Life is good 42LM670S Flat Panel Television Service manual

OKBX-I-O Rev B

Outdoor Knight XL

Installation & Operation Manual

Models: 400 - 801

 WARNING

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.

Save this manual for future reference.

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.

2

Outdoor Knight XL Installation & Operation

Manual

Please read before proceeding

 WARNING

Installer – Read all instructions, including

When servicing boiler –

this manual and the Outdoor Knight XL

Service Manual, before installing. Perform

• To avoid electric shock, disconnect electrical supply steps in the order given.

before performing maintenance.

NOTICE

User – This manual is for use only by

a qualified heating installer/service technician. Refer to the User’s Information

Manual for your reference.

• To avoid severe burns, allow boiler to cool before

Boiler operation –

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

• Do not block fl ow of combustion or ventilation air to

the boiler.

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

• 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.

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.

• 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.

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

 WARNING

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

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.

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

• 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.

 WARNING

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.





CAUTION

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.

performed by a qualifi ed installer,

service agency, or the gas supplier.

3


Manual

The Outdoor Knight XL - How it works...

1. Stainless steel heat exchanger

Allows system water to fl ow through specially designed coils for maximum heat transfer, while providing protection 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.

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.

inlet

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

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.

4

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

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 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 exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.

40.

Over-temp switch (located underneath vent cover - 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.

42.

Vent Cover

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

Flow switch

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.


Manual


(continued)

Model 400

32

31

19

10

IMG00404

IMG00405

11

25

Front View - Model 400 Rear View - Model 400

20

22

4

33

20

36

26

8

4

39

7

39

13

21

24

Left Side (inside unit) - Model 400

IMG00406

30 2

27

IMG00407

Right Side (inside unit) - Model 400

17

34

3

1

37

16

5


Manual


Model 501

15

32

35

19

33

15

28

17

4

41

IMG00408

Rear View - Model 501

Models 601 - 801

31

23

15

11

41

Rear View - Models 601 - 801

6

29

7

39

Left Side (inside unit) - Model 501

IMG00409

20

16

22

3

5

18

4

29

8

18

14

IMG00323

1

34

IMG00324

21

IMG00324

24

Left Side (inside unit) - Models 601 - 801

2

30

10


Manual

Ratings

Outdoor Knight XL Boiler

AHRI Rating

Model Number

Input

MBH

Note: Change “N” to

(Note 4)

“L” for L.P. gas models.

Min Max

OKN400 80 399

OKN501

OKN601

OKN701

OKN801

100

120

140

160

500

600

700

800

463

566

658

748

Gross

Output

MBH

(Note 1)

370

402

493

572

651

Net

AHRI

Ratings

Water,

MBH

(Note 2)

322

Other Specifi cations

Boiler Water

Content

Gallons

Water

Connections

Gas

Connections

Air Size

NOTICE

Maximum allowed working pressure is located on the rating plate.

3.4

4.2

4.2

5.0

5.7

1-1/2"

1-1/2"

2"

2"

2"

1"

1"

1"

1"

1"

4"

4"

4"

4"

4"

Notes:

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

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.

7


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

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.

 WARNING

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

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.



CAUTION

8

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

 WARNING

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.

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

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.

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.


Manual

1

Determine boiler location

(continued)

Provide clearances:

Clearances from combustible materials

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

2. 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.

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

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.

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

Recommended service clearances

Front: 30" (762mm)

Top: 24" (610mm)

Left side: 24" (610mm)

Rear: 24" (610mm)

Products to avoid:

Spray cans containing chloro/fl uorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Outdoor vent / air intake location:

Chlorine-based swimming pool chemicals

 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.

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

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.

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

Flooring and foundation

Flooring

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

Furniture refi nishing areas and establishments

New building construction

Remodeling areas

 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.

Garages with workshops

9


Manual

2

Prepare boiler

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

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

Figure 2-1 Boiler Mounted on Shipping Pallet

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

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.

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.

. 2

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

601

WALL STRAP

AND SCREWS

BIRD SCREEN

VENT PIPE

ELBOW

IMG00444

FLUE

ADAPTER

NOTE: VERIFY THAT GASKET IS SEATED EVENLY

INSIDE THE GROOVE IN ELBOW AND ADAPTER

10

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).

 CAUTION

Do NOT use grease or other lubricant on the vent seals. Only water may be used for this purpose. Grease or other lubricant can make the seal brittle or cause tearing of the seal surface which can result in fl ue gas leakage.

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

ELBOW

WALL STRAP

SCREWS

CLAMP

VENT COVER

IMG00446


Manual

11


Manual

2

Prepare boiler

Gas conversions

 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).

 WARNING

 DANGER

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.

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

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

O-RING

VENTURI

SCREWS

QTY. 3

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.

SCREWS

QTY. 4

O-RING

BRASS ORIFICE

GAS VALVE

12


Manual

2

Prepare boiler

(continued)

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).

 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.

3. Use a combustion analyzer to verify CO

2

is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO

2

and clockwise to lower CO

2

(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

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.

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

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

Figure 2-5 Gas Valve Adjustment - Model 501

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

2

is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO

2

and clockwise to lower CO

2

(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

RAISE

LOWER

13


Manual

3

Hydronic piping

System water piping methods General piping information

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.

14

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.

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

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).

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

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.


Manual

3

Hydronic piping

(continued)

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.

Figure 3-1 Flow Switch, Relief Valve and Temperature and

Pressure Gauge Installation_Models 400 - 501

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

RELIEF VALVE

FLOW SWITCH

PADDLE

TEMPERATURE &

PRESSURE GAUGE

TEE WITH FITTING

ON TOP

(FIELD PROVIDED)

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).

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 1" FITTING ON TOP

CLOSE NIPPLE

TEE WITH 3/4"

FITTING ON TOP

IMG00390

8' NIPPLE

(REQUIRED FOR MODELS 400 - 701)

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

Figure 3-2 Flow Switch, Relief Valve and Temperature and

Pressure Gauge Installation_Models 601 - 801

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

RELIEF VALVE 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).

FLOW SWITCH

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

15


Manual

3

Hydronic piping

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

SENSITIVITY SCREW

ADJUSTMENT

Note: Paddles are included with the fl ow switch.

400

501

601

701

801

#3

#3

#3

#3

#3

7½ turns

5½ turns

7¼ turns

5¼ turns

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.

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

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.

Figure 3-3 Flow Switch Adjustment

NORMALLY

OPEN

SENSITIVITY

ADJUSTMENT

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

16

COMMON

NORMALLY

CLOSED

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

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

11. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to


Manual

3

Hydronic piping

(continued)

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.

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

SYSTEM PUMP

SYSTEM SENSOR

AIR SEPARATOR

DRAIN

(TYPICAL)

AIR VENT VALVE

LOW LOSS HEADER

(TYPICAL)

TO

SY

ST

EM

FR

OM

SY

ST

EM

FAST FILL VALVE

EXPANSION TANK

Y-STRAINER

(RECOMMENDED)

DRAIN

VALVE

FR

OM

INDIRECT

DOMESTIC

HOT WATER

TANK

TO

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.

Near boiler piping connections

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

FR

OM

SY

ST

EM

SYSTEM SENSOR

AIR SEPARATOR

SYSTEM PUMP

DOMESTIC HOT

WATER PUMP

FR

OM

TO

INDIRECT

DOMESTIC

HOT WATER

TANK

BOILER PUMP

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

TO

EM

SY

ST

Y-STRAINER

(RECOMMENDED)

BOILER PUMP

TO FLOOR

DRAIN

IMG00413

- 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 Multi-

Temperature Loop Control Board Kit (RLY30086).

17

3

Hydronic piping

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

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

8

6

4

2

0

0

20

18

16

14

12

10

5 10 15 20 25

Flow Rate (GPM)

30 35 40


Manual

45

O KBN501

O KBN400

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

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

60

50

40

30

20

O KBN801

O KBN701

O KBN601

10

0

0 10 20 30 40 50 60

Flow Rate (GPM)

70 80 90

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

TEMPERATURE RISE APPLICATIONS

20°F 25°F 30°F

Model

MINIMUM

PIPE

SIZE

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

400

501

601

701

801

18

1 1/2"

1 1/2"

2"

2"

2"

37

46

55

65

74

21

23

31

30

33

30

37

44

52

60

14

16

22

20

23

26

32

38

45

51

11

13

18

16

18

GPM

21

26

32

37

42

35°F

FT/HD

8

10

13

11

12


Manual

3

Hydronic piping

(continued)

Figure 3-7 Single Boiler - Multiple Temperatures

TEMPERATURE

LOOP 1

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 3

LOOP SENSOR (3X)

MAKE UP WATER

AIR SEPARATOR

PRESSURE

GAUGE

BACK FLOW

PREVENTER

WIRES TO LOOP SENSORS

120VAC

TO PUMPS

TO

SYSTEM

FROM

SYSTEM

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

24V SIGNAL TO

MIXING VALVES

BALL VALVE

(TYPICAL)

PRESSURE

REDUCING

VALVE

EXPANSION

TANK

INDIRECT DHW

TANK

PRESSURE

RELIEF

VALVE

HOT WATER OUT

ANTI-SCALD

MIXING VALVE

COLD WATER IN

DOMESTIC

HOT WATER

CIRCULATOR

UNION (TYPICAL)

Y-STRAINER (RECOMMENDED)

FLOW CHECK VALVE

(TYPICAL)

BOILER CIRCULATOR

SHIELDED CABLE

TO BOILER CONTROL

BOILER

IMG00392

Mixing valves are required for the protection of low temperature loops.

