Lochinvar 151-286 User Manual

OKB-I-O Rev C

Outdoor Knight Boiler

Installation & Operation

Manual

Models: 151 - 286

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Outdoor Knight Boiler Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE OUTDOOR KNIGHT BOILER -- HOW IT WORKS 4-6

RATINGS ........................................................................... 7

1. DETERMINE BOILER LOCATION

Provide Clearances ............................................................ 9

Corrosive Contaminants and Sources ............................... 9

2. PREPARE BOILER

Remove Boiler from Wood Pallet ..................................... 10

Gas Conversions ......................................................... 10-11

Leveling the Boiler ...................................................... 11

3. HYDRONIC PIPING

System Water Piping Methods ......................................... 12

Low Water Cutoff Device ................................................. 12

Chilled Water System ....................................................... 12

Freeze Protection ............................................................. 12

General Piping Information .............................................. 12

Relief Valve / T & P Installation ....................................... 13

Near Boiler Piping Components .................................. 13-14

Near Boiler Piping Connections ....................................... 14

Circulator Sizing ............................................................... 14

Variable Speed Pump Option .......................................... 16

4. GAS CONNECTIONS

Connecting Gas Supply Piping ................................... 24-25

Natural Gas ...................................................................... 25

Pipe Sizing for Natural Gas ........................................ 25

Natural Gas Supply Pressure Requirements ............. 25

Propane Gas .................................................................... 25

Pipe Sizing for Propane Gas ...................................... 25

Propane Supply Pressure Requirements ................... 25

Check Inlet Gas Supply ................................................... 26

Gas Pressure ................................................................... 27

Gas Valve Replacement .................................................. 27

5. FIELD WIRING

Line Voltage Connections ................................................ 28

Low Voltage Connections ................................................ 28

Wiring of the Cascade ...................................................... 30

6. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 32

7. STARTUP ............................................................... 33-38

8. OPERATING INFORMATION

General ............................................................................. 39

Cascade ........................................................................... 42

Sequence of Operation ............................................... 43-44

Outdoor Knight Boiler Control Module ............................. 45

Status Display Screens ............................................... 46-48

9. MAINTENANCE

Maintenance and Annual Startup ................................ 49-53

10. DIAGRAMS

Ladder Diagram ............................................................... 54

Wiring Diagram................................................................. 55

Revision Notes .................................................. Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Outdoor Knight Boiler Installation & Operation Manual

Please read before proceeding

 WARNING

NOTICE

 WARNING

Installer – Read all instructions, including this manual and the Outdoor Knight Boiler Service Manual, before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

When servicing boiler –

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation –

• Do not block flow of combustion or ventilation air to the boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water –

• Thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in boiler or piping must be repaired at once to prevent makeup water.

 CAUTION

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Outdoor Knight Boiler Installation & Operation Manual

The Outdoor Knight Boiler - How it works...

1. Stainless steel heat exchanger

Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

2. Combustion chamber access cover

Allows access to the combustion side of the heat exchanger coils.

3. Blower

The blower pulls in air and gas through the venturi (item

5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

4. Gas valve

The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

5. Venturi

The venturi controls air and gas flow into the burner.

6. Flue gas sensor (limit rated)

This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.

7. Boiler outlet temperature sensor (housed with the high limit sensor)

This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.

8. Boiler inlet temperature sensor

This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.

9. Temperature and pressure gauge (field installed, not shown)

Monitors the outlet temperature of the boiler as well as the system water pressure.

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial and a multiple line liquid crystal display.

11. Flue pipe adapter

Allows for the connection of the vent system to the boiler.

12. Burner (not shown)

Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

13. Water outlet (system supply)

NPT water connection that supplies hot water to the system, either 1" or 1-1/4", depending on the model.

14. Water inlet (system return)

NPT water connection that returns water from the system to the heat exchanger, either 1" or 1-1/4", depending on the model.

15. Gas connection pipe

Threaded pipe connection, either 1/2" or 3/4", depending on the model. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

16. SMART SYSTEM Control Module

The SMART SYSTEM Control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the heating demand.

17. Manual air vent

Designed to remove trapped air from the heat exchanger coils.

18. High voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

19. Boiler drain port

Location from which the heat exchanger can be drained.

20. Low voltage connection board

The connection board is used to connect external low voltage devices.

21. Low voltage wiring connections

Conduit connection points for the low voltage connection board.

22. Condensate drain connection

Connects the condensate drain line to a 1/2" PVC union.

23. Access cover - top front

Provides protection of the control panel / display from outside elements.

