Lochinvar Boiler User Manual

Boiler
Product Line
Brochure

Lochinvar Corporation

300 Maddox Simpson Pkwy

Lebanon, TN 37090

615-889-8900 / Fax: [phone]

www.Lochinvar.com

From the SolutionTM to the SYNC®, Lochinvar Boilers are noted for their
range of benefits and application flexibility. Collectively, they represent the most
complete product line in the industry. From a company with a long history of
innovation and a reputation for excellence.
You’ll find there’s a Lochinvar product for any application imaginable – from
standard residential units to the advanced Intelli-Fin

®

. And with selection, comes
opportunity.
In fact, the diversity and performance of our product line is surpassed only by
it’s quality–in design, construction, and training. A commitment that is reinforced
by the Lochinvar Tech Center, a state-of-the-art testing and training facility
equipped with the very latest in CAD/CAM technology and a comprehensive
R&D lab.
Quality, efficiency, features, service, and selection. For more than 90 years,
these have been the hallmarks of Lochinvar products.

Contents

CREST 1

SYNC® 3

Power-Fin

KNIGHT XL 7

Copper-Fin II

Copper-Fin

Copper-Fin

®

5

®

9

®

11

®

Atmospheric 13

Lochinvar...the innovator in boiler technology.

This emblem means a product has a NOx
rating which exceeds the requirements of
the South Coast Air Quality Management
District and Texas Commission of
Environmental Quality.

This emblem means the Stack Frame is
available for use with that product. See page
27 for details.

This catalog is designed to provide a convenient, condensed overview of the entire Lochinvar boiler product
line. For a complete list of features, specifications and technical data on a particular product, see the full line
catalog, your local distributor or contact Lochinvar. Every Lochinvar product is designed and built to meet
or exceed the fuel efficiency and safety standards of one or more of these agencies, wherever applicable.

KNIGHTTM 15

Efficiency+

Solution

®

19

TM

21

Buffer Tanks 23

Squire Buffer Tank 24

Squire Stainless Steel 25

Stack Frame 27

Low Temperature Valve 29

Electric Boilers 30

99

CREST allows system designers tremendous flexibility to vary the flow rate through the boiler. It can service systems that operate
with widely fluctuating flow rates depending on demand. CREST can be installed with primary/secondary piping or in a full-flow
arrangement. Typical design techniques include full-flow systems or variable flow systems using variable frequency drives on the
heating water pumps. In either case, CREST excels in these applications and allows the flow through the boiler to vary based on
system demand. * 35 GPM min. flow on FB1500 model, 80 GPM on FB3500 model.

Sequences up to an 8-boiler system using simple 2-wire daisy-chain
connection, eliminating cost and uncertainty of separate “third party”
sequencer. On demand, one boiler functions as the leader and modulates
to capacity. Increasing load then “cascades” to additional “lag” boilers
in sequence as needed. Lead-lag rotation shifts “first on” boiler role
every 24 hours, distributing equal lead-lag runtimes to each unit.

CREST’s ability to sequence up to eight units that each have as much
as 25:1 turndown means that the combined system has the potential of
operating with modulation of up to 200:1 turndown. A bank of eight

2.0M Btu CRESTs would be able to provide as little as 80,000 Btu/hr and as much as 16,000,000 Btu/hr of heating output. In addition,
the CREST Cascade can be set for “Efficiency Optimization” with each boiler firing at the same low BTU/hr input rates to receive
the benefits of the highest thermal efficiency.

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Fire Tube Innovation up to 3.5 Million BTU

Lochinvar® has taken the fire-tube concept in an innovative new direction with the
CREST® modulating-condensing boiler. With sizes that range from 1.5 to 3.5 million
Btu/hr, you finally have the opportunity to utilize Lochinvar leading-edge technology
in your largest applications. W ith thermal efficiencies up to 99% in low water temperature
applications, CREST is positioned to provide exceptional energy-saving performance.

The advanced CREST introduces a combustion system with a unique burner design with
up to 25:1 turndown. The burner fires into an array of 316L stainless steel fire-tubes that
transfer the heat to the surrounding water with exceptionally high efficiency.

CREST communicates seamlessly and in real time with building management systems
by utilizing an on-board Modbus protocol. The SMART TOUCH™ control has a built­in cascading feature that communicates with up to eight units, providing total command
without an external control or complex and expensive control logic programming by the
BMS integrator.

Yes, innovative fire-tube boiler technology integrated with our SMART TOUCH™
operating control makes the CREST a genuine game-changer among commercial boilers.

