XL 400 Commercial Boiler
Product Information
Product Name: Installation & Operation Manual
Model: 400 – 1000 Series 100 & 101
Manual Version: 100329949_2000586636_Rev P
Hazard Definitions
The manual uses the following terms to indicate various levels
of risk or important information regarding the product:
- DANGER: Indicates an imminently hazardous
situation that could result in death or serious injury. - WARNING: Indicates a potentially hazardous
situation that could result in death or serious injury. - CAUTION: Indicates a potentially hazardous
situation that may result in minor or moderate injury. - NOTICE: Indicates special instructions on
installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Product Usage Instructions
Please read the entire manual, including the Knight XL Service
Manual, before proceeding with the installation. Follow the steps
in the order given to ensure proper installation.
It is recommended to have this boiler serviced or inspected by a
qualified service technician at least once a year to ensure its
proper functioning.
When determining the location for the boiler, consider piping
and installation requirements.
If there are any claims for damage or shortage in shipment, they
must be filed immediately against the transportation company by the
consignee.
Note that the factory warranty does not apply to units that are
improperly installed or operated.
Adhere to the guidelines provided in the manual to avoid severe
personal injury, death, or substantial property damage.
Failure to follow the instructions in the manual exactly may
result in a fire or explosion causing property damage, personal
injury, or loss of life.
Do not install this appliance in any location where gasoline or
flammable vapors are likely to be present.
What to Do If You Smell Gas
If you smell gas, follow these steps:
- Extinguish any open flames.
- Do not operate electrical switches.
- Do not use telephones.
- Evacuate the area immediately.
- Call your gas supplier from a neighbor’s phone. Follow their
instructions.
California Proposition 65 Warning
This product contains a chemical known to the State of
California to cause cancer, birth defects, or other reproductive
harm. There may be low-level exposure to some of the substances
listed in the Act.
Room/Environment Requirements
Do not install the units in rooms or environments that contain
corrosive contaminants. Refer to Table 1A for a list of corrosive
contaminants. Failure to comply could result in severe personal
injury, death, or substantial property damage.
100329949_2000586636_Rev P
Installation & Operation Manual Models: 400 – 1000 Series 100 & 101
WARNING
This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight XL Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS ………………………………………….. 2 PLEASE READ BEFORE PROCEEDING ………………… 3 THE KNIGHT XL — HOW IT WORKS ……………………. 4-6 RATINGS ……………………………………………………………….. 7 1. DETERMINE BOILER LOCATION Provide Air Openings to Room …………………………………. 10 Flooring and Foundation …………………………………………. 10 Residential Garage Installation …………………………………. 10 Vent and Air Piping …………………………………………………. 10 Prevent Combustion Air Contamination ……………………… 10 Corrosive Contaminants and Sources ……………………….. 11 Using an Existing Vent System to Install a New Boiler … 11 Removing a Boiler from Existing Common Vent………….. 12 2. PREPARE BOILER Remove Boiler from Wood Pallet ………………………………. 13 Gas Conversions………………………………………………… 13-14 3. GENERAL VENTING Direct Venting Options …………………………………………….. 15 Install Vent and Combustion Air Piping ……………………… 16 Requirements for Installation in Canada…………………….. 17 Sizing ……………………………………………………………………. 17 Min./Max. Combustion Air & Vent Piping Lengths ………… 17 Materials…………………………………………………………………. 18 Optional Room Air …………………………………………………… 19 PVC/CPVC ………………………………………………………… 19-20 Polypropylene…………………………………………………………. 21 Stainless Steel Vent ………………………………………………… 22 4. SIDEWALL DIRECT VENTING Vent/Air Termination – Sidewall…………………………….. 23-26
Determine Location………………………………………… 23-25 Prepare Wall Penetrations………………………………. 25-26 Multiple Vent/Air Terminations ………………………………….. 26 Sidewall Termination – Optional Concentric Vent ……. 27-29 5. VERTICAL DIRECT VENTING Vent/Air Termination – Vertical ……………………………… 30-31 Determine Location…………………………………………….. 30 Prepare Roof Penetrations ………………………………….. 31 Multiple Vent/Air Terminations ………………………………….. 31 Vertical Termination – Optional Concentric Vent……… 32-33 Alternate Vertical Concentric Venting ……………………. 34-35
6. OUTDOOR INSTALLATIONS …………………………. 36-37 7. HYDRONIC PIPING System Water Piping Methods………………………………….. 38 Low Water Cutoff Device …………………………………………. 38 Chilled Water System………………………………………………. 38 Freeze Protection ……………………………………………………. 38 General Piping Information ………………………………………. 38 Near Boiler Piping Components………………………………… 40 Circulator Sizing ……………………………………………………… 41 Near Boiler Piping Connections ………………………………… 41 8. GAS CONNECTIONS Connecting Gas Supply Piping …………………………………. 48 Natural Gas ……………………………………………………………. 49
Pipe Sizing for Natural Gas …………………………………. 49 Natural Gas Supply Pressure Requirements …………. 49 Propane Gas ………………………………………………………….. 49 Pipe Sizing for Propane Gas ……………………………….. 49 Propane Supply Pressure Requirements ………………. 49 Check Inlet Gas Supply …………………………………………… 50 Gas Pressure …………………………………………………………. 51 Gas Valve Replacement ………………………………………….. 51 9. FIELD WIRING Line Voltage Connections ………………………………………… 52 Low Voltage Connections ………………………………………… 52 Wiring of the Cascade……………………………………………… 54 10. CONDENSATE DISPOSAL Condensate Drain …………………………………………………… 56 11. START-UP …………………………………………………… 57-66 12. OPERATING INFORMATION General………………………………………………………………….. 67 Cascade ………………………………………………………………… 70 Sequence of Operation ……………………………………………. 71 Knight XL Control Module ………………………………………… 72 13. MAINTENANCE Maintenance and Annual Startup………………………….. 73-77 14. DIAGRAMS Wiring Diagram ………………………………………………….. 78 Ladder Diagram ………………………………………………… 79 Revision Notes ………………………………………….. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
2
Installation & Operation Manual
Please read before proceeding
WARNING
Installer Read all instructions, including this manual and the Knight XL Service
Manual, before installing. Perform steps in
the order given.
User This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for your reference.
Have this boiler serviced/inspected by a qualified service technician, at least annually.
Failure to comply with the above could result in severe personal injury, death or substantial property damage.
NOTICE
When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate.
Consider piping and installation when determining boiler location.
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.
WARNING
Failure to adhere to the guidelines on this page can result in severe personal injury,
death, or substantial property damage.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance.
· Do not touch any electric switch; do not use any phone in your building.
· Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.
· If you cannot reach your gas supplier, call the fire department.
· Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
WARNING
The California Safe Drinking Water and Toxic Enforcement Act requires the
Governor of California to publish a list of
substances known to the State of California
to cause cancer, birth defects, or other
reproductive harm, and requires businesses
to warn of potential exposure to such
substances.
This product contains a chemical known to
the State of California to cause cancer, birth
defects, or other reproductive harm. This
boiler can cause low level exposure to some
of the substances listed in the Act.
When servicing boiler
· To avoid electric shock, disconnect electrical supply before performing maintenance.
· To avoid severe burns, allow boiler to cool before performing maintenance.
Boiler operation
· Do not block flow of combustion or ventilation air to the boiler.
· Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
· Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.
Boiler water
· Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.
Freeze protection fluids
· NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
WARNING DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A). Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
3
Installation & Operation Manual
The Knight XL – How it works…
1. Stainless steel heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.
2. Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils.
3. Blower The blower pulls in air and gas through the venturi. Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.
4. Gas valve The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.
5. Venturi The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if the flue gas temperature gets too hot. This protects the flue pipe from overheating.
7. Boiler outlet temperature sensor (housed with the high limit sensor) This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.
8. Boiler inlet temperature sensor This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.
9. Temperature and pressure gauge (field installed, not shown) Monitors the outlet temperature of the boiler as well as the system water pressure.
10. Electronic display Digital controls with SMART TOUCH screen technology, full color display, and an 7″ user interface screen.
11. Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler.
12. Burner (not shown) Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet (system supply) A 2″ (Models 400 – 800) or 2.5″ (Model 1000) water connection that supplies hot water to the system.
14. Water inlet (system return) A 2″ (Models 400 – 800) or 2.5″ (Model 1000) copper water connection that returns water from the system to the heat exchanger.
15. Gas connection pipe Threaded pipe connection of 1″ or 1 1/4″ (depending on the model). This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.
16. SMART TOUCH Control Module The SMART TOUCH Control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the heating demand.
17. Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler.
18. High voltage junction box The junction box contains the connection points for the line voltage power and all pumps.
4
19. Boiler drain port Location from which the heat exchanger can be drained.
20. Low voltage connection board The connection board is used to connect external low voltage devices.
21. Low voltage wiring connections (knockouts) Conduit connection points for the low voltage connection board.
22. Condensate drain connection Connects the condensate drain line to a 1/2″ PVC connection.
23. Access cover – front Provides access to the gas train and the heat exchanger.
24. Ignition electrode Provides direct spark for igniting the burner.
25. Flame inspection window The quartz glass window provides a view of the burner surface and flame.
26. Relief valve Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 PSI.
27. Flame sensor Used by the control module to detect the presence of burner flame.
28. Line voltage wiring connections (knockouts) Conduit connection points for the high voltage junction box.
29. Top panel Removable panel to gain access to the internal components.
30. Power switch Turns 120 VAC ON/OFF to the boiler.
31. Air box The air box houses the combustion air filter.
32. Air pressure switch (400 and 800 models only) The air pressure switch detects blocked flue/inlet conditions. break the control circuit, shutting the boiler down.
33. Pump relays The pump relay is used to connect the boiler, system and DHW pumps.
34. Transformer The transformer provides 24V power to the integrated control.
35. High limit sensor (housed with the outlet temperature sensor) Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.
36. Air Filter (not shown)
The air filter prevents dirt and debris from entering the burner.
37. Flow Switch
The flow switch is a safety device that ensures flow through
the heat exchanger during operation. This appliance is low
mass and should never be operated without flow. The flow
switch makes contact when flow is detected and allows the unit
to operate. If flow is discontinued during oepration for any
reason, the flow switch will break the control circuit and the
unit will shut down.