24. Access cover - bottom front

Provides access to the burner.

25. Ignition electrode

Provides direct spark for igniting the burner.

26. Flame inspection window

The quartz glass window provides a view of the burner surface and flame.

27. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 30 psi.

28. Flame sensor

Used by the control module to detect the presence of burner flame.

29. Line voltage wiring connections

Conduit connection points for the high voltage junction box.

30. Top access cover

Provides access to the internal components.

31. Power switch

Turns 120 VAC ON/OFF to the boiler.

32. Leveling legs

Used to allow the heat exchanger to be leveled. This is needed for the proper draining of the condensate from the combustion chamber.

33. Air pressure switch

The air pressure switch detects blocked inlet conditions.

34. Transformer

The transformer provides 24V power to the integrated control.

35. High limit sensor (housed with the outlet temperature sensor)

Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.

36. Gas shutoff switch

An electrical switch designed to cut power to the gas valve to prevent releasing any gas.

37. Over-temp switch (Model 286 Only) (located underneath access cover)

An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger, directly above the flue connection exceeds 604°F (318°C). This is a one time switch and could warrant a heat exchanger replacement. Check the integrity of the rear refractory at the back of the upper coil if the switch opens.

38. Air cover

Covers the over-temp switch and the flue collar with flue sensor.

39. Flue pipe assembly

Factory supplied components for a complete venting system.

Outdoor Knight Boiler Installation & Operation Manual

The Outdoor Knight Boiler - How it works... (continued)

Models 151 - 211

Front View - Models 151 - 211

IMG00365

Rear View - Models 151 - 211

IMG00366

IMG00367

Left Side (inside unit) - Models 151 - 211

4 5

IMG00368

Right Side (inside unit) - Models 151 - 211

Outdoor Knight Boiler Installation & Operation Manual

The Outdoor Knight Boiler - How it works...

Model 286

IMG00379

IMG00380

Front View - Model 286

Rear View - Model 286

4 5

Left Side (inside unit) - Model 286

IMG00381

IMG00382

Right Side (inside unit) - Model 286

Ratings

Outdoor Knight Boiler Installation & Operation Manual

Outdoor Knight Boiler

AHRI Rating

Input

Model Number

Note: Change “N” to

“L” for L.P. gas models.

OKN151 30 150 141 122 94 OKN211 42 210 197 171 94 OKN286 57 285 266 232 94

NOTICE

MBH

(Note 4)

Max Min

Maximum allowed working pressure is located on the rating plate.

Notes:

1. As an Energy Star Partner, Lochinvar has determined that outdoor boilers meet the Energy Star guidelines for energy efficiency.

2. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

3. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

4. Standard outdoor boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

5. Ratings have been confirmed by the Hydronics Section of AHRI.

6. Outdoor boilers temperature controls comply with the requirements of CSD-1 Section CW-400 requirements. The manual reset high limit provided with the outdoor boiler is listed to UL353.

Heating

Capacity

MBH

(Note 2,5)

Net

AHRI

Ratings

Water,

MBH

(Note 3,5)

AFUE

(Note 1, 5)

Other Specifications

Boiler

Water Content Gallons

1.3 1" 1/2" 3"

1.7 1" 1/2" 3"

2.4 1-1/4" 3/4" 4"

Water

Connections

Gas

Connections

Air

Size

Outdoor Knight Boiler Installation & Operation Manual

1 Determine boiler location

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

NOTICE

 WARNING

CAUTION

The Outdoor Knight gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.

Outdoor models must be installed outdoors only and must use the outdoor vent kit assembly supplied by the manufacturer. Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors. All covers, doors and jacket panels must be properly installed to ensure proper operation and prevent a hazardous situation.

This product contains a condensate management and disposal system that may be subject to freezing if exposed to sustained temperatures below 32°F. Precautions should be taken to protect the condensate trap and drain lines during extended periods of outdoor temperatures below 32°F.

Before locating the boiler, check:

1. Check for nearby connection to:

• Water piping

• Gas supply piping

• Electrical power

2. - Keep venting areas free of obstructions.

- Keep area clean and free of combustible and flammable materials.

- To avoid a blocked air inlet or blocked flue condition, keep the outdoor air inlet and flue outlet clear of leaves, debris, etc.

CAUTION

Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block or pressure-treated wood platform.

 CAUTION

 WARNING

CAUTION

3. Check area around the boiler. Remove any combustible materials, gasoline and other flammable liquids.

 WARNING

Do not locate unit so that high winds can deflect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion or damage to controls. Locate unit at least 3 feet (0.91m) from any wall or vertical surface to prevent wind conditions from affecting performance.

