water temperature (system The relief valve provided with the unit is set at 30 psi. return). If selected as the controlling sensor, the control 26. Flame sensor module adjusts the boiler firing rate so the inlet temperature is Used by the control module to detect the presence of burner correct. flame. 9. Temperature and pressure gauge(field installed,not 27. Line voltage wiring connections shown) Conduit connection points for the high voltage junction box. Monitors the outlet temperature of the boiler as well as the 28. Top panel system water pressure. Removable panel allows access to the gas train and combustion 10. Electronic LCD display chamber. The display features a high resolution liquid crystal screen,three (3) buttons, and a navigation dial. A serial and USB port 29. Gas shutoff switch(Models 056-286 only) support additional communication with the control. An electrical switch designed to cut power to the gas valve to 11. Flue pipe adapter prevent releasing any gas. Allows for the connection of the vent system to the 30. Power switch boiler. Turns 120 VAC ON/OFF to the boiler. 12. Burner(not shown) 31. Auto air vent(Models 56-286 only,not shown) Made with metal fiber and stainless steel construction, Used to allow removal of trapped air from the heat exchanger. the burner uses pre-mixed air and gas and provides a 32. Transformer wide range of firing rates. The transformer provides 24V power to the integrated control. 13. Water outlet(system supply) 33. High limit sensor (housed with the outlet Copper connection that supplies hot water to the system, temperature sensor) either 1"NPT, 1-1/4"NPT,or 1-1/2"sweat,depending on the model. Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will 14. Water inlet(system return) break the control circuit,shutting the boiler down. Copper connection that returns water from the system to the heat exchanger, either 1" NPT, 1-1/4" NPT, or 1-1/2" 34. Stainless steel flue collector sweat,depending on the model. Flue gas and condensate enter the stainless flue collector through 15. Gas connection pipe the fire tubes. A 1 1/4"drain connection allows condensate to flow Threaded pipe connection. This pipe should be connected through the collector into a condensate trap for disposal. to the incoming gas supply for the purpose of delivering 35. Manual air vent gas to the boiler. Used to allow removal of trapped air from the ECIEIVE D 16. SMART SYSTEM Control Module For Models 56-286 a coin vent is provided in tl*% The SMART SYSTEM Control responds to internal and for installations where top connections are not used. 10/0 9/18 external signals to regulate the blower, gas valve, and pump 4 - ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual The Knight Wall Hung Fire Tube Boiler - How it works... (continued) m FRONT OF UNIT CD 43) ID 1 aae 0JJ 0 f m • j......4 m 0 . NIL.114y -41h.4111 CM DIR#2nnnsa4na2 nn Bottom View C5 4) ILI L . f r .. tip- DIR#2000543091 00 in / •!+,• I IF; . --- b. Front View • Of 0 o f m 9 �— m DIR#2000544036 00 Top View(inside unit) 25 35 (25 4 (35 17) 13 4 -1�1 3 I e 4 _ 29) II _ tt as . , :At P r•. Q Ill'. !.� .. .' `c • �13)� — �'I+ • 19; r 1 0 32 \'� I 5 • I �14� • µ ;�,,re: 18; C14 i I. ' ' I 26 15 � , 111 1 ( 0 15 6 I% .....,to 0 ,•F -,: '— i.k !'• - **N'N„ 4 Ai -Ito* ea a ii---,_ DIR#2000544032 OC - �• CEIVED DIR#200010/00 0 9/18 21 Front View(inside unit Model 400) Left Side (inside unit) — —0SIENIM BUILDING DEPARTMENT 41!ptl . Installation & Operation Manual Ratings QES 16,1, AS rin7A7 la) ME DOE -e"lir a C RT1FlED H ENERGY STAR �RTIF�� C� C� A.ANIAI CERTIFIED* Knight Wall Hung Fire Tube Boiler Other Specifications AHRI Rating HtiInputn Net ea AFUE MBH Capacity RaHngls Model Number MBH Water, Boiler Vent MBH Water Water Gas Air Size Note:Change"N"to (Note 5) Content Connections Connections Size "L"for L.P.gas models. Gallons (Note 4,8) Min Max (Note 2,7) (Note 3,7) (Note 1,7) WHNO56 8.2 55 51 44 95 2.3 1" 1/2" 2" 2" WHNO86 8.5 85 79 69 95 2.2 1" 1/2" 2" 2" WHN111 11 110 102 89 95 2.3 1" 1/2" 3" 3" WHN156 15.5 155 144 125 95 3.2 1" 1/2" 3" 3" WHN200 20 199 184 160 95 5.2 1-1/4" 1/2" 3" 3" WHN286 28.5 285 264 229 95 I 4.9 1-1/4" 1/2" 3" 3" WHN400* 80 399 379 330 94.4* I 6.5 1-1/2" 3/4" 4" 4" *Note: WHN400 value is thermal efficiency. NOTICE I Maximum allowed working pressure is located on the rating plate. Notes: 8. Models WH056 - 086 can be alternatively vented using a 1. As an Energy Star Partner, Lochinvar has determined that 3"vent/air size. If a 2"vent/air size is used,the maximum Knight Wall Hung Fire Tube boilers meet the Energy Star vent/air pipe lengths for the WH056 model is 80 feet and guidelines for energy efficiency. 50 feet for the WH086 model. The WH111 model can be 2. The ratings are based on standard test procedures prescribed alternatively vented using a 2"vent/air size. If the 2"vent/ by the United States Department of Energy. air size is used, the maximum vent/air pipe lengths are 3. Net AHRI ratings are based on net installed radiation of limited to 40 equivalent feet each. The WH286 model can sufficient quantity for the requirements of the building be alternatively vented using a 4" vent/air size. If the 3" and nothing need be added for normal piping and pickup. vent/air size is used, the maximum vent/air pipe lengths Ratings are based on a piping and pickup allowance of 1.15. are limited to 50 equivalent feet each. 4. Knight Wall Hung Fire Tube boilers require special gas 9. The manual reset high limit provided with the Knight Wall venting. Use only the vent materials and methods specified Hung Fire Tube is listed to UL353. in the Knight Wall Hung Fire Tube Installation and Operation Manual. 5. Standard Knight Wall Hung Fire Tube boilers are equipped , - - to operate from sea level to 4,500 feet only. The boiler will /' UNIT FT TO EQUIPPED FOR FT 1 �;1 � , de-rate by 4%for each 1,000 feet above sea level up to 4,500 1 HIGH ALTITUDE r feet. I� 3,000 FT T09,800 FT ` a \\ 11 _ hii 6. High altitude Knight Wall Hung Fire Tube boilers are \ // f equipped to operate from 3,000 to 9,600 feet only. The - _ - boiler will not de-rate up to 5,000 feet and will de-rate 1.7% for each 1000 feet above 5000 feet. The operation given in - I A 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 _ i ECEIVED and CO2's adjusted to the recommended levels. 7. Ratings have been confirmed by the Hydronics Section of 10/0 9/18 AHRI. m 6 m Figure A High Altitude Label Location ASPEN BUILDING DEPARTMENT yKN� HT Installation & Operation Manual 7 Determine boiler location Installation must comply with: Q WARNING' This appliance is certified as an indoor • Local, state, provincial, and national codes, laws, appliance. Do not install the appliance regulations,and ordinances. outdoors or locate where the appliance • National Fuel Gas Code,ANSI Z223.1 -latest edition. will be exposed to freezing temperatures • Standard for Controls and Safety Devices for Automatically or to temperatures that exceed 100°F. Fired Boilers,ANSI/ASME CSD-1,when required. Do not install the appliance where the • National Electrical Code. relative humidity may exceed 93%. • For Canada only: B149.1 Installation Code, CSA C22.1 Do not install the appliance where Canadian Electrical Code Part 1 and any local codes. condensation may form on the inside The Knight Wall Hung Fire Tube boiler or outside of the appliance, or where NOTICE J gas manifold and controls met safe lighting condensation may fall onto the appliance. and other performance criteria when the Failure to install the appliance indoors boiler underwent tests specified in ANSI could result in severe personal injury, Z21.13 -latest edition. death,or substantial property damage. Before locating the boiler, check: This appliance requires a special venting 1. Check for nearby connection to: WARNING system. If using PVC the vent connection • System water piping to the appliance must be made with the •Venting connections starter CPVC pipe section provided with • Gas supply piping the appliance. The field provided vent •Electrical power fittings must be cemented to the CPVC 2. Locate the appliance so that if water connections should pipe section. Use only the vent materials, leak,water damage will not occur. When such locations primer and cement specified in this cannot be avoided, it is recommended that a suitable manual to make the vent connections. drain pan, adequately drained, be installed under the Failure to follow this warning could result appliance. The pan must not restrict combustion air in fire,personal injury,or death. flow. Under no circumstances is the manufacturer to be Closet and alcove installations held responsible for water damage in connection with A closet is any room the boiler is installed in which the room this appliance,or any of its components. volume is less than the room volume listed in the table below. 3. Check area around the boiler. Remove any combustible An alcove is any room which meets the criteria for a closet, materials,gasoline and other flammable liquids. but it does not have a door. WARNING Failure to keep boiler area clear and free of combustible materials, gasoline, and Table 1A Room Volume other flammable liquids and vapors can Model Room Volume(in cubic feet) result in severe personal injury, death, or 56-086 90 substantial property damage. 111 -200 _ 108 4. The Knight Wall Hung Fire Tube boiler must be installed 286 _I 124 so that gas control system components are protected 400 178 from dripping or spraying water or rain during operation or service. Example: Room dimensions = 4 feet long, 3 feet wide, 5. If a new boiler will replace an existing boiler, check for and 8 foot ceiling=4 x 3 x 8=96 cubic feet. This would be and correct system problems,such as: considered a closet for a WHN286 model. •System leaks causing oxygen corrosion or heat For closet and alcove installations CPVC, exchanger cracks from hard water deposits. 0 WARNING polypropylene or stainless steel vent •Incorrectly-sized expansion tank. material must be used. The ventilating air •Lack of freeze protection in boiler water causing system openings shown in FIG. 1-1 are required and boiler to freeze and leak. for closet installations. Failure to follow •Debris left from existing piping, if not flushed and this warning could result in fire, personal cleaned with an appropriate cleaner. injury,or death. 6. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or Recommended clearances for service access the boiler combustion air supply(see Table 1B on page - Front/Top/Bottom 24" - 10). Prevent combustion air contamination. Remove Left Side 12" - Right Side 0" any of these contaminants from the boiler area. DO NOT install units in rooms or NOTICE If you do not provideCk I i WARNING, environments that contain corrosive service clearances sho � vt contaminants (see Table 1B on page 10). possible to service the b i r y� t removingit from the space. / 8 Failure to comply could result in severe P personal injury, death, or substantial MS (r property damage. BUILDING DEPARTMENT K4,!,P.tT` Installation & Operation Manual 1 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances 0 WARNING For closet installations, CPVC, LEFT polypropylene or stainless steel 0"MINIMUM TOP vent material MUST BE used in 6"MINIMUM a closet structure due to elevated temperatures. Failure to follow / this warning could result in fire, .- t26. personal injury,or death. op, , _ ,--; - --10°. RIGHT 0'MINIMUM 1"MINIMUM CLEARANCE I/ VENTILATING AROUND VENT PIPE a AIR OPENING* CLOSED DOOR 001 t,- VENTILATING AIR OPENING* *AREA OF EACH OPENING: 1 SQ.INCH PER 1000 BTU PER HOUR INPUT 26" T WITH A MINIMUM OF 100 SQ.INCHES. FRONT 6"MINIMUM 1/4"MINIMUM CLEARANCE AROUND HOT WATER PIPES DIR#2000543098 00 BOTTOM 0"MINIMUM Required Clearances to Combustible Materials - Front/Top 6" - Bottom 0" - Left/Right Side 0" Figure 1-2 Alcove Installation -Minimum Required Clearances WARNINI For alcove installations, CPVC, LEFT polypropylene or stainless steel /- 0"MINIMUM TOP 6"MINIMUM vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to 11 t follow this warning could result in fire,personal injury,or death. RIGHT 0"MINIMUM 1"MINIMUM CLEARANCE AROUND VENT PIPE ++ OPEN FRONT 0/ FRONT 6"MINIMUM 1/4"MINIMUM CLEARANCE ���� AROUND HOT WATER PIPES (.� BOTTOM 0"MINIMUM Required Clearances to Combusti ferials. DIR#2000543097 00 - Front/Top- Bottom �Q l.d�,(9. /18 _ 8 - - Left/Right Side 0" ASPEN BUILDING DEPARTMENT KNIP.HT Installation & Operation Manual 7 Determine boiler location (continued) Provide clearances: Residential garage installation Clearances from combustible materials Precautions 1. Hot water pipes—at least 1/4" (6 mm) from combustible materials. Take the following precautions when installing the appliance 2. Vent pipe - at least 1" (25 mm) from combustible in a residential garage. If the appliance is located in a materials. residential garage, it should be installed in compliance with 3. See FIG.'s 1-1 and 1-2 on page 8 for other clearance the latest edition of the National Fuel Gas Code,ANSI Z223.1 minimums. and/or CAN/CGA-B149 Installation Code. . Appliances located in residential garages and in Provide air openings to room: adjacent spaces that open to the garage and are not part Knight Wall Hung Fire Tube boiler alone in boiler of the living space of a dwelling shall be installed so that room all burners and burner ignition devices are located not less than 18 inches(46 cm)above the floor. 1. No air ventilation openings into the boiler room are • The appliance shall be located or protected so that it is needed when the total room volume is greater than the not subject to physical damage by a moving vehicle. values given for closet installations (see Table 1A). For spaces that do NOT fit this criteria, provide one square Vent and air piping inch free area per 1,000 Btu/hr of boiler input. The Knight Wall Hung Fire Tube boiler requires a special vent system,designed for pressurized venting. Knight Wall Hung Fire Tube boiler in same space with other gas or oil-fired appliances The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room 1. Follow the National Fuel Gas Code(U.S.)or CSA B149.1 air is considered, see Section 3, General Venting. Note (Canada)to size/verify size of the combustion/ventilation prevention of combustion air contamination below when air openings into the space. considering vent/air termination. The space must be provided with Vent and air must terminate near one another and may be A WARNING! g vented verticallythrough the roof or out a side wall, unless combustion/ventilation air openings correctly sized for all other appliances otherwise specified. You may use any of the vent/air piping located in the same space as the Knight methods covered in this manual. Do not attempt to install Wall Hung Fire Tube boiler. the Knight Wall Hung Fire Tube boiler using any other means. Do not install the boiler in an attic. Be sure to locate the boiler such that the vent and air piping Failure to comply with the above warnings can be routed through the building and properly terminated. could result in severe personal injury, The vent/air piping lengths,routing and termination method death,or substantial property damage. must all comply with the methods and limits given in this manual. 2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed Prevent combustion air contamination for the Knight Wall Hung Fire Tube boiler because Install air inlet piping for the Knight Wall Hung Fire Tube it takes its combustion air from outside (direct vent boiler as described in this manual. Do not terminate vent/air installation). in locations that can allow contamination of combustion air. Wall mounting location Refer to Table 1B,page 10 for products and areas which may Ensure the wall for which the boiler is intended to be cause contaminated combustion air. mounted is composed of either, cement, brick, block, or p WARNING You must pipe combustion air to the boiler wooden studs spaced 16 inches apart from center. Ensure the air intake.Ensure that the combustion air wall is capable of supporting at least 250 pounds for Models will not contain any of the contaminants 056-286 and 300 pounds for the 400 models. in Table 1B, page 10. Contaminated combustion air will damage the boiler, If flooding is possible,elevate the boiler sufficiently to prevent resulting in possible severe personal water from reaching the boiler. injury, death or substa 4 r- Ensure the boiler is installed in a location that minimizes the damage. Do not pipe comt t ;� !'� VE P risk of water damage due to valves,pumps,etc. a swimming pool, for examp e. • so, avoid areas subject to exhaust f /ii9/18 laundry facilities. These areas will always contain contaminants. psiiiGN BUILDING DEPARTMENT KN, HT Installation & Operation Manual I Determine boiler location Table 1B Corrosive Contaminants and Sources When using an existing vent system to install a new boiler: Products to avoid: Spray cans containing chloro/fluorocarbons r L WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide Permanent wave solutions emissions, causing severe personal injury or death. Chlorinated waxes/cleaners Check the following venting components before installing: Chlorine based swimming pool chemicals • Material-For materials listed for use with this appliance, Calcium chloride used for thawing see Section 3 - General Venting. For polypropylene or stainless steel venting, an adapter of the same Sodium chloride used for water softening manufacturer must be used at the flue collar connection. Refrigerant leaks • Size-To ensure proper pipe size is in place,see Table 3A. Paint or varnish removers Check to see that this size is used throughout the vent system. Hydrochloric acid/muriatic acid • Manufacturer - For a stainless steel or YP of ro PYlene P Cements and glues I application,you must use only the listed manufacturers and their type product listed in Tables 3E and 3F for CAT Antistatic fabric softeners used in clothes dryers IV positive pressure venting with flue producing condensate. Chlorine-type bleaches,detergents,and cleaning solvents found in household laundry rooms • Supports - Non-combustible supports must be in place Adhesives used to fasten building products and other allowing a minimum 1/4" rise per foot. The supports similar products should adequately prevent sagging and vertical slippage, Areas likely to have contaminants by distributing the vent system weight. For additional information, consult the vent manufacturer's Dry cleaning/laundry areas and establishments instructions for installation. Swimming pools . Terminations-Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air Metal fabrication plants terminations are met and orientation of these fit the Beauty shops appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For Refrigeration repair shops stainless steel vent,only use terminations listed in Table 3H for the manufacturer of the installed vent. Photo processing plants • Seal-With prior requirements met,the system should be Auto body shops tested to the procedure listed in parts (c) through (f) of Plastic manufacturing plants the Removal of an Existing Boiler Section on page 11. Furniture refinishing areas and establishments With polypropylene and stainless steel vent,seal and connect all pipe and components as specified by the vent manufacturer New building construction used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 20. Remodeling areas Garages with workshops r 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. RECEIVED 10/09/18 — 10 _ ASPEN BUILDING DEPARTMENT 134v,PHT Installation & Operation Manual 7 Determine boiler location (continued) When removing a boiler from existing common vent system: DANGER Do not install the Knight Wall Hung g. Any improper operation of the common venting system Fire Tube boiler into a common vent should be corrected so the installation conforms with the with any other appliance. This will cause National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or flue gas spillage or appliance malfunction, CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting resulting in possible severe personal injury, death, or substantial property system, the common venting system should be resized damage. 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 0 WARNING Failure to follow all instructions can result and Propane Installation Code. in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. 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. RECEIVED 10/09/18 /ASPEN BUILDING DEPARTMENT KN!.GT` Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet To gain access and remove the venturi - All 1. After removing the outer shipping carton from the boiler, Models: remove the parts box. 1. If boiler is already installed, you must turn off the 2. To remove the boiler from the pallet: gas supply, turn off the power, and allow the a. Remove the two (2) lag bolts securing the bottom boiler to cool before proceeding. of the unit to the pallet. 2. Remove the front access cover from the unit (no tools b. Lift the boiler off the wall bracket mounted to required for removal). the pallet. 3. Remove the three (3) lag bolts securing the wall bracket 3. Disconnect the air inlet piping from the venturi to the wood pallet. Be certain not to lose the wall bracket by loosening the band clamp around the rubber as it will be needed for securing the boiler to the wall boot coupling. Slide the rubber boot off of the (FIG.2-1). venturi. NOTICE Do not drop the boiler or bump the jacket 4. Disconnect the gas piping from the valve or venturi. on the floor or pallet. Damage to the On Models WH56 - 286 loosen the threaded nut on the boiler can result. venturi. Remove the gasket between the gas piping and Figure 2-1 Boiler Mounted on Shipping Pallet venturi. On the WH400 model disconnect the Molex plug from the gas valve. Using a 5 mm Allen wrench, remove the screws securing the gas pipe to the gas valve. �• ` 5. Remove the bolts (using a 4 mm Allen wrench for models WH56 - 286 and a 6 mm Allen wrench on the WH400 REMOVE SHIPPING model) connecting the venturi to the fan and proceed . [WALL]BRACKET to remove the venturi from the unit, making sure not to DO NOT DISCARD- ,' ! I WILL BE NEEDED TO damage the blower 0-ring gasket(FIG.'s 2 2 and 2 3). SECURE THE BOILER TO THE WALL LP conversion procedure- Models WH56-286 1. Install theLP air shutter provided in thekitTable 2A . st s utte ov ded (see ab e P ) DIR#2000543285 00 a. Disconnect the wiring from the fan and remove the bolts securing the fan to the combustion chamber Gas conversions access cover. For a boiler already installed, you must b. Remove the fan and gasket. Install the LP air shutter. WARNING turn off gas supply, turn off power and Note: On the WHL200 model, the air shutter MUST be allow boiler to cool before proceeding. installed in the proper direction. Install the air shutter so You must also completely test the boiler that the hole in the corner is oriented towards the back after conversion to verify performance right corner of the unit (opposite the front door and gas as described under Start-up, Section 10 piping). of this manual. Failure to comply could c. Replace all torn or damaged gaskets and reassemble result in severe personal injury, death, or the fan. substantial property damage. d. Reconnect the wiring harness before operation. For models WH56-286 you must install a propane venturi and any additional components supplied in the kit to 2. Install the propane venturi and verify the following: operate the Knight Wall Hung Fire Tube boiler on propane a. The UP arrow on the plastic housing is pointing up. gas. On the WH400 model, a propane orifice must be b. The threaded connection for the gas piping is facing installed. Verify when installing that the venturi label and towards the front of the unit. orifice marking matches the boiler size(see Table 2A). 3. Models WHL111 - 200 ONLY require an Table 2A LP Conversion Table orifice to be installed in the threaded venturi connection: Venturi 0 Orifice 0 Air Orifice a. Locate the propane orifice from the Model Kit# (mm) Bottom Top Shutter Stamping conversion kit bag and verify the stamping 56 100268040 20 mm 2.45 mm 2.65 mm 100150434 N/A on the orifice matches the boiler size (see 86 100268104 20 mm 2.45 mm 2.55 mm 100150434 N/A Table 2A). 111 100285815 22 mm 3.00 mm 2.85 mm 100284510 .250 b. With the stamped side facing inwards, _156_100285817 24 mm 3.35 mm 2.95 mm_100284509 .302 place the orifice in the cavity provided in 200 100285818 24 mm 3.40 mm 3.00 mm 100150947 .302 the threaded connection. 286 100268109 30 mm 4.20 mm 4.00 mm 100150947 N/A 4. Reassemble the gas Y pipeRK '�D 400 100159011 N/A N/A N/A N/A 8.0 connection on the venturi. eplace torn or *Note:The WHL200 air shutter should have the hole oriented towards damaged gasket(s)and ensure theY000 97t8 the back right corner of the unit. is seated properly before tightening the nut on _ _ the venturi. ASPEN 12 BUILDING DEPARTMENT N!GHT. Installation & Operation Manual 2 Prepare boiler (continued) LP conversion procedure- Model WH400 1. Using a 5 mm Allen wrench, remove the venturi from Figure 2-3 Install Orifice Model 400 the gas valve. 2. Locate the propane orifice from the conversion kit bag —% BLOWER and verify the stamping on the orifice matches the boiler o , 0-RING VENTURI size(see Table 2A). SCREWS 3. Place the orifice into the black rubber grommet in the o)1._ r'-'-'! QTY.3 side of the gas valve and secure inside the gas valve(FIG. / �,* �, 2-3). tkv it ��il i 1 4. Reattach the venturi to the gas valve and reposition the r► gas valve venturi assembly inside the unit. Reattach the n ip (� �`' \I__ gas pipe to the gas valve. Reattach the air intake and 1. l coupler and tighten down on the band clamp. SCREWS 0-RING \� QTY.4 O C' a�� 0 5. Reattach the Molex plug to the gas valve. BRASS ORIFICE 1 GAS VALVE Reassemble the appliance and complete installation-All Models .A, WARNING After converting to LP, check combustion per the Start-up procedure in Section 10 1. Reconnect the rubber boot on the air inlet to the venturi of this manual. Failure to check and verify inlet and tighten the band clamp at this connection. combustion could result in severe personal 2. After installation is complete, attach the propane injury,death,or substantial property damage. conversion label (inside the conversion kit) next to the boiler rating plate. Attach the LP caution label (inside Mounting the boiler the conversion kit bag) to the left side of the boiler See page 9 of this manual for boiler mounting location underneath the gas supply piping. instructions. 