Advanced Negative Regulation Technology

CREST safely and reliably operates with supply gas pressure
as low as 4 inches water column. Because Negative Regulation
(Neg/Reg) technology draws fuel gas into a pre-mix combustion
system instead of relying on utility pressure through the gas valve, operation is steady in low gas
pressure systems or when peak demands occur on supply lines. Plus, Neg/Reg automatic fan speed
control fine-tunes the correct fuel/air ratio entering the burner, providing even, consistent combustion
for a cleaner burning flame achieving high combustion efficiency.

Fully Modulating up to 25:1 Turndown

F

25:1 turndown means the burner can fire at a rate as low as 4% of its maximum input. For example,
a 2 million Btu/hr CREST unit can modulate from 80,000 up to 2,000,000 Btu/hr depending on
demand. High turndown greatly reduces “short cycling” when demand is low. All boiler systems are
designed to provide enough heat to maintain a facility’s heat loss on the coldest days. When the
system is zoned, the CREST’s high turndown works to match the actual system demand and, in
return, reduces the customer’s fuel bill and provides better comfort by load matching the heat loss
of the system. Greater seasonal efficiencies will be realized due to the extremely large turndown
offered by CREST.

As Low As 35 GPM* to Full 350 GPM Flow Rates

CREST allows system designers tremendous flexibility to vary the flow rate through the boiler. It can service systems that operate
with widely fluctuating flow rates depending on demand. CREST can be installed with primary/secondary piping or in a full-flow
arrangement. Typical design techniques include full-flow systems or variable flow systems using variable frequency drives on the
heating water pumps. In either case, CREST excels in these applications and allows the flow through the boiler to vary based on
system demand. * 35 GPM min. flow on FB1500 model, 80 GPM on FB3500 model.

Built-in Cascading Sequencer

Sequences up to an 8-boiler system using simple 2-wire daisy-chain
connection, eliminating cost and uncertainty of separate “third party”
sequencer. On demand, one boiler functions as the leader and modulates
to capacity. Increasing load then “cascades” to additional “lag” boilers
in sequence as needed. Lead-lag rotation shifts “first on” boiler role
every 24 hours, distributing equal lead-lag runtimes to each unit.

CREST’s ability to sequence up to eight units that each have as much
as 25:1 turndown means that the combined system has the potential of
operating with modulation of up to 200:1 turndown. A bank of eight

2.0M Btu CRESTs would be able to provide as little as 80,000 Btu/hr and as much as 16,000,000 Btu/hr of heating output. In addition,
the CREST Cascade can be set for “Efficiency Optimization” with each boiler firing at the same low BTU/hr input rates to receive
the benefits of the highest thermal efficiency.

1

CREST® Boiler Dimensions & Specifications

H

HIGH
VOLTAGE

DRAIN

J

K

WATER
OUTLET

WATER
INLET

LOW
VOLTAGE

Crest Heating Boiler Dimensions and Specifications

Model Input Input NET
Number MBH MBH Thermal Output I=B=R Turndown
Min. Max. Efficiency MBH MBH

FBN1500 60 1,500 92.0% 1,380 1,200 25:1
FBN2000 80 2,000 92.0% 1,840 1,600 25:1
FBN2500 125 2,500 92.0% 2,300 2,000 20:1
FBN3000 150 3,000 92.0% 2,760 2,400 20:1
FBN3500 200 3,500 92.0% 3,220 2,800 18:1

Notes: Indoor installation only. All information subject to change. Change "N" to "L" for LP gas models. Low NOx on FB2500 - FB3500 models, consult factory.
*Turndown rate reduced on LP gas models.

*

Smart Touch™ Features

• SMART TOUCH™ Touchscreen Operating Control

• Full-Color 8” Touchscreen LCD Display

• Built-in Cascading Sequencer for up to 8 Boilers

• Building Management System Integration with

0-10 VDC Input

• Modbus Communications

• Outdoor Reset Control with Outdoor Air Sensor

• Password Security

• Domestic Hot Water Prioritization

• 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 / 60 Hertz / 1 Phase Power Supply

• System and Boiler Pump Contacts

• Low-Voltage Terminal Strip

• 24 VAC Auxiliary Device Relay

• Auxiliary Proving Switch Contacts

• Alarm on Any Failure Contacts

• Runtime Contacts

• Unit Enable/Disable Contacts

• System Sensor Contacts

• DHW Tank Sensor Contacts

• Outdoor Air Sensor Contacts

• Cascade Contacts

• 0-10 VDC BMS External Control Contact

Standard Features

• 92% Thermal Efficiency (AHRI)

• Up to 99% Thermal Efficiency in Low

• Modulating Burner with up to 25:1

• Low-NOx Operation

• Sealed Combustion

• Vertical or Horizontal Venting

• Category IV Venting up to 100 Feet

• ASME “H” Stamped Heat Exchanger

• 316L Stainless Steel Fire Tubes

• 160 psi Working Pressure

• Adjustable High Limit with Manual Reset

• Low Water Cutoff with Manual Reset & Test

• High & Low Gas Pressure Switches w/

• Low Air Pressure Switches

RELIEF
VALVE

4" FLG
OUTLET

80"

66-5/8"

4" FLG

DRAIN

14-7/8"

10 -1/4"

Gas Air Vent Operating Shipping
A B C D E F G H Conn. Inlet Size Wt. (lbs.) Wt. (lbs.)

