OKB-I-O Rev C
Outdoor Knight Boiler
Installation & Operation
Manual
Models: 151 - 286
This manual must only be used by
ƽ WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Knight Boiler Service
Manual, before installing. Perform
steps in the order given. Failure
to comply could result in severe
personal injury, death, or substantial
property damage.
Save this manual for future reference.
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Outdoor Knight Boiler Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
this manual and the Outdoor Knight
Boiler Service Manual, before installing.
Perform steps in the order given.
When servicing boiler –
ƽ WARNING
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
User – This manual is for use only
• To avoid severe burns, allow boiler to cool before
performing maintenance.
by
a
qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Boiler operation –
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
NOTICE
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
Boiler water –
• Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.
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.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
ƽ WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
ƽ WARNING
Do not use petroleum-based cleaning or
ƽ CAUTION
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present.
Do not use “homemade cures” or “boiler
patent medicines”. Serious damage to
WHAT TO DO IF YOU SMELL GAS
ƽ CAUTION
the boiler, personnel, and/or property
may result.
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
3
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Outdoor Knight Boiler Installation & Operation Manual
The Outdoor Knight Boiler - How it works...
1. Stainless steel heat exchanger
17. Manual air vent
Allows system water to flow through specially designed
coils for maximum heat transfer, while providing
Designed to remove trapped air from the heat exchanger
coils.
protection against flue gas corrosion.
encased in a jacket that contains the combustion process.
The coils are
18. High voltage junction box
The junction box contains the connection points for the line
voltage power and all pumps.
2. Combustion chamber access cover
Allows access to the combustion side of the heat
exchanger coils.
19. Boiler drain port
Location from which the heat exchanger can be drained.
20. Low voltage connection board
The connection board is used to connect external low voltage
devices.
21. Low voltage wiring connections
Conduit connection points for the low voltage
connection board.
22. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
23. Access cover - top front
3. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the
burner, where they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the
blower, allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
5. Venturi
Provides protection of the control panel / display from outside
elements.
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated)
24. Access cover - bottom front
Provides access to the burner.
25. Ignition electrode
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides
surface and flame.
27. Relief valve
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 30 psi.
28. Flame sensor
Used by the control module to detect the presence of burner
flame.
29. Line voltage wiring connections
Conduit connection points for the high voltage junction box.
30. Top access cover
Provides access to the internal components.
31. Power switch
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
7. Boiler outlet temperature sensor (housed with the
a
view of the burner
high limit sensor)
This sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control
module adjusts boiler firing rate so the outlet temperature is
correct.
8. Boiler inlet temperature sensor
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the boiler firing rate so the inlet temperature is
correct.
9. Temperature and pressure gauge (field installed, not
shown)
Monitors the outlet temperature of the boiler as well as the
system water pressure.
Turns 120 VAC ON/OFF to the boiler.
32. Leveling legs
10. Electronic LCD display
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
The electronic display consists of 4 buttons, a navigation dial
and a multiple line liquid crystal display.
11. Flue pipe adapter
33. Air pressure switch
The air pressure switch detects blocked inlet conditions.
34. Transformer
The transformer provides 24V power to the integrated control.
35. High limit sensor (housed with the outlet
temperature sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will
break the control circuit, shutting the boiler down.
36. Gas shutoff switch
Allows for the connection of the vent system to the
boiler.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
13. Water outlet (system supply)
NPT water connection that supplies hot water to the
system, either 1" or 1-1/4", depending on the
model.
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
37. Over-temp switch (Model 286 Only) (located underneath
access cover)
14. Water inlet (system return)
NPT water connection that returns water from the
system to the heat exchanger, either 1" or 1-1/4",
depending on the model.
An electrical switch designed to shut down boiler operation in
the event the outer back of the heat exchanger, directly above the
flue connection exceeds 604°F (318°C). This is a one time
switch and could warrant a heat exchanger replacement. Check
the integrity of the rear refractory at the back of the upper coil if
the switch opens.
15. Gas connection pipe
Threaded pipe connection, either 1/2" or 3/4",
depending on the model. This pipe should be connected
to the incoming gas supply for the purpose of delivering
gas to the boiler.
16. SMART SYSTEM Control Module
38. Air cover
The SMART SYSTEM Control responds to internal and
external signals and controls the blower, gas valve, and pumps
to meet the heating demand.