3. Replace the front access cover removed in Step 1 of the "To Gain Access and Remove the Venturi" section on The Knight Wall Hung Fire Tube boiler is page 12 and resume operation. NOTICE not intended for floor installation. 0 DANGER When removing the natural gas Mounting to a wood studded wall: venturi, inspect the gasket at the gas connection and the 0-ring at the 1. The wall mount bracket is designed for a stud spacing of blower. These gaskets must be in 16 inches from center. For other stud spacing a solid good condition and must be installed. mounting surface must be provided by the installer. Failure to comply will cause a gas Do not mount the boiler to a hollow wall. leak, resultinginpersonal A WARNING severe Be sure to mount the boiler to the studs injury or death. only. Figure 2-2 Install LP Air Shutter and Orifice-Models 56- 286 2. Mount the wall bracket using the 3 1/4" lag bolts provided. Make sure the top edge of the bracket is away BLOWER 0-RING from the wall. Ensure the bracket is level when mounted. FAN/BLOWER GASKET VENTURI Extreme care is needed to ensure the bolts are secured in ORIFICE (MODELS WHL111-2000NLY) the center of the studs. VENTURI GASKET 3. Hang the boiler on the bracket and secure the bottom of A "$ the boiler with two (2) additional lag bolts provided. GASKET `, a , '�% AIR SHUTTER 1el. ittpr GASKET ' g I RECEIVED . ,...,_ . . (. 10/09/18 i • SF _ 1 010 02000544505 00 11 Ar_N BUILDING DEPARTMENT NPG!iT` Installation & Operation Manual 2 Prepare boiler 0 WARNING The boiler is too heavy for a single person to lift. A minimum of two people is Figure 2-4 Mounting the Boiler needed for mounting the boiler onto the WALL: bracket. WOOD OR METAL STUDS ON 16"CENTERS-OR- Mounting to a concrete wall: MASONRY/POURED CONCRETE 1. Mount the wall bracket using the two(2)wedge anchor MOUNTING BRACKET (FACTORY SUPPLIED) bolts provided with the bracket. To mount the wedge anchor bolts,drill a 1/4"diameter hole 1 1/8" deep and insert anchor.Hangthebracket from the anchor and secure with the two nuts provided. Make sure the top edge of the bracket is away from the wall.Ensure bracket is level when i mounted. Extreme care is needed to ensure the bolts are \.-' secured in the center of the studs. FASTENERS APPROPRIATE Note: If wall thickness does not allow a 1 1/8" deep hole, FOR WALL TYPE field supplied hardware suitable for the application should WY:a be provided. 2. Hang the boiler on the bracket and secure thebottomofthe boiler with two (2) remaining anchors, following the DIR#2000543307 00 instructions above. 0 WARNING!_A The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket. Mounting to a metal studded wall: 1. The wall mount bracket is designed for a stud spacing of 16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer. 0 WARNING, Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only. 2. Mount the wall bracket using two (2) field supplied toggle bolts capable of supporting 100 pounds each. Ensure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs. 3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2)field supplied toggle bolts. rA WARNING The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket. RECEIVED 10/09/18 14 ASPEN BUILDING DEPARTMENT -KN1014 Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent • • • • j, • Ii • • • • •• ,, . ,. • • DIR#2000543112 00 • DIR#2000543090 00 • •Figure 3-1 Two-Pipe Sidewall Termination-See page Figure 3-2 PVC/CPVC Concentric Sidewall 23 for more details • Termination - See page 27 for more details Direct venting options - Vertical Vent • • • • fit• . •1 • (i • • i 0 • �'�- • I > • • • • . al • • DIR#2000543107 00 loll 000543103 00 : DIR#2000543106 00 • • Figure 3-3 Two-Pipe Vertical :Figure 3-4 PVC/CPVC Concentric : Figure 3-5 Vertical Ve► lR 1�1'r E0 Termination - See page 30 for :Vertical Termination - See page 32 : Air more details :for more details 10/0 /18 BUILDING DEPARTMENT T Installation & Operation Manual 3 General venting Install vent and combustion air piping DANGER The Knight Wall Hung Fire Tube boiler The Knight Wall Hung Fire Tube boiler vent and air piping can must be vented and supplied with be installed through the roof or through a sidewall. Follow the combustion and ventilation air as described procedures in this manual for the method chosen. Refer to the in this section. Ensure the vent and air information in this manual to determine acceptable vent and piping and the combustion air supply air piping length. comply with these instructions regarding You may use any of the vent/air piping methods covered in this vent system,air system,and combustion air manual. Do not attempt to install the Knight Wall Hung Fire quality. See also Section 1 of this manual. Tube boiler using any other means. Inspect finished vent and air piping thoroughly to ensure all are airtight and You must also install air piping from outside to the boiler comply with the instructions provided and air intake adapter unless following the Optional Room Air with all requirements of applicable codes. instructions on page 19 of this manual. The resultant installation Failure to provide a properly installed vent is direct vent(sealed combustion). and air system will cause severe personal Air intake/vent connections injury or death. 1. Combustion Air Intake Connector (FIG. 3-6) - Used to WARNIN This appliance requires a special venting provide combustion air directly to the unit from outdoors. system. Use only approved stainless steel, A fitting is provided on the units for final connection. PVC, CPVC or polypropylene pipe and Combustion air piping must be supported per guidelines fittings listed in Tables 3D, 3E, and 3F for listed in the National Mechanical Code,Section 305,Table vent pipe, and fittings. Failure to comply 305.4 or as local codes dictate. could result in severe personal injury, death,or substantial property damage. 2. Vent Connector(FIG.'S 3-7 thru 3-10) - Used to provide a passageway for conveying combustion gases to the WARNING DO NOT mix components from different outside. A transition fitting is provided on the unit for systems. The vent system could fail, final connection. Vent piping must be supported per the causing leakage of flue products into the National Building Code, Section 305, Table 305.4 or as living space. Mixing of venting materials will void the warranty and certification of local codes dictate. the appliance. Figure 3-6 Near Boiler Air Piping 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. For closet and alcove installations, CPVC, AIR INTAKE CONNECTOR WARNIN polypropylene or stainless steel material ®�0 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. .- Follow the instructions in Section 1,page NOTICE 11 of this manual when removing a boiler from an existing vent system. 0 WARNIN Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply • could result in severe personal injury, death,or substantial property damage. { 1 DIR#2000543326 00 REC E I f L IP 10/09/18 16 ImASPEN BUILDING DEPARTMENT KN.!, tT' Installation & Operation Manual 3 General venting (continued) Requirements for installation in When determining equivalent combustion air and vent length,add 5 feet for each 90°elbow and 3 feet for each 45° Canada elbow. 1. Installations must be made with a vent pipe system EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) certified to ULC-S636. 45° elbows + (1) concentric vent kit (100269005) = 49 2. The first three (3) feet of plastic vent pipe from the equivalent feet of piping. appliance flue outlet must be readily accessible for visual inspection. NOTICE The appliance output rating will reduce 3. The components of the certified vent system must not be by up to 2.3% for each 25 feet of vent interchanged with other vent systems or unlisted length. Consult factory to determine pipe/fittings. For concentric vent installations, the inner de-rate values. vent tube must be replaced with field supplied certifiedvent material to comply with this requirement. Table 3B Approved Concentric Vent Systems 4. The 2", 3" and 4" Concentric Vent Kit available from Lochinvar(see Section 4-Sidewall Termination-Optional Concentric Vent) and the 2",3"and 4"Concentric Vent Kit Vent Vent Vent Part Number available from IPEX are both approved for use on the Diameter Supplier Material Knight Wall Hung Fire Tube boiler. Both kits are listed to 2 inch Lochinvar PVC 100140485 the ULC-5636 standard for use in Canada. 3 inch Lochinvar PVC 100269005 Sizing 4 inch Lochinvar PVC 100140484 The Knight Wall Hung Fire Tube boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 2 inch IPEX PVC 196005 3A below. 3 inch IPEX PVC 196006 Table 3A Air Intake/Vent Piping Sizes 4 inch IPEX PVC 196021 Inlet Vent Maximum 3 inch IPEX CPVC 197009 Model Diameter Diameter Length 4 inch IPEX CPVC 197021 56 2 inches/3 inches 2 inches/3 inches 80 feet/ 100 feet 86 2 inches/3 inches 2 inches/3 inches 50 feet/ 100 feet 111 2 inches/3 inches 2 inches/3 inches 40 feet/ 100 feet 156 3 inches 3 inches 100 feet 200 3 inches 3 inches 100 feet 286 3 inches/4 inches 3 inches/4 inches 50 feet/ 100 feet 400 4 inches 4 inches 100 feet NOTICE Increasing or decreasing combustion air or vent piping sizes is not authorized. NOTICE For Models 56 - 111 using 2" venting and Model 286 using 3" venting, the first seven (7) equivalent feet of vent must be CPVC or polypropylene (field supplied). This includes any transition piece used to increase or decrease the vent diameter. NOTICE The minimum combustion air and vent piping length is 12 equivalent feet. RECEIVED 10/09/18 11 ASPEN BUILDING DEPARTMENT KN!q!IT Installation & Operation Manual 1 3 General venting Materials Air inlet pipe materials: The PVC,CPVC,or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable sealed with the pipe manufacturer's recommended solvents combustion air inlet pipe materials from the following list: and standard commercial pipe cement for the material used. The PVC,CPVC,ABS,Dryer Vent or Flex Duct air inlet pipe PVC,CPVC,Polypropylene or ABS should use a silicone sealant to ensure a proper seal at the Dryer Vent or Sealed Flexible Duct (not recommended appliance connection and the air inlet cap connection. Dryer for rooftop air inlet) vent or flex duct should use a screw type clamp to seal the vent Galvanized steel vent pipe with joints and seams sealed as to the appliance air inlet and the air inlet cap. Proper sealing specified in this section. of the air inlet pipe ensures that combustion air will be free of Type"B"double-wall vent with joints and seams sealed as contaminants and supplied in proper volume. specified in this section. AL29-4C, stainless steel material to be sealed to Follow the polypropylene manufacturer's instructions when specification of its manufacturer. using polypropylene material as an inlet pipe. *Depending on the installation,a field provided adapter may When a sidewall or vertical rooftop combustion air supply be required to transition between the air inlet connection on system is disconnected for any reason, the air inlet pipe the appliance and the air inlet piping. must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume. WARNING Using air intake materials other than those specified can result in personal injury, 0 DANGER Failure to properly seal all joints and seams death or property damage. as required in the air inlet piping may result in flue gas recirculation, spillage The use of double wall vent or insulated of flue products and carbon monoxide NOTICE emissions causing severe personal injury material for the combustion air inlet pipe is recommended in cold climates to prevent or death. 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. RECEIVED 10/09/18 18 ASPEN BUILDING DEPARTMENT KN!I!-T` Installation & Operation Manual 3 General venting (continued) Optional room air Air contamination Optional room air is intended for Pool and laundry products and common household and hobby NOTICE commercial applications. Combustion products often contain fluorine or chlorine compounds. When air piping to the outside is recommended these chemicals pass through the boiler, they can form strong for residential applications. acids. The acid can eat through the boiler wall,causing serious Commercial applications utilizing the Knight Wall Hung Fire damage and presenting a possible threat of flue gas spillage or Tube boiler may be installed with a single pipe carrying the boiler water leakage into the building. flue products to the outside while using combustion air from Please read the information given in Table 1B, page 10, the equipment room. In order to use the room air venting listing contaminants and areas likely to contain them. If option the following conditions and considerations must be contaminating chemicals will be present near the location of the followed. boiler combustion air inlet, have your installer pipe the boiler The unit MUST be installed with the appropriate combustion air and vent to another location,per this manual. • room air kit(Table 3C). If the boiler combustion air inlet is located in • The equipment room MUST be provided with L WARNING a laundry room or pool facility,for example, properly sized openings to assure adequate these areas will always contain hazardous combustion air. Please refer to instructions provided contaminants. with the room air kit. • There will be a noticeable increase in the noise level Q WARNING To prevent the potential of severe personal during normal operation from the inlet air opening. injury or death,check for areas and products • Using the room air kit makes the unit vulnerable to listed in Table 1B, page 10 before installing combustion air contamination from within the the boiler or air inlet piping. building. Please review Section 1, Prevent If contaminants are found,you MUST: Combustion Air Contamination, to ensure proper •Remove contaminants permanently. installation. —OR— • Vent system and terminations must comply with the •Relocate air inlet and vent terminations standard venting instructions set forth in this to other areas. manual. I 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. Table 3C Optional Room Air Kit Model Vent Part Number Diameter 56 - 86 2 inch 100157614 111 - 286 3 inch 100157615 400 4 inch 100157616 RECEIVED 10/09/18 ASPr_N BUILDING DEPARTMENT yKN;.G!T' Installation & Operation Manual 3 General venting PVC/CPVC 1. Work from the boiler to vent or air termination. Do not This product has been approved for use with the PVC/CPVC exceed the lengths given in this manual for the air or vent vent materials listed in Table 3D. piping. 2. Cut pipe to the required lengths and deburr the inside Installing vent and air piping and outside of the pipe ends. Use only cleaners, primers, and solvents 3. Chamfer outside of each pipe end to ensure even NOTICE that are approved for the materials which cement distribution when joining. are joined together. 4. Clean all pipe ends and fittings using a clean dry rag. All PVC vent pipes must be glued,properly (Moisture will retard curing and dirt or grease will NOTICE prevent adhesion.) supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot 5. Dry fit vent or air piping to ensure proper fit up before back to the boiler (to allow drainage of assembling any joint. The pipe should go a third to condensate). two-thirds into the fitting to ensure proper sealing after WARNING Insulation should not be used on PVC cement is applied. or CPVC venting materials. The use of 6. Priming and Cementing: insulation will cause increased vent wall a. Handle fittings and pipes carefully to prevent temperatures, which could result in vent contamination of surfaces. pipe failure. b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" Table 3D PVC/CPVC Vent Pipe, and Fittings beyond the socket depth. Approved PVC/CPVC Vent Pipe and Fittings c. Apply a second primer coat to the fitting socket. d. While primer is still wet, apply an even coat of Item Material Standard approved cement to the pipe equal to the depth of PVC Schedule 40, 80 ANSI/ASTM D1785 the fitting socket along with an even coat of Vent pipe PVC - DWV ANSI/ASTM D2665 approved cement to the fitting socket. CPVC Schedule 40, 80 ANSI/ASTM F441 e. Apply a second coat of cement to the pipe. PVC Schedule 40 ANSI/ASTM D2466 f. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as PVC Schedule 80 ANSI/ASTM D2467 you insert it. NOTE: If voids are present, Vent fittings CPVC Schedule 40 I ANSI/ASTM F438 sufficient cement was not applied and joint could CPVC Schedule 80 ANSI/ASTM F439 be defective. PVC - DMV ANSI/ASTM D2665 g. Wipe excess cement from the joint removing ring Pipe Cement/ PVC ANSI/ASTM D2564 or beads as it will needlessly soften the pipe. Primer CPVC ANSI/ASTM F493 Figure 3-7 Near Boiler PVC/CPVC Venting NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE1 NOTE: In Canada, CPVC and PVC vent pipe,fittings and cement/ CPVC T H BOILER g PIECE SUPPLI E ED WITH BOILER primer must be ULC-S636 certified. (MODELS 56-286 ONLY) oft A • � EC was EIVED 10/09/18 20 ASPEN BUILDING DEPARTMENT IKtl.!PtiT Installation & Operation Manual ml NOTICE All vent connections MUST be secured 3 General venting (continued) by the vent manufacturer's joint connector Polypropylene (FIG" 3 9)" This product has been approved for use with polypropylene Q WARNING Insulation should not be used on vent with the manufacturers listed in Table 3E. polypropylene venting materials. The use All terminations must comply with listed options in this of insulation will cause increased vent wall manual and be a single wall vent offering. temperatures, which could result in vent For support and special connections required, see the pipe failure. manufacturer's instructions. All vent is to conform to standard L I A WARNING Use only the adapters and vent system listed diameter and equivalent length requirements established. in Table 3E. DO NOT mix vent systems of When determining equivalent combustion air and vent length different types or manufacturers. Failure for polypropylene single-wall piping: to comply could result in severe personal • 1 foot of Duravent 4 inch single-wall pipe is equivalent injury, death, or substantial property to 1.6 feet of piping damage. Flexible polypropylene Installations must comply with For use of flex pipe,it is recommended to have the vent material NOTICE _I applicable national, state, and local in 32°F or higher ambient space before bending at installation" codes. For Canadian installation, No bends should be made to greater than 45° and ONLY polypropylene vent must be listed as installed in vertical or near vertical installations(FIG.3-8). a ULC-S636 approved system. Figure 3-8 Near Boiler Flexible Polypropylene Venting NOTICE Installation of a polypropylene vent system should adhere to the Duravent 3" Duravent 4" vent manufacturer's installation CAP "A"DIM "B"DIM "A"DIM "B"DIM 1 CHIMNEY 3"RIGID 3"FLEX 4"FLEX 4"RIGID 4"FLEX 5"FLEX instructions supplied with the vent 10 FT 60 FT 90 FT 10 FT 30 FT 90 FT 20 FT 53 FT 80 FT 20 FT 27 FT 80 FT system. B 30 FT 47 FT 70 FT 30 FT 23 FT 70 FT 40 FT 40 FT 60 FT 40 FT 20 FT 60 FT 50 FT 33 FT 50 FT 50 FT 17 FT 50 FT Figure 3-9 Near Boiler Polypropylene Venting 60 FT 27 FT 40 FT 60 FT 13 FT 40 FT 70 FT 20 FT 30 FT 70 FT 10 FT 30 FT 80 FT 13 FT 20 FT 80 FT 7FT 20 FT CD 90 FT 7FT 10 FT 90 FT 3FT 10 FT -' A Centrotherm 3" Centrotherm 4" "A"DIM "B"DIM "A"DIM"B"DIM 4"RIGID'3_ELEX4"FLEX 4"RIGID 4"FLEX 10 FT 45 FT 90 FT 10 FT 33 FT _20 FT 40 FT 80 FT 20 FT 29 FT 30 FT 35 FT 70 FT 30 FT 26 FT 40 FT 30 FT 60 FT 40 FT 22 FT 50 FT 25 FT 50 FT 50 FT 18 FT I r JOINT CONNECTOR SOFT 20 FT 40 FT 60 FT 15 FT _70 FT 15 FT 30 FT 70 FT 11 FT 80 FT 10 FT 20 FT 8O FT 7 FT PVC tQ POLYPROPYLENE 90 FT 5 FT 10 FT 90 FT 4 FT ADAPTER 671 "NOTES 1)FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION 2)ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE _ EQUIVALENT LENGTHS. ^�"�\ 3)SECTION A IS EQUIVALENT FEET OF RIGID PIPE,WHICH MAY INCLUDE 45 AND 90"ELBOWS.PLEASE SEE SIZING SECTION 4 FOR DETERMINING EQUIVALENT FEET. IMG00840 � , NOTICE —1 The installer must use a specific vent starter adapter at the flue collar connection.This adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. Discard CPVC starter piece. ..... Table 3E Approved Polypropylene System Adapters Vent PVC Adapter Joint Sidewall Diameter ManufacturerNbdel Type Adapter Clamp Connector Kit 2 inch Centrotherm Innoflue Single-Wall/ Flex ISAGL0202 IAFCO2 IANS02 ISLTK02* 3 inch Centrotherm Innoflue Single-Wall/ Flex ISAGL0303 IAFC03 IANS03 ISLTKO3* 4 inch Centrotherm Innoflue Single-Wall/ Flex ISAGL0404 IAFC04 IANSO4 ISLTKO4* 2 inch DuraVent PolyPro Single-Wall/ Flex 2PPS-ADL Included 2PPS-LB 2PPS-HLKL* 3 inch DuraVent PolyPro Single-Wall/ Flex 3PPS-ADL Included 3PPS-LBDepro D 4 inch DuraVent PolyPro Single-Wall/ Flex 4PPS-ADL Included 4PPS-LBr4P L *The sidewall kit components are only needed if the sidewall termination assembly is used(see FIG.4-1B on page 1 /0 9/18 _ ASPEN BUILDING DEPARTMENT : ••cT Installation & Operation Manual 3 General venting Stainless steel vent NOTICE Installation of a stainless steel vent system This product has been approved for use with stainless steel should adhere to the stainless steel vent using the manufacturers listed in Table 3F. manufacturer's installation instructions Use only the materials,vent systems, and supplied with the vent system. f . WARNING terminations listed in Table 3F. DO NOT Figure 3-10 Near Boiler Stainless Steel Venting mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage. STAINLESS STEEL NOTICE The installer must use a specific vent ADAPTER starter adapter at the flue connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3F for CPVC STARTER PIECE , MODELS 56-286 ONLY approved vent adapters. Refer to adapter (FACTORY PROVIDED) /11.1i notation in Table 3F to determine if a '- 4` CPVC starter piece is needed. ' ' .. 11 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-5636 approved system for Canada. DIR#2000543310 00 Table 3F Approved Stainless Steel (S.S.) Venting System Adapters and Terminations Manufacturer Model Vent Adapters and Terminations Description Size _ Part Number DuraVent FasNSeal* Flue Coupler Adapter 2"to3" FSA-2PVCS-3FNSF1 DuraVent FasNSeal* Flue Coupler Adapter 3"(4') FSA,3(4)PVCS-3(4)FNSF1 DuraVent FasNSeal* Flue CPVC Starter Adapter 3"(4') FSA 3(4)PVCO-3(4)FNSF2 _ DuraVent FasNSeal* Flue Flue Collar Adapter 4" FSAKNWH3993 DuraVent FasNSeal* Bird Screen Termnation 3"(4') FSBS3(4) IXuaVent FasNSeal* Rain Cap Termination 3"(4') FSRC3(4) Heat Fab Saf-T-Vent Flue Coupler Adapter 3"(4') 93(4)01PVC1 Heat Fab Saf-T-Vent Flue Collar Adapter 4" WH00043 Heat Fab Saf-T-Vent Bird Screen Teonwiation 3"(4') 93(4)92 Heat Fab Saf-T-Vent Rain Cap Termination 3"(4') 53(4)00CI Heat Fab Saf-T-Vent Elboww/Screen Termination 3"(4') 93(4)12TERM ZFlex Z-Vent Flue Coupler Adapter 3" 2SVSTTA031 ZFlex Z-Vent Flue Coupler Adapter 3"to 4" 2SVSTTA041 ZFlex Z-Vent Flue Coupler Adapter 4" 2SVSTTA04.51 Z-Flex Z-Vent Flue Collar Adapter 4" 2SVAKA043 Z-Flex Z-Vent Bird Screen Termination 3"(4') 2SVSTP03(4) _ Z-Flex Z-Vent Rain Cap Termination 3"(4') 2SVSRCF03(4) ZFlex Z-Vent Elbow w/Screen Termination 3"(4') 2SVSTE))3(4)90 *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. 1)Install adapter directly into the flue vent coupler connector. An approved high-temperature RTV silicone sealant MUST be used to make the joint between the flue vent and adapter. 2)A CPVC starter piece must be properly cemented into the flue collar connection before installing the adapter E1s ilie'tlfe�' starter piece is an appropriate length such that the adapter inner sleeve can fit into the piping and the outer sleeve .vil1•sedurel clamp. 3)For use on Model WH400 ONLY. Replace the appliance secured CPVC flue vent with the flue collar adapter list dP/0 9/18 22 — ASPEN BUILDING DEPARTMENT �I 4!.P.mT Installation & Operation Manual 4 Sidewall direct venting Vent/air termination - sidewall Figure 4-1A PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings WARNING Follow instructions below when TO BOILER determining vent location to avoid INTAKE AIR R FACTORY PROVIDED CONNECTION ir'. BIRD SCREEN possibility of severe personal injury, death, or substantial property damage. \ FROM BOILER ' -VENT PIPE V 12"MIN A gas vent extending through an exterior CONNECTION 15"MAX A WARNING wall shall not terminate adjacent to a wall or below building extensions such as eaves, AC 7.. parapets, balconies, or decks. Failure to comply could result in severe personal TERMINATION 0 11- : , injury, death, or substantial property PLATE damage. 4 r 12" MIN Determine location FACTORY PROVIDED BIRD SCREEN Locate the vent/air terminations using the following guidelines: GE L OR 1. The total length of piping for vent or air must not exceed If using the sidewall termination: the limits given in the General Venting Section on page 17 3. The air piping must terminate in a down-turned elbow of this manual. as shown in FIG. 4-1A. This arrangement avoids recirculation of flue products into the combustion air 2. You must consider the surroundings when terminating stream. the vent and air: a. Position the vent termination where vapors will 4. The vent piping must terminate in an elbow pointed not damage nearby shrubs, plants or air 1 outward or away from the air inlet,as shown in FIG.4-1A. conditioning equipment or be objectionable. I A WARNING Do not exceed the maximum lengths of l b. The flue products will form a noticeable plume as the outside vent piping shown in FIG. they condense in cold air. Avoid areas where the 4 lA. Excessive length exposed to the outside could cause freezing of condensate plume could obstruct window views. c. Prevailing winds could cause freezing of in the vent pipe,resulting in potential boiler condensate and water/ice buildup where flue shutdown. products impinge on building surfaces or plants. When venting out a sidewall using PVC,CPVC,or Polypropylene d. Avoid possibility of accidental contact of flue vent materials,an optional sidewall vent termination kit can be products with people or pets. ordered(reference Table 4A for kit numbers). e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, Table 4A Alternate Sidewall Vent Kits such as inside building corners, near adjacent Vent Supplier Part Number buildings or surfaces, window wells, stairwells, Diameter _ alcoves,courtyards,or other recessed areas. 