LOCHINVAR KNIGHT XL KBN601 (01) PDF Document

If you smell gas, follow these instructions precisely to avoid a potential fire or explosion.

• 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.

To ensure safe operation of your LOCHINVAR KNIGHT XL KBN601 boiler, adhere to the following guidelines:

• 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 underwater. A flooded appliance can have extensive damage and present safety hazards. Any appliance that has been underwater must be replaced.

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

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

Proper water quality is essential for the longevity and efficiency of your LOCHINVAR KNIGHT XL KBN601.

• 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 reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Oxygen in makeup water can cause internal corrosion. 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, as gaskets and seals may be damaged.

• Do not use “homemade cures” or “boiler patent medicines,” as they can cause serious damage to the boiler, personnel, or property.

NEVER use automotive antifreeze in your LOCHINVAR KNIGHT XL KBN601 system. 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.

The specifications for the LOCHINVAR KNIGHT XL KBN601 model are as follows:

Notes:

1. Ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net AHRI ratings are based on net installed radiation of sufficient quantity for the building’s requirements, with a piping and pickup allowance of 1.15.

3. The boiler requires special gas venting. Use only the vent materials and methods specified in the manual.

4. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

5. Maximum allowed working pressure is located on the rating plate.

Proper clearances are required for safety and service access. For a closet or alcove installation, the following minimum clearances must be maintained:

Clearances from Combustible Materials:

• Top: 13 inches

• Front: 6 inches (Closet) or 18 inches (Alcove)

• Rear: 14 inches

• Left Side: 12 inches

• Right Side: 0 inches

• Hot Water Pipes: At least 1/4 inch (6 mm) from combustible materials.

• Vent Pipe: At least 1 inch (25 mm) from combustible materials.

Recommended Service Clearances:

• Front: 30 inches (762 mm)

• Top: 24 inches (610 mm)

• Left Side: 24 inches (610 mm)

• Rear: 24 inches (610 mm)

If you do not provide the minimum service clearances, it may not be possible to service the boiler without removing it from the space.

You must pipe combustion air to the boiler air intake and ensure that the combustion air will not contain any corrosive contaminants. Contaminated combustion air will damage the boiler. Do not terminate vent/air in locations that can allow contamination. For example, do not pipe combustion air near a swimming pool or in areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

Products to Avoid:

• Spray cans containing chloro/fluorocarbons

• Permanent wave solutions

• Chlorinated waxes/cleaners

• Chlorine-based swimming pool chemicals

• Calcium chloride used for thawing

• Sodium chloride used for water softening

• Refrigerant leaks

• Paint or varnish removers

• Hydrochloric acid/muriatic acid

• Cements and glues

• Antistatic fabric softeners used in clothes dryers

• Chlorine-type bleaches, detergents, and cleaning solvents

• Adhesives used to fasten building products

Areas Likely to Have Contaminants:

• Dry cleaning/laundry areas and establishments

• Swimming pools

• Metal fabrication plants

• Beauty shops

• Refrigeration repair shops

• Photo processing plants

• Auto body shops

• Plastic manufacturing plants

• Furniture refinishing areas and establishments

• New building construction and remodeling areas

• Garages with workshops

Models 601-801, including the KBN601, do not require an orifice installation for propane operation but do require a valve adjustment. Before starting, turn off the gas supply, turn off power, and allow the boiler to cool. After conversion, you must completely test the boiler as described in the Start-up section.

1. Remove the top access cover from the unit (no tools required).

2. Remove the cover on top of the gas valve.

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns.

4. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2.

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

6. Replace the gas valve cover along with the top access cover.

Proper leveling is necessary for the correct draining of condensate from the combustion chamber.

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

2. Adjust the leveling legs as necessary. Use a screwdriver in the slot at the top of the leg to raise or lower it.

To set the sensitivity screw for the flow switch on your LOCHINVAR KNIGHT XL KBN601, first turn the screw clockwise with a Phillips driver until it stops. Then, turn the screw counterclockwise by the amount specified below.

• Model: 601

• Paddle Size: #3

• Sensitivity Screw Adjustment: 7 1/4 turns

Note: Turning the sensitivity screw clockwise increases the flow rate required to activate the switch. Turning it counterclockwise decreases the required flow rate.

1. Turn the main power switch to the “OFF” position.

2. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

3. On the KBN601, remove the 1/8″ (3 mm) pipe plug on the inlet flange to the valve and install a suitable 1/8″ (3 mm) fitting (field supplied) for the manometer tubing. Place the tubing of the manometer over the fitting.