The Knight XL – How it works… (continued)
Model 400 – 500
Installation & Operation Manual
29 10
23
Front View – Model 400
8 1 7 35 4 2
31
Left Side (inside unit) – Model 400
21
26
37
13
19 6 11
22
Rear View – Model 400
18 30
24
32
3
5
28 14 15
17
20
16 33 34 25 27
Right Side (inside unit) – Model 400
5
The Knight XL – How it works…
Model 650 – 1000
Installation & Operation Manual
29 10
23
Front View – Model 1000
DIR #2000582923 00
20 16 30
33
34
7
8
35
1
4 2
5
DIR #2000582932 00
Rear View – Model 1000
6
28 21 37 26
13
14 19 15 6 11
22 17
DIR #2000582924 00
Left Side (inside unit) – Model 1000
18
31
DIR #2000582937 00
3
Left Side (inside unit) – Model 1000
25 24 27
Ratings
Installation & Operation Manual
Knight XL Boiler AHRI Rating
Other Specifications
Model Number
Note: Change “N” to “L” for L.P. gas models.
KBX0400(N,L)
Input MBH
(Note 2)
Min
Max
39.9
399
Gross Output MBH
(Note 1)
387
Net AHRI Ratings Water, MBH (Note 2)
337
Boiler Water Content Gallons
Water
Gas
Air Vent
Connections Connections Size Size
(Note 3)
4.4
2″
1″
4″ 4″
KBX0500(N,L)
50
500
485
422
4.9
2″
1″
4″ 4″
KBX0650(N,L)
65
650
631
549
6.2
2″
1-1/4″
4″ 6″
KBX0800(N,L)
80
800
776
675
7.3
2″
1-1/4″
4″ 6″
KBX1000(N,L)
99.9
999
969
843
8.8
2-1/2″
1-1/4″
6″ 6″
KBX0400-O(N,L)
39.9
399
384
334
4.4
2″
1″
4″ 4″
KBX0500-O(N,L)
50
500
482
419
4.9
2″
1″
4″ 4″
KBX0650-O(N,L)
65
650
626
544
6.2
2″
1-1/4″
4″ 6″
KBX0800-O(N,L)
80
800
770
670
7.3
2″
1-1/4″
4″ 6″
KBX1000-O(N,L)
99.9
999
962
837
8.8
2-1/2″
1-1/4″
6″ 6″
NOTICE Maximum allowed working pressure is located on the rating plate.
Notes:
1. Knight XL boilers require special gas venting Use only the vent materials and methods specified in the Knight XL Installation & Operation Manual.
2. Standard Knight XL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. Above 2,000 feet elevation, the boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet. De-rate values are based on proper combustion calibration and CO2 adjusted to the recommended levels.
4. For Canadian installations above 2,000 feet elevation, follow all applicable local codes and regulations.
5. Ratings have been confirmed by the Hydronics Section of AHRI.
6. Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Knight XL is listed to UL353 or UL60730-2-9.
3. High altitude Knight XL boilers are equipped to operate from 3,000 to 9,600 feet only. See chart for de-rates. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard models. A high altitude label is also affixed to the unit. De-rate vlues are based on proper combustion calibration and CO2 adjusted to the recommended levels.
Model
0400 0500 0650 0800 1000
Derate per 1,000 feet
Derate up to 5,200 feet
Derate 5,200 feet to 9,600 feet
0.00%
1.70%
0.50%
1.80%
1.20%
1.90%
2.00%
2.10%
3.00%
2.30%
7
Installation & Operation Manual
1 Determine boiler location
Installation must comply with:
· Local, state, provincial, and national codes, laws, DO NOT install the boiler in a room likely to freeze.
regulations, and ordinances. · National Fuel Gas Code, ANSI Z223.1 latest edition. · Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required. · National Electrical Code.
WARNING
Unless specified as an outdoor boiler, this appliance is certified as an indoor appliance.
Do not install the appliance outdoors or locate where the
appliance will be exposed to freezing temperatures
Do not install the appliance where condensation may form on
the inside or outside of the appliance, or where condensation
· For Canada only: B149.1 Installation Code, CSA C22.1 may fall onto the appliance.
Canadian Electrical Code Part 1 and any local codes.
Failure to install the appliance indoors could result in severe
NOTICE
The Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 latest edition.
Before locating the boiler, check:
1. Check for nearby connection to: · System water piping · Venting connections · Gas supply piping · Electrical power
2. Locate the appliance so that if water connections should
personal injury, death, or substantial property damage.
WARNING
This appliance requires a special venting system. The vent connection to the appliance
must be made with the starter CPVC/stainless steel pipe section. The field provided PVC vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Closet and alcove installations
leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components. 3. Check area around the boiler. Remove any combustible materials, gasoline and other flammable liquids.
Failure to keep boiler area clear and free WARNING of combustible materials, gasoline, and
other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.
4. The Knight XL must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.
A closet is any room the boiler is installed in which is less than 26 cubic feet for KBX400-500 models, 35 cubic feet for KBX650800 models, and 39 cubic feet for KBX1000 models.
An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.
Example: Room dimensions = 5 feet long, 4 feet wide, and 8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would be considered a closet for a Knight XL Boiler.
WARNING
For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC or stainless steel
vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.
Provide clearances:
5. If a new boiler will replace an existing boiler, check for Clearances from combustible materials
and correct system problems, such as:
1. Hot water pipes–at least 1/4″ (6 mm) from combustible
· System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.
· Incorrectly-sized expansion tank.
materials. 2. Vent pipe Follow special vent system manufacturer’s
instructions. 3. See FIG.’s 1-1 and 1-2 for other clearance minimums.
· Lack of freeze protection fluids in boiler water causing
system and boiler to freeze and leak.
· Debris left from existing piping, if not flushed and
cleaned with an appropriate cleaner.
6. Check around the boiler for any potential air
contaminants that could risk corrosion to the boiler
or the boiler combustion air supply (see Table 1A).
Prevent combustion air contamination. Remove any of
these contaminants from the boiler area.
WARNING
DO NOT install units in environments that contain
rooms or corrosive
contaminants (see Table 1A). Failure to
8
comply could result in severe personal injury, death, or substantial property
Recommended clearances for service access – Front / Top / Rear………………………………………………………. 24″
NOTICE
Multiple appliances can be installed side by side with no clearances between adjacent
appliances because the appliances are approved for zero
clearances from combustible surfaces; however, service access
will be limited from the sides. Consult with the local inspection
authority for approval.
NOTICE
If you do not provide the recommended service clearances shown, it may not be
possible to service the boiler without removing it from the
space.
damage.
Installation & Operation Manual
1 Determine boiler location (continued)
Figure 1-1 Closet Installation – Minimum Required Clearances
WARNING
For closet installations, CPVC, polypropylene or stainless steel
vent material MUST BE used in
a closet structure due to elevated
temperatures. Failure to follow
this warning could result in fire,
personal injury, or death.
AIR OPENING
AIR OPENING
REAR
AREA OF EACH OPENING
Figure 1-2 Alcove Installation – Minimum Required Clearances
1/4″ (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1″ (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE
WARNING
For alcove installations, CPVC, polypropylene or stainless steel
vent material MUST BE used in
an alcove structure due to elevated
temperatures. Failure to follow
13″ this warning could result in fire, TOP personal injury, or death.
0″ LEFT
14″ (356 MM) REAR
OPEN FRONT
0″ RIGHT
18″ (457 MM) FRONT
2000582944 01
9
Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
Residential garage installation
Knight XL alone in boiler room
Precautions
1. No air ventilation openings into the boiler room are needed when clearances around the Knight XL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.
Knight XL in same space with other gas or oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.
WARNING
The space must be combustion/ventilation
provided with air openings
correctly sized for all other appliances
located in the same space as the Knight
XL.
Do not install the boiler in an attic.
Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage. 2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Knight XL because it takes its combustion air from outside (direct vent installation).
Flooring and foundation
Flooring
The Knight XL is approved for installation on combustible flooring, but must never be installed on carpeting.
WARNING
Do not install the boiler on carpeting even if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.
Seismic bracing
For installations requiring seismic bracing, the base legs of the appliance are designed to allow for the use of unistrut channel to meet seismic requirements.
10
Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
· Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.
· The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.
Vent and air piping
The Knight XL requires a special vent system, designed for pressurized venting.
The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see the General Venting Section. Note prevention of combustion air contamination below when considering vent/air termination.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight XL using any other means.
Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.
Prevent combustion air contamination
Install air inlet piping for the Knight XL as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A for products and areas which may cause contaminated combustion air.
WARNING
You must pipe combustion air to the boiler air intake. Ensure that the combustion air
will not contain any of the contaminants
in Table 1A. Contaminated combustion
air will damage the boiler, resulting in
possible severe personal injury, death
or substantial property damage. Do not
pipe combustion air near a swimming
pool, for example. Also, avoid areas
subject to exhaust fumes from laundry
facilities. These areas will always contain
contaminants.
Installation & Operation Manual
1 Determine boiler location (continued)
Table 1A Corrosive Contaminants and Sources
Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning/laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops
When using an existing vent system to
install a new boiler:
WARNING
Failure to follow all instructions can result in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
Check the following venting components before installing:
· Material – For materials listed for use with this appliance, see Section 3 – General Venting. For polypropylene or stainless steel venting, an adapter of the same manufacturer must be used at the flue collar connection.
· Size – To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.
· Manufacturer – For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in Tables 3H and 3I for CAT IV positive pressure venting with flue producing condensate.
· Supports – Non-combustible supports must be in place allowing a minimum 1/4″ rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.
· Terminations – Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3J for the manufacturer of the installed vent.
· Seal – With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section of this manual.
With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section of this manual.
If any of these conditions are not met, WARNING 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.
11
Installation & Operation Manual
1 Determine boiler location
When removing a boiler from existing common vent system:
DANGER
Do not install the Knight XL into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
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.
g. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.
12
Installation & Operation Manual
2 Prepare boiler
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler, remove the parts box.
2. To remove the boiler from the pallet remove the four (4) lag bolts located at the front and rear of the boiler (FIG. 2-1).
NOTICE
Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.
Figure 2-1 Boiler Mounted on Shipping Pallet
LAG BOLTS (QTY. 2)
LEFT
DIR #2000585120 00
RIGHT
LAG BOLTS (QTY. 2)
Gas conversions
WARNING
For a boiler already installed, you must turn off gas supply, turn off power and
allow boiler to cool before proceeding.