INLET

11"

8"

CONDENSATE
DRAIN

VENT

B

C

D

E

G

A

30-3/4" 71-1/2" 65-3/4" 14-3/8" 22-3/8" 8-1/2" 25-1/4" 8-1/8" 1-1/2" 7" 7" 2,496 1,900
30-3/4" 71-1/8" 65-1/8" 14-7/8" 22-3/8" 8-1/4" 25-3/8" 9-5/8" 1-1/2" 8" 8" 3,054 2,150
34-1/4" 76-3/8" 70-1/4" 17-3/4" 26-1/8" 9-3/4" 27-3/8" 11-3/8" 2" 8" 9" 3,652 2,560
40-1/2" 83-5/8" 76-3/8" 17-3/8" 31-3/8" 9-7/8" 34-3/4" 11-1/2" 2" 10" 10" 4,126 2,920
40-1/2" 83-1/4" 75-5/8" 17-1/4" 31-3/8" 9-7/8" 34-3/4" 12-7/8" 2" 10" 10" 4,744 3,225

• System Sensor Outdoor Air Sensor

• Inlet & Outlet Temperature Sensors

•

High Voltage Terminal Strip

• Low Voltage Terminal Strip

• Downstream Gas Test Cocks

• 50 psi ASME Relief Valve

•

DHW Thermostat Contacts

• Temperature & Pressure Gauge

•

Zero Clearances to Combustible Materials

• 10-Year Limited Warranty
(See Warranty for Details)

• 1-Year Warranty on Parts
(See Warranty for Details)

Optional Equipment

• Alarm Bell

• BMS Gateway - BACnet or LonWorks

• Condensate Neutralization Kit

•

•

Temperature Applications

Turndown

•

Direct-Spark Ignition

SMART TOUCH PC Software

• Common Vent Kits

• Vent Termination Kits

• Dual Fuel Gas Train - Consult factory

• Electrical Options:
208V/3Ø/60Hz

•

Low Gas Pressure Operation

240V/1Ø/50Hz
480V/3Ø/60Hz

600V/3Ø/60Hz

Codes & Registrations

• ANSI Z21.13/CSA Certified

•

•

On/Off Switch

Manual Reset

ASME certified, “H” Stamp / National Board

• California Code Compliant

• CSD1 / Factory Mutual / GE Gap Compliant

• South Coast Air Quality Management
District Qualified

• Canadian Registration Number (CRN)

•

AHRI Certified

LOW
VOLTAGE

HIGH
VOLTAGE

AIR

GAS

F

2

Building on a Tradition of Innovation

s t

.

Lochinvar’s commitment to research and development once again brings
innovation to the industry! The SYNC™ Commercial Boiler combines stainless
steel heat exchanger technology with Modulating Condensing combustion to
deliver thermal efficiencies as high as 98% in low-temperature applications.

With models at 1.0, 1.3 and 1.5 million BTU/hr inputs, SYNC will serve a
large range of commercial applications and add the “green” touch that building
owners and facility managers desire.

SYNC also reaches new levels of innovation with SMART TOUCH™…
touchscreen technology that puts total operational control at your fingertips!
With SMART TOUCH, it’s easier than ever to set up a perfectly synchronized
“green” system, and access a complete onboard database of real-time operational
data and performance history.

Other features in SYNC include space-saving footprints, direct-vent design with
intake and exhaust runs up to 100 feet, and a built-in cascading sequencer for up
to 8 boilers, delivering up to 12 million BTU/hr heating capacity.

Total Control, at Your Fingertips

The full-color SMART TOUCH Main Menu screen is your gateway to
complete control of all SYNC functions, and total access to system performance data and
history. Do it all and see it all right here, using our SMART TOUCH software.

