Lochinvar KNIGHT 399 Installation & Operation Manual
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Lochinvar KNIGHT 399 Installation & Operation Manual

Commercial boiler
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See also: Installation and Servicing Manual
KBX-I-O Rev H
Installation & Operation Manual
Models: 399 - 800
This manual must only be used by a
WARNING
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.

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Summary of Contents for Lochinvar KNIGHT 399

  • Page 1 KBX-I-O Rev H Installation & Operation Manual Models: 399 - 800 This manual must only be used by a WARNING 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.

  • Page 2: Table Of Contents

    Models 600 - 800 ......14 Leveling the Boiler ......14 3.

  • Page 3: Please Read Before Proceeding

    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.

  • Page 4: The Knight Xl - How It Works

    The venturi controls air and gas flow into the burner. Flue gas sensor 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.

  • Page 5: Model 399

    Left Side (inside unit) - Model 399 Installation & Operation Manual (continued) 37. Pump relay board The pump relay board is used to connect the boiler, system and DHW pumps. Rear View - Model 399 Right Side (inside unit) - Model 399...

  • Page 6: The Knight Xl -- How It Works

    The Knight XL - How it works... Model 500 Rear View - Model 500 Models 600 - 800 Rear View - Models 600 - 800 Installation & Operation Manual Left Side (inside unit) - Model 500 Left Side (inside unit) - Models 600 - 800...

  • Page 7: Ratings

    Knight XL Installation and Operation Manual. Standard Knight XL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

  • Page 8: Determine Boiler Location

    WARNING Closet and alcove installations A closet is any room the boiler is installed in which is less than 171 cubic feet for KBN399 models, 193 cubic feet for KBN500 models, 223 cubic feet for KBN600 models, 247 cubic feet for KBN700 models and 278 cubic feet for KBN800 models.
  • Page 9 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances 1" (25 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES AND VENT PIPE 12" (305 MM) LEFT 14" (356 MM) REAR RECOMMENDED SERVICE CLEARANCES: Front 30" (762 mm) 24" (610 mm) Left Side - 24"...

  • Page 10: Provide Air Openings To Room

    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.

  • Page 11: Corrosive Contaminants And Sources

    • 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 on page 12. With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used;...

  • Page 12: Removing A Boiler From Existing Common Vent

    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.

  • Page 13: Prepare Boiler

    Remove the two lag bolts from the wood pallet inside the boiler (FIG. 2-1). Detach the boiler from the lag bolts in the rear of the unit, see FIG. 2-1. Do not drop the boiler or bump the jacket NOTICE on the floor or pallet.

  • Page 14: Model 500

    (FIG. 2-3). 4. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

  • Page 15: Direct Venting Options

    Installation & Operation Manual General venting Direct venting options - Sidewall Vent PVC/CPVC Two Pipe Stainless Steel See Figure 4-1A Two Pipe Models 399 - 600 Only See Figure 4-1C Models 399 - 600 Only PVC/CPVC Alternate Two Pipe See Figure 4-2A PVC/CPVC Concentric Stainless Steel Alternate Two Pipe...

  • Page 16: General Venting

    Installation & Operation Manual General venting Direct venting options - Vertical Vent PVC/CPVC Stainless Steel PVC/CPVC Two Pipe Two Pipe Concentric See Figure 5-1A See Figure 5-1B See Figure 5-5 Direct venting options - Vertical Vent, Sidewall Air PVC/CPVC Stainless Steel Vertical Vent, Sidewall Air Vertical Vent, Sidewall Air Stainless steel vent/air design and terminations will vary slightly by manufacturer.

  • Page 17: Install Vent And Combustion Air Piping

    Installing vent or air piping NOTICE Z223.1 U.S. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

  • Page 18: Pvc/Cpvc Air Intake/Vent Connections

    Transition fittings are provided with 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. Figure 3-9 Near Boiler PVC/CPVC Venting - Models 399 - 600 VENT * 4”...

  • Page 19: Air Inlet Pipe Materials

    General venting Air inlet pipe materials: The air inlet pipe(s) must be sealed. combustion air inlet pipe materials from the following list: PVC, CPVC 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.

  • Page 20: Stainless Steel Air Intake/Vent Connections

    303888 Only) * = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-11, unless approved vent other than standard diameter is used. Consult a Heat Fab representative for questions.

  • Page 21: Min./Max. Combustion Air & Vent Piping Lengths

    Vent 4 inches (102 mm) 6 inches (152 mm) You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion). You may use any of the vent/air piping methods covered in this allowable manual.

  • Page 22: Optional Room Air

    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.

  • Page 23: Sidewall Direct Venting Vent/Air Termination - Sidewall

    6 inch vent 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. 12" OVER- HANG 12"...
  • Page 24 INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION Figure 4-2B Termination Models 700 - 800 w/Field Supplied Fittings TO BOILER INTAKE BIRD SCREEN AIR CONNECTION 12" (305 MM) MIN FROM BOILER VENT 15" (381 MM) MAX PIPE CONNECTION NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.

