Lochinvar Knight XL KBN400 Boiler Instruction Manual

Manual Lochinvar Knight XL KBN400 Boiler Instruction Manual

Lochinvar Knight XL KBN400 Boiler Instruction Manual

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Lochinvar Knight XL KBN400 Boiler

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Lochinvar Knight XL KBN400 Boiler

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Lochinvar Knight XL KBN400 Boiler

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Lochinvar Knight XL KBN400 Boiler

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Lochinvar Knight XL KBN400 Instructions

Here we offer the Lochinvar Knight XL KBN400 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 KBN400 Boiler, we suggest checking the Frequently Asked Questions (FAQs) section of this manual.


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Lochinvar Knight XL KBN400 Boiler Specifications

Specification Value (KBN400 Model)
Model Number KBN400
AHRI Gross Input (MBH) 399
AHRI Net Output (MBH) 326
Boiler Water Content (Gallons) 3.4
Water Connections Size 1-1/2" NPT
Gas Connections Size 1" NPT
Air Intake Pipe Size 4 inches (102 mm)
Vent Pipe Size 4 inches (102 mm)
Electrical Supply 120 VAC, 15 Amp (recommended disconnect)
Maximum Working Pressure (Relief Valve Setting) 50 PSI
Natural Gas Supply Pressure (Min/Max flowing) 4 inches w.c. / 14 inches w.c.
Propane Gas Supply Pressure (Min/Max flowing) 8 inches w.c. / 14 inches w.c.
Minimum Combustion Air Piping Length 12 equivalent feet (3.7 m)
Maximum Combustion Air Piping Length 100 equivalent feet (30.5 m)
Minimum Vent Piping Length 12 equivalent feet (3.7 m)
Maximum Vent Piping Length 100 equivalent feet (30.5 m)
Modulation Range 20% to 100%

Lochinvar Knight XL KBN400 Boiler Details

The Lochinvar Knight XL KBN400 Boiler represents a pinnacle in high-efficiency heating solutions, leveraging advanced engineering to deliver optimal performance. Its core is a durable stainless steel heat exchanger, designed for full condensing operation. This ensures maximum heat transfer efficiency while effectively resisting corrosion from flue gases. The robust construction promises extended operational life and consistent heating output.

At the heart of its intelligent operation is the SMART SYSTEM Control Module. This sophisticated electronic control unit features an intuitive LCD display and a navigation dial, allowing both users and qualified technicians to monitor and adjust operating conditions. It provides comprehensive access to temperature settings, operational modes, and diagnostic information, ensuring precise control over the heating process.

The boiler's combustion system integrates a high-performance blower, a precise gas valve, and a venturi to create an optimal air-gas mixture. Its metal fiber and stainless steel burner provides a wide range of firing rates, from 20% to 100% modulation. This capability allows the KBN400 to match varying heating demands efficiently, reducing energy consumption during periods of lower load.

For venting, the KBN400 utilizes a specialized pressurized system compatible with several materials, including PVC, CPVC, Polypropylene, and Stainless Steel. This flexibility accommodates various installation scenarios, whether through a sidewall or vertically through a roof. Proper installation is critical to prevent combustion air contamination, safeguarding the boiler's performance and longevity.

Safety is paramount, with multiple integrated features protecting the system. These include a flue gas sensor, a boiler outlet temperature sensor acting as a high limit, and an air pressure switch to detect blockages. Additional layers of protection are provided by an over-temp switch, a burner door temperature switch, and a relief valve set at 50 PSI, all working in concert to ensure safe operation.

The KBN400 also boasts advanced freeze protection and anti-cycling mechanisms. The freeze protection feature automatically activates the boiler and system pumps, and even the burner, if the inlet temperature drops too low, preventing costly damage. Anti-cycling intelligently manages burner operation, preventing frequent starts and stops that could reduce efficiency and component lifespan.

For larger applications, the KBN400 can be integrated into a Cascade System, allowing up to eight boilers to operate in sequence. This system can be configured for Lead/Lag or Efficiency Optimization control, ensuring balanced run-time and optimal performance across multiple units. This scalability makes it a versatile choice for commercial and large residential heating demands.