Covers the over-temp switch and the flue collar with flue sensor.
39. Flue pipe assembly
Factory supplied components for a complete venting system.
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4
Outdoor Knight Boiler Installation & Operation Manual
The Outdoor Knight Boiler - How it works...
Models 151 - 211
(continued)
21
30
31
29
10
23
24
IMG00366
11
6
IMG00365
38
Front View - Models 151 - 211
Rear View - Models 151 - 211
18
20
16
39
33
15
7
35
34
8
14
27
10
25
3
4
5
36
1
17
2
26
28
13
19
1
32
22
IMG00368
IMG00367
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Right Side (inside unit) - Models 151 - 211
Left Side (inside unit) - Models 151 - 211
5
Outdoor Knight Boiler Installation & Operation Manual
The Outdoor Knight Boiler - How it works...
29
Model 286
38
21
30
39
31
15
37
10
23
24
IMG00380
6
IMG00379
11
Rear View - Model 286
Front View - Model 286
34
18
20
10
33
16
4
15
8
5
36
3
14
27
25
28
2
1
13
17
19
32
IMG00381
IMG00382
22
Left Side (inside unit) - Model 286
Right Side (inside unit) - Model 286
6
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Outdoor Knight Boiler Installation & Operation Manual
Ratings
A
S
M
E
H
Outdoor Knight Boiler
AHRI Rating
Other Specifications
Heating
Capacity
MBH
Input
MBH
AFUE
%
Net
AHRI
Ratings
Water,
MBH
Model Number
Boiler
Water
Air
Size
Water
Gas
Content Connections Connections
Gallons
(Note 4)
Note: Change “N” to
“L” for L.P. gas models.
Max
Min
150
(Note 2,5)
141
(Note 1, 5)
94
(Note 3,5)
122
1.3
1.7
2.4
1"
1"
1/2"
1/2"
3/4"
3"
3"
4"
OKN151
OKN211
OKN286
30
42
57
210
285
197
266
171
232
94
94
1-1/4"
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
1. As an Energy Star Partner, Lochinvar has determined that
outdoor boilers meet the Energy Star guidelines for energy
efficiency.
2. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
3. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
4. Standard outdoor boilers are equipped to operate from sea
level to 4,500 feet only with no adjustments. The boiler will
de-rate by 4% for each 1,000 feet above sea level up to 4,500
feet.
5. Ratings have been confirmed by the Hydronics Section of
AHRI.
6. Outdoor boilers temperature controls comply with the
requirements of CSD-1 Section CW-400 requirements.
The manual reset high limit provided with the outdoor
boiler is listed to UL353.
7
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Outdoor Knight Boiler Installation & Operation Manual
1 Determine boiler location
Do not locate unit so that high winds can
deflect off of adjacent walls, buildings
or shrubbery causing recirculation.
Recirculation of flue products may cause
operational problems, bad combustion or
damage to controls. Locate unit at least
3 feet (0.91m) from any wall or vertical
surface to prevent wind conditions from
affecting performance.
Installation must comply with:
ƽ CAUTION
•
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.
The outdoor unit must not be installed in
an area that is enclosed by walls or a fence
that will block free wind movement around
the unit. Free movement of wind around
the outdoor unit is required to carry away
the flue products and provide combustion
air. The flue outlet/combustion air inlet
of an outdoor unit must not be installed
closer than 10 feet from an inside corner of
an L-shaped structure. Walls or enclosed
fencing may cause eddy currents which
can recirculate the flue products into the
combustion air inlet. Recirculation of flue
products may cause operational problems,
bad combustion or non-warrantable damage
to controls.
The Outdoor Knight gas manifold and
NOTICE
controls met safe lighting and other
performance criteria when the boiler
underwent tests specified in ANSI Z21.13
– latest edition.
Outdoormodelsmustbeinstalledoutdoors
ƽ WARNING
only and must use the outdoor vent kit
assembly supplied by the manufacturer.
Personal injury or product damage may
result if any other cap is used or if an
outdoor model is used indoors. All covers,
doors and jacket panels must be properly
installed to ensure proper operation and
prevent a hazardous situation.
This product contains
a
condensate
CAUTION
-Do not install the outdoor unit under a
deck.
