Lochinvar Kight XL 400-801 User Manual

OKBX-I-O Rev B

Outdoor Knight XL

Installation & Operation Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

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

Contents

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

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

THE OUTDOOR KNIGHT XL -- HOW IT WORKS......... 4-6

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

1. DETERMINE BOILER LOCATION

Flooring and Foundation .................................................... 9

Prevent Combustion Air Contamination ............................. 9

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

2. PREPARE BOILER

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

Install Flue Pipe Assembly .......................................... 10-11

Gas Conversions .............................................................. 12

Model 400 ....................................................................12

Model 501 ................................................................... 13

Models 601 - 801 ........................................................ 13

Leveling the Boiler ............................................................ 13

3. HYDRONIC PIPING

System Water Piping Methods ..........................................14

Low Water Cutoff Device ................................................. 14

Chilled Water System ........................................................14

Freeze Protection ............................................................. 14

General Piping Information ............................................... 14

Flow Switch and Relief Valve Installation ....................... 15

Flow Switch Adjustment...............................................16

Circulator Sizing ............................................................... 17

4. GAS CONNECTIONS

Connecting Gas Supply Piping .........................................24

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 ............................................28-29

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 XL Control Module .................................. 45

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

9. MAINTENANCE

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

10. DIAGRAMS

Wiring Diagram ........................................................... 54

Ladder Diagram ...........................................................55

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

Hazard deﬁ nitions

The following deﬁ ned 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.

Please read before proceeding

 WARNING

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

When servicing boiler –

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

Outdoor Knight XL Installation & Operation Manual

NOTICE

 WARNING

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 qualiﬁ ed 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 ﬁ led 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 ﬁ re 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 ﬂ ammable 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 ﬁ re department.

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

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

Boiler operation –

• Do not block ﬂ ow 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 ﬂ ooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water –

• Thoroughly ﬂ ush the system (without boiler connected) to remove sediment. The high-efﬁ ciency 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 ﬂ uids –

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

The Outdoor Knight XL - How it works...

Outdoor Knight XL Installation & Operation Manual

1. Stainless steel heat exchanger

Allows system water to ﬂ ow through specially designed coils for maximum heat transfer, while providing protection against ﬂ ue 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 ﬂ ow only if the gas valve is powered and combustion air is ﬂ owing.

5. Venturi

The venturi controls air and gas ﬂ ow into the burner.

6. Flue gas sensor (limit rated - not shown)

This sensor monitors the ﬂ ue gas exit temperature. The control module will modulate and shut down the boiler if the ﬂ ue gas temperature gets too hot. This protects the ﬂ ue 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 ﬁ ring 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 ﬁ ring rate so the inlet temperature is correct.

9. Temperature and pressure gauge (ﬁ eld 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 assembly Factory-supplied components for complete venting

system.

12. Burner (not shown)

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

13. Water outlet (system supply)

A 1-1/2" or 2" NPT (depending on the model) water connection that supplies hot water to the system.

14. Water inlet (system return)

A 1-1/2" or 2" NPT (depending on the model) water connection that returns water from the system to the heat exchanger.

15. Gas connection pipe

Threaded pipe connection of 1". 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. Air intake

Provides combustion air to the appliance.

19. Air Intake Cover Provides protection from outdoor elements.

20. High voltage junction box

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

21. Boiler drain port

Location from which the heat exchanger can be drained.

22. Low voltage connection board

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

23. Low voltage wiring connections (plugs)

Conduit connection points for the low voltage connection board.

24. Condensate drain connection

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

25. Access cover - front

Provides access to the gas train and the heat exchanger.

26. Ignition electrode

Provides direct spark for igniting the burner.

27. Flame inspection window

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

28. Gas shutoff valve

Manual valve used to isolate the gas valve from the gas supply.

29. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 PSI.

30. Flame sensor

Used by the control module to detect the presence of burner ﬂ ame.

31. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

32. Top panel

Removable panel to gain access to the internal components.

33. Power switch

Turns 120 VAC ON/OFF to the boiler.

34. 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.

35. Air shroud (Model 501 only)

The air shroud controls air and gas ﬂ ow into the burner.

36. Air pressure switch

The air pressure switch detects blocked ﬂ ue/inlet conditions. break the control circuit, shutting the boiler down.

37. Pump relay board

The pump relay board is used to connect the boiler, system and DHW pumps.