2 inch Lochinvar 100157609 3 inch Lochinvar I 100157610 A WARNING Sidewall vent and air inlet terminations 4 inch Lochinvar 100157611 must terminate in the same pressure zone. f. Do not terminate above any door or window. Figure 4-1B Alternate PVC/CPVC/Polypropylene Condensate can freeze,causing ice formations. Sidewall Termination of Air and Vent g. Locate or guard vent to prevent condensate damage O BOILER KE AIR to exterior finishes. � CONNECTION FROM BOILER } VENT PIPE CONNECTION ✓- 12" -f O POSSIBLE ORIENTATIONS -IMIN .. V '_,_: ` ER- ,.�.. HANG /� VED VENT/AIRY TERMINATION ,--,-,,,-- ,--h, , s 1 1,,,,,,1 411 0/09118 IIII 1 IIII i / GRADE OR SNOW LINE as. I� BUILDING ' 'ARTMENT KNIP.HT Installation & Operation Manual 1 4 Sidewall direct venting Vent/air termination - sidewall 6. Locate terminations so they are not likely to be damaged Figure 4-1C Alternate PVC/CPVC/SS/Polypropylene Venting by foreign objects, such as stones or balls, or subject to Arrangement(if Space Allows) w/Field Supplied Fittings buildup of leaves or sediment. TO BOILER n.., INTAKE AIR / COUPLING 1 CONNECTION Figure 4-2A Clearance to Gravity Air Inlets \ 12"MIN Vie FROM TOER 7:� VENT PIPE � r �`L CONNECTION ® BIRD SCREEN JI1___fIIi 12 4 12" MIN. IN BIRD SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT 11 (IF SPACE PERMITS) VENT/AIR TERMINATION Figure 4-1D Alternate SS Venting Arrangement - 12" Typical Stainless Steel Sidewall Termination of Air and MIN. Vent w/Field Supplied Fittings, Utilizing a Hood Intake n12" IN TO BOILER BIRD SCREEN Figure 4-2B Alternate Clearance to Gravity Air Inlets w/ INTAKE AIR Field Supplied Fittings ,CONNECTION 114140 12 (385 MM)MIN e 15"(381 MM)MAX 4 r- . FROM BOILERAP).„'".it: 1 11, VENT PIPE 1 CONNECTION •01 .41 12" MIN 25Y 12"(305 MM)MIN _�/ �I II,--" BIRD GRADE OR II SCREEN SNOW LINE (TYPICAL) 5. Maintain clearances as shown in FIG.'S 4-lA thru 4-3B, - - . - 12" pages 23 -25. Also maintain the following: MIN. a. Vent must terminate: / 1N MIN. •At least 6 feet from adjacent walls. •No closer than 12 inches below roof overhang. Figure 4-3A Clearance to Forced Air Inlets •At least 7 feet above any public walkway. IF LESS • At least 3 feet above any forced air intake within 4 THAN 10' 10 feet. • No closer than 12 inches below or horizontally VENT/AIR 1111111110 36" from any door or window or any other gravity air MIN. inlet. elo i_ b. Air inlet must terminate at least 12 inches above FORCED AIR grade or snow line; at least 12 inches below the vent '% INLET termination; and the vent pipe must not extend C more than 24 inches vertically outside the building 1 - 4 as shown in FIG. 4-1B. Condensate could freeze and block vent pipe. 7'MIN.ABOVE ANY YiPUBLIC WALKWAY RECEIVED c. Do not terminate closer than 4 feet horizontally ‘. from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or 10/0 9/18 below any of these within 4 feet horizontally. 24 ASPEN BUILDING DEPARTMENT 141IC:T Installation & Operation Manual 4 Sidewall direct venting (continued) Figure 4-3B Alternate Clearance to Forced Air Inlets w/ 9. Stainless steel terminations are designed to penetrate Field Supplied Fittings walls with a thickness up to 9.25 inches of standard construction. IF LESS 4 THAN 10' - ss° Figure 4-4A PVC/CPVC Sidewall Termination Assembly MIN.w�iui,�110; ' FORCED / INLET < `rt I �i'� BIRD I ( •te} '9� SCREEN I (TYPICAL) \ 7'MIN.ABOVE ANY A PUBLIC WALKWAY ' � AIR PIPING CENTERLINE WIDTH / lie /\ / VENT PIPING V / � - _ /�VENT PLATE WALL PLATE--- ) � WENT CAP i 11 Prepare wall penetrations GALVANIZED LVTHIA I ED �.��. 1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Figure 4-4B Polypropylene Sidewall Termination Assembly Vent pipe penetration: SIDEWALL a. Cut a hole for the vent pipe. For either combustible (AIR)ADAPTER WALL or noncombustible construction, size the vent pipe PLATE hole with at least a 1/2 inch clearance around the SIDEWALL vent pipe outer diameter: PLATE RETAINING • 3' inch hole for 2 inch vent pipe •41/2 inch hole for 3 inch vent pipe VENT • 51/2 inch hole for 4 inch vent pipe PLATE Drill 3/16"diameter holes for inserting the plastic anchors °0-fj VENT into the wall. CAP 2. For Polypropylene Only: Install the vent and air intake SIDEWALL 0 �' sidewall adapters from Table 3E on page 21 into the vent (VENT)ADAPTER �;/" plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate(FIG.4-4B). 3. For PVC/CPVC Only: Install the vent and air intake piping through the wall into the vent plate openings. GALVANIZED IM000085 Use RTV silicone sealant to seal the air pipe. Use the THIMBLE cement/primer listed in Table 3D on page 20 to seal the vent pipe. 4. Mount and secure the vent plate to the wall,using stainless steel screws. 5. Seal all gaps between the pipes and wall. Seal around the plate to the wall assuring no air gaps. 6. Assemble the vent cap to the vent plate (see FIG.'s 4-4A and 4-4B). 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. RECEIVED 8. PVC/CPVC terminations are designed to accommodate 1,� any wall thickness of standard constructions per the 10/0 9/18 directions found in this manual. "g _ ASPr_N BUILDING DEPARTMENT Installation & Operation Manual 4 Sidewall direct venting Prepare wall penetrations (Alternate - Figure 4-5A Multiple Vent Terminations (must also Field Supplied Option) comply with Figure 4-1A) 1. Air pipe penetration: 12"MIN.BETWEEN EDGE OF AIR a. Cut a hole for the air pipe. Size the air pipe hole as INLET AND ADJACENT VENT OUTLET close as desired to the air pipe outside diameter. VENT j 2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible AIR or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent AB pipe outer diameter: • 31/2 inch hole for 2 inch vent pipe •41/2 inch hole for 3 inch vent pipe (.(0 • 51/2 inch hole for 4 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG.4-4C. 3. Use a sidewall termination plate as a template for correct VENT/AIR TERMINATION location of hole centers. 4. Follow all local codes for isolation of vent pipe when passing through floors or walls. Figure 4-5B Alternate Multiple Vent Terminations w/Field 5. Seal exterior openings thoroughly with exterior caulk. Supplied Fittings (must also comply with Figure 4-1 B) VENT Figure 4-4C Alternate Sidewall Termination Assembly w/Field Supplied Fittings ELBOW 12" MIN. AIR PIPING I 15" MAX. VENT PIPING 16 /��� f ��((�r BIRD SCREEN � 12" MIN. BETWEEN EDGE OF AIR GALVANIZED PIPE AND ADJACENT VENT PIPE Artu AP THIMBLE ELBOW SIDEWALL BIRD SCREEN AIR TERMINATION PLATE Multiple vent/air terminations 1. When terminating multiple Knight Wall Hung Fire Tube boilers terminate each vent/air connection as described in this manual(FIG.4-5A). A WARN I N J All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage. 2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code. RECEIVED 3. The air inlet of a Knight Wall Hung Fire Tube boiler is part of a direct vent connection. It is not classified as a 10/0 9/18 forced air intake with regard to spacing from adjacent boiler vents. ASPEN 26 BUILDING DEPARTMENT KN�gtir Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination - optional concentric vent Description and usage Lochinvar offers optional concentric combustion air and 3. Cut one (1) hole (5 inch diameter for #100269005 vent pipe termination kits (Factory Kit #100140485 for 2" installations, 4 inch diameter for #100140485, or 7 inch diameter - Models 56 - 86, #100269005 for 3" diameter - diameter for #100140484 installations) into the structure Models 56 - 200 and #100140484 for 4" diameter - Models to install the termination kit. 286 400). Both combustion air and vent pipes must attach 4. Partially assemble the concentric vent termination kit. to the termination kit. The termination kits must terminate Clean and cement using the procedures found in these outside the structure and must be installed as shown below instructions. in FIG.4-6. a. Cement the Y concentric fitting to the larger kit pipe The required combustion air and vent pipe materials are (FIG.'S 4-7 and 4-8). b. Cement the rain cap to the smaller diameter kit pipe listed in Table 3D,on page 20 of this manual. (FIG.'s 4-7 and 4-8). Figure 4-6 Concentric Sidewall Termination Figure 4-7 Kit Contents_100140485 & 100269005 OVERHANG (reference Table 38 on page 17) OR ROOF 3"CONCENTRIC /, VENT KIT �/►�► 1 4"DIA RAIN CAP �/( SDR-26 PIPE '� 2 1/2"DIA. SDR-26 PIPE - 12" MIN *0 1 ,rt, ; + 3'DIA rJLi' SDR-26 PIPE 1 - ti "y'"•n,. Kl:*.:.,,`;i "Y"CONCENTRIC 2"DIA. * FITTING SDR-26 PIPE i-�Y � ��:§ Z VENT KITRIC "Sad�% r." 12" ��'�''� ., MIN Figure 4-8 Kit Contents_100140484 (reference Table 38 GRADE/SNOW LINE on page 17) Sidewall termination installation RAIN CAP 1. Determine the best location for the termination kit (see FIG.4-6). 6"(152 MM)TO 4"(102 MM)REDUCER PO I 2. Reference the Determine Location Section on page 23 of AVoi this manual for general termination considerations. s°(152 MM)DIA. 6"(152 MM)DIA. t i� 4"(102 MM)DIA. "Y"CONCENTRIC FITTING 6"(152 MM)DIA. "FLEXIBLE"PIPE RECEIVED COUPLING 10/09/18 AST_N BUILDING DEPARTMENT 14410141 Installation & Operation Manual 4 Sidewall direct venting Sidewall termination - optional concentric vent Figure 4-9 2"and 3"Concentric Vent Dimensional Figure 4-10 4"Concentric Vent Dimensional Drawing Drawing (reference Table 3B on page 17) (reference Table 38 on page 17) -"8"DIA. A., y "B"DIA NOMINAL PVC 3" (AIR) * 1-3/16" O. (76 MM) alibill"M"LliMdbFill " NM 111111111111111.11111111 "I" 1 I lb "L PVC NOMINAL PVC 1 1/2" (VENT) "C"DIA "H"DIA. „F" "B"DIA.PVC VENT/EXHAUST "A" "B" "C" "D" "E" "F" A l B_ C ID I E l F I G I H 2"VENT KIT 33-3/8" 2" 3-1/2" 16-5/8" 6-1/4" 5-3/4" 60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8" 3"VENT KIT 38-7/8" 3" 4-1/2" 21-1/8" 7-3/8" 6-1/2" (1524 MM) (102 MM) (152 MM) (537 MM) (254 MM) (194 MM) (76 MM) (168 MM) NOTICE Instead of cementing the smaller pipe 5. Install the Y concentric fitting and pipe assembly through to the rain cap, a field-supplied stainless the structure's hole from an inside wall. steel screw may be used to secure the two (2) components together when field NOTICE Do not allow insulation or other materials to disassembly is desired for cleaning (see accumulate inside the pipe assembly when FIG.4-11). installing through the hole. WARNIN When using the alternate screw assembly 6. Install the rain cap and small diameter pipe assembly into method, drill a clearance hole in the rain the Y concentric fitting and large pipe assembly from an cap and a pilot hole in the vent pipe for outside wall. Ensure small diameter pipe is bottomed the screw size being used. Failure to and cemented in the Y concentric fitting for #100140485 drill adequate holes may cause cracking of and#100269005 installations and fastened tightly into the PVC components, allowing combustion rubber adapter for#100140484 installations. products to be recirculated. Failure to follow this warning could result in personal 7. Secure the assembly to the structure as shown in FIG.4-12 injury or death. using field-supplied metal strapping or equivalent support Do not operate the appliance with the rain material. WARNING cap removed or recirculation of combustion products may occur. Water may also collect NOTICE Ensure termination location clearance inside the larger combustion air pipe and dimensions are as shown in FIG.4-6. flow to the burner enclosure. Failure to If assembly needs to be extended to allow follow this warning could result in product NOTICE damage or improper operation, personal sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced injury,or death. by using the same diameter, field-supplied Figure 4-11 Rain Cap to Vent Pipe Alternate Assembly SDR-26 PVC (D2241) pipe for #100140485 and #100269005 and standard schedule STAINLESS STEEL SCREW 40 PVC for #100140484. Do not extend (FIELD SUPPLIED) dimension D* more than 60 inches (see FIG.'s 4-9 and 4-10). DRILL CLEARANCE HOLE IN RAIN CAP&PILOT HOLE IN VENT PIPE NOTICE If assembly depth needs to be reduced, dimension D can be as short as possible. RECEIVED 10/09/18 — 28 — ASPEN BUILDING DEPARTMENT ,I'T Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination - optional concentric vent Figure 4-12 Concentric Vent Sidewall Attachment ELBOW (FIELD SUPPLIED) STRAP (FIELD SUPPLIED) COMBUSTION COMBUSTION AIR IOW AIR 1 .4 VENT -mi.111M IM _N._ it VENT Note: 100269005 shown for illustration purposes. CAUTION DO NOT use field-supplied couplings Multi-venting sidewall terminations to extend pipes. Airflow restriction will occur and may cause intermittent When two (2) or more direct vent appliances are vented near operation. each other, each appliance must be individually vented (see FIG.4-13). NEVER common vent or breach vent this appliance. 8. Cement appliance combustion air and vent pipes to When two (2) or more direct vent appliances are vented near the concentric vent termination assembly. See FIG. each other,two(2)vent terminations maybe installed as shown 4-12 for proper pipe attachment. in FIG.4-13. It is important that vent terminations be made as 9. Operate the appliance one (1) heat cycle to ensure shown to avoid recirculation of flue gases. combustion air and vent pipes are properly connected to the concentric vent termination connections. �' / • / - /� i/ —: / i - <- '- ; - J i .L .7.Y, Y,,,,,,.....-- 4i -f �. Nv riii11' k^. 12" t . ,- MINIMUM .1 A _ VENT COMBUSTION AIR RECEIVED Figure 4-13 Concentric Vent and Combustion Air Termination 10/09/18 ASkN BUILDING DEPARTMENT Rimy it Installation & Operation Manual 5 Vertical direct venting Vent/air termination - vertical Figure 5-1A PVC/CPVC/Polypropylene Vertical 0 WARNING Follow instructions below when Termination of Air and Vent determining vent location to avoid ALTERNATE INTAKE LOCATIONS: possibility of severepersonal injury,death INTAKE PIPES MAY BE LOCATED P YANYWHERE WITHIN 24"OF VENT or substantial property damage. PIPE Determine location BIRD SCREEN (TYPICAL) Locate the vent/air terminations using the following guidelines: VENT dr COUPLING 1. The total length of piping for vent or air must not exceed (FIELD SUPPLIED)0 6"MINIMUM the limits given in the General Venting Section on page U ABOVE ROOF/ 17 of this manual. It& SNOW LINE 2. Prepare the vent termination and the air termination VENT OUTLET U • 12"MINIMUM COMBUSTION elbow(FIG.5-1A)by inserting bird screens.Bird screens ABOVE AIR INLET AIR should be obtained locally. 3. The vent must terminate at least 3 feet above the highest Figure 5-1 B Stainless Steel Vertical Termination of Air place in which the vent penetrates the roof and at least and Vent 2 feet above any part of a building within 10 horizontal ALTERNATE INTAKE LOCATIONS: feet. INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24"(610 MM) 4. The air piping must terminate in a down-turned 180° OF VENT PIPE return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue —BIRD SCREEN products into the combustion air stream. ` [TYPICAL] 5. The vent piping must terminate in an up-turned coupling VENT OUTLET 36"[914 MM]MINIMUM as shown in FIG. 5-lA. The top of the coupling must ABOVE AIR INLET be at least 1 foot above the air intake. When the vent „ �.`�i -6"(152 MM)MINIMUM ,�� ABOVE ROOF/ earlre4SNOW LINE termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. The COMB air inlet pipe and vent pipe can be located in any desired , position on the roof,but must always be no further than 2 feet(.6 m) apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel,above the air 8. Locate terminations so they are not likely to be damaged intake. by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment. 6. Maintain the required dimensions of the finished termination piping as shown in FIG.5-1A. 7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe. A 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. RECEIVED 10/09/18 30 I ASPEN BUILDING DEPARTMENT KNIGHT` Installation & Operation Manual 5 Vertical direct venting (continued) Vent/air termination - vertical Prepare roof penetrations Figure 5-2 Vertical Terminations with Multiple Boilers 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as 12"MINIMUM VERTICALLY FROM VENT OUTLET TO close as desired to the air pipe outside diameter. ANY AIR INLET VENT AIR 2. Vent pipe penetration: 12"MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT a. Cut a hole for the vent pipe. For either combustible VENT PIPE FROM ANOTHER BOILER or noncombustible construction, size the vent pipe AIR hole with at least a 1/2 inch clearance around the vent pipe outer diameter: IS •31/2 inch hole for 2 inch vent pipe •41/2 inch hole for 3 inch vent pipe • 51/2 inch hole for 4 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole. Figure 5-3 Alternate Vertical Terminations with Multiple 3. Space the air and vent holes to provide the minimum Boilers spacing shown in FIG.5-1A,page 30. 4. Follow all local codes for isolation of vent pipe when passing through floors,ceilings,and roofs. VENT 5. Provide flashing and sealing boots sized for the vent pipe VENT and air pipe. 1 MINIMUM VERTICALLY FROM VENT OUTLET TO Multiple vent/air terminations .. ANY AIR INLET ,I AIR 1. When terminating multiple Knight Wall Hung Fire Tube i boilers, terminate each vent/air connection as described AIR in this manual(FIG. 5-2). 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. 2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG.5-2). For Canadian installations,provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of a Knight Wall Hung 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. RECEIVED 10/09/18 ASPLN BUILDING DEPARTMENT 1Ku HT Installation & Operation Manual 5 Vertical direct venting Vertical termination - optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and 2. Cut one (1) hole (5 inch diameter for #100269005 vent pipe termination kit. Both combustion air and vent installations,4 inch diameter for#100140485, or 7 inch pipes must attach to the termination kit. The termination kit diameter for#100140484 installations)into the structure must terminate outside the structure and must be installed as to install the termination kit. shown in FIG. 5-4. 3. Partially assemble the concentric vent termination kit. Field supplied pipe and fittings are required to complete the Clean and cement following the cleaning procedures in installation. these instructions. The required combustion vent pipe and fittings are listed in a. Cement the Y concentric fitting to the larger Table 3D,on page 20 of this manual. diameter kit pipe(see FIG.'S 4-7 and 4-8,page 27). b. Cement rain cap to the smaller diameter kit pipe(see Vertical termination installation FIG.'s 4-7 and 4-8,page 27). 1. See Section 5, Vertical Direct Venting - Determine NOTICE Instead of cementing the smaller pipe Location(where applicable) (FIG.5-1A). to the rain cap, a field supplied stainless steel screw may be used to secure the Figure 5-4 Concentric Vertical Termination two (2) components together when field disassembly is desired for cleaning (see FIG.4-11,page 28). VENT 0 WARNI A When using the alternate screw assembly method, drill a clearance hole in the rain COMBUSTION cap and a pilot hole in the vent pipe for AIR 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 12"(18"FOR CANADA) personal injury or death. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24"ABOVE ROOF. Figure 5-5 Do Not Install U-Bend to Rain Cap p. A RECEIVED 10/09/18 mi 32 ASPEN BUILDING DEPARTMENT 134!A iTo Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination - optional concentric vent WARNING Do not operate the appliance with CAUTION 1 DO NOT use field-supplied couplings the rain cap removed or recirculation to extend pipes. Airflow restriction will of combustion products may occur. occur. Water may also collect inside the larger combustion air pipe and flow to the 6. Install the rain cap and the small diameter pipe assembly burner enclosure. Failure to follow this into the roof penetration assembly. Ensure the small warning could result in product damage diameter pipe is cemented and bottomed in the Y or improper operation, personal injury, concentric fitting for #100269005 and #100140485 or death. installations and fastened tightly into the rubber adapter for#100140484 installations. 4. Install the Y concentric fitting pipe assembly up through the structure's hole and field supplied roof boot/flashing. 7. Cement the appliance combustion air and vent pipes to Do not allow insulation or other materials the concentric vent termination assembly. See FIG. 5-6 NOTICE for proper pipe attachment. to accumulate inside the pipe assembly when installing through the hole. 8. Operate the appliance through one(1)heat cycle to ensure 5. Secure the assembly to the roof structure as shown combustion air and vent pipes are properly connected to below in FIG.5-6 using field supplied metal strapping or the concentric vent termination connections. equivalent support material. Multi-venting vertical terminations Figure 5-6 Concentric Vent Roof Installation When two (2) or more direct vent appliances are vented Note: 100269005 shown for illustration purposes. near each other, each appliance must be individually vented VENT (see FIG. 5-7). NEVER common vent or breach vent this 1 12"(18"FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST appliance. When two (2) or more direct vent appliances ANTICIPATED SNOW are vented near each other, two (2) vent terminations may LEVEL. MAXIMUM OF COMBUSTION 24"ABOVE ROOF. be installed as shown in FIG. 5-7. It is important that vent AIR "'' °' terminations be made as shown to avoid recirculation of flue gases. ROOF BOOT/ FLASHING (FIELD SUPPLIED) • Figure 5-7 Concentric Vent and Combustion Air Vertical Termination SUPPORT 12" � (FIELD SUPPLIED) AlMINIMUM ELBOW (FIELD SUPPLIED) Akt 4. Ii 1 I i COMBUSTION 4, _VENT AIR I COMBUSTION I AIR(TYPICAL) NOTICE Ensure termination height is above the I 1 roof surface or anticipated snow level 1 (12 inches in U.S.A. or 18 inches in b- / // " i/ Canada)as shown in FIG.5-4,page 32. NOTICE If assembly is too short to meet height requirement, the two (2) pipes 12"(18"FOR CANADA) supplied in the kit may be replaced MINIMUM CLEARANCE ABOVE HIGHEST by using the same diameter, field ANTICIPATED SNOW supplied SDR-26 PVC (D2241) pipeLEVEL.MAXIMUM OF PP 24"ABOVE ROOF. for 100269005/100140485 and standard RECEIVES schedule 40 PVC for 100140484. Do not extend dimension D* more than 10/0 9/18 60 inches(see FIG.'s 4-9 and 4-10,page 28). 33 ASPr_N BUILDING DEPARTMENT �KN�GHT Installation & Operation Manual 5 Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent Figure 5-8 Concentric Vent Example 1 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 FLUE EXHAUST air routing. SEAL Concentric Venting Arrangement COMBUSTION AIR / AIR INLET The venting is to be vertical through the roof. The annular W/SCREEN space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion 12" EXISTING MIN. air source. SEALED CAP The minimum size of the existing vent system required to SEAL , ,-1 achieve enough annular space for combustion air can be 1=� found in Table 5A below. FLUE OUTLET 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 5-8 and 5-9. r- Approved venting materials must be used as specified in DIR#2000sas,osoo Table 3D on page 20. `For concept illustration only. Individual installations Follow all vent/ air termination and clearance requirements may vary due to job site specific equipment. per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code. Figure 5-9 Concentric Vent Example 2 The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section. FLUE EXHAUST SEAL If an existing unused venting system is converted for use with this method of concentric venting, the installer must114- ensure that the existing venting system is clean and free from COMBUSTION AIR particulate contamination that will harm this appliance and AIR INLET cause increased nuisance calls or maintenance. See Table 1B � W/SCREEN on page 10 for a list of corrosive contaminants and sources. EXISTING i SEAL Two example scenarios of a concentric venting arrangement SEAL are shown for illustrative purposes in FIG.'s 5-8 and 5-9. SEALED CAP Table 5A Alternate Vertical Concentric Vent/Chase Sizes FLUE OUTLET Vent / Air Minimum Existing Inlet Size Vent / Chase Size 2" 4" 3" 5"4 7 DIR#20001E1 s'E IVE "For concept illustration only. Individual installatir0/0 9/18 may vary due to job site specific equipment. 34 ASPEN BUILDING DEPARTMENT INti-!T Installation & Operation Manual 5 Vertical direct venting (continued) 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 5-10 Existing Vent as a Chase FLUE EXHAUST AIR INLET -`c ifs._ 1 SEAL 1 EXISTING CAP 4 , -- SEAL FLUE OUTLET i DIR#2000543111 00 *For concept illustration only. Individual installations may vary due to job site specific equipment. RECEIVED 10/09/18 i 33 ASPEN BUILDING DEPARTMENT KN� HT Installation & Operation Manual 6 H yd ro n i c piping The WH56 - 286 models are equipped with optional water connections from the top or bottom. These models ship from System water piping methods the factory configured for bottom connections. A relief valve The Knight Wall Hung Fire Tube is designed to function and fittings are provided in the install kit shipped with the boiler in a closed loop pressurized system not less than 12 psi. and are to be field installed on the top outlet connection(see FIG. (Non-metallic system piping must have an oxygen barrier to 6-1 on page 37). If bottom connections are not used, reinstall be considered a closed loop). A temperature and pressure the factory provided cap on the outlet piping connection and a gauge is included to monitor system pressure and outlet field provided drain on the inlet piping connection as shown in temperature and should be located on the boiler outlet. FIG.6-2 on page 37. It is important to note that the boiler has a minimal Note: The threaded NPT connections MUST be used for initial connection. DO NOT attempt to change the boiler internal amount of pressure drop and must be figured in when sizing the circulators. Each boiler installation must have piping. an air elimination device, which will remove air from A WARNING Use two (2) wrenches when tightening the system. Install the boiler so the gas ignition system water piping at the boiler. Using one of the wrenches to prevent the boiler interior components are protected from water (dripping, spraying, piping from turning. Failure to support the etc.)during appliance operation for basic service of circulator boiler piping connections to prevent them replacement,valves,and others. from turning could cause damage to boiler Observe a minimum of 1/4 inch(6 mm)clearance around all components. un-insulated hot water pipes when openings around the 1. Connect the system return marked"Inlet". pipes are not protected by non-combustible materials. 