You must also completely test the boiler
after conversion to verify performance
as described under Start-up, Section 10
of this manual. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
DANGER
Inspect the O-ring when the blower is disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.
Models 400-1000 (Venturi)
1. Remove the front access panel from the unit (no tools required for removal).
2. For Models 400-500: Disconnect the air inlet piping from the venturi by loosening the band clamp around the rubber boot coupling. Slide the rubber boot off of the venturi. For Models 650-1000: Disconnect the venturi from the air box by removing the four (4) bolts securing it to the air box.
3. For Models 400-500: Disconnect the gas piping from the venturi by loosening the threaded nut on the venturi. Replace gasket if damaged. For Models 650-1000: Disconnect the gas piping from the venturi by removing the four (4) bolts securing the pipe to the venturi.
4. Remove the bolts connecting the venturi to the fan. Remove the natural venturi from the unit (FIG.’s 2-2A and 2-2B).
5. Install the LP venturi onto the fan taking note of the following: a. The UP arrow on the plastic housing is indeed pointing up. b. The connection for the gas piping is facing towards the top of the unit. Reinstall the bolts connecting the venturi to the fan.
6. Reassemble the gas pipe to the venturi. Install the new gasket provided in the kit and ensure it is seated properly before tightening.
7. For Models 400-500: Reconnect the rubber boot on the air inlet to the venturi inlet and tighten the band clamp at this connection. For Models 650-1000: Reinstall the four (4)bolts connecting the venturi to the air box and tighten.
8. After installation is complete, attach the propane conversion label (in the conversion kit) next to the boiler rating plate. Attach the LP caution label (in the conversion kit) to the rear of the boiler underneath the gas supply piping.
Figure 2-2A Installing Propane Orifice – Models 400-500 Figure 2-2B Installing Propane Orifice – Models 650-1000
SCREWS QTY. 4
O-RING
SCREWS QTY. 3
2000618215 00
BLOWER O-RING VENTURI
GASKET
NUTS QTY. 4
SCREWS QTY. 7
DIR #2000582948 00
VENTURI
BLOWER O-RING
13
Installation & Operation Manual
2 Prepare boiler
10. For Models 400-500: Remove the front panel from the unit (no tools required for removal).
For Models 650-1000: Remove the top access cover from the unit (no tools required for removal).
Figure 2-4 Gas Valve Adjustment – Models 650 – 1000
COVER
11. For Models 650-1000: Remove the cover on top of the gas valve (FIG. 2-4).
ALLEN WRENCH
12. Use a combustion analyzer to verify CO2 is within the range of 9.4 10.4%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3 and 2-4).
ADJUSTMENT SCREW
13. Replace the gas valve cover and access covers.
14. Replace the front access panel removed in Step 1 and resume operation.
WARNING
After converting to LP, check combustion per the Start-up procedure in Section 11
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property
damage.
Combustion air filter
Figure 2-3 Gas Valve Adjustment – Models 400-500
ALLEN WRENCH
ADJUSTMENT SCREW
This unit has a standard air filter located at the combustion air inlet. This air filter is provided to help ensure clean air is used for the combustion process. Check this filter every month and replace when it becomes dirty. You can find these commercially available filters at any home center or HVAC supply store. Filters by model sizes: KBX0400-1000 / 12 x 12 x 1 filter
Note: Replacement filter should have a MERV rating no greater than 4.
DIR #2000582949 00
Follow the steps below when replacing the combustion air filter: 1. Locate the combustion air filter box. 2. Lift and remove the air filter box cover to gain access to the
air filter. 3. Slide the air filter out the top of the air filter box. 4. Inspect the air filter for dirt and debris, replace if necessary. 5. Replace the air filter and the air filter box cover.
14
3 General venting
Direct venting options – Sidewall Vent
Installation & Operation Manual
DIR #2000583013 00
DIR #2000583014 00
Two Pipe Sidewall
Direct venting options – Vertical Vent
PVC/CPVC Concentric Sidewall Models 400 – 500 Only
DIR #2000583015 00
Two Pipe Vertical
DIR #2000583016 00
PVC/CPVC Concentric Vertical Models 400 – 500 Only
DIR #2000583017 00
Vertical Vent, Sidewall Air
15
Installation & Operation Manual
3 General venting
Install vent and combustion air piping
DANGER
The Knight XL boiler must be vented and supplied with combustion and ventilation
The Knight XL boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures
air as described in this section. Ensure the in this manual for the method chosen. Refer to the information
vent and air piping and the combustion in this manual to determine acceptable vent and air piping
air supply comply with these instructions length.
regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.
Failure to provide a properly installed vent
You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight XL boiler using any other means.
You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions in this manual. The resultant installation is direct vent (sealed combustion).
and air system will cause severe personal Air intake/vent connections
injury or death.
1. Combustion Air Intake Connector (FIG. 3-1) – Used to
WARNING
This appliance requires a special venting system. Use only approved stainless steel,
provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection.
PVC, CPVC or polypropylene pipe and
Combustion air piping must be supported per guidelines
fittings listed in Tables 3H, 3I, and 3J 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, 2. Vent Connector (FIG.’s 3-2 thru 3-5) – Used to provide a
death, or substantial property damage.
passageway for conveying combustion gases to the
WARNING
DO NOT mix components from different systems. The vent system could fail,
causing leakage of flue products into the
living space. Mixing of venting materials
will void the warranty and certification of
outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
the appliance.
Figure 3-1 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.
WARNING
For closet and alcove installations, CPVC, polypropylene or stainless steel material
MUST BE used in a closet/alcove structure.
Failure to follow this warning could result
in fire, personal injury, or death.
CAUTION NOTICE
Improper installation of venting systems may result in injury or death.
Follow the instructions in Section 1 of this manual when removing a boiler from an existing vent system.
WARNING
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.
DIR #2000585133 00
16
Installation & Operation Manual
3 General venting (continued)
Requirements for installation in
Canada
1. Installations must be made with a vent pipe system certified to ULC-S636.
2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.
3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.
4. The 4″ Concentric Vent Kit available from Lochinvar (see Section 4 Sidewall Termination Optional Concentric Vent) and the 4″ Concentric Vent Kit available from IPEX are both approved for use on the Knight XL (400 – 500 models only) boiler. Both kits are listed to the ULC-S636 standard for use in Canada.
Minimum / Maximum allowable combustion air and vent piping lengths are as follows:
Combustion Air = 12 equivalent feet (3.7 m) minimum / 150 equivalent feet (30.5 m) maximum
Vent = 12 equivalent feet (3.7 m) minimum / 150 equivalent feet (30.5 m) maximum
When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.
EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows + (3) 45° elbows + (1) concentric vent kit (100140484) = 49 equivalent feet (15 m) of piping.
Sizing
The Knight XL uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.
Table 3A Air Intake/Vent Piping Sizes
Model
Air Intake
Vent
400 – 500 4 inches (102 mm) 4 inches (102 mm)
650 – 800 4 inches (102 mm) 6 inches (152 mm)
1000
6 inches (152 mm) 6 inches (152 mm)
NOTICE
Increasing or decreasing combustion air or vent piping sizes is not authorized.
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Table 3C Room Air Minimum/Maximum Allowable Vent Lengths
Model 400
Vent Diameter
4″
Vent
Input De-Rate
per 25 Feet
Vent Min. Vent Max. Length Length
of Vent
12′
150′
0.56%
500
4″
12′
150′
0.50%
650N*
4″
12′
80′
0.30%
650L*
4″
12′
30′
0.82%
650
6″
12′
150′
0.10%
800
6″
12′
150′
0.50%
Model
400 500
Kit Number
100140484 100140484
Equivalent Vent Length 30 Feet (9 m) 30 Feet (9 m)
1000
6″
12′
150′
0.66%
*When using 4″ vent for the 650 model, the allowable vent length for propane models is different from the allowable vent length for natural gas models.
Table 3D Direct Vent Minimum/Maximum Allowable Air/Vent Lengths
Air Inlet
Vent
Input De-Rate
Model
Air Intake Diameter
Air Intake Min. Length
Air Intake Max. Length
Vent Diameter
Vent Min. Length
Vent Max. Length
per 25 Feet of Vent
400
4″
12′
150′
4″
12′
150′
0.78%
500
4″
12′
150′
4″
12′
150′
0.83%
650N*
4″
12′
80′
4″
12′
80′
0.29%
650L*
4″
12′
30′
4″
12′
30′
0.81%
650
4″
12′
150′
6″
12′
150′
2.00%
650
6″
12′
150′
6″
12′
150′
0.60%
800
4″
12′
100′
6″
12′
100′
0.63%
800
6″
12′
150′
6″
12′
150′
0.38%
1000
6″
12′
150′
6″
12′
150′
1.00%
*When using 4″ vent for the 650 model, the allowable vent length for propane models is different from the allowable vent length for natural
gas models.
17
Installation & Operation Manual
3 General venting
Air inlet pipe materials:
Common venting
The air inlet pipe(s) must be sealed. Choose acceptable Knight XL boilers may be common vented; however, the
combustion air inlet pipe materials from the following list:
following criteria MUST BE followed:
PVC, CPVC, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.
1. Only Knight XL boilers may be connected to the common vent. DO NOT mix other manufacturer’s appliances or other Lochinvar models.
2. Knight XL boilers connected to the common vent must all be of the same size.
3. Each Knight XL boiler must have a Lochinvar supplied flue damper installed (see Table 3E).
4. A condensate drain must be installed above the flue damper.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.
WARNING Using air intake materials other than those specified can result in personal injury, death or property damage.
NOTICE
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of horizontal runs.
c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.
5. Only vertical direct vent, positive pressure, Category IV or vertical/chimney vent, negative pressure, Category II may be used when common venting Knight XL boilers. Sidewall common venting is not allowed.
6. Knight XL boilers in a common vent must be connected and controlled with the integral Knight XL SMART TOUCH Cascade.
a. The leader may be controlled through the Knight XL SMART TOUCH control through BMS (external 0-10V signal), ModBus, BACnet, or its own internally calculated set point.
b. The Cascade (Members) must be controlled by the Knight XL Leader water heater using the Lead/Lag Cascade option.
For approved common vent sizing, contact the factory.
Knight XL boilers cannot be connected using a common air system.
WARNING When Knight XL boilers are common vented, the criteria above MUST BE followed. Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.