Direct-Venting up to 100 Feet

SYNC offers tremendous flexibility for building plan placement because it permits direct-vent air intake
and exhaust runs up to 100 equivalent feet using PVC, CPVC or AL29-4C stainless steel vent pipe. Intake
and exhaust runs can terminate horizontally through a sidewall or vertically through the roof

Advanced Negative Regulation Technology

SYNC safely and reliably operates with supply gas pressure as low as 4 inches water column, because Negative Regulation (Neg/Reg)
technology automatically adjusts fan speed to ensure the correct volume of fuel and air entering the burner.

“Fail-Safe” Direct-Spark Ignition

With each call for heat, two electrodes ignite the fuel/gas mixture. A third electrode then senses for flame. SMART TOUCH will lock
out and display the fault if ignition does not occur.

Two-in-One Stainless Steel Heat Exchanger

A primary heat exchanger combined with a secondary exchanger captures flue gas heat and allows
very low return water temperatures and does not require a low-temperature bypass. The stainless

steel, pH-tolerant design features a weld-sealed assembly with no O-rings or gaskets, and does not
require special glycol. ASME Section IV approved and stamped.

Fully Modulating Burner

SMART TOUCH allows fully modulating combustion with 10:1 turndown. The combustion system can operate as low as 10% of

maximum input, and modulates the firing rate up to 100% as demand increases. The burner design incorporates a woven steel mesh
sleeve over a stainless steel burner tube and fires in a 360° pattern along the entire length of the primary heat exchanger. These together
allow SYNC’s compact size to excel compared to units with larger multiple burners.

Built-in Cascading Sequencer

Sequences up to an 8-boiler system using simple 2-wire daisy-chain connection,
eliminating cost and uncertainty of separate “third party” sequencer. On demand,
one boiler functions as the “leader”, and modulates to capacity. Increasing load
then “cascades” to additional “lag” boilers in sequence as needed. Lead-lag
rotation shifts “first on” boiler role every 24 hours, distributing equal lead-lag

runtimes to each unit.

3

SYNCTM Boiler Dimensions & Specifications

FLUE

AIR INTAKE

49"

C

LEFT

Sync Heating Boiler

Input Net
Model Min. Max. Thermal Output I=B=R
Number MBH MBH Efficiency MBH MBH

SBN1000 100 1,000 94.1% 941 818

SBN1300 130 1,300 95.4% 1,240 1,078

SBN1500 150 1,500 96.2% 1,443 1,255

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

• Up to 96.2% Thermal Efficiency

• Modulating Burner with 10:1 Turndown

• Direct-Spark Ignition

• Low NOx Operation

• Sealed Combustion

• Low Gas Pressure Operation

• Vertical & Horizontal Venting

• Category IV Venting up to 100 Feet

• PVC, CPVC or AL29-4C Vent Material

• Sidewall Vent Terminations Provided

• ASME Stainless Steel Heat Exchanger

• ASME Certified, “H” Stamped

• Gasketless Design

• 160 psi Working Pressure

• On/Off Switch

• Adjustable High Limit with Manual Reset

• Low Water Cutoff with Manual Reset & Test

• Low Air Pressure Switch

• High & Low Gas Pressure Switches

with Manual Reset

• Inlet & Outlet Temperature Sensors

• Two Easy Access Terminal Strips

• Downstream Test Cocks

• 50 psi ASME Relief Valve

• Temperature & Pressure Gauge

• Zero Clearance to Combustible Material

• Approved for Combustible Floor Installation

• 1 Year Warranty on Parts

• 10 Year Limited Warranty

(see warranties for details)

Inlet Outlet
Gas Water Water Air Vent Shipping
A B C D E F Conn. Conn. Conn. Inlet Size Wt. (lbs.)

