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  5. Installation & Operation Manual

Lochinvar Knight XL 400 Installation & Operation Manual

Manual is about: Lochinvar Boiler User Manual

Summary of Knight XL 400

  • Page 1

    Installation & operation manual models: 400 - 801 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...

  • Page 2

    2 contents hazard definitions the following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.  danger  warning  caution caution notice danger indicates an imminently ha...

  • Page 3

    Installation & operation manual please read before proceeding installer – read all instructions, including this manual and the knight xl service manual, before installing. Perform steps in the order given. User – this manual is for use only by a qualified heating installer/service technician. Refer ...

  • Page 4

    Installation & operation manual 4 the knight xl - how it works... 1. Stainless steel heat exchanger allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combu...

  • Page 5

    Installation & operation manual front view - model 400 27 35 8 7 20 13 28 23 14 29 25 4 5 37 38 left side (inside unit) - model 400 19 21 36 16 1 3 17 33 26 2 right side (inside unit) - model 400 the knight xl - how it works... (continued) rear view - model 400 5 model 400 10 31 24 18 11 6 15 32 22 ...

  • Page 6

    Installation & operation manual 6 the knight xl - how it works... 18 15 27 rear view - model 501 27 15 18 rear view - models 601 - 801 left side (inside unit) - models 601 - 801 left side (inside unit) - model 501 model 501 models 601 - 801 34 4 5 4.

  • Page 7

    Installation & operation manual ratings notes: 1. The ratings are based on standard test procedures prescribed by the united states department of energy. 2. Net i=b=r ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added fo...

  • Page 8

    8 installation & operation manual the knight xl gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ansi z21.13 – latest edition. Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liq...

  • Page 9

    9 installation & operation manual 1 determine boiler location (continued) alcove installation open front 1" minimum clearance around hot water pipes and vent pipe 18" (457 mm) front 0" right 13" (330) top 12" (305 mm) left 14" (356 mm) rear recommended service clearances: front - 30” (762 mm) top - ...

  • Page 10

    10 installation & operation manual 1 determine boiler location provide air openings to room: knight xl alone in boiler room 1. No air ventilation openings into the boiler room are needed when clearances around the knight xl are at least equal to the service clearances shown in fig.’s 1-1 and 1-2. Fo...

  • Page 11

    11 installation & operation manual 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 re...

  • Page 12

    Installation & operation manual 1 determine boiler location 12 when removing a boiler from existing common vent system: do not install the knight xl into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, ...

  • Page 13

    Installation & operation manual 2 prepare boiler 13 remove boiler from wood pallet 1. After removing the outer shipping carton from the boiler, remove the parts box. 2. Remove the front door to access the lag bolts in front of the unit (fig. 2-1). 3. To remove the boiler from the pallet (after remov...

  • Page 14

    Installation & operation manual 2 prepare boiler 14 screwdriver slot lower raise figure 2-5 leveling legs on the boiler leveling the boiler 1. Set the boiler in place and check level. A) adjust legs if necessary to level boiler, see fig. 2-5 below. Allen wrench adjustment screw figure 2-3 gas valve ...

  • Page 15

    Installation & operation manual 15 pvc/cpvc two pipe see figure 4-1a models 400 - 601 only pvc/cpvc alternate two pipe see figure 4-2a stainless steel alternate two pipe see figure 4-2b stainless steel two pipe see figure 4-1c models 400 - 601 only pvc/cpvc concentric see figure 4-7 models 400 - 601...

  • Page 16

    Installation & operation manual 16 direct venting options - vertical vent, sidewall air 3 general venting direct venting options - vertical vent pvc/cpvc two pipe see figure 5-1a stainless steel two pipe see figure 5-1b pvc/cpvc concentric see figure 5-5 pvc/cpvc vertical vent, sidewall air stainles...

  • Page 17

    Installation & operation manual 17 3 general venting (continued) pvc/cpvc vent piping materials use only the materials listed in table 3a (pg. 18) for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage. Installation must comply wi...

  • Page 18

    Installation & operation manual 18 3 general venting 6. Priming and cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces. B. Apply a liberal even coat of primer to the fitting socket. C. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyon...

  • Page 19

    Installation & operation manual 19 3 general venting (continued) air inlet pipe materials: the air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: pvc, cpvc or abs dryer vent or sealed flexible duct (not recommended for rooftop air inlet) ...