WARNING When Knight XL boilers are common vented, hot water generators must be piped to the primary heating loop and tank thermostats must not be connected to the Knight XL.
NOTICE
A field supplied inline condensate collection section MUST BE installed directly above the backflow preventer.
Table 3E Flue damper kits
Flue Damper Kits
Follow the polypropylene manufacturer’s instructions when using polypropylene material as an inlet pipe.
When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.
DANGER
18
Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.
Model 400 500 650 800 1000
Damper Size 4″ 4″ 6″ 6″ 6″
Kit Number 100056141 100056141 100056142 100056142 100056142
Installation & Operation Manual
3 General venting (continued)
Common venting CAT II:
Flues of multiple appliances may be combined by incorporating a vent increaser to change the Category IV appliance to a Category II vent system which can be common vented using an engineered vent system. An increaser must be used and the combined engineered vent system must be designed to ensure that flue products will be properly exhausted from the building at all times. Failure to use the correct vent increaser or a properly sized vent system may result in a hazardous condition where flue gases spill into an occupied living space. Consult a vent designer to determine the diameter of the common vent pipe required for combined vent installation. It is recommended that all vent joints and seams are sealed gastight. This vent system has specific vent material and installation requirements. The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation (approximately 2 to 5 minutes).
Table 3F Category IV to Category II Conversion Chart
Model 400
Category IV Standard Vent
Size
4″
Category II Maximum Increaser Size Vent Length
6″
150′
500
4″
6″
150′
650
6″
8″
150′
800
6″
8″
150′
1000
6″
8″
150′
Optional room air
NOTICE
Optional room air is intended for commercial applications. Combustion air piping to
the outside is recommended for residential
applications.
Commercial applications utilizing the Knight XL boiler may
be installed with a single pipe carrying the flue products to
the outside while using combustion air from the equipment
room. In order to use the room air venting option the following
conditions and considerations must be followed.
· The unit MUST be installed with the appropriate room
air kit (Table 3G).
· The equipment room MUST be provided with properly
sized openings to assure adequate combustion air.
Please refer to instructions provided with the room air
kit.
· There will be a noticeable increase in the noise level
during normal operation from the inlet air opening.
· Using the room air kit makes the unit vulnerable to
combustion air contamination from within the
building. Please review Section 1, Prevent Combustion
Air Contamination, to ensure proper installation.
· Vent system and terminations must comply with the
standard venting instructions set forth in this manual.
WARNING
When utilizing the single pipe method, provisions for combustion and ventilation
air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
Table 3G Optional Room Air Kit
Model
Description
Kit Number
400 – 1000 90° Elbow with Screen 100157616
Air contamination
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
Please read the information given in Table 1A listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.
WARNING
If the boiler combustion air inlet is located in a laundry room or pool facility, for example,
these areas will always contain hazardous
contaminants.
WARNING
To prevent the potential of severe personal injury or death, check for areas and products
listed in Table 1A before installing the boiler
or air inlet piping.
If contaminants are found, you MUST:
· Remove contaminants permanently.
–OR–
· Relocate air inlet and vent terminations
PVC/CPVC
to other areas.
This product has been approved for use with the PVC/CPVC vent materials listed in Table 3H.
Installing vent and air piping
WARNING The vent connection to the appliance must be made with the CPVC pipe section if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3H to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
NOTICE
Use only cleaners, primers, and solvents that are approved for the materials which are joined together.
NOTICE
All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).
WARNING
Insulation should not be used on PVC or CPVC venting materials. The use of
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
19
Installation & Operation Manual
3 General venting
Table 3H PVC/CPVC Vent Pipe and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
Item
Material
Standard
PVC Schedule 40, 80 ANSI/ASTM D1785
Vent pipe PVC – DWV
ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
PVC Schedule 40 ANSI/ASTM D2466
PVC Schedule 80 ANSI/ASTM D2467 Vent fittings CPVC Schedule 80 ANSI/ASTM F439
PVC – DWV
ANSI/ASTM D2665
Pipe Cement / PVC
Primer
CPVC
ANSI/ASTM D2564 ANSI/ASTM F493
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/ primer must be ULC-S636 certified.
1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.
2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)
Figure 3-2 Near Boiler PVC/CPVC Venting – Models 400 – 1000
5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2″ beyond the socket depth.
c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.
g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.
VENT
20
*CPVC STREET ELBOW MAY BE SUBSTITUTED
NOTE: WHEN USING A PVC/CPVC VENT SYSTEM, THE FIRST CONNECTION TO THE APPLIANCE MUST BE MADE WITH CPVC.
DIR #2000585151 00
Installation & Operation Manual
3 General venting (continued)
Polypropylene
This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3H.
All terminations must comply with listed options in this manual and be a single-wall vent offering.
NOTICE
Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.
Figure 3-3 Near Boiler Flexible Polypropylene Venting
For support and special connections required, see the manufacturer’s instructions. All vent is to conform to standard diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length for polypropylene single-wall piping:
· 1 foot of Duravent 4 inch single-wall pipe is equivalent to 1 foot of piping
Flexible polypropylene
CAP CHIMNEY
Duravent 3″
Duravent 4″
“A” DIM
“B” DIM
“A” DIM
“B” DIM
3″ RIGID 3″ FLEX 4″ FLEX 4″ RIGID 4″ FLEX 5″ FLEX
10 FT 60 FT 90 FT
10 FT 30 FT 90 FT
20 FT 53 FT 80 FT
20 FT 27 FT 80 FT
30 FT 47 FT 70 FT
B
40 FT 40 FT 60 FT
30 FT 23 FT 70 FT 40 FT 20 FT 60 FT
50 FT 33 FT 50 FT
50 FT 17 FT 50 FT
60 FT 27 FT 40 FT 70 FT 20 FT 30 FT
60 FT 13 FT 40 FT 70 FT 10 FT 30 FT
80 FT 13 FT 20 FT
80 FT 7 FT 20 FT
90 FT 7 FT 10 FT
90 FT 3 FT 10 FT
For use of flex pipe, it is recommended to have the vent material
in 32°F or higher ambient space before bending at installation.
No bends should be made to greater than 45° and ONLY
installed in vertical or near vertical installations (FIG. 3-3).
NOTICE
The installer must use a specific vent starter adapter at the flue collar connection. The
adapter is supplied by the vent manufacturer
to adapt to its vent system. See Table 3H
A
Centrotherm 3″
Centrotherm 4″
“A” DIM
“B” DIM
“A” DIM “B” DIM
3″ RIGID 3″ FLEX 4″ 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
60 FT 20 FT 40 FT
60 FT 15 FT
70 FT 15 FT 30 FT
70 FT 11 FT
80 FT 10 FT 20 FT
80 FT 7 FT
90 FT 5 FT 10 FT
90 FT 4 FT
for approved vent adapters. Discard CPVC
starter piece.
NOTICE
All vent connections MUST be secured by the vent manufacturer’s joint connector
(FIG. 3-4).
WARNING
Insulation should not be used on polypropylene venting materials. The use of insulation will
*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
FOR DETERMINING EQUIVALENT FEET.
IMG00840
Figure 3-4 Near Boiler Polypropylene Venting
cause increased vent wall temperatures, which
could result in vent pipe failure.
WARNING
Use only the adapters and vent system listed in Tables 3H and 3I. DO NOT mix vent systems
of different types or manufacturers. Failure to
comply could result in severe personal injury,
NOTICE
death, or substantial property damage. Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.
CPVC STARTER
DURAVENT ADAPTER
Table 3I Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make Centrotherm Eco Systems
Model InnoFlue SW/Flex
JOINT CONNECTION REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM
CPVC XF POLYPRO ADAPTER
DIR #2000536703 00
Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex
Table 3J Approved PolypropyleneTerminations
Model
400-500
Centrotherm InnoFlue SW
Polypropylene Adapter
Joint
Connector
Sidewall Retaining Bracket*
Sidewall Adapter*
Low Profile Wall Termination
ISAAL0404
IANS04
IATP0404
ISTAGL0404
ISLPT0404
Concentric Wall Termination
ICWT462 & ICT0446
650-1000 ISAAL0606 Not Required
IATP0606
ISTAGL0606
ISLPT0606 ICWT610 & ICTC06610
DuraVent Polypro
Model
Polypropylene Adapter
Joint Connector
Sidewall Kit* * These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B).
400-500
4PPS-AD-M
4PPS-LB 4PPS-HLK
21
650-1000 6PPS-06PVCM-6PPF Not Required 6PPS-HLK
Installation & Operation Manual
3 General venting
Stainless steel vent
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3K.
WARNING
Use only the materials, vent systems, and terminations listed in Tables 3I and 3K. DO
NOT mix vent systems of different types or
manufacturers. Failure to comply could
result in severe personal injury, death, or
NOTICE
substantial property damage. The installer must use a specific vent starter
adapter at the flue collar connection,
supplied by the vent manufacturer to
adapt to its vent system. See Table 3K for
approved vent adapters. Discard CPVC
NOTICE
starter piece. Installations must comply with applicable
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system for
NOTICE
Canada. Installation of a stainless steel vent system should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
Figure 3-5 Near Boiler Stainless Steel Venting Models 400 – 1000
VENT
HORIZONTAL ADAPTER
DIR #2000585159 00
Table 3K Stainless Steel Vent Pipe and Fittings
Approved Stainless Steel Vent Manufacturers
Make
Model
Dura Vent (M & G Group)
Z-Flex (Nova Flex Group) Heat Fab (Selkirk Corporation) Metal Fab Security Chimney ICC Van Packer
FasNSeal Vent / FasNSeal Flex* Vent Z-Vent
Saf-T Vent Corr/Guard Secure Seal
VIC —
*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.
