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KBX-I-O Rev H
Installation & Operation Manual
Models: 399 - 800
This manual must only be used by a
WARNING
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 severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Contents HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 31 PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 Vertical Termination - Optional Concentric Vent . . . . 32-33 THE KNIGHT XL -- HOW IT WORKS . . . . . . . . . . . . . . . 4-6 6. HYDRONIC PIPING RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 System Water Piping Methods . . . . . . . . . . . . . . . .
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Installation & Operation Manual Please read before proceeding Installer – Read all instructions, When servicing boiler – WARNING including this manual and the Knight XL � To avoid electric shock, disconnect electrical supply Service Manual, before installing. before performing maintenance. Perform steps in the order given. User – This manual is for use only by a � To avoid severe burns, allow boiler to cool before qualified heating installer/service performing maintenance. technician. Refer
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Installation & Operation Manual The Knight XL - How it works... 1. Stainless steel heat exchanger 16. SMART Control Module Allows system water to flow through specially designed The SMART Control responds to internal and external signals coils for maximum heat transfer, while providing and controls the blower, gas valve, and pumps to meet the protection against flue gas corrosion. The coils are heating demand. encased in a jacket that contains the combustion process. 17. Automatic air vent D
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Installation & Operation Manual The Knight XL - How it works... (continued) 37. Pump relay board 36. Air pressure switch The air pressure switch detects blocked flue/inlet conditions. The pump relay board is used to connect the boiler, system and DHW pumps. Model 399 32 31 10 18 22 33 15 11 24 6 Front View - Model 399 Rear View - Model 399 19 21 27 36 37 4 16 7 5 8 1 25 14 2 3 29 26 13 28 34 20 30 23 17 Left Side (inside unit) - Model 399 Right Side (inside unit) - Model 399 5
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Installation & Operation Manual The Knight XL - How it works... Model 500 35 18 15 4 27 Left Side (inside unit) - Model 500 Rear View - Model 500 Models 600 - 800 5 18 4 15 27 Rear View - Models 600 - 800 Left Side (inside unit) - Models 600 - 800 6
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Installation & Operation Manual Ratings Knight XL Boiler Other Specifications I=B=R Rating Net Input I=B=R Gross Boiler Model Number MBH Vent Ratings Air Output Water Water Gas Water, MBH Content Connections Connections Note: Change “N” to Size Size (Note 4) MBH Gallons “L” for L.P. gas models. (Note 1) (Note 2) (Note 3) Min Max KBN399 80 399 373 324 3.4 1-1/2" 1" 4" 4" KBN500 100 500 467 406 4.2 1-1/2" 1" 4" 4" KBN600 120 600 567 493 4.2 2" 1" 4" 4" KBN700 140 700 660 574 5.0
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Installation & Operation Manual 1 Determine boiler location This appliance is certified as an indoor Installation must comply with: WARNING appliance. Do not install the appliance � Local, state, provincial, and national codes, laws, outdoors or locate where the appliance will regulations, and ordinances. be exposed to freezing temperatures or to � National Fuel Gas Code, ANSI Z223.1 – latest edition. temperatures that exceed 100°F (37.8°C). � Standard for Controls and Safety Devices for Fai
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Installation & Operation Manual 1 Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances CLOSET INSTALLATION For closet installations, CPVC or 1" (25 MM) MINIMUM CLEARANCE WARNING stainless steel material MUST BE AROUND HOT WATER PIPES AND VENT PIPE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in 13" (330 MM) fire, personal injury, or death. TOP VENTILATING* AIR OPENING CLOSED DOOR VENTILATING
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Installation & Operation Manual 1 Determine boiler location Provide air openings to room: Residential garage installation Knight XL alone in boiler room Precautions Take the following precautions when installing the appliance 1. No air ventilation openings into the boiler room are in a residential garage. If the appliance is located in a needed when clearances around the Knight XL are at least residential garage, it should be installed in compliance with equal to the SERVICE clearances shown i
