Lochinvar OKN400, OKN501, OKN601, OKN701, OKN801 Installation Manual

OKBX-I-O_100161604_2000015636_Rev J

Outdoor Knight XL

Installation & Operation Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

 is manual must only be used by a quali 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

 e following de 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 –  is 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 quali 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  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  re or explosion may result causing property damage, personal injury or loss of life.

 is appliance MUST NOT be installed in any location where gasoline or  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  re department.

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

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

Boiler operation –

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

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

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

Boiler water –

•  oroughly  ush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment.  e high e ciency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

• 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.  is 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 speci cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Outdoor Knight XL Installation & Operation Manual

The Outdoor Knight XL - How it works...

1. Stainless steel heat exchanger

Allows system water to  ow through specially designed coils for maximum heat transfer, while providing protection against  ue gas corrosion.  e 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

 e 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

 e gas valve senses the negative pressure created by the blower, allowing gas to  ow only if the gas valve is powered and combustion air is  owing.

5. Venturi

 e venturi controls air and gas  ow into the burner.

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

 is sensor monitors the  ue gas exit temperature.  e control module will modulate and shut down the boiler if the  ue gas temperature gets too hot.  is protects the  ue pipe from overheating.

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

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

8. Boiler inlet temperature sensor

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

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

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

10. Electronic LCD display

 e 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  ber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of  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

 readed pipe connection of 1".  is pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

16. SMART SYSTEM Control Module

 e 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

 e 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

 e 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

 e quartz glass window provides a view of the burner surface and  ame.

28. Gas shuto 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.  e 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  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.  is is needed for the proper draining of the condensate from the combustion chamber.

35. Air shroud (Model 501 only)

 e air shroud controls air and gas  ow into the burner.

36. Air pressure switch

 e air pressure switch detects blocked  ue/inlet conditions. break the control circuit, shutting the boiler down.

37. Pump relay board

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

38. Transformer (not shown)

 e 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  ue connection exceeds 604°F (318°C).  is 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  ue collar with  ue sensor.

42. Flow switch

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

43. Burner door temperature switch

An electrical switch designed to shut down boiler operation in the event the combustion chamber access cover exceeds 500°F (260°C).  is switch may only be reset by a quali ed boiler service technician AFTER the underlying cause has been identi ed and corrected. Check the integrity of the front refractory on the inside of the combustion chamber access cover if the switch opens.

Outdoor Knight XL Installation & Operation Manual

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

Model 400

Front View - Model 400

IMG00405

IMG00406

Rear View - Model 400

IMG00407

Left Side (inside unit) - Model 400

Right Side (inside unit) - Model 400

Outdoor Knight XL Installation & Operation Manual

The Outdoor Knight XL - How it works...

Model 501

Rear View - Model 501

Models 601 - 801

IMG00408

IMG00409

Left Side (inside unit) - Model 501

Rear View - Models 601 - 801

IMG00324

Left Side (inside unit) - Models 601 - 801

IMG00324

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.  e 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 su 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.  e boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

4. Ratings have been con 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.  e manual reset high limit provided with the Outdoor Knight XL is listed to UL353.

Outdoor Knight XL 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

Table 1A - Ambient Temperature

Model Kit Number

OK 151/211 OA 151/200

OK/OA 286 100157672 5°F

OK/OA

501 - 801

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  ammable

materials.

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

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

 e Outdoor Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests speci 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. Consult the manufacturer

(and see Table 1A below) for an optional condensate trap kit recommended for areas which may experience temperatures below 32°F. Note:  is condensate option is only available for Models OK 151 - 286 and 501 - 801.

Model OK 400 is NOT suitable for installation in areas which may experience temperatures below 32°F.

Requirements

Minimum Allowable

Ambient Temperature

100157671 5°F

100157673

10°F (OK/OA 501)

5°F (OK/OA 601 - 801)

CAUTION

 CAUTION

CAUTION

 WARNING

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

• Debris le from existing piping, if not  ushed and cleaned with an appropriate cleaner.

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 de ect o of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of  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 a ecting performance.

 e 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  ue products and provide combustion air.  e  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  ue products into the combustion air inlet. Recirculation of  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 runo 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  ammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

1 Determine boiler location (continued)

•  is 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.

5. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1B). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

 WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B). Failure to comply could result in severe personal injury, death, or substantial property damage.

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) Le side: 24" (610mm) Rear: 24" (610mm)

Outdoor vent / air intake location:

 WARNING

To prevent recirculation of the  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.

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

Flooring and foundation

Flooring

 e Outdoor Knight XL is approved for installation on combustible  ooring.

 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  ooding is possible, elevate the boiler su 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 1B for products and areas which may cause contaminated combustion air.

Table 1B Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/ uorocarbons Permanent wave solutions Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals Calcium chloride used for thawing

Sodium chloride used for water so ening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric so eners 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 re nishing areas and establishments New building construction Remodeling areas

Garages with workshops

Outdoor Knight XL Installation & Operation Manual

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

2 Prepare boiler

Outdoor Knight XL Installation & Operation Manual

Remove boiler from wood pallet

1. A er 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 (a er 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  oor or pallet. Damage to the boiler can result.