Enervex
Powervent
Jeremias
—
Table 3L Approved Stainless Steel Terminations and Adapters
DuraVent
Heat Fab
Model
Boiler
FasNSeal
Flue
Intake Air
Saf-T Vent
Boiler Flue
Intake Air
Adapter Termination Termination Adapter Termination Termination
400-500
FSA-4PVC4FNS
FSBS4 FSRC4
FSAIH04
9401PVC
9492 5400CI
9414TERM
650-800
FSA-6PVC6FNS
FSBS6 FSRC6
FSAIH04
9601PVC
9690 9692
9414TERM
Z Flex
Z-Vent
Boiler
Flue
Intake Air
Adapter Termination Termination
2SVSLA04
2SVSTP(F,X)04 2SVSRCX04
2SVSTEX0490
2SVSTTA06 2SVSTPX06 2SVSTEX0490 2SVSRCX06
1000
FSA-6PVC6FNS
FSBS6 FSRC6
FSAIH06
9601PVC
9690 9692
9614TERM
2SVSTTA06 2SVSTPX06 2SVSEE0690 2SVSRCX06 & 2SVSTPX06
Metal Fab
Security Chimney
ICC
Model
Corr/Guard
Boiler
Flue
Intake Air
Adapter Termination Termination
400-500 4CGPVCA
4CGSWHT 4CGSWC
4CGSW90LT
Secure Seal
Boiler Flue
Intake Air
Adapter Termination Termination
SS4PVCU
SS4STU SS4RCBU
SS4ST90AU
Boiler Adapter
HO-04PA
VIC Flue Termination
HM-04MC HM-04SR
Intake Air Termination HE-04E90
HM-04SR
650-800
6FCGPVCA
6FCGSWMC 6FCGSWC
4CGSW90LT
SS6PVCU
SS6STU SS6RCBU
SS4ST90AU
HO-06PA
HM-06MC HM-06SR
HE-04E90 HM-04SR
1000
6FCGPVCA
6FCGSWMC 6FCGSWC
6FCGSW90L
SS6PVCU
SS6STU SS6RCBU
SS6ST90AU
HO-06PA
HM-06MC HM-06SR
HE-06E90 HM-06SR
3 General venting
Table 3L Approved Stainless Steel Terminations and Adapters Continued
Model
400-500
Enervex Powervent
Boiler Adapter Flue Termination
801.0676.4604 801.0679.1004
Intake Air Termination
801.0676.4604
650-800 801.0676.4606 801.0679.1006 801.0676.4604
1000
801.0676.4606 801.0679.1006 801.0676.4606
Model
Boiler Adapter
Jeremias
Flue Termination
Intake Air Termination
Boiler Adapter
C04PVC04.38B/ C04PVC04.38B C04PVC04.38B/ C06PVC06.50B C06PVC06.50B/ C06PVC06.50B
400-500 SWKL4-KLC
SWKL4-WRC
SWKL4-90ET
650-800 SWKL6-KLC
SWKL6-WRC
SWKL4-90ET
1000
SWKL6-KLC
SWKL6-WRC
SWKL6-90ET
Installation & Operation Manual
Van Packer
Flue Termination
Intake Air Termination
M0490EB & M04SCTB M0490EB & M04SCTB
M0690EB & M06SCTB M0490EB & M04SCTB
M0690EB & M06SCTB M0690EB & M06SCTB
23
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination sidewall
WARNING
Follow instructions below determining vent location to
when avoid
possibility of severe personal injury, death,
or substantial property damage.
WARNING
A gas vent extending through an exterior wall shall not terminate adjacent to a
wall or below building extensions such
as eaves, parapets, balconies, or decks.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section of this manual.
2. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.
WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone.
f. Do not terminate above any door or window. Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior finishes.
Figure 4-1A PVC/CPVC/Polypropylene Sidewall
Termination of Air and Vent
TO BOILER INTAKE AIR CONNECTION
FROM BOILER VENT PIPE
CONNECTION POSSIBLE ORIENTATIONS
VENT / AIR TERMINATION
12″ MIN TO OVERHANG
12″ MIN
GRADE OR SNOW LINE
Table 4A Sidewall Vent Kits
Model Kit Number Air Intake Vent Size
400 – 500 100157611
4″
650 – 800 100157613
4″
1000
100157612
6″
4″ vent 6″ vent 6″ vent
If using the alternate sidewall termination:
3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation of flue products into the combustion air stream.
4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.
WARNING
Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B.
Excessive length exposed to the outside could
cause freezing of condensate in the vent pipe,
resulting in potential boiler shutdown.
Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings
24
Installation & Operation Manual
4 Sidewall direct venting
Vent/air termination sidewall
Figure 4-2A Alternate PVC/CPVC/ Polypropylene Sidewall Termination w/Field Supplied Fittings
TO BOILER INTAKE AIR CONNECTION
BIRD SCREEN
FROM BOILER VENT PIPE
CONNECTION
12″ (305 MM) MIN
c. Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally.
6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
Figure 4-3A Clearance to Gravity Air Inlets
BIRD SCREEN
12″ (305 MM) MIN
GRADE OR SNOW LINE
Figure 4-2B Alternate Stainless Steel Sidewall Termination w/Field Supplied Fittings
12″ MIN.
12″ MIN.
4′ MIN.
VENT / AIR TERMINATION
TO BOILER INTAKE AIR CONNECTION
FROM BOILER VENT PIPE CONNECTION
12″ (305 MM) MIN 12″ (305 MM) MIN
Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings
GRADE OR SNOW LINE
NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4B. Also maintain the following: a. Vent must terminate: · At least 6 feet (1.8 m) from adjacent walls. · No closer than 12 inches (305 mm) below roof overhang. · At least 7 feet (2.1 m) above any public walkway. · At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m). · No closer than 12 inches (305 mm) below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches (305 mm) above grade or snow line; at least 12 inches (305 mm) below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches (610 mm) vertically outside the building.
12″ MIN.
12″ MIN.
4′ MIN.
BIRD SCREEN (TYPICAL)
25
Installation & Operation Manual
4 Sidewall direct venting (continued)
Vent/air termination sidewall
Figure 4-4A Clearance to Forced Air Inlets
IF LESS THAN 10′
VENT / AIR TERMINATION
36″ MIN.
FORCED AIR INLET
7′ MIN. ABOVE ANY PUBLIC WALKWAY
Figure 4-4B Alternate Clearance to Forced Air Inlets w/Field Supplied Fittings
IF LESS THAN 10′ (3 M)
36″ (914 MM) MIN
2. For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3H into the vent 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. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3H to seal the vent pipe.
3. 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 4-5A and 4-5B). 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.
8. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.
9. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.
Figure 4-5A PVC/CPVC Sidewall Termination Assembly
7′ (2.1 M) MIN ABOVE ANY PUBLIC WALKWAY
FORCED AIR INLET
BIRD SCREEN (TYPICAL)
VENT AIR
AIR PIPING
CENTERLINE WIDTH
Prepare wall penetrations
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.
Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe
Drill 3/16″ diameter holes for inserting the plastic anchors into the wall.
26
VENT PIPING
WALL PLATE
GALVANIZED THIMBLE
VENT PLATE VENT CAP
Table 4B Sidewall Vent Centerline Dimensions
Model Air
400 – 500
4″
650 – 800
4″
1000
6″
Vent Centerline Width
4″
5 5/8″
6″
7 3/4″
6″
7 3/4″
Installation & Operation Manual
4 Sidewall direct venting
Figure 4-5B Polypropylene Sidewall Termination Assembly Multiple vent/air terminations
SIDEWALL
ADAPTER
(AIR)
WALL
PLATE
SIDEWALL RETAINING PLATE
VENT PLATE
1. When terminating multiple Knight XL’s terminate each vent/air connection as described in this manual (FIG. 4-6A).
WARNING
All vent pipes and air inlets must terminate at the same height to avoid possibility of
severe personal injury, death, or substantial
property damage.
SIDEWALL ADAPTER (VENT)
VENT 2. Place wall penetrations to obtain minimum clearance of
CAP
12 inches (305 mm) between vent pipe and adjacent air
inlet elbow, as shown in FIG. 4-6A for U.S. installations.
For Canadian installations, provide clearances required
by CSA B149.1 Installation Code.
GALVANIZED THIMBLE
IMG00085
Prepare wall penetrations (Alternate – Field Supplied Option)
1. 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.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-5C.
3. Use a sidewall termination plate as a template for correct location of hole centers.
4. Follow all local codes for isolation of vent pipe when passing through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
3. The air inlet of a Knight XL is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.
Figure 4-6A Multiple Vent Terminations (must also comply with Figure 4-1A)
VENT
12″ MIN. BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET
AIR
VENT / AIR TERMINATION
Figure 4-6B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1B)
VENT
Figure 4-5C A Typical Sidewall Termination Assembly – PVC/ CPVC/ Polypropylene or Stainless Steel
SIDEWALL TERMINATION PLATE
VENT PIPING
GALVANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES)
ELBOW
AIR PIPING
12″ (305 MM) MIN
BIRD SCREEN
ELBOW BIRD SCREEN
12″ (305 MM) MIN. BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE
AIR
27
Installation & Operation Manual
4 Sidewall direct venting (continued)
Sidewall termination optional concentric vent: Models 400 – 500 Only
Description and usage
Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#100140484 for 4″ (102 mm) diameter – Models 400 – 500). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7.
The required combustion vent pipe materials are listed in Table 3H of this manual.
3. Cut one (1) hole 7 inch (178 mm) diameter for #100140484 installations into the structure to install the termination kit.
4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.
a. Cement the Y concentric fitting to the larger kit pipe (FIG. 4-8).
b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-8).
Figure 4-7 Concentric Sidewall Termination
OVERHANG OR ROOF
Figure 4-8 Kit Contents_100140484 – Models 400 – 500
RAIN CAP
6″ (152 MM) TO 4″ (102 MM) REDUCER
6″ (152 MM) DIA.
12″ (305 MM) MIN
12″ (305 MM) MIN
6″ (152 MM) DIA.
4″ (102 MM) DIA. “Y” CONCENTRIC FITTING 6″ (152 MM) DIA. “FLEXIBLE” PIPE COUPLING
GRADE / SNOW LINE
Sidewall termination installation 1. Determine the best location for the termination kit
(see FIG. 4-7).
2. Reference the Determine Location Section of this manual for general termination considerations.
Table 4C Alternate Centrotherm Concentric Vent Terminations
Roof Terminations
Size
Part No.
4″
ICRT4679
Wall Terminations
Size
Part No.
4″
ICWT462
28
Installation & Operation Manual
4 Sidewall direct venting
Sidewall termination optional concentric vent: Models 400 – 500 Only
Figure 4-9 Concentric Vent Dimensional Drawing – Models 400 – 500
“A”
“C” DIA.
“B” DIA.
3″
“D”
(76 MM)
“E”
“G”
“H” DIA.