CAUTION

NOTICE


Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

19


Manual

3

Hydronic piping

Figure 3-8 Single Boiler - Primary/Secondary Piping

AIR SEPARATOR

DRAIN POINT

(TYPICAL)

SYSTEM SUPPLY SENSOR

(WHEN USED)

SYSTEM CIRCULATOR

MAY SUBSTITUTE

LOW LOSS HEADER

FR

OM

SY

ST

EM

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BALL VALVE

(TYPICAL)

EXPANSION TANK

TO

SY

ST

EM

MAKE UP WATER

BACK FLOW

PREVENTER

PRESSURE REDUCING

VALVE

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

HOT WATER OUT

DOMESTIC

HOT WATER

CIRCULATOR

COLD WATER IN

FLOW CHECK

VALVE (TYPICAL)

UNION (TYPICAL)

Y-STRAINER

(RECOMMENDED)

BOILER CIRCULATOR

BOILER

DRAIN

PRESSURE RELIEF

VALVE

IMG00393

CAUTION

NOTICE

NOTICE

NOTICE

20

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not not exceed indirect water heater transfer capabilities.


System fl ow should always remain higher than the required fl ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.



Manual

3

Hydronic piping

(continued)

Figure 3-9 Multiple Boilers - Multiple Temperatures

Number of Units

Model

2 3 4 5 6 7 8

Manifold Pipe Sizes in Inches (mm)

400

2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

501 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)

601

3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

701

3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

801 4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

WIRES TO

LOOP SENSORS

TEMPERATURE

LOOP 3

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 1

LOOP SENSOR (3X)

AIR SEPARATOR

MAKE UP WATER

BALL VALVE

(TYPICAL)

120VAC

TO PUMPS

TO

SYSTEM

FROM

SYSTEM

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

24V SIGNAL TO

MIXING VALVES

SHIELDED CABLE

TO BOILER CONTROL

Y-STRAINER

(RECOMMENDED)

FLOW CHECK

VALVE (TYPICAL)

BACK FLOW

PREVETER

PRESSURE

GAUGE

DRAIN POINT

(TYPICAL)

EXPANSION

TANK

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

COLD WATER IN

DOMESTIC

HOT WATER

CIRCULATOR

PRESSURE

RELIEF

VALVE

UNION (TYPICAL)

BOILER 1

BOILER 2

TEMPERATURE/PRESSURE

GAUGE

BOILER CIRCULATOR

IMG00394

CAUTION

CAUTION



NOTICE



21

NOTICE


Manual

3

Hydronic piping

Figure 3-10 Multiple Boilers - Primary/Secondary Piping

Number of Units

Model

2 3 4 5 6 7 8

Manifold Pipe Sizes in Inches (mm)

400 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

501

3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)

601 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

701

3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

801 4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

MAY SUBSTITUTE

LOW LOSS HEADER

AIR SEPARATOR

DRAIN POINT

(TYPICAL)

SYSTEM SUPPLY SENSOR

(WHEN USED)

SYSTEM CIRCULATOR

MAKE UP WATER

BALL VALVE

(TYPICAL)

FR

OM

SY

ST

EM

NO

T T

O

EX

CE

ED

4

PI

PE

DI

A

OR

M

AX

. O

F 1

2"

AP

AR

T

Y-STRAINER

(TYPICAL)

(RECOMMENDED)

TO

SY

ST

EM

BACK FLOW

PREVENTER

PRESSURE REDUCING

VALVE

PRESSURE GAUGE

INDIRECT DHW

TANK

ANTI-SCALD

MIXING VALVE

HOT WATER OUT

DOMESTIC

HOT WATER

CIRCULATOR

COLD WATER IN

FLOW CHECK

VALVE (TYPICAL)

EXPANSION

TANK

BOILER CIRCULATOR

(TYPICAL)

UNION (TYPICAL)

BOILER 2

(MEMBER 1)

BOILER 1

(LEADER)

PRESSURE RELIEF

VALVE

DRAIN

TEMPERATURE /

PRESSURE GAUGE

BOILER 3

(MEMBER 2)

BOILER 4

(MEMBER 3)

IMG00417

CAUTION

NOTICE

NOTICE



System fl ow should always remain higher than the required fl ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.


NOTICE

22


Manual

3

Hydronic piping

(continued)

Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone

TEMPERATURE

LOOP 1

LOOP SENSOR (3X)

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 3

MAKE UP WATER

AIR SEPARATOR

BACK FLOW

PREVENTER

PRESSURE

GAUGE

BALL VALVE

(TYPICAL)

PRESSURE

REDUCING

VALVE

DRAIN POINT

(TYPICAL)

EXPANSION

TANK

INDIRECT DHW

TANK

HOT WATER OUT

ANTI-SCALD

MIXING VALVE

COLD WATER IN

DOMESTIC

HOT WATER

CIRCULATOR

PRESSURE RELIEF

VALVE

UNION (TYPICAL)

DRAIN

TEMPERATURE / PRESSURE

GAUGE

WIRES TO

LOOP SENSORS

120VAC TO

PUMPS

TO

SYSTEM

FROM

SYSTEM

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

Y-STRAINER

(RECOMMENDED)

24VAC SIGNAL

TO MIXING VALVES

FLOW CHECK

VALVE (TYPICAL)

BOILER CIRCULATOR

SHIELDED CABLE

TO BOILER CONTROL

BOILER

IMG00412

CAUTION

CAUTION



NOTICE


Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

NOTICE


NOTICE

23


Manual

4

Gas connections

Connecting gas supply piping

1. Remove the top access panel and refer to FIG.’s 4-1 thru

4-3 to pipe gas to the boiler.

a. Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements.

2. Install sediment trap / drip leg.

Figure 4-1 Gas Supply Piping - Model 400

Figure 4-3 Gas Supply Piping - Models 601 - 801

GAS SUPPLY

MANUAL SHUTOFF VALVE

(FACTORY SUPPLIED)

UNION

GAS SUPPLY

IMG00328

SEDIMENT TRAP

/ DRIP LEG

SEDIMENT TRAP /

DRIP LEG

MANUAL

SHUTOFF

VALVE

(FIELD SUPPLIED)

IMG00411

Figure 4-2 Gas Supply Piping - Model 501

UNION

(FACTORY INSTALLED)

GAS SUPPLY

3. Support piping with hangers, not by the boiler or its accessories.

 WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks.

a. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG

(3.5 kPa).

b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG

SEDIMENT TRAP/

DRIP LEG

MANUAL

SHUTOFF VALVE

(FACTORY SUPPLIED)

IMG00410 c. The appliance and its gas connection must be leak tested before placing it in operation.

 WARNING

Do not check for gas leaks with an open fl ame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas fl ow.

24


Manual

4

Gas connections

(continued)

 WARNING

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

 WARNING

Use two wrenches when tightening gas piping at boiler (FIG. 4-4), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Figure 4-4 Inlet Pipe with Backup Wrench

NOTICE

USE BACKUP WRENCH

TO PREVENT PIPE FROM

ROTATING

IMG00420

Maximum inlet gas pressure must not exceed the value specifi ed. Minimum value listed is for the purposes of input adjustment.

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 4A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).

a. Table 4A is only for natural gas with specifi c gravity

0.60 inches, with a pressure drop through the gas piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.5 kPa) with no fl ow

(lockup) or with boiler on.

• Minimum 4 inches w.c. (.99 kPa) with gas fl owing (verify

during boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa) maximum.

Propane Gas:

 WARNING

Outdoor Knight XL boilers are typically shipped ready to fi re on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifi ce or by making a gas valve adjustment

(see page 12). In order to operate on LP gas, an orifi ce MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. (3.2 kPa) maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.2 kPa) with no fl ow (lockup)

or with boiler on.

• Minimum 8 inches w.c. (1.9 kPa) with gas fl owing (verify

during boiler startup).

 WARNING

Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the appliance.

25


Manual

4

Gas connections

Table 4A Natural Gas Pipe Size Chart

Nominal

Iron Pipe

Size

(inches)

10 20 30 40

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet

50 60 70 80 90 100 125 150 175 200

1/2

3/4

1

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

369 256 205 174 155 141 128 121 113 106 95 86 79 74

697 477 384 328 292 267 246 236 210 200 179 164 149 138

1-1/4

1400 974 789 677 595 543 502 472 441 410 369 333 308 287

1-1/2

2150 1500 1210 1020 923 830 769 707 666 636 564 513 472 441

2 4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820

2-1/2 6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300

3

4

11200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340

23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720

Maximum

Capacity of Pipe in Thousands of

Btu/hr per hour for gas pressures of 14 Inches

Water Column

(0.5 PSIG) or less and a pressure drop of 0.5 Inch

Water Column

(Based on NAT

GAS, 1025 Btu/ hr per Cubic Foot of Gas and 0.60

Specifi c Gravity)

Check inlet gas supply

NOTICE

CSA or UL listed fl exible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fi re at full rate. Consult with local codes for proper installation or service procedures.