Install ﬂ ue pipe assembly Models 400 - 601

 is 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  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  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  ue gas leakage.

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

. 2

601

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  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  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

2 Prepare boiler

Gas conversions

Outdoor Knight XL Installation & Operation Manual

 WARNING

For a boiler already installed, you must turn o gas supply, turn o power and allow boiler to cool before proceeding. You must also completely test the boiler a er 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 ori ce to operate the Outdoor Knight XL on propane gas. Verify when installing that the ori ce size marking matches boiler size (Model 400 - 8.0 LP ori ce stamping).

Models 501 - 801 do not require an ori 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 ori ce disk from the conversion kit bag.Verify that the stamping on the ori ce disk matches the boiler size (Model 400 - 8.0 LP ori ce stamping).

5. Remove the existing ori ce from the O-ring in the side of the gas valve and replace it with the ori ce from the kit. Position and secure the ori 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. A er 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 le side of the unit in the lower le corner.

9. Replace the top and front access covers.

 WARNING

A er 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.  e 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.  en 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. A er 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 le side of the unit in the lower le 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 CO of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-6).

5. A er 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 le side of the unit in the lower le corner.

6. Replace the gas valve cover along with the top access cover.

is within the range

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

Outdoor Knight XL Installation & Operation Manual

3 Hydronic piping

System water piping methods

 e Outdoor Knight XL is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa) (Nonmetallic system piping must have an oxygen barrier to be considered a closed loop). 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  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 cuto device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units,  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.  is includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system  uid is correct for the glycol concentration and inhibitor level.  e 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 speci 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 shuto valve and drain on system return to purge air out of each zone.

4. Install a back 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  eld-supplied pump is used, install per the manufacturer’s speci 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 speci 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:  e boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi (103 kPa).

11.  is 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. Install a  eld supplied strainer to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre-existing system, a strainer/ lter capable of removing debris le in the system is recommended.

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

 e relief valve, tee and any other necessary  ttings are shipped in the install kit with the boiler and are to be  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  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  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  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  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  tting positioned vertically and on the top (FIG. 3-1).

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

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

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

8. Install a  eld provided tee with the gauge  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  tting of the tee (a bushing may be necessary) installed in Step 8 (FIG.’s 3-1 and 3-2).

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

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

NOTICE

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

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  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  ow rate required to activate the switch. Turn the sensitivity screw counterclockwise to decrease the  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  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.)  e 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.)  e pump MUST be sized to meet the speci ed minimum  ow requirements listed in FIG.’s 3-5 and 3-6. Consult the indirect water heater operating guide to determine  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 speci ed minimum  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  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  ow condition during pump(s) o 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  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.  e 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.  e pressure relief valve is sized to ASME speci cations.

3 Hydronic piping (continued)

Outdoor Knight XL Installation & Operation Manual

12. Boiler purge valve:

Field supplied.  e 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.  e sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction.  e sensor should be located far enough downstream to sense system diluted water temperature.

14. Water Meter:

Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.

15. Y-Strainer:

Field supplied. Install a Y-strainer or equivalent multi purpose strainer just before the boiler pump at the inlet of the heat exchanger.  is item is used to remove system debris from older hydronic systems and to protect newer systems.

Circulator sizing

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

WATER METER

FAST FILL VALVE

EXPANSION TANK

INDIRECT DOMESTIC

HOT WATER

TANK

LOW LOSS HEADER (TYPICAL)

Y-STRAINER

FLOW CHECK

VALVE

BOILER PUMP

SYSTEM PUMP

SYSTEM SENSOR

AIR SEPARATOR

DRAIN (TYPICAL)

AIR VENT VALVE

DRAIN VALVE

 e 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.

Near boiler piping connections

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

WATER

SYSTEM SENSOR

AIR SEPARATOR

SYSTEM PUMP

BOILER PUMP

METER

Y-STRAINER

DOMESTIC HOT WATER PUMP

DIR #2000548018 00

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR DRAIN

DIR #2000547995 00

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

 e Outdoor Knight XL boiler is capable of producing up to three (3) set point temperatures to meet di erent 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 o ers the MultiTemperature Loop Control Board Kit (100167843).

0 5 10 15 20 25 30 35 40 45

KBN501

KBN400

0 102030405060708090

KBN801

KBN701

KBN601

3 Hydronic piping

Figure 3-5 Pressure Drop vs. Flow - Models 400 and 501

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Pressure Drop (Feet of Head)

Flow Rate (GPM)

Outdoor Knight XL Installation & Operation Manual

O O

Figure 3-6 Pressure Drop vs. Flow - Models 601 thru 801

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Pressure Drop (Feet of Head)

Flow Rate (GPM)

Table 3B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F

Model

400 1 1/2" 37 21 30 14 26 11 21 8

501 1 1/2" 46 23 37 16 32 13 26 10

601 2" 55 31 44 22 38 18 32 13

701 2" 65 30 52 20 45 16 37 11

801 2" 74 33 60 23 51 18 42 12

MINIMUM

PIPE SIZE

TEMPERATURE RISE APPLICATIONS

20°F 25°F 30°F 35°F

GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD

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