4. Slowly turn on the gas supply at the field-installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel to call for heat.

7. Observe the gas supply pressure as the burner fires at 100% of rated input. The percent of burner input will be displayed on the control panel.

8. Ensure the inlet pressure is within the specified range. Minimum and maximum gas supply pressures are specified in the manual.

9. If the gas supply pressure is within the normal range, proceed to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, or a qualified service agency to determine the necessary steps to provide proper gas pressure.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve.

13. Remove the manometer from the pressure tap. Remove the 1/8″ (3 mm) field-supplied fitting and reinstall the pipe plug removed in Step 3.

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.

WHAT TO DO IF YOU SMELL GAS

• 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 neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

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 on this label.

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 top cover.

6. Turn 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 above on this label. If you don’t smell gas, go to the next step.

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

9. Install top cover.

10. Turn on all electric power to the appliance.

11. Set 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 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 top cover.

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

5. Install top cover.

Before starting the boiler, perform these final checks:

• Familiarize yourself with the SMART SYSTEM control module operation.

• Verify the boiler and system are full of water and components are set correctly.

• Fill the vent condensate trap with water.

• Verify electrical connections are correct and secure.

• Inspect vent and air piping for deterioration, damage, or sagging.

If the boiler does not start correctly, check the following:

• Are there loose connections, a blown fuse, or is the service switch off?

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

• Is the thermostat set below room temperature?

• Is the gas turned on at the meter or boiler?

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

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 (like 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 Flue Products Chart. CO levels should be less than 150 ppm for a properly installed unit.

Flue Products Chart

8. Once the analysis is complete, test the safety shutoff by turning the manual shutoff valve to OFF and ensuring the boiler shuts down and registers an alarm. Turn the manual shutoff to 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.

The NAVIGATION dial can be used during normal operation to adjust the space heating and tank set point temperatures.

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 clock must be set when the boiler is installed and anytime the boiler 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 changes to read [PASSWORD].

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and 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 Saving Time and will require manual adjustment.

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The flow switch and/or LWCO must close.

3. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close.

4. The control starts the prepurge cycle by 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, the control will perform a postpurge, then try to light the burner again. The control will lock out if the second attempt fails.

7. If flame is detected, it holds the firing rate steady for a few seconds to stabilize, then modulates the firing rate based on the set point or other command.

8. If a DHW call for heat starts during a space heating call, the boiler will switch to DHW mode.

9. If both space heating and DHW calls remain active, the boiler will switch back and forth between the two modes until one is satisfied (not applicable to Cascade systems).

10. Once both calls for heat are satisfied, the burner turns off. The blower continues to run for the postpurge period.

11. Any running pumps will continue to run for their pump delay times. A 60-second anti-cycle period will start, delaying any new call for heat.

12. The boiler is in Standby, ready for a new cycle.

Owner Maintenance

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

Service Technician (Annual Start-up)

• Address reported problems.

• Inspect interior; clean and vacuum if necessary.

• Clean condensate trap and fill with fresh water.

• Check for leaks (water, gas, flue, condensate).

• Verify flue and air lines are in good condition and sealed tight.

• Check system water pressure/system piping/expansion tank.

• Check control settings.

• Check ignition and flame sense electrodes (sand off deposits; clean and reposition).

• Check wiring and connections.

• Perform start-up checkout and performance verification.

• Perform flame inspection (stable, uniform).

• Check flame signal (at least 10 microamps at high fire).

• Clean the heat exchanger if flue temperature is more than 54°F (30°C) above return water temperature.

If combustion or performance indicate need:

• Clean heat exchanger.

• Remove and clean burner using compressed air only.

• Clean the blower wheel.

1. Inspect the condensate drain line, 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 it makes contact with the drain.

7. Replace the retaining screw.

The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line.

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

2. The valve lever must be operated AT LEAST ONCE A YEAR to ensure waterways are clear. When manually operating the lever, water will discharge; take precautions to avoid contact with hot water and prevent 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 testing, replace it. Ensure the cause is the valve itself and not over-pressurization of the system due to an expansion tank issue.

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. To remove the burner, reference the burner assembly diagrams in the manual.

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

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions in the Service Manual.

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

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

3. Remove the nuts securing the heat exchanger access cover and set them 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 dry thoroughly.

10. Remove the field-supplied rear refractory cover from the back of the combustion chamber 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.

12. Perform start-up and check-out procedures.

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