38. Transformer (not shown)

The transformer provides 24V power to the integrated control.

39. 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.

40. Over-temp switch (located underneath vent cover not shown)

An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger, directly above the ﬂ ue 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.

41. Vent Cover

Covers Over-temp switch and ﬂ ue collar with ﬂ ue sensor.

42. Flow switch

The ﬂ ow switch is a safety device that ensures ﬂ ow through the heat exchanger during operation. This appliance is low mass and should never be operated without ﬂ ow. The ﬂ ow switch makes contact when ﬂ ow is detected and allows the unit to operate. If ﬂ ow is discontinued during operation for any reason the ﬂ ow switch will break the control circuit and the unit wll shut down.

Outdoor Knight XL Installation & Operation Manual

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

Model 400

Front View - Model 400

IMG00405

IMG00404

Rear View - Model 400

Left Side (inside unit) - Model 400

IMG00406

IMG00407

Right Side (inside unit) - Model 400

Outdoor Knight XL Installation & Operation Manual

The Outdoor Knight XL - How it works...

Model 501

IMG00408

Rear View - Model 501

Models 601 - 801

Left Side (inside unit) - Model 501

IMG00409

IMG00323

IMG0

0324

IMG00324

Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801

Ratings

Outdoor Knight XL Installation & Operation Manual

Outdoor Knight XL Boiler

Other Speciﬁ cations

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

OKN400 80 399 370 322

OKN501 100 500 463 402

OKN601 120 600 566 493

OKN701 140 700 658 572

OKN801 160 800 748 651

NOTICE

Min Max

Maximum allowed working pressure is located on the rating plate.

Input MBH

(Note 4)

Gross

Output

MBH

(Note 1)

Notes:

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

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Boiler Water

Content Gallons

3.4 1-1/2" 1" 4"

4.2 1-1/2" 1" 4"

4.2 2" 1" 4"

5.0 2" 1" 4"

5.7 2" 1" 4"

Water

Connections

Gas

Connections

Air Size

2. Net AHRI ratings are based on net installed radiation of sufﬁ cient 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.

3. Standard Outdoor Knight XL 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.

4. Ratings have been conﬁ rmed by the Hydronics Section of AHRI.

5. Outdoor Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Outdoor Knight XL is listed to UL353.

1 Determine boiler location

Outdoor Knight XL Installation & Operation Manual

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

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

Outdoor models must be installed outdoors only and must use the outdoor vent assembly supplied by the manufacturer. Personal injury or product damage may result if any other venting 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 condition.

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:

• System water piping

• Gas supply piping

• Electrical power

2. - Keep venting areas free of obstructions.

- Keep area clean and free of combustible and ﬂ ammable

materials.

- To avoid a blocked air inlet or blocked ﬂ ue condition,

keep the outdoor air inlet and ﬂ ue outlet clear or leaves, debris, etc.

CAUTION

 CAUTION

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

Do not locate unit so that high winds can deﬂ ect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of ﬂ ue 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.

 CAUTION

CAUTION

 WARNING

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

 WARNING

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.

• This unit is not intended for installations where temperatures may reach below 32°F (0°C). Exposure to freezing temperatures will cause the system and boiler to freeze and leak.

The unit must not be installed in an area that is enclosed by walls or a fence that will block free wind movement around the appliance. Free movement of wind around the outdoor unit is required to carry away the ﬂ ue products and provide combustion air. The ﬂ ue 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 ﬂ ue products into the combustion air inlet. Recirculation of ﬂ ue products may cause operational problems, bad combustion or non-warrantable damage to controls.

Locate the unit at least 3 feet (0.91m) outside any overhang.

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

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

Do not install the unit under a deck.

Do not install the 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 may result in severe personal injury, death or substantial property damage.

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

1 Determine boiler location (continued)

Outdoor Knight XL Installation & Operation Manual

Provide clearances:

Clearances from combustible materials

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

2. Jacket—minimum of 0" from right side and 14" from rear side for proximity from combustible materials.

3. Vent—minimum of 1" from combustible materials.

Clearances for service access

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

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

Recommended service clearances

Front: 30" (762mm) Top: 24" (610mm) Left side: 24" (610mm) Rear: 24" (610mm)

Outdoor vent / air intake location:

 WARNING

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

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

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/ﬂ uorocarbons

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

To prevent recirculation of the ﬂ ue 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 or 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" clearance to 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 the unit at least 10 feet (3.05m) away from any forced inlet.