-Do not install an outdoor unit in a well,
stairwell, alcove, courtyard or other
recessed area.
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.
ƽ WARNING
-Do not install outdoor units on stack
frames.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
Before locating the boiler, check:
1. Check for nearby connection to:
• Water piping
• Gas supply piping
• Electrical power
- Do not install outdoor units in locations
where rain from building runoff drains
will spill onto the unit.
CAUTION
- Do not locate the outdoor unit so that
water from sprinklers may spray directly
onto it. Water may damage controls or
other electrical components.
2. -Keep venting areas free of obstructions.
-Keep area clean and free of combustible and flammable
materials.
-To avoid a blocked air inlet or blocked flue condition,
keep the outdoor air inlet and flue outlet clear of leaves,
debris, etc.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
Do not install outdoor models directly
CAUTION
Failure to keep the boiler area clear and free
ƽ WARNING
on the ground. You must install the
of combustible materials, gasoline and other
outdoor unit on a concrete, brick, block or
pressure-treated wood platform.
flammable liquids and vapors can result in
severe personal injury, death or substantial
property damage.
4. If a new boiler will replace an existing boiler, check for and
correct system problems, such as:
• System leaks causing oxygen corrosion or heat exchanger
cracks from hard water deposits.
• Incorrectly-sized expansion tank.
8
• Lack of freeze protection in boiler water causing system
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and boiler to freeze and leak.
Outdoor Knight Boiler Installation & Operation Manual
1 Determine boiler location
(continued)
Flooring and foundation
Flooring
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6 mm) from combustible
materials.
TheOutdoorKnightisapprovedforinstallationoncombustible
flooring.
2. Vent pipes—minimum of 14" (356mm) from the rear and
0" on the right side from combustible materials.
Do not install the boiler on carpeting even if
ƽ WARNING
foundation is used. Fire can result, causing
severe personal injury, death, or substantial
property damage.
Clearances for service access
1. If you do not provide the minimum clearances, it may
not be possible to service the boiler without
removing it from the space.
Under no circumstances is the manufacturer to be held
responsible for water damage in connection with this appliance,
or any of its components. If flooding is possible, elevate the
boiler sufficiently to prevent water from reaching the boiler.
Recommended service clearances:
Front
Top
Left side -
Rear
-
-
24" (610mm)
24" (610mm)
24" (610mm)
24" (610mm)
Prevent combustion air contamination
Do not install unit in locations that can allow contamination
of combustion air. Refer to Table 1A for products and areas
which may cause contaminated combustion air.
-
Outdoor vent / air intake location
The flue products discharged from the
Table 1A Corrosive Contaminants and Sources
ƽ WARNING
flue outlet on the outdoor vent may be
very hot. Avoid touching or other direct
contact with the flue gases or the vent
termination assembly. These components
are hot and direct contact can result in
burns.
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
To prevent recirculation of the flue products into the
combustion air inlet, follow all instructions in this section.
Flue gas condensate can condense on exterior walls or on the
vent. Some discoloration to exterior building or unit surfaces
can be expected. Adjacent brick or masonry surfaces should
be protected with a rust resistant sheet metal plate.
Paint or varnish removers
Hydrochloric acid/muriatic acid
Maintain a minimum of 24" (610mm) clearance to the side
of the air inlet.
Cements and glues
Antistatic fabric softeners used in clothes dryers
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.
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other similar
products
Locate outdoor unit at least 10 feet (3.05m) away from any
forced air inlet.
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Multiple outdoor unit installations require 24" (.61m)
clearance between each vent termination.
Clearances around outdoor installations can change with
time. Do not allow the growth of trees, shrubs or other plants
to obstruct the proper operation of the outdoor vent system.
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
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9
Outdoor Knight Boiler Installation & Operation Manual
2 Prepare boiler
Remove boiler from wood pallet
Figure 2-2 Install Flue Pipe Assembly
1. After removing the outer shipping carton from the boiler,
WALL STRAP SCREWS
remove the installation kit.
2. Remove the front access covers to access the lag bolts in
front of the unit (FIG. 2-1).
BIRD SCREEN
WALL STRAP
3. To remove the boiler from the pallet (after removing the
front access covers):
a. Remove the two lag bolts from the wood pallet
inside the boiler (FIG. 2-1).