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Installation & Operation Manual 1 Determine boiler location (continued) Table 1A Corrosive Contaminants and Sources When using an existing vent system to install a new boiler: Products to avoid: Failure to follow all instructions can result WARNING Spray cans containing chloro/fluorocarbons in flue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions or death. Chlorinated waxes/cleaners Check the following venting components before installing: Ch
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Installation & Operation Manual 1 Determine boiler location When removing a boiler from existing common vent system: Do not install the Knight XL into a g. Any improper operation of the common venting DANGER common vent with any other appliance. system should be corrected so the installation This will cause flue gas spillage or conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural appliance malfunction, resulting in Gas and Propane Installation Code. Wh
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Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet Model 399 1. After removing the outer shipping carton from the boiler, 1. Remove the top and front access covers from the unit (no remove the parts box. tools required for removal). 2. Remove the three screws securing the venturi to the blower. 2. Remove the front door to access the lag bolts in front of Note: When separating the venturi from the blower, take the unit (FIG. 2-1). care not to damage the O-ring inside
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Installation & Operation Manual 2 Prepare boiler Model 500 After converting to LP, check combustion WARNING per the Start-up procedure in Section 10 1. Remove the top access cover from the unit (no tools of this manual. Failure to check and verify required for removal). combustion could result in severe 2. Turn the adjustment screw on the gas valve clockwise until personal injury, death, or substantial it stops. Then turn the adjustment screw counterclockwise property damage. four and three
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Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent PVC/CPVC Two Pipe Stainless Steel See Figure 4-1A Two Pipe Models 399 - 600 Only See Figure 4-1C Models 399 - 600 Only PVC/CPVC Alternate Two Pipe See Figure 4-2A PVC/CPVC Concentric Stainless Steel See Figure 4-7 Alternate Two Pipe Models 399 - 600 Only See Figure 4-2B 15
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Installation & Operation Manual 3 General venting Direct venting options - Vertical Vent PVC/CPVC Stainless Steel PVC/CPVC Two Pipe Two Pipe Concentric See Figure 5-1A See Figure 5-1B See Figure 5-5 Direct venting options - Vertical Vent, Sidewall Air PVC/CPVC Stainless Steel Vertical Vent, Sidewall Air Vertical Vent, Sidewall Air NOTICE Stainless steel vent/air design and terminations will vary slightly by manufacturer. 16
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Installation & Operation Manual 3 General venting (continued) Install vent and combustion air piping The Knight XL must be vented and DANGER Requirements for installation in supplied with combustion and ventilation air as described in this section. Ensure the Canada vent and air piping and the combustion air 1. Installations must be made with a vent pipe system supply comply with these instructions certified to ULC-S636. regarding vent system, air system, and IPEX is an approved vent manufa
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Installation & Operation Manual 3 General venting 6. Priming and Cementing: f. While primer is still wet, apply an even coat of a. Handle fittings and pipes carefully to prevent approved cement to the fitting socket. contamination of surfaces. g. Apply a second coat of cement to the pipe. b. Apply a liberal even coat of primer to the fitting h. While the cement is still wet, insert the pipe into the socket. fitting, if possible twist the pipe a 1/4 turn as you insert c. Apply a liberal ev
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Installation & Operation Manual 3 General venting (continued) Air inlet pipe materials: When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must The air inlet pipe(s) must be sealed. Choose acceptable be resealed to ensure that combustion air will be free of combustion air inlet pipe materials from the following list: contaminants and supplied in proper volume. PVC, CPVC or ABS Failure to properly seal all joints and DANGER Dry
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Installation & Operation Manual 3 General venting Table 3B Approved Stainless Steel Terminations and Adapters ProTech Heat Fab Z Flex FasNSeal Saf-T Vent Z-Vent Model Intake Intake Boiler Flue Boiler Intermediate Flue Boiler Flue Intake Air Air Air Adapter Termination Adapter Adapter Termination Adapter Termination Termination Termination Termination FSBS4 FSAIH04 9492 2SVSTP04 399-600 F303759 KB285600 9454BUREZ-1* 9414TERM 2SVSLA04 2SVSTEX0490 FSRC4(R.C) 303888 5400CI 2SVSRCX04 F303759 FSAIH0
