Lochinvar Knight XL KBN801 Boiler Instruction Manual

Manual Lochinvar Knight XL KBN801 Boiler Instruction Manual

Lochinvar Knight XL KBN801 Boiler Instruction Manual

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Lochinvar Knight XL KBN801 Boiler

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Lochinvar Knight XL KBN801 Boiler

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Lochinvar Knight XL KBN801 Boiler

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Lochinvar Knight XL KBN801 Boiler

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Lochinvar Knight XL KBN801 Instructions

Here we offer the Lochinvar Knight XL KBN801 Boiler manual completely free and in English. We have cataloged this manual in the Boilers section on Manualverse, and it has been rated by 1 users with an average rating of 5. If you have any specific questions about Lochinvar Knight XL KBN801 Boiler, we suggest checking the Frequently Asked Questions (FAQs) section of this manual.


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Lochinvar Knight XL KBN801 Boiler Specifications

Specification Value (KBN801)
Model Number KBN801
Input MBH Gross 800
AHRI Output MBH 752
Net AHRI Ratings Water, MBH 654
Water Content 5.7 Gallons
Water Connections 2 inches
Gas Connections 1 inch
Air Inlet Size 4 inches
Vent Size 6 inches
Maximum Allowed Working Pressure 50 PSI
Electrical Supply 120 VAC
Natural Gas Supply Pressure (Min.) 4 inches w.c.
Natural Gas Supply Pressure (Max.) 14 inches w.c.
Propane Gas Supply Pressure (Min.) 8 inches w.c.
Propane Gas Supply Pressure (Max.) 14 inches w.c.
Maximum Flue Temperature (Shutdown) 225°F (107°C)
Maximum Outlet Temperature (Shutdown) 195°F (90°C)
Maximum Delta T (Outlet - Inlet) 60°F (15°C)
Minimum Inlet Water Temp (Burner Fire) 37°F (2.8°C)

Lochinvar Knight XL KBN801 Boiler Details

At the core of the Lochinvar Knight XL KBN801 is its advanced stainless steel heat exchanger, meticulously designed to maximize heat transfer efficiency while offering robust protection against flue gas corrosion. This critical component is encased within a specialized jacket, containing the entire combustion process for optimal performance and safety. Its construction ensures longevity and reliable heating.

The KBN801 employs an integrated blower and gas valve system. The blower actively pulls in the precise mixture of air and gas via a venturi, then pushes this blend into the burner. The gas valve intelligently senses negative pressure, ensuring gas flows only when the system is powered and sufficient combustion air is present, enhancing safety and efficiency.

Central to the boiler's operation is the SMART SYSTEM Control Module, an intelligent electronic brain that receives inputs from various sensors and external devices. It precisely activates and controls the blower, gas valve, and pumps, modulating heat input to meet specific demands. Users interact with this system via an intuitive electronic LCD display, featuring a navigation dial and two select keys for setting temperatures and monitoring operational status.

The boiler incorporates multiple temperature sensors, including those for the boiler outlet (system supply), boiler inlet (system return), and flue gas. These sensors allow the control module to precisely adjust the boiler's firing rate, ensuring optimal heating and efficiency. Crucially, an over-temp switch protects the rear of the heat exchanger (604°F/318°C), and a dedicated burner door temperature switch guards the combustion chamber cover (500°F/260°C), preventing damage from excessive heat.

Efficient condensate management is vital for this high-efficiency appliance, which produces slightly acidic condensate (pH 3-5). It features a dedicated drain connection and trap, with an optional neutralizer kit available to meet local code requirements for pH balancing. Reliable ignition is assured through a direct spark ignition electrode and a robust flame sensor, providing quick and consistent burner activation.

For enhanced versatility, the KBN801 supports three individual space heating set points (SH1, SH2, SH3), enabling precise zone control. It also accommodates domestic hot water (DHW) production in either Normal or Zone mode and can be integrated into a cascade operation for controlling up to eight boilers. This adaptability makes it suitable for diverse and demanding heating applications.