2. Connect the system supply marked"Outlet". Low water cutoff device 3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone. On a boiler installed above radiation level, some states and 4. Install a backflow preventer on the cold feed make-up water local codes require a low water cutoff device at the time of line. installation. 5. Install a pressure reducing valve on the cold feed make- Chilled water system up water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a If the boiler supplies hot water to heating coils in air handler minimum pressure of 12 psi. units,flow control valves or other devices must be installed to 6. Install a circulator as shown on the piping diagrams in this prevent gravity circulation of heater water in the coils during section. Make sure the circulator is properly sized for the the cooling cycle. A chilled water medium must be piped in system and friction loss. parallel with the heater. 7. Install an expansion tank on the system supply. Consult Freeze protection the tank manufacturer's instruction for specific information Freeze protection for new or existing systems must use relating to tank installation. Size the expansion tank for the glycol that is specially formulated for this purpose. This required system volume and capacity. includes inhibitors,which prevent the glycol from attacking 8. Install an air elimination device on the system supply. the metallic system components. Make certain to check that 9. Install a drain valve at the lowest point of the system. the system fluid is correct for the glycol concentration and Note: The boiler cannot be drained completely of water inhibitor level. The system should be tested at least once without purging the unit with an air pressure of 15 psi. a year and as recommended by the producer of the glycol 10. This appliance is supplied with a relief valve sized in solution. Allowance should be made for the expansion of the accordance with ASME Boiler and Pressure Vessel Code, glycol solution in the system piping. Section IV ("Heating Boilers"). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure A WARNING Use only inhibited propylene glycol relief. Pipe the discharge to a drain. Provide piping that is solutions,which are specifically formulated the same size as the safety relief valve outlet. Never block for hydronic systems. Ethylene glycol is the outlet of the safety relief valve. toxic and can attack gaskets and seals used The relief valve, tee and any necessary in hydronic systems. L NOTICE fittings are shipped in the install kit with the General piping information boiler and are to be field installed(FIG.6-1). On the WII400 model the relief valve is IMPORTANT All boiler piping must contain an installed at the factory on the left side of the oxygen barrier. This will help prevent boiler. any excess oxygen from entering the 11. Install a field supplied strainer to prevent damage to the system. heat exchanger caused by debris entering from the system Basic steps are listed in this section along with illustrations on piping. When installing in a pre-existing syit _ ti ENE D the following pages (FIG.'s 6-5 thru 6-15), which will guide filter capable of removing debris left irOt )1see you through the installation of the Knight Wall Hung Fire recommended. n/n A/18 Tube boiler. *See the piping illustrations included in this section, .s'6'S thru 6-15 for suggested guidelines in piping the Knight Wall 36 Hung Fire Tube boiler with either zone valves or cirkafiEN pumps. BUILDING DEPARTMENT KN!RHT Installation & Operation Manual 6 Hydronic piping (continued) NOTICE Please note that these illustrations are Figure 6-2 Bottom Connections Installation meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. AUTO AIR VENT The Knight Wall Hung Fire Tube boiler is CAUTION ' BUSHING capable of servicing multiple temperature I loop systems. It is the responsibility of the ` TEE with 3/4" installer to protect the loops with lower FITTING p RELIEF VALVE temperature requirements from higher 3/4"ELBOW I temperatures that may be required by other '^ loops. Ii !<=�' Relief valve, automatic air vent, and temperature and pressure gauge installation (Models WH56 - 286) Basic steps are listed below to guide you through the installation of the relief valve,automatic air vent,and the temperature and pressure(T&P)gauge provided with the unit(reference FIG.'S 6-1 and 6-2). 1. Install the tee with the 3/4" fitting positioned 3/a"BUSHING horizontally towards the left side of the boiler. `�"IE`°PR°"°E°' (FIELDDPEOVIVIDED) 'R T&P GAUGE 2. Install the 3/4" elbow into the tee installed in Step 1, .Vf DIR#2000543955 00 with the fitting positioned vertically and on the top. 3. Install the relief valve into the 3/4" fitting of the elbow installed in Step 2. 4. Using field provided fittings, install a tee with a 3/8" Near boiler piping components fitting positioned horizontally towards the front of the boiler. For installations with top water connections, 1. Boiler system piping: locate the tee directly above the relief valve tee installed Boiler system piping MUST be sized per the pipe in Step 1. If top connections are not used, connect the requirements listed in Table 6B. Reducing the pipe size tee directly to the bottom outlet piping. can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system 5. Install the temperature and pressure (T & P) gauge performance. provided with the unit into the front of the fitting of the tee installed in Step 4. 2. Boiler circulating pump: 6. If top connections are not used,install a 1/4"bushing and A Grundfos UPS15 58FC pump for Models 56 156 the automatic air vent into the relief valve tee installed in and a Grundfos UPS26-99FC for Models 200 400 will be Step 1. provided by the factory as the boiler circulation pump. Knight Wall Hung Fire Tube boilers Figure 6-1 Top Connections Installation are capable of controlling a variable speed boiler TEE circulator. Variable speed circulators MUST be sized I3i LD PROVIDED) to meet the specified minimum flow requirements listed CLOSE NIPPLE P q (FIELD PROVIDED) H"BUSHING TEE with 3/4" ir (FIELD PROVIDED) in Table 6B on page 40 at full speed. FITTING O. �T&P GAUGE 3. Domestic hot water circulating pump: RELIEF VALVE "----141111° Field supplied. The pump MUST be sized to meet 3/4"ELBOW M' the specified minimum flow requirements listed in �. Table 6B. Consult the indirect water heater operating 1� guide to determine flow characteristics for the selected ! REMOVE FACTORY % ",40010'I` product used. PROVIDED CAP 4. Boiler isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a REINSTALL FACTORY restricted flow rate through the boil1ECEIVED R PROVIDED CAPON OUTLET INSTALL FIELD 10/09/18 PROVIDED DRAIN or DIR#200054395600 _ 7 — CAP ON INLET ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual 6 Hydronic piping 5. Check valves: Field supplied. Check valves are recommended for The Knight Wall Hung Fire Tube boiler is pre-configured installation as shown in FIG.'s 6-5 thru 6-14. Failure to to control the operation of the DHW pump with install check valves could result in a reverse flow Domestic Hot Water Prioritization programming. The condition during pump(s) off cycle. DHW programming is designed to control and balance the 6. Domestic indirect hot water isolation valves: space heating demand by switching between DHW and Field supplied. Full port ball valves are required. Failure space heating. to use full port ball valves could result in a restricted flow Lochinvar offers the Squire which is a series of indirect rate through the boiler. water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger. 7. Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is It is up to the installer to ensure the recommended when storing domestic hot water above CAUTION minimum system flow is not less than the 115°F. minimum boiler flow at any time. 8. Unions: .L WARNING The National Standard Plumbing Code, the Field supplied. Recommended for unit serviceability. National Plumbing Code of Canada and the 9. Temperature and pressure gauge: Uniform Plumbing Code limit the pressure Factory supplied. The temperature and pressure gauge of the heat transfer fluid to less than the is shipped loose. It is the responsibility of the contractor minimum working pressure of the potable to install the temperature and pressure gauge on the water system up to 30 psi maximum. Also, boiler water outlet. the heat transfer fluid must be water or other non-toxic fluid having a toxicity of 10. Pressure relief valve: Class 1, as listed in Clinical Toxicology of Factory supplied. The pressure relief valve is sized to Commercial Products,5th Edition. ASME specifications. 14. Water Meter: 11. Boiler purge valve: Field supplied. A water meter to monitor makeup water is Factory supplied. The boiler purge valve is used to recommended. Makeup water volume should not exceed remove entrapped air from the heat exchanger during 5%of total system per year. start-up. 15. Y-Strainer: 12. System temperature sensor: Field supplied. Install a Y-strainer or equivalent multi- Lochinvar supplies a system temperature sensor. purpose strainer just before the boiler pump at the inlet of The sensor is to be installed in the heating loop the heat exchanger. This item is used to remove system downstream from the boiler hot water piping and debris from older hydronic systems and to protect newer heating loop junction. Typically the sensor will be systems. located far enough downstream to sense system diluted water temperature. Circulator sizing 13. Indirect water heaters: The Knight Wall Hung Fire Tube boiler heat exchanger does The Knight Wall Hung Fire Tube have a pressure drop,which must be considered in your system boiler may be piped to an indirect design. Refer to the graph in FIG.6-2 for pressure drop through water heater to heat domestic hot water with the space heat the Knight Wall Hung Fire Tube boiler heat exchanger. transfer medium. As depicted on pages 41 through 49 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 RECEIVED water heater's temperature will be regulated by the Knight Wall Hung Fire Tube boiler's control. 10/09/18 38 ASPEN BUILDING DEPARTMENT aKNr HT° Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-3 Pressure Drop vs. Flow WHD36 ••61••WHD86 -et-WHlll -U-WH136 �wn20C ••01/.•'Ak1286 • III .WI-400 00 10 11 24 I 14 j .1 d i 21 1A ii I / tl a IA ii N 2 iJ = TO 0 to. • 11 i IS 1e•• / OA 1A OA Ol• OA• .0 4.0 O.O 8 7 7 lq 10 70 ?0 O S• 7 7 '''go 7 3 4 �0 O O 7 O �O 0 O 'O 'O �O SO 'r0 �O 'TO �0 944 94 g'0A g'0M .944 OBp� °944 B'00 Spy 9,0,4 9•°y7 9Ay, Spy 90y7 9p47 g'00 904, 90, 94, 94, badury Provided Circrlawrs Rec6wided Variable Speed Pumps(Fell Speed) -tiPS 14-71 FC ---UPS 13-38 FC -Gnocras UP 26-96 DVS ---TACO 0013-IFC - ■■■■®■C■■ Ell■■■■QC=■ 10 \10■■ ■■■■■■■■■■ . . MOM ■■l.■■■■0 11II ....a�� ........0 21 ` _ ....mow.. .......... II .�.�..-. - �, ■■■■ESii! 4iio■■■■■■ s I' t ...►\...... 12. .. •.....`..0 10 4 I i I`'- 'j ®l �■►■■ '; • . i : • : i INN �� - 00 ?0 90 SO g0 70 72 ` 74 70 78 �O �2 24 -'O 20 `20 O 7 4 6 O 7 7 7 7 7 0 7 0 .4 'IT .1 90 O'0 90 9,0 9i 09,, 090 0910 090 O9. °9.0 090 .09,0 09, °90 09,0 '090 '090 '090 °90 '090 QO 70 40 QO 00 QO 70 0000 QO M M M � T 0 M � � � M � 0 0 0 M M T � T ,, 80M 9p0 90T 90,, 940 90,,, 90,,? 00T 9p0 90M 90,,, Table 6A-Boiler Flow Requirements Temperature Rise and Head Loss Based on Boiler Output in Btu/hr Minimum Factory Maximum Minimum Flow Model Provided 20°F 25°F 35°F Pipe 0 Circulator Flow High Fire Low Fire 56 1" UPS 15-58 FC 3.0 gpm 0.1 ft/hd 4.2 gpm 0.2 ft/hd 5.2 gpm 0.3 ft/hd 17.0 gpm 3.1 ft/hd 2.1 gpm ' 1.0 gpm 86 I 1" UPS 15-58 FC 4.6 gpm 0.3 ft/hd 6.5 gpm 0.6 ft/hd 8.1 gpm 1.0 ft/hd 117.0 gpm 4.3 ft/hd 3.2 gpm 1.0 gpm 111 1" UPS 15-58 FC 6.0 gpm 0.5 ft/hd 8.4 gpm 1.1 ft/hd 10.5 gpm 1.7 ft/hd 17.0 gpm 4.4 ft/hd 4.2 gpm 1.0 gpm 156 1" UPS 15-58 FC 8.4 gpm 1.5 ft/hd 11.8 gpm 2.9 ft/hd 14.7 gpm 4.5 ft/hd 17.0 gpm 6.0 ft/hd 5.9 gpm 1.0 gpm 200 1-1/4" UPS 26-99 FC 10.9 gpm 0.4 ft/hd 15.2 gpm 0.7 ft/hd 19.0 gpm 1.1 ft/hd 27.0 gpm 2.3 ft/hd 7.6 gpm 1.5 gpm 286 _ 1-1/4" UPS 26-99 FC 15.5 gpm 0.8 ft/hd 21.7 gpm 1.6 ft/hd 27.0 gpm 2.4 ft/hd 27.0 gpm 2.4 ft/hd 10.8 gpm 1.5 gpm 400 1-1/2" UPS 26-99 FC 21.7 gpm 0.5 ft/hd 30.4 gpm 0.9 ft/hd 38.0 gpm 1.4 ft/hd 38.0 gpm 1.4 ft/hd 15.2 gpm 4.5 gpm NOTICE Pump sizing and flow requirements are based on 20 feet of piping,4 - 90° elbows, and 2 - fully ported ball valves.NOTICE Reference Table 6B for pump speed selection. RECEIVED 10/09/18 RiSeillm BUILDING DEPARTMENT KtvAgtiT` Installation & Operation Manual 6 Hydronic piping Table 6B Pump Speed Selection Chart Model Speed TACO Bell & Gossett Armstrong High 005F,007F,008F,0010E-1FC,00R-MSF1-IFC,0015 NRF-22,LR-20WR Astro 0,Astro 30-(3),Astro 50-3,Astro 230CI,Compass UPS 15-58 FC Medium 005F-(IFC),007F-(IFC),008F-(IFC),0010E-IFGOOR NRF9F/LW,NRF-25-SP-1&2 Astro 25,Astro 30-3 IFC,00R-MSF1-IFC Low 005F-(IFC),006-(IFC),00R-MSF1-IFC -- Astro 20 High 0013(B)-IFC NRF-36 SP-2,NRF-45 SP-2,H-41(B) E7(B),Astro 50(B)-(3) UPS 26-99 FC Medium 0011(B)-(IFC),0014(B)-(IFC) Series 100,PL-30,PR,NRF-36 SP-1,NRF-45 Sp-1 Astro 50(B),H41 Low LR-15BWR Astro 30(B) High 1400-45(B),1400-50(B),2400-45 PL-55(B) E15(B) UPS 26-150 F Medium 0011(B,SF),0013(B,SF),1400-20(B),1400-30(B), PL-36(B) E8(B),E9(B),E11(B),E13(B) 1400-40(B),2400-30 Low 2400-20,2400-40 NRF(NBF)-36 Sp-2&3 E7(B),E10(B) Variable speed pump setup SMART SYSTEM / Multi-temperature loop Before operation,ensure the following: control option - Pump is set for an input signal of 0 10Vdc by the dip The Knight Wall Hung Fire Tube boiler is capable of producing switches on the pump control up to three (3) set point temperatures to meet different space - Pump is set for external signal control(if applicable) heating demands. When using more than one temperature - Pump is set for linear output(if applicable) demand it is necessary to protect the lower temperature - If pump does not come equipped with a 0 10 Vdc input loop from overheating. To help aid with this protection, option, an optional module will be required from the Lochinvar offers the Multi-Temperature Loop Control Board vendor Kit(#100167843). Figure 6-4 Supply Return Locations r WATER OUTLET (SYSTEM SUPPLY) WATER INLET (SYSTEM RETURN) I , DIR#200052136400 RE It CEIVE D 10/09/18 - 40 � ASPEN BUILDING DEPARTMENT KNu !-T' Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-5 Single Boiler- Single Temperature with Zone Valves - DHW Priority I IIIIIIIIIIIIIIIIIIIIIIII ZONE#1 IIIIIIIIIIIIIIIIIIIIIIII PRESSURE PRESSURE I REDUCING VALVE GAUGE I ZONE#2 ZONE#3 ZONE#4 BACKFLOW_ 1----1 1----1 1----1 PREVENTER L - - J L____Li L____Li L___-i WATER METER ZONE VALVES (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSORa a z DIFFERENTIAL PRESSURE BYPASS VALVE(IF USED) AIR SEPARATORk \ � t C t C � C ti I ' SYSTEM CIRCULATOR EXPANSIONLC) LCI ' LC) I I TANK I I - G= ' _IW MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE LC) I NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12"APART (TYPICAL) Y-STRAINER HOT WATER (TYPICAL) DRAIN POINT OUT 4111 (TYPICAL) " FLOW CHECK DOMESTIC ANTI-SCALD VALVE HOT WATER MIXING VALVE In CIRCULATOR BOILER SCOLD CIRCULATOR A a WATER I.' IN f FLOW CHECK • a CI VALVE - PRESSURE RELIEF VALVE - �/ G TEMPERATURE/ UNION J PRESSURE (TYPICAL) GAUGE arr till m I DRAIN DIR#2000543518 00 NOTICE Please note that these illustrations are meant to show system piping concept only, thEIVEn responsible for all equipment and detailing required by local codes. ,, }) 10/09/18 i 4 ASPEN BUILDING DEPARTMENT KN!G!-T Installation & Operation Manual 6 Hydronic piping Figure 6-6 Single Boiler- Single Temperature Zoned with Circulators -DHW Priority I IIIIIIIIIIIIIIIIIIIIIIII ZONE 1 IIIIIIIIIIIIIIIIIIIIIIII PRESSURE PRESSURE I REDUCING VALVE GAUGE I I ZONE 2 ZONE 3 ZONE 4 r----I r----! r----I BACKFLOW L - - J L____Li I __J-i I ___I PREVENTER FLOW CHECK WATER VALVE METERRI IA (TYPICAL) MAKE UP WATER * * 1 SYSTEM SUPPLY SENSOR el t t 1 t ZONE CIRCULATORS (TYPICAL) AIR SEPARATOR- / EXPANSION LC) C C C J I , TANK 1 1 , E.Ci_4MAY SUBSTITUTE LOW LOSS HEADER' BALL VALVE (TYPICAL) NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART HOT DRAIN POINT WATER (TYPICAL)--....„. TYPICAL) Y-STRAINER OUT 0 (TYPICAL) DOMESTIC ANTI-SCALD 4 HOT WATER MIXING VALVE BOILER f CIRCULATOR CIRCULATOR I ® COLD '' di � �WATER IVALVE • PRESSURE RELIEF VALVE / TEMPERATURE/ UNION J PRESSURE (TYPICAL) GAUGE I. to INDIRECT DHW TANK DRAIN DIR#2000543519 00 NOTICE Please note that these illustrations are meant to show system piping concept only,the installer is onsibl for all equipment and detailing required by local codes. REC.; 10/09/18 42 ASPEN BUILDING DEPARTMENT yKmiHT° Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-7 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority Recommended Water Pipe Diameter-Cascade Model 1 2 3 4 5 6 7 8 Unit Units Units Units Units Units Units Units 56 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 86 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 111 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 156 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 200 1 1/4" 1 1/2" 2" 2 1/2".2 1/2" 3" 3" 3 1/2" 286 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3 1/2" 1400 1 1/2" 2" 2 1/2" 3" 3" 3 1/2" 4" 4" IIIIIIIIIIIIIIIIIIIIIIII I ZONE 1 I IIIIIIIIIIIIIIIIIIIIIIII I PRESSURE REDUCING VALVE PRESSURE GAUGE 1 ZONE 2 ZONE 3 ZONE 4 WATER BACKFLOW L _ _I __ __ __ PREVENTER METER 8 FLOW CHECK MAKE UP SYSTEM SUPPLY VALVE (TYPICAL) WATER SENSOR AIR SEPARATOR i ZONE CIRCULATORS (TYPICAL) EXPANSION I TANK 1 I i BALL VALVE MAY SUBSTITUTE LOW LOSS HEADER (TYPICAL) • • DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART (TYPICAL) j V, ANTI-SCALD Y-STRAINER MIXING VALVE HOT ■: " (TYPICAL) WATER DOMESTIC OUT I �� HOT WATER BOILER CIRCULATOR COLD CIRCULATOR 6 WATER i ` TEMPERATURE/ - 0 0 0 0 PRESSURE UNION - GAUGE UNION -11 PRESSURE RELIEF VALVE k.17 a, u$ BOILER 2 BOILER 1 INDIRECT DRAIN (MEMBER 1) DRAIN (LEADER) DHW TANK DIR#2000543508 00 NOTICE Required pipe diameter is based on maximum flow(17 gpm for Models 56- 156,27 gpm for Models 200-286 and 38 gpm for Model 400)through all units in Cascade. It is the responsibility of the installer to maintain flow rates based on system piping requirements. y piping p y ������� NOTICE Please note that these illustrations are meant to show systemconcept only,the installe for all equipment and detailing required by local codes. 10/09/18 om 4R33 SPEN BUILDING DEPARTMENT KNIP.HT Installation & Operation Manual 6 Hydronic piping Figure 6-8 Single Boiler- Multiple Temperatures - DHW Priority PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW REDUCING VALVE LOOPO_ #1 LOOPO_ #2 LOOP#3 PREVENTER r� —I MIXING VALVES PRESSURE i - 11 (TYPICAL) WATER S< GAUGE METER log 0 ■i CIO I. - SYSTEM4 MAKE SUPPLY UP SENSOR WATER AIR SEPARATO,, T EXPANSION 3...- TANK MAY SUBSTITUTE WIRES TO LOW LOSS HEADER c_S LOOP SENSORS IA —.1-1 NOT TO EXCEED 4 PIPE DIA 120VAC TO PUMPS <_) BALL VALVE OR MAX.OF 12"APART MULTI-TEMP (TYPICAL) Der Y-STRAINER 24V SIGNAL TO�<D LOOP CONTROL (TYPICAL) MIXING VALVES BOILER SHIELDED CABLE TO DRAIN POINT CIRCULATOR BOILER CONTROL � (TYPICAL) _) DOMESTIC HOT WATER FLOW CHECK CIRCULATOR ® VALVE HOT ANTI-SCALD WATER r OUT MIXING VALVE 41) -COLD -� WATER Ll cl IN iPRESSURE RELIEF VALVE I _■A +� 09\\ BOILER N UNION (TYPICAL) DRAIN TEMPERATURE/ PRESSURE GAUGE DIR#2000543515 00 CAUTION 1 Mixing valves are required for the protection of low temperature loops. D NOTICE Please note that these illustrations are meant to show system piping concept only,the in1REC !slbl for all equipment and detailing required by local codes. 10/0 9/18 44 ASPEN BUILDING DEPARTMENT KN P:::- Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-9 Multiple Boilers -Multiple Temperatures -DHW Piped as a Zone Recommended Water Pipe Diameter-Cascade Model 1 2 3 4 5 6 7 8 Unit Units Units Units Units Units Units Units 56 1" _ 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 86 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 111 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 156 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 200 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3 1/2" 286 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3 1/2" 400 1 1/2" 2" 2 1/2" 3" 3" 3 1/2" 4" 4" PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW REDUCING VALVE LOOP#1 LOOP#2 LOOP#3 PREVENTER n--y r— I r- J WATER PRESSURE _- GAUGE METER SYSTEM MIXING VALVES MAKE SUPPLY UP SENSOR WATER AIR SEPARATOR A Ill- f'it- 1 I `V TA�EXPANNKON SI lAY ` 1 1—LOW SLOSS HEADER BALL VALVEI'� q NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART i (TYPICAL) LC) DRAIN ICAPOLINT DOMESTIC TYP HOT WATER ( ) ! '.' !figs. CIRCULATOR FLOW CHECK LLfn o To t i VALVE HOT JI I.I ANTI-SCALD WATER MIXING VALVE OUT 1 ICI a u u 0j �O ki I`I i•i -COLD BOILER ` t ~ WATER CIRCULATOR MI IN Y-STRAINER y ■ (TYPICAL) l a Iii TEMPERATURE/ /_...0 41 PRESSURE UNION GAUGE _ III; UNION PRESSURE RELIEF VALVE 1 11-✓F i1 !Fl• INDIRECT ai DHW TANK I BOILER 2 f BOILER 1 DRAIN (MEMBER 1) DRAIN— (LEADER) DIR#2000543506 00 NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone. CAUTION Mixing valves are required for the protection of low temperature loops. NOTICE Required pipe diameter is based on maximum flow(17 gpm for Models 56- 156,27 gpm for �\��� and 38 gpm for Model 400)through all units in Cascade. It is the responsibility of the insta y flow rates based on system piping requirements. //n(�t�Q(� NOTICE Please note that these illustrations are meant to show system piping concept only,the installer is relp s35 /18 for all equipment and detailing required by local codes. — 44SIRN BUILDING DEPARTMENT NPGHT. Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-11 Multiple Boilers- Single Temperature Zoned with Valves Recommended Water Pipe Diameter-Cascade Model 1 2 3 4 5 6 7 8 Unit Units Units Units Units Units Units Units 56 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 86 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 111 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 156 1" 1 1/4" 1 1/2" 1 1/2" 2" 2" 2 1/2" 2 1/2" 200 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3 1/2" 286 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3" 3 1/2" 400 1 1/2" 2" 2 1/2" 3" 3" 3 1/2" 4" 4" r IIIIIIIIIIIIIIIIIIIIIIII L IIIIIIIIIIIIIIIIIIIIIIII ZONE 1I 1 PRESSURE BACKFLOW REDUCING I I ZONE 2 ZONE 3 ZONE 4 PREVENTER VALVE PRESSURE WATER GAUGE L J C__1J2 1� E-- BALL VALVE ZONE VALVES METER (TYPICAL) (TYPICAL) MAKE UP WATER BU Ill Iil f DIFFERENTIAL PRESSURE SYSTEM SUPPLY A / (RECOMMENDED) SENSOR AIR SEPARATOR r P C C 110 ,----1---, SYSTEM I EXPANSION_ CIRCULATOR 'I I TANK i ii) it 1! I MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX.OF 12"APART (TYPICAL) LC Im, vim ANTI-SCALD Y-STRAINER MIXING VALVE ;'(TYPICAL) -\iHOT U UHOT WAT R t WATER BOILER CIRCULATOR OUT CIRCULATOR SCOLD of PRESSURE ® ® WATER 4ELIEFVALVE IN 4 i f d ICA 1 21, di 0 . BOILER 2 15 0 I BOILER 1 07 (MEMBER 1) , i Q W . (LEADER) INDIDHW TECT ANK TEMPERATURE/ DRAIN PRESSURE UNION GAUGE (TYPICAL) DIR#2000543511 00 NOTICE Required pipe diameter is based on maximum flow(17 gpm for Models 56- 156,27 gpm for Models 200-286 and 38 gpm on Model 400) through all units in Cascade. It is the responsibility of the instalRIvE ID flow rates based on system piping requirements. k!CI NOTICE Please note that these illustrations are meant to show system piping concept only,the installer is respp7ible/18 for all equipment and detailing required by local codes. 11 V VV``JJ — 46 — ASPEN BUILDING DEPARTMENT Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-13 Single Boiler- Full Flow- Single Temperature - Zoned with Zone Valves - DHW Priority 1 IIIIIIIIIIIIIIIIIIIIIIII 1 IIIIIIIIIIIIIIIIIIIIIIII ZONE 1 1 L -I I PRESSURE PRESSURE I 1 REDUCING VALVE GAUGE I ZONE 2 ZONE 3 ZONE 4 I----I I---I I----I BACKFLOW L - - _I L____Li Li___+i L______i WATER PREVENTER METER ZONE VALVES 7(TYPICAL) MAKE UP SYSTEM SUPPLY i DIFFERENTIAL WATER SENSOR ,I� PRESSURE BYPASS VALVE AIR SEPARATOR (RECOMMENDED) ))1: C ( ( L I EX TANK ANSION C C IC C I L i i i BALL VALVE (TYPICAL) DRAIN POINT--t- (TYPICAL) Y-STRAINER HOT (TYPICAL) DOMESTIC WATER HOT WATER OUT FLOW CHECK CIRCULATOR VALVE ANTI-SCALD BOILER MIXING VALVE CIRCULATOR Iy -COLD •i C1 V WATER IN PRESSURE RELIEF VALVE I. 0.A a.r mal 1 o 0 ) UNION) + DRAIN (TYPICAL) TEMPERATURE PRESSURE GAUGE DIR#2000543514 00 NOTICE 1 Please note that these illustrations are meant to show system piping concept only,the installer is responsible for all equipment and detailing required by local codes.NOTICE It is the responsibility of the installer to ensure that the minimum flow requirements of REic 'aEiLVaE ID all times during boiler operation. If the minimum flow requirements cannot be met at any timethe . 9�18 be hydraulically separated from the system. SPE A N BUILDING DEPARTMENT tKN1g.tT` Installation & Operation Manual 6 Hydronic piping Figure 6-14 Single Boiler- Full Flow- Single Temperature Zoned with Valves- DHW Piped as a Zone 1 IIIIIIIIIIIIIIIIIIIIIIII ZONE IIIIIIIIIIIIIIIIIIIIIIII PRESSURE I REDUCING VALVE PRESSURE— ZONE 2 ZONE 3 ZONE 4 GAUG I ---1 ---1 ---1 BACKFLOW L —__I L___+i LT__ti L___J PREVENTER II WATER METER ZONE VALVES (TYPICAL) MAKE WATER SYSTEM SUPPLY Ea ,i; f� SENSOR LJ� DIFFERENTIAL PRESSURE AIR SEPARATOR iliBYPASS VALVE (RECOMMENDED) C C C JIC ICI IC LO I EXPANSION TANK I L J B VV (TYPICAL)ALLALE • HOT WATER DRAIN POINT—7- Y-STRAINER OUT (TYPICAL) (TYPICAL) AN MIXING VALVE BOILER CIRCULATOR —COLD WATER FLOW CHECK IN VALVE cl ,�a PRESSURE d RELIEF VALVE id 0 J UNION DRAIN (TYPICAL) TEMPERATURE/ PRESSURE GAUGE DIR#2000543513 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. NOTICE It is the responsibility of the installer to ensure that the minimum flow requirements of the boiler are met at all times during boiler operation. If the minimum flow requirements cannot be met at any • l • 11 bE D must be hydraulically separated from the system. NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone. 10/09/18 48 ASPEN BUILDING DEPARTMENT KN! HT Installation & Operation Manual 6 Hydronic piping (continued) Figure 6-15 Single Boiler- Full Flow- Single Temperature Zoned with Circulators - DHW Piped as a Zone I IIIIIIIIIIIIIIIIIIIIIIII ZONE 1 I IIIIIIIIIIIIIIIIIIIIIIII 1 I PRESSURE PRESSURE I I REDUCING VALVE GAUGE I I ZONE 2 ZONE 3 ZONE 4 BACKFLOW L — _ 1 ' __J—i ' __J—i ' ___I PREVENTER FLOW CHECK WATER VALVE METER 0 (TYPICAL) MAKE UP ' WATER SYSTEM SUPPLY SENSOR ZONE CIRCULATORS AIR SEPARATOR ■ 4 I f 4 (TYPICAL) 'II J LO LO LO L EXPANSION ) TANK 11 a Y-STRAINER JJ DOMESTIC HOT (TYPICAL) �■_ p� HOT WATER WATER I[J CIRCULATOR OUT DRAIN POINT > I (TYPICAL) BALL VALVE ANTI-SCALD (TYPICAL) MIXING VALVE • COLD ` to eN WATER IN 45 TEMPERATURE/ C3 0 / PRESSURE PRESSURE GAUGE / RELIEF VALVE — UNION J (TYPICAL) -s L I ,. ,...A ciii6 INDIRECT BOILER DHW TANK DRAIN DIR#2000543512 00 RECEIVED 10/09/18 i 4 AS ?