  • Page 25: Prepare Wall Penetrations

    Sidewall direct venting Vent/air termination – sidewall Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings 12” (305 MM) 12” (305 MM) 12” (305 MM) Figure 4-4A Clearance to Forced Air Inlets THAN 10’ VENT / AIR TERMINATION 7' MIN.

  • Page 26: Termination And Fittings

    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)

  • Page 27: Sidewall Termination - Optional Concentric Vent

    Sidewall termination – optional concentric vent: Models 399 - 600 Only Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#CVK3007 for 4" (102 mm) diameter - Models 399 - 600). Both combustion air and vent pipes must attach to the termination kit.
  • Page 28 Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 399 - 600 "B" DIA. PVC VENT / EXHAUST 60" (1524 MM) (102 MM) Instead of cementing the smaller pipe to the NOTICE rain cap, a field-supplied stainless steel screw may be used to secure the two (2)

  • Page 29: Sidewall Termination - Optional Concentric Vent

    Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-11 Concentric Vent Sidewall Attachment ELBOW (FIELD SUPPLIED) COMBUSTION AIR VENT DO NOT use field-supplied couplings to CAUTION extend pipes. Airflow restriction will occur and may cause intermittent operation.

  • Page 30: Vertical Direct Venting Vent/Air Termination - Vertical

    Vertical direct venting Vent/air termination – vertical Follow instructions WARNING determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to the WARNING vent pipe or multiple boilers to a common vent pipe.

  • Page 31: Prepare Roof Penetrations

    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.

  • Page 32: Vertical Termination - Optional Concentric Vent

    Vertical termination – optional concentric vent: Models 399 - 600 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.
  • Page 33 Vertical direct venting Vertical termination – optional concentric vent: Models 399 - 600 Only Do not operate the appliance with the rain WARNING removed combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure.

  • Page 34: Hydronic Piping

    It is important to note that the boiler has a minimal amount of pressure drop which must be figured in when sizing the circulators.

  • Page 35: Flow Switch And Relief Valve Installation

    Hydronic piping Flow switch, relief temperature pressure installation Basic steps are listed below to guide you through the installation of the flow switch, relief valve, and temperature and pressure gauge provided with the unit. For Models 399 - 500 install the close nipple on the outlet connection of the heat exchanger.

  • Page 36: Flow Switch Adjustment

    SYSTEM PUMP ADJUSTMENT 7½ turns 5½ turns BOILER PUMP 7¼ turns 5¼ turns 3¼ turns Y-STRAINER (RECOMMENDED) Figure 6-4B Near Boiler Piping w/Low Loss Header SENSITIVITY ADJUSTMENT LOW LOSS HEADER (TYPICAL) Y-STRAINER (RECOMMENDED) Installation & Operation Manual DOMESTIC HOT WATER PUMP...
  • Page 37 PIPE SIZE 1 1/2" 1 1/2" 2" 2" 2" (continued) Pressure Drop vs Flow (Includes Boiler Secondary Piping) Flow Rate (GPM) Pressure Drop vs Flow (Includes Boiler Secondary Piping) Flow Rate (GPM) 20°F 25°F FT/HD FT/HD Installation & Operation Manual...

  • Page 38: Near Boiler Piping Components

    12. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction.
  • Page 39 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in NOTICE operation to prevent short cycling and high limit issues.
  • Page 40 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in NOTICE operation to prevent short cycling and high limit issues.

  • Page 41: Gas Connections

    SHUTOFF VALVE (FACTORY SUPPLIED) GAS SUPPLY DRIP LEG UNION 3. Support piping with hangers, not by the boiler or its accessories. The gas valve and blower will not support WARNING the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories.

  • Page 42: Natural Gas

    Natural gas: Pipe sizing for natural gas 1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas...

  • Page 43: Check Inlet Gas Supply

    NOTICE 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. DO NOT adjust or attempt to measure gas WARNING valve outlet pressure.

  • Page 44: Gas Pressure

    (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.

  • Page 45: Field Wiring

    Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. NOTICE If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 –...

  • Page 46: Low Voltage Connections

    6°F (3°C) below the tank set point, and finishes the call for heat when the tank temperature reaches the tank set point. The tank sensor included with the Lochinvar Squire® indirect DHW tanks (TST2032) is the only sensor suitable for use with the SMART SYSTEM control.

  • Page 47: Wiring Of The Cascade

    Cascade, daisy chain the wiring from the Sequencing terminals on the second boiler to the Sequencing terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers.
  • Page 48 Installation & Operation Manual Field wiring Figure 8-3 Low Voltage Field Wiring Connections CUTOFF WATER...

  • Page 49: Condensate Disposal Condensate Drain

    Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) PVC union for connection of a 1/2 inch (12.7 mm) PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter.