“B” DIA. PVC
“F”
VENT / EXHAUST
A
B
C
D
E
F
G
H
60″
4″
6″ 21 1/8″ 10″ 7 5/8″ 3″ 6 5/8″
(1524 MM) (102 MM) (152 MM) (537 MM) (254 MM) (194 MM) (76 MM) (168 MM)
NOTICE
Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-10).
WARNING
When using the alternate screw assembly method, drill a clearance hole in the rain
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
WARNING
Do not operate the appliance with the rain cap removed or recirculation of combustion
products may occur. Water may also collect
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to
follow this warning could result in product
damage or improper operation, personal
injury, or death.
Figure 4-10 Rain Cap to Vent Pipe Alternate Assembly
STAINLESS STEEL SCREW (FIELD SUPPLIED)
DRILL CLEARANCE HOLE IN RAIN CAP & PILOT HOLE IN VENT PIPE
5. Install the Y concentric fitting and pipe assembly through the structure’s hole from an inside wall.
NOTICE
Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.
6. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly from an outside wall. Ensure small diameter pipe is fastened tightly into the rubber adapter for #100140484 installations.
7. Secure the assembly to the structure as shown in FIG. 4-11 using field-supplied metal strapping or equivalent support material.
NOTICE
Ensure termination location clearance dimensions are as shown in FIG. 4-7.
NOTICE
If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied standard schedule 40 PVC. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9).
NOTICE
If assembly depth needs to be reduced, dimension D can be as short as possible.
29
Installation & Operation Manual
4 Sidewall direct venting (continued)
Sidewall termination optional concentric vent: Models 400 – 500 Only
Figure 4-11 Concentric Vent Sidewall Attachment
ELBOW (FIELD SUPPLIED)
STRAP (FIELD SUPPLIED)
COMBUSTION AIR
COMBUSTION AIR
VENT
VENT
CAUTION
DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.
8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-11 for proper pipe attachment.
9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.
Multiventing sidewall terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-12). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-12. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
VENT
12″ MINIMUM
COMBUSTION AIR Figure 4-12 Concentric Vent and Combustion Air Termination
30
Installation & Operation Manual
5 Vertical direct venting
Vent/air termination vertical
WARNING
Follow instructions below determining vent location to
when avoid
possibility of severe personal injury, death
or substantial property damage.
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section of this manual.
2. Prepare the vent termination and the air termination elbow (FIG. 5-1A) by inserting bird screens.
3. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.
4. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.
5. The vent piping must terminate in an up-turned coupling as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36″ (914 mm) above the air inlet. The air inlet pipe and vent 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 above the air intake.
6. Maintain the required dimensions of the finished termination piping as shown in FIG. 5-1A.
Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ (610 MM) OF VENT PIPE
BIRD SCREEN (TYPICAL)
COUPLING (FIELD SUPPLIED)
VENT OUTLET 12″ MINIMUM
ABOVE AIR INLET
VENT
COMBUSTION AIR
6″ (152 MM) MINIMUM ABOVE ROOF / SNOW LINE
Figure 5-1B Stainless Steel Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ (610 MM) OF VENT PIPE
BIRD SCREEN
VENT
(TYPICAL)
6″ (152 MM) MINIMUM ABOVE ROOF / SNOW LINE
VENT OUTLET 36″ (914 MM) MINIMUM
ABOVE AIR INLET
COM,BUSTION AIR
8. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.
WARNING
Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent, Sidewall Air Section.
31
Installation & Operation Manual
5 Vertical direct venting (continued)
Vent/air termination vertical
Prepare roof penetrations
1. 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 5-2 Vertical Terminations with Multiple Boilers
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe
b. Insert a galvanized metal thimble in the vent pipe hole (when required by local codes).
3. Space the air and vent holes to provide the minimum spacing shown in FIG.’s 5-1A and 5-1B.
VENT AIR
VENT AIR
12″ (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET
12″ (305 MM) MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER
Figure 5-3 Alternate Vertical Terminations with Multiple Boilers
4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe and air pipe.
Multiple vent/air terminations
1. When terminating multiple Knight XL boilers, terminate each vent/air connection as described 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 recirculation of flue products and
the possibility of severe personal injury,
death, or substantial property damage.
VENT
VENT
AIR AIR
12″ (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET
2. Place roof penetrations to obtain minimum clearance of 12 inches (305 mm) 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 XL 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.
32
Installation & Operation Manual
5 Vertical direct venting
Vertical termination optional concentric vent: Models 400 – 500 Only
Description and usage
Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
The required combustion vent pipe fittings are listed in Table 3H.
Vertical termination installation
1. See Section 5, Vertical Direct Venting – Determine Location (where applicable).
Figure 5-4 Concentric Vertical Termination
2. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 installations) into the structure to install the termination kit.
3. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions. a. Cement the Y concentric fitting to the larger diameter kit pipe (see FIG. 4-8). b. Cement rain cap to the smaller diameter kit pipe (see FIG. 4-8).
NOTICE
Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-10).
VENT
12″ (305 MM) (18″ (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24″ (610 MM) ABOVE ROOF.
COMBUSTION AIR
WARNING When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.
Figure 5-5 Do Not Install U-Bend to Rain Cap
33
Installation & Operation Manual
5 Vertical direct venting (continued)
Vertical termination optional concentric vent: Models 400 – 500 Only
WARNING
Do the
not rain
operate the cap removed
appliance with or recirculation
of combustion products may occur.
Water may also collect inside the larger
combustion air pipe and flow to the
burner enclosure. Failure to follow this
warning could result in product damage
or improper operation, personal injury,
or death.
4. Install the Y concentric fitting pipe assembly up through the structure’s hole and field supplied roof boot/flashing.
CAUTION
DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.
6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is fastened tightly into the rubber adapter for #100140484 installations.
7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.
NOTICE
Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.
5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.
Figure 5-6 Concentric Vent Roof Installation
COMBUSTION AIR
ROOF BOOT / FLASHING (FIELD SUPPLIED)
VENT
12″ (305 MM) (18″ (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24″ (610 MM) ABOVE ROOF.
8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.
Multiventing vertical terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
SUPPORT (FIELD SUPPLIED)
ELBOW (FIELD SUPPLIED)
Figure 5-7 Concentric Vent and Combustion Air Vertical Termination
12″ MINIMUM
VENT
COMBUSTION AIR
NOTICE NOTICE
Ensure termination height is above the roof surface or anticipated snow level (12 inches (305 mm) in U.S.A. or 18 inches (457 mm) in Canada) as shown in FIG. 5-4.
If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied standard schedule 40 PVC for 100140484. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9).
34
12″ (18″ FOR CANADA) MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF
24″ ABOVE ROOF.
COMBUSTION AIR (TYPICAL)
Installation & Operation Manual
5 Vertical direct venting
Alternate vertical concentric venting
This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.
Concentric Venting Arrangement
The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.
The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A.
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.
Figure 5-8 Concentric Vent Example 1
FLUE EXHAUST
AIR INLET W/ SCREEN
12″ MIN.
SEAL COMBUSTION AIR
EXISTING
SEAL
SEALED CAP
FLUE OUTLET
DIR #2000585169 00
Approved venting materials must be used as specified in Table 3H.
Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.
The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.
*For concept illustration only. Individual installations may vary due to job site specific equipment.
Figure 5-9 Concentric Vent Example 2
SEAL
FLUE EXHAUST
If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A for a list of corrosive contaminants and sources.
Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
AIR INLET W/ SCREEN
SEAL
COMBUSTION AIR EXISTING
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
Model
Vent / Air Inlet Size
400 – 500
4″
650 – 1000
6″
Minimum Existing Vent / Chase Size
7″ 10″
SEAL
SEALED CAP
DIR #2000585169 00
FLUE OUTLET
*For concept illustration only. Individual installations may vary due to job site specific equipment.
35
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
AIR INLET
FLUE EXHAUST
SEAL
EXISTING
Installation & Operation Manual
CAP
SEAL
FLUE OUTLET
DIR #2000585169 00
*For concept illustration only. Individual installations may vary due to job site specific equipment.
36
Installation & Operation Manual
6 Outdoor installations
Outdoor venting
· In order to properly install the appliance in an outdoor configuration, the appropriate outdoor ready model (ex. KBX0400N-O) must be purchased WITH a factory supplied outdoor installation kit.
· In order to properly install the appliance in an outdoor configuration the optional outdoor kit must be used (see Table 6A).
· Vent materials for outdoor venting are to be field supplied. · Vent materials must be stainless steel. · The vent must terminate at least 36 inches above the top of
the unit. · All vent materials must be supported as recommended by
the vent manufacturer. · The terminations in Table 6B must be used.
Table 6A Indoor to Outdoor Conversion Kit
Model
Indoor to Outdoor Conversion Kit
400 – 1000
100331712
NOTICE
Before installing a venting system, follow all requirements found in the General Venting section of this manual.
Units are self-venting and can be used outdoors when installed with the optional outdoor kit. All vent materials must be field supplied and supported per the vent manufacturer’s instructions.
Outdoor vent / air inlet location
Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain minimum clearances to combustibles as stated in this manual.
Location of unit
For outdoor models, you must install a flue termination. Instructions for mounting the flue termination are included in this manual. Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block, or other non-combustible pad. See Outdoor Installation Venting. A wind proof cabinet protects the unit from weather.
WARNING
This product contains a condensate management and disposal system that may be subject to freezing if exposed to sustained temperatures below 32°F. Precautions should be taken to protect the condensate trap and drain lines during extended periods of outdoor temperatures below 32°F.
CAUTION
This unit is not intended for installations where temperatures may reach below 32°F (0°C). Exposure to freezing temperatures will cause the system and appliance to freeze and leak.
Figure 6-1 Outdoor installation
WARNING
Only use the vent caps specified in this manual. Personal injury or product damage may result if any other cap is used, or if an indoor model is used outdoors. Properly install all covers, doors, and jacket panels to ensure proper operation and prevent a hazardous condition.
Combustion air supply must be free of contaminants (see the Combustion and Ventilation Air Requirements section of this manual). To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section.