_N BUILDING DEPARTMENT 1K1!GHT` Installation & Operation Manual 7 Gas connections Connecting gas supply piping 3. Purge all air from the gas supply piping. 1. Reference FIG.'s 7-1 and 7-2 to pipe gas to the boiler. 4. Before placing the boiler in operation, check the boiler a. Install a field supplied sediment trap / drip leg and its gas connection for leaks. upstream of the boiler gas controls. a. The appliance must be disconnected from the gas b. Install a ground joint union for servicing, when supply piping system during any pressure testing of required. that system at a test pressure in excess of 1/2 PSIG c. Install a manual shutoff valve in the gas (3.5 kPa). supply piping outside the boiler jacket when b. The appliance must be isolated from the gas supply required by local codes or utility requirements. piping system by closing a manual shutoff valve d. In Canada - When using manual main shutoff duringanypressure testingof the supplyi valves,it must be identified by the installer. gas piping in g system at test pressures equal to or less than 1/2 PSIG (3.5 kPa). Figure 7-1 Union Connection and Gas Supply Piping 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. 5. 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. A WARNING) Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. UNION as WARNING Knight Wall Hung Fire Tube boilers MANUAL are typically shipped ready to fire on GAS SUPPLY SHUTOFF natural gas. Check boiler rating plate to VALVE determine which fuel the boiler is set for. DRIP DIR#2000543315 00 If set to natural gas, it may be converted to LP by installing an LP venturi and any LEG additional components provided in the LP conversion kit (Models WH56 - WH286 2. Support piping with hangers, not by the boiler or its only) or by installing a propane orifice accessories. (Model WH400 only) (see pages 12 and WARNING The gas valve and blower will not support 13). In order to operate on LP gas, these the weight of the piping. Do not attempt components MUST BE installed. Failure to support the weight of the piping with to comply could result in severe personal the boiler or its accessories. Failure to injury, death, or substantial property comply could result in severe personal damage. injury, death, or substantial property damage. RECEIVED 10/09/18 50 ASPEN BUILDING DEPARTMENT I HT Installation & Operation Manual 7 Gas connections (continued) WARNING Use two wrenches when tightening gas Propane Gas: piping at boiler (FIG. 7-2), using one wrench to prevent the boiler gas line Knight Wall Hung Fire Tube boilers connection from turning. Failure to WARNING are typically shipped ready to fire on support the boiler gas connection pipe to natural gas. Check boiler rating plate to prevent it from turning could damage gas determine which fuel the boiler is set for. line components. If set to natural gas, it may be converted to LP by installing an LP venturi and any Figure 7-2 Inlet Pipe with Backup Wrench additional components provided in the LP conversion kit (Models WH56 - WH286 only) or by installing a propane orifice (Model WH400 only) (see pages 12 and Zagawur 13). In order to operate on LP gas, these ®� components MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage. Pipe sizing for propane gas Iom` 1. Contactgas supplier to size pipes,tanks, and 100%lockup mem I PP P P gas pressure regulator. • . 3 v Propane Supply Pressure Requirements DIR#2000543316 00 USE BACKUP WRENCH 1. Adjust propane supply regulator provided by the gas TO PREVENT PIPE FROM ROTATING supplier for 14 inches w.c.maximum pressure. 2. Pressure required at gas valve inlet pressure port: NOTICE Maximum inlet gas pressure must not . Maximum 14 inches w.c. with no flow (lockup) or with exceed the value specified. Minimum boiler on. value listed is for the purposes of input • Minimum 8 inches w.c. with gas flowing (verify during adjustment. boiler startup). Natural gas: A WARNING Ensure that the high gas pressure regulator Pipe sizing for natural gas - is at least 6 - 10 feet upstream of the 1. Refer to Table 7A for pipe length and diameter. Based on appliance. 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 1. Pressure required at the gas valve inlet pressure port: • Maximum 14 inches w.c. with no flow (lockup) or with boiler on. • Minimum 4 inches w.c. with gas flowing (verify during boiler startup). 2. Install 100%lockup gas pressure regulator in supply line if RECEIVED inlet pressure can exceed 14 inches w.c.at any time. Adjust 10/0 9/18 lockup regulator for 14 inches w.c.maximum. ASPEN BUILDING DEPARTMENT NIGHT. Installation & Operation Manual 7 Gas connections 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 Length of Pipe in Straight Feet Size (Inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A 3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A 1 514 353 284 243 215 195 179 167 I 157 148 131 I 119 109 102 1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209 1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313 2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602 21/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960 3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700 4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460 Knight Wall Hung Fire Tube boilers are typically shipped ready to fire on natural gas. Check boiler rating WARNINGI 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 and any additional components provided in the LP conversion kit (Models WH56 - WH286 only) or by installing a propane orifice (Model WH400 only) (see pages 12 and 13). In order to operate on LP gas,these components MUST BE installed. Failure to comply could result in severe personal injury,death, or substantial property damage. Check inlet gas supply 3. Loosen the set screw one (1) full turn from inside the NOTICE CSA or UL listed flexible gas connections pressure tap on top of the gas valve. Place the tubing of are acceptable, but you must exercise the manometer over the tap once the set screw is caution to ensure that the line has adequate loosened as shown in FIG.7-3. capacity to allow your boiler to fire at full 4. Slowly turn on the gas supply at the field installed rate. Consult with local codes for proper manual gas valve. installation or service procedures. 5. Turn the power switch to the"ON"position. WARNING, DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct 6. Locate the pinhole button above the RESET button on outlet pressure. This setting is suitable the display board (FIG. 11-1 on page 75). Insert a thin for natural gas and propane, requiring wire (such as a paper clip) into the hole and press the no field adjustment. Attempting to button once and hold for 5 seconds to place the boiler alter the gas valve outlet pressure could into Service Mode. In Service Mode the boiler will fire at result in damage to the valve, causing ignition speed and will then modulate up to full fire. potential severe personal injury, death,or 7. Observe the gas supply pressure as the burner fires at substantial property damage. 100% of rated input. Percent of burner input will be The gas piping must be sized for the proper flow and length displayed on the control panel. of pipe,to avoid excessive pressure drop. Both the gas meter 8. Ensure inlet pressure is within specified range. and the gas regulator must be properly sized for the total gas Minimum and maximum gas supply pressures are load. specified in this section of the manual. If you experience a pressure drop greater than 1 inch w.c., 9. If gas supply pressure is within normal range and no the meter, regulator, or gas line is undersized or in need of adjustments are needed,proceed on to Step 11. service. Perform the steps below when checking inlet gas 10. If the gas pressure is out of range,contact the gas utility, supply: gas supplier, qualified installer or sery ��r 1. Turn the main power switch to the"OFF"position. determine the necessary steps to proviElVED 2. Shut off gas supply at the manual gas valve in the gas pressure to the control. piping to the appliance. 11. Place the boiler back into normal operation byl3R /iPfg9/'18 � STOP. 52 ASPEN BUILDING DEPARTMENT IKtn HT Installation & Operation Manual 7 Gas connections (continued) WARNING When re-tightening the set screw,be sure Gas Pressure to tighten securely to prevent gas leaks. The gas pressure must remain between 4 inches w.c.(natural), Do not check for gas leaks with an open 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and flame -- use the bubble test. Failure to LP) maximum during stand-by (static) mode and while in use the bubble test or check for gas leaks operating (dynamic) mode. If an in-line regulator is used, can cause severe personal injury,death,or it must be a minimum of 10 feet from the Knight Wall substantial property damage. Hung Fire Tube boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. 12. Turn the power switch to the"OFF"position. Failure to properly purge the lines or improper line sizing, 13. Shut off the gas supply at the manual gas valve in the gas will result in ignition failure. piping to the appliance. The problem is especially noticeable in NEW LP installations 14. Remove the manometer from the pressure tap on top of and also in empty tank situations. This can also occur when the gas valve. Re-tighten the set screw inside the pressure a utility company shuts off service to an area to provide tap. maintenance to their lines. 15. Turn on the gas supply at the manual gas valve. Gas valve replacement 16. Turn the power switch to the"ON"position. The gas valve MUST NOT be replaced with a conventional 17. Check burner performance by cycling the system while gas valve under any circumstances. you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system p WARNING]Failure to follow all precautions could off and allow burner to cool,then cycle burner again to result in fire,explosion,or death! ensure proper ignition and flame characteristics. Figure 7-3 Inlet Gas Supply Check- Models WH56 - 286 LOOSEN THE SET SCREW ONE(1)FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP si Or" i DETAIL A DIR#2000507872 00 Figure 7-4 Inlet Gas Supply Check-Model WH400 LOOSEN THE SET SCREW ONE(1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP I \\ '1 C' -y r rLJJ Vlijr 1/ --- :"111111 I 11111 RECEIVED 0 10/09/18 jo 53 NW SIR M200059A53400 AS FM BUILDING DEPARTMENT yKN� T' Installation & Operation Manual 8 Field wiring WARNINal ELECTRICAL SHOCK HAZARD-For your Installation must comply with: safety,turn off electrical power supply before making any electrical connections to avoid 1. National Electrical Code and any other national, state, possible electric shock hazard. Failure to do provincial,or local codes,or regulations. so can cause severe personal injury or death. Wiring must be N.E.C.Class 1. 2. In Canada,CSA C22.1 Canadian Electrical Code Part 1, NOTICE and any local codes. If original wiring as supplied with boiler must be replaced, use only type 105°C wire Line voltage connections or equivalent. Boiler must be electrically grounded as 1. Connect 120 VAC power wiring to the line voltage required by National Electrical Code ANSI/ terminal strip in the junction box,as shown in FIG.8-1. NFPA 70-latest edition. 2. Provide and install a fused disconnect or service switch NOTICE This boiler is equipped with a feature that (15 amp recommended) as required by the code (see saves energy by reducing the boiler water FIG.8-1). temperature as the heating load decreases. This feature is equipped with an override, 3. The boiler pump is shipped loose. Wire the boiler which is provided primarily to permit the use pump as shown in FIG. 8-1. of an external energy management system that serves the same function. This override 4. When connecting a domestic hot water(DHW)pump, MUST NOT be used unless at least one of the connect the wiring to the line voltage terminal strip as following conditions is true: shown in FIG.8-1. 1. An external energy management 5. To activate a system pump,wire as shown in FIG. 8-1. system is installed that reduces the If the motor is larger than 1/8 hp or 1.8 amps,you must boiler water temperature as the heating isolate with a relay. load decreases. 2. This boiler is not used for any space Low voltage connections heating. 3. This boiler's input is 300,000 Btu/ 1. Route all low voltage wires through the openings on the hr or greater or is part of a modular or bottom, as shown in FIG.8-2. multiple boiler system having a total 2. Connect low voltage wiring to low voltage connection input of 300,000 Btuh/hr or greater. board as shown in FIG. 8-3 on page 58 of this manual 4. This boiler is equipped with a tankless coil. and the boiler wiring diagram. CAUTION, Label all wires prior to disconnection when Figure 8-2 Routing Field Wiring servicing controls. Wiring errors can cause improper and dangerous operation. Figure 8-1 Line Voltage Field Wiring Connections ' rill 0 0 � �-y LOW VOLTAGE oHwPOUaoi OUTPUTS M SUPPLY • i` CONNECTION BOARD 111 C+'�c`c`````©+ • `iliATERWM4 LOW VOLTAGE �'c�;•' WIRING OPENINGS 0 0 `. HIGH VOLTAGE '►etn JUNCTION BOX MI 00, HIGH VOLTAGE DIRm000saaaiaoo WIRING OPENINGS W W W BK G W RECEIVED LINE GROUND NEUTRAL DOMESTIC BOILER SYSTEM 120V SUPPLY 10/0 9/18 HOT WATER PUMP PUMP PUMP SERVICE SWITCH 54 — ASPEN BUILDING DEPARTMENT KNIP.HT Installation & Operation Manual 8 Field wiring (continued) Thermostat Louver relay 1. Connect the room thermostats or end switches (isolated If louvers need to operate when the boiler fires, they can be contact only) to Heat/Loop Demand 1,2,or 3,as shown controlled by this output. Connect these terminals to a 24 VAC in FIG. 8-3. relay coil,which is wired to operate the louvers(FIG.8-3). 2. Install the thermostat on the inside wall away from Louver proving switch influences of drafts, hot or cold water pipes, lighting When the operation of the louvers needs to be verified before fixtures,television,sunlight,or fireplaces. the boiler fires, remove the jumper wire from these terminals 3. Thermostat anticipator(if applicable): and connect them to the normally open contacts on its proving a. If connected directly to boiler,set for 0.1 amps. switch(FIG.8-3). b. If connected to relays or other devices, set to match High gas pressure switch total electrical power requirements of connected devices. See device manufacturers' specifications If a switch is provided to detect excessive gas pressure,remove and thermostat instructions for details. the jumper wire from the terminals on the connection board, Outdoor temperature sensor and then connect them to its normally closed contacts (FIG. In the absence of an external energy management system,an 8-3). outdoor temperature sensor must be used for all models with Low gas pressure switch inputs less than 300,000 Btu/hr. 1. If a switch is provided to detect low gas pressure, remove 1. Mount the sensor on an exterior wall, shielded from the jumper wire from the terminals on the connection direct sunlight or flow of heat or cooling from other board and connect them to its normally open contacts(FIG. sources. 8-3) 2. Route sensor wires through a knockout at the rear of the 2. If both a high and low gas pressure switch is used,connect boiler(see FIG.8-2). their respective contacts in series,and connect them to the 3. Connect outdoor temperature sensor (FIG. 8-3) to the terminals on the connection board(FIG.8-3). outdoor sensor terminals on the connection board to Variable speed system pump enable outdoor reset operation of the Knight Wall Hung Fire Tube boiler. If a variable speed pump is used in the primary loop, and a DHW thermostat 0-10y signal is available from the pump speed control, this signal can be used by the SMART SYSTEM control to anticipate Connect storage indirect water heater (DHW) thermostat changes in the building heat load. By connecting this 0 - 10V (FIG. 8-3) to the DHW thermostat terminals on the signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or connection board. If a tank sensor is connected (see DHW cascade) can modulate up and down as the primary flow Tank Sensor below)the tank thermostat is ignored. increases and decreases. DHW tank sensor Boiler pump speed output 1. By installing a tank sensor,the SMART SYSTEM control This 0- 10V output is available to control the speed of a variable can perform the tank thermostat function. The SMART speed boiler pump. The SMART SYSTEM control will vary SYSTEM control automatically detects the presence of the speed of this pump in order to maintain a minimum AT this sensor and generates a DHW call for heat when across the heat exchanger,as well as prevent high limit lockouts the tank temperature drops 6°F (3°C) below the tank when the flow in the primary loop is extremely low.Note: This set point and finishes the call for heat when the tank feature is to be used with Primary Secondary Piping systems temperature reaches the tank set point. only. A system supply sensor must be installed. Connect this 2. The tank sensor included with the Lochinvar Squire output to the 0- 10V input on the boiler pump speed control. Indirect DHW tank (#100170544) is the only sensor Rate output suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals This output provides a 0- 10V signal that is proportional to the on the Low Voltage Connection Board(FIG. 8-3). firing rate of the boiler. This may be used by a BMS system to monitor the actual rate of the boiler. WARNIN1 Failure to use the correct sensor may result in the tank temperature being either above Mod Bus/BACnet or below the set point. When the optional ModBus or BACnet interface module is 3. If the #100170544 is not compatible with the indirect installed,the RS-485 cable is connected to these terminals. Use tank, a tank thermostat can be used to control the shielded, 2-wire twisted pair cable. If des l boiler. The tank thermostat should be installed per be connected to ground by installing a ju e e the manufacturers instructions and wired to the DHW terminals 1 and 3 on connector X5 on the optiolB,u1/8 Thermostat terminals on the Low Voltage Connection BACnet interface module. , 1 Board. TSP#NI BUILDING DEPARTMENT yKN!P!-Tr Installation & Operation Manual 8 Field wiring Flow switch Runtime contacts 1. A flow switch is used to guarantee flow through the The SMART SYSTEM control closes a set of dry contacts boiler before allowing it to fire. The flow switch must be whenever the burner is running. This is typically used by installed at the boiler outlet. Building Management Systems to verify that the boiler is 2. Remove the jumper wire from these terminals, and responding to a call for heat. connect these terminals to the normally open contacts on the flow switch(FIG.8-3). Alarm contacts System supply sensor The SMART SYSTEM control closes another set of contacts 1. By installing the system supply sensor into the supply whenever the boiler is locked out or the power is turned off. of the primary loop, the temperature of the primary This can be used to turn on an alarm, or signal a Building supply can be controlled. The SMART SYSTEM control Management System that the boiler is down. automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system DHW recirculation sensor supply temperature to the set point (if the outlet sensor The Knight Wall Hung Fire Tube boiler is able to control control is currently selected). If it is desired to control the a DHW recirculation pump. To operate this feature, a system return temperature, then program the SMART #100170581 temperature sensor must be installed in the SYSTEM control to use the inlet sensor as the controlling circulation loop return. Connect this sensor to the DHW sensor. See the Knight Wall Hung Fire Tube Boiler recirculation sensor terminals on the Low Voltage Connection Service Manual for instructions on how to use the inlet Board. sensor as the controlling sensor. When the inlet sensor is programmed as the controlling sensor, it is vital that the SYSTEM SUPPLY sensor be installed. DO NOT DHW recirculation pump INSTALL THE SYSTEM SUPPLY SENSOR INTO THE When the DHW recirculation sensor (as described above) is SYSTEM RETURN. connected,the Knight Wall Hung Fire Tube SMART SYSTEM 2. The#100170581 sensor provided with the boiler must be control will output 24 VAC to control a DHW recirculation used for the system sensor. pump relay (field supplied). Connect the coil of the DHW 3. Connect these terminals to the system supply sensor recirculation pump relay to the 24 VAC recirculation pump (FIG.8-3). relay coil terminals on the Low Voltage Connection Board. Boiler management system Wiring of the cascade The United States Energy Policy and Conservation Act When wiring the boilers for Cascade operation, select one requires residential heating boilers with inputs less than boiler as the Leader boiler. The remaining boilers will be 300,000 Btu/hr be equipped with a control that automatically designated as Members. See page 65 "Configuration of the adjusts boiler water temperature in relation to heat demand. Cascade"for a detailed explanation of this procedure. An external control may be connected to control the firing rate or the set point of the boiler provided that either an Connect the system supply sensor and outdoor air sensor (if external energy management system is installed that reduces used) to the Leader boiler. For the Cascade system to work the boiler water temperature as the heating load decreases, properly the system supply sensor must be installed. The the boiler is not used for any space heating, or the boiler is location of the system supply sensor should be downstream part of a modular or multiple boiler system having a total of the boiler connections in the main system loop(FIG.'s 6-7, input of 300,000 Btu/hr or greater. 6-8, and 6-9). The system supply sensor should be wired to 1. An external control may be connected to control either the Low Voltage Connection Board at the terminals marked the firing rate or the set point of the boiler. If the external for the system sensor (see FIG. 8 3). The Leader control will control uses a set of contacts to enable the boiler,connect use the water temperature at the system supply sensor to the contacts to the Heat/Loop Demand 1 terminals. control the operation of the Cascade. Otherwise,the SMART SYSTEM control will be enabled by the 0-10V signal. 2. Make sure the (-) terminal is connected to the (-) or common output terminal of the external control, and the 0 - 10 Vdc terminal is connected to the 0 - 10 Vdc RECEIVED terminal of the external control. Make sure the (-) voltage is not below ground. 10/0 9/18 56 — ASPEN BUILDING DEPARTMENT Installation & Operation Manual 8 Field wiring (continued) If outdoor air reset is desired,the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 8-3). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters. If the outdoor air sensor is not connected, the Leader control will maintain the fixed water temperature set point that is programmed into the control. If a Thermostat, Zone Control enable output, or Building Management System enable output is available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the heat/ loop demands 1-3 (FIG. 8-3). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the heat/loop demand input.This will initiate a call for heat on the Cascade. Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards(FIG. 8-3). If more than two boilers are on the Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler,then from the third to the forth,and so on.The connections between boilers can be made in any order,regardless of the addresses of the boilers. Try to keep each cable as short as possible. When the Member 1 boiler is programmed as an alternate leader this allows the Member 1 boiler to automatically assume control of the Cascade should it lose communications with the Leader boiler. When programmed to YES, it is recommended that the Member 1 boiler have its own set of external sensors installed (such as the system supply sensor), to maintain the same level of temperature control as with the Leader boiler. Voltage signals(such as 0- 10V system pump speed input)can be connected to both boilers. WARNING DO NOT connect the sensors connected to the Leader boiler to the Member 1 boiler. The actual water temperatures will be higher than expected,which could lead to property damage,personal injury, or death. When communication is re-established with the Leader boiler,Member 1 will automatically relinquish control of the Cascade to the Leader boiler. RECEIVED 10/09/18 57 — ASPEN BUILDING DEPARTMENT KNigHT Installation & Operation Manual 8 Field wiring Figure 8-3 Low Voltage Field Wiring Connections I -1 N M = z d I 0 O ppd 8a < a p W u U O o _I 0OO 0 /I.L'1 0 (Ul a) a) ~`n SNO ¢ <z < zl�Z V [IY�]w $ kl U - 0cc F <E.c o a BD 20 '0 ' 01<-I=--o.~. L J N.HU-.-. Jo > J > ZZZz <z <�ED J3 U_ <3O aWd.03OJO o QD cc 3 1C 3 CY 3 Ct 3 W N LOLL OM Z z EDE ZNO 3I- MO 0 g co w DD ao co ro ED J z°= o Im o I fn Nt u) NM In�0 N m O N N N NI Q ❑o ❑B a w AEI L N M o O < a a ¢ 0 CC > 0_>- N U) H N = >1- O 0 0- W CC d CC CC re re w c O co 0 w 00 W W W - z > I I 1- 1- o 5 O a O• 0 Z lJl a' J 0 Cr 0 °o r a it U W U U_ —-Q- - 1- \ K % E WO00mu CO � cc U oa � a� aaaW ❑o a❑ z N Y W �W �i a uZi = = s m o ai a m o ¢ m o l�ii 8NO Q O J N 0) 0 CO 0 CO H CO CO <.CO CO + 1 + I + I + i CO <CO CO UD 0• D w a 7 £NO OO N IZ• w 0O co 9NO N a 0 1- w =WO I� p A m O p m < I 0 >- O N NNNNm m mtAAIMM M(OM.I - Nm �FN�F V^M 0 H ❑ 0 CO _--____ 111 t 1 H W J O W O111 1-Z W <m ❑ 0 i W ' <W _ _i cn d0 WUJ H 0 o -� w& w3z z Z Kg o m u Lu E- ' ❑(5,0 m Z a) 2 W °5W RECEIVED W ix U.O w 0 CO CC 03 10/09/18 58 ASPEN BUILDING DEPARTMENT K.II HT° Installation & Operation Manual 9 Condensate disposal Condensate drain 11. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, 1. This boiler is a high efficiency appliance that produces select one approved for use with condensing boilers and condensate. furnaces. The pump should have an overflow switch to 2. The bottom of the boiler has a 1 1/4 inch pipe for prevent property damage from condensate spillage. The connection of the condensate trap (FIG.9-1). switch should be wired in series with the air pressure 3. The provided condensate trap is equipped with a ball switch inside the boiler. that acts as a seal against harmful flue gases escaping NOTICE Use materials approved by the authority in case there is no condensate in the trap. If this ball is having jurisdiction. In the absence of other not present, flue gases may be able to pass through the authority,PVC and CPVC pipe must comply trap when there is no condensate present,resulting in an with ASTM D1785 or D2845. Cement and unsafe environment. It is important to check and make primer must comply with ASME D2564 or sure the ball is located in the trap,acting as a seal against F493. For Canada use CSA or ULC certified flue gases. PVC or CPVC pipe,fittings,and cement. 