LOCHINVAR KNIGHT XL KBN801 (01) PDF Document

The installation and operation manual for the LOCHINVAR KNIGHT XL KBN801 must only be used by a qualified heating installer or service technician. All instructions must be read before installing, and steps must be performed in the order given. The boiler should be serviced and inspected at least annually by a qualified service technician.

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.

For safe operation of your LOCHINVAR KNIGHT XL KBN801 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.

Follow these guidelines for the boiler water:

• Thoroughly flush the system (without the boiler connected) to remove sediment, as it can damage the high-efficiency heat exchanger.

• Continual fresh make-up water will reduce boiler life due to mineral buildup and 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 they can damage gaskets and seals.

• 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. Only use inhibited propylene glycol solutions that are specifically formulated for hydronic systems. Ethylene glycol is toxic and can damage gaskets and seals used in hydronic systems.

The ratings and specifications for the LOCHINVAR KNIGHT XL KBN801 boiler are as follows:

Notes:

• The maximum allowed working pressure is located on the rating plate.

• Standard LOCHINVAR KNIGHT XL KBN801 boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

• High altitude models are equipped to operate from 3,000 to 12,000 feet only with no field adjustments and will de-rate by 2% for each 1,000 feet above 3,000 feet.

Installation of the LOCHINVAR KNIGHT XL KBN801 must comply with local, state, provincial, and national codes, including the National Fuel Gas Code (ANSI Z223.1) and National Electrical Code.

Before locating the boiler, check for:

• Nearby connections to system water piping, venting, gas supply, and electrical power.

• A location where water leaks will not cause damage. If unavoidable, a suitable drain pan should be installed.

• The area is clear of combustible materials, gasoline, and other flammable liquids.

Location and Clearances:

• This is an indoor appliance. Do not install it outdoors or where it will be exposed to freezing temperatures, temperatures over 100°F, or relative humidity exceeding 93%.

• The boiler requires a special venting system. Use only the specified materials.

• For closet installations (rooms less than 278 cubic feet for a KBN801), CPVC or stainless steel vent material must be used inside the structure, and ventilating air openings are required.

• Provide minimum clearances from combustible materials: 1/4″ for hot water pipes and 1″ for the vent pipe.

• Provide recommended service clearances: 30″ (front), 24″ (top, left, rear), and 0″ (right).

You must pipe combustion air to the boiler air intake and ensure the air does not contain corrosive contaminants. Contaminated air will damage the boiler. Do not terminate the air inlet near a swimming pool or in areas subject to exhaust fumes from laundry facilities.

The following products and areas should be avoided as they can cause contamination:

The LOCHINVAR KNIGHT XL KBN801 must not be installed into a common vent with any other appliance. When removing an existing boiler, follow these steps for each appliance remaining connected to the common venting system:

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

b. Visually inspect the venting system for proper size and horizontal pitch. Check for blockages, restrictions, leakage, corrosion, or other deficiencies.

c. Close all building doors and windows. Turn on clothes dryers and any non-connected appliances. Turn on exhaust fans (range hoods, bathroom exhausts) to maximum speed. Close fireplace dampers.

d. Place the appliance being inspected into operation. Adjust the thermostat so it operates continuously.

e. After 5 minutes of main burner operation, test for spillage at the draft hood relief opening using the flame of a match or smoke from a cigarette.

f. After confirming proper venting, return doors, windows, exhaust fans, and other gas-burning appliances to their previous conditions.

g. Correct any improper operation of the common venting system to conform with the National Fuel Gas Code. If resizing is needed, the system should be resized to approach the minimum size as determined by the appropriate tables in the code.

For a boiler already installed, you must turn off the gas supply, turn off power, and allow the boiler to cool before proceeding. Models 601 – 801 do not require an orifice installation but will require a valve adjustment.

To convert Models 601 – 801 to propane:

1. Remove the top access cover from the unit.

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

3. Turn the adjustment screw on top of the gas valve clockwise one turn for the 801 Model.

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

5. After adjustment is complete, attach the propane conversion label next to the boiler rating plate and 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.

Set the boiler in place and check the level. If necessary, adjust the leveling legs to level the boiler. You can use a screwdriver in the slot on top of the leg to raise or lower it.

The LOCHINVAR KNIGHT XL KBN801 uses model-specific piping sizes. For the KBN801 model, the required sizes are:

Increasing or decreasing these sizes is not authorized.

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

• Combustion Air: 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

• Vent: 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum

When calculating equivalent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (0.9 m) for each 45° elbow. The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

To install PVC or CPVC vent piping, follow these steps:

1. Work from the boiler to the vent termination. Do not exceed the specified pipe lengths.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer the outside of each pipe end to ensure even cement distribution.

4. Clean all pipe ends and fittings with a clean dry rag.

5. Dry fit the piping to ensure a proper fit before cementing. The pipe should go a third to two-thirds into the fitting.

