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Lochinvar Knight XL KBN701 User Manual

Lochinvar Knight XL KBN701
80 pages
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Installation & Operation Manual
Models: 400 - 801
is manual must only be used by a
quali ed 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.
WARNING
Save this manual for future reference.
KBXII-I-O_100161488_2000013409_Rev P

Table of Contents

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Lochinvar Knight XL KBN701 Specifications

General IconGeneral
ModelKBN701
TypeCondensing Boiler
Input BTU/hr700, 000
Efficiency95%
Modulation Ratio5:1
Fuel TypeNatural Gas or Propane
Water Connection Size2" NPT
Electrical Supply120V
Gas Connection Size2" NPT

Summary

Please Read Before Proceeding

General Safety and Installation Warnings

Covers warnings on installation, hazardous locations, and system fluids.

How the Knight XL Works

Control and Safety Components

Describes gas valve, sensors, LCD, pressure switch, and relief valve.

Determine Boiler Location

Installation Codes and Requirements

Lists all applicable codes and standards for boiler installation.

Pre-Installation Site Checks

Covers checks for connections, contaminants, and location suitability.

Installation Location Restrictions

Addresses outdoor, humidity, and condensation hazards.

Boiler Location and Air Supply

Combustion Air Contamination Prevention

Guidance on avoiding contaminants in air supply.

Venting System and Contaminant Checks

Corrosive Contaminants and Sources

Lists materials and areas to avoid for air intake.

Prepare the Boiler

Gas Conversions to Propane

Steps for converting the boiler for propane fuel.

Vent and Combustion Air Piping

Installing Vent and Air Piping

Instructions and warnings for installing piping systems.

Optional Room Air and Air Contamination

Air Contamination Hazards

Discusses risks from contaminants and necessary actions.

PVC/CPVC Vent Piping Installation

PVC/CPVC Piping Assembly Procedures

Detailed steps for priming, cementing, and assembling pipes.

Optional Concentric Sidewall Vent

Concentric Sidewall Vent Description and Usage

Explains the concentric sidewall vent kit.

Optional Concentric Vertical Vent

Concentric Vertical Vent Description and Usage

Explains the concentric vertical vent kit.

Hydronic Piping

General Piping Information and Steps

Important notes and installation steps for piping.

Hydronic Piping Components Installation

Flow Switch, Relief Valve, Gauge Installation

Instructions for installing key components.

Gas Connections

Connecting Gas Supply Piping

Instructions for connecting gas supply.

Gas Connections and Pressure Requirements

Propane Gas Conversions and Pressure

Rules for propane conversion and pressure.

Checking Inlet Gas Supply

Inlet Gas Supply Check Procedure

Steps to test gas supply pressure.

Gas Pressure and Valve Safety

Gas Valve Replacement Warnings

Safety warnings regarding gas valve replacement.

Field Wiring Requirements

Installation Code Compliance

Lists applicable electrical codes.

Line Voltage and Low Voltage Connections

Instructions for connecting power and control wiring.

Field Wiring System Integration

Cascade Boiler Wiring

Instructions for wiring multiple boilers in a cascade.

Condensate Disposal System

Condensate Drain Connection and Maintenance

How to connect and maintain the condensate drain.

Boiler Start-Up Procedures

Fill Water and Water Quality Checks

Instructions for filling the boiler and checking water chemistry.

Start-Up Water System Checks

Filling and Testing the Water System

Procedures for filling and testing the system.

Start-Up Safety and System Checks

Gas Leak Checks and Warnings

Procedures for checking gas leaks and related warnings.

Condensate System Inspection and Filling

Checking and filling the condensate trap.

Final Checks Before Boiler Startup

Pre-Startup Checklist

A comprehensive checklist before initiating startup.

Troubleshooting Startup Issues

Guidance for when the boiler fails to start correctly.

System and Boiler Component Checks

Verifying system piping and components.

Venting, Gas Piping, and Flame Checks

Checks for venting, gas, and flame integrity.

Propane Conversion Verification

Ensuring the boiler is correctly set up for propane.

Operating Instructions for Startup

Safety Warnings Before Operation

Critical safety information to read before operating.

Gas Leak Detection and Procedure

Steps for detecting and responding to gas leaks.

Boiler Startup Sequence

Step-by-step instructions for starting the boiler.

Boiler Startup Flame and Operation Checks

Flame and Combustion Analysis

Detailed procedure for checking flame and combustion.

Setting Space Heating Operation

Configuring heating parameters.

Boiler Startup DHW and Cascade Configuration

Setting Domestic Hot Water (DHW) Operation

Configuring DHW modes and temperatures.

Cascade System Configuration

Steps for setting up multiple boilers in a cascade.

Operating Information - Control Logic

Protection Features - Over-Temperature

How the boiler protects against overheating.

Operating Information - Monitoring and Limits

High Limit Operations and Testing

Description and testing of high limit safety features.

Operating Information - System Modes

Low Water Cutoff Protection

How the system handles low water conditions.

Cascade System Operation

Managing multiple boilers in a cascade setup.

Cascade Sequence and DHW/Setback Modes

How boilers switch and operate in a cascade.

Operating Information - Sequence of Operation

Boiler Startup and Safety Checks Sequence

Steps from call for heat to ignition and prepurge.

Ignition Trial and Flame Stabilization Sequence

Process of igniting the burner and stabilizing flame.

Knight XL Control Module Interface

Control Panel Overview and Button Functions

Description of the control panel layout and buttons.

Control Panel Status Display Screens

Overview of Status Display Screens

Explains the different screens shown on the control panel.

Control Panel Status Display Screens (continued)

Control Panel Navigation and Key Functions

Maintenance and Annual Startup

Service Technician Maintenance Schedule

Tasks for professional technicians.

Boiler Area and Internal Inspections

Maintenance - Venting and Water Systems

Maintenance - Electrodes, Wiring, and Controls

Performing Startup and Burner Checks

Initial startup procedures and burner inspection.

Maintenance - Flame Signal and Heat Exchanger

Cleaning the Boiler Heat Exchanger

Detailed procedure for cleaning the heat exchanger.

Diagrams

Wiring Diagram (Figure 13-1)

Schematic of the boiler's electrical connections.

Diagrams - Ladder Logic

Ladder Diagram (Figure 13-2)

Representation of the control logic in ladder format.

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