4. Fill condensate trap with enough water to make the ball NOTICE To allow for proper drainage on large float(FIG.9-1). horizontal runs, a second line vent may 5. Loosen compression fitting(FIG.9-1). be required and tubing size may need to increase to 1 inch. 6. Slide the condensate trap onto the condensate drain The condensate line must remain at the bottom of the unit. As the trap is pressed on, a unobstructed, allowing free flow of stainless steel retaining ring will engage the drain pipe condensate. If condensate is allowed to allowing the trap to be pushed on,but not pulled off. freeze in the line or if the line is obstructed in 7. Tighten compression fitting. any other manner,condensate can exit from 8. Slope condensate tubing down and away from the the condensate trap vent opening, resulting boiler into a drain or condensate neutralizing filter. in potential water damage to property. Condensate from the Knight Wall Hung Fire Tube boiler A WARNING The stainless steel retaining ring must be will be slightly acidic (typically with a pH from 3 to 5). installed between the rubber sealing gasket Install a neutralizing filter if required by local codes. and the compression fitting(FIG.9-1). The A Neutralizer Kit is available from the factory compression fitting must be tightened. (100157721). The condensate trap must have the float ball 9. Do not expose condensate line to freezing temperatures. (FIG.9-1) in place during all times of boiler 10. Use only plastic tubing or piping as a condensate drain operation to avoid flue gas emission from the condensate drain line. Failure to ensure line(FIG.9-1). the float ball is in place could result in severe personal injury or death. Figure 9-1 Condensate Disposal COMPRESSION ,4111100 FITTING 0 RETAINING RING GASKET ak CONDENSATE CONDENSATE DRAIN CONNECTION- ROUTE TO FLOOR DRAIN OR FLOAT BALL DRAIN CONDENSATE TRAP NEUTRALIZING FILTER USING 3/4'PVC TUBING : IM REMOVABLE CAP FOR CLEANING TRAP \16/11 RECEIVES it DIR 31200054329200 ` %,rl REMOVABLE CAP TO 10/09/18 CLEAN OUT TRAP im 59 IMG00209 ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual 10 Start-up Pre-Commissioning Cleaning Boiler water 1. Prior to fill and start-up,flush the entire heating system. CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system. 2. Clean the entire heating system with an approved pre Gaskets and seals in the system may be commissioning cleaner (comparable to Sentinel X300 or damaged. This can result in substantial X400 and Fernox F3 or DS40) in accordance with the property damage. manufacturer's recommendation to remove debris and prolong the life of the heat exchanger. DO NOT use "homemade cures" or 3. Clean all water filtering devices in the system. "boiler patent medicines". Serious damage to boiler, personnel, and/or 4. Flush the cleaning solution out of the entire system and property may result. refill. Fill water Table 10A Boiler Water Chemistry Check/control fill water chemistry IMPORTANT Conduct water quality testing prior to BOILER WATER CHEMISTRY installing the appliance. Various solutions Specification Range are available to adjust water quality. Dissolved Solids <2000 ppm The manufacturer recommends the following for properly pH Level 6.5 to 9.5 filling your boiler with the appropriate water chemistry for closed loop boilers. Good fill water quality will help extend Chloride < 150 ppm the life of the appliance by reducing the effects of lime scale • Monitoring pH, chlorides, TDS, and hardness buildup and corrosion in closed loop systems. levels can prolong the life of the appliance by reducing Hardness between 5 and 12 grains per gallon lime scale buildup, corrosion, and erosion. Check for leaks to ensure that fresh water is not entering the 1. Consult local water treatment companies for hard water system. areas(above 12 grains per gallon hardness). • Continual fresh makeup water will reduce boiler life. 2. Hardness levels that are above 12 grains/gallon can lead to lime scale buildup throughout the boiler system. If the • Mineral buildup in the heat exchanger reduces heat fill water is below 5 grains/gallons,usually due to use of a transfer, overheats the stainless steel heat exchanger, water softener,it is recommended to mix in some potable and causes failure. water at the inlet to increase the hardness of the water to The addition of oxygen carried in by makeup water above 5 grains/gallons. can cause internal corrosion in system components. pH between 6.5 and 8.5 • Leaks in the boiler or piping must be repaired at once to prevent excessive makeup water. For this purpose, 1. pH levels below 6.5 can cause an increase in the rate of it is recommended to install a water meter to easily corrosion. pH of 8.5 or higher can potentially cause lime check the amount of makeup water entering the scale buildup. system. Makeup water volume should not exceed 5% Total Dissolved Solids (TDS) less than 350 ppm of the total system volume per year. Note: When makeup water is added, make sure the chemical 1. Total dissolved solids are all minerals, salts, metals, and additives are added to maintain the correct level. charged particles that are dissolved in water. • An approved multi-metal corrosion inhibitor 2. The greater the amounts of TDS present, the higher the (comparable to Sentinel X100 or Fernox F1) is corrosion potential due to increased conductivity in the recommended at the correct concentration and in the water. manner recommended by the manufacturer. Chlorine concentration less than 150 ppm Freeze protection 1. Do not fill boiler or operate with water containing chlorine in excess of 150 ppm. L WARNING Ethylene glycol is toxic, DO NOT use as your freeze protection. Ethylene glycol has a 2. Filling with fresh drinking water should be acceptable. sweet aroma which chil • • mistake as food and ing .I ; • �1 3. Do not use the boiler to directly heat swimming pool or spa water. 10/09/18 60 ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual 10 Start-Lip (continued) 1. Use glycol only if needed for freeze protection. Fill and test water system 2. Propylene glycol is the recommended freeze protection. 1. Fill system only after ensuring the water meets the 3. Make sure to flush the boiler system before adding glycol. requirements of this manual. 4. Determine the freeze protection fluid quantity using 2. Close automatic and manual air vents and boiler drain system water content, following the fluid manufacturer's valve. instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content. 3. Fill to correct system pressure. Correct pressure will vary with each application. 5. Local codes may require a backflow preventer or actual a. The minimum cold water fill pressure for a system is disconnect from city water supply. 12 psi. 6. When using freeze protection fluid with automatic fill, b. Pressure will rise when the boiler is turned ON and it is suggested to install a water meter to monitor water system water temperature increases. makeup. Freeze protection fluid may leak before the water begins to leak, causing the concentration to drop, 4. At initial fill and during boiler startup and testing, check which reduces the freeze protection level. the system thoroughly for any leaks. Repair all leaks before proceeding further. 7. The freeze protection set points may be lowered when freeze protection fluid is used(see the Knight Wall Hung purge air from water system Fire Tube Service Manual). 8. Consult the glycol manufacturer for details on the 1. Purge air from system: suggested mix of glycol and water for the desired freeze a. Connect a hose to the purge valve (see purge/drain protection level and the de-rate effect it will have on the valve in the piping diagrams on pages 41 through 49). boiler output. Route the hose to an area where water can drain and be seen. Test/ replace freeze protection fluid b. Close the boiler or system isolation valve between the 1. For systems using freeze protection fluids,follow the fluid purge valve and fill connection to the system. manufacturer's instructions. c. Close zone isolation valves. d. Open the quick-fill valve on the cold water makeup 2. Freeze protection fluid must be replaced periodically due line. to degradation of inhibitors over time. e. Open purge valve. 3. It is recommended to test the glycol concentration f. Open the isolation valves one zone at a time. Allow annually and adjust within the desired set points. water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close Oxygen prevention the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged. CAUTION Eliminate all system leaks. Continual g. Close the quick-fill water valve and purge valve and fresh makeup water will reduce boiler remove the hose. Open all isolation valves. Watch that life. Minerals can build up in the heat system pressure rises to correct cold-fill pressure. exchanger, reducing heat transfer, h. After the system has operated for a while, eliminate overheating the heat exchanger, and any residual air by using the manual air vents located causing heat exchanger failure. throughout the system. Dissolved oxygen can have a negative effect on the boiler i. If purge valves are not installed in the system,open the manual air vents in the system one at a time,beginning system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion with the lowest floor. Close the vent when water on non-stainless steel parts of the system. A low pH level squirts out. Repeat with remaining vents. combined with oxygen further enhances its corrosive effects. 2. Open the automatic air vent (diaphragm-type or bladder After boiler installation, check for air leaks in the following type expansion tank systems only)one turn. areas: •Suction gasket 3. Open other vents: •Pump a. Starting on the lowest floor, open air vents one at a •Air valve time until water squirts out. •0-ring gaskets b. Repeat with remaining vents. RECEIVED Precautions include installing a water meter to evaluate the 4. Refill to correct pressure. fresh water volume entering the system (should be no more 1 9 18 than 5% system volume). Additional volumes of fresh water could indicate that a leak is present. g ASPEN BUILDING DEPARTMENT Ti<iv.G!T' Installation & Operation Manual 10 Start-up Check for gas leaks Final checks before starting the boiler WARNING Before starting the boiler, and during ❑ Read the Knight Wall Hung Fire Tube Boiler Service initial operation, smell near the floor and Manual to familiarize yourself with SMART SYSTEM around the boiler for gas odorant or any control module operation. Read this manual,pages 66 and unusual odor. Remove the top access 67 for proper steps to start boiler. panel and smell the interior of the boiler enclosure. Do not proceed with startup ❑ Verify the boiler and system are full of water and all system if there is any indication of a gas leak. components are correctly set for operation. Use an approved leak detection solution. Repair any leaks at once. ❑ Verify the preparation procedures of Section 10,pages 60 thru 63 have been completed. 0 WARNING DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct ❑ Verify electrical connections are correct and securely outlet pressure. This setting is suitable attached. for natural gas and propane, requiring no field adjustment. Attempting to ❑ Inspect vent piping and air piping for signs of deterioration alter the gas valve outlet pressure could from corrosion, physical damage or sagging. Verify air result in damage to the valve, causing piping and vent piping are intact and correctly installed potential severe personal injury, death,or per this manual. substantial property damage. Propane boilers only - Your propane Start the boiler WARN I N supplier mixes an odorant with the propane PP P P 1. Read and follow the Operating instructions in FIG.'s 10-2 to make its presence detectable. In some and 10-3,pages 66 and 67. instances, the odorant can fade, and the gas may no longer have an odor. Before If boiler does not start correctly startup (and periodically thereafter), have the propane supplier verify the correct 1. Check for loose connections,blown fuse or service switch odorant level in the gas. off? Check thermostat circuit(s) 2. Is boiler water temperature above 200°F? 1. Disconnect the two external wires connected to each 3. Is thermostat set below room temperature? of the heat/loop demand terminals on the connection board. 4. Is gas turned on at meter or boiler? 2. Connect a voltmeter across these two incoming wires. 5. Is incoming gas pressure less than 4 inches w.c.? Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter If none of the above corrects the problem, refer to the reading across the incoming wires. Troubleshooting Section of the Knight Wall Hung Fire Tube 3. There should NEVER be a voltage reading. Boiler Service Manual. 4. If a voltage does occur under any condition, check and Check system and boiler correct the external wiring. (This is a common problem ❑ Check water piping when using 3-wire zone valves.) 1. Check system piping for leaks. If found, shut down the 5. Once the external thermostat circuit wiring is checked boiler and repair immediately. (See WARNINGS on pages and corrected if necessary, reconnect the external 60 thru 63 (startup) regarding failure to repair leaks.) thermostat circuit wires to the connection board. 2. Vent any remaining air from the system using manual Inspect condensate system vents. Air in the system will interfere with circulation and Inspect/check condensate lines and fittings cause heat distribution problems and noise. 1. Inspect the condensate drain line, condensate fittings and condensate trap to ensure the trap is properly installed and connected to the condensate pipe under RECEIVED the boiler. Reference Section 9: Condensate Disposal for installation instructions. 10 0 9 18 62 — ASPEN BUILDING DEPARTMENT KNigkir Installation & Operation Manual 10 Start-up (continued) ❑ Check vent piping and air piping NOTICE Please note that the brackets ([]) denote 1. Check for gastight seal at every connection, seam of air screen status. piping,and vent piping. Venting system must be sealed gastight 4. Place the boiler into the active position by pressing the A WARNIN� to prevent flue gas spillage and carbon RIGHT SELECT [ON] key(FIG. 11-1, page 75). monoxide emissions, which will result in 5. Locate the pinhole button above the RESET button on severe personal injury or death. the display board(FIG. 11-1). Insert a thin wire(such as ❑ Check gas piping a paper clip)into the hole and press the button once and 1. Check around the boiler for gas odor following the hold for 5 seconds to place the boiler into Service Mode. procedure on page 50 of this manual (connecting gas In Service Mode the boiler will fire at ignition speed and supply piping). will then modulate up to full fire. If you discover evidence of any gas leak, 6. Insert the probe from a combustion analyzer into the hole A WARNING shut down the boiler at once. Find the left by the removal of the 1/2"combustion plug or the flue leak source with a bubble test and repair temperature sensor. immediately. Do not start the boiler again 7. Once the boiler has modulated up to full fire, measure until corrected. Failure to comply could the combustion. The values should be in the range listed result in severe personal injury, death, or in Table 10B below. The CO levels should be less than substantial property damage. 200 ppm for a properly installed unit. If the combustion is not within the specified range, ❑ Propane boilers-verify conversion reference the Troubleshooting Section of the Knight Wall 1. Verify propane conversion has been completed per the Hung Fire Tube Boiler Service Manual for possible causes Propane Conversion instructions. and corrective actions. WARNING DO NOT adjust gas valve outlet pressure. Table 10B Flue Products Chart The gas valve is factory-set for the correct outlet pressure. This setting is suitable Natural Gas for natural gas and propane, requiring Input Target Range no field adjustment. Attempting to I Rate I CO2 02 CO2 02 alter the gas valve outlet pressure could High Fire 9.2% 4.5% 9.0%- 10.5% 2.1%-4.8% result in damage to the valve, causing potential severe personal injury,death,or Low Fire I 9.0% 4.8% 8.8%-9.5% 3.9%-5.2% substantial property damage. WARNIN� Knight Wall Hung Fire Tube boilers are Propane typically shipped ready to fire on natural Input Target Range gas. Check boiler rating plate to determine Rate which fuel the boiler is set for. If set to CO2 02 CO2 02 natural gas, it may be converted to LP by High Fire 10.8% 4.5% 10.5% - 11.5% 3.5% -5.0% installing an LP venturi and any additional Low Fire 10.5% 5.0% 10.0% - 11.0% 4.2% -5.8% components provided in the LP conversion kit (Models WH56 - WH286 only), or 8. Once the combustion analysis is complete,test the safety by installing a propane orifice (Model shutoff device by turning the manual shutoff switch to WH400 only) (see pages 12 and 13). In order the OFF position and ensuring that the boiler shuts to operate on LP gas, these components down and registers an alarm. Turn the manual shutoff MUST BE installed. Failure to comply switch to the ON position and reset the control. could result in severe personal injury, death,or substantial property damage. 9. Turn the main power off to the boiler and re-install the 1/2" combustion plug or replace the flue temperature Check flame and combustion sensor into the flue pipe connection. 1. Turn the main power off to the boiler by placing the 10. Place the boiler back into normal operation. "On/Off'switch in the OFF position. You must replace the flue gas temperature 2. When using PVC/CPVC remove the 1/2" combustion 0 WARNING sensor/ 1/2"combustion plug(depending plug from the tee supplied in the installation kit. For on venting option) to prevent flue gas all other venting options, remove the flue temperature spillage into the room. i e 1 sensor from the flue pipe connection. Note: Combustion could result in sever measurements will be made at this point. damage. p death,or substantial proper y damage. 3. Turn the main power on to the boiler by placing the"On/ 10/0 9/18 Off'switch in the ON position. Ts r BUILDING DEPARTMENT �KN� HT° Installation & Operation Manual 10 Start-up Set space heating operation Set domestic hot water (DHW) operation Determine controlling sensor Verify DHW mode There are two (2) modes of operation for DHW. In Normal For space heating systems, the temperature control can be Mode, when a DHW demand begins, the control will start based on one of three sensors; the inlet, outlet, or system the DHW pump,turn off the boiler pump (if running), and supply sensor. The SMART SYSTEM control is programmed modulate to bring the outlet temperature to the DHW boiler at the factory to control the temperature of the outlet set point. The maximum firing rate may be limited in this sensor. The control will automatically switch to the system mode if desired. supply sensor once it is connected. If it is desired to base In Zone Mode it is assumed that the indirect DHW tank is the temperature control on the inlet sensor, the appropriate piped as a zone on the primary loop. When a DHW demand parameter must be changed in the control. See the Knight begins,the control will turn on the DHW pump output,and Wall Hung Fire Tube Boiler Service Manual for a detailed raise the system temperature set point to the DHW boiler set explanation of this procedure. point (if higher). The boiler pump will be turned on. The Verify space heat circulator mode system pump may be forced on, forced off, or not changed, depending on the System Pump Mode selected (reference The Space Heating Mode controls both the system pump the Knight Wall Hung Fire Tube Service Manual for details). (if connected), and the boiler pump. When the SMART In this mode, any low temperature zones (such as radiant SYSTEM control receives a space heating call for heat, it heating) may need additional controls to limit the water turns on the system pump. If the boiler is not heating an temperature sent to those zones. indirect DHW (Domestic Hot Water) tank, and the set Set DHW boiler target temperature point is not met,it also turns on the boiler pump. After the When in the DHW Mode, the control will modulate to space heating call for heat ends,the system pump continues maintain the boiler outlet temperature or system supply to run for a short period of time. The system pump can be programmed to run continuously, except during outdoor temperature to a set point. This set point is set at the factory shutdown. If the boiler pump was running, it continues to to 180°F. If a different set point is desired, the appropriate run for a short period of time as well. These pump delays are parameter in the control must be changed. See the Knight factory set to 30 seconds. If different delays are desired,the Wall Hung Fire Tube Boiler Service Manual for a detailed appropriate parameters in the control must be changed. See explanation of this procedure. the Knight Wall Hung Fire Tube Boiler Service Manual for a Set maximum DHW fan speed detailed explanation of this procedure. If the rated input of the indirect tank is less than the maximum output of the boiler,change the maximum DHW Adjust set point temperature(s) fan speed setting to limit the boiler output accordingly, see NOTICE Please note that the brackets ([]) denote the Knight Wall Hung Fire Tube Boiler Service Manual for a screen status. detailed explanation of this procedure. The NAVIGATION dial may be used during normal Set clock operation to adjust the space heating and tank set point Please note that the brackets ([]) denote temperatures. NOTICE screen status. 1. From the Status Screen press the NAVIGATION dial. The SMART SYSTEM control has a built-in clock that it 2. Turn the NAVIGATION dial counterclockwise to select uses for its night setback feature and for logging events. This the appropriate set point. clock must be set when the boiler is installed, and anytime 3. Press the NAVIGATION dial to adjust the temperature. the boiler has been powered off for more than 4 hours. Use 4. Once the desired temperature is displayed, press the the following procedure to set the clock: RIGHT SELECT [SAVE] key. 1. Press and hold the LEFT SELECT [MENU] key for at 5. If necessary repeat Steps 3 and 4 to make adjustments to least 5 seconds. additional set points. 2. The display changes to read [PASSWORD], 6. Press the RIGHT SELECT [HOME[ key to upload the with four(4) zeros below it. changes. 3. Press the RIGHT SELECT [SAVE] key. 7. If the RIGHT SELECT [SAVE] key is not pressed, the 4. The display will then show a menu with the time and new settings will be discarded. date and temperature unit. 5. Press the NAVIGATION dial twice. E air D 6. Turn the NAVIGATION dial to ad' the NAVIGATION dial. 10/09/18 64 ASPEN BUILDING DEPARTMENT 14110141 Installation & Operation Manual 10 Start-up (continued) 7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial. 8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial. 9. Turn the NAVIGATION dial to adjust the date. Press the NAVIGATION dial. 10. Turn the NAVIGATION dial to adjust the year. Press the RIGHT SELECT [SAVE] key. 11. Press the RIGHT SELECT [HOME] key. NOTICE The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment. The clock is automatically updated whenever a PC is connected and the Win Pro-Installer program is started. Configuration of the cascade NOTICE Please note that the brackets ([]) denote screen status. When installed in a Cascade system,the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters. Press the [MENU] key for at least five (5) seconds. Input the Installer code as described in the Knight Wall Hung Fire Tube Boiler Service Manual. Once the control parameters have been accessed,use the NAVIGATION dial to select the Control Mode parameters. Press the NAVIGATION dial to access these parameters. Rotate the NAVIGATION dial to select the parameter "Cascade Address". Press the NAVIGATION dial to access this parameter. Each appliance in the Cascade system must be programmed with its own address. The boiler designated as the Leader will have an address of 0.The remaining boilers in the Cascade will be Members and have addresses from 1 - 7. Rotate the NAVIGATION dial to select the appropriate address.Press the RIGHT SELECT [SAVE] key. Press the RIGHT SELECT [HOME] key to upload the address into the control.Repeat this procedure for all boilers in the Cascade, designating the Leader control and the Member controls. RECEIVED 10/09/18 i 55 — 6ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual 10 Start-up Figure 10-2 Operating Instructions Models WH56- WH286 FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is Immediately call your gas supplier from a equipped with an ignition device which neighbor's phone. Follow the gas supplier's automatically lights the burner. Do not try instructions. to light the burner by hand. If you cannot reach your gas supplier, call B. BEFORE OPERATING smell all around the fire department. the appliance area for gas. Be sure to C. Use only your hand to move the gas control smell next to the floor because some gas switch. Never use tools. If the switch will not is heavier than air and will settle on the move by hand, don't try to repair it, call a floor. qualified service technician. Force or attempted WHAT TO DO IF YOU SMELL GAS repair may result in a fire or explosion. Do not try to light any appliance. D. Do not use this appliance if any part has been under water. Immediately call a qualified Do not touch any electric switch; do service technician to inspect the appliance and not use any phone in your building. to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety information 8. Move the switch to the "ON" position. above on this label. 9. Install front door. 2. Set the thermostat to lowest setting. 10. Turn on all electric power to appliance. 3. Turn off all electric power to the 11. Set thermostat to desired setting. appliance. 