The KBN801 features advanced system protection and diagnostics. It offers outdoor air reset for energy efficiency, a "Boost" function for sustained heat demand, and "Night Setback" for programmable temperature reductions. Ramp delay, gradient limiting, anti-cycling, and comprehensive freeze protection ensure smooth, safe operation. The unit also logs errors, tracks run hours and cycles, and provides a service reminder, with seamless integration capabilities for Building Management Systems (BMS) via 0-10V or ModBus/BACnet.

Frequently Asked Questions (FAQs)

Can't find the answer you need? Here are some frequently asked questions about the Lochinvar Knight XL KBN801 Boiler, and we answer them below.


What should I do if I smell gas?
Immediately evacuate the building, do not operate any electrical switches or phones. Call your gas supplier or the fire department from a neighbor's phone.

Can this boiler be used if it has been under water?
No, if any part of the boiler has been under water, it must be replaced by a qualified service technician due to potential extensive damage and safety hazards.

How often should the KBN801 boiler be serviced?
The boiler must be inspected and started annually by a qualified service technician. Additionally, owner maintenance (checking boiler area, gauges, piping, etc.) should be performed daily, monthly, and periodically as outlined in the manual.

What type of water should be used in the boiler system?
For closed-loop systems, fill water hardness should be between 5 and 12 grains per gallon, pH between 6.5 and 8.5, and Total Dissolved Solids (TDS) less than 350 ppm. Chlorine concentration must be less than 150 ppm. An approved multi-metal corrosion inhibitor is recommended.

What type of freeze protection fluid is recommended?
Only inhibited propylene glycol solutions specifically formulated for hydronic systems should be used. Automotive antifreeze (ethylene glycol) is toxic and can damage system components.

How do I test the low water cutoff device?
If installed, the low water cutoff (LWCO) should be tested periodically during the heating season according to the manufacturer's instructions. After testing, press the RESET button on the LWCO to restart the unit.

Is a condensate neutralizer required for the KBN801?
The Knight XL KBN801 produces slightly acidic condensate (pH 3-5). A neutralizing filter is required if mandated by local codes. A factory-available neutralizer kit can be installed by a qualified service technician.

What are the maximum and minimum gas supply pressures for the KBN801?
For Natural Gas, minimum pressure is 4 inches w.c. and maximum is 14 inches w.c. For Propane Gas, minimum is 8 inches w.c. and maximum is 14 inches w.c. These pressures are measured at the gas valve inlet.

Can I install the KBN801 in a room with corrosive contaminants?
No, the boiler must NOT be installed in environments containing corrosive contaminants (e.g., chlorine, fluorine compounds found in laundry or pool products). These chemicals can form acids, severely damaging the boiler. Air intake and vent terminations must be relocated if contaminants cannot be removed permanently.

What is the purpose of the SMART SYSTEM control module?
The SMART SYSTEM control module is the intelligent brain of the boiler, receiving inputs from sensors and external devices to activate and control the blower, gas valve, and pumps. It modulates heat input, manages operating modes, and can be programmed for specific system needs.

How do I access installer-level settings on the control panel?
Installer-level settings are accessed by pressing and holding the LEFT SELECT [MENU] key for 5 seconds and then entering the installer password (5309). This provides access to advanced parameters not available to the general user.

What does it mean if the display shows 'SERVICE DUE'?
If the display shows "SERVICE DUE" and turns yellow, it indicates that a scheduled service is due based on set time frames, running hours, or cycles. The installer's name and phone number can be programmed to appear on this screen for easy contact.

How long should the combustion air and vent piping be for the KBN801?
The minimum allowable length for both combustion air and vent piping is 12 equivalent feet (3.7 m), and the maximum is 100 equivalent feet (30.5 m). Each 90° elbow adds 5 equivalent feet, and each 45° elbow adds 3 equivalent feet. The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

What are the main over-temperature protection features of the KBN801?
The boiler includes several over-temperature protections: the flue gas sensor modulates/shuts down if flue temperature exceeds 215°F/225°F, the outlet temperature sensor triggers a shutdown if water exceeds 195°F (90°C), and a high Delta T (outlet-inlet) shutdown occurs if the difference exceeds 60°F (15°C). Additionally, an over-temp switch (604°F) and burner door temp switch (500°F) provide physical protection.

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