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Knight 80 User Manual

Knight 80
72 pages
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Installation & Operation Manual
Models: 80 - 285
Starting Serial #H07H10040039
This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight Boiler Service Manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
WARNING
Save this manual for future reference.

Table of Contents

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Knight 80 Specifications

General IconGeneral
BrandKnight
Model80
CategoryBoiler
LanguageEnglish

Summary

Please Read Before Proceeding

The Knight Boiler - How it Works

Ratings

Determine Boiler Location

Closet and Alcove Installations

Specific requirements for installing the boiler in confined spaces like closets and alcoves.

Determine Boiler Location (Continued)

Provide Air Openings to Room

Ventilation requirements for the boiler room to ensure proper combustion and air exchange.

Prevent Combustion Air Contamination

Critical information on avoiding corrosive elements in the air intake to protect the boiler.

Determine Boiler Location (Continued)

Removing from Existing Common Vent System

Steps for safely disconnecting from an old vent system to prevent hazards.

Prepare Boiler

Remove Boiler from Wood Pallet

Instructions for safely unboxing and preparing the boiler unit for placement.

Gas Conversions

Guidance on converting the boiler to operate on propane gas, including orifice changes.

General Venting

Direct Venting Options

Overview of different direct vent configurations available for boiler installation.

General Venting (Continued)

Install Vent and Combustion Air Piping

Procedures for connecting the vent and combustion air pipes securely and correctly.

Vent Piping Materials

Specifies approved materials for vent pipes and fittings to ensure system integrity and safety.

General Venting (Continued)

Air Contamination

Risks associated with contaminated combustion air and necessary prevention methods.

Sidewall Direct Venting

Vent/Air Termination – Sidewall

Specifics on where and how to terminate vent and air pipes externally through a wall.

Determine Location

Guidelines for choosing the best sidewall termination point, considering surroundings.

Sidewall Direct Venting (Continued)

Prepare Wall Penetrations

Steps for cutting and sealing wall penetrations for vent and air pipes.

Termination and Fittings

Guidance on correctly assembling and installing vent termination components.

Sidewall Direct Venting (Continued)

Multiple Vent/Air Terminations

Requirements for spacing and routing multiple vent/air outlets to prevent interference.

Sidewall Direct Venting (Continued)

Sidewall Termination – Optional Concentric Vent

Details on using concentric kits for a combined vent/air termination.

Sidewall Termination Installation

Step-by-step guide for installing the concentric sidewall termination kit.

Vertical Direct Venting

Vent/Air Termination – Vertical

Specifics on where and how to terminate vent and air pipes on the roof.

Determine Location

Guidelines for choosing the best rooftop termination point, considering clearance.

Vertical Direct Venting (Continued)

Prepare Roof Penetrations

Steps for cutting and sealing roof penetrations for vent and air pipes.

Termination and Fittings

Guidance on correctly assembling and installing roof termination components.

Hydronic Piping

System Water Piping Methods

Overview of different ways to connect the boiler to the heating system.

Low Water Cutoff Device

Importance and installation of low water cutoff devices for safety.

Freeze Protection

Guidance on using glycol for freeze protection in the heating system.

General Piping Information

Basic steps and considerations for system piping installation and best practices.

Relief Valve and Temperature and Pressure Gauge Installation

How to install essential safety and monitoring devices for boiler operation.

Hydronic Piping (Continued)

Circulator Sizing

How to select and size circulation pumps based on system requirements and flow.

Hydronic Piping (Continued)

Near Boiler Piping Components

Lists and describes crucial components for boiler plumbing connections and serviceability.

Gas Connections

Connecting Gas Supply Piping

Procedures for routing and connecting the gas line to the boiler securely.

Gas Connections (Continued)

Natural Gas

Guidelines for natural gas pipe sizing and pressure requirements.

Propane Gas

Guidelines for propane gas pipe sizing and pressure requirements.

Gas Connections (Continued)

Check Inlet Gas Supply

Procedure for verifying gas supply pressure and flow rate for safe operation.

Gas Connections (Continued)

Gas Pressure

Specifies required gas pressure ranges for safe and efficient boiler operation.

Gas Valve Replacement

Warnings and procedures related to the gas valve's proper function and replacement.