FLUE PIPE
b. Detach the boiler from the lag bolts in the rear of the
unit, see FIG. 2-1.
Do not drop the boiler or bump the jacket
NOTICE
on the floor or pallet. Damage to the
boiler can result.
ELBOW
Figure 2-1 Boiler Mounted on Shipping Pallet
NOTE: VERIFY GASKETS ARE
SEATED EVENLY INSIDE
THE GROOVE.
IMG00443
FLUE ADAPTER
AIR COVER
5. Slide the vent pipe through the wall strap and insert it
into the elbow.
6. Install the bird screen into the top of the flue pipe.
. 2
Gas conversions
For a boiler already installed, you must
turn off gas supply, turn off power and
ƽ WARNING
Install flue pipe assembly (reference FIG. 2-2 for flue
pipe assembly)
allow boiler to cool before proceeding.
You must also completely test the boiler
after conversion to verify performance
as described under Start-up, Section 7
of this manual. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
The outdoor boiler is shipped with all the necessary vent
components. All components must be installed prior to
operation. Basic installation steps are as follows:
1. Locate all venting components from the installation kit
and carton.
You must install a propane orifice to
operate the outdoor boiler on propane
gas. Verify when installing that the orifice
size marking matches boiler size (Table
2A).
2. Before connecting the flue pipe sections or components,
verify the gasket is seated evenly inside the groove in the
female end of the elbow and flue adapter.
3. Remove the kit provided screws from the air cover and
use them to install the wall strap.
1. Remove the top and front access covers from the unit
(tools required for removal).
4. Insert the elbow into the flue adapter.
2. Remove the three screws securing the gas valve to the
venturi (FIG. 2-3).
Do not use grease or other lubricant
on the vent seals. Only water may be
ƽ CAUTION
3. Locate the propane orifice disk from the conversion kit
bag. Verify that the stamping on the orifice disk matches
the boiler size (see Table 2A).
used for this purpose. Grease or other
lubricant can make the seal brittle or it
can result in tears in the surface of the
seal, this will result in flue gas leakage.
Place the orifice into the black rubber grommet in the
side of the gas valve and secure in the valve (FIG. 2-3).
4. Reposition the gas valve against the venturi and replace
the screws (FIG. 2-3) securing the valve to the venturi.
10
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Outdoor Knight Boiler Installation & Operation Manual
2 Prepare boiler
(continued)
5. After installation is complete, attach the propane
conversion label (in the conversion kit bag) next to the
boiler rating plate. Attach the LP caution label (in the
conversion kit bag) to the left side of the unit in the
lower left corner.
Leveling the boiler
1. Set the boiler in place and check level.
a) Adjust legs if necessary to level boiler, see FIG. 2-4
below.
Figure 2-4 Leveling Legs on the Boiler
6. Replace the top and front access covers.
Table 2A LP Conversion Table
LP Conversion Table
Model
LP Orifice Stamping
151
211
286
150
210 / W150
285
After converting to LP, check combustion
per the Start-up procedure in Section
7 of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
ƽ WARNING
Figure 2-3 Installing Propane Orifice
11
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
System water piping methods
General piping information
The outdoor boiler is designed to function in a closed loop Basic steps are listed in this section along with illustrations on
pressurized system not less than 12 psi. A temperature and the following pages (FIG.’s 3-4 thru 3-10), which will guide you
pressure gauge is included to monitor system pressure and through the installation of the outdoor boiler (reference FIG.’s
outlet temperature and should be located on the boiler outlet. 3-2A and 3-2B).
It is important to note that the boiler has a minimal 1. Connect the system return marked “Inlet”.
amount of pressure drop and must be figured in when
2. Connect the system supply marked “Outlet”.
sizing the circulators. Each boiler installation must have
3. Install purge and balance valve or shutoff valve and drain
an air elimination device, which will remove air from
on system return to purge air out of each zone.
the system. Install the boiler so the gas ignition system
4. Install a backflow preventer on the cold feed make-up water
components are protected from water (dripping, spraying,
etc.) during appliance operation for basic service of circulator
line.
replacement, valves, and others.
5. Install a pressure reducing valve on the cold feed make-
up water line, (15 psi nominal). Check temperature and
pressure gauge (shipped separately), which should read a
minimum pressure of 12 psi.
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.
