LOCHINVAR KNIGHT XL KBN400 (01) PDF Document

If you smell gas, follow these steps immediately:

• 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 nearby 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.

When servicing your LOCHINVAR KNIGHT XL KBN400 boiler, adhere to the following safety precautions:

• To avoid electric shock, disconnect the electrical supply before performing maintenance.

• To avoid severe burns, allow the boiler to cool before performing maintenance.

For safe operation of your LOCHINVAR KNIGHT XL KBN400, please follow these guidelines:

• Do not block the flow of combustion or ventilation air to the boiler.

• Should overheating occur or if the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the 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.

Proper water quality is essential for the longevity and efficiency of your LOCHINVAR KNIGHT XL KBN400. Follow these guidelines:

• Thoroughly flush the system (without the boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. The addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once to prevent makeup water.

• Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged, which can result in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

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.

To prevent damage to your LOCHINVAR KNIGHT XL KBN400, you must avoid combustion air contamination from certain products and areas. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death, or substantial property damage.

To convert the LOCHINVAR KNIGHT XL KBN400 to operate on propane gas, you must install a propane orifice. For a boiler that is already installed, you must first turn off the gas supply, turn off power, and allow the boiler to cool before proceeding.

1. Remove the top and front access covers from the unit.

2. Remove the three screws securing the venturi to the blower. When separating the venturi from the blower, be careful not to damage the O-ring inside the blower.

3. Remove the four star-drive screws securing the gas valve to the venturi.

4. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size (Model 400 – 8.0 LP orifice stamping).

5. Remove the existing orifice from the O-ring in the side of the gas valve and replace it with the orifice from the kit. Position and secure the orifice in the valve.

6. Reposition the gas valve against the venturi and replace the star-drive screws securing the valve to the venturi.

7. Inspect the O-ring inside the blower. Handle the O-ring with care and do not damage it. Reposition the venturi against the blower and replace the screws securing the venturi to the blower.

8. After installation is complete, attach the propane conversion label (from the conversion kit) next to the boiler rating plate. Attach the LP caution label (from the conversion kit) to the left side of the unit in the lower left corner.

9. Replace the top and front access covers.

After converting, you must completely test the boiler to verify performance as described in the Start-up section of the manual. Inspect the O-ring when the blower is disassembled; it must be in good condition and installed correctly to prevent a gas leak.

1. Set the boiler in place and check the level.

2. Adjust the legs if necessary to level the boiler. The leveling legs have a slot for a screwdriver to raise or lower them.

To adjust the flow switch, refer to the table below for the proper setting of the sensitivity screw. Before setting, turn the screw clockwise with a Phillips driver until it stops. Then, turn the screw counterclockwise the number of turns listed for your model.

Note: Paddles are included with the flow switch. To increase the flow rate required to activate the switch, turn the sensitivity screw clockwise. To decrease the flow rate required, turn it counterclockwise.

Before placing the boiler in operation, you must check the boiler and its gas connections for leaks.

1. 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).

2. 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).

3. The appliance and its gas connection must be leak tested before placing it in operation. Do not check for gas leaks with an open flame; use the bubble test. Failure to use the bubble test can cause severe personal injury, death, or substantial property damage.

The LOCHINVAR KNIGHT XL KBN400 is a high-efficiency appliance that produces condensate. Proper management of the condensate is crucial.

1. The boiler has a 1/2 inch PVC union for connecting a 1/2 inch PVC pipe.

2. Slope the condensate tubing down and away from the boiler into a drain or a condensate neutralizing filter. The condensate is slightly acidic (pH 3 to 5), so a neutralizing filter may be required by local codes.

3. Install the 1/2 inch PVC tee assembly (shipped with the unit).

4. Leave the top of the 1/2 inch tee OPEN to act as a vacuum break.

5. Do not expose the condensate line to freezing temperatures.

6. Use only plastic tubing or piping for the condensate drain line.

7. If the boiler is below the drain, a condensate removal pump approved for condensing boilers is required. The pump should have an overflow switch to prevent spillage, wired in series with the blocked drain switch inside the boiler.

The condensate line must remain unobstructed to allow free flow. A frozen or obstructed line can cause condensate to exit from the boiler tee, leading to potential water damage.

To ensure the proper functioning and longevity of your LOCHINVAR KNIGHT XL KBN400, adhere to the following water chemistry standards:

Hardness less than 7 grains:

• Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm:

• Do not fill the boiler or operate with water containing chlorine in excess of 200 ppm.

• Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

• Do not use the boiler to directly heat a swimming pool or spa water.

1. Fill the system only after ensuring the water meets the requirements outlined in the manual.

2. Close manual and automatic air vents and the boiler drain valve.

3. Fill to the correct system pressure. The minimum cold water fill pressure for a commercial system is 12 psi (82.7 kPa). Pressure will rise when the boiler is turned on and the system water temperature increases.

4. At initial fill and during boiler startup and testing, check the system thoroughly for any leaks. Repair all leaks before proceeding further. Continual fresh makeup water from leaks will reduce boiler life.

1. Purge air from the system:

a. Connect a hose to the purge valve and route it to a drain.

b. Close the boiler or system isolation valve between the purge valve and the fill connection.

c. Close zone isolation valves.

d. Open the quick-fill valve on the cold water makeup line.

e. Open the purge valve.

f. One zone at a time, open the isolation valves and allow water to run through the zone until no noticeable air is present. Close the zone isolation valves and proceed to the next zone.

g. Once all zones are purged, close the quick-fill water valve and purge valve, then remove the hose. Open all isolation valves and watch that the system pressure rises to the correct cold-fill pressure.

h. After the system has operated for a while, eliminate any residual air by using the manual air vents throughout the system.

i. If purge valves are not installed, open the manual air vents one at a time, starting with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open the automatic air vent (for diaphragm-type or bladder-type expansion tank systems only) one turn.

3. Open other vents by starting on the lowest floor and opening air vents one at a time until water squirts out. Repeat with remaining vents.

4. Refill to the correct pressure.

First, inspect the condensate drain line, PVC fittings, and condensate trap for any issues.

To fill the condensate trap with water:

1. Remove the PVC cap retaining screw from the PVC cap.

2. Remove the 2-inch PVC cap with the switch located at the top of the trap.

3. Fill with fresh water until the water begins to pour out of the drain.

4. Replace the cap. Press the cap onto the trap until it makes contact with the drain.

5. Replace the retaining screw.

The condensate trap must be filled with water at all times during boiler operation to prevent flue gas from emitting from the condensate drain line.

If your LOCHINVAR KNIGHT XL KBN400 boiler fails to start correctly, check the following:

1. Are there any loose connections, a blown fuse, or is the service switch off?

2. Is the boiler water temperature above 200°F (93°C)?

3. Is the thermostat set below room temperature?

4. Is the gas turned on at the meter or boiler?

5. Is the incoming gas pressure less than 4 inches w.c. (.99 kPa)?

If none of these correct the problem, refer to the Troubleshooting Section of the Knight XL Service Manual.

This procedure should only be performed by a qualified service technician.

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. Combustion measurements will be made at this point.

3. Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key.

5. Locate the pinhole button below the RESET button on the display board. Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode, the boiler will fire at ignition speed and then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.

7. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in the table below. CO levels should be less than 150 ppm for a properly installed unit.

8. Once the analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring the boiler shuts down and registers an alarm. Turn the manual shutoff switch back ON and reset the control.

9. Turn the main power off and replace the flue temperature sensor into the flue pipe connection.

10. Place the boiler back into normal operation.

FOR YOUR SAFETY READ BEFORE OPERATING

This appliance does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do not try to light the burner by hand.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information on the label.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. Remove the top cover.

5. Turn the gas shutoff valve counterclockwise to “OFF”. The handle will be perpendicular to the pipe. Do not force.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! and follow the “WHAT TO DO IF YOU SMELL GAS” procedure. If you don’t smell gas, go to the next step.

7. Turn the gas shutoff valve clockwise to “ON”. The handle will be parallel to the pipe.

8. Install the top cover.

9. Turn on all electric power to the appliance.

10. Set the thermostat to the desired setting.

11. If the appliance will not operate, follow the instructions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove the top cover.

4. Turn the gas shutoff valve counterclockwise to “OFF”. The handle will be perpendicular to the pipe. Do not force.

5. Install the top cover.

The NAVIGATION dial can be used during normal operation to adjust the space heating and tank set point temperatures. Note that brackets ([]) denote screen status.

1. From the Status Screen, press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select the appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the RIGHT SELECT [SAVE] key.

5. If necessary, repeat Steps 3 and 4 to make adjustments to additional set points.

6. Press the RIGHT SELECT [HOME] key to upload the changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the new settings will be discarded.

The SMART SYSTEM control has a built-in clock for night setback and event logging. This clock must be set when the boiler is installed and anytime it has been powered off for more than 4 hours.

