Table of Contents
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KBX-I-O Rev D
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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Table of Contents
Related Manuals for Lochinvar KBN399
Summary of Contents for Lochinvar KBN399
- Page 1 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.
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Page 2: Table Of Contents
Multiple Vent/Air Terminations ....23 Knight XL Control Module ......59-60 Sidewall Termination - Optional Concentric Vent . -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Installer – Read instructions, When servicing boiler – WARNING including this manual and the Knight XL • To avoid electric shock, disconnect electrical supply Service Manual, before installing. before performing maintenance. Perform steps in the order given. -
Page 4: The Knight Xl - How It Works
Installation & Operation Manual The Knight XL - How it works... Stainless steel heat exchanger 16. SMART Control Module Allows system water to flow through specially designed The SMART Control responds to internal and external signals coils maximum heat transfer, while... - Page 5 Installation & Operation Manual The Knight XL - How it works... (continued) 37. Pump relay board 36. Air pressure switch The pump relay board is used to connect the boiler, system and The air pressure switch detects blocked flue/inlet conditions.
- Page 6 Installation & Operation Manual The Knight XL - How it works... Model 500 Rear View - Model 500 Left Side (inside unit) - Model 500 Models 600 - 800 Rear View - Models 600 - 800 Left Side (inside unit) - Models 600 - 800...
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Page 7: Ratings
Ratings are based on a piping and pickup allowance of 1.15. UNIT EQUIPPED FOR 3. Knight XL boilers require special gas venting. Use only the HIGH ALTITUDE vent materials and methods specified in the Knight XL 3,000 FT. -
Page 8: Determine Boiler Location
A closet is any room the boiler is installed in which is less than • Electrical power 171 cubic feet for KBN399 models, 193 cubic feet for KBN500 Locate the appliance so that if water connections should models, 223 cubic feet for KBN600 models, 247 cubic feet for leak, water damage will not occur. - Page 9 Installation & Operation Manual Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances CLOSET INSTALLATION For closet installations, CPVC or WARNING 1" (25 MM) MINIMUM CLEARANCE stainless steel material MUST BE AROUND HOT WATER PIPES AND VENT PIPE used in a closet structure due to elevated temperatures.
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Page 10: Provide Air Openings To Room
The Knight XL is approved for installation on combustible flooring, but must never be installed on carpeting. Install air inlet piping for the Knight XL as described in this manual. Do not terminate vent/air in locations that can allow Do not install the boiler on carpeting even contamination of combustion air. -
Page 11: Corrosive Contaminants And Sources
Table 1A Corrosive Contaminants and Sources When removing a boiler from existing common vent system: Products to avoid: Do not install the Knight XL into a DANGER Spray cans containing chloro/fluorocarbons common vent with any other appliance. This will cause flue gas spillage or... -
Page 12: Prepare Boiler
For the 399 Model you must install a propane Figure 2-2 Installing Propane Orifice - Model 399 orifice to operate the Knight XL on propane gas. Verify when installing that the orifice size marking matches boiler size (Model 399 - 8.0 BLOWER LP orifice stamping). -
Page 13: Model 500
Installation & Operation Manual Prepare boiler (continued) Model 500 After converting to LP, check combustion WARNING per the Start-up procedure in Section 10 of 1. Remove the top access cover from the unit (no tools this manual. Failure to check and verify required for removal). -
Page 14: General Venting
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 15 Installation & Operation Manual General venting (continued) 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 Optional Room Air Stainless Steel PVC/CPVC Room Air...