6. Install a circulator as shown on the piping diagrams in this
section. Make sure the circulator is properly sized for the
system and friction loss.
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.
7. Consult the factory for a pump and/or pump cover. If a
field-supplied pump is used, install per the manufacturer’s
specifications in regard to indoor or outdoor location. An
outdoor rated pump is recommended.
Chilled water system
If the boiler supplies hot water to heating coils in air handler
units, flow control valves or other devices must be installed to
prevent gravity circulation of heater water in the coils during
the cooling cycle. A chilled water medium must be piped in
parallel with the heater.
8. Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
9. Install an air elimination device on the system supply.
Freeze protection, heat exchanger
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.
Freeze protection for new or existing systems must use glycol
that is specially formulated for this purpose. This includes
inhibitors, which prevent the glycol from attacking the
metallic system components. Make certain to check that
the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once
a year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
11. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). Pipe the discharge of the
safety relief valve to prevent injury in the event of pressure
relief. Provide piping that is the same size as the safety relief
valve outlet. Never block the outlet of the safety relief valve.
Use only inhibited propylene glycol
ƽ WARNING
solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
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12
Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
The relief valve, tee and any necessary fittings
are shipped in the install kit with the boiler
and are to be field installed (FIG. 3-1).
Near boiler piping components
ƽ WARNING
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe
requirements listed in Table 3A. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on 20 feet of piping,
4 - 90° elbows, and 2 - fully ported ball valves.
*See the piping illustrations included in this section, FIG.’s 3-4
thru 3-10 for suggested guidelines in piping the outdoor boiler
with either zone valves or circulator pumps.
*Please note that these illustrations are
NOTICE
meant to show system piping concept only,
2. Boiler system pump w/pump cover:
the installer is responsible for all equipment
and detailing required by local codes.
A Grundfos UPS26-99F pump and pump cover will be
provided by the factory (for standard altitude models) as
the boiler circulation pump based on 20 feet of piping,
4 - 90° elbows, and 2 - fully ported ball valves.
The outdoor boiler is capable of servicing
multiple temperature loop systems. It is the
CAUTION
responsibility of the installer to protect the
loops with lower temperature requirements
from higher temperatures that may be
required by other loops.
Outdoor boilers are capable of controlling
a
variable speed boiler circulator. Variable speed circulators
MUST be sized to meet the specified minimum flow
requirements listed in FIG. 3-3 on page 15 at full
speed.
Relief valve and temperature and pressure
gauge installation
Basic steps are listed below to guide you through the installation
of the relief valve and the temperature and pressure (T & P)
gauge provided with the unit.
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG. 3-3. Consult the indirect water heater operating
guide to determine flow characteristics for the selected
product used.
1. Install the tee with the 3/4 inch fitting positioned
vertically and on the top as shown in FIG. 3-1.
2. Install the relief valve into the 3/4 inch fitting of the tee
installed in Step 1 (FIG. 3-1).
3. Install a field provided 5 inch long nipple and tee with the
fitting positioned vertically on the top on the
downstream side of the relief valve (see FIG. 3-1).
4. Install the temperature and pressure gauge provided with
the unit into the top fitting of the tee (a bushing may be
necessary) installed in Step 3 (FIG. 3-1).
4. Boiler isolation valves:
Field supplied. Full port ball valves are required.
Failure to use full port ball valves could result in a
restricted flow rate through the boiler.
5. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 3-4 thru 3-10. Failure to
install check valves could result in a reverse flow
condition during pump(s) off cycle.
6. Domestic indirect hot water isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
Figure 3-1 Relief Valve / T & P Installation
7. Anti-scald mixing valve:
Field supplied.
An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F.
8. Unions:
Field supplied. Recommended for unit serviceability.
9. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
RELIEF VALVE
TEMPERATURE &
PRESSURE GAUGE
TEE W/FITTING ON TOP
(FIELD PROVIDED)
10. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
11. Boiler purge valve:
CLOSE NIPPLE
(FIELD PROVIDED)
IMG00369
TEE WITH 3/4" FITTING
Field supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
ON TOP
CLOSE NIPPLE
13
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
12. System temperature sensor:
Lochinvar offers the Squire which is a series of indirect
water heaters. The Squire features a stainless steel vessel
with a single wall stainless steel heat exchanger.
Lochinvar supplies
a
system temperature sensor.