Multiple unit outdoor installations require 24" (1.22m) 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.

Flooring and foundation

Flooring

The Outdoor Knight XL is approved for installation on combustible ﬂ ooring.

 WARNING

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

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 reﬁ nishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

2 Prepare boiler

Outdoor Knight XL Installation & Operation Manual

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler, remove the parts box.

2. Remove the front door 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 door):

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.

NOTICE

Figure 2-1 Boiler Mounted on Shipping Pallet

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

Install ﬂ ue pipe assembly Models 400 - 601

This unit is provided with all of the necessary venting components. All components must be installed prior to operation.

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

2. Before connecting the vent pipe sections or components, verify that the gasket is seated evenly inside the groove in the female end of the elbow and ﬂ ue adaptor (FIG. 2-2).

3. Remove the provided screws from the vent cover and use them to install the vent strap (FIG. 2-2).

4. Insert the elbow into ﬂ ue adaptor (FIG. 2-2).

 CAUTION

5. Slide the vent pipe through the wall strap and insert it into the elbow (FIG. 2-2).

6. Install the bird screen into the top of the vent.

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 cause tearing of the seal surface which can result in ﬂ ue gas leakage.

Figure 2-2 Install ﬂ ue pipe assembly - Models 400 -

VENT PIPE

ELBOW

601

WALL STRAP AND SCREWS

FLUE ADAPTER

NOTE: VERIFY THAT GASKET IS SEATED EVENLY INSIDE THE GROOVE IN ELBOW AND ADAPTER

IMG00444

. 2

BIRD SCREEN

2 Prepare boiler (continued)

Models 701 - 801

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

2. Before connecting the vent pipe sections or components, verify that the gasket is seated evenly inside the groove in the female end of the elbow and ﬂ ue adapter (FIG. 2-3).

3. Remove the vent cover from the back of the unit as shown in FIG. 2-3.

4. Insert the elbow into the ﬂ ue adapter and tighten the clamp using a 5/16" nut driver (FIG. 2-3).

5. Re-install the vent cover removed in Step 3.

6. Remove the provided screws from the vent cover and use them to install the wall strap (FIG. 2-3).

Outdoor Knight XL Installation & Operation Manual

 CAUTION

7. Slide the vent pipe through the wall strap and insert it into the elbow. Tighten the clamp (FIG. 2-3).

8. Install the termination into the top of the vent and tighten the clamp.

Figure 2-3 Install ﬂ ue pipe assembly - Models 701 - 801

NOTE: VERIFY THAT GASKET IS SEATED EVENLY INSIDE THE GROOVE IN ELBOW AND ADAPTER

VENT

TERMINATION

VENT PIPE

WALL

STRAP

WALL STRAP

SCREWS

ELBOW

IMG00446

CLAMP

VENT COVER

2 Prepare boiler

Gas conversions

Outdoor Knight XL Installation & Operation Manual

 WARNING

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 10 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

For the 400 Model you must install a propane oriﬁ ce to operate the Outdoor Knight XL on propane gas. Verify when installing that the oriﬁ ce size marking matches boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

Models 501 - 801 do not require an oriﬁ ce installation for propane operation, but they will require a valve adjustment.

Model 400

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

2. Remove the three screws securing the venturi to the blower. Note: When separating the venturi from the blower, take care not to damage the O-ring inside the blower (FIG. 2-4).

3. Remove the four star-drive screws securing the gas valve to the venturi (FIG. 2-4).

4. Locate the propane oriﬁ ce disk from the conversion kit bag.Verify that the stamping on the oriﬁ ce disk matches the boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

5. Remove the existing oriﬁ ce from the O-ring in the side of the gas valve and replace it with the oriﬁ ce from the kit. Position and secure the oriﬁ ce in the valve as shown in FIG. 2-4.

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

7. Inspect the O-ring inside the blower. Handle the O-ring with care, do not damage. Reposition the venturi against the blower and replace the screws securing the venturi to the blower (FIG. 2-4).

8. 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.

9. Replace the top and front access covers.

 WARNING

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

 DANGER

Model 400: Inspect the O-ring when the blower is disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Figure 2-4 Installing Propane Oriﬁ ce - Model 400

BLOWER

SCREWS QTY. 4

O-RING

BRASS ORIFICE

VENTURI

SCREWS QTY. 3

GAS VALVE

2 Prepare boiler (continued)

Outdoor Knight XL Installation & Operation Manual

Model 501

1. Remove the top access cover from the unit (Philips Head screwdriver required for removal).

2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-5).