 WARNING

DO NOT adjust gas valve outlet pressure.

Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

The gas piping must be sized for the proper fl ow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c.

(249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

3. On Models 400 - 501 loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. On

Models 601 - 801 remove the 1/8" (3 mm) pipe plug on the fi tting (fi eld supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the set screw is loosened or the 1/8" (3 mm) fi tting is installed

(depending on model) as shown in FIG.’s 4-5 thru 4-7 on

4. Slowly turn on the gas supply at the fi eld installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner fi res at

100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within specifi ed range.

Minimum and maximum gas supply pressures are

specifi ed in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualifi ed installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. On Models 400 - 501 re-tighten the set screw inside the pressure tap. On Models 601 - 801 remove the 1/8" (3 mm) fi eld supplied fi tting and reinstall the pipe plug removed in Step 3.

26


Manual

4

Gas connections

(continued)

 WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open fl ame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and fl ame characteristics.

Figure 4-5 Inlet Gas Supply Check - Model 400

LOOSEN THE SET SCREW ONE (1) FULL TURN

AND PLACE THE MANOMETER TUBING OVER

THE PRESSURE TAP

Figure 4-7 Inlet Gas Supply Check - Models 601 - 801

REMOVE THE 1/8” (3 MM) PIPE PLUG ON

THE INLET FLANGE TO THE VALVE AND

INSTALL A SUITABLE 1/8” (3 MM) FITTING

(FIELD SUPPLIED) FOR THE MANOMETER

TUBING.

DETAIL

IMG00414

Figure 4-6 Inlet Gas Supply Check - Model 501

LOOSEN THE SET SCREW ONE (1) FULL TURN

AND PLACE THE MANOMETER TUBING OVER

THE PRESSURE TAP

IMG00415

DETAIL

DETAIL

Gas pressure

The gas pressure must remain between 4 inches w.c. (.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for

Natural gas and between 8 inches w.c. (1.9 kPa) minimum and 14 inches w.c. (3.2 kPa) maximum for LP gas during standby (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet (3 m) from the Outdoor Knight XL boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a fl anged connection to the venturi and blower.

 WARNING

Failure to follow all precautions could result in fi re, explosion, or death!

 WARNING


Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

27


Manual

5

Field wiring

 WARNING

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

NOTICE

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code

ANSI/NFPA 70 – latest edition.

Ensure that all wiring external to the unit is enclosed in approved conduit.

 CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Figure 5-1 Line Voltage Field Wiring Connections

120V SUPPLY

NEUTRAL

W

GROUND

G

LINE

BK

SERVICE

SWITCH

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

Line voltage connections

1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG.5-1.

2. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code (see

FIG. 5-1).

3. When connecting a domestic hot water (DHW) pump, connect the wiring to the line voltage terminal strip as shown in FIG. 5-1.

4. To activate a system pump, wire as shown in FIG. 5-1. Dry contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 5-2.

2. Connect low voltage wiring to the low voltage connection board as shown in FIG. 5-3 on page 29 of this manual and the boiler wiring diagram.

Figure 5-2 Routing Field Wiring

LOW VOLTAGE

CONNECTION

BOARD

LINE VOLTAGE

JUNCTION BOX

SYSTEM

PUMP

BK

G

W

LOW VOLTAGE

WIRING

KNOCKOUT

PLUGS

BOILER

PUMP

BK

G

W

IMG00329

LINE VOLTAGE

WIRING KNOCKOUT

PLUGS

DOMESTIC

HOT WATER

PUMP

BK

G

W

L2/N G L1

28


Manual

5

Field wiring

(continued)

Thermostat

1. Connect the room thermostats or end switches (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in

FIG. 5-3.

If TST20015 is not compatible with the indirect tank, a tank thermostat can be used to control the boiler. The tank thermostat should be installed per the manufacturer’s instructions and wired to the DHW Thermostat terminals on

2. Install the thermostat on the inside wall away from infl uences of drafts, hot or cold water pipes, lighting fi xtures, television, sunlight, or fi replaces.

3. Thermostat anticipator (if applicable): a. If connected directly to boiler, set for 0.1 amps.

b. If connected to relays or other devices, set to match total electrical power requirements of connected devices. See device manufacturers’ specifi cations and thermostat instructions for details.

the low voltage connection board (FIG. 5-3).

High gas pressure switch

1. If a switch is provided to detect excessive gas pressure, remove the jumper wire from the terminals on the connection board, and then connect them to its normally closed contacts (FIG. 5-3).

Low gas pressure switch

Outdoor temperature sensor

1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts

(FIG. 5-3).

1. Mount the sensor on an exterior wall, shielded from direct sunlight or fl ow of heat or cooling from other sources.

2. Route sensor wires through a knockout at the rear of the boiler (see FIG. 5-2).

3. Connect the outdoor temperature sensor (FIG. 5-3) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Outdoor Knight

XL. If fi xed temperature operation is required, do not install outdoor sensor.

2. If both a high and low gas pressure switch is used, connect their respective contacts in series, and connect them to the terminals on the connection board (FIG. 5-3).

Variable speed system pump

If a variable speed pump is used in the primary loop, and a 0-10V signal is available from the pump speed control, this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load. By connecting this

DHW (Domestic Hot Water) thermostat

0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler

(or cascade) can modulate up and down as the primary fl ow increases and decreases.

Connect storage indirect water heater (DHW) thermostat

Boiler pump speed output

(FIG. 5-3) to the DHW thermostat terminals on the connection board. If a tank sensor is connected (see DHW

This 0 - 10V output is available to control the speed of a variable

Tank Sensor below) the tank thermostat is ignored.

speed boiler pump. The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum T across

DHW tank sensor

the heat exchanger, as well as prevent high limit lockouts when the fl ow in the primary loop is extremely low. Connect this

By installing a tank sensor, the SMART SYSTEM control can output to the 0 - 10V input on the boiler pump speed control.

perform the tank thermostat function. The SMART SYSTEM control automatically detects the presence of this sensor, and generates a DHW call for heat when the tank temperature

Rate output

drops 6°F (3°C) below the tank set point, and fi nishes the call

This output provides a 0 - 10V signal that is proportional to the for heat when the tank temperature reaches the tank set point.

fi ring rate of the boiler. This may be used by a BMS system to

The tank sensor included with the Lochinvar Squire® indirect monitor the actual rate of the boiler.

DHW tanks (TST20015) is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals on the low voltage connection board (FIG. 5-3).

 WARNING

Failure to use the correct sensor may result in the tank temperature being either above or below the set point.

29


Manual

5

Field wiring

ModBus

When the optional ModBus interface module is installed, the

RS-485 ModBus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus interface module.

Flow switch

before allowing it to fi re. The fl ow switch must be installed at the boiler outlet.

Alarm contacts

The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off.

This can be used to turn on an alarm, or signal a Building

Management System that the boiler is down.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See page 36 “Confi guration of the

Cascade” for a detailed explanation of this procedure.

2. Remove the jumper wire from the terminals on the connection board and connect these terminals to the normally open contacts on the fl ow switch (FIG. 5-3).

System supply sensor

1. By installing the system supply sensor into the supply of the primary loop, the temperature of the system supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler fi ring rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected).

See the Outdoor Knight XL Service Manual for instructions on how to use the inlet sensor as the controlling sensor.

When the inlet sensor is programmed as the controlling sensor, it is vital that the SYSTEM SUPPLY sensor be installed. DO NOT INSTALL THE SYSTEM SUPPLY

SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be used for the system sensor.

Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop (FIG.’s 3-7 through 3-11). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG. 5-3). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 5-3). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters. If the outdoor air sensor is not connected, the Leader control will maintain the fi xed water temperature set point that is programmed into the control.

3. Connect these terminals to the system supply sensor

(FIG. 5-3).

Boiler management system

1. An external control may be connected to control either the fi ring rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the heat/loop demand 1 terminals.

Otherwise, the SMART SYSTEM control will be enabled by the 0-10V signal.

2. Make sure the (-) terminal is connected to the (-) or common output terminal of the external control, and the (+) terminal is connected to the 0 - 10 VDC or (+) terminal of the external control. Make sure that the (-) voltage is not below ground.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by

Building Management Systems to verify that the boiler is responding to a call for heat.

If a Thermostat or Zone Control enable output is available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the heat/loop demands 1-3 (FIG. 5-3). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the heat/loop demand input. This will initiate a call for heat on the Cascade.

Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards.

Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards (FIG. 5-3). If more than two boilers are on the Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible.