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Page 16: Install Vent And Combustion Air Piping
Installation & Operation Manual General venting Install vent and combustion air piping The Knight XL must be vented and supplied All PVC vent pipes must be glued, properly DANGER NOTICE with combustion and ventilation air as supported, and the exhaust must be pitched described in this section. -
Page 17: Pvc/Cpvc Air Intake/Vent Connections
Installation & Operation Manual General venting (continued) Combustion air piping to the outside MUST Air inlet pipe materials: NOTICE BE used. Use of combustion air from the The air inlet pipe(s) must be sealed. Choose acceptable room via louvers, plenums, or any other combustion air inlet pipe materials from the following list: device is not authorized. -
Page 18: Stainless Steel Vent And Air Piping
Installation & Operation Manual General venting When a sidewall or vertical rooftop combustion air supply system is Stainless steel intake/vent disconnected for any reason, the air inlet pipe must be resealed to connections ensure that combustion air will be free of contaminants and supplied Combustion Air Intake Connector (FIG.’s 3-11 and in proper volume. -
Page 19: Min./Max. Combustion Air & Vent Piping Lengths
Vent, air piping and termination: as follows: The Knight XL vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this Combustion Air = 12 equivalent feet (3.7 m) minimum / 100 manual for the method chosen. -
Page 20: Determine Location
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-1A PVC/CPVC Sidewall Termination of Air and Vent Follow instructions below when determining WARNING vent location to avoid possibility of severe TO BOILER INTAKE AIR personal injury, death, or substantial CONNECTION property damage. -
Page 21: Sidewall Direct Venting Vent/Air Termination - Sidewall
Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Maintain clearances as shown in FIG.’s 4-1A thru 4-4B, pages 20 thru 22. Also maintain the following: Figure 4-1C Alternate Vent Termination - Typical Vent must terminate: • At least 6 feet (1.8 m) from adjacent walls. Stainless Steel Sidewall Termination of Air and Vent •... -
Page 22: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Prepare wall penetrations Figure 4-3B Alternate Clearance to Gravity Air Use the factory supplied wall plate as a template to locate Inlets w/Field Supplied Fittings the vent and air intake holes and mounting holes. Air pipe penetration: Cut a hole for the air pipe. -
Page 23: Termination And Fittings
Insert a galvanized metal thimble in the vent pipe 3. The air inlet of a Knight XL is part of a direct vent hole as shown in FIG. 4-5B. connection. It is not classified as a forced air intake with 3. -
Page 24: Sidewall Termination - Optional Concentric Vent
Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 Only Description and usage Lochinvar offers an optional concentric combustion air and You must consider the surroundings when terminating the vent pipe termination kit (#CVK3007 for 4" (102 mm) vent and air: diameter - Models 399 - 600). - Page 25 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 399 - 600 "A" "B" DIA. "C" DIA. "D" 3" (76 MM) "E" "G"...
- Page 26 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent: Models 399 - 600 Only Figure 4-11 Concentric Vent Sidewall Attachment STRAP (FIELD SUPPLIED) ELBOW (FIELD SUPPLIED) COMBUSTION AIR COMBUSTION AIR VENT VENT DO NOT use field-supplied couplings to Multiventing sidewall terminations CAUTION extend pipes.
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Page 27: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining WARNING Rooftop vent and air inlet terminations WARNING vent location to avoid possibility of severe must terminate in the same pressure zone. personal injury, death or substantial property damage. -
Page 28: Prepare Roof Penetrations
CSA B149.1 Installation Code. hole (when required by local codes). 3. The air inlet of a Knight XL boiler is part of a direct vent 3. Space the air and vent holes to provide the minimum connection. It is not classified as a forced air intake with spacing shown in FIG.’s 5-1A and 5-1B, page 27. -
Page 29: Vertical Termination - Optional Room Air
Vertical termination – optional room air The Knight XL may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. The vent pipe may terminate vertically above the roof line in a conventional vent manner (see FIG. 5-4). -
Page 30: Vertical Termination - Optional Concentric Vent
Installation & Operation Manual Vertical direct venting Vertical termination – optional concentric vent: Models 399 - 600 Only Description and usage 3. You must consider the surroundings when terminating the Lochinvar offers an optional concentric combustion air and vent and air: vent pipe termination kit. - Page 31 Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 399 - 600 Only Do not operate the appliance with the rain DO NOT use field-supplied couplings to WARNING CAUTION cap removed or recirculation of combustion extend pipes.
