LOCHINVAR KNIGHT XL KBN501 (01) PDF Document

This manual must only be used by a qualified heating installer or service technician. It is crucial to 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.

If you smell gas, follow these instructions precisely:

• 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 KBN501 boiler, adhere to the following safety measures:

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

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

For safe operation of your LOCHINVAR KNIGHT XL KBN501, please follow these rules:

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

• If overheating occurs or 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. A flooded appliance can have extensive damage and present numerous safety hazards. Any appliance that has been under water must be replaced.

Proper water management is crucial for the longevity and safety of your LOCHINVAR KNIGHT XL KBN501 boiler:

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

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger can reduce heat transfer, overheat the stainless steel heat exchanger, and cause failure. Oxygen in makeup water can cause internal corrosion. Leaks in the boiler or piping must be repaired at once to prevent the need for makeup water.

• Do not use petroleum-based cleaning or sealing compounds in the boiler system, as gaskets and seals may be damaged, leading to substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”. This could result in serious damage to the boiler, personnel, and/or property.

NEVER use automotive antifreeze. Only use inhibited propylene glycol solutions that are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack the gaskets and seals used in hydronic systems.

To purge air from the system, follow these steps:

1. Purge air from the system:

a. Connect a hose to the purge valve. Route the hose to an area where water can drain and be seen.

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

c. Close zone isolation valves.

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

e. Open the purge valve.

f. Open the isolation valves one zone at a time. Allow water to run through the zone, pushing out the air, until no noticeable air flow is present. Close the zone isolation valves and proceed to the next zone. Follow 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 the correct cold-fill pressure.

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

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

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

3. Open other vents:

a. Starting on the lowest floor, open air vents one at a time until water squirts out.

b. Repeat with remaining vents.

4. Refill the system to the correct pressure.

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

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 avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

FOR YOUR SAFETY READ BEFORE OPERATING. 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. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

C. Use only your hand to turn the gas control knob. Never use tools. If the handle will not turn by hand, don’t try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Remove the top cover.

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

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information. If you don’t smell gas, go to the next step.

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

9. Install the top cover.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. 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 the gas supply to your appliance, follow these steps:

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 it.

5. Install the top cover.

To check the flame and combustion, perform the following steps:

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

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

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

4. 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.

5. If combustion is not within the specified range, refer to the Troubleshooting Section of the Knight XL Service Manual.

6. 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 to the ON position and reset the control.

7. Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection.

8. Place the boiler back into normal operation.

The NAVIGATION dial can be used during normal operation to adjust the space heating and tank set point temperatures. Note that brackets ([]) denote the 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 its night setback feature and for logging events. This clock must be set when the boiler is installed and anytime the boiler has been powered off for more than 4 hours. Follow this procedure:

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

2. The display will change to read [PASSWORD], with four zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then 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 clock is automatically updated when a PC is connected and the Win_Pro-Installer program is started.

The LOCHINVAR KNIGHT XL KBN501 has several built-in protection features:

Outlet temperature, flue temperature, and temperature rise limiting:

• The outlet temperature is monitored by a sensor. If it exceeds 185°F, the fan speed reduces. If it exceeds 195°F (90°C), the unit shuts down until it cools.

• A sensor in the flue exhaust monitors flue temperature. If it exceeds 215°F (102°C), the maximum fan speed is reduced. If it exceeds 240°F (115°C), the unit shuts down and restarts automatically once the temperature drops and the minimum off time has expired.

• The temperature difference between the inlet and outlet is monitored. If it exceeds 55°F (13°C), the fan speed is reduced. If it exceeds 60°F (15°C), the unit shuts down and restarts automatically once the difference drops below 55°F (13°C) and the minimum off time has expired.

Freeze protection:

The SMART SYSTEM control module provides freeze protection for the boiler itself (not the entire system) when the boiler water temperature drops below 45°F (7°C):

• 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 can be programmed for systems with anti-freeze solutions. This feature does not eliminate the possibility of freezing and proper installation practices must be followed.

To test the manual reset high limit (MRHL), follow these steps. Please note that brackets ([]) denote screen status.

1. Turn ON the main power to the boiler by placing the ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating the NAVIGATION dial counterclockwise, then press the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current outlet temperature (or to its minimum setting, whichever is higher) by turning the NAVIGATION dial counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL set point, the MRHL will function, causing a boiler lockout. If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL set point, locate the pinhole (SERVICE button) below the RESET button on the display board. Insert a thin probe (such as a paper clip) into the hole and press the button continuously for five (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will fire at ignition speed and will then modulate up to full fire.

10. Once the outlet temperature rises up to the MRHL set point, the MRHL will function, causing the boiler to shut down and lock out.

11. Repeat Steps 2, 3 and 4.

12. Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise.

13. Repeat Steps 6 and 7.

14. Press the RESET button to clear the lockout.

15. If needed, press the RIGHT SELECT [STOP] key to exit Service Mode.

To equalize the run time of all boilers in a Cascade system, the firing sequence is automatically changed at set intervals. The sequence will change once every 24 hours as follows:

If a boiler locks out or is used to heat an indirect DHW tank, it will automatically be given the lowest priority for the rest of that 24-hour period.

Access Modes:

• User: You can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “↓SETPOINTS” is flashing at the bottom of the display. The date, time, and temperature units can also be changed.

• Installer: Most parameters are available only to the installer, accessible by entering the installer password found in the Knight XL Service Manual.

Saving Parameters:

Please note that brackets ([]) denote screen status.

• 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 again to return to the menu listings. Remember to press the RIGHT SELECT [HOME] key when finished programming in order to save the changes made.

The following maintenance tasks should be performed by the owner at the specified intervals. For detailed instructions, refer to the Knight XL User’s Information Manual.

Daily:

• Check boiler area.

• Check pressure/temperature gauge.

Monthly:

• Check vent piping.

• Check air piping.

• Check air and vent termination screens.

• Check relief valve.

• Check condensate drain system.

• Check air vents.

Periodically:

• Test low water cutoff (if used).

• Reset button (low water cutoff).

Every 6 months:

• Check boiler piping (gas and water) for leaks.

• Operate relief valve.

End of season months:

• Shut boiler down (unless boiler is used for domestic hot water).

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear.

1. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 – Hydronic Piping before proceeding.

2. Inspect the relief valve and lift the lever to verify flow. When manually operating the lever, water will discharge. Precautions must be taken to avoid contact with hot water and to avoid water damage. 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 the test, replace it. Ensure the reason for weeping is the valve itself and not over-pressurization of the system due to an expansion tank issue.

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