30

5

Field wiring

(continued)

Figure 5-3 Low Voltage Field Wiring Connections


Manual

A B

A B

31


Manual

6

Condensate disposal

Condensate drain

1. This boiler is a high effi ciency appliance that produces condensate.

NOTICE

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or

F493.

2. The side of the boiler has a 1/2 inch (12.7 mm) PVC union for connection of a 1/2 inch (12.7 mm) PVC pipe

(FIG. 6-1).

3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing fi lter. Condensate from the Outdoor Knight XL will be slightly acidic

(typically with a pH from 3 to 5). Install a neutralizing fi lter if required by local codes.

A Neutralizer Kit (FIG. 6-1) is available from the factory

(KIT3087 for Models 400 - 501 and KIT3046 for Models

601 - 801).

NOTICE

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch (25 mm).

The condensate line must remain unbstructed, allowing free fl ow of condensate.

If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.

4. Install the 1/2 inch (12.7 mm) PVC tee assembly (shipped with the unit) as shown in FIG. 6-1.

5. Leave the top of the 1/2 inch (12.7 mm) tee OPEN. This is needed as a vacuum break.

6. Do not expose condensate line to freezing temperatures.

Precautions should be taken to protect the condensate management and disposal system during extended periods of outdoor temperatures below 32°F.

8. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces.

The pump should have an overfl ow switch to prevent property damage from condensate spillage. The switch should be wired in series with the blocked drain switch inside the boiler (see FIG. 7-1 on page 34).

7. Use only plastic tubing or piping as a condensate drain line (FIG. 6-1).

Figure 6-1 Condensate Disposal

1/2" PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

32

FLOOR DRAIN OR

DRAIN PAN

IMG00331

1/2" PVC UNION

(FACTORY SUPPLIED)

NEUTRALIZER KIT

KIT3087 shown for illustration purposes.


Manual

7

Start-up

Check/control water chemistry

 CAUTION

Do not use petroleum-based cleaning or sealing compounds in the boiler system.

Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

Hardness less than 7 grains

1. Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not fi ll boiler or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or spa water.

Test/replace freeze protection fl uid

1. For systems using freeze protection fl uids, follow fl uid manufacturer’s instructions.

to degradation of inhibitors over time. Follow all fl uid manufacturer’s instructions.

Freeze protection (when used)

system water content, following fl uid manufacturer’s instructions. Boiler water content is listed on page 7.

Remember to include expansion tank water content.

2. Local codes may require a backfl ow preventer or actual disconnect from city water supply.

3. When using freeze protection fl uid with automatic fi ll, install a water meter to monitor water makeup. Freeze protection fl uid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

4. The freeze protection set points may be lowered when freeze protection fl uid is used (see the Outdoor Knight

XL Service Manual).

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close manual and automatic air vents and boiler drain valve.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water fi ll pressure for a commercial system is 12 psi (82.7 kPa).

b. Pressure will rise when boiler is turned on and system water temperature increases. system thoroughly for any leaks. Repair all leaks before proceeding further.

 WARNING

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life.

Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Purge air from water system

1. Purge air from system: a. Connect a hose to the purge valve (see purge/drain valves, in piping diagrams on page 22). Route the hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between the purge valve and fi ll connection to the system.

c. Close zone isolation valves.

e. Open purge valve.

f. One zone at a time, open the isolation valves. Allow water to run through the zone, pushing out the air.

Run until no noticeable air fl ow is present. Close the zone isolation valves and proceed with the next zone.

Follow this procedure until all zones are purged.

g. Close the quick-fi ll water valve and purge valve and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fi ll pressure.

h. After the system has operated for a while, eliminate any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in the system, open the manual air vents in the system one at a time, beginning with the lowest fl oor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open automatic air vent (diaphragm-type or bladdertype expansion tank systems only) one turn.

a. Starting on the lowest fl oor, open air vents one at a time until water squirts out.

b. Repeat with remaining vents.

4. Refi ll to correct pressure.

33


Manual

7

Start-up

Check for gas leaks

 WARNING

Before starting the boiler, and during initial operation, smell near the fl oor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak.

Use an approved leak detection solution.

Repair any leaks at once.

 WARNING


The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring

Figure 7-1 Condensate Trap

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

TO FLOOR

DRAIN

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

 WARNING

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to each of the heat/loop demand terminals on the connection board.

2. Connect a voltmeter across these two incoming wires.

Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board. Allow the boiler to cycle.

Inspect/fi ll condensate system

Inspect/check condensate lines and fi ttings

1. Inspect the condensate drain line, condensate PVC fi ttings and condensate trap.

Fill condensate trap with water

1. Remove the PVC cap retaining screw from the PVC cap

(FIG. 7-1).

2. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 7-1).

3. Fill with fresh water until the water begins to pour out of the drain.

4. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

5. Replace the retaining screw.

 WARNING

The condensate trap (FIG. 7-1) must be fi lled with water during all times of boiler operation to avoid fl ue gas emission from the condensate drain line. Failure to fi ll the trap could result in severe personal injury or death.

34


Manual

7

Start-up

(continued)

Final checks before starting the boiler

 Read the Outdoor Knight XL Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, page 33 for proper steps to start boiler.

 Verify the boiler and system are full of water and all system components are correctly set for operation.

 Verify the preparation procedures of Section 7, pages 33 and 34 have been completed.

 Fill the vent condensate trap with water (removing the retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap). Replace the cap. Press the cap onto the trap until the cap makes contact with the drain. Replace the retaining screw.

 Verify electrical connections are correct and securely attached.

Start the boiler

1. Read and follow the Operating instructions in FIG. 7-2, page 36.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is boiler water temperature above 200°F (93°C)?

3. Is thermostat set below controlling sensor temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?

If none of the above corrects the problem, refer to the

Troubleshooting Section of the Outdoor Knight XL Service

Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 33 and 34 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 46 of this manual (connecting gas supply piping).

 WARNING

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the

Propane Conversion instructions.

 WARNING


The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifi ce or by making a gas valve adjustment (see page 12). In order to operate on LP gas, an orifi ce MUST

BE installed or a gas valve adjustment

MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check fl ame and combustion

1. Turn the main power off to the boiler by placing the

“On/Off” switch in the OFF position.

2. Combustion measurements will be made from exhaust opening.

3. Turn the main power on to the boiler by placing the

“On/Off” switch in the ON position.

35


Manual

7

Start-up

Figure 7-2 Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury, or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which

automatically lights the burner. Do not try

to light the burner by hand.

B. BEFORE OPERATING smell all around

the appliance area for gas. Be sure to

smell next to the floor because some gas

is heavier than air and will settle on the

floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call

the fire department.

C. Use only your hand to turn the gas control knob.

Never use tools. If the handle will not turn by

hand, don’t try to repair it, call a qualified service

technician. Force or attempted repair may result

in a fire or explosion.

• Do not touch any electric switch; do

not use any phone in your building.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified

service technician to inspect the appliance and

to replace any part of the control system and

any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the

appliance.

4. This appliance is equipped with an

ignition device which automatically lights

the burner. Do not try to light the burner

by hand.

5. Remove top cover.

6. Turn gas shutoff valve counterclockwise

to “OFF”. Handle will be perpendicular to

pipe. Do not force.

7. Wait five (5) minutes to clear out any gas.

If you then smell gas, STOP! Follow “B”

in the safety information above on this label.

If you don’t smell gas, go to next step.

8. Turn gas shutoff valve clockwise to “ON”.

Handle will be parallel to pipe.

9. Install top cover.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and

call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance

if service is to be performed.

3. Remove top cover.

4. Turn gas shut off valve counterclockwise to

“OFF”. Handle will be perpendicular to pipe.

Do not force.

5. Install top cover.

LBL2284 REV -

36


Manual

7

Start-up

(continued)

Check fl ame and combustion

(continued)

4. Place the boiler into the active position by pressing the

RIGHT SELECT [ON] key (FIG. 8-1, page 43).

5. Locate the pinhole button below the RESET button on the display board (FIG. 8-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service

Mode. In Service Mode the boiler will fi re at ignition speed and will then modulate up to full fi re.

6. Once the boiler has modulated up to full fi re, measure the combustion. The values should be in the range listed in Table 7A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specifi ed range, reference the Troubleshooting Section of the Outdoor

Knight XL Service Manual for possible causes and corrective actions.

Table 7A Flue Products Chart

Natural Gas Propane

CO

2

O

2

CO

2

O

2

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

7. Once the combustion analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down and registers an alarm. Turn the manual shutoff switch to the ON position and reset the control.

