LOCHINVAR KNIGHT XL KBN701 (01) PDF Document

This manual must only be used by a 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.

The LOCHINVAR KNIGHT XL KBN701 boiler should be serviced/inspected by a qualified service technician at least annually.

If you smell gas, follow these instructions 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.

Follow these guidelines for safe boiler operation:

• 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 underwater. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been underwater must be replaced.

• Thoroughly flush the system (without the boiler connected) to remove sediment before installation. 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 and oxygen corrosion can cause failure. 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 may be damaged.

• For freeze protection, NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions specifically formulated for hydronic systems.

The following are the specifications for the LOCHINVAR KNIGHT XL KBN701 model:

Clearances from Combustible Materials:

• Hot water pipes: at least 1/4″ (6 mm) from combustible materials.

• Vent pipe: at least 1″ (25 mm) from combustible materials.

• Top: 13″ (330 mm)

• Left Side: 12″ (305 mm)

• Right Side: 0″

• Rear: 14″ (356 mm)

• Front (Closet Installation): 6″ (152 mm)

• Front (Alcove Installation): 18″ (457 mm)

Recommended Service Clearances:

• Front: 30″ (762 mm)

• Top: 24″ (610 mm)

• Left Side: 24″ (610 mm)

• Rear: 24″ (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.

Contaminated combustion air will damage the boiler. Ensure the combustion air intake is not placed in a location where it can be exposed to the following corrosive contaminants and sources.

The LOCHINVAR KNIGHT XL KBN701 must not be installed into a common vent with any other appliance. At the time of removal of an existing boiler, the following steps must be followed with each appliance remaining connected to the common venting system placed in operation:

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test the vent system. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the 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 operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, it should be resized to approach the minimum size as determined using the appropriate tables in the code.

The LOCHINVAR KNIGHT XL KBN701 model does not require an orifice installation for propane operation, but it does require a valve adjustment. Follow these steps:

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

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

3. Turn the adjustment screw on top of the gas valve clockwise one and a half (1 1/2) 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) 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.

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

The LOCHINVAR KNIGHT XL KBN701 requires specific sizes for its combustion air intake and vent piping:

• Air Intake: 4 inches (102 mm)
• Vent: 6 inches (152 mm)

The allowable lengths for both combustion air and vent piping are as follows:

• Minimum: 12 equivalent feet (3.7 m)
• Maximum: 100 equivalent feet (30.5 m)

When calculating the equivalent length, add 5 feet (1.5 m) for each 90° elbow and 3 feet (0.9 m) for each 45° elbow. Increasing or decreasing the specified piping sizes is not authorized.

Follow these steps to install the flow switch, relief valve, and temperature/pressure gauge on your LOCHINVAR KNIGHT XL KBN701:

1. Install the tee directly to the outlet connection of the heat exchanger with the 3/4 inch fitting positioned vertically and on top.

2. Install the 3/4 inch close nipple in the tee. Install the relief valve on the 3/4 inch close nipple.

3. Install a close nipple on the downstream side of the relief valve tee.

4. Install a tee with a 1 inch fitting positioned vertically and on top.

5. Attach paddle #3 to the flow switch per the manufacturer’s instructions.

6. Install the assembled flow switch into the 1 inch fitting of the tee installed in Step 4. Ensure the arrow on the flow switch points in the direction of flow.

7. Install a field-provided close nipple on the downstream side of the flow switch.

8. Install a field-provided tee with the gauge fitting positioned vertically and on top.

9. Install the temperature and pressure gauge provided with the unit into the top fitting of the tee (a bushing may be necessary).

For the LOCHINVAR KNIGHT XL KBN701, the flow switch requires paddle size #3. To set the sensitivity, first turn the sensitivity screw clockwise with a Phillips driver until it stops. Then, turn the screw counterclockwise by 5 1/4 turns. To increase the flow rate required to activate the switch, turn the screw clockwise. To decrease the flow rate required, turn it counterclockwise.

1. Remove the top access panel to pipe gas to the boiler.

a. Install a ground joint union for servicing, if required.

b. Install a manual shutoff valve in the gas supply piping outside the boiler jacket as required by local codes.

c. In Canada, when using a manual main shutoff valve, it must be identified by the installer.

2. Install a sediment trap / drip leg.

3. Support the piping with hangers, not by the boiler or its accessories. The gas valve and blower will not support the weight of the piping.

4. Purge all air from the gas supply piping.

5. Before 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 a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing at pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. 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.

6. Use a pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

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.

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 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”. Handle will be perpendicular to 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 next step.

8. Turn gas shutoff valve clockwise to “ON”. Handle will be parallel to pipe.

9. Install top cover.

10. Turn on all electric power to appliance.

11. Set thermostat to 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 lowest setting.

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

3. Remove top cover.

4. Turn gas shut off valve counterclockwise to “OFF”. Handle will be perpendicular to pipe. Do not force.

5. Install top cover.

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 will 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. The CO levels should be less than 150 ppm for a properly installed unit.

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

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

10. Place the boiler back into normal operation.

To equalize the run time of all boilers in a Cascade system, the firing sequence will automatically be changed at set intervals. The sequence will be changed once every 24 hours. The switching on/off sequence will be 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.

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 after the sparking ends, the control will perform a postpurge, then start another prepurge cycle and try to light the burner again. The control will lock out if this second attempt also fails.

7. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command (such as a 0-10V BMS signal).

8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on first, then the boiler pump will turn off. This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead. The control will then modulate to maintain the outlet temperature to the DHW 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 modes until one of them is satisfied.

10. Once both calls for heat are satisfied, the control will turn off the burner. The blower will continue to run during the postpurge period.

11. Any pumps that are running will continue to run for their respective pump delay times before turning off, unless programmed to remain on continuously. A 60 second anti-cycle period will start, which will delay any new call for heat until it times out.

12. In Standby, the boiler is ready to start a new cycle.

The status display screen provides detailed information about the boiler’s operation. Here is a breakdown of the different sections and what they mean:

Regular maintenance is crucial for the efficiency and reliability of your boiler. The tasks are divided between the owner and a qualified service technician.

Owner Maintenance Schedule:

Service Technician Maintenance (Annual Start-Up):

General:

• 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 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 any deposits; clean and reposition)
• Check wiring and connections
• Perform start-up checkout and performance verification per Section 10.
• Flame inspection (stable, uniform)
• 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

Follow these steps to clean the heat exchanger. Recommended materials are available in Heat Exchanger Cleaning Kit KIT30064.

1. Shut down the boiler by 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 to the heat exchanger 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. CAUTION: 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.

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