  • Page 20

    Installation & operation manual 20 3 general venting figure 3-12 near boiler stainless steel venting models 701 - 801 4" s.S. Adapter vent 4" s.S. Intermediate (for saf-t vent only) figure 3-11 near boiler stainless steel venting models 400 - 601 table 3c stainless steel vent termination kit(s) mode...

  • Page 21

    Installation & operation manual 21 model kit number equivalent vent length 400 cvk3007 5 feet (1.5 m) 501 cvk3007 30 feet (9 m) 601 cvk3007 30 feet (9 m) 3 general venting (continued) vent, air piping and termination: the knight xl vent and air piping can be installed through the roof or through a s...

  • Page 22

    Installation & operation manual 22 3 general venting if the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants. To prevent the potential of severe personal injury or death, check for areas and products listed...

  • Page 23

    Installation & operation manual 23 4 sidewall direct venting vent/air termination – sidewall follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not termina...

  • Page 24

    Installation & operation manual 12" (305 mm) min 15" (381 mm) max 12" (305 mm) min from boiler vent pipe connection to boiler intake air connection bird screen grade or snow line figure 4-1c alternate stainless steel vent termination - typical stainless steel sidewall termination of air and vent mod...

  • Page 25

    Installation & operation manual 25 12” (305 mm) min bird screen (typical) 12” (305 mm) min 12” (305 mm) min figure 4-3b alternate clearance to gravity air inlets w/field supplied fittings 36” (914 mm) min 7’ (2.1 m) min above any public walkway if less than 10’ (3 m) forced air inlet bird screen (ty...

  • Page 26

    Installation & operation manual 26 4 sidewall direct venting sidewall termination plate vent piping galvanized thimble (when required by local codes) elbow elbow air piping bird screen bird screen figure 4-5b a typical sidewall termination assembly - models 400 - 801 pvc/cpvc or stainless steel term...

  • Page 27

    Installation & operation manual 27 4 sidewall direct venting (continued) 4" (102 mm) dia. 6" (152 mm) dia. Rain cap "y" concentric fitting "flexible" pipe coupling 6" (152 mm) dia. 6" (152 mm) dia. 6" (152 mm) to 4" (102 mm) reducer figure 4-8 kit contents_cvk3007 - models 400 - 601 sidewall termina...

  • Page 28

    Installation & operation manual 28 4 sidewall direct venting sidewall termination – optional concentric vent: models 400 - 601 only figure 4-9 concentric vent dimensional drawing - models 400 - 601 instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be u...

  • Page 29

    Installation & operation manual 29 4 sidewall direct venting (continued) sidewall termination – optional concentric vent: models 400 - 601 only multiventing sidewall terminations when two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see f...

  • Page 30

    Installation & operation manual 30 5 vertical direct venting vent/air termination – vertical follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Installation must comply with local requirements and with the na...

  • Page 31

    Installation & operation manual 31 5 vertical direct venting (continued) vent/air termination – vertical prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a ...

  • Page 32

    Installation & operation manual 32 5 vertical direct venting vertical termination – optional concentric vent: models 400 - 601 only description and usage lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termin...

  • Page 33

    Installation & operation manual 33 5 vertical direct venting (continued) vertical termination – optional concentric vent: models 400 - 601 only elbow (field supplied) support (field supplied) roof boot / flashing (field supplied) vent combustion air vent 12" (305 mm) (18" (457 mm) for canada) minimu...

  • Page 34

    Installation & operation manual 34 5 vertical direct venting alternate vertical concentric venting this appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for...

  • Page 35

    Installation & operation manual 35 5 vertical direct venting (continued) existing vent as a chase follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the general venting section of this manual. Figure 5-10 existing vent...

  • Page 36

    Installation & operation manual 36 6 hydronic piping system water piping methods the knight xl is designed to function in a closed loop pressurized system not less than 12 psi (83 kpa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be locat...

  • Page 37

    Installation & operation manual 37 relief valve flow switch paddle temperature and pressure gauge tee with fitting on top (field provided) close nipple (field provided) tee with 1” fitting on top close nipple tee with 3/4” fitting on top close nipple notice be sure to install the flow switch so that...

  • Page 38

    Installation & operation manual 6 hydronic piping figure 6-3 flow switch adjustment flow switch adjustment refer to table 6a for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a phillips driver until it stops (fi...

  • Page 39

    Installation & operation manual 39 6 hydronic piping (continued) near boiler piping connections y-strainer (recommended) boiler pump indirect domestic hot water tank system pump to floor drain to fr om fr om sy st em to sy st em domestic hot water pump system sensor dirt separator figure 6-4a near b...