8. Place the boiler back into normal operation.

Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be based on one of three sensors; the inlet, outlet, or system supply sensor. The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor. The control will automatically switch to the system supply sensor once it is connected. If it is desired to base the temperature control on the inlet sensor, the appropriate parameter must be changed in the control. See the Outdoor

Knight XL Service Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system pump

(if connected), and the boiler pump. When the SMART

SYSTEM control receives a space heating call for heat, it turns on the system pump. If the boiler is not heating an indirect

DHW (Domestic Hot Water) tank, and the set point is not met, it also turns on the boiler pump. After the space heating call for heat ends, the system pump continues to run for a short period of time. The system pump can be programmed to run continuously, except during outdoor shutdown. If the boiler pump was running, it continues to run for a short period of time as well. These pump delays are factory set to

30 seconds. If different delays are desired, the appropriate parameters in the control must be changed. See the Outdoor


Adjust set point temperature(s)

NOTICE

Please note that the brackets ([]) denote screen status.

The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures.

1. From the Status Screen press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select the appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the

RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to additional set points.

6. Press the RIGHT SELECT [HOME[ key to upload the

changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the new settings will be discarded.

37


Manual

7

Start-up

Set domestic hot water (DHW) operation

Verify DHW mode

There are two (2) modes of operation for DHW. In Normal

Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum fi ring rate may be limited in this mode if desired.

In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop. When a DHW demand begins, the control will turn on the DHW pump output, and raise the system temperature set point to the DHW boiler set point (if higher). The boiler pump will be turned on. The system pump may be forced on, forced off, or not changed, depending on the System Pump Mode selected (reference the Outdoor Knight XL Service Manual for details). In this mode, any low temperature zones (such as radiant heating) may need additional controls to limit the water temperature sent to those zones.

7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial.

9. Turn the NAVIGATION dial to adjust the date. Press the

10. Turn the NAVIGATION dial to adjust the year. Press the


11. Press the RIGHT SELECT [HOME] key.

NOTICE

The internal clock does not adjust for

Daylight Savings Time and therefore, will require a manual adjustment.

The clock is automatically updated whenever a PC is connected and the Win_Pro-Installer program is started.

Set DHW boiler target temperature

When in the DHW Mode, the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point. This set point is set at the factory to 180°F. If a different set point is desired, the appropriate parameter in the control must be changed. See the Outdoor


Confi guration of the cascade

NOTICE


When installed in a Cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters.

Set maximum DHW fan speed

If the rated input of the indirect tank is less than the maximum output of the boiler, change the maximum DHW fan speed setting to limit the boiler output accordingly, see the Outdoor


Set clock

NOTICE


The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 4 hours. Use the following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

2. The display changes to read [PASSWORD], with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

Press the [MENU] key for at least fi ve (5) seconds. Input the

Installer code as described in the Outdoor Knight XL Service

Manual. Once the control parameters have been accessed, use the NAVIGATION DIAL to select the Control Mode parameters. Press the NAVIGATION DIAL to access these parameters.

Rotate the NAVIGATION dial to select the parameter “Cascade

Address”. Press the NAVIGATION dial to access this parameter.

Each appliance in the Cascade system must be programmed with its own address. The boiler designated as the Leader will have an address of 0. The remaining boilers in the Cascade will be Members and have addresses from 1 - 7. Rotate the

NAVIGATION dial to select the appropriate address. Press the


Press the RIGHT SELECT [HOME] key to upload the address into the control. Repeat this procedure for all boilers in the

Cascade, designating the Leader control and the Member controls.

38


Manual

8

Operating information

General

How the boiler operates

Room thermostat

The Outdoor Knight XL can also be programmed to accept a call for heat from a 0 - 10V signal, reference the Outdoor Knight

XL Service Manual for a detailed explanation of this procedure.

The Outdoor Knight XL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes fl ue products out of the boiler through the heat exchanger and fl ue piping. The control module regulates blower speed to control the boiler fi ring rate. The gas valve senses the amount of air fl owing into the boiler and allows only the right amount of gas to fl ow.

How the control module operates

DHW priority

The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board.

When a tank sensor is connected, the DHW thermostat input is ignored. When a boiler is programmed for DHW Normal

Mode, the maximum fi ring rate can be limited to match the input rating of the indirect tank coil.

The SMART SYSTEM control module receives inputs from boiler sensors and external devices. The control module activates and controls the blower and gas valve to regulate heat input and switches the boiler, Domestic Hot Water

(DHW), and system pumps on and off as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature, boiler inlet water temperature, system temperature, a 0 - 10V signal, or

Modbus, depending on the parameter settings.

Control inputs and outputs

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is in progress, and the DHW is in Normal Mode, the control will start the DHW pump and shut the boiler pump off. The system pump will remain on. For stand-alone boilers, if the space heating call is still active while the DHW call is in operation, the control will wait for 30 minutes (time adjustable by installer) then it will switch back to the space heating demand. There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating. The control will switch back and forth until one of the heat demands end. This function does not apply to cascade systems.

Programmable controlling sensor

There are three (3) heat/loop demand connections available on this control. These inputs tell the boiler to provide water for space heating. Each demand connection has its own set point and outdoor air reset curve. When multiple demands have a call for heat the control will give priority to the demand with the highest set point.

The control module is programmed to use the outlet sensor as the control sensor by default. If a system supply sensor is connected, the control automatically uses it as the control sensor. For stand-alone boilers, the control sensor can be changed by the installer to the inlet sensor. If the inlet sensor is chosen as the controlling sensor, it is recommended that the system supply sensor be installed in the system supply in order to provide the best control of the inlet temperature.

Example: Assume that both heat/loop demand 1 and heat/ loop demand 2 have a call for heat. Demand 1 has a set point of 110°F. Demand 2 has a set point of 140°F. The boiler will regulate the system temperature to 140°F until Demand 2 has been satisfi ed. Once Demand 2 has been satisifi ed the boiler will provide 110°F water to the system.



CAUTION

When multiple temperature loops are used, mixing valves are required for the protection of any low temperature loops.

Anti-cycling

After the burner turns off, the control will delay the next burner cycle for a set time period (time is adjustable by the installer).

The time delay will be bypassed if the inlet water temperature drops too far during the delay.

Boiler and system pump control

SMART SYSTEM Multi-temp loop control

The Outdoor Knight XL boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. This device controls the temperatures of up to three (3) separate loops, based on the settings for the three (3) heat/loop demands (reference Lochinvar kit

RLY30086).

The boiler pump will run whenever the burner is fi ring, unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank. The boiler pump will run during Freeze

Protection Mode as well. It will continue to run for a short time after the burner turns off or the Freeze Protection Mode ends.

0 - 10V input (set point or power)

The Outdoor Knight XL can be controlled by a Building

Management System (BMS) using a 0 - 10 VDC signal. The control can be confi gured by the installer to use this signal to either control set point or fi ring rate.

The system pump will run whenever there is a space heating call for heat, or the boiler goes into Freeze Protection Mode. It may be programmed to run during a DHW call for heat when the

DHW is programmed for Zone Mode. It will continue to run for a short time after the end of the heat demand or the Freeze

Protection Mode. The system pump can be programmed to run continuously if desired, except during outdoor shutdown and/ or a DHW call for heat.

39


Manual

8


Temperature control

Modulation

The Outdoor Knight XL is capable of modulating its fi ring rate from a minimum of 20% to a maximum of 100%. The fi ring rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations.

Ramp delay

For systems with lower fl ow, the SMART SYSTEM can limit the fi ring rate (when enabled) when a space heating call for heat starts, or when switching from a DHW call for heat to a space heating call for heat. There are six (6) limits that can be programmed, as well as six (6) time intervals corresponding to each limit. The sixth limit will also limit the fi ring rate for the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the fi ring rate to its lowest setting.

Outdoor air reset

If an outdoor air sensor is connected, the control module will calculate the set points of the three (3) space heating demands based on the programmed reset curves. The installer can change the slope of the reset curves by several adjustable parameters. The user can limit the maximum set point for the system using the space heating set points.

Boost function

If outdoor air reset is active, and any space heating demand has been active continuously for a set period of time (time adjustable by installer) and there has been no

DHW demands, the control will increase the set point of that demand by a fi xed number of degrees (adjustable by installer). This process will continue until the space heating demand ends, the set point reaches the programmed set point or a maximum of 20 increases has occurred. Once the system heat demand is satisfi ed, the set point will revert to the value determined by the reset curve.

Night setback

The controller may be programmed to reduce the space heating and DHW set points during certain times each week.

Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback.

Flame current support

To prevent nuisance shutdowns when the boiler is fi ring at minimum rates, the control will increase the fi ring rate when the fl ame signal drops too low.

Protection features

Outlet temperature, fl ue temperature, and temperature rise limiting

The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds

185°F, the unit will reduce the fan speed. If the outlet water temperature exceeds 195°F (90°C) the control will shut the unit down until it cools off.

The control module monitors the fl ue temperature by a sensor located in the fl ue exhaust. If the fl ue temperature exceeds

215°F (102°C) the control will reduce the maximum fan speed.

If the fl ue temperature exceeds 240°F (115°C) the control will shut the unit down. The unit will restart automatically once the fl ue temperature drops 25°F (-4°C) and the minimum off time has expired.

The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F

(13°C) the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F (15°C) the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F (13°C) and the minimum off time has expired.

Freeze protection

DO NOT install the boiler in a location where it is likely to freeze.