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Page 32: Hydronic Piping
Hydronic piping System water piping methods General piping information The Knight XL is designed to function in a closed loop Basic steps are listed below along with illustrations on the pressurized system not less than 12 psi (83 kPa). following pages (FIG.’s 6-7 and 6-8), which will guide you temperature and pressure gauge is included to monitor system through the installation of the Knight XL (reference FIG. -
Page 33: Flow Switch And Relief Valve Installation
Installation & Operation Manual Hydronic piping Flow switch, relief valve and temperature Figure 6-2 Flow Switch, Relief Valve and Temperature and pressure gauge installation and Pressure Gauge Installation_Models 600 - 800 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. -
Page 34: Circulator Sizing
Refer to the graphs should be turned clockwise with a Phillips driver until it stops in FIG’s 6-5 and 6-6 for pressure drop through the Knight XL (FIG. 6-3). Proceed to turn the screw counterclockwise the heat exchanger. - Page 35 Figure 6-5 Pressure Drop vs. Flow - Models 399 and 500 Pressure Drop vs Flow (Includes Boiler Secondary Piping) KBN500 KBN399 Flow Rate (GPM) Figure 6-6 Pressure Drop vs. Flow - Models 600 thru 800 Pressure Drop vs Flow (Includes Boiler Secondary Piping)
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Page 36: Near Boiler Piping Components
Installation & Operation Manual Hydronic piping 5. Check valves: Pump sizing and flow requirements are NOTICE based on 20 feet (6 m) of piping, 4 - 90° Field supplied. Check valves are recommended for elbows, and 2 - fully ported ball valves. installation as shown in FIG.’s 6-7 and 6-8. - Page 37 Installation & Operation Manual Hydronic piping (continued) Figure 6-7 Single Boiler - Primary/Secondary Piping AIR SEPARATOR DRAIN POINT (TYPICAL) BALL VALVE SYSTEM SUPPLY SENSOR (TYPICAL) NOT TO EXCEED 4 PIPE DIAMETERS OR A MAXIMUM OF 12” APART SYSTEM CIRCULATOR PRESSURE GAUGE EXPANSION TANK BOILER CIRCULATOR MAKE UP WATER...
- Page 38 Installation & Operation Manual Hydronic piping Figure 6-8 Multiple Boilers - Primary/Secondary Piping Number of Units Model Manifold Pipe Sizes in Inches (mm) 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152) 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 3 1/2 (89) 4 (102)
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Page 39: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping Figure 7-3 Gas Supply Piping - Models 600 - 800 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the boiler. Install ground joint union for servicing, when MANUAL SHUTOFF VALVE required. -
Page 40: Natural Gas
14 inches w.c. (3.5 kPa) at any time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa) maximum. Propane Gas: Knight XL boilers are typically shipped WARNING ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. -
Page 41: Check Inlet Gas Supply
Installation & Operation Manual Gas connections (continued) Table 7A Natural Gas Pipe Size Chart Maximum Nominal Natural Gas Pipe Capacity Chart Capacity of Pipe Iron Pipe Length of Pipe in Straight Feet in Thousands of Size Btu/hr per hour (inches) 175 200 for gas pressures of 14 Inches... -
Page 42: 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 43: Field Wiring
Installation & Operation Manual Field wiring ELECTRICAL SHOCK HAZARD – For Installation must comply with: WARNING your safety, turn off electrical power 1. National Electrical Code and any other national, state, supply before making any electrical provincial, or local codes, or regulations. connections to avoid possible electric shock hazard. -
Page 44: Low Voltage Connections
Low gas pressure switch Outdoor Sensor terminals on the connection board to enable outdoor reset operation of the Knight XL. Do not 1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection install the outdoor sensor. -
Page 45: Wiring Of The Cascade
(if the outlet sensor control is currently selected). used) to the Leader boiler. For the Cascade system to work See the Knight XL Service Manual for instructions on how properly the system supply sensor must be installed. The to use the inlet sensor as the controlling sensor. - Page 46 Installation & Operation Manual Field wiring Figure 8-3 Low Voltage Field Wiring Connections...
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Page 47: Condensate Disposal
Condensate required and tubing size may need to increase from the Knight XL will be slightly acidic (typically with to 1 inch (25 mm). a pH from 3 to 5). Install a neutralizing filter if required... -
Page 48: Startup
Installation & Operation Manual Start-up Check/control water chemistry 4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before Do not use petroleum-based cleaning or proceeding further. CAUTION sealing compounds in the boiler system. Eliminate all system leaks. - Page 49 Installation & Operation Manual Start-up (continued) Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the Before starting the boiler, and during propane to make its presence detectable. WARNING initial operation, smell near the floor and In some instances, the odorant can fade, around the boiler for gas odorant or any and the gas may no longer have an odor.
- Page 50 Final checks before starting the boiler Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air Read the Knight XL Service Manual to familiarize piping, and vent piping. yourself with SMART SYSTEM control module Venting system must be sealed gastight to operation.
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Page 51: For Your Safety Read Before Operating
Installation & Operation Manual 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. •... - Page 52 The SMART SYSTEM control is programmed 5. Locate the pinhole button above the “T” in the Knight at the factory to control the temperature of the outlet sensor. XL logo on the display board (FIG. 11-1). Insert a thin...