6. For priming and cementing:

a. Handle fittings and pipes carefully to prevent contamination.

b. Apply a liberal, even coat of primer to the fitting socket and the pipe end.

c. Apply a second primer coat to the fitting socket.

d. While the primer is still wet, apply an even coat of approved cement to the pipe and fitting socket.

e. Apply a second coat of cement to the pipe.

f. While the cement is still wet, insert the pipe into the fitting. If possible, twist the pipe a 1/4 turn as you insert it.

g. Wipe excess cement from the joint.

All PVC vent pipes must be glued, properly supported, and pitched a minimum of 1/4 inch per foot back to the boiler to allow for condensate drainage.

To set the sensitivity screw on the flow switch, first turn it clockwise with a Phillips driver until it stops. Then, turn the screw counterclockwise the number of turns listed in the table below based on your model.

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

The following table provides sizing information for temperature rise applications of 20°F, 25°F, 30°F, and 35°F for the LOCHINVAR KNIGHT XL KBN801.

Follow these steps to connect the gas supply piping:

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.

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 cannot 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 or below 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak-tested before operation. Do not check for leaks with an open flame; use the bubble test.

6. Use a pipe sealing compound compatible with propane gases. Apply it sparingly only to male threads of the pipe joints to avoid blocking gas flow.

Before starting the boiler, perform the following checks and procedures:

1. Check/Control Water Chemistry:

• Hardness should be less than 7 grains.

• Chlorine concentration should be less than 200 ppm.

2. Fill and Test Water System:

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

• Fill to the correct system pressure (minimum 12 psi for commercial systems).

• Check the entire system thoroughly for leaks and repair any found.

3. Purge Air From Water System:

• Use purge/drain valves to systematically purge air from each zone until no noticeable air flow is present.

• After purging, close valves and ensure system pressure returns to the correct cold-fill pressure.

• Eliminate any residual air using manual air vents throughout the system.

4. Check for Gas Leaks:

• Before starting, smell near the floor and around the boiler for any gas odor. Do not proceed if a gas leak is indicated. Use an approved leak detection solution to find and repair leaks.

5. Inspect/Fill Condensate System:

• Inspect the condensate drain line, fittings, and trap.

• Fill the condensate trap with fresh water until water begins to pour out of the drain. This must be done to avoid flue gas emission.

6. Final Checks:

• Verify the boiler and system are full of water.

• Verify electrical connections are correct and secure.

• Inspect vent and air piping for any damage or sagging.

FOR YOUR SAFETY READ BEFORE OPERATING

This appliance is equipped with an automatic ignition device and does not have a pilot. 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. 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.

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow the “WHAT TO DO IF YOU SMELL GAS” instructions. 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 “To Turn Off Gas To Appliance” instructions 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.

Follow these steps to check the flame and combustion:

1. Turn the main power off to the boiler.

2. Remove the flue temperature sensor from the flue pipe connection to insert a combustion analyzer probe.

3. Turn the main power on.

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) and press the button for 5 seconds to place the boiler into Service Mode. The boiler will fire at ignition speed and then modulate to full fire.

6. Insert the probe from a combustion analyzer into the hole.

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

8. After analysis, test the safety shutoff by turning the manual gas shutoff valve to the OFF position. The boiler should shut down and register an alarm. Turn the shutoff valve back ON and reset the control.

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

10. Place the boiler back into normal operation.

When multiple LOCHINVAR KNIGHT XL KBN801 boilers are installed, they can be wired in a cascade sequence (maximum of eight boilers). One boiler is designated as the Leader and the others as Members.

• The Leader control receives the call for heat and determines the set point, either from a fixed temperature or calculated based on an outdoor air sensor.

• If the system water temperature is below the set point, the Leader initiates a call for heat and energizes the lead boiler in the cascade.

• To equalize the run time of all boilers, the firing sequence is automatically changed at set intervals. For example, the sequence changes every 24 hours.

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

• DHW, Night Setback, and Ramp Delay operations are also available for cascade systems.

The maintenance is divided between owner maintenance and service technician maintenance.

Annual Start-Up (Service Technician):

• Address reported problems.

• Inspect and clean interior.

• 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, piping, and expansion tank.

• Check control settings.

• Check ignition and flame sense electrodes.

• Check wiring and connections.

• Perform start-up checkout and performance verification.

• Perform flame inspection.

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

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

If combustion or performance indicates a need, the technician should also clean the heat exchanger, burner, and blower wheel.

To clean the heat exchanger, follow these steps:

1. Shut down the boiler by 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. Cover the refractory in the back of the combustion chamber.

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 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 it thoroughly with clean water.

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

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

For recommended materials and tools, refer to the Heat Exchanger Cleaning Kits (KIT30064 for models 501-801).