The following integral feature of the SMART SYSTEM control module provides some protection for the boiler only -- not for the system.

• The SMART SYSTEM control module provides freeze-up protection as follows when the boiler water temperature drops below 45°F (7°C):

• Below 45°F (7°C), the boiler and system pumps operate constantly.

• Below 37°F (3°C), the boiler turns on.

• Boiler and pumps turn off if boiler water temperature rises above 45°F (7°C).

• Lower temperatures may be programmed for systems with anti-freeze solutions.

NOTICE

When system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust.

 CAUTION

This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.

40


Manual

8


(continued)

Monitor external limits High limit operations

Connections are provided on the connection board for external limits such as fl ow switch, low water cutoff and gas pressure switches. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open.

The Outdoor Knight XL is equipped with adjustable automatic reset and manual reset high limits. The automatic reset high limit has a maximum set point of 200°F and the manual reset high limit has a maximum set point of 210°F.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the boiler is running, and when it is unable to operate.

When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 190°F, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at 210°F.

Run-time and cycle counting

The control uses two timers to monitor the total hours of burner operation. One timer monitors the time the boiler is in the Space Heating Mode. The other timer monitors the time the boiler is fi ring in the DHW Mode.

The control uses two (2) ignition counters to monitor the amount of boiler cycles. The fi rst counter counts all ignitions of the control. The second counter counts only ignition attempts that have failed.

High limit test procedure

NOTICE


Service reminder

The control can be programmed for service reminder notifi cation. This notifi cation will become active when either a set time frame has expired, or a set amount of running hours or cycles has expired (all adjustable by the installer). The display will show a Maintenance Required screen. The installer’s name and phone number can be programmed into the control. This information will appear on the Maintenance Required screen. The service reminder notifi cation can be reset or disabled by the installer.

The time dependent feature has been disabled by the manufacturer. To enable this feature change the parameter to the desired time interval, reference the Outdoor Knight

XL Service Manual for details regarding parameters.

Error logging

The control will hold in memory the last 10 lockouts as well as the last 10 blockings. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences of each will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water temperature and regulates boiler fi ring and fi ring rate to achieve a target temperature. The target temperature can be set between 70°F (21°C) and 190°F (88°C).

• Target temperature is fi xed when the outdoor sensor is not installed.

• Target temperature is calculated as described on this page under “Outdoor Reset Operation” and “Target Temperature Boost” when the outdoor sensor is connected.

1. Turn ON the main power to the boiler by placing the

ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating the NAVIGATION dial counterclockwise, then press the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current outlet temperature (or to its minimum setting, whichever

is higher) by turning the NAVIGATION dial

counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL set point, the MRHL will function causing boiler lockout.

If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL set point, locate the pinhole (SERVICE button) below the

RESET button on the display board. Insert a thin probe

(such as a paper clip) into the hole and press the button continuously for fi ve (5) seconds to place the boiler into

Service Mode. In Service Mode, the boiler will fi re at ignition speed and will then modulate up to full fi re.

10. Once the outlet temperature rises up to the MRHL set point, the MRHL will function, causing the boiler to shut down and lock out.

11. Repeat Steps 2, 3 and 4.

12. Set the MRHL to the appropriate set point by turning the

NAVIGATION dial clockwise.

13. Repeat Steps 6 and 7.

14. Press the RESET button to clear the lockout.

15. If needed, press the RIGHT SELECT [STOP] key to exit

41


Manual

8


Low water cutoff protection

Sequence of the cascade

1. The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger. If the fl ow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low fl ow conditions.

To equalize the run time of all boilers on the Cascade, the fi ring sequence will automatically be changed at set intervals.

The sequence will be changed once every 24 hours. The switching on/off sequence will be as follows:

TIME SWITCHING ON SEQUENCE

2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available from the factory (WTR30024).

Start

1 hour

2 hours

L-M1-M2-M3-M4-M5-M6-M7

M1-M2-M3-M4-M5-M6-M7-L

M2-M3-M4-M5-M6-M7-L-M1

Outdoor reset operation, if used

Target temperature with outdoor reset

If a boiler locks out or is used to heat an indirect DHW tank, it will automatically be given the lowest priority for the rest of that 24 hour period.

This feature improves the system’s effi ciency as the outdoor temperature warms up.

DHW, Night Setback, and Ramp Delay operation with cascade

See the Outdoor Knight XL Service Manual to change the settings.

Reset curve

The reset curves look at outdoor air temperature and adjusts the set points.

Cascade

For normal mode DHW operation any boiler(s) in the Cascade can be selected to provide heat for a DHW call. Select a boiler to be designated as the DHW boiler. Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection

Board marked for the corresponding device. When the boiler receives a DHW call, the Leader control will take that boiler out of the Cascade sequence. If another boiler is available, the

Leader will start it up to take its place.

When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/Lag or Effi ciency

Optimization control methods.

The DHW boiler will adjust its set point to the programmed

DHW boiler set point and will adjust its fi ring rate to maintain this. Once the DHW call has been satisfi ed, the Leader control will place that boiler back into the Cascade sequence.

Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade

Mode.

Once the Leader boiler receives a call for heat from a room thermostat, BMS, or Modbus, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage

Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve parameters.

See the Outdoor Knight XL Service Manual to program the reset curve. If outdoor air reset is not desired, do not connect the outdoor air sensor. A fi xed temperature set point can be programmed into the control. See page 59 of this manual to program the set point.

When DHW is programmed for Zone Mode, connect the DHW thermostat or tank sensor to the Leader boiler. When a DHW call is received, the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point (if higher).

Night Setback operation of the boilers within the Cascade is available. Programming of the Night Setback will be done through the Leader boiler. Refer to the Outdoor Knight XL

Service manual for information regarding Night Setback.

If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade

(see the Outdoor Knight XL Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the

Leader boiler.

Ramp Delay operation of the boilers as described in the Outdoor

Knight XL Service Manual is available when the boilers are part of a Cascade system.

42

8


(continued)

Sequence of operation

OPERATION

1. Upon a call for heat, the gas pressure switch(es) must be closed.


Manual

DISPLAY

2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The fl ow switch and/or LWCO must close.

3. The air pressure switch and blocked drain switch must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by fi ring the spark electrode and opening the gas valve.

perform a postpurge, then start another prepurge cycle and try

to light the burner again. On the 501 and larger models, the control

will lock out if this second attempt also fails. On the 400 model,

the control will perform a total of 4 attempts before locking out.

7. If fl ame is detected, it holds the fi ring rate steady for a few seconds to let the fl ame stabilize, then it begins to modulate the fi ring rate based on a set point or some other command (such as a 0-10V BMS signal).

43

8


Sequence of operation

(continued)

OPERATION

8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the

DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on fi rst, then the boiler pump will turn off (boiler and DHW pump operation briefl y overlap to ensure fl ow is maintained through the unit). This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead. The control will then modulate to maintain the outlet temperature to the DHW boiler set point.

9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisfi ed.


Manual

DISPLAY

10. Once both calls for heat are satisfi ed, the control will turn off

the burner.The blower will continue to run during the postpurge

period.

11. Any pumps that are running will continue to run for their respective pump delay times before turning off, unless programmed to remain on continuously. A 60 second anti-cycle period will start, which will delay any new call for heat until it times out.

12. In Standby, ready to start a new cycle.

44


Manual

8


(continued)

Outdoor Knight XL control module

Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor boiler operation.

Figure 8-1 Control Panel

NAVIGATION DIAL

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the

NAVIGATION dial (in the center):

MENU = Left SELECT Key

SETPOINTS = NAVIGATION Dial - Pressing Down

SHDN = Right SELECT Key

Access modes

User

The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is fl ashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 36).

Installer

Most parameters are available only to the installer, accessible by entering the installer password, see the Outdoor Knight XL

Service Manual.

Saving parameters

(reference the Parameter Table in the Outdoor Knight XL Service Manual)

NOTICE


To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the

RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the parameter listings; press again to return to the menu listings.

Remember to press the RIGHT SELECT [HOME] key when fi nished programming in order to save the changes made.

See the Outdoor Knight XL Service Manual for a detailed description of parameters and access modes.

45


Manual

8


Figure 8-2 Status Display Screen

A

(BOILER

STATUS)

B

(CALL FOR

HEAT)

C

(OPERATIONAL

INFORMATION)

D

(LEFT SELECT

KEY)

F

(RIGHT SELECT KEY)

Section

A

(Boiler Status

Bar)

B

(Call for Heat

Indicators)

E

(NAVIGATION DIAL)

Display

STANDBY

Status Display Screens

Description

The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.

START

The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE

The unit has initiated a prepurge period on a call for heat.

IGNITION

%

POSTPURGE

SHUTDOWN

The unit has begun a spark period to ignite the main burner.

The unit has fi red and is running at the displayed percentage.

The call for heat has been satisfi ed and the unit runs the fan for an additional postpurge period to clear the combustion chamber and vent system of residual fl ue products.

The unit has been placed in the OFF position.

BLOCKED

The controlled temperature has exceeded its set point and its offset.

