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KBXII-I-O Rev D
Installation & Operation Manual
Models: 400 - 801
This manual must only be used by
WARNING
a qualifi 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.
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 Alternate Vertical Concentric Venting ................... 34-35 RATINGS ........................................................................... 7 6. H
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Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including When servicing boiler – WARNING this manual and the Knight XL Service • To avoid electric shock, disconnect electrical supply Manual, before installing. Perform steps in before performing maintenance. the order given. User – This manual is for use only by • To avoid severe burns, allow boiler to cool before a qualified heating installer/service performing maintenance. techni
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Installation & Operation Manual The Knight XL - How it works... 1. Stainless steel heat exchanger 19. High voltage junction box Allows system water to fl ow through specially designed The junction box contains the connection points for the line coils for maximum heat transfer, while providing protection voltage power and all pumps. against fl ue gas corrosion. The coils are encased in a jacket that 20. Boiler drain port contains the combustion process. Location from which the heat ex
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Installation & Operation Manual The Knight XL - How it works... (continued) Model 400 31 30 10 18 22 32 15 39 11 24 6 Front View - Model 400 Rear View - Model 400 19 21 37 27 35 36 4 16 5 25 8 1 2 14 3 29 28 26 13 7 38 33 20 17 23 Left Side (inside unit) - Model 400 Right Side (inside unit) - Model 400 5
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Installation & Operation Manual The Knight XL - How it works... Model 501 34 18 15 27 4 39 Left Side (inside unit) - Model 501 Rear View - Model 501 Models 601 - 801 5 18 15 27 4 39 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801 6
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Installation & Operation Manual Ratings Knight XL Boiler Other Specifi cations I=B=R Rating Input Net Model Number Boiler Gross I=B=R MBH Water Water Gas Air Vent Output Ratings Size Content Connections Connections Size (Note 4) MBH Water, Note: Change “N” to Gallons MBH “L” for L.P. gas models. (Note 3) Min Max (Note 1) (Note 2) KBN400 80 399 373 324 3.4 1-1/2" 1" 4" 4" 4.2 1-1/2" 1" 4" 4" KBN501 100 500 467 406 4.2 2" 1" 4" 4" KBN601 120 600 567 493 5.0
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Installation & Operation Manual 1 Determine boiler location This appliance is certifi ed 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 temperatures that exceed 100°F (37.8°C). • National Fuel Gas Code, ANSI Z223.1 – latest edition. • Standard for Controls and Safety Devi
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Installation & Operation Manual 1 Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC or CLOSET INSTALLATION WARNING 1/4" (6 MM) MINIMUM CLEARANCE stainless steel vent material MUST AROUND HOT WATER PIPES 1” (25 MM) MINIMUM CLEARANCE BE used in a closet structure due to AROUND VENT PIPE elevated temperatures. Failure to follow this warning could result in 13" fi re, personal injury, or death. TOP VENTILAT
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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 residential garage, it should be installed in compliance with at least equal to the SERVICE clearance
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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/fl uorocarbons in fl ue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions or death. Chlorinated waxes/cleaners Check the following venting components before insta
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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 conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA This will cause fl ue gas spillage or appliance 54 and/or CAN/CSA B149.1, Natural Gas and Propane malfunction, resulting in possible
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Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet Model 400 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
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Installation & Operation Manual 2 Prepare boiler Model 501 After converting to LP, check combustion WARNING per the Start-up procedure in Section 1. Remove the top access cover from the unit (no tools 10 of this manual. Failure to check and required for removal). verify 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. fou
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Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent Stainless Steel PVC/CPVC Two Pipe Two Pipe See Figure 4-1A See Figure 4-1C PVC/CPVC Alternate Two Pipe See Figure 4-2A PVC/CPVC Concentric Stainless Steel See Figure 4-7 Alternate Two Pipe Models 400 - 601 Only See Figure 4-2B 15
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Installation & Operation Manual 3 General venting Direct venting options - Vertical Vent PVC/CPVC PVC/CPVC Stainless Steel Two Pipe Concentric Two Pipe See Figure 5-1A See Figure 5-5 See Figure 5-1B Models 400 - 601 Only Direct venting options - Vertical Vent, Sidewall Air PVC/CPVC Stainless Steel Vertical Vent, Sidewall Air Vertical Vent, Sidewall Air Stainless steel vent/air design and terminations will vary slightly by manufacturer. NOTICE 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 Insulation should not be used on PVC DANGER WARNING supplied with combustion and ventilation or CPVC venting materials. The use of air as described in this section. Ensure the insulation will cause increased vent wall vent and air piping and the combustion temperatures, which could result in vent air supply comply with these instructions pip
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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 fi ttings and pipes carefully to prevent approved cement to the fi tting socket. contamination of surfaces. g. Apply a second coat of cement to the pipe. b. Apply a liberal even coat of primer to the fi tting h. While the cement is still wet, insert the pipe into the socket. fi tting, if possible twist the pipe a 1/4 turn as you insert c.
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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 se
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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 400-601 F303759 KB285600 9454BUREZ-1* 9414TERM 2SVSLA04 2SVSTEX0490 FSRC4(R.C) 303888 5400CI 2SVSRCX04 F303759