12. If the appliance will not operate, follow the 4. This appliance is equipped with an instructions "To Turn Off Gas To Appliance" and ignition device which automatically lights call your service technician or gas supplier. the burner. Do not try to light the burner by hand. 5. Remove front door. 6. Move switch to the "OFF" position. r 7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow"B" C1 EI in the safety information above this label. If you don't smell gas, go to next step. (OFF ON TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to lowest setting. 4. Move switch the "OFF" position. 2. Turn off all electric power to the appliance 5. Install front door. if service is to be performed. 3. Remove front door. RECEIVE 10/09/18 66 ASPEN BUILDING DEPARTMENT KN� HT Installation & Operation Manual 10 Start-up (continued) Figure 10-3 Operating Instructions Model WH400 IMEIVOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life a This appliance does not have a plot. It is • Immediately call your gas supplier from a equipped with an ignition device which neighbor's phone. Follow the gas suppliers automatically lights the burner Do ngl try nstrudtons to light the burner by hand. • If you cannot reach your gas supplier.call B BEFORE OPERATING smell all around the fre department the appliance area for gas Be sure to C Use only your hand to turn the gas control knob smell next to the floor because some gas Never use tools If the handle will not turn by is heavier than air and will settle on the hand, don't try to repair it cal a qualified service floor tecmtaan Force or attempted repair may WHAT TO DO IF YOU SMELL GAS result in a fire or explosion • Do not try to light any appliance. D Do not use this appliance if any part has been under water Immediately call a qualified • Do not touch any electric switch:do service technician to inspect the appliance and not use any phone in your bulking to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety intormatior. b Turn gas shutoff valve dockwtse to"ON' above on this label Handle will be parallel to pipe 2. Set Vie Ihermostat to lowest setting 9 Install top cover 3. Turn offal electric power to the 10 Turn on all electnc power to applianceappliance. 11 Set thermostat to desired setting 4. This appliance is equipped with an 12. If the appliance wll not operate follow the ignition device which automatically lights instructions'To Turn Off_is To Appliance'and the boner Do not try to light the burner call your service technician or gas suppler by hand_ Gas Vat.* Gas valve 5 Remove top cover OPEN CLOSED 6. Turn gas shutoff valve counterclockwise — Iti to'OFF' Handle will be perpendicular to w CLOSE / 11141\ OnE 1 pipe Do not force I( 1 _R„ 7 Walt five(5)minutes to clear out any gas ` If you then smell gas. STOP! Follow-B' in the safety information above this label If you don't smell gas go to next step TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setti-1: 4 Turn gas shut off valve counterclockwise to 2 Turn off all electric power to the appliance 'OFF' Handle will be perpendicular to pipe if service is to be performed_ Do not force 3 Remove top cover 5 Install top cover. RECENEID 10/09/18 - 67 ASPEN BUILDING DEPARTMENT 441014T Installation & Operation Manual 11 Operating information General SMART SYSTEM Multi-temp loop control The Knight Wall Hung Fire Tube boiler is capable of producing How the boiler operates up to three (3) set point temperatures to meet different space The Knight Wall Hung Fire Tube boiler uses an advanced heating demands. This device controls the temperatures of up stainless steel heat exchanger and electronic control module to three (3) separate loops,based on the settings for the three that allows fully condensing operation. The blower pulls (3)heat/loop demands(reference Lochinvar kit#100167843). in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module 0 - 10V input (set point or power) regulates blower speed to control the boiler firing rate. The The Knight Wall Hung Fire Tube boiler can be controlled by gas valve senses the amount of air flowing into the boiler and a Building Management System(BMS)provided that either an allows only the right amount of gas to flow. external energy management system is installed that reduces the boiler water temperature as the heating load decreases, How the control module operates the boiler is not used for any space heating, the boiler has an The SMART SYSTEM control module receives inputs from input rate of 300,000 Btu/hr or greater, or the boiler is part of boiler sensors and external devices. The control module a modular or multiple boiler system having a total input of activates and controls the blower and gas valve to regulate 300,000 Btu/hr or greater. heat input and switches the boiler, Domestic Hot Water The control can be configured by the installer to use a 0 - 10 (DHW), and system pumps on and off as needed. The user Vdc signal to either control set point or firing rate. programs the module to meet system needs by adjusting The Knight Wall Hung Fire Tube boiler can also be programmed control parameters. These parameters set operating to accept a call for heat from a 0 - 10V signal, reference the temperatures and boiler operating modes. Boiler operation Knight Wall Hung Fire Tube Boiler Service Manual for a can be based on boiler outlet water temperature,boiler inlet detailed explanation of this procedure. water temperature, system temperature, a 0-10y signal or ModBus or BACnet,depending on the parameter settings. DHW priority The SMART SYSTEM control allows the connection of a DHW Control inputs and outputs thermostat or tank sensor to the low voltage connection board. Room thermostat When a tank sensor is connected, the DHW thermostat input There are three (3) heat/loop demand connections available is ignored. When a boiler is programmed for DHW Normal on this control. These inputs tell the boiler to provide water Mode, the maximum firing rate can be limited to match the for space heating. Each demand connection has its own set input rating of the indirect tank coil. point and outdoor air reset curve. When multiple demands DHW/space heating (SH) cycling have a call for heat the control will give priority to the demand with the highest set point. If a DHW call for heat is received while a space heating call is in progress,and the DHW is in Normal Mode,the control will Example: Assume that both heat/loop demand start the DHW pump and shut the boiler pump off. The system 1 and heat/loop demand 2 have a call for heat. pump will remain on. For stand-alone boilers, if the space Demand 1 has a set point of 110°F. Demand 2 has a set point heating call is still active while the DHW call is in operation, of 140°F. The boiler will regulate the system temperature to the control will wait for 30 minutes (time adjustable by 140°F until Demand 2 has been satisfied. Once Demand 2 installer)then it will switch back to the space heating demand. has been satisfied the boiler will provide 110°F water to the There is a timer to switch from space heating to DHW and a system. timer to switch from DHW to space heating. The control will When multiple temperature loops are switch back and forth until one of the heat demands end. CAUTION used, mixing valves are required for the protection of any low temperature loops. Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default. If a system supply sensor is connected, the control automatically uses it as the control sensor. For stand-alone boilers, the control sensor can be changed by the installer to the inlet sensor. If the inlet sensor is chosen as the controlling sensor,it is recommended that the system supply sensor be installed in the system supply in order to provide the best control of the inlet tem �'�E IVE D 10/09/18 68 ASPEN BUILDING DEPARTMENT 4410HT` Installation & Operation Manual 11 Operating information (continued) Anti-cycling Ramp delay After the burner turns off, the control will delay the next For systems with lower flow, the SMART SYSTEM can burner cycle for a set time period (time is adjustable by the limit the firing rate (when enabled) when a space heating installer). The time delay will be bypassed if the inlet water call for heat starts,or when switching from a DHW call for temperature drops too far during the delay. heat to a space heating call for heat. There are six(6)limits that can be programmed, as well as six (6) time intervals Boiler and system pump control corresponding to each limit. The sixth limit will also limit The boiler pump will run whenever the burner is firing, the firing rate for the rest of the call for heat. unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank. The boiler pump will run Gradient limiting during Freeze Protection Mode as well. It will continue to If during operation of the boiler the outlet water temperature run for a short time after the burner turns off or the Freeze is rising too quickly,the control will reduce the firing rate to Protection Mode ends. its lowest setting. The system pump will run whenever there is a space heating Outdoor air reset call for heat,or the boiler goes into Freeze Protection Mode. It may be programmed to run during a DHW call for heat With the outdoor air sensor connected,the control module when the DHW is programmed for Zone Mode. It will will calculate the set points of the three (3) space heating continue to run for a short time after the end of the heat demands based on the programmed reset curves. The demand or the Freeze Protection Mode. The system pump installer can change the slope of the reset curves by several can be programmed to run continuously if desired, except adjustable parameters. The user can limit the maximum during outdoor shutdown and/or a DHW call for heat. set point for the system using the space heating set points. DHW recirculation pump control Boost function When a DHW recirculation loop is used, the Knight Wall If outdoor air reset is active,and any space heating demand Hung Fire Tube boiler can control the recirculation pump. To has been active continuously for a set period of time activate this function, simply install the DHW recirculation (time adjustable by installer) and there has been no DHW sensor into the return water from the DHW circulation loop. demands, the control will increase the set point of that The control will turn on the DHW recirculation pump when demand by a fixed number of degrees (adjustable by the return water drops 10°F(5.5°C)below the DHW tank set installer). This process will continue until the space heating point, and will turn back off when the return water rises to demand ends, the set point reaches the programmed set within 5°F (2.5°C) of the DHW tank set point. The control point or a maximum of 20 increases has occurred. Once the will turn the DHW recirculation pump off whenever DHW system heat demand is satisfied,the set point will revert to night setback is active. the value determined by the reset curve. Night setback Temperature control The controller may be programmed to reduce the space Modulation heating and DHW set points during certain times each week. The Knight Wall Hung Fire Tube boiler is capable of Seven different start and stop times may be programmed for modulating its firing rate on WH56 models only from a the space heating setback and seven start and stop times minimum of 15% to a maximum of 100%, WH86 - 286 for the DHW setback. Any night setback event scheduled models from a minimum of 10%to a maximum of 100%and within the next seven(7)days can be temporarily bypassed the WH400 model from a minimum of 20%to a maximum if desired. of 100%. The firing rate is dictated by the call for heat(i.e., Vacation mode space heating or domestic hot water),the heating load,ramp delay(if enabled),and various other temperature limitations. Vacation Mode is used to lower the Space Heat (SH) and/ or DHW set points much like Night Setback. The set points will remain lowered until Vacation Mode is disabled. Night Setback will not function when Vacation Mode is enabled. Flame current support To prevent nuisance shutdowns when the boiler isfirm at minimum rates, the control will inc when the flame signal drops too low. EI D 10/09/18 g ASPEN BUILDING DEPARTMENT y.NJGHT° Installation & Operation Manual 11 Operating information Protection features Low voltage blocking Outlet temperature, flue temperature, and The blower and gas valve require a minimum amount of temperature rise limiting voltage in order to operate properly. If an ignition attempt is made when the line voltage is temporarily low(such as during a The outlet temperature is monitored by the boiler outlet brownout),the control could enter a manual reset lockout. To temperature sensor. When the outlet temperature exceeds prevent this, the control monitors the voltage and blocks any 185°F,the unit will reduce the fan speed. If the outlet water heat demands until the voltage returns to an acceptable level. temperature exceeds 195°F the control will shut the unit down until it cools off. Monitor external limits The control module monitors the flue temperature by a Connections are provided on the connection board for external sensor located in the flue exhaust. If the flue temperature limits such as flow switch, low water cutoff, gas pressure exceeds 215°F the control will reduce the maximum fan switches, and a louver proving switch. The SMART SYSTEM speed. If the flue temperature exceeds 240°F the control will will shut off the burner and inhibit relighting whenever any of shut the unit down. The unit will restart automatically once these external limits open. the flue temperature drops 25°F and the minimum off time has expired. Run-time and alarm outputs The control monitors the temperature difference between The boiler provides dry contacts for indicating when the boiler the inlet and the outlet sensor. If this difference exceeds is running,and when it is unable to operate. 55°F the control will reduce the maximum fan speed. If Run-time and cycle counting the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once The control uses two timers to monitor the total hours of the temperature difference has dropped below 55°F and the burner operation. One timer monitors the time the boiler is minimum off time has expired. firing in the Space Heating Mode. The other timer monitors the time the boiler is firing in the DHW Mode. Freeze protection The control uses two (2) ignition counters to monitor the DO NOT install the boiler in a room likely to freeze. amount of boiler cycles. The first counter counts all ignitions of the control. The second counter counts only ignition The following integral feature of the SMART SYSTEM attempts that have failed. control module provides some protection for the boiler only --not for the system. Service reminder The SMART SYSTEM control module provides The control can be programmed for service reminder • notification. This notification will become active when either a freeze-up protection as follows when the boiler set time frame has expired,or a set amount of running hours or water temperature drops below 45°F: cycles has expired(all adjustable by the installer). The display • Below 45°F, the boiler and system pumps operate will show a Maintenance Required screen. The installer's name constantly. and phone number can be programmed into the control. This • Below 37°F,the boiler turns on. information will appear on the Maintenance Required screen. • Boiler and pumps turn off if boiler water The service reminder notification can be reset or disabled by temperature rises above 45°F. Lower temperatures may be programmed for the installer. • systems with anti-freeze solutions. Error logging NOTICE When system return temperatures The control will hold in memory the last 10 lockouts as well as are maintained below the dew point, the last 10 blockings. The date and time of the occurrence will condensation will form on the inside of be recorded as well. Only the 10 most current occurrences of the boiler jacket causing some internal each will be held in memory. sheet metal components to rust. 0 CAUTION This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to RECEIVED prevent freeze potential for the boiler and system. 10/0 9/18 70 Im ASPEN BUILDING DEPARTMENT 134.49P.mr Installation & Operation Manual 11 Operating information (continued) Boiler temperature regulation 9. If the current outlet temperature is below the new MRHL set point,locate the pinhole (SERVICE button) above the Operating temperature (target) RESET button on the display board. Insert a thin probe The SMART SYSTEM control module senses water (such as a paper clip) into the hole and press the button temperature and regulates boiler firing and firing rate to continuously for five (5) seconds to place the boiler into achieve a target temperature. The target temperature can be Service Mode. In Service Mode, the boiler will fire at set between 32°F and 190°F. ignition speed and will then modulate up to full fire. • Target temperature is calculated as described in the 10. Once the outlet temperature rises up to the MRHL set "Outdoor Reset Operation" section, when the point,the MRHL will function, causing the boiler to shut outdoor sensor is connected. down and lock out. • If the outdoor sensor is not connected, the target 11. Repeat Steps 2 - 7 to adjust the MRHL to its normal temperature is fixed at SH (1 - 3) set points. An outdoor sensor fault will remain on the display settings. screen until the outdoor sensor is reconnected. Low water cutoff protection High limit operations 1. The SMART SYSTEM control module uses temperature The Knight Wall Hung Fire Tube boiler is equipped with sensing of both supply and return areas of the heat adjustable automatic reset and manual reset high limits. The exchanger. If the flow rate is too low or the outlet automatic reset high limit has a maximum set point of 200°F temperature too high, the control module modulates and and the manual reset high limit has a maximum set point of shuts the boiler down. This ensures boiler shutdown in the 210°F. event of low water or low flow conditions. 2. Some codes and jurisdiction may accept these integral When the outlet temperature exceeds 200°F, the automatic features of the control in lieu of requiring an additional high limit action occurs. The boiler shuts down until the limit control or low water cutoff. Consult local jurisdiction outlet water temperature cools below 190°F,and a 60 second to determine. A low water cutoff is available from the timer has expired. If the outlet temperature continues to factory(#100208651). increase, the manual reset high limit action will occur at 210°F. Outdoor reset operation High limit test procedure Target temperature with outdoor reset Please note that the brackets ([1) denote This feature improves the system's efficiency by decreasing NOTICEsetpoint as the outdoor temperature increases. For boilers screen status. P with input rates less than 300,000 Btu/hr Energy Efficiency 1. Turn ON the main power to the boiler by placing the Standards require the use of a control that automatically ON/OFF switch in the ON position. adjusts set point in relation to heat demand. In the absence of an external energy management system,this feature MUST 2. From the Status Screen,press the NAVIGATION dial to BE used. access the Set Points Screen. See the Knight Wall Hung Fire Tube Boiler Service Manual to 3. Press the LEFT SELECT(LIMITS)key. change the settings. 4. Select the manual reset high limit (MRHL) by rotating the NAVIGATION dial counterclockwise, then press Reset curve the NAVIGATION dial. The reset curve looks at outdoor air temperature and adjusts 5. Decrease the set point of the MRHL to below the current the set point in relation to heat demand. outlet temperature(or to its minimum setting,whichever is higher) by turning the NAVIGATION dial counterclockwise. 6. Press the RIGHT SELECT [SAVE] key. 7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control. 8. If the current outlet temperature is above the new MRHL RECEIVED set oint,the MRHL will function causing boiler lockout. If this occurs,skip to Step 11. 10/09/180 ASPEN BUILDING DEPARTMENT 13w� HT. Installation & Operation Manual 11 Operating information Cascade Sequence of the cascade When multiple boilers are installed, they can be wired To equalize the run time of all boilers on the Cascade, the together in a cascade sequence. A maximum of eight boilers firing sequence will automatically be changed at set intervals. can be controlled from a single control. In this application one boiler would be designated as the Leader control and all During the first 24 hours of operation, the sequence will change every hour. After that, the sequence will change others would be designated as Member controls. Member 1 can be configured to take over control of the Cascade every 24 hours. The switching on/off sequence will be as should the Leader stop communicating with the members. follows: The Leader control can be programmed to use Lead/Lag or Efficiency Optimization control methods. TIME I SWITCHING ON SEQUENCE Once the Leader boiler receives a call for heat from a room Start L M1 M2 M3 M4 M5 M6 M7 thermostat, BMS, or ModBus or BACnet, the control will 1 hour M1 M2 M3 M4 M5 M6 M7 L determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on 2 hours M2 M3 M4 M5 M6 M7 L M1 the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed After the first 24 hours,the sequence will change every night reset curve parameters. See the Knight Wall Hung Fire Tube at 2:00 a.m. If a boiler locks out or is used to heat an indirect Boiler Service Manual to program the reset curve. If outdoor DHW tank,it will automatically be given the lowest priority air reset is not desired,do not connect the outdoor air sensor. until 2:00 a.m. A fixed temperature set point can be programmed into the DHW, Night Setback, and Ramp Delay operation control.See page 64 of this manual to program the set point. with cascade If the water temperature at the system supply sensor is less For Normal Mode DHW operation any boiler(s) in the than the set point+the turn-off offset-the off-on differential, Cascade can be selected to provide heat for a DHW call. then the control will initiate a call for heat on the Cascade(see Select a boiler to be designated as the DHW boiler. Connect the Knight Wall Hung Fire Tube Boiler Service Manual for the DHW thermostat or sensor to the terminals on the Low an explanation of the offset and differential).The Leader will Voltage Connection Board marked for the corresponding energize the lead boiler on the Cascade.For a new startup this device. When the boiler receives a DHW call, the Leader will be the Leader boiler. control will take that boiler out of the Cascade sequence. If another boiler is available, the Leader will start it up to take its place. The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its firing rate to maintain this. Once the DHW call has been satisfied, the Leader control will place that boiler back into the Cascade sequence. Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode. When DHW is programmed for Zone Mode, connect the DHW thermostat or tank sensor to the Leader boiler. When a DHW call is received, the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point(if higher). Night Setback operation of the boilers within the Cascade is available. Programming of the Night Setback will be done through the Leader boiler. Refer to the Knight Wall Hung Fire Tube Boiler Service Manual for information regarding Night Setback. Ramp Delay operation of the boilers as dRE VE 0 Knight Wall Hung Fire Tube Boiler Service Manual is available when the boilers are part of a Cascade syslia,0 9/18 l� 72 l� ASPEN BUILDING DEPARTMENT KNIGHT Installation & Operation Manual 11 Operating information (continued) Sequence of operation OPERATION DISPLAY STANDBY Cr SYSTEM() DHU TANK° BOILER° DHU CIRCO SYSTEM: 117°F(118) 1. Upon a call for heat,the gas pressure switch(es)must be closed. TANK: 124°F(130) OUTDOOR: 56°F INLET: 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU SZ'SCREEN SHDN STANDBY Q SYSTEM* DHU TANK° 2. Once the gas pressure switch(es) are closed, the control turns BOILER* DHU CIRCO on the appropriate pumps (system and boiler pumps for space SYSTEM: 117°F(118) heating, DHW pump for DHW). The flow switch and/or LWCO TANK: 124°F(130) must close. IINLET R� 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU SCREEN SHDN START Q SYSTEM* DHU TANK() BOILER* DHU CIRCO 3. The control turns on power to the louver relay. The louver SYSTEM: 117°F(118) TANK: 124°F(130) proving switch, and blocked drain switch must close. OUTDOOR: 56°F INLET:OUTLET: 124°F DHU RECIRC: 115°F MENU SZ'SCREEN SHDN PRE-PURGE Q SYSTEM* DHU TANK° BOILER* DHU CIRCO SYSTEM: 117°F(118) 4. The control starts the prepurge cycle by initiating the blower. TANK: 124°F(130) OUTDOOR: 56°F INLET: 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU SZ'SCREEN SHDN IGNITION Q SYSTEM* DHU TANK° BOILER* DHW CIRCO 5. The control starts the trial for ignition by firing the spark SYSTEM: 117°F(118) electrode and opening the gas valve. OUTDOOR: 124°FC56°F INLET: 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU SCREEN SHDN POST-PURGEQ SYSTEM* DHW TANK° 6. If flame is not detected after the sparking ends, the control will BOILER* DHU CIRCO perform a postpurge, then start another prepurge cycle and try SYSTEM: 117°F(118) to light the burner again. The control willperform a total of 4 TANK: 124°Fc 13° 9 9 OUTDOOR: 109° attempts before locking out. DHU RECIRC: 115°F 10/09/18 MENU SCREEN SHDN BUILDING CtrARTMENT KNgg14 Installation & Operation Manual 11 Operating information Sequence of operation (continued) OPERATION DISPLAY 41% 6 p SYSTEM* DHU TANK° 7. If flame is detected, it holds the firing rate steady for a few BOILER* DHU CIRCA seconds to let the flame stabilize, then it begins to modulate the SYSTEM: 117°F(118) firing rate based on a set point or some other command (such as OUTDOOR: 124°F(56°F a O-10V BMS signal). INLET: 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU 4Z'SCREEN SHDN 8. If the space heating call for heat is active,and the tank thermostat 41% 6 1 or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a SYSTEM* DHU TANK* zone), the DHW pump will turn on first, then the boiler pump will BOILER° DHU CIRCO turn off(boiler and DHW pump operation briefly overlap to ensure SYSTEM: 124°F(130) flow is maintained through the unit). This will divert the boiler's OUTDOOR: 156°F outlet water from the heating system and send it to the tank coil OUTLET: 124°F instead. The control will then modulate to maintain the outlet DHU RECIRC: 115°F temperature to the DHW boiler set point. MENU 'SCREEN SHDN 41% A Cr SYSTEM* DHU TANK() 9. If the boiler is not part of a Cascade, and both the space heating BOILER* DHU CIRCO and DHW calls for heat remain active long enough, the boiler will SYSTEM: 117°F(118) switch back and forth between the two heating modes until one of OUTDOOR: 124°F(130) them is satisfied. INLET: 109°F OUTLET: 124°F DHU RECIRC: 115°F MENU 'SCREEN SHDN POST-PURGE RNTI—CYCLING SYSTEM* DHU TANK O O 10. Once both calls for heat are satisfied, the control will turn off BOILER* DHU CIRC the burner. The blower will continue to run during the postpurge SYSTEM: 124°F(130) period. OTDIINLET: 109°F OUTLET: 124°F DHU RECIRC: 115°F MENU 'SCREEN SHDN BLOCKED RNTI—CYCLING SYSTEM* DHU TANK() 11. Any pumps that are running will continue to run for their respective BOILER* DHU CIRCO pump delay times before turning off, unless programmed to SYSTEM: 117°F(118) remain on continuously. A 60 second anti-cycle period will start, TANK: 124°F(130) OUTDOOR: 56°F which will delay any new call for heat until it times out. INLET: 109°F OUTLET: 124°F DHW RECIRC: 115°F MENU Se SCREEN SHDN STANDBY SYSTEM() DHU TANK() BOILER DHW CIRCO 12. In Standby, ready to start a new cycle. TANK:EM: 124°F(130) OUTDOOR: 56°F INLET: RECIRC: 1124°F05°F RECEIVED OUTLET: DHW MENU 4Z'SCREEN SHDN 1 0/0 9/1 8 74 ASPEN BUILDING DEPARTMENT �KN� HT` Installation & Operation Manual 11 Operating information (continued) SMART Knight Wall Hung Fire Tube boiler control module SYSTEM Use the control panel(FIG. 11-1)to set temperatures,operating conditions,and monitor boiler operation. Figure 11-1 Control Panel • • USB Memory Drive c" I 1 PC Connection ■ 1111:16Ct =Ma'r 10) —• (0) • • DIR#2000544469 00 The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial(in the center): MENU=Left SELECT Key SETPOINTS=NAVIGATION Dial- Pressing Down SHDN=Right SELECT Key Access modes NOTICE Please note that the brackets ([]) denote screen status. User To save parameters and exit programming: The user can adjust space heating and tank target temperatures Press the RIGHT SELECT [SAVE] key and then press the by pressing the NAVIGATION dial when"1SETPOINTS"is RIGHT SELECT [HOME] key. flashing at the bottom of the display. The date and time,and the temperature units can also be changed(see page 64). To enter a parameter and continue programming: Installer Press the RIGHT SELECT [SAVE] key 1 time to return to the parameter listings; press again to return to the menu listings. Most parameters are available only to the installer, accessible Remember to press the RIGHT SELECT [HOME] key when by entering the installer password,see the Knight Wall Hung finished programming in order to save the changes made. Fire Tube Boiler Service Manual. See the Knight Wall Hung Fire Tube Boiler Service Manual for Saving parameters (reference the Parameter Table in a detailed description of parameters and access modes. the Knight Wall Hung Fire Tube Boiler Service Manual) RECEIVED 10/00Z9/18 ASF'F_N BUILDING DEPARTMENT KN!RHT Installation & Operation Manual 11 Operating information Figure 11-2 Status Display Screen A—�11_�U% 6 Cr 2 3 41 B (BOILER (CALL FOR STATUS) HEAT) SYSTEM{ DHU TANK() BOILER( DHU C I RC{> SYSTEM' 117° F( 118) C —*TANK: 124° F( 130) F (OPERATIONAL OUTDOOR: 109° INFORMATION) 109 F CIUTLET: 12H° F DHU REC I RC: 115° F D >MENCI '_;C:REEf-1 '_;HDNE F (LEFT SELECT T (RIGHT SELECT KEY) KEY) E (NAVIGATION DIAL) Status Display Screens NOTE: All screens show burner status,heat demands,lockout/blocking,pump status,and soft keys. Section Display Description STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat. START The unit has begun a burn cycle and is checking all safety circuits. PREPURGE The unit has initiated a prepurge period on a call for heat. IGNITION The unit has begun a spark period to ignite the main burner. A % 6 The unit has fired and is running at the displayed percentage. (Boiler Status The call for heat has been satisfied and the unit runs the fan for an Bar) POSTPURGE additional postpurge period to clear the combustion chamber and vent system of residual flue products. SHUTDOWN The unit has been placed in the OFF position. SETPOINT MET The controlled temperature has exceeded its set point and its offset. BLOCKED The unit has detected a condition that has temporarily interrupted the current call for heat. 1 Room Thermostat 1 has a call for heat. Room Thermostat 2 has a call for heat. B _ Room Thermostat 3 has a call for heat. (Call for Heat HaI'I The tank thermostat or sensor has a call for heat. Indicators) Li l Indicates which room thermostat demand has prc'E(E IVE )j L�J The unit is being controlled by a 0- 10V BMS signal: ICI The member unit is supplying heat while in Cascade IViict/0 9/18 76 ASPEN BUILDING DEPARTMENT 15 kpkt . Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont'd) NOTE: All screens show burner status,heat demands,lockout/blocking,pump status,and soft keys. Section Display Description a. SYSTEM TEMP b. TANK TEMP c. OUTDOOR TEMP DETAILS SCREEN 1 d. INLET TEMP e. OUTLET TEMP f. DHW RECIRC TEMP - The temperature read by the DHW recirculation sensor(if connected). a. DELTA T b. FLUE TEMP c. FLAME CURRENT d. FAN SPEED DETAILS SCREEN 2 e. LOOP 1 TEMP - The temperature of Loop 1 reported by the MTLC control. f. LOOP 2 TEMP - The temperature of Loop 2 reported by the MTLC control. g. LOOP 3 TEMP - The temperature of Loop 3 reported by the MTLC control. a. GAS PRESS SW-The state of the gas pressure switch. b. FLOW SW-The state of the flow switch. C I/O SCREEN c. LOUVER RELAY-The state of the louver relay output. d. LOUVER SW-The state of the louver proving switch. (Operational e. BLOCKED DRAIN-The state of the blocked drain switch. Information) f. GAS VALVE-The state of the gas valve output. a. 0- 10V BMS IN b. 0- 10V RATE OUT BMS SCREEN c. BMS ADDRESS d. BMS CONTROL? e. SYS PUMP SPEED f. BLR PUMP OUT a. SH RUN TIME-Total time running for Space Heat(SH). b. SH CYCLES-Total Space Heat(SH) demand cycles. c. DHW RUN TIME-Total time running for DHW. HISTORY SCREEN d. DHW CYCLES-Total DHW demand cycles. e. POWER TIME-Total time powered ON. f. IGNITIONS-Total number of successful ignitions. g. IGN ATTEMPTS-Total number of ignition attempts. a. FAULT NO. LAST 10 FAULTS b. FAULT c. DATE d. TIME RECEIVED 10/09/18 77 ' ASPEN BUILDING DEPARTMENT j�H10HT, Installation & Operation Manual 11 Operating information Status Display Screens (cont'd) NOTE: All screens show burner status,heat demands,lockout/blocking,pump status,and soft keys. Section Display Description C a. CASCADE STATUS CASCADE STATUS b. CASCADE POWER (Operational c. PRESENT Information cont.) a. TRIGGER 1 -Next Space Heat(SH)night setback trigger. NIGHT SETBACK b. TRIGGER 2-Next DHW night setback trigger. D (LEFT SELECT USB Press the LEFT SELECT key to access the USB and Installer menu. key function) E (NAVIGATION MODIFY Pressing the NAVIGATION dial will allow the installer to change the text. dial function) SHDN Press the RIGHT SELECT key to turn the boiler OFF. ON Press the RIGHT SELECT key to turn the boiler ON. F (RIGHT SELECT NO Press the RIGHT SELECT key to cancel the shutdown operation. key function) SAVE Press the RIGHT SELECT key to save the current change. HOME Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes. RECEIVED 10/09/18 78 — ASPEN BUILDING DEPARTMENT Installation & Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician Owner maintenance (see the Knight Wall Hung Fire Tube User's (see the following pages for instructions) Information Manual for instructions) General: • Check boiler area • Address reported problems Daily • Check pressure / temperature • Inspect interior; clean and vacuum if gauge necessary; • Clean condensate trap and fill with fresh water • Check vent piping •Check for leaks (water, gas, flue, condensate) • Check air piping •Verify flue and air lines in good condition • Check air and vent termination a and sealed tight screens Monthly •Check system water pressure/system • Check relief valve piping/expansion tank • Check fill water meter • Check condensate drain system C/) • Test boiler water. When test indicates, •Check air vents clean system water with approved Z system restorerfollowing manufacturer's Z information • Check control settings •Test low water cutoff(if used) •Check ignition and flame sense Periodically electrodes (sand off any deposits; clean • Reset button (low water cutoff) and reposition) • Check wiring and connections • Perform start-up checkout and performance verification per Section 10 • Check boiler (gas and of this manual. piping • Flame inspection (stable, uniform) Every water) for leaks • Flame signal (at least 10 microamps at 6 months • Operate relief valve high fire) •Clean the heat exchanger if flue temperature is more than 54°F above return water temperature If combustion or performance indicate need: • Clean heat exchanger End • Remove and clean burner using of season • Shut boiler down(unless boiler compressed air only months used for domesti �� IVED • Clean the blower wheel 10/09/18 EPV BUILDIm DEPARTMENT jKN! aT Installation & Operation Manual 12 Maintenance 0 WARNING Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury,death,or substantial property damage. A WARNING The boiler should be inspected annually only by a qualified service technician. In addition,the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure. WARNING Electrical shock hazard - Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death. Address reported problems Annual cleaning: 1. The condensate trap should be cleaned at least once 1. Inspect any problems reported by the owner and correct annually,or at the end of each heating season,by removing before proceeding. the bottom cap and cleaning out any sediment that exists. 2. The provided condensate trap is equipped with a ball Inspect boiler area that acts as a seal against harmful flue gases escaping in case there is no condensate in the trap. If this ball is not 1. Verify that boiler area is free of any combustible materials, present, flue gases may be able to pass through the trap gasoline and other flammable vapors and liquids. when there is no condensate present,resulting in an unsafe environment. It is important to check and make sure the 2. Verify that air intake area is free of any of the contaminants ball is still located in the trap, acting as a seal against flue listed in Section 1 of this manual. If any of these are gases at least once annually and after every cleaning. present in the boiler intake air vicinity, they must be 3. After the condensate trap is cleaned or serviced,it must be removed. If they cannot be removed,reinstall the air and checked to ensure that it is installed and draining properly. vent lines per this manual and the Knight Wall Hung Fire Reference Section 9 - Condensate Disposal for installation Tube Boiler Service Manual. instructions. Inspect boiler interior Figure 12-1 Condensate Trap COMPRESSION FITTING 1. Remove the front access cover and inspect the interior of411100 RETAINING the boiler. GASKRINGET IMO 2. Vacuum any sediment from inside the boiler and components. Remove any obstructions. )+ CONDENSATE FLOAT BALL DRAIN Clean condensate trap 1. Inspect the condensate drain line, condensate PVC fittings,and condensate trap. g P All' REMOVABLE CAP TO CLEAN OUT TRAP Inspect condensate trap Check all piping for leaks Monthly inspection: 1. The condensate trap should be inspected monthly to A WARNING Eliminate all system or boiler leaks. ensure the trap is properly installed and connected to the Continual fresh makeup water will condensate pipe under the boiler,see FIG. 12-1. reduce boiler life. Minerals can build up in sections, reducing heat transfer, 2. The condensate line should be inspected monthly overheating heat exchanger, and causing for obstructions, making sure it allows free flow for heat exchanger failure. Leaking water may condensate to drain. also cause severe property damage. 3. Inspect the neutralizing kit (if installed) monthly to 1. Insect all water and gas piping and verify1 e r. ensure the condensate is draining properly, and there is 2. Look for signs of leaking lines coR st still an adequate amount of neutralizing agent available. found. 3. Check gas line using the procedure found14P ieQ9I1 8 80 - - Gas Connections. ASPEN BUILDING DEPARTMENT iNIGHT' Installation & Operation Manual 12 Maintenance (continued) Flue vent system and air piping Check boiler relief valve 1. Visually inspect the entire flue gas venting system and air 1. Inspect the relief valve and lift the lever to verify flow. piping for blockage,deterioration or leakage. Repair any Before operating any relief valve,ensure that it is piped with joints that show signs of leakage.Verify that air inlet pipe its discharge in a safe area to avoid severe scald potential. is connected and properly sealed. Read Section 6-Hydronic Piping before proceeding further. 2. Verify that boiler vent discharge and air intake are clean WARNING] Safety relief valves should be re-inspected and free of obstructions. AT LEAST ONCE EVERY THREE YEARS,by a licensed plumbing contractor WARNING Failure to inspect for the above conditions or authorized inspection agency,to ensure and have them repaired can result in that the product has not been affected severe personal injury or death. by corrosive water conditions and to ensure that the valve and discharge line Check water system have not been altered or tampered with illegally. Certain naturally occurring 1. Verify all system components are correctly installed and conditions may corrode the valve or its operational. components over time, rendering the 2. Check the cold fill pressure for the system. Verify it is valve inoperative. Such conditions are correct(must be a minimum of 12 psi). not detectable unless the valve and its components are physically removed and 3. Watch the system pressure as the boiler heats up(during inspected. This inspection must only testing) to ensure pressure does not rise too high. be conducted by a plumbing contractor Excessive pressure rise indicates expansion tank sizing or or authorized inspection agency - not performance problem. by the owner. Failure to re-inspect the boiler relief valve as directed could result 4. Inspect automatic air vents and air separators. Remove in unsafe pressure buildup, which can air vent caps and briefly press push valve to flush vent. result in severe personal injury, death, or Replace caps. Make sure vents do not leak. Replace any substantial property damage. leaking vents. Following installation, the valve lever 0 WARNINGI must be operated AT LEAST ONCE Check expansion tank A YEAR to ensure that waterways are clear. Certain naturally occurring 1. Expansion tanks provide space for water to move in mineral deposits may adhere to the valve, and out as the heating system water expands due to rendering it inoperative. When manually temperature increase or contracts as the water cools. operating the lever, water will discharge Tanks may be open, closed or diaphragm or bladder and precautions must be taken to avoid type. See Section 6-Hydronic Piping for suggested best contact with hot water and to avoid water location of expansion tanks and air eliminators. damage. Before operating lever, check to see that a discharge line is connected Check fill water meter to this valve directing the flow of hot water from the valve to a proper place 1. Check fill water meter for water usage. If the amount of disposal. Otherwise severe personal exceeds 5% of your system volume, you could have a injury may result. If no water flows,valve leak. Have the system checked for leaks and fixed by a is inoperative. Shut down the boiler until qualified service technician. a new relief valve has been installed. 2. After following the above warning directions,if the relief Test boiler water valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is 1. Test boiler water. Reference the Knight Wall Hung the valve and not over-pressurization of the system due Fire Tube Installation and Operation Manual for to expansion tank waterlogging or under ' guidelines. When test indicates,clean system water with IVE approved system restorer following the manufacturer's information. 10/0 9/18 8A1SPEN BUILDING DEPARTMENT \\KNIgOT Installation & Operation Manual 12 Maintenance Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from the 2. If the flame is unsatisfactory at either high fire or low fire, boiler heat exchanger access cover. turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot compressed air. Do not use compressed air to clean burner be cleaned satisfactorily,replace with new ones. if performed inside a building. 3. Replace ignition/flame sense electrode, making sure 3. Remove the burner,reference FIG. 12-2 below. gasket is in good condition and correctly positioned. 4. When replacing the burner, ensure gasket is in good Check ignition ground wiring condition and positioned correctly(FIG. 12-2). 1. Inspect boiler ground wire from the heat exchanger Figure 12-2 Burner Assembly access cover to ground terminal strip. 2. Verify all wiring is in good condition and securely FAN TOP PLATE • attached. 3. Check ground continuity of wiring using continuity • FAN TOP PLATE GASKET afr meter. IWO 4. Replace ground wires if ground continuity is not satisfactory. %OW BURNER GASKET • BURNER Check all boiler wiring �^ �h. - FIBER BOARD 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. to? Check control settings DIR#2000544497 00 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 Check flame signal of Knight Wall Hung Fire Tube Boiler Service Manual. 1. At high fire the flame signal shown on the display should Adjust settings if necessary. See Section 1 of the be at least 10 microamps. Knight Wall Hung Fire Tube Boiler Service Manual for 2. A lower flame signal may indicate a fouled or damaged adjustment procedures. flame sense electrode. If cleaning the flame sense electrode does not improve,ground wiring is in good condition,and 2. Check settings of external limit controls (if any) and ground continuity is satisfactory, replace the flame sense adjust if necessary. electrode. 3. See Section 3 - Troubleshooting of the Knight Wall Hung Perform start-up and checks Fire Tube Boiler Service Manual for other procedures to deal with low flame signal. 1. Start boiler and perform checks and tests specified in Section 10-Start-up. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. RECEIVED 10/09/18 82 ASPEN BUILDING DEPARTMENT 14410141 Installation & Operation Manual 12 Maintenance (continued) Review with owner p WARNING The boiler contains ceramic fiber 1. Review the Knight Wall Hung Fire Tube Boiler User's materials. Use care when handling these Information Manual with the owner. materials per instructions in the Service Manual. Failure to comply could result in 2. Emphasize the need to perform the maintenance schedule severe personal injury. specified in the Knight Wall Hung Fire Tube Boiler User's Information Manual(and in this manual as well). 8. Remove the condensate trap from the bottom of the 3. Remind the owner of the need to call a licensed contractor boiler. Place a bucket underneath the condensate fitting should the boiler or system exhibit any unusual behavior. attached to the heat exchanger. 4. Remind the owner to follow the proper shutdown 9. Use a vacuum cleaner to remove any accumulation on the procedure and to schedule an annual start-up at the boiler heating surfaces. Do not use any solvent. beginning of the next heating season. 10. Using a clean cloth dampened with warm water,wipe out Cleaning boiler heat exchanger the combustion chamber. Rinse out debris with a low 1. Shut down boiler: pressure water supply. •Follow the"To Turn Off Gas to Appliance"instructions 11. Allow the heat exchanger to thoroughly dry. for the boiler in Section 10- Startup. • Do not drain the boiler unless it will be exposed to 12. Reassemble the unit in reverse order of component freezing temperatures. If using freeze prevention fluid removal,and re-install the condensate hose. in system,do not drain. Damaged gaskets and seals in the 0 CAUTION system can result in substantial property 2. Allow time for the boiler to cool to room temperature if damage. Ensure that damaged or torn it has been firing. gaskets are replaced. 3. Remove the front access panel (no tools required for 13. Perform a combustion analysis by following the removal). Use a Phillips head screwdriver to remove the instructions in Section 10 - Startup - Check Flame and top access panel. Combustion on page 63 of this manual. 4. Remove the wiring from the ignitor, flame rod, and the 14. Resume operation. fan. Remove the reference tubing from the air intake. 5. Loosen the band clamp on the air intake coupling using a field provided 5/16"driver and disconnect the air inlet from the venturi. 6. On Models WH56 - WH286 loosen the threaded nut on the venturi. Remove the gasket between the gas piping and venturi. On the WH400 model disconnect the Molex plug from the gas valve. Using a 5 mm Allen wrench, remove the screws securing the gas pipe to the gas valve. 7. Remove the 10 mm nuts securing the heat exchanger top plate to gain access to the heat exchanger and set aside. RECEIVED 10/09/18 $ASPEN BUILDING DEPARTMENT \, -KNIGHT Installation & Operation Manual 13 Diagrams Figure 13-1 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL GROUND ® RVUPRP ■ TZMASYP ® i— I ' 2 QW CND• II ,— o X-e Xt., X p;17 n - PSYuSTEM S15A ®N • F1 SYSTEM 1 GND• III BOILER PUMF BOILER SA Xt-0 P PU®N. RELAY —.3 F-1i_._r> BOILER PUMP D5-5E)R 1 GND• III PUMP F3 REI Y I X1-9 PU6'L" r li PUDHWD HW D ®N. —• HW PUMP �y R TERMINAL TERMINAL SA 24V DC STRIP DHW STRIP 3UPP )- LUMFI XS9 S1 . ,20 PAC X43 W 24 VAC X I CONNECTION BOARD I INTEGRATED CONTROL LnJ 24°AD 1 •. > <12 °NT 1 L — J -2 DNp 1 . • ® COSD<, FIT/LT..0 ® • • ® ° <s ro-D� >-<2 • • . > - CI ® rT E N00 Prssa P 53eE1 - • O L H SWITCH - m� »-<< 1 13 OU•R OU 0 ED<< o PROVING CH I RELAY kr LOUVER 20°° IL 1 13 1i INTEGRATED cN> � �1 CONTROL W REc i 1 Ei I -a, RELO of ° • 1.: _ xT L J RIBBON CABLE PC INTERFACE xs` .44 AIR h I srHN <— SWITCH 21 1 s.s� 0E0 OAS VALVE o <2 I— m 22 LAY < VALVE LM`� 16 9EN9« <"GG BLOWER «� �I w 7 CONNECTION <xsu 2r<B b _ _ _I BOARD _ 21 B cxs,>>«xC >—« L CONTACTS _122 © AERR>)_<<0014 �«' r 7 9 m C004>>_«� I I xR2 L caxrAcrs J 20 B COEI0>�«DOE •• CC rI SYSTEM SB 23 9 GG)—((E FLAME ROD L SENSOR 24 0 . cxa))—C<xe ROD i OUTDOOR S5 26 0 Cxs>>—(<xs — L SENSOR _I 27$. CAUTION HIGH VOLTAGE SPARK LEAD TANK S4 31 0 cxs>>—N<NE I_ SENSOR 32, SHIELD 33-0--• CASCADE A 34 0 '®cN8))—<C B 35 0 xa>—«'N NOTES: SHIELD 36 0 . cxe>>_<<m 1.Where possible,switches are shown without utilities(gas,water or EONS+ 37 r3 cx'>)--«. electricity)connected to the unit.As such,actual switch states may o-mv_ nT hone i IN- 3E 0 c"`)>--«>m vary from those shown on diagrams depending upon whether utilities S-YS PUMP+ D-10V 39 0 cxe>)_«'N are connected or a fault condition is present. N I _ 40 0 cxe>)—«m 2.See wiring diagram for additional notes. B-LR PUMP+ — —I 41 0 cxs>>—«x° D-10V OUT_ 42 0 } cxs>>—C<: RATE+ -I 43 0 cxa>>« rPTIONA ITEM1 OUT_ 0-10V 44 LIWARNING LPTIONAL ITEM) 1 SHIELD 45 © — LOW VOLTAGE r A �I 46 0 c">>-< . - )<8 DISCONNECTFOWER — VAC RECEIVE!) Mooaus e 47 © °"g�x"' "'k BEFORE SERVICING HIGH VOLTAGE i_ SHIELD JI 48 0 • ru=j>{xw - >j�C DHWREO �1-29 © COB>) (C.L SENSOR 30 _iii -1 LADDER RERV A 10/0 9/18 mi 84 ASPEN BUILDING DEPARTMENT yK.P,PAIT` Installation & Operation Manual 13 Diagrams (continued) Figure 13-2 Wiring Diagram 0 LOW VOLTAGE r BOX DEPICTS-1 AWARNING O 120 VAC LPTIONAL ITEM) ® HIGH VOLTAGE I:a INGL a BOX DEPICTS DISCONNECT POWER o El LisDUAL SENSOR BEFORE SERVICING CONNECTION 0 0 0 BOARD/ _ INTEGRATED FOX OX DEPIC I�I 124 VAC DHW RECIRC ¢ 7 17-0 CONTROL CNS-15 JUNCTION OPTIONAL 7 PUMP RELAY COIL 18 @ I BOX L ITEMS J ALARM 21— \ rc CONTACTS -22 �jl �\ X-7 X1-3 OR L-0•� I DHW 1 a RUN-TIME 19-0 PUMP w CONTACTS 20-0 w—N-®x 24 VAC LOUVER 15—� • xi I BR L a _ (BOILER (PUMP w RELAY COIL 16 0-G a m LOUVER —BK 1 4-16 �W_N'Qx PROVING WITCH�v 14-0 —CN5-1 BK I; -14 X1-2 PR -L�� pSy��SYSTEM GASPRESSURE �11-0 CN5-9 0 G—P�/PUMP] �,N5-10—BK 14-13 LOW 24vncr H CN7-1 t,N5-3 BK 14-5 WATER COM C CN7-3-CN7-2 • CN5-11—BK 1 4-12 ON/OFF N L CUT-OFF I- c J CN7-4— CN5-12 BK 14-11 SWITCH z� CN5-4 BK 14-4 x1-s BK�---OAG—L- NDL 120V O r FLOW r0-t 6� 9 & • CN5-5 BK I4-3 X1-5I w • _N,© N SUPPLY J L SWITCH "" 10—(S)— TANK CN5-15 BK �I 4-8 I T N S 7 CN5-13 BK 11 4-10 _k-- THERMOSTAT ~ 8—® CN5-6 BK L J HEAT/LOOP 3 O!O—5—® - —CN5-14 BK '1 4-9 X1-8 G DEMAND _ 6—® CCNS-7 BK -I 4-1 HEAT/LOOP 0�O-ro 3—® • xi R DEMAND I _ ' 4—5— • HEAT/LOOP 1 C[_Yro_ 1 —® • • TRANSFORMER L DEMAND I _ ' A 2—5 — —1g I— SYSTEM 1 23-0 RWG SENSOR _ 24—O rOUTDOOR - 26—O OB© SENSOR K 27-0—. TANK �31-5 BLOWER SENSOR 32—O y SHIELD 33—®—* — 1012111 - '®-. CASCADE A 35—G)SHIELD I 36-0� I DHW 30—&—• CN6 - X6 X5-7 R RECIRC�—I 29—OJ X5-16 T LSENSOR _I , X5-8 W r BMS + -II 37-0— p IN _0-10V I 38-0 X5-15 BK � X5-9 Y/BK CN9 Y- ISYS PUMP + 39— IN N _0-10V 40— BLR PUMP + 41—� xs-1 BL I BL- 1_ OUT _0-10V 42—& • RATE + 43—® X5-2 O OUT _0-10V —44-0 x5-1S P SHIELD 145—@ AIR PRESSURE SWITCH MODBUS A -46—® X5-11 0/BK OPTION B 47 ® X5-4 R/BK OPERATING SENSOR S1a L SHIELD \\\ _I48—@ • _ X5-12 GY HIGH LIMIT SENSOR S1b O O O 1 X5-6 P/BK INLET SENSOR S2 zFz X5-5 W/BK FLUE SENSOR S3a X5-13 PR FLUE SENSOR S3b RBLG P , X5-14 y I XXXX X2-2 BK I /� 11GAS VALVE X4-1 O XSO X2-1 Y T-°e24VAC X4-2 In GY X9-2 MODBUS BOARD X4-3 I� G - X9-3 i X1-7 W/R— -FLAME SENSOR • SHIELD MTR-S1 X4-4 ii -4 SPARK � GROUNDING IMI X52 I MUSLIN HIGH VOLTAGE SPARK LEAD] L JUMPER I X1-1 W X1-2�� W X1-3 I G Notes: L 1.All wiring must be installed in accordance with: local,state,provincial and national code requirements per either N.E.C.in USA or C.S.A.in Canada. I 2.If any original equipment wire as supplied with the appliance must be replaced,it must be replaced with wire having same wire gauge(AWG)and rated for a minimum of 105C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components. 3.Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using WIRING*IA RA diagrams to troubleshoot unit. 100209.;a 3 v: 9/18 8 SPEN BUILDING DEPARTMENT KN!.gHT Installation & Operation Manual Notes RECEIVED 10/09/18 86 ASPEN BUILDING DEPARTMENT 1.t1.,P IT' Installation & Operation Manual Notes RECEIVED 10/09/18 I\7SPEN BUILDING DEPARTMENT Lochinvar® rf'FIRiP .��. FF,��E��r s...&,VArER�... Revision Notes: Revision A (Process 300'000891 Chan e 300 Maddox Simpson Parkway #500009028)initial release. Lebano615-88-90 37090Fa 10/09/18 615-889-8900/Fax:615-547-]000 www.Lochinvar.com MM#100287110_DIR#2000544742 Rev A ASPEN/17 BUILDING DEPARTMENT