Lochinvar Knight KBN400 Installation & Operation Manual Download Page 1 | Manualshive

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Installation & Operation Manual

Models: 400 - 801

Th

is manual must only be used by a

qualifi ed 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.



WARNING

Save this manual for future reference.

KBXII-I-O_100161488_2000013409_Rev P

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Summary of Contents for Knight KBN400

Page 1: ...ce technician Read all instructions includingthismanualandtheKnight XL Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death...

Page 2: ...ll 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 2...

Page 3: ...oxic and can attack gaskets and seals used in hydronic systems When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and...

Page 4: ...on of the PVC air intake pipe to the boiler 19 High voltage junction box The junction box contains the connection points for the line voltage power and all pumps 20 Boiler drain port Location from whi...

Page 5: ...13 7 38 20 23 4 25 29 5 IMG00858 40 Left Side inside unit Model 400 19 21 36 16 1 3 17 33 26 2 Right Side inside unit Model 400 The Knight XL How it works continued Rear View Model 400 5 Model 400 10...

Page 6: ...How it works Rear View Model 501 Rear View Models 601 801 Left Side inside unit Models 601 801 Left Side inside unit Model 501 Model 501 Models 601 801 IMG00860 4 34 40 IMG00862 5 4 40 Installation O...

Page 7: ...tude operation but the operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit Derate values are based on proper com...

Page 8: ...pipe at least 1 25 mm from combustible materials 3 See FIG s 1 1 and 1 2 on page 9 for other clearance minimums Clearances for service access 1 See FIG s 1 1 and 1 2 on page 9 for recommended service...

Page 9: ...llations CPVC polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or dea...

Page 10: ...lation 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 burne...

Page 11: ...e 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 applicat...

Page 12: ...he 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...

Page 13: ...ired for removal 2 Remove the three screws securing the venturi to the blower Note When separating the venturi from the blower take care not to damage the O ring inside the blower FIG 2 2 3 Remove the...

Page 14: ...801 1 Remove the top access cover from the unit no tools required for removal 2 Remove the cover on top of the gas valve FIG 2 4 3 Turn the adjustment screw on top of the gas valve clockwise one and t...

Page 15: ...e page 27 for more details Direct venting options Sidewall Vent 3 General venting Installation Operation Manual Two Pipe Vertical See page 30 for more details Vertical Vent Sidewall Air PVC CPVC Conce...

Page 16: ...ction Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 2 thru 3 7 Used to provid...

Page 17: ...ce output rating will reduce by up to 1 5 for each 25 feet of vent length NOTICE Sizing Increasing or decreasing combustion air or vent piping sizes is not authorized NOTICE Model Air Intake Vent 400...

Page 18: ...sted 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 s...

Page 19: ...venting option the following conditions and considerations must be followed The unit MUST be installed with the appropriate room air kit Table 3C The equipment room MUST be provided with properly size...

Page 20: ...Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe Table 3D PVC CPVC Vent Pipe and Fittings Approved PVC CPVC Vent Pipe and Fittings Item Material Standard...

Page 21: ...pylene vent system should adhere to the vent manufacturer s installation instructions supplied with the vent system Approved Polypropylene Vent Manufacturers Make Model Centrotherm Eco Systems InnoFlu...

Page 22: ...steel vent system should adhere to the stainless steel vent manufacturer s installation instructions supplied with the vent system NOTICE Table 3H Stainless Steel Sidewall Vent Termination Kit s Model...

Page 23: ...s 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 are...

Page 24: ...y 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 i...

Page 25: ...Manual 2 For Polypropylene Only Install the vent and air intake sidewall adapters from Table 3F on page 21 into the vent plate Slide the sidewall retaining bracket down the sidewall adapters flush to...

Page 26: ...Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B WARNING Prepare wall penetrations Alternate Field Supplied Option 1 Air pipe penetration a Cut a hole...

Page 27: ...ent 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 Sidewall terminatio...

Page 28: ...PIPE Figure 4 10 Rain Cap to Vent Pipe Alternate Assembly 5 Install the Y concentric fitting and pipe assembly through the structure s hole from an inside wall Do not allow insulation or other materia...

Page 29: ...to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 12 Concentric Vent and Combustion Air Termination COMBUSTION AIR VENT VENT COMBUSTION AIR STRAP FIELD SUPPLIED ELBOW FIELD...

Page 30: ...let 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...

Page 31: ...tiple Knight XL boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation o...

Page 32: ...g see FIG 4 10 page 28 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 h...

Page 33: ...toensure 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 nea...

Page 34: ...s 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 If an existing unu...

Page 35: ...wable pipe lengths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase FLUE EXHAUST AIR INLET FLUE OUTLET EXISTING CAP SEAL SE...

Page 36: ...ct 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 w...