58-3/4" 31" 48" 35" 4-1/2" 15" 1-1/2" 2" x 2" 3" 6" 6" 786

58-3/4" 31" 52-1/4" 34-3/4" 3-1/2" 6-3/4" 1-1/2" 2" x 2" 3" 6" 6" 856

58-3/4" 31" 56-1/2" 34-3/4" 3-1/2" 6-3/4" 1-1/2" 2" x 2" 3" 6" 6" 926

SMART TOUCH™ Features

• SMART TOUCH™ Touchscreen Operating Control

• Full-Color Touchscreen LCD Display

• Built-in Cascading Sequencer for up to 8 Boilers

• Building Management System Integration with

0-10 VDC Input

• Outdoor Reset Control with Outdoor Air Sensor

• Dual Level Password Security

• Domestic Hot Water Prioritization

• 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

• Boost Temperature & Time

• Three Pump Control

• System Pump

• Boiler Pump

• Domestic Hot Water Pump

Dimensions and Specifications

A

• High Voltage Terminal Strip

• 120 VAC / 60 Hertz / 1-Phase

Power Supply

• Three Sets of Pump Contacts

• 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

• Unit Enable/Disable Contacts

• System Sensor Contacts

• DHW Tank Sensor Contacts

• Outdoor Air Sensor Contacts

• Cascade Contacts

Optional Equipment

• Alarm Bell

• Condensate Neutralization Kit

• SMART SYSTEM PC Software

• Modbus Communications

• Stainless Steel Vent Kits

Codes & Registrations

• ANSI Z21.13a-2010 certified

• ASME certified, “H” stamp

• California Code compliant

• CSD1 / FM / GE Gap

• Massachusetts Code compliant

• South Coast Air Quality Management

District registered

Registered under U.S. Patent # 7,506,617

4

500,000 to 2,000,000 Btu/hr models

The Next Generation

The latest generation of Power-Fin continues to evolve, with
new “Built-in Advantages” from Lochinvar Corporation
These include expanded burner modulation and the advanced
SMART SYSTEM™ operating control, including a built­in cascading sequencer for up to eight boilers. It has been
designed to operate more efficiently at lower inputs, which
can add up to big savings. Plus, with numerous venting
capabilities, the Power-Fin is even more flexible to install.
And it’s easy to see how the Power-Fin is performing thanks
to a digital control panel. Take a look at what the next
generation of Power-Fin has to offer

.

Control

• Built-in cascading sequencer controls up to 8 units

• 2-line 16-character LCD readout of setup, system status

and diagnostic data in words, not codes.

• Password security

• Pump control for operation of water heater pump

• Pump delay w/freeze protection

• Low NOx operation

• 0-10 Vdc BMS input for easy integration into Building

Management Systems

• Optional SMART SYSTEM PC software for advanced

setup and diagnostics

®

.

Infinite Modulation

With thermal efficiencies up to 87%,
Power-Fin boilers feature infinitely
modulating burner firing rates
(turndown), precisely matching the
firing rate to domestic water load
requirements. The result is better overall
efficiency and less cycling. Power-Fin

boilers may be specified as either 5:1
turndown (502 - 2001), 2:1 turndown (1501 - 2001), or 100% ON/
OFF (502 - 1302). With 5:1 turndown the burner fires as low as
20% of maximum input when demand is lowest and increases
the firing rate up to 100% as demand increases. Models with 2:1
turndown modulate from 50% to 100% of maximum input.

Venting Options

DirectAire Horizontal

Vents horizontally up to 50
equivalent feet using Category IV
vent materials. Draws combustion
air up to 50 ft. from a different
pressure zone.

DirectAire Vertical

Vertical venting up to 50 equivalent
feet using Category I or IV vent
materials. Draws combustion air up
to 50 ft. from a different pressure

5

zone.

Direct Vent

Horizontal or vertical venting up to 50
equivalent feet using Category IV vent
materials. Draws combustion air from
the same pressure zone. This option
only available with 5:1 (M) firing
code models.

Common Venting

Vents multiple units vertically
through one vent termination with
Category II vent materials and draws
combustion air from the room, roof
or sidewall. Vent kit and Category IV
to II conversion kit required.

Gasketless Heat Exchanger

The Power-Fin heat exchanger features an array
of 20 or 24 copper-finned tubes surrounding the
burner for maximum heat transfer. Lochinvar also
pioneered the “gasketless” heat exchanger, which
eliminates the use of O-rings and gaskets. Because
of the time-proven reliability of this design, the
Power-Fin heat exchanger is backed by a 5 year
limited warranty.

Sidewall

Horizontal venting up to 50
equivalent feet using Category
IV vent materials. Draws
combustion air from the room.

Vertical

Vertical venting using
Category I or Category IV
vent materials. Draws
combustion air from
the room.

Power-Fin® Boiler Dimensions & Specifications

J

K

M

B

G

P

L

N

C

Power-Fin Boiler Dimensions and Specifications

B9/F9 Net M9 Net
Model Input Thermal Output I=B=R Thermal Output I=B=R B9/F9 M9
Number MBH Efficiency MBH MBH Efficiency MBH MBH A B C D E E F G