  • Page 40

    Installation & operation manual 40 figure 6-5 pressure drop vs. Flow - models 400 and 501 table 6b sizing information for temperature rise applications_20°f, 25°f, 30°f and 35°f figure 6-6 pressure drop vs. Flow - models 601 thru 801 0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 20 25 30 35 40 45 kbn501 kbn...

  • Page 41

    Installation & operation manual 41 6 hydronic piping (continued) expansion tank air separator pressure reducing valve back flow preventer ball valve (typical) union (typical) pressure relief valve flow check valve (typical) indirect dhw tank boiler temperature / pressure gauge pressure gauge drain d...

  • Page 42

    Installation & operation manual 42 6 hydronic piping expansion tank air separator pressure reducing valve back flow preventer ball valve (typical) union (typical) pressure relief valve flow check valve (typical) indirect dhw tank boiler temperature / pressure gauge pressure gauge drain drain point (...

  • Page 43

    Installation & operation manual 43 6 hydronic piping (continued) expansion tank air separator pressure reducing valve back flow preventer ball valve (typical) union (typical) pressure relief valve flow check valve (typical) indirect dhw tank boiler 1 temperature / pressure gauge pressure gauge drain...

  • Page 44

    Installation & operation manual 44 6 hydronic piping expansion tank air separator pressure reducing valve back flow preventer ball valve (typical) union (typical) pressure relief valve flow check valve (typical) indirect dhw tank boiler 1 (leader) temperature / pressure gauge pressure gauge drain dr...

  • Page 45

    Installation & operation manual 45 6 hydronic piping (continued) expansion tank air separator pressure reducing valve back flow preventer ball valve (typical) union (typical) pressure relief valve flow check valve (typical) indirect dhw tank boiler temperature / pressure gauge pressure gauge drain d...

  • Page 46

    Installation & operation manual 46 7 gas connections connecting gas supply piping 1. Remove the top access panel and refer to fig.’s 7-1 thru 7-3 to pipe gas to the boiler. A. Install ground joint union for servicing, when required. B. Install a manual shutoff valve in the gas supply piping outside ...

  • Page 47

    Installation & operation manual 47 7 gas connections (continued) failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Use two wrenches when tightening gas piping at boiler (fig. 7-4), using one wrench to preven...

  • Page 48

    Installation & operation manual 48 nominal iron pipe size (inches) natural gas pipe capacity chart length of pipe in straight feet maximum capacity of pipe in thousands of btu/hr per hour for gas pressures of 14 inches water column (0.5 psig) or less and a pressure drop of 0.5 inch water column (bas...

  • Page 49

    Installation & operation manual 49  warning when re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or sub...

  • Page 50

    Installation & operation manual 50 8 field wiring electrical shock hazard – for your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be n.E.C. Class 1. I...

  • Page 51

    Installation & operation manual 51 8 field wiring (continued) thermostat 1. Connect the room thermostats or end switches (isolated contact only) to room thermostat 1, 2, or 3, as shown in fig. 8-3. 2. Install the thermostat on the inside wall away from influences of drafts, hot or cold water pipes, ...

  • Page 52

    Installation & operation manual 52 8 field wiring modbus when the optional modbus interface module is installed, the rs-485 modbus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between ter...

  • Page 53

    Installation & operation manual 53 8 field wiring (continued) lo u v er r e la y flow s w itch ta n k t h e r m o s t a t ro o m t h e r m o s t a t 3 sy st em s u ppl y sen s o r b u il di ng ma n a g e me n t sy st em lou v er pr ovin g sw itc h co m no low w a t e r c u toff ou t d oo r senso r t...

  • Page 54

    Installation & operation manual 54 9 condensate disposal condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch (12.7 mm) pvc union for connection of a 1/2 inch (12.7 mm) pvc pipe (fig. 9-1). 3. Slope condensate tubing down a...

  • Page 55

    Installation & operation manual 55 10 start-up check/control water chemistry do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consul...

  • Page 56

    Installation & operation manual 56 10 start-up check for gas leaks before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with...

  • Page 57

    Installation & operation manual 57 10 start-up (continued) final checks before starting the boiler read the knight xl service manual to familiarize yourself with smart system control module operation. Read this manual, page 58 for proper steps to start boiler. Verify the boiler and system are full o...

  • Page 58: Operating Instructions

    Installation & operation manual 58 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...

  • Page 59

    Installation & operation manual 59 10 start-up (continued) check flame and combustion (continued) 4. Place the boiler into the active position by pressing the right select [on] key (fig. 11-1, page 67). 5. Locate the pinhole button below the reset button on the display board (fig. 11-1). Insert a th...

  • Page 60

    Installation & operation manual 60 set domestic hot water (dhw) operation verify dhw mode there are two (2) modes of operation for dhw. In normal mode, when a dhw demand begins, the control will start the dhw pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature t...

  • Page 61

    Installation & operation manual general how the boiler operates the knight xl uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue p...

  • Page 62

    Installation & operation manual 62 11 operating information ramp delay for systems with lower flow, the smart system can limit the firing rate (when enabled) when a space heating call for heat starts, or when switching from a dhw call for heat to a space heating call for heat. There are six (6) limi...

  • Page 63

    Installation & operation manual 63 11 operating information (continued) monitor external limits connections are provided on the connection board for external limits such as flow switch, low water cutoff, gas pressure switches, and a louver proving switch. The smart system will shut off the burner an...

  • Page 64

    Installation & operation manual 64 11 operating information outdoor reset operation, if used target temperature with outdoor reset this feature improves the system’s efficiency as the outdoor temperature warms up. See the knight xl service manual to change the settings. Reset curve the reset curves ...

  • Page 65

    Installation & operation manual 65 11 operating information (continued) sequence of operation operation display 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...

  • Page 66

    Installation & operation manual 66 operation display 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 th...

  • Page 67

    Installation & operation manual 67 11 operating information (continued) knight xl control module navigation dial figure 11-1 control panel use the control panel (fig. 11-1) to set temperatures, operating conditions, and monitor boiler operation. The information on the bottom of the display shows the...

  • Page 68

    Installation & operation manual 68 access modes user the user 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 and time, and the temperature units can also be changed (see page 60). Installer mo...

  • Page 69

    Installation & operation manual 69 11 operating information (continued) status display screens section display description a (boiler status bar) standby the unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a dhw thermostat. Start the unit has be...

  • Page 70

    Installation & operation manual 70 11 operating information status display screens (cont’d) section display description c (operational information) system: the temperature read by the system supply sensor (if connected). Tank: the temperature read by the tank sensor (if connected). Outdoor: the temp...

  • Page 71

    Installation & operation manual 71 11 operating information (continued) status display screens (cont’d) section display description e (navigation dial function) turning the navigation dial will select the next or previous status screen. Pressing the navigation dial will show the next fault, nsb (nig...

  • Page 72

    Installation & operation manual 72 maintenance and annual startup table 12a service and maintenance schedules service technician (see the following pages for instructions) general: • address reported problems • inspect interior; clean and vacuum if necessary; • clean condensate trap and fill with fr...

  • Page 73

    Installation & operation manual 73 12 maintenance (continued) follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to foll...

  • Page 74

    Installation & operation manual 74 12 maintenance flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed. 2...

  • Page 75

    Installation & operation manual 75 12 maintenance (continued) inspect ignition and flame sense electrodes 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the el...

  • Page 76

    Installation & operation manual 76 12 maintenance check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground w...

  • Page 77

    Installation & operation manual 77 figure 13-1 wiring diagram 13 diagrams x1-7 or or br pr or br br pr pr cn2-4 cn2-1 cn1-5 cn1-6 cn1-3 cn1-4 cn1-1 cn1-2 k1 k2 k3 relay board on/off switch junction box bk w 1 2 3 4 5 g r r w 3.5a r t w bk y bl kb 801 only blower -t high limit sensor s1b operating se...

  • Page 78

    Figure 13-2 ladder diagram box depicts optional items ladder diagram lbl20141 rev b 120 vac 24 vac 120vac terminal strip 120v supply "l" on / off switch x1-6 x1-2 f2 neutral terminal strip 120v supply "n" flow cn5-6 cn5-12 cn5-11 x4-2 x4-10 x4-11 integrated control low gas pressure switch high gas p...

  • Page 79

    Notes installation & operation manual 79.

  • Page 80

    Revision notes: revision a (eco #c05747) initial release. Reflects the new model numbers for the knight xl upgrade. Revision b (eco #c06188) reflects changes made to fig. 6-10 (ecr #r03474) remove ghost pipe, changes made to fig.’s 6-7, 6-9, and 6- 11 (r03563) change the direction of the arrows, and...