The unit has detected a condition that has temporarily interrupted the current call for heat.

Room Thermostat 1 has a call for heat.



The tank thermostat or sensor has a call for heat.

Indicates which room thermostat demand shows priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

46


Manual

8


(continued)

Section


(cont’d)

Display

SYSTEM:

Description

The temperature read by the system supply sensor (if connected).

TANK:

OUTDOOR:

INLET TEMP:

OUTLET TEMP:

DELTA T:

FLUE TEMP:

FLAME CURRENT:

The temperature read by the tank sensor (if connected).

The temperature read by the outdoor sensor (if connected).

The temperature read at the inlet to the heat exchanger.

The temperature read at the outlet of the heat exchanger.

The temperature difference between the inlet and the outlet of the heat exchanger.

The temperature read by the fl ue sensor.

The current measured by the fl ame sense circuit.

C

(Operational

Information)

FAN SPEED:

The speed of the combustion blower.

BOILER PUMP:

SYSTEM PUMP:

DHW PUMP:

The status of the boiler pump output.

The status of the system pump output.

The status of the DHW pump output.

BMS VOLTAGE:

The voltage received from a BMS system.

BLR PUMP OUTPUT:

The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT:

The speed signal received from a variable speed system pump control.

RATE OUTPUT:

SH RUN HOURS:

SH CYCLES:

A 0 - 10V signal indicating the fi ring rate of the boiler.

The total hours of operation in the Space Heating Mode.

The total burner cycles in the Space Heating Mode.

DHW RUN HOURS:

The total hours of operation in the DHW Mode.

DHW CYCLES:

The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:*

The last 10 lockouts.

NIGHT SETBACK

Shows the next Night Setback trigger (if active).

47


Manual

8


Section

MENU


(cont’d)

Display Description

Press and hold the LEFT SELECT key for 5 seconds to enter the Menu

Screen.

EXIT

D

(LEFT SELECT key function)

E

(NAVIGATION

Dial Function)

YES

LIMITS

HOME

SKIP

Press the LEFT SELECT key to exit the current screen or setting.

Press the LEFT SELECT key to confi rm that the boiler needs to shutdown.

Press the LEFT SELECT key to enter the screen that allows you to adjust the limit settings.

Press the LEFT SELECT key to return to the Status Screen and upload parameter changes.

Press the LEFT SELECT key when in the Night Setback Screen to access the Night Setback Skip Screen.

Turning the NAVIGATION dial will select the next or previous Status

Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night

Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by the cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

F

(RIGHT SELECT key function)

SHDN

ON

NO

SAVE

HOME

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current setting.

Press the RIGHT SELECT key to turn the boiler OFF.

Press the RIGHT SELECT key to turn the boiler ON.

Press the RIGHT SELECT key to cancel the shutdown operation.

Press the RIGHT SELECT key to save the current change.

Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes.

48

9

Maintenance

Maintenance and annual startup

Table 9A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)


Manual

Owner maintenance

(see the Outdoor Knight XL User’s Information

Manual for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and fi ll with fresh water

• condensate)

Daily

• Check boiler area

• gauge

condition and sealed tight

• Check system water pressure/system

• Check control settings

•

electrodes (sand off any deposits; clean

Monthly

• screens

• Check relief valve

• Check condensate drain system

• Check wiring and connections

verifi cation per Section 7.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at

• Test low water cutoff (if used)

Periodically

• Reset button (low water cutoff)

•

is more than 54°F (30°C) above return water

temperature.

Every

6 months

• Check boiler piping (gas and

water) for leaks

If combustion or performance indicate need:

• Clean heat exchanger

•

compressed air only

• Clean the blower wheel

• Operate relief valve

End of season months

• Shut boiler down (unless boiler

used for domestic hot water)

49


Manual

9

Maintenance

 WARNING

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

 WARNING

The boiler should be inspected annually only by a qualifi ed service technician. In addition, the maintenance and care of the boiler designated in Table 9A and explained on the following pages must be performed to assure maximum boiler effi ciency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

 WARNING

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

Figure 9-1 Condensate Trap

1. Inspect any problems reported by the owner and correct before proceeding.

RETAINING

SCREW

Inspect boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other fl ammable vapors and liquids.

2” PVC CAP WITH


PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of the boiler.

CONDENSATE FROM

HEAT EXCHANGER

TO FLOOR

DRAIN

2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.

Clean condensate trap

1. Inspect the condensate drain line, condensate PVC fi ttings, and condensate trap.

2. Remove the PVC cap retaining screw from the PVC cap

(FIG. 9-1).

3. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 9-1).

4. Remove any sediment in the trap.

 WARNING

The condensate trap must be fi lled with water during all times of boiler operation to avoid fl ue gas emission from the condensate drain line. Failure to fi ll the trap could result in severe personal injury or death.

Check all piping for leaks

 WARNING

Eliminate all system or boiler leaks.

Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

5. Fill with fresh water until the water begins to pour out of the drain.

1. Inspect all water and gas piping and verify to be leak free.

6. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

2. Look for signs of leaking lines and correct any problems found.

7. Replace the retaining screw.

3. Check gas line using the procedure found in Section 4 -

Gas Connections.

50


Manual

9

Maintenance

(continued)

Flue vent system and air piping

1. Visually inspect the entire fl ue gas venting system for blockage, deterioration or leakage.

2. Verify that boiler vent discharge and air intake openings are clean and free of obstructions.

 WARNING

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and operational.

2. Check the cold fi ll pressure for the system. Verify it is correct (must be a minimum of 12 psi (82.7 kPa)).

3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high.

Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect automatic air vents and air separators. Remove air vent caps and briefl y press push valve to fl ush vent.

Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools.

Tanks may be open, closed or diaphragm or bladder type. See Section 3 - Hydronic Piping for suggested best location of expansion tanks and air eliminators.

 WARNING

Safety relief valves should be re-inspected

AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.

Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

 WARNING

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative.

When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the fl ow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water fl ows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify fl ow.

Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 3 - Hydronic Piping before proceeding further.

2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

51


Manual

9

Maintenance

Inspect ignition and fl ame sense electrodes

1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/fl ame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/fl ame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to

Parameter Mode and check all settings. See Section 1 of the Outdoor Knight XL Service Manual. Adjust settings if necessary. See Section 1 of the Outdoor Knight XL

Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests specifi ed in

Section 7 - Start-up.

Figure 9-2 Burner Assembly - Model 400

IMG00437

IMG00438

BURNER

BURNER

GASKET

AIR / GAS

ARM

Figure 9-3 Burner Assembly - Model 501

GASKET

AIR / GAS

ARM

Figure 9-4 Burner Assembly - Models 601 - 801

AIR / GAS

ARM

SCREWS

(5)

SCREWS

(5) pressure does not go too high.

Check burner fl ame

2. If the fl ame is unsatisfactory at either high fi re or low fi re, turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG.’s 9-2 thru 9-4.

4. When replacing the burner, ensure gasket is in good condition and positioned correctly (FIG.’s 9-2 thru 9-4).

52

IMG00439

BURNER

GASKET

SCREWS

(5)


Manual

9

Maintenance

(continued)

Check fl ame signal

be at least 10 microamps.

2. A lower fl ame signal may indicate a fouled or damaged fl ame sense electrode. If cleaning the fl ame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the fl ame sense electrode.

3. See Section 3 - Troubleshooting in the Outdoor Knight

XL Service Manual for other procedures to deal with low fl ame signal.

Review with owner

1. Review the Outdoor Knight XL User’s Information

Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specifi ed in the Outdoor Knight XL User’s Information

Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see

Table 9B - Heat Exchanger Cleaning Kits.

6. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.

7. Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the fi eld supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

11. Close isolation valves on piping to isolate boiler from system. Attach a hose to the boiler drain and fl ush boiler thoroughly with clean water by using purging valves to allow water to fl ow through the water make-up line to the boiler.

12. Perform start-up and check-out procedures in the Check

Flame and Combustion - Section 7 - Startup on pages 35 and 37 of this manual.

13. Replace the access cover and restore boiler to operation.

Table 9B Heat Exchanger Cleaning Kits

Model

400

Kit

Number

Part

Number

CTN20005

Component

Description

Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

KIT30063

501 - 801 KIT30064

MSC20084 3mm Allen Wrench

MSC20086 1/4" x 24" Drill Extension

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*



• Follow the “To Turn Off Gas to Appliance” instructions

for the boiler in Section 7 - Startup.

• Do not drain the boiler unless it will be exposed to

freezing temperatures. If using freeze prevention fl uid

in system, do not drain.

2. Allow time for the boiler to cool to ambient temperature if it has been fi ring.

3. Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

4. Remove the heat exchanger access cover, burner, and gas/air arm assembly.

 CAUTION

* Do NOT use a metal brush. Only use the kit provided brush or an equivalent replacement nylon brush.

Figure 9-5 Rope Gasket - Heat Exchanger Door

ROPE GASKET

 WARNING

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions in the Service

Manual. Failure to comply could result in severe personal injury.

