Lochinvar KNIGHT XL KBN500 User Manual

H IG H E F FICIE NCY COMM ERCIAL COND ENSING B OILE R S  
O
PERATING CONTROL FE
A
TURING  
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  
Up to 94.6%  
Thermal Efficiency  
lochinvar.com  
The Brain
That Drives  
Brilliant
P
erformance
!  
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  
15-1/2”  
zero clearance  
to combustibles  
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  
The 4-unit installation shown illustrates  
the space-saving KNIGHT XL footprint,  
and the ease and versatility of the  
two-pipe direct-vent design.  
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  
Including  
a Built-in  
Cascading  
Sequencer!  
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 sequenceuntil 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.  
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.  
®
Knight XL Boiler Dimensions and Specifications  
LOW VOLTAGE  
ELECTRICAL  
CONNECTIONS  
K
HIGH VOLTAGE  
ELECTRICAL  
CONNECTIONS  
Model Number Guide  
700 M13  
GAS  
AIR INLET  
KB  
N
J
HEAT  
EXCHANGER  
DRAIN  
INLET  
OUTLET  
3/4" NPT  
A
FLUE  
Knight XL Boiler,  
38-3/4"  
39-1/2"  
I
CONDENSATE  
DRAIN  
Natural Gas,  
H
FLUE  
700,000 Btu/hr input,  
18-3/4"  
M13 firing controls  
13-3/4"  
3-1/2"  
9"  
1/4" - 1-1/4"  
8"  
G
F
ADJUSTABLE  
B
E
FRONT  
D
C
BACK  
LEFT SIDE  
Knight XL Heating Boiler  
Dimensions and Specifications  
Input  
Min Max
 
Thermal  
Number MBH
 
MBH Efficiency  
Net  
I=B=R  
MBH  
A
B
C
D
E
F
G
H
I
J
K
Gas Water Air Vent Shipping  
Conn. Conn. Inlet Size Wt. (lbs.)  
Model  
Output  
MBH  
42-1/2” 15-1/2”  
42-1/2” 15-1/2”  
42-1/2” 15-1/2”  
42-1/2” 15-1/2”  
42-1/2” 15-1/2”  
27-3/4” 3-3/4” 20-3/4” 21”  
31-1/4” 3-3/4” 25-1/2” 21”  
14”  
14”  
14”  
17”  
17”  
34”  
34”  
2”  
2”  
18-3/4” 1”  
18” 1”  
1-1/2” 4”  
1-1/2” 4”  
4”  
4”  
4”  
6”  
6”  
280  
310  
340  
370  
405  
KBN399  
KBN500  
KBN600  
KBN700  
KBN800  
80  
399  
500  
600  
700  
800  
93.3%  
93.3%  
94.6%  
94.3%  
94.0%  
372  
467  
567  
660  
752  
324  
406  
493  
574  
654  
32-1/2” 36”  
100  
120  
140  
160  
36-1/4” 3-3/4” 25”  
40-1/4” 3-3/4” 29”  
21”  
23”  
36”  
36”  
36”  
32-3/4” 5-1/2” 19-1/2” 1”  
32-3/4” 3-1/4” 23-1/2” 1”  
32-3/4” 3-1/4” 27-3/4” 1”  
2”  
2”  
2”  
4”  
4”  
4”  
45-1/4” 3-3/4” 33-1/4” 23”  
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.  
Standard Features  
Smart System Features  
> 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  
> Up to 94.6% Thermal Efficiency  
> Modulating Burner with 5:1 Turndown  
> Direct-Spark Ignition  
> 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  
> Low NOx Operation  
> Sealed Combustion  
> Building Management System Integration  
> 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  
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  
> 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  
> Condensate Trap  
> Zero Clearances to Combustible Material  
> 10 Year Limited Warranty  
> M9  
> M7  
> M13  
Standard Construction  
California Code  
CSD1 / FM / GE Gap (KB500-KB800)  
(See Warranty for Details)  
Patent # 7,506,617  
300 Maddox Simpson Parkway, Lebanon, TN 37090  
|
615 -889 - 8900  
|
fax: 615 -547- 1000  
|
w w w.lochinvar.com  
5M-4/09-Printed in U.S.A.  
KBX-03 (Replaces KBX-02 6/08)  

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