Page 37: ...close nipple in the tee Install the relief valve on the 3 4 inch close nipple FIG 6 2 For Models 400 601 install the relief valve directly into the 3 4 inch fitting on the tee FIG 6 1 3 Install the cl...

Page 38: ...ves 3 Domestic hot water circulating pump Field supplied The pump MUST be sized to meet the specified minimum flow requirements listed in FIG s 6 5 and 6 6 Consult the indirect water heater operating...

Page 39: ...r Field supplied A Y strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems Var...

Page 40: ...w Rate GPM Pressure Drop Feet of Head 0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80 90 KBN801 KBN701 KBN601 Pressure Drop vs Flow Includes Boiler Secondary Piping Flow Rate GPM Pressure Drop Feet of H...

Page 41: ...ystem 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...

Page 42: ...trations 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 i...

Page 43: ...are required for the protection of low temperature loops CAUTION Indirect water heaters are capable of transferring a limited number of Btu s into the water Ensure boiler output does not not exceed in...

Page 44: ...n higher than the required flow for the boiler s when the boiler s is in operation to prevent short cycling and high limit issues Please note that these illustrations are meant to show system piping c...

Page 45: ...or each system component The installer is responsible for compliance with local codes NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone NOTICE C...

Page 46: ...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...

Page 47: ...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 Pipe sizing for propane gas 1 Co...

Page 48: ...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 12 Shut off the gas supply a...

Page 49: ...he 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 The problem is especially noticeable i...

Page 50: ...15 amp recommended as required by the code see FIG 8 1 3 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 8 1 4 To activate a system...

Page 51: ...of the louvers needs to be verified before the boiler fires remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch FIG 8 3 High gas pressure s...

Page 52: ...G 8 3 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to th...

Page 53: ...M THERMOSTAT 3 SYSTEM SUPPLY SENSOR BUILDING MANAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO LOW WATER CUTOFF OUTDOOR SENSOR TANK SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER ROOM T...

Page 54: ...845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 7 A condensate removal pump is required if the boiler is below the dr...

Page 55: ...he following for properly filling your boiler with the appropriate water chemistry for closed loop boilers Good fill water quality will help extend the life of the appliance by reducing the effects of...

Page 56: ...this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressur...

Page 57: ...voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVE...

Page 58: ...g and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions whic...

Page 59: ...ch has been under water If you cannot reach your gas supplier call the fire department 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all elec...

Page 60: ...Hot Water tank and the set point is not met it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a short period of time The system pump can...

Page 61: ...AVIGATION dial to adjust the date Press the NAVIGATION dial 10 Turn the NAVIGATION dial to adjust the year Press the RIGHT SELECT SAVE key 11 Press the RIGHT SELECT HOME key Please note that the brack...

Page 62: ...ty The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the DHW thermostat input is ignored When a boil...

Page 63: ...To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low Protection features Outlet temperature flue temp...

Page 64: ...sensor is not installed Target temperature is calculated as described on this page under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operation...

Page 65: ...ives 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 poi...

Page 66: ...initiating the blower 5 The control starts the trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected after the sparking ends the control will perform a...

Page 67: ...boiler set point 9 If the boiler is not part of a Cascade and both the space heating and DHW calls for heat remain active long enough the boiler will switch back and forth between the two heating mode...

Page 68: ...to set temperatures operating conditions and monitor boiler operation The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial i...

Page 69: ...able in the Knight XL Service Manual 11 Operating information continued Please note that the brackets denote screen status NOTICE To save parameters and exit programming Press the RIGHT SELECT SAVE ke...

Page 70: ...ar the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position The controlled temperature has exceeded its set point and its offset BLOCKED T...

Page 71: ...measured by the flame sense circuit FAN SPEED The speed of the combustion blower BOILER PUMP The status of the boiler pump output SYSTEM PUMP The status of the system pump output DHW PUMP The status...

Page 72: ...ack Skip Screen E NAVIGATION Dial Function Turning the NAVIGATION dial will select the next or previous Status Screen Pressing the NAVIGATION dial will show the next fault NSB Night Setback trigger or...

Page 73: ...ps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C above return water temperature Test low water flow conditions reference the Knight XL Service Manual If combustion o...

Page 74: ...hey must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight XL Service Manual Inspect boiler interior 1 Remove the front access cover and inspect the...

Page 75: ...Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corro...

Page 76: ...SYSTEM control module display to Parameter Mode and check all settings See Section 1 of the Knight XL Service Manual Adjust settings if necessary See Section 1 of the Knight XL Service Manual for adju...

Page 77: ...a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re v...

Page 78: ...block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit WIRING DIAGRAM LBL20401 REV A BOX DEPICTS...

Page 79: ...O D B U S 29 34 9 5 6 7 8 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diag...

Page 80: ...refl ects the addition of Metal Fab and Security Chimney as approved suppliers along with placing check valves on the outlet side of the pump on all of the piping diagrams and updates made to the poly...

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