The outdoor unit must not be installed in an area that is enclosed by walls or a fence that will block free wind movement around the unit. Free movement of wind around the outdoor unit is required to carry away the flue products and provide combustion air. The flue outlet/combustion air inlet of an outdoor unit must not be installed closer than 10 feet from an inside corner of an L-shaped structure. Walls or enclosed fencing may cause eddy currents which can recirculate the flue products into the combustion air inlet. Recirculation of flue products may cause operational problems, bad combustion or non-warrantable damage to controls.

- Do not install the outdoor unit under a deck.

- Do not install an outdoor unit in a well, stairwell, alcove, courtyard or other recessed area.

- Do not install outdoor units on stack frames. Failure to comply with the above could result in severe personal injury, death or substantial property damage.

- Do not install outdoor units in locations where rain from building runoff drains will spill onto the unit.

- Do not locate the outdoor unit so that water from sprinklers may spray directly onto it. Water may damage controls or other electrical components.

Failure to keep the boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

4. If a new boiler will replace an existing boiler, check for and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

Outdoor Knight Boiler Installation & Operation Manual

1 Determine boiler location (continued)

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" (6 mm) from combustible materials.

2. Vent pipes—minimum of 14" (356mm) from the rear and

0" on the right side from combustible materials.

Clearances for service access

1. If you do not provide the minimum clearances, it may

not be possible to service the boiler without removing it from the space.

Recommended service clearances:

Front - 24" (610mm) Top - 24" (610mm) Left side - 24" (610mm) Rear - 24" (610mm)

Outdoor vent / air intake location

 WARNING

To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section.

Flue gas condensate can condense on exterior walls or on the vent. Some discoloration to exterior building or unit surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

Maintain a minimum of 24" (610mm) clearance to the side of the air inlet.

Locate the outdoor vent termination at least 48" (1.22m) below and 48" (1.22m) horizontally from any window, door, walkway or gravity air intake.

Locate outdoor unit at least 10 feet (3.05m) away from any forced air inlet.

Multiple outdoor unit installations require 24" (.61m) clearance between each vent termination.

Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs or other plants to obstruct the proper operation of the outdoor vent system.

The flue products discharged from the flue outlet on the outdoor vent may be very hot. Avoid touching or other direct contact with the flue gases or the vent termination assembly. These components are hot and direct contact can result in burns.

Flooring and foundation

Flooring

The Outdoor Knight is approved for installation on combustible flooring.

 WARNING

Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components. If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

Prevent combustion air contamination

Do not install unit in locations that can allow contamination of combustion air. Refer to Table 1A for products and areas which may cause contaminated combustion air.

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Outdoor Knight Boiler Installation & Operation Manual

2 Prepare boiler

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler,

remove the installation kit.

2. Remove the front access covers to access the lag bolts in

front of the unit (FIG. 2-1).

3. To remove the boiler from the pallet (after removing the

front access covers):

a. Remove the two lag bolts from the wood pallet inside the boiler (FIG. 2-1). b. Detach the boiler from the lag bolts in the rear of the unit, see FIG. 2-1.

Figure 2-2 Install Flue Pipe Assembly

WALL STRAP SCREWS

BIRD SCREEN

FLUE PIPE

WALL STRAP

NOTICE

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

Figure 2-1 Boiler Mounted on Shipping Pallet

. 2

Install flue pipe assembly (reference FIG. 2-2 for flue

pipe assembly)

The outdoor boiler is shipped with all the necessary vent

components. All components must be installed prior to operation. Basic installation steps are as follows:

1. Locate all venting components from the installation kit and carton.

2. Before connecting the flue pipe sections or components, verify the gasket is seated evenly inside the groove in the female end of the elbow and flue adapter.

3. Remove the kit provided screws from the air cover and use them to install the wall strap.

4. Insert the elbow into the flue adapter.

 CAUTION

Do not use grease or other lubricant on the vent seals. Only water may be used for this purpose. Grease or other lubricant can make the seal brittle or it can result in tears in the surface of the seal, this will result in flue gas leakage.

ELBOW

NOTE: VERIFY GASKETS ARE SEATED EVENLY INSIDE THE GROOVE.

FLUE ADAPTER

AIR COVER

IMG00443

5. Slide the vent pipe through the wall strap and insert it into the elbow.

6. Install the bird screen into the top of the flue pipe.

Gas conversions

 WARNING

1. Remove the top and front access covers from the unit (tools required for removal).

2. Remove the three screws securing the gas valve to the venturi (FIG. 2-3).

3. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size (see Table 2A).