PBN0502 500 85.0% 425 370 85.0% 425 370 44-1/2” 28-1/2” 23-1/4” 34” 17-3/4” 19-1/2” 6-1/2” 6”
PBN0752 750 85.0% 638 554 85.0% 638 554 52” 28-1/2” 23-1/4” 41-1/2” 17-3/4” 19-1/2” 6-3/4” 6”
PBN1002 999 85.0% 850 739 85.0% 850 739 59-1/4” 28-1/2” 23-1/4” 48-3/4” 17-3/4” 19-1/2” 7-1/4” 6”
PBN1302 1,300 85.0% 1,105 961 85.0% 1,105 961 67-3/4” 28-1/2” 23-1/4” 57-1/4” 17-3/4” 19-1/2” 8-1/4” 6”
PBN1501 1,500 84.0% 1,260 1,096 85.0% 1,275 1,109 65-1/2” 29-3/4” 27-1/4” 58-3/4” 21” 21” 13-1/2” 8”
PBN1701 1,700 84.0% 1,428 1,242 85.0% 1,445 1,257 70” 29-3/4” 27-1/4” 63-1/4” 21” 21” 13-1/2” 8”
PBN2001 2,000 84.0% 1,680 1,461 85.0% 1,700 1,478 76-3/4” 29-3/4” 27-1/4” 70” 21” 21” 13-1/2” 8”

Vent Sizes Shipping
Model B9/F9 M9 Gas Air B9/F9 M9* M9 Wt.
Number H J K L M N P P Conn. Inlet Cat I Cat II Cat IV (lbs)

PBN0502 8” 7-3/4” 23” 11-1/2” 11-1/4” 17-1/2” 15-1/4” 15-1/4” 1” 5” 7” 7” 4” 505
PBN0752 8” 7-3/4” 30-1/2” 11-1/2” 11-1/4” 17-1/2” 15-1/4” 15-1/4” 1-1/4” 5” 9” 9” 5” 554
PBN1002 8” 7-3/4” 37-3/4” 11-1/2” 11-1/4” 17-1/2” 15-1/4” 15-1/4” 1-1/4” 6” 10” 10” 6” 603
PBN1302 8” 7-3/4” 46-1/4” 11-1/2” 19-1/2” 17-1/2” 15-1/4” 15-1/4” 1-1/4” 6” 12” 12” 8” 652
PBN1501 10” 9-1/2” 43-1/2” 5-3/4” 22-1/4” 21-1/2” 24-1/2” 19-1/2” 1-1/2” 6” 12” 8” 6” 1,065
PBN1701 10” 9-1/2” 48” 5-3/4” 25” 21-1/2” 24-1/2” 19-1/2” 1-1/2” 7” 14” 9” 7” 1,100
PBN2001 10” 9-1/2” 54-3/4” 5-3/4” 27-1/2” 21-1/2” 24-1/2” 19-1/2” 1-1/2” 8” 14” 10” 8” 1,127

Notes: Change ‘N’ to ‘L’ for LP Gas Model. No deration on LP models. All water connections are 2-1/2” *w/CAT II conversion kit

Standard Features

• Up to 87% Thermal Efficiency (M)

• Up to 85% Thermal Efficiency (B/F)

• Modulating Burner with 5:1 Turndown

• Hot Surface Ignition

• Low NOx Operation

• Sealed Combustion

• Low Gas Pressure Operation

• Vertical & Horizontal Venting

• Venting up to 50 Feet

• Category I or Category IV Venting

• Cat IV converts to Cat II
w/ optional vent kit

• ASME Copper-Finned Tube

Heat Exchanger

• ASME Certified, “H” Stamped

• Gasketless design

• 160 psi working pressure

• On/Off Switch

• Adjustable High Limit w/ Manual Reset

• Flow Switch

• Low Air Pressure Switch

• Downstream Test Cocks

• 50 psi ASME Relief Valve

• Combustion Air Filtration

• Temperature & Pressure Gauge

• Zero Clearances to Combustible Material

• 1 Year Warranty on Parts

• 10 Year Limited Warranty

(See Warranties for Details)

Smart System Features

• SMART SYSTEM Operating Control

• 2 line, 16 Character Display

• Dual Level Password Security

• Domestic Hot Water Prioritization

• Built in Cascading Sequencer

for up to 8 Boilers

• Building Management System

Integration 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

• 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

• 0-10 VDC BMS External
Control Contact

Firing Control Systems

• M Indicates 5:1 Turndown, Category IV

• B Indicates 2:1 Turndown, Category I

• F Indicates 100% On/Off Fire, Category I

• M9 Standard

• B9 or F9 Special Order,

Factory Trimmed

• M7, B7 or F7 California Code

• M13, B13 or F13 CSD1/FM/GE Gap

Optional Equipment

• Alarm Bell

• Cupro-Nickel Heat Exchanger

• High & Low Gas Pressure Switches

w/ Manual Reset

• Low Water Cutoff

w/ Manual Reset & Test

• SMART SYSTEM PC Software

• Vent Kits:

- Horizontal Exhaust Cap

- Horizontal Air Intake Cap

- Horizontal Direct Vent Kit

- Category IV to Category II
Conversion Kit

Registered under U.S. Patent # 7,506,617

500,000 - 2,000,000 Btu/hr models

6

The Smartest Choice for Condensing Boiler Performance

The KNIGHT® XL, engineered with Lochinvar’s exclusive SMART SYSTEM™ control
and an array of other innovative features, places it far ahead of any commercial heating
boiler in its class. It promises and delivers ultimate ease of installation and maintenance.
With up to 94.6% thermal efficiency, low-NOx emissions and a fully modulating burner,
it is the best ”green choice” for today’s environmentally focused market.

