Lochinvar XL 801, XL 400 User Manual

OKBX-USER Rev A

Outdoor Knight XL

User’s Information Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Outdoor Knight 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

1. PREVENT COMBUSTION AIR CONTAMINATION ..... 4

2. MAINTENANCE SCHEDULE ....................................... 5

Maintenance Procedures ................................................... 6

Boiler Must Be Serviced and Maintained .................... 6

Check Boiler Area ......................................................... 6

Check Pressure Temperature Gauge ........................... 6

Check Vent Piping ........................................................ 6

Check Air Piping ........................................................... 6

Check Relief Valve ....................................................... 6

Check Condensate Drain System ............................. 6-7

Check Air Vents ............................................................ 8

Test Low Water Cutoff (if installed) .............................. 8

Reset Button (low water cutoff) .................................... 8

Check Boiler Piping (gas and water) ............................ 8

Operate Relief Valve .................................................... 8

Shut Boiler Down .......................................................... 8

Hazard definitions

3. OPERATING INSTRUCTIONS ..................................... 9

4. SMART SYSTEM CONTROL MODULE

SMART SYSTEM Control Module ................................... 10

Access Modes ............................................................ 10

Saving Parameters ..................................................... 10

Adjusting Parameters ................................................. 10

Temperature Settings ............................................ 10-11

Status Display Screens ......................................... 12-14

Notes................................................................................ 15

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

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

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

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

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

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

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

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

Please read before proceeding

Outdoor Knight XL User’s Information Manual

NOTICE

 WARNING

The Outdoor Knight Boiler Installation and Operation Manual along with the Outdoor Knight Boiler Service Manual are for use only by a qualified heating installer/service technician. Refer only to this User’s Information Manual for your reference. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury (exposure to hazardous materials) or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instruction before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

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

Consider piping and installation when determining boiler location.

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

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

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

Boiler service and maintenance –

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

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

Boiler operation –

 WARNING

• Do not block flow of combustion or ventilation air to the boiler. This boiler is equipped with a control which will automatically shut down the boiler should air or vent be blocked. If vent or air blockage is easily accessible and removable, remove it. The boiler should attempt to restart. If blockage is not obvious or cannot be removed, have the boiler and system checked by a qualified service technician.

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

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

Do NOT install the appliance where it will be exposed to freezing temperatures.

Boiler water –

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

• 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.

• 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. Leaks in boiler or piping must be repaired at once to prevent makeup water.

Freeze protection fluids –

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

Outdoor Knight XL User’s Information Manual

1 Prevent combustion air contamination

 WARNING

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

Please read the information listed in Table 1. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per the Outdoor Knight Boiler Installation and Operation Manual.

 WARNING

If the boiler combustion air inlet is located in any area likely to cause contamination, or if products which would contaminate the air cannot be removed, you must have the combustion air and vent re-piped and terminated to another location. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death, or substantial property damage.

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1 before installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

Table 1 Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

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

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

2 Maintenance schedule

Outdoor Knight XL User’s Information Manual

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and fill with fresh water

• Check for leaks (water, gas, flue, condensate)

• Verify flue and air passage ways in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and flame sense electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

ANNUAL START-UP

• Perform start-up checkout and performance verification per Section 10.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high fire)

• Clean the heat exchanger if flue temperature is more than 54°F (30°C) above return water temperature.

If combustion or performance indicate need:

Owner maintenance

(see the Outdoor Knight XL User’s Information

Manual for instructions)

• Check boiler area

Daily

• Check pressure/temperature gauge

• Check air and vent termination

Monthly

Periodically

Every

6 months

screens

• Check relief valve

• Check condensate drain system

• Test low water cutoff (if used)

• Reset button (low water cutoff)

• Check boiler piping (gas and water) for leaks

• Operate relief valve

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

 WARNING

Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the boiler or system, resulting in severe personal injury, death, or substantial property damage.

End

of season

months

• Shut boiler down (unless boiler used for domestic hot water)

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