Place the orifice into the black rubber grommet in the

side of the gas valve and secure in the valve (FIG. 2-3).

4. Reposition the gas valve against the venturi and replace the screws (FIG. 2-3) securing the valve to the venturi.

For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 7 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

You must install a propane orifice to operate the outdoor boiler on propane

gas. Verify when installing that the orifice size marking matches boiler size (Table 2A).

2 Prepare boiler (continued)

Outdoor Knight Boiler Installation & Operation Manual

5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

6. Replace the top and front access covers.

Table 2A LP Conversion Table

LP Conversion Table

Model LP Orifice Stamping

151 150 211 210 / W150 286 285

 WARNING

Figure 2-3 Installing Propane Orifice

After converting to LP, check combustion per the Start-up procedure in Section 7 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

Leveling the boiler

1. Set the boiler in place and check level. a) Adjust legs if necessary to level boiler, see FIG. 2-4 below.

Figure 2-4 Leveling Legs on the Boiler

Outdoor Knight Boiler Installation & Operation Manual

3 Hydronic piping

System water piping methods

The outdoor boiler is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.

Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection, heat exchanger

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

 WARNING

Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

General piping information

Basic steps are listed in this section along with illustrations on the following pages (FIG.’s 3-4 thru 3-10), which will guide you through the installation of the outdoor boiler (reference FIG.’s 3-2A and 3-2B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed makeup water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.

6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Consult the factory for a pump and/or pump cover. If a field-supplied pump is used, install per the manufacturer’s specifications in regard to indoor or outdoor location. An outdoor rated pump is recommended.

8. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

9. Install an air elimination device on the system supply.

10. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.

11. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

3 Hydronic piping (continued)

Outdoor Knight Boiler Installation & Operation Manual

 WARNING

The relief valve, tee and any necessary fittings

are shipped in the install kit with the boiler and are to be field installed (FIG. 3-1).

*See the piping illustrations included in this section, FIG.’s 3-4 thru 3-10 for suggested guidelines in piping the outdoor boiler with either zone valves or circulator pumps.

NOTICE

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

CAUTION

The outdoor boiler is capable of servicing multiple temperature loop systems. It is the responsibility of the installer to protect the loops with lower temperature requirements from higher temperatures that may be required by other loops.

Relief valve and temperature and pressure gauge installation

Basic steps are listed below to guide you through the installation of the relief valve and the temperature and pressure (T & P) gauge provided with the unit.

1. Install the tee with the 3/4 inch fitting positioned vertically and on the top as shown in FIG. 3-1.

2. Install the relief valve into the 3/4 inch fitting of the tee installed in Step 1 (FIG. 3-1).

3. Install a field provided 5 inch long nipple and tee with the fitting positioned vertically on the top on the downstream side of the relief valve (see FIG. 3-1).

4. Install the temperature and pressure gauge provided with the unit into the top fitting of the tee (a bushing may be necessary) installed in Step 3 (FIG. 3-1).

Figure 3-1 Relief Valve / T & P Installation

RELIEF VALVE

TEMPERATURE & PRESSURE GAUGE

TEE W/FITTING ON TOP (FIELD PROVIDED)

CLOSE NIPPLE (FIELD PROVIDED)

TEE WITH 3/4" FITTING ON TOP

CLOSE NIPPLE

IMG00369

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 3A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler system pump w/pump cover:

A Grundfos UPS26-99F pump and pump cover will be provided by the factory (for standard altitude models) as the boiler circulation pump based on 20 feet of piping,

4 - 90° elbows, and 2 - fully ported ball valves.

Outdoor boilers are capable of controlling a variable speed boiler circulator. Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG. 3-3 on page 15 at full

speed.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in FIG. 3-3. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.

4. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

5. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 3-4 thru 3-10. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

7. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

8. Unions:

Field supplied. Recommended for unit serviceability.

9. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

10. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME specifications.

11. Boiler purge valve:

Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.

3 Hydronic piping

Outdoor Knight Boiler Installation & Operation Manual

12. System temperature sensor:

Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.

13. Indirect water heaters:

The outdoor boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. As depicted on pages 17 through 23 there are two options when utilizing an indirect water heater.

A. The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.

B. The indirect water heater is connected to the system supply piping. A pump controlled by the outdoor boiler’s control will regulate the flow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the outdoor boiler’s control.

The outdoor boiler is pre-configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming. The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating.

Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.

CAUTION

It is up to the installer to ensure the minimum system flow is not less than the minimum boiler flow at any time.

 WARNING

The National Standard Plumbing Code and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th Edition.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems.

Circulator sizing

The outdoor boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 3-3 for pressure drop through the outdoor boiler heat exchanger.

Near boiler piping connections

Figure 3-2A Near Boiler Piping w/Y-Strainer

FROM SYSTEM

Y-STRAINER

SYSTEM PUMP

TO SYSTEM

(RECOMMENDED)

BOILER PUMP

DRAIN (TYPICAL)

TO FLOOR

DRAIN

DOMESTIC HOT WATER PUMP

FROM

INDIRECT

DOMESTIC

HOT WATER

TANK

IMG00377

Figure 3-2B Near Boiler Piping w/Low Loss Header

AIR VENT VALVE

LOW LOSS HEADER

(TYPICAL)

Y-STRAINER

(RECOMMENDED)

BOLIER PUMP

SYSTEM SENSOR

AIR SEPARATOR

DRAIN VALVE

TO FLOOR DRAIN

DRAIN (TYPICAL)

FILL VALVE

INDIRECT

DOMESTIC

HOT WATER

EXPANSION TANK

IMG00378

3 4 5 6 7 8 9 10111213141516171819202122232425

151

211

286

Outdoor Knight Boiler Installation & Operation Manual

3 Hydronic piping (continued)

Figure 3-3 Pressure Drop vs. Flow

Pressure Drop vs. Flow (Includes Secondary Piping)

Pressure Drop (Feet of Head)

Flow Rate (GPM)

Table 3A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°

20°F Temperature Rise Applications

Model GPM FT/HD

151 14 20 1" UPS26-99F 0011 NRF-36 E7 211 20 29 1" UPS32-160 1400-50 PL-55 E9* 286 27 15 1-1/4" UPS32-80 1400-20 PL-36 E11

*NOTICE

These pumps are only slightly above 20° rise flows, but are the closest available. To reach a 20° rise or less, an upsized pump will be required.

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

Pump

25°F Temperature Rise Applications

Model GPM FT/HD

151 11 13 1" UPS26-99F 0014 NRF-36 E7 211 16 19 1" UPS26-99F 0013 NRF-36 E7 286 21 12 1-1/4" UPS26-99F 0011 NRF-36 E7

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

Pump

35°F Temperature Rise Applications

Model GPM FT/HD

151 810 1" UPS15-58FC 008/0010 NRF-36 Astro-30 211 11 9 1" UPS15-58FC 0010 NRF-36 Astro-50 286 15 7 1-1/4" UP26-64F 008/0010 NRF-36 E7

Minimum Pipe

Size

Grundfos TACO B & G Armstrong

Pump

NOTICE

Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude models.

Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude models.

The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.

Outdoor Knight Boiler Installation & Operation Manual

3 Hydronic piping

Variable speed pump option

Table 3B Recommended Variable Speed Pumps

Minimum Temperature Rise*

Pump

Model

151 21 20 19 211 27 25 24 286 27 24 22

*The minimum temperature rise is derived from the chart in FIG. 3-3 with the firing rate and pump speed at 100% as shown in the table above.

The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are

to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 3B to the boiler high voltage terminal strip.)

Grundfos

UP26-96 FC/VS

TACO

0013 IFC VS

Wilo

Stratos 1.25 3 x 30

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control

- Pump is set for external signal control (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module will be required from the vendor

NOTICE

Pump sizing and flow requirements are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

It is required that near boiler piping systems utilize the Primary/Secondary configuration shown in FIG. 3-10 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance.

SMART SYSTEM / Multi-temperature loop control option

The outdoor boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop from overheating. To help aid with this protection, Lochinvar offers the MultiTemperature Loop Control Board Kit (RLY30086).

Outdoor Knight Boiler Installation & Operation Manual

3 Hydronic piping (continued)

Figure 3-4 Single Boiler - Single Temperature Zoned with Circulators

ZONE #1

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

PRESSURE

GAUGE

SYSTEM SUPPLY

SENSOR

(WHEN USED)

ZONE #2 ZONE #3 ZONE #4

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

Y-STRAINER (RECOMMENDED)

BOILER CIRCULATOR

DOMESTIC

HOT WATER

CIRCULATOR

FLOW CHECK

ZONE CIRCULATORS

ANTI-SCALD

MIXING VALVE

VALVE

(TYPICAL)

HOT

WATER

OUT

COLD

WATER

NOTICE

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

BOILER

INDIRECT

DHW TANK

IMG00370

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Indoor tank shown for illustration purposes.

+ 39 hidden pages