Five modulating/condensing stainless steel KNIGHT XL boilers are available with
399,999–800,000 Btu/hr inputs and remarkably small space-saving footprints. All are
equipped for direct-vent installation with air intake and exhaust runs up to 100 feet
using PVC, CPVC or AL29-4C vent materials. This range of choices is ideal for light­duty applications such as small hotels, schools and office buildings. For higher-demand
applications, up to eight KNIGHT XL units can be installed utilizing the built-in cascading
sequencer to deliver up to 6.4 million Btu/hr heating capacity.

Control

SMART SYSTEM provides unequalled control and monitoring functions that are easy to
understand and use.

• Multi-Color Graphic LCD Display

• Navigation Dial

• USB Port

• Modbus Capability (Optional)

• DHW Modulation Limiting

• DHW Night Setback*

• Controls up to three different setpoint temperatures

• 0-10 V Boiler Rate Output

• 0-10V Signal to control variable speed boiler pump*

• 0-10V System Pump Signal Input*

• Heat Demand from 0-10V Input

• Installer to Program Name and Number into the Boiler

• Freeze Protection Parameters Installer Adjustable

• Separately adjustable SH/DHW Switching times*

• Installer access to BMS and ramp delay settings

*Exclusive to Lochinvar Smart System

Advanced Negative Regulation Technology

KNIGHT XL safely and reliably operates with supply gas pressure as low as 4
inches water column. Negative Regulation (Neg/Reg) technology automatically
adjusts fan speed that ensures the correct volume and mix of fuel and air
throughout the firing range.

Two-in-One Stainless Steel Heat Exchanger

A primary heat exchanger combined with a secondary heat exchanger captures
flue gas heat and condenses to utilize available latent energy. The stainless steel,
pH-tolerant design features a weld-sealed assembly with no O-rings or gaskets
and does not require special glycol. ASME Section IV approved and stamped.

Fully Modulating Burner

The SMART SYSTEM allows fully modulating combustion with 5:1 turndown.
The burner can fire as low as 20% of maximum input and modulates the firing
rate up to 100% as demand increases. The burner is a single stainless steel
assembly covered with woven steel mesh and fires in a 360° pattern along the entire length of the primary heat exchanger. This
allows the compact KNIGHT XL to exceed the capacity of units with larger multiple burners.

Direct Venting up to 100 Feet

KNIGHT XL offers 7 venting options and 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. A sidewall vent termination kit is
shipped standard with every KNIGHT boiler.

7

KNIGHT XL® Boiler Dimensions & Specifications

A

LOW VOLTAGE
ELECTRICAL
CONNECTIONS

GAS

HIGH VOLTAGE
ELECTRICAL
CONNECTIONS

K

AIR INLET

39-1/2"

FLUE

B

BACK

J

INLET

38-3/4"

I

H

FLUE

13-3/4"

8"

18-3/4"

D

3-1/2"

OUTLET

G

F

E

C

LEFT SIDE

HEAT
EXCHANGER
DRAIN
3/4" NPT

CONDENSATE
DRAIN

9"

Knight XL Heating Boiler Dimensions and Specifications

Input Net
Model Min Max Thermal Output I=B=R

Number MBH MBH Efficiency MBH MBH

KBN400 80 399 93.3% 373 324
KBN501 100 500 93.3% 467 406
KBN601 120 600 94.6% 567 493
KBN701 140 700 94.3% 660 574

KBN801 160 800 94.0% 752 654

Notes: Indoor installation only. All information subject to change. Change “N” to “L” for LP gas models.