1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

2. The display will show [PASSWORD] with four zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will show a menu with the time, date, and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial.

9. Turn the NAVIGATION 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.

Note: The internal clock does not adjust for Daylight Savings Time and will require manual adjustment.

The LOCHINVAR KNIGHT XL KBN400 includes several built-in protection features:

• Outlet temperature, flue temperature, and temperature rise limiting: The control monitors the outlet water temperature, flue exhaust temperature, and the difference between inlet and outlet temperatures. If any of these exceed preset limits, the control will first reduce the firing rate and then shut the unit down if necessary to prevent damage. It will restart automatically once conditions return to a safe range.

• Freeze protection: This integral feature provides some protection for the boiler only, not the entire system. Do not install the boiler in a room likely to freeze.

– Below 45°F (7°C), the boiler and system pumps operate constantly.

– Below 37°F (3°C), the boiler turns on.

– The boiler and pumps turn off if the boiler water temperature rises above 45°F (7°C).

– Lower temperatures may be programmed for systems with anti-freeze solutions.

The control panel is used to set temperatures, operating conditions, and monitor boiler operation. It consists of:

• RESET KEY: Used to reset the boiler after a lockout.

• LEFT SELECT KEY (SOFT KEY): The function is shown on the bottom left of the display (e.g., MENU).

• RIGHT SELECT KEY (SOFT KEY): The function is shown on the bottom right of the display (e.g., SHDN for Shutdown).

• NAVIGATION DIAL (PRESS OR TURN): Used to navigate menus and change values. Pressing the dial often selects an option (e.g., SETPOINTS).

The information on the bottom of the display shows the functions of the two SELECT keys and the NAVIGATION dial.

• MENU = Left SELECT Key

• SETPOINTS = NAVIGATION Dial – Pressing Down

• SHDN = Right SELECT Key

To save parameters and exit programming:

• Press the RIGHT SELECT [SAVE] key and then press the RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

• Press the RIGHT SELECT [SAVE] key one time to return to the parameter listings; press it again to return to the menu listings. Remember to press the RIGHT SELECT [HOME] key when you are finished programming to save the changes you have made.

Regular maintenance is essential for the efficiency and longevity of your boiler. The schedule is divided between owner maintenance and tasks for a qualified service technician.

1. Inspect the condensate drain line, condensate PVC fittings, and condensate trap.

2. Remove the PVC cap retaining screw from the PVC cap.

3. Remove the 2 inch PVC cap with the switch located at the top of the trap.

4. Remove any sediment in the trap.

5. Fill with fresh water until the water begins to pour out of the drain.

6. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

7. Replace the retaining screw.

1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential.

2. Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. When manually operating the lever, water will discharge; precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating the lever, check that a discharge line is connected to the valve directing the flow to a proper place of disposal. If no water flows, the valve is inoperative. Shut down the boiler until a new relief valve has been installed.

3. If the relief valve weeps or will not seat properly after testing, replace the relief valve. Ensure the reason for weeping is the valve itself and not over-pressurization of the system.

Safety relief valves should also be re-inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency.

1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace them with new ones.

3. Replace the ignition/flame sense electrode, making sure the gasket is in good condition and correctly positioned.

1. Inspect the flame through the observation window.

2. If the flame is unsatisfactory at either high or low fire, turn off the boiler and allow it to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean the burner if performed inside a building.

3. Remove the burner for cleaning if necessary.

4. When replacing the burner, ensure the gasket is in good condition and positioned correctly.

1. At high fire, the flame signal shown on the display should be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve the signal, and the ground wiring and continuity are satisfactory, replace the flame sense electrode.

3. Refer to the Troubleshooting section in the Knight XL Service Manual for other procedures to deal with a low flame signal.

This procedure should only be performed by a qualified service technician.

1. Shut down the boiler following the “To Turn Off Gas to Appliance” instructions.

2. Allow time for the boiler to cool to room temperature if it has been firing.

3. Remove the nuts securing the heat exchanger access cover and set aside.

4. Remove the heat exchanger access cover, burner, and gas/air arm assembly.

5. Remove the condensate hose from the heat exchanger end. Connect a field-supplied 3/4″ diameter hose to a drain pan. Using field-supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.

6. Use 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. Do NOT use a metal brush. Re-vacuum the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low-pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the field-supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

11. Close isolation valves on piping to isolate the boiler from the system. Attach a hose to the boiler drain and flush the boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler.

12. Perform start-up and check-out procedures as described in the manual.

13. Replace the access cover and restore the boiler to operation.