Field Wiring

Line Voltage Connections

How to safely connect the main 120 VAC power supply to the boiler.

Field Wiring (Continued)

Low Voltage Connections

How to connect low voltage wiring to the control board for system operation.

Thermostat

Wiring instructions for connecting room thermostats to the boiler control.

DHW Tank Sensor

Connecting the sensor for domestic hot water temperature control and monitoring.

Field Wiring (Continued)

System Supply Sensor

Connecting the sensor for system water temperature monitoring and control.

Wiring of the Cascade

Instructions for interconnecting multiple boilers to operate in a cascade system.

Condensate Disposal

Condensate Drain

Instructions for installing the condensate drain system and trap for proper drainage.

Start-up

Check/Control Water Chemistry

Ensuring proper water quality before boiler operation to prevent damage.

Fill and Test Water System

Procedures for filling the system and checking for leaks before initial operation.

Purge Air from Water System

How to remove air from the hydronic system for efficient operation.

Start-up (Continued)

Check for Gas Leaks

Crucial safety step to detect gas leaks before operation using a bubble test.

Check Thermostat Circuit(s)

Verifying the wiring and function of thermostat connections for proper control.

Inspect/Fill Condensate System

Checking and preparing the condensate trap for proper function and safety.

Start-up (Continued)

Final Checks Before Starting the Boiler

A comprehensive checklist before initial boiler startup to ensure readiness.

Check Flame and Combustion

Procedures for verifying proper burner flame and combustion analysis for efficiency.

Start-up (Continued)

Set Space Heating Operation

How to configure the boiler for space heating mode and control settings.

Start-up (Continued)

Set Domestic Hot Water (DHW) Operation

Configuring the boiler for heating domestic hot water and setting target temperature.

Configuration of the Cascade

Programming multiple boilers to work together in a cascade system for increased output.

Operating Information

How the Boiler Operates

Basic explanation of the boiler's functionality, heat exchange, and control module.

Control Inputs and Outputs

Description of signals the control module uses for boiler operation and monitoring.

DHW Priority

How the system prioritizes calls for domestic hot water heating over space heating.

Operating Information (Continued)

Protection Features

Overview of built-in safety mechanisms for boiler operation, like temperature limits.

Freeze Protection

How the control module provides protection against freezing of system water.

Operating Information (Continued)

Monitor External Limits

How the boiler responds to external safety devices and operational limits.

Boiler Temperature Regulation

How the boiler controls and maintains its target operating temperature using sensors.

Cascade

How multiple boilers are wired and controlled together for increased heating capacity.

Operating Information (Continued)

Sequence of the Cascade

How boilers are automatically sequenced for optimal run-time and load balancing.

Operating Information (Continued)

Sequence of Operation

Step-by-step description of the boiler's firing and pump cycles during operation.

Operating Information (Continued)

SMART Knight Boiler Control Module

Overview of the boiler's primary control unit and its interface for operation.

Operating Information (Continued)

Access Modes

Explanation of user and installer access levels for parameter adjustments and settings.

Operating Information (Continued)

Status Display Screens

Description of the various screens and information displayed by the control panel.

Operating Information (Continued)

Operation of the Cascade

Details on how the cascade system status is displayed and interpreted.

Maintenance

Maintenance and Annual Startup

Outlines daily, monthly, and periodic maintenance tasks for optimal performance.

Maintenance (Continued)

Address Reported Problems

How to handle issues reported by the owner before performing maintenance.

Clean Condensate Trap

Steps for cleaning and maintaining the condensate trap for proper function and safety.

Maintenance (Continued)

Flue Vent System and Air Piping

Instructions for inspecting the venting system for damage or blockages.

Check Boiler Relief Valve

Procedures for inspecting and testing the safety relief valve.

Maintenance (Continued)

Inspect Ignition and Flame Sense Electrodes

Cleaning and checking electrodes for proper ignition and flame detection.

Check Burner Flame

Inspecting the burner flame for correct pattern and operation.

Maintenance (Continued)

Check Flame Signal

Verifying the strength of the flame signal for proper combustion monitoring.

Cleaning Boiler Heat Exchanger

Steps for cleaning the internal heat exchanger surfaces for optimal heat transfer.

Diagrams

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