Standard Features

• Up to 94.6% Thermal Efficiency

• Modulating Burner with 5:1 Turndown

• Direct-Spark Ignition

• Low NOx Operation

• Sealed Combustion

• Low Gas Pressure Operation

• ASME Stainless Steel Heat Exchanger

• ASME Certified, ”H” Stamped
Gasketless Heat Exchanger

• 160 psi Working Pressure

• 50 psi ASME Relief Valve

• Highly efficient, condensing design

• 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

• Smart System Control

• Other Features

• On/Off Switch

• Adjustable High Limit w/ Manual Reset

• Automatic Reset High Limit

• Flow Switch

• Flue Temperature Sensor

• Low Air Pressure Switch

• Temperature & Pressure Gauge

• Adjustable Leveling Legs

• Condensate Trap

• Zero Clearances to Combustible Material

• 10 Year Limited Warranty (See Warranty)

Firing Control Systems

• M9 Standard Construction

• M7 California Code

• M13 CSD1 / FM / GE Gap (KB501-KB801)

A B C D E F G H I J K Gas Water Air Vent Shipping
Conn. Conn. Inlet Size Wt. (lbs.)

42-1/2” 15-1/2” 27-3/4” 3-3/4” 20-3/4” 21” 14” 34” 34” 2” 18-3/4” 1” 1-1/2” 4” 4” 280
42-1/2” 15-1/2” 31-1/2” 3-3/4” 25-1/2” 21” 14” 32-1/2” 36” 2” 18” 1” 1-1/2” 4” 4” 310
42-1/2” 15-1/2” 36-1/4” 3-3/4” 25” 21” 14” 36” 32-3/4” 5-1/2” 19-1/2” 1” 2” 4” 4” 340
42-1/2” 15-1/2” 40-1/4” 3-3/4” 29” 23” 17” 36” 32-3/4” 3-1/4” 23-1/2” 1” 2” 4” 6” 370

42-1/2” 15-1/2” 45-1/4” 3-3/4” 33-1/4” 23” 17” 36” 32-3/4” 3-1/4” 27-3/4” 1” 2” 4” 6” 405

Smart System Features

• SMART SYSTEM Digital Operating Control

• Multi-Colored Graphic LCD Display w/ Navigation Dial

• Three Reset Temperature Inputs
with curves for three set point temperature inputs

• Built in Cascading Sequencer for up to 8 Boilers

• Lead Lag

• Efficiency Optimization

• Outdoor Reset Control with Outdoor Air Sensor

• Programmable System Efficiency Optimizers

• Night Setback

• DHW Night Setback

• Anti-Cycling

• Outdoor Air Reset Curve

• Ramp Delay

• Boost Temperature & Time

• Three Pump Control

System Pump With Parameter for Continuous Operation

•

• Boiler Pump With Variable Speed Pump Control*

• Domestic Hot Water Pump

• Domestic Hot Water Prioritization

• DHW tank piped with priority in the boiler loop

• DHW tank piped as a zone in the system with
the pumps controlled by the Smart System

• DHW Modulation Limiting

• Separately Adjustable SH/DHW Switching Times*

• Building Management System Integration

• 0-10VDC Input to Control Modulation or Set Point

• 0-10VDC Input Signal from Variable Speed
System Pump*

• 0-10VDC Modulation Rate Output

• 0-10VDC Input to Enable/Disable call for heat

• Access to BMS Settings through Display

Optional Equipment

• Alarm Bell

• Condensate Neutralization Kit)

• Concentric Vent Kit (KB400-KB601)

• High & Low Gas Pressure Switches

w/ Manual Reset (KB501-KB801)

1-1/4"1/4" -

ADJUSTABLE

FRONT

• High Voltage Terminal Strip

• 120 VAC / 60 Hertz / 1 Phase Power Supply

• Three sets of Pump Contacts with Pump Relays

• Low Voltage Terminal Strip

• 24 VAC Device Relay

• Proving Switch Contacts

• Flow Switch Contacts

• Alarm on Any Failure Contacts

• Runtime Contacts

• DHW Thermostat Contacts

• 3 Space Heat Thermostat Contacts

• System Sensor Contacts

• DHW Tank Sensor Contacts

• Outdoor Air Sensor Contacts

• Cascade Contacts

• 0-10 VDC BMS External Control Contact

• 0-10VDC Boiler Rate Output Contacts

•

0-10VDC Variable Speed System Pump Signal Input

• 0-10VDC Signal to Control Variable Speed Boiler Pump

• Modbus Contacts

• Time Clock

• Data Logging

• Hours Running, Space Heating

• Hours Running, Domestic Hot Water

• Ignition Attempts

• Last 10 Lockouts

• Other Features

• Low Water Flow Safety Control & Indication

• Password Security

• Inlet & Outlet Temperature Readout

• Customizable Freeze Protection Parameters

• Custom Maintenance Reminder with Contractor Info

*Exclusive feature, available only from Lochinvar

• Modbus Communication

• Low Water Cutoff w/Manual Reset & Test

• SMART SYSTEM PC Software

• Stainless Steel Vent Kits (KB701-KB801)

• Stack Frame

8