36″
DIR #2000586797 00
Table 6B Approved Stainless Steel Adapters and Rain Caps
Model
400 – 500 650 – 1000
DuraVent
Adapter Rain Cap
FSA-4PVC-4FNS
FSRC4
810005231
FSRC6
Z-Flex
Adapter Rain Cap
2SVSLA04 2SVSXITC04
–
–
Heat Fab Adapter Rain Cap
9401PVC CCA04EX06 9601PVC CCA06EX08
Metal Fab Adapter Rain Cap
4CGPVCA 4FCSEC-C60 6CGPVCA 6FCSEC-C60
Security Chimney
Adapter Rain Cap
SS4PVCU
SS4ECU
SS6PVCU
SS6ECU
37
Installation & Operation Manual
6 Outdoor installations (continued)
Outdoor venting
NOTICE Before installing a venting system, follow all requirements found in the General Venting section. Units are self-venting and can be used outdoors when installed with the optional outdoor kit. Combustion air supply must be free of contaminants (see Combustion and Ventilation Air, page 10). To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section. Outdoor vent/air inlet location Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain a minimum clearance of 3″ (76 mm) to combustible surfaces and a minimum of 36″ (915 mm) clearance to the air inlet. To avoid a blocked air inlet or blocked flue condition, keep the air inlet, flue outlet, and condensate trap clear of leaves, debris, etc. Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block, or other noncombustible pad. Do not locate unit so that high winds can deflect off of adjacent walls, buildings, or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion, or damage to controls. Multiple unit outdoor installations require 48″ (1.22 m) clearance between each vent cap. Locate outdoor cap at least 48″ (1.22m) below and 48″ (1.22 m) horizontally from any window, door, walkway, or gravity air intake. Locate unit at least 10 feet (3.05 m) away from any forced air inlet. Locate unit at least 3 feet (0.91 m) outside any overhang. Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs, or other plants to obstruct the proper operation of the outdoor vent system. Do not install in locations where rain from building runoff drains will spill onto the unit.
Figure 6-2 Outdoor Venting – Stainless Steel
RAIN CAP (FIELD SUPPLIED)
STAINLESS STEEL VENT PIPE (FIELD SUPPLIED)
RAIN CHANNEL COVER
DIR #2000586797 00
90° STAINLESS STEEL ELBOW (FIELD SUPPLIED AS NEEDED)
VENT ADAPTER (FIELD SUPPLIED) CONDENSATE TRAP COVER
NOTE: See Table 6B for approved stainless steel adapters and rain caps.
38
Installation & Operation Manual
7 Hydronic piping
System water piping methods
Water connections
The Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa) (Nonmetallic system piping must have an oxygen barrier to be considered a closed loop). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.
It is important to note that the boiler has a minimal amount of pressure drop which must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation or basic service of circulator replacement, valves, and others.
The inlet and outlet water connections on the KBX0400 KBX0800 are 2″ copper sweat. The inlet and outlet water connections on the KBX1000 are 2-1/2″ copper sweat. The KBX1000 water connections also have a groove in case a groovelock fitting is preferred. For copper-to-copper connections, Victaulic style 607 QuikVic rigid couplings are recommended. For copper-to-stainless steel connections, Victaulic style 644 transition couplings are recommended. For copper-to-carbon steel connections, Victaulic style 647 dielectric transitions are recommended. For other groove-lock connection styles contact the factory.
Figure 7-1A Sweat connection for 1000
Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.
Low water cutoff device
On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.
Chilled water system
General piping information
2000612893 00
IMPORTANT
All boiler piping must contain an oxygen barrier. This will help prevent any excess
oxygen from entering the system.
If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.
Freeze protection fluids
Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.
WARNING
Use only inhibited propylene glycol solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-7 through 6-11), which will guide you through the installation of the Knight XL (reference FIG.’s 7-2A and 7-2B).
1. Connect the system return marked “Inlet”.
2. Connect the system supply marked “Outlet”.
3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.
4. Install a backflow preventer on the cold feed make-up water line.
5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).
6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.
NOTICE
The relief valve, tee and any other necessary fittings are shipped in the install kit with the boiler and are to be field installed (FIG. 7-1).
39
Installation & Operation Manual
7 Hydronic piping (continued)
7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi (103 kPa).
10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to a suitable drain to prevent injury in the event of pressure relief. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.
11. Install a field supplied strainer/filter to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre-existing system, a strainer/filter capable of removing debris left in the system is recommended.
NOTICE
A magnetic separator is recommended when a unit is installed in a retrofit system or a system containing steel and/or cast iron pipe.
See the piping illustrations included in this section, FIG.’s 7-4 thru 7-8 for suggested guidelines in piping the Knight XL.
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.
Temperature and pressure gauge
installation
Basic steps are listed below to guide you through the installation of the temperature and pressure gauge provided with the unit.
1. Install a field provided tee with the gauge fitting positioned vertically and on the top (FIG. 7-1B)
2. Install the temperature and pressure gauge provided with the unit into the top fitting of the tee (a bushing may be necessary) installed in Step 8 (FIG. 7-1B).
Figure 7-1B Temperature and Pressure Gauge Installation
12. Install a field supplied magnetic separator in the heating system return line as close as practical to the boiler per the manufacturer’s instructions.
FLOW SWITCH RELIEF VALVE
TEMPERATURE & PRESSURE GAUGE
TEE WITH FITTING ON TOP (FIELD PROVIDED)
DIR #2000585175 00
40
Installation & Operation Manual
7 Hydronic piping
Near boiler piping components
1. Boiler system piping: Boiler system piping MUST be sized per the pipe requirements listed in Table 6B. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on 20 feet (6 m) of piping, 4 – 90° elbows, and 2 – fully ported ball valves.
2. Boiler system circulating pump: Field supplied. The boiler circulating pump should be based on the heat exchanger pressure drop and any additional piping.
3. Domestic hot water circulating pump: Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in FIG. 7-3. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.
4. Variable speed boiler system circulator: Knight XL boilers are capable of controlling a variable speed boiler system circulator. Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG. 7-3 at full speed.
5. Boiler isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
6. Check valves: Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-7 through 6-11. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.
7. Domestic indirect hot water isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
8. Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F (46°C).
9. Unions: Field supplied. Recommended for unit serviceability.
10. Temperature and pressure gauge: Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.
11. Pressure relief valve: Factory supplied. The pressure relief valve is sized to ASME specifications.
12. Boiler purge valve: Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.
13. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. The sensor should be located far enough downstream to sense system diluted water temperature.
14. Water Meter: Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.
15. Strainer/Filter: Field supplied. Install a Y-strainer or equivalent multipurpose strainer/filter just before the boiler pump at the inlet of the heat exchanger. This item is used to remove system debris from older hydronic systems and to protect newer systems.
16. Magnetic Separator: Field supplied. Install a magnetic separator in the heating system return line as close as practical to the boiler per the manufacturer’s instructions.
41
Installation & Operation Manual
7 Hydronic piping (continued)
Circulator sizing
The Knight XL heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graphs in FIG 7-3 pressure drop through the Knight XL heat exchanger.
Near boiler piping connections
Figure 7-2A Near Boiler Piping w/Y-Strainer
FROM SYSTEM
TO SYSTEM
P MAKE UP WATER
TP
BOILER
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DRAIN PORT EXPANSION TANK FLOW SWITCH MAGNETIC SEPARATOR
PRESSURE RLEEDGUECNIDNG VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
SYSTEM SUPPLY SENSOR
STRAINER / FILTER T P TEMPERATURE &
PRESSURE GAUGE WATER METER
PIPING
DIR #2000585376 00
Variable speed pump option
Variable speed pump setup
Before operation, ensure the following:
– Pump is set for an input signal of 0 – 10VDC by the dip switches on the pump control
– Pump is set for external signal control (if applicable)
– Pump is set for linear output (if applicable)
– If pump does not come equipped with a 0 – 10 VDC input option, an optional module will be required from the vendor
SMART TOUCH / Multi-temperature loop control option
The Knight XL boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help aid with this protection, Lochinvar offers the Multi- Temperature Loop Control Board Kit (100167843).
Figure 7-2B Near Boiler Piping w/Low Loss Header
TO SYSTEM
FROM SYSTEM
MAKE UP WATER
LOW LOSS HEADER
TP P
BOILER
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DRAIN PORT EXPANSION TANK FLOW SWITCH MAGNETIC SEPARATOR
PRESSURE RLEEDGUECNIDNG VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
SYSTEM SUPPLY SENSOR
STRAINER / FILTER T P TEMPERATURE &
PRESSURE GAUGE WATER METER
PIPING
DIR #20005857530 00
42
Installation & Operation Manual
7 Hydronic piping
Figure 7-3 Pressure Drop vs. Flow
60
PRESSURE DROP VS FLOW (HEAT EXCHANGER ONLY)
400 500 650 800 1000
50
PRESSURE DROP (FT. HD)
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
FLOW RATE (GPM)
Table 7A Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F
TEMPERATURE RISE APPLICATIONS
Model
MINIMUM PIPE SIZE
20°F GPM FT/HD
25°F GPM FT/HD
30°F GPM FT/HD
400
2″
38
10
30
7
25
5
500
2″
48
14
38
12
32
9
650
2″
62
16
50
11
41
9
800
2″
76
17
61
13
51
10
1000
2 1/2″
96
18
76
11
64
8
35°F
GPM FT/HD
22
4
27
8
36
7
44
9
54
6
43
Installation & Operation Manual
7 Hydronic piping (continued)
Figure 7-4 Single Boiler – Multiple Temperatures
WIRES TO LOOP SENSORS
120VAC TO PUMPS
SHIELDED CABLE TO BOILER
MULTI TEMP. LOOP CNTL (OPTIONAL)
24VAC SIGNAL TO MIXING VALVES
SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3
TEMP LOOP 1
TEMP LOOP 2
TEMP LOOP 3
SENSOR 1
SENSOR 2
SENSOR 3
PUMP 1 VALVE 1
PUMP 2 VALVE 2
PUMP 3 VALVE 3
TO SYSTEM
P
MAKE UP WATER
FROM SYSTEM
DHW HOT WATER OUT
COLD WATER IN
INDIRECT DHW TANK
TP
BOILER
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE
FLOW SWITCH
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
T P TEMPERATURE & PRESSURE GAUGE
WATER METER
SYSTEM SUPPLY SENSOR
2 WAY MOTORIZED VALVE (OPTIONAL)
STRAINER / FILTER
PIPING WIRING
DIR #2000585754 00
CAUTION NOTICE
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.
44
7 Hydronic piping
Figure 7-5 Single Boiler – Primary/Secondary Piping
Installation & Operation Manual
TO SYSTEM
MAKE UP WATER
MAY SUBTITUTE LOW LOSS HEADER
P
FROM SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX OF 12″ APART
DHW HOT WATER OUT
COLD WATER IN
INDIRECT DHW TANK
TP
BOILER
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE
FLOW SWITCH
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
T P TEMPERATURE & PRESSURE GAUGE
WATER METER
SYSTEM SUPPLY SENSOR
2 WAY MOTORIZED VALVE (OPTIONAL)
STRAINER / FILTER
PIPING WIRING
DIR #2000585755 00
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not not exceed indirect water heater transfer capabilities.
NOTICE NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.
45
Installation & Operation Manual
7 Hydronic piping (continued)
Figure 7-6 Multiple Boilers – Multiple Temperatures
SHIELDED CABLE TO BOILER
WIRES TO LOOP SENSORS
120VAC TO PUMPS
MULTI TEMP. LOOP CNTL (OPTIONAL) 24VAC SIGNAL TO MIXING VALVES
Model
400 500 650 800 1000
Number of Units
2
3
4
5
6
7
8
Required Pipe Sizes in NPT (Based on 30°)
2.5
3
3
4
4
4
6
6
6
4
4
6
6
6
3
4
4
6
6
6
6
4
4
6
6
6
6
8
4
6
6
6
8
8
8
SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3
TEMP LOOP 1
TEMP LOOP 2
TEMP LOOP 3
SENSOR 1
SENSOR 2
SENSOR 3
PUMP 1 VALVE 1
PUMP 2 VALVE 2
PUMP 3 VALVE 3
TO SYSTEM
P
MAKE UP WATER
FROM SYSTEM
DHW HOT WATER OUT
COLD WATER IN
INDIRECT DHW TANK
TP
BOILER 1
TP
BOILER 2
CAUTION
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE
FLOW SWITCH
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
T P TEMPERATURE & PRESSURE GAUGE
WATER METER
SYSTEM SUPPLY SENSOR
2 WAY MOTORIZED VALVE (OPTIONAL)
STRAINER / FILTER
PIPING WIRING
DIR #2000585756 00
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not not exceed indirect water heater transfer capabilities.
CAUTION Mixing valves are required for the protection of low temperature loops.
NOTICE
46
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.
Installation & Operation Manual
7 Hydronic piping
Figure 7-7 Multiple Boilers – Primary/Secondary Piping
Model
400 500 650 800 1000
Number of Units
2
3
4
5
6
7
8
Required Pipe Sizes in NPT (Based on 30°)
2.5
3
3
4
4
4
6
6
6
4
4
6
6
6
3
4
4
6
6
6
6
4
4
6
6
6
6
8
4
6
6
6
8
8
8
TO SYSTEM
MAKE UP WATER
MAY SUBTITUTE LOW LOSS HEADER
P NOT TO EXCEED 4 PIPE DIA OR MAX OF 12″ APART
FROM SYSTEM
DHW HOT WATER OUT
COLD WATER IN
INDIRECT DHW TANK
TP
BOILER 1 (LEADER)
TP
BOILER 2
TP
BOILER 3
TP
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE
FLOW SWITCH
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
T P TEMPERATURE & PRESSURE GAUGE
WATER METER
SYSTEM SUPPLY SENSOR
2 WAY MOTORIZED VALVE (OPTIONAL)
STRAINER / FILTER
PIPING WIRING
DIR #2000585757 00
BOILER 4
CAUTION NOTICE NOTICE
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not not exceed indirect water heater transfer capabilities.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.
47
Installation & Operation Manual
7 Hydronic piping (continued)
Figure 7-8 Single Boiler – Multiple Temperatures with DHW Piped as a Zone
WIRES TO LOOP SENSORS
120VAC TO PUMPS
SHEILDED CABLE TO BOILER
MULTI TEMP. LOOP CNTL (OPTIONAL)
24VAC SIGNAL TO MIXING VALVES
SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3
TEMP LOOP 1
TEMP LOOP 2
TEMP LOOP 3
SENSOR 1
SENSOR 2
SENSOR 3
PUMP 1 VALVE 1
PUMP 2 VALVE 2
PUMP 3 VALVE 3
TO SYSTEM
P
MAKE UP WATER
FROM SYSTEM
TP
BOILER
INDIRECT DHW TANK
AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP
DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE
FLOW SWITCH
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
T P TEMPERATURE & PRESSURE GAUGE
WATER METER
SYSTEM SUPPLY SENSOR
2 WAY MOTORIZED VALVE (OPTIONAL)
STRAINER / FILTER
PIPING WIRING
DIR #2000585758 00
DWH HOT WATER OUT
COLD WATER IN
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not not exceed indirect water heater transfer capabilities.
CAUTION Mixing valves are required for the protection of low temperature loops.
NOTICE NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
48
Installation & Operation Manual
8 Gas connections
Connecting gas supply piping
1. Remove the top access panel and refer to FIG.’s 8-1 thru 8-2 to pipe gas to the boiler. a. Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada When using manual main shutoff valves, it must be identified by the installer.
2. Install sediment trap / drip leg.
Figure 8-1 Gas Supply Piping – Models 400 – 500
GAS SUPPLY
SEDIMENT TRAP / DRIP LEG
MANUAL SHUTOFF VALVE (FACTORY SUPPLIED) UNION (FIELD PROVIDED)
DIR #2000585192 00
Figure 8-2 Gas Supply Piping – Models 650 – 1000
3. Support piping with hangers, not by the boiler or its accessories.
WARNING
The gas valve and blower will not support the weight of the piping. Do not attempt
to support the weight of the piping with
the boiler or its accessories. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
4. Purge all air from the gas supply piping.
5. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).
b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).
c. The appliance and its gas connection must be leak tested before placing it in operation.
WARNING
Do not check for gas leaks with an open flame use the bubble test. Failure to use
the bubble test or check for gas leaks can
cause severe personal injury, death, or
substantial property damage.
6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.
GAS SUPPLY
SEDIMENT TRAP / DRIP LEG
MANUAL SHUTOFF VALVE (FACTORY SUPPLIED) UNION (FIELD PROVIDED)
DIR #2000585192 00
49
Installation & Operation Manual
8 Gas connections (continued)
WARNING
Failure to apply pipe sealing compound as detailed in this manual can result
in severe personal injury, death, or
substantial property damage.
WARNING
Use two wrenches when tightening gas piping at boiler (FIG. 8-3), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
Figure 8-3 Inlet Pipe with Back-up Wrench
USE BACK-UP WRENCH TO PREVENT PIPE FROM ROTATING
DIR #2000588342 00
NOTICE
Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.
50
Natural gas:
Pipe sizing for natural gas
1. Refer to Table 8A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).
a. Table 8A 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. (3.5 kPa) with no flow (lockup) or with boiler on.
· Minimum 4 inches w.c. (.99 kPa) with gas flowing (verify during boiler startup).
2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa) maximum.
Propane Gas:
WARNING
Knight XL boilers are typically shipped ready to fire on natural gas. Check boiler
rating plate to determine which fuel the
boiler is set for. If set to natural gas, it may
be converted to LP by installing a LP venturi
and making a gas valve adjustment (see
pages 13 and 14). In order to operate on LP
gas, an orifice MUST BE installed (for 500
models) or a gas valve adjustment MUST
BE made. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. (3.2 kPa) maximum pressure.
2. Pressure required at gas valve inlet pressure port:
· Maximum 14 inches w.c. (3.2 kPa) with no flow (lockup) or with boiler on.
· Minimum 8 inches w.c. (1.9 kPa) with gas flowing (verify during boiler startup).
WARNING
Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the
appliance.
Installation & Operation Manual
8 Gas connections
Table 8A 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 1 1 1/4 1 1/2
273 188 151 129 114 104 95 89
83
79
70
63
58 N/A
514 353 284 243 215 195 179 167 157 148 131 119 109 102
1,060 726 583 499 442 400 368 343 322 304 269 244 224 209
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
2 1/2 3 4
4,860 3,340 8,580 5,900 17,500 12,000
2,680 4,740 9,660
2,290 4,050 8,270
2,030 3,590 7,330
1,840 3,260 6,640
1,690 3,000 6,110
1,580 2,790 5,680
1,480 2,610 5,330
1,400 2,470 5,040
1,240 2,190 4,460
1,120 1,980 4,050
1,030 1,820 3,720
960 1,700 3,460
Check inlet gas supply
NOTICE
CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.
4. Slowly turn on the gas supply at the field installed manual gas valve.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the display of the SMART TOUCH control module to call for heat.
WARNING
DO NOT adjust gas valve outlet pressure. Attempting to alter the gas valve outlet
pressure could result in damage to the valve,
causing potential severe personal injury,
death, or substantial property damage.
7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the display.
8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.
The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:
9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.
11. Turn the power switch to the “OFF” position.
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.
3. On Models 400 – 500 loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. On Models 650 – 1000 remove the 1/8″ (3 mm) pipe plug on the inlet flange to the valve and install a suitable 1/8″ (3 mm) fitting (field supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the set screw is loosened or the 1/8″ (3 mm) fitting is installed (depending on model) as shown in FIG.’s 8-4 thru 8-5.
12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.
13. Remove the manometer from the pressure tap on top of the gas valve. On Models 400 – 500 re-tighten the set screw inside the pressure tap. On Models 650 – 1000 remove the 1/8″ (3 mm) field supplied fitting and reinstall the pipe plug removed in Step 3.
51
Installation & Operation Manual
8 Gas connections (continued)
When re-tightening the set screw, be sure WARNING to tighten securely to prevent gas leaks.
Figure 8-5 Inlet Gas Supply Check – Models 650 – 1000
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. 14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the display of the SMART TOUCH control module to the desired water temperature so the appliance will call for heat.
17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.
Figure 8-4 Inlet Gas Supply Check – Model 400 – 500
DETAIL
DETAIL
DIR #2000585203 00
REMOVE THE 1/8″ (3 MM) PIPE PLUG ON THE INLET FLANGE TO THE VALVE AND INSTALL A SUITABLE 1/8″ (3 MM) FITTING (FIELD SUPPLIED) FOR THE MANOMETER TUBING.
Gas pressure
The gas pressure must remain between 4 inches w.c. (.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for Natural gas and between 8 inches w.c. (1.9 kPa) minimum and 14 inches w.c. (3.2 kPa) maximum for LP gas during standby (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet (3 m) from the Knight XL boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.
DIR #2000585203