- Page 53 The SMART SYSTEM control has a built-in clock that it uses Input the Installer code as described in the Knight XL Service for its night setback feature and for logging events. This clock Manual. Once the control parameters have been accessed, use must be set when the boiler is installed, and anytime the boiler the DOWN arrow key to select the H Control Mode parameters.
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Page 54: Operating Information
Modulation DHW priority The Knight XL is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is The SMART SYSTEM control module allows connection of a DHW thermostat to the low voltage connection board. - Page 55 Installation & Operation Manual Operating information (continued) Ramp delay Protection features For systems with lower flow, the SMART SYSTEM can limit Outlet temperature, flue temperature, the firing rate (when enabled) when a space heating call for temperature rise limiting heat starts, or when switching from a DHW call for heat to a space heating call for heat.
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Page 56: Cascade
This feature improves the system’s efficiency as the outdoor but can be reset by the installer. temperature warms up. Service reminder See the Knight XL Service Manual to change the settings. The control can be programmed for service reminder notification. This notification will become active when Reset curve... - Page 57 As the heat demand decreases further, the second to last boiler will modulate down and shut off. This Ramp Delay operation of the boilers as described in the Knight will continue until the demand is satisfied and all boilers are XL Service Manual is not active when the boilers are part of a shut off.
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Page 58: Sequence Of Operation
Installation & Operation Manual Operating information Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pumps BLR: Standby (system and boiler pumps for space heating call; DHW pump OUT: 123.8F(129) for DHW call). 2. -
Page 59: Knight Xl Control Module
Installation & Operation Manual Operating information (continued) 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 • Press to turn boiler off or • Hold 5 seconds to enter code... - Page 60 Press the MENU/EXIT button 1 time to return to the parameter listings; press again to return to the menu listings. Remember to press the ENTER/RESET button when finished programming in order to save the changes made. See the Knight XL Service Manual for a detailed description of parameters and access modes.
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Page 61: Status Display Screens
Installation & Operation Manual Operating information (continued) Status Display Screens 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 62 Installation & Operation Manual Operating information Status Display Screens (cont’d) 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 63 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) 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 Installation & Operation Manual Operating information Status Display Screens (cont’d) 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 of the individual items and what they can display: Screen Display shows:...
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Page 65: Maintenance Maintenance And Annual Startup
Installation & Operation Manual Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the Knight XL User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •... -
Page 66: Address Reported Problems
Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual and the Knight XL Service Manual. TO FLOOR... -
Page 67: Check Expansion Tank
Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected AT WARNING LEAST ONCE EVERY THREE YEARS, by a Visually inspect the entire flue gas venting system and air licensed plumbing contractor or authorized piping for blockage, deterioration or leakage. -
Page 68: Check Burner Flame
Knight XL Service Manual. Adjust settings if Figure 12-3 Burner Assembly - Model 500 necessary. See Section 1 of the Knight XL Service Manual for adjustment procedures. 2. Check settings of external limit controls (if any) and adjust if necessary. -
Page 69: Check Flame Signal
7. Finish cleaning using a clean cloth dampened with warm water. 3. See Section 3 - Troubleshooting in the Knight XL Service Manual for other procedures to deal with low flame 8. Install access cover gasket, chamber insulation assembly signal. -
Page 70: Diagrams
Installation & Operation Manual Diagrams Figure 13-1 Wiring Diagram LOW VOLTAGE DISPLAY 120 VAC BOX DEPICTS OPTIONAL ITEMS HIGH VOLTAGE INTEGRATED CONTROL JUNCTION RELAY BOARD INTERFACE CONNECTION BOARD X1-3 CN2-4 CN1-5 AUX. PUMP DEVICE CN2-1 PILOT CN1-6 CN2-16 SUPPLY X1-4 CN4-8 X6-8 CN1-3... -
Page 71: Ladder Diagram
Installation & Operation Manual Diagrams (continued) Figure 13-2 Ladder Diagram BOX DEPICTS OPTIONAL ITEMS JUNCTION BOX 120VAC NEUTRAL GROUND LOW VOLTAGE TERMINAL STRIP TERMINAL STRIP 120 VAC 120V SUPPLY "L" 120V SUPPLY "N" HIGH VOLTAGE INTEGRATED CONTROL ON / OFF SWITCH SYSTEM PUMP RELAY... -
Page 72: 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...