3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-5).

4. After adjustment 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.

5. Replace the top access cover.

 WARNING

Figure 2-5 Gas Valve Adjustment - Model 501

 WARNING

Figure 2-6 Gas Valve Adjustment - Models 601 - 801

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

ALLEN WRENCH

ADJUSTMENT SCREW

Models 601 - 801

1. Remove the top access cover from the unit (Philips Head screwdriver required for removal).

2. Remove the cover on top of the gas valve (FIG. 2-6).

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 601 Model, one and a half (1 1/2) turns on the 701 Model, and one turn on the 801 Model (see FIG. 2-6).

4. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-6).

5. After adjustment 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 gas valve cover along with the top access cover.

Leveling the boiler

1. Set the boiler in place and check level.

a) Adjust legs if necessary to level boiler, see FIG. 2-7 below.

Figure 2-7 Leveling Legs on the Boiler

SCREWDRIVER SLOT

LOWER

RAISE

3 Hydronic piping

Outdoor Knight XL Installation & Operation Manual

System water piping methods

The Outdoor Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). 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 which must be ﬁ gured 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 or 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, ﬂ ow 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

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 ﬂ uid 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 speciﬁ cally 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 below along with illustrations on the following pages (FIG.’s 3-7 through 3-11), which will guide you through the installation of the Outdoor Knight XL (reference FIG.’s 3-4A and 3-4B).

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 backﬂ ow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).

6. Consult the factory for a pump and/or pump cover. If a ﬁ eld-supplied pump is used, install per the manufacturer’s speciﬁ cations in regard to indoor or outdoor location. An outdoor rated pump is recommended.

7. 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.

8. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for speciﬁ c 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 (103 kPa).

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. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

 WARNING

12. On any pre-existing system, it is good practice to install a ﬁ eld supplied strainer to prevent damage to the heat exchanger.

See the piping illustrations included in this section, FIG.’s 3-7 and 3-11 for suggested guidelines in piping the Outdoor Knight XL.

NOTICE

The relief valve, tee and any other necessary

ﬁ ttings are shipped in the install kit with the boiler and are to be ﬁ eld installed (FIG.’s 3-1 and 3-2).

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.

3 Hydronic piping (continued)

Outdoor Knight XL Installation & Operation Manual

Flow switch, relief valve and temperature and pressure gauge installation

Basic steps are listed below to guide you through the installation of the ﬂ ow switch, relief valve, and temperature and pressure gauge provided with the unit.

1. For Models 400 - 501 install the close nipple on the outlet connection of the heat exchanger. Install the tee with the 3/4 inch ﬁ tting positioned vertically and on the top as shown in FIG. 3-1. For Models 601 - 801 install the tee directly to the outlet connection of the heat exchanger with the 3/4 inch ﬁ tting positioned vertically and on the top (see FIG. 3-2).

2. For Models 701 - 801 install the 3/4 inch close nipple in the tee. Install the relief valve on the 3/4 inch close nipple (FIG. 3-2). For Models 400 - 601 install the relief valve directly into the 3/4 inch ﬁ tting on the tee (FIG. 3-1).

3. Install the close nipple on the downstream side of the relief valve tee (FIG. 3-1).

4. Install the tee with the 1 inch ﬁ tting positioned vertically and on the top (FIG. 3-1).

5. Attach paddle #3 to the ﬂ ow switch per the manufacturer’s instructions.

6. Install the assembled ﬂ ow switch into the 1 inch ﬁ tting of the tee installed in Step 4 (see FIG. 3-1).

7. Install a ﬁ eld provided close nipple on the downstream side of the ﬂ ow switch (see FIG.’s 3-1 and 3-2).

8. Install a ﬁ eld provided tee with the gauge ﬁ tting positioned vertically and on the top (FIG.’s 3-1 and 3-2)

9. Install the temperature and pressure gauge provided with the unit into the top ﬁ tting of the tee (a bushing may be necessary) installed in Step 8 (FIG.’s 3-1 and 3-2).

NOTICE

Be sure to install the ﬂ ow switch so that the arrow on the ﬂ ow switch is pointing in the direction of the ﬂ ow (see FIG. 3-3).

Figure 3-1 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 400 - 501

RELIEF VALVE

FLOW SW ITCH

PADDLE

TEMPERATURE &

PRESSURE GAUGE

TEE WITH FITTING

ON TOP

(FIELD PROVIDED)

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 1" FITT ING ON TOP

CLOSE NIPPLE

TEE WITH 3/4"

FITTING ON TOP

8' NIPPLE

(REQUIRED FOR MODELS 400 - 701)

IMG00390

Figure 3-2 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 601 - 801

RELIEF VALVE

FLOW SWI TCH

PADDLE

TEMPERATURE &

PRESSURE GAUGE

TEE WITH FITTING

(FIELD PROVIDED)

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 1" FITTING

ON TOP

CLOSE NIPPLE

TEE WITH 3/4"

FITTING ON TOP

IMG00389

3 Hydronic piping

Outdoor Knight XL Installation & Operation Manual

Flow switch adjustment

Refer to Table 3A for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a Phillips driver until it stops (FIG. 3-3). Proceed to turn the screw counterclockwise the amount of turns listed in Table 3A based on the model.

Consult the manufacturer’s instructions for wiring the ﬂ ow switch to your system.

Table 3A Paddle Size / Sensitivity Screw Adjustment

MODEL PADDLE SIZE

Note: Paddles are included with the ﬂ ow switch.

400 #3 7½ turns 501 #3 5½ turns 601 #3 7¼ turns 701 #3 5¼ turns 801 #3 3¼ turns

NOTICE

Turn the sensitivity screw clockwise to increase the ﬂ ow rate required to activate the switch. Turn the sensitivity screw counterclockwise to decrease the ﬂ ow rate required to activate the switch.

Figure 3-3 Flow Switch Adjustment

SENSITIVITY SCREW

ADJUSTMENT

NORMALLY OPEN

SENSITIVITY ADJUSTMENT

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 3B. Reducing the pipe size can restrict the ﬂ ow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on 20 feet (6 m) of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler system circulating pump:

(Field supplied.) The boiler circulating pump should be based on 20 feet (6 m) of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

3. Domestic hot water circulating pump:

(Field supplied.) The pump MUST be sized to meet the speciﬁ ed minimum ﬂ ow requirements listed in FIG.’s 3-5 and 3-6. Consult the indirect water heater operating guide to determine ﬂ ow characteristics for the selected product used.

4. Variable speed boiler system circulator: Outdoor Knight XL boilers are capable of controlling

a variable speed boiler system circulator. Variable speed circulators MUST be sized to meet the speciﬁ ed minimum ﬂ ow requirements listed in FIG.’s 3-5 and 3-6 on page 16 at full speed.

5. Boiler isolation valves:

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

GROUND

COMMON

NORMALLY CLOSED

6. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 3-7 through 3-11. Failure to install check valves could result in a reverse ﬂ ow condition during pump(s) off cycle.

7. 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 ﬂ ow rate through the boiler.

8. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F (46°C).

9. Unions:

Field supplied. Recommended for unit serviceability.

10. 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.

11. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME speciﬁ cations.

3 Hydronic piping (continued)

Outdoor Knight XL Installation & Operation Manual

12. Boiler purge valve:

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

13. 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. The sensor should be located far enough downstream to sense system diluted water temperature.

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 Knight XL heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graphs in FIG’s 3-5 and 3-6 for pressure drop through the Outdoor Knight XL heat exchanger.

Figure 3-4B Near Boiler Piping w/Low Loss Header

SYSTEM PUMP

LOW LOSS HEADER (TYPICAL)

Y-STRAINER

(RECOMMENDED)

BOILER PUMP

SYSTEM SENSOR

AIR SEPARATOR

DRAIN (TYPICAL)

AIR VENT VALVE

DRAIN VALVE

FAST FILL VALVE

EXPANSION TANK

INDIRECT DOMESTIC HOT WATER TANK

Near boiler piping connections

Figure 3-4A Near Boiler Piping w/Y-Strainer

AIR SEPARATOR

SYSTEM PUMP

SYSTEM SENSOR

Y-STRAINER

(RECOMMENDED)

BOILER PUMP

TO FLOOR DRAIN

DOMESTIC HOT WATER PUMP

IMG00413

INDIRECT DOMESTIC HOT WATER TANK

IMG00391

TO FLOOR DRAIN

Variable speed pump option

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

SMART SYSTEM / Multi-temperature loop control option

The Outdoor Knight XL 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).

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