  • Page 50: Startup

    200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the boiler to directly heat swimming pool or spa water. Test/replace freeze protection fluid 1.
  • Page 51 Check for gas leaks Before starting the boiler, and during WARNING initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure.
  • Page 52 Check flame and combustion 1. Turn the main power off to the boiler by placing the “On/Off ” switch in the OFF position. 2. Remove the flue temperature sensor from the flue pipe connection.

  • Page 53: For Your Safety Read Before Operating

    Start-up (continued) Figure 10-2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.
  • Page 54 (if connected), and the boiler (secondary) pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect DHW (Domestic Hot Water) tank, it also turns on the boiler pump.

  • Page 55: Startup

    When the tank thermostat calls for heat, the SMART SYSTEM control will turn on the DHW pump and turn off the boiler pump (if running). If the system pump is running, it will remain on. When the DHW call for heat ends, and there is no space heating call for heat, the DHW pump will continue to run for a period of time.

  • Page 56: Operating Information General

    As long as the space heating call for heat is on, the system pump will remain on. If a DHW call for heat is on, the boiler pump will wait to turn on until just before the DHW pump turns off. After the space heating call for heat ends, both pumps will run for an additional period of time.
  • Page 57 55°F (13°C) and the minimum off time has expired. Freeze protection DO NOT install the boiler in a room likely to freeze. The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system.

  • Page 58: Cascade

    Leader control and all others would be designated as Member controls. Once the Leader boiler receives a call for heat from a room thermostat, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler.

  • Page 59: Cascade

    DHW Thermostat. When the boiler receives a DHW call, the Leader control will take that boiler out of the Cascade sequence. If another boiler is available, the Leader will start it up to take its place. The DHW boiler will adjust its set point to the programmed DHW set point and will adjust its firing rate to maintain this.

  • Page 60: Sequence Of Operation

    DHW boiler set point. 8. If the boiler is not part of a cascade, and the DHW call for heat remains active for more than 30 minutes, and the space heating...

  • Page 61: Knight Xl Control Module

    Operating information Knight XL control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level...
  • Page 62 USER code (0704), the user can also change temperature units, time and date, and night setback settings. In User Mode, the following parameters can be viewed but not changed: • Boiler outlet water target temperature in DHW Mode • Boiler model number • Software version •...

  • Page 63: Status Display Screens

    Operating information By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 64 Operating information By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the eight (8) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
  • Page 65 The call for heat has been satisfied and the boiler pump is running for a fixed time to remove any residual heat. arrow key on the SMART SYSTEM display to access Screen #9.

  • Page 66: Status Display Screens

    Operation of the cascade The boiler designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description...

  • Page 67: Maintenance Maintenance And Annual Startup

    • Check condensate drain system • Check air vents • Test low water cutoff (if used) • Reset button (low water cutoff) • Check boiler piping (gas and water) for leaks • Operate relief valve • Shut boiler down (unless boiler...

  • Page 68: Inspect Boiler Area

    The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance WARNING and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

  • Page 69: Check Expansion Tank

    2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi (82.7 kPa)). 3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high.

  • Page 70: Check Burner Flame

    4. Replace ground wires if ground continuity is not satisfactory. Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings.

  • Page 71: Check Flame Signal

    • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

  • Page 72: Diagrams

    AIR PRESS. SWITCH X5-11 X5-3 X5-4 X5-10 X5-8 X5-1 X5-2 X5-9 X2-2 X2-1 X1-7 Installation & Operation Manual JUNCTION CN1-5 PUMP CN1-6 CN1-3 BOILER PUMP CN1-4 CN1-1 SYSTEM PUMP CN1-2 120V SUPPLY MANUAL RESET HI-LIMIT BLOCKED DRAIN INLET SENSOR OUTLET SENSOR FLUE...

  • Page 73: Ladder Diagram

    EXTERNAL CN1-2 0-10V CONTROL CN1-1 JUNCTION BOX NEUTRAL GROUND TERMINAL STRIP 120V SUPPLY "N" SYSTEM PUMP RELAY X1-2 SYSTEM PUMP RELAY BOILER PUMP RELAY X1-4 BOILER PUMP RELAY DHW PUMP RELAY X1-3 DHW PUMP RELAY BLOWER X1-1 BLOWER RELAY X1-5...
  • Page 74 Notes...
  • Page 75 Notes...

  • Page 76: Revision Notes

    Revision Notes: Revision B (ECO #C02407) reflects gas valve adjustment, room air, new sidewall vent termination, piping diagrams, flow switch, relief valve, T & P gauge, Maintenance Section, FIG. 8-1 (Line Voltage), and high altitude changes. Revision C (ECO #C02545) reflects the addition of references to the safety shutoff testing and instructions, sediment trap, periodic cleaning of screens in vent terminations, removal of B149.2 references, changed the arrow direction on FIG.

This manual is also suitable for:

Knight 800Knight xl kbn399Knight xl kbn500Knight xl kbn600Knight xl kbn700Knight xl kbn800

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