5. Remove the condensate hose from the heat exchanger end. Connect a fi eld supplied 3/4" diameter hose to a drain pan. Using fi eld supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.

NOTICE

CAUTION:

I

F GASKET IS DAMAGED

DO NOT

REUSE, THE HEAT EXCHANGER DOOR

MUST BE REPLACED.

Rope gasket is intended for sealing combustion

(FIG. 9-5). If damaged DO NOT reuse, the heat exchanger door must be replaced. Consult factory for replacement heat exchanger door

(kit WTR3080 and WTR3086).

53


Manual

10

Diagrams

Figure 10-1 Wiring Diagram

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

HEAT/LOOP

DEMAND

3

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

2

1

15

16

17

18

11

12

13

14

19

20

7

8

5

6

1

2

3

4

9

10

CONNECTION BOARD

CN5-1

CN5-8

CN5-2

CN5-9

CN5-3

CN5-10

CN5-11

CN5-4

CN5-5

CN5-14

CN5-12

CN5-6

CN5-13

CN5-7

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

X4-7

X4-14

X4-6

X4-13

X4-5

X4-12

X4-11

X4-4

X4-3

X4-8

X4-10

X4-2

X4-9

X4-1

INTEGRATED

CONTROL

X-7

X1-3

OR

CN2-4

X1-4

BR

CN2-2

X1-2 PR

CN2-3

CN2-1

RELAY

BOARD

K1

K2

K3

CN1-5

OR

CN1-6

CN1-3

OR

BR

CN1-4

CN1-1

BR

PR

CN1-2

PR

JUNCTION

BOX

L

ON/OFF

SWITCH

X1-6

X1-5

BK

W

DHW

PUMP

BOILER

PUMP

SYSTEM

PUMP

L

GND

N

120V

SUPPLY

N

X1-8

X1-1

G

R

TRANSFORMER

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

A

CASCADE

B

SHIELD

25

26

27

28

21

22

23

24

29

30

31

32

R W G

1 2 3

BLOWER

1 2 3 4 5

3.5A

KB 801

ONLY

BMS

IN

SYS PUMP

IN

BLR PUMP

OUT

RATE

OUT

SHIELD

MODBUS

OPTION

A

B

SHIELD

LOW

WATER

CUT-OFF

+

-

0-10V

+

-

0-10V

+

-

0-10V

+

-

0-10V

24 VAC

COM

37

38

39

40

33

34

35

36

41

42

43

44

CN7-1

CN7-2

CN7-3

CN7-4

CN6

X6

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

R

T

W

BK

Y

BL

O

P


O-TEMP HEX SW

AIR PRESSURE SWITCH

O/BK

-T

R/BK OPERATING SENSOR S1a

-T

GY HIGH LIMIT SENSOR S1b

-T

P/BK

INLET SENSOR S2

-T

W/BK FLUE SENSOR S3a

-T

PR FLUE SENSOR S3b

Y

SHIELD

GROUNDING

JUMPER

X5-1

X5-2

MODBUS BOARD

MTR-01

X4-1

X4-2

X4-3

X4-4

O

GY

G

X9-1

X9-2

X9-3

X9-4

X2-2

X2-1

X1-7

TR2

BK

Y

W/R

GAS VALVE

@24VAC

FLAME SENSOR

SPARK

ROD

CAUTION

G

HIGH VOLTAGE SPARK LEAD

X1-1

X1-2

X1-3

BK

W

G

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

WIRING DIAGRAM

LBL20116 REV E

54


Manual

10

Diagrams

(continued)

Figure 10-2 Ladder Diagram

120VAC

TERMINAL STRIP

120V SUPPLY "L"

JUNCTION BOX

NEUTRAL

TERMINAL STRIP

120V SUPPLY "N"

ON / OFF

SWITCH

X1-6

X4-3

X5-9

3.5A

KB 801

ONLY

INTEGRATED CONTROL

F2

3.15A

F1

5A

X1-1

1

BLOWER

X1-2

SYSTEM PUMP

RELAY

X1-3

SYSTEM PUMP

RELAY

DHW PUMP

RELAY

X1-4

DHW PUMP

RELAY

BOILER PUMP

RELAY

BOILER PUMP

RELAY

3

2

F3

.8A

24V DC

SUPPLY

X5-1

120 VAC

24 VAC

CONNECTION BOARD

CN5-5

LWCO

CN7-3

CN7-4

11

24 VAC

CN7-1 CN7-2

HEAT/LOOP

DEMAND

1

19

20

HEAT/LOOP

DEMAND

2

17

18

HEAT/LOOP

DEMAND

3

15

16

TANK

THERMOSTAT

13 14

LOW GAS

PRESSURE

SWITCH

HIGH GAS

PRESSURE

SWITCH

10

INTEGRATED

CONTROL

RIBBON CABLE

PC INTERFACE

1

2

6

13

ALARM

CONTACTS

RUN-TIME

CONTACTS

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

A

B

SHIELD

BMS

IN

+

-

SYS PUMP

IN

+

-

BLR PUMP

OUT

+

-

RATE

OUT

+

-

SHIELD

MODBUS

A

B

SHIELD

S6

S5

S4

0-10V

0-10V

0-10V

0-10V

3

4

26

27

29

30

31

32

21

22

23

24

38

39

40

41

33

34

35

36

37

42

43

44

INLET

SENSOR

OPERATING

SENSOR

S2

S1a

HIGH LIMIT

SENSOR

S1b

FLUE

SENSOR

S3a

FLUE

SENSOR

CONNECTION

BOARD

S3b

1

2

CN8-1

CN8-2

CN8-3

CN6

CN6

CN5-1

CN5-8

CN5-2

CN5-9

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

CN6

X6-1

X6-2

X6-3

M

O

D

B

U

S

X4-1

X4-2

X4-3

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X6

X4-7

X4-14

X4-6

X4-13

X9-2

X9-1

X9-3

X7

GROUND

FLOW

SWITCH

L

IN

12

SYSTEM

PUMP

CONTACTS

BOILER

PUMP

CONTACTS

DHW

PUMP

CONTACTS

RELAY BOARD

CN5-14 X4-8

CN5-10 X4-12

CN5-7 X4-1

CN5-13 X4-9

CN5-6 X4-2

CN5-12 X4-10

SYSTEM

PUMP

BOILER

PUMP

DHW

PUMP

L

OUT

INTEGRATED

CONTROL

CN5-11 X4-11

CN5-3

X4-5

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

5

6

7

CN5-4 X4-4

8

O-TEMP HEX SW

AIR PRESSURE

SWITCH

X5-2

BLOCKED

DRAIN SWITCH

X5-10

X5-11

GAS VALVE

X2-2

BLOWER

X2-1

4

5

1

2

X5-7

X5-16

X5-8

X5-15

TR2

X1-7

FLAME ROD

GAS VALVE

RELAY

SPARK

ROD

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possible, switches are shown without utilities (gas, water or

electricity) connected to the unit. As such, actual switch states may

vary from those shown on diagrams depending upon whether utilities

are connected or a fault condition is present.

2. See wiring diagram for additional notes.

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

LADDER DIAGRAM

LBL20141 REV D

55

Revision Notes: Revision A (ECO #C11234) initial release.

Revision B (ECO #C11235) refl ects updates made to the freezing conditions warnings.

OKBX-I-O Rev B

10/12

Life is good 42LM670S Flat Panel Television Service manual

Outdoor Knight XL

Installation & Operation Manual

Models: 400 - 801

 WARNING

Save this manual for future reference.

Contents

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

Installer – Read all instructions, including

When servicing boiler –

NOTICE

User – This manual is for use only by

Boiler operation –

Boiler water –

WHAT TO DO IF YOU SMELL GAS

CAUTION

CAUTION

Freeze protection fl uids –

1. Stainless steel heat exchanger

2. Combustion chamber access cover

3. Blower

5. Venturi

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

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

inlet

9. Temperature and pressure gauge (fi eld installed, not

shown)

10. Electronic LCD display

11. Flue pipe assembly

12. Burner (not shown)

13. Water outlet (system supply)

14. Water inlet (system return)

15. Gas connection pipe

16. SMART SYSTEM Control Module

17. Manual air vent

18. Air intake

19. Air Intake Cover

20. High voltage junction box

21. Boiler drain port

22. Low voltage connection board

23. Low voltage wiring connections (plugs)

24. Condensate drain connection

25. Access cover - front

26. Ignition electrode

27. Flame inspection window

28. Gas shutoff valve

29. Relief valve

30. Flame sensor

31. Line voltage wiring connections (knockouts)

32. Top panel

33. Power switch

34.

Leveling legs

35. Air shroud (Model 501 only)

36. Air pressure switch

37.

Pump relay board

38.

Transformer (not shown)

39.

High limit sensor (housed with the outlet temperature

sensor)

40.

Over-temp switch (located underneath vent cover - shown)

41.

42.

Vent Cover

Flow switch

Model 400

Model 501

Models 601 - 801

Outdoor Knight XL Boiler

AHRI Rating

Other Specifi cations

NOTICE

Notes: