Lochinvar KNIGHT XL KBN399 User manual

Up to 94.6%
Thermal Efficiency
lochinvar.com
HIGH EFFICIENCY COMMERCIAL CONDENSING BOILERS
OPERATING CONTROL FEATURING
A BUILT-IN CASCADING SEQUENCER
5 MODELS: 399,000 – 800,000 BTU/HR
FIRING RATE MODULATION TO 5:1
LESS THAN 20 ppm NOx
DIRECT-VENT FLEXIBILITY TO 100 FEET
O
PERATING C
O
NTR
O
L FE
A

The KNIGHT®XL, engineered with Lochinvar’s exclusive SMART SYSTEM™control and an
array of other innovative features, places it far ahead of any commercial heating boiler
in its class. It promises and delivers ultimate ease of installation and maintenance. With
up to 94.6% thermal efficiency, low-NOx emissions and a fully modulating burner, it is
the best ”green choice” for today’s environmentally focused market.
Five modulating/condensing stainless steel KNIGHT XL boilers are available, with
399,000–800,000 Btu/hr inputs, with remarkably small space-saving footprints. All are
equipped for direct-vent installation with air intake and exhaust runs up to 100 feet using
PVC, CPVC or AL29-4C venting materials. This range of choices is ideal for light-duty
applications such as small hotels, schools and office buildings. For higher-demand
applications, up to eight KNIGHT XL units can be installed utilizing the built-in cascading
sequencer to deliver up to 6.4 million Btu/hr heating capacity.
THE KNIGHT XL BOILER reflects Lochinvar’s constant commitment to providing all the
options you need to serve every application.
The Knight XL Combustion System
Advanced Negative Regulation Technology
KNIGHT XL safely and reliably operates with supply gas pressure as low as 4 inches water column, as Negative
Regulation (Neg/Reg) technology automatically adjusts fan speed that ensures the correct volume and mix of
fuel and air throughout the firing range.
”Fail-Safe” Direct-Spark Ignition
With each call for heat, two electrodes ignite the fuel/gas mixture. A third
electrode then senses for flame. SMART SYSTEM will lock out and display
the fault if ignition does not occur.
Two-in-One Stainless Steel Heat Exchanger
A combined primary and secondary heat exchanger captures flue gas heat
and allows entering water temperatures as low as 50°F. The stainless steel,
pH-tolerant design features a weld-sealed assembly with no O-rings or gaskets,
and does not require special glycol. ASME Section IV approved and stamped.
Fully Modulating Burner
The SMART SYSTEM allows fully modulating combustion with 5:1 turndown. The burner can fire as
low as 20% of maximum input, and modulates the firing rate up to 100% as demand increases.
The burner is a single stainless steel assembly covered with woven steel mesh, and fires in a 360°
pattern along the entire length of the primary heat exchanger. This allows the compact KNIGHT XL
to exceed the capacity of units with larger multiple burners.
Th KNIGHT
®
XL i d i h
hL hi ’ l i SMART SYSTEM
™
ld
The Smartest Choice for Condensing Boiler Performance
,
k
ed
. The burner can fire as
a
s demand increases.
,
kets,
d.

The Brain That Drives
Brilliant Performance!
SMART SYSTEM provides unequalled control
and monitoring functions that are easy to
understand and use.
2-Line, 16-Character LCD Display
Setup and diagnostic information in words, not codes
Password Security
Dual password levels for installer and user
Building Management System Control (0 – 10 V)
BMS-driven input for control of modulation rate or temperature
PC Connection
Can be used with KNIGHT XL PC software to program and
troubleshoot SMART SYSTEM functions, and to track historical
data, including faults, trends and energy consumption
Outdoor Reset
Outdoor temperature monitor guides the reset schedule to meet
heat loss/load of the building
Night Setback
Program a setback for any time of the day, each day of the week
System Pump Control and Boiler Pump Control
Switching contacts control power to both system and boiler
pumps on a call for heat. Programmable pump delay orders
pumps to operate after a call has been satisfied
Pump Relay with Freeze Protection
Ensures water temperature does not fall below 40°F
Hot Water Generator Compatibility
One boiler in a sequence can be assigned for Domestic Hot Water
Prioritization (DHWP) to meet domestic water demand
Inlet/Outlet and System Temperature Sensors
Installer can select which sensor controls the setpoint
Low Water Flow Indicator
Protects against high temperature differential in the heat
exchanger with reduced firing rate or shutdown
Product Service Indicator
Program reminders for cycle count, operation hours or last service
Field Connection Versatility
User-friendly terminal strip allows for 28 low-voltage field
connections. Plus 4 line voltage connections supply power to
the unit, and up to 3 pumps operated by the SMART SYSTEM
15-1/2”
zero clearance
to combustibles
The 4-unit installation shown illustrates
the space-saving KNIGHT XL footprint,
and the ease and versatility of the
two-pipe direct-vent design.
T
hat
D
rive
s
P!

In commercial buildings requiring a multiple boiler system, modulating
operation of individual units should be sequenced so that the system
functions as an integrated whole.
SMART SYSTEM includes a built-in cascading sequencer for up to 8
KNIGHT XL units. This eliminates the initial cost and labor required
with installation of a separate sequencer. And, because it’s engineered
specifically for Lochinvar boilers, it removes any uncertainty about
using a ”third-party” sequencer, to ensure precise, dependable
cascading operation.
When utilizing the built-in cascading sequencer, KNIGHT XL boilers
communicate through a simple 2-wire daisy chain connection. On
demand, one boiler in the system functions as the leader, and
modulates with demand to capacity. The additional load then
”cascades” to the second boiler, which fires and modulates to meet
added demand via a patented process to match system load and
reduce equipment short cycling.
Cascading continues as additional boilers fire in sequence, until all
units are in operation or demand is satisfied. When demand drops,
the patented cascading process reverses, with the precision, control
and performance you expect from Lochinvar.
SMART SYSTEM also controls Lead-Lag Rotation. Every 24 hours the
lead boiler role is shifted to the next unit in the sequence. This rotation
ensures long life by distributing ”lead-lag” runtimes equally over each
unit in the system.
I
n commercial
b
uildings requiring a
op
er
at
io
n
of
i
nd
iv
id
ua
l
un
it
s
sh
ou
ld
Including
a Built-in
Cascading
Sequencer!
Ca
sc
ad
in
g
co
nt
in
ue
s
as
a
dd
it
io
na
l
bo
il
er
s
fi
re
i
n
se
qu
en
ce
,
un
ti
l
al
l
Includin
n
g

Easy Handling
on the Jobsite
Because of its compact design and stainless steel heat
exchanger, KNIGHT XL boilers are remarkably lightweight
and easy to handle on the jobsite.
Direct-Venting
up to 100 Feet
KNIGHT XL offers tremendous flexibility for placement of
units within the building, because it permits direct-vent
air intake and exhaust runs up to 100 equivalent feet
using either PVC, CPVC or AL29-4C stainless steel vent
pipe. Intake and exhaust runs can terminate horizontally
through a sidewall or vertically through the roof.
Easy Access to
Internal Components
The front and top panels of the KNIGHT XL boiler can be
quickly removed without any tools. This provides fast,
easy access to internal components and electrical
connections during installation and service.

>Low Voltage Terminal Strip
>24 VAC Auxiliary Device Relay
>Auxiliary Proving Switch Contacts
>Flow Switch Contacts
>Alarm on Any Failure Contacts
>Runtime Contacts
>DHW Thermostat Contacts
>Room Thermostat Contacts
>System Sensor Contacts
>DHW Tank Sensor Contacts
>Outdoor Air Sensor Contacts
>Cascade Contacts
>0-10 VDC BMS External Control Contact
Optional Equipment
>Alarm Bell on Any Failure
>Condensate Neutralization Kit
>High & Low Gas Pressure Switches w/ Manual
Reset (KB500-KB800)
>Low Water Cutoff w/Manual Reset & Test
>SMART SYSTEM PC Software
>Stainless Steel Vent Kits (KB700-KB800)
>Multi-Stack Frame
Firing Codes
>M9 Standard Construction
>M7 California Code
>M13 CSD1 / FM / GE Gap (KB500-KB800)
Standard Features
>Up to 94.6% Thermal Efficiency
>Modulating Burner with 5:1 Turndown
>Direct-Spark Ignition
>Low NOx Operation
>Sealed Combustion
>Low Gas Pressure Operation
>Vertical & Horizontal Direct-Vent
>Category IV venting up to 100 feet
>PVC, CPVC or AL29-4C Venting up to 100 Feet
>Factory Supplied Sidewall Vent Termination
>ASME Stainless Steel Heat Exchanger
>ASME Certified, ”H” Stamped
>Gasketless Heat Exchanger
>160 psi Working Pressure
>Highly efficient, condensing design
>On/Off Switch
>Adjustable High Limit w/ Manual Reset
>Flow Switch
>Inlet & Outlet Temperature Sensors
>Flue Temperature Sensor
>Low Air Pressure Switch
>50 psi ASME Relief Valve
>Temperature & Pressure Gauge
>Adjustable Leveling Legs
>Condensate Trap
>Zero Clearances to Combustible Material
>10 Year Limited Warranty
(See Warranty for Details)
Smart System Features
>SMART SYSTEM Digital Operating Control
>2 line, 16 Character Display
>Dual Level Password Security
>Domestic Hot Water Prioritization
>Built in Cascading Sequencer for up to 8 Boilers
>Building Management System Integration
with 0-10 VDC Input
>Outdoor Reset Control with Outdoor Air Sensor
>Low Water Flow Safety Control & Indication
>Inlet & Outlet Temperature Readout
>Freeze Protection
>Service Reminder
>Time Clock
>Data Logging
>Hours Running, Space Heating
>Hours Running, Domestic Hot Water
>Ignition Attempts
>Last 10 Lockouts
>Programmable System Efficiency Optimizers
>Night Setback
>Anti-Cycling
>Outdoor Air Reset Curve
>Ramp Delay
>Boost Temperature & Time
>Three Pump Control
>System Pump
>Boiler Pump
>Domestic Hot Water Pump
>High Voltage Terminal Strip
>120 VAC / 50-60 Hertz / 1 Phase Power Supply
>Three sets of Pump Contacts with Pump Relays
KBX-03 (Replaces KBX-02 6/08) 5M-4/09-Printed in U.S.A.
300 Maddox Simpson Parkway, Lebanon, TN 37090 | 615-889-8900 | fax: [phone] | www.lochinvar.com
Knight®XL Boiler Dimensions and Specifications
Model Number Guide
KB N 700 M13
Model
Firing Controls
Natural Gas
Btu/hr Input
Input Net
Model Min Max Thermal Output I=B=R
Number MBH MBH Efficiency MBH MBH
KBN399 80 399 93.3% 372 324
KBN500 100 500 93.3% 467 406
KBN600 120 600 94.6% 567 493
KBN700 140 700 94.3% 660 574
KBN800 160 800 94.0% 752 654
A B C D E F G H I J K Gas Water Air Vent Shipping
Conn. Conn. Inlet Size Wt. (lbs.)
42-1/2” 15-1/2” 27-3/4” 3-3/4” 20-3/4” 21” 14” 34” 34” 2” 18-3/4” 1” 1-1/2” 4” 4” 280
42-1/2” 15-1/2” 31-1/4” 3-3/4” 25-1/2” 21” 14” 32-1/2” 36” 2” 18” 1” 1-1/2” 4” 4” 310
42-1/2” 15-1/2” 36-1/4” 3-3/4” 25” 21” 14” 36” 32-3/4” 5-1/2” 19-1/2” 1” 2” 4” 4” 340
42-1/2” 15-1/2” 40-1/4” 3-3/4” 29” 23” 17” 36” 32-3/4” 3-1/4” 23-1/2” 1” 2” 4” 6” 370
42-1/2” 15-1/2” 45-1/4” 3-3/4” 33-1/4” 23” 17” 36” 32-3/4” 3-1/4” 27-3/4” 1” 2” 4” 6” 405
Notes: Change ‘N’ to ‘L’ for L.P. Gas Model. No deration on L.P. models. Performance data based on manufacturer test results. 120 VAC /15 AMP circuit required.
All dimensions shown in inches.
Knight XL Heating Boiler Dimensions and Specifications
Knight XL Boiler,
Natural Gas,
700,000 Btu/hr input,
M13 firing controls
>
Mo
>
D
i
>
L
o
>
S
e
>
L
o
>
Ve
r
>
C
a
>
P
V
>
F
a
>
AS
M
>
A
S
>
G
a
>
1
6
>
H
i
>
On
/
>
Ad
j
>
Fl
o
w
>
In
le
>
F
l
u
e
>
Lo
w
>
50
>
Te
m
>
Ad
j
>
Co
n
>
Ze
r
>
10
(Se
KB
X-
0
300
I
n
put
Net
npu
tet
Mo
del
Mi
n
Max
Th
erm
al
Out
put
I=
B=R
odel a e al Output
Number MBH MBH Effici
enc
y MBH MBH
A
B C
D
E F
G
H I
J
A
B
C
D
E
F
G
H
I
J
K
night
XL
H
eating
B
oile
r
D
imensions and Specification
s
LEFT SIDE
FRONT
BACK
8"
39-1/2"
13-3/4"
18-3/4"
H
K
D
G
F
E
C
9"
A
1-1/4"1/4" -
ADJUSTABLE
AIR INLET
FLUE
LOW VOLTAGE
ELECTRICAL
CONNECTIONS
GAS
INLET OUTLET
HEAT
EXCHANGER
DRAIN
3/4" NPT
CONDENSATE
DRAIN
FLUE
B
I
J
HIGH VOLTAGE
ELECTRICAL
CONNECTIONS
38-3/4"
3-1/2"
Patent # 7,506,617