Maintenance is streamlined with owner-level daily, monthly, and periodic checks, alongside annual service by a qualified technician. Key tasks include cleaning the condensate trap, inspecting heat exchanger surfaces, and verifying all piping for leaks. The SMART SYSTEM Control Module also incorporates a service reminder notification, making proactive upkeep straightforward and efficient.

Frequently Asked Questions (FAQs)

Can't find the answer you need? Here are some frequently asked questions about the Lochinvar Knight XL KBN400 Boiler, and we answer them below.


What should I do if I smell gas near my Lochinvar Knight XL KBN400 Boiler?
If you smell gas, do not try to light any appliance or touch any electrical switch. Immediately call your gas supplier from a nearby phone. If you cannot reach them, call the fire department. Installation and service must always be performed by a qualified professional.

How often does the KBN400 boiler require professional service?
The boiler must be inspected and started annually at the beginning of the heating season by a qualified service technician. Additionally, owners should perform regular maintenance outlined in the user manual for optimal efficiency and reliability.

What type of water is recommended for use in the KBN400 boiler system?
Lochinvar recommends maintaining fill water hardness between 5 and 12 grains per gallon, a pH level between 6.5 and 8.5, and Total Dissolved Solids (TDS) less than 350 ppm. Chlorine concentration should be less than 150 ppm. Avoid continuous fresh make-up water to prevent mineral buildup and corrosion.

Can automotive antifreeze be used for freeze protection in the KBN400 boiler?
No, absolutely not. Only inhibited propylene glycol solutions specifically formulated for hydronic systems should be used. Ethylene glycol, found in automotive antifreeze, is toxic and can damage system gaskets and seals, potentially leading to severe injury or property damage.

What is the function of the SMART SYSTEM Control Module?
The SMART SYSTEM Control Module is the boiler's advanced electronic brain. It features an LCD display and navigation dial, allowing users and installers to set temperatures, operating conditions, and monitor boiler operation. It manages inputs from sensors and external devices to control firing rate, pumps, and various safety features.

How do I adjust the KBN400 boiler's temperature settings?
For users, space heating and tank target temperatures can be adjusted by pressing the NAVIGATION dial when "SETPOINTS" is flashing on the display. More advanced temperature parameters and system limits are accessible to qualified installers via a password-protected menu.

What materials are approved for the KBN400 boiler's venting system?
The Knight XL KBN400 is approved for use with PVC, CPVC, Polypropylene, or Stainless Steel vent pipes and fittings. It is crucial to use only listed materials and methods as specified in the installation manual to ensure safety and prevent flue gas spillage.

What is the purpose of the condensate trap?
The condensate trap must be filled with water at all times of boiler operation. Its purpose is to prevent flue gas emissions from exiting through the condensate drain line, which is critical for safety and proper operation of the high-efficiency appliance.

What happens if the combustion air for the KBN400 is contaminated?
Contaminated combustion air, particularly from chemicals containing fluorine or chlorine compounds (e.g., from laundry products, pool chemicals), can form strong acids within the boiler. This acid can severely damage the heat exchanger, leading to system failure, property damage, and a risk of flue gas spillage.

Can multiple KBN400 boilers be installed together in a system?
Yes, the KBN400 can be integrated into a Cascade System, allowing up to eight boilers to be controlled as a single unit. This setup uses a "Leader" boiler to manage the "Member" boilers, optimizing performance through Lead/Lag or Efficiency Optimization control methods.

What is the modulation range of the KBN400 boiler?
The Lochinvar Knight XL KBN400 boiler is capable of modulating its firing rate from a minimum of 20% up to a maximum of 100%. This allows the boiler to precisely match heating demands, enhancing energy efficiency and reducing wear and tear.

How do I reset a lockout fault on the KBN400 boiler?
Many lockout faults on the SMART SYSTEM control module require a manual reset. After identifying and correcting the underlying condition, press the "RESET" button on the SMART SYSTEM display panel. For specific fault codes and troubleshooting, refer to the Service Manual.

What is the 'Night Setback' feature on the KBN400 boiler?
The Night Setback feature allows the boiler to programmatically reduce space heating and domestic hot water (DHW) set points during specified times each week (e.g., unoccupied hours). This helps to save energy by operating at a lower temperature when demand is reduced. It can be overridden or adjusted by users and installers.

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