The sensor is to be installed in the heating loop
downstream from the boiler hot water piping and
heating loop junction. Typically the sensor will be
located far enough downstream to sense system diluted
water temperature.
It is up to the installer to ensure the
minimum system flow is not less than the
CAUTION
minimum boiler flow at any time.
13. Indirect water heaters:
The National Standard Plumbing Code
ƽ WARNING
The outdoor boiler may be piped to an indirect
water heater to heat domestic hot water with the space heat
transfer medium. As depicted on pages 17 through 23
there are two options when utilizing an indirect water
heater.
and the Uniform Plumbing Code limit the
pressure of the heat transfer fluid to less
than the minimum working pressure of the
potable water system up to 30 psi maximum.
Also, the heat transfer fluid must be water
or other non-toxic fluid having a toxicity of
Class 1, as listed in Clinical Toxicology of
Commercial Products, 5th Edition.
A. The space heating piping will branch off to flow the
space heat transfer medium through a single wall
heat exchanger coil inside the indirect water heater.
B. The indirect water heater is connected to the system
14. Y-Strainer:
supply piping.
A
pump controlled by the
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.
outdoor boiler’s control will regulate the flow of
water through the indirect water heater. The indirect
water heater’s temperature will be regulated by the
outdoor boiler’s control.
Circulator sizing
The outdoor boiler is pre-configured to control the
operation of the DHW pump with Domestic Hot Water
Prioritization programming. The DHW programming is
designed to control and balance the space heating
demand by switching between DHW and space heating.
The outdoor boiler heat exchanger does have a pressure drop,
which must be considered in your system design. Refer to the
graph in FIG. 3-3 for pressure drop through the outdoor boiler
heat exchanger.
Near boiler piping connections
Figure 3-2A Near Boiler Piping w/Y-Strainer
Figure 3-2B Near Boiler Piping w/Low Loss Header
SYSTEM SENSOR
AIR VENT VALVE
AIR SEPARATOR
LOW LOSS HEADER
(TYPICAL)
FILL VALVE
Y-STRAINER
(RECOMMENDED)
DRAIN
DOMESTIC HOT
WATER PUMP
(TYPICAL)
EXPANSION TANK
DRAIN VALVE
SYSTEM
PUMP
BOILER
PUMP
INDIRECT
DOMESTIC
HOT WATER
TANK
INDIRECT
DOMESTIC
HOT WATER
Y-STRAINER
(RECOMMENDED)
BOLIER PUMP
DRAIN
(TYPICAL)
IMG00377
TO FLOOR
DRAIN
IMG00378
TO FLOOR
DRAIN
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14
Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-3 Pressure Drop vs. Flow
Pressure Drop vs. Flow (Includes Secondary Piping)
25
20
15
10
5
151
211
286
0
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Flow Rate (GPM)
Table 3A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°
20°F Temperature Rise Applications
Pump
TACO
0011
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
UPS26-99F
UPS32-160
UPS32-80
B & G
NRF-36
PL-55
Armstrong
151
211
286
14
20
27
20
29
15
1"
1"
1-1/4"
E7
1400-50
1400-20
E9*
E11
PL-36
These pumps are only slightly above 20° rise flows, but are the closest available. To reach a 20° rise or less, an
upsized pump will be required.
*NOTICE
25°F Temperature Rise Applications
Pump
Minimum Pipe
Size
Model
GPM
FT/HD
Grundfos
TACO
B & G
Armstrong
151
211
286
11
16
21
13
19
12
1"
1"
1-1/4"
UPS26-99F
UPS26-99F
UPS26-99F
0014
0013
0011
NRF-36
NRF-36
NRF-36
E7
E7
E7
35°F Temperature Rise Applications
Pump
TACO
008/0010
0010
008/0010
Minimum Pipe
Model
GPM
FT/HD
Size
Grundfos
UPS15-58FC
UPS15-58FC
UP26-64F
B & G
NRF-36
NRF-36
NRF-36
Armstrong
Astro-30
Astro-50
E7
151
211
286
8
10
9
7
1"
1"
1-1/4"
11
15
Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude
models.
NOTICE
Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude
models.
NOTICE
NOTICE
The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.
15
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
Variable speed pump option
Table 3B Recommended Variable Speed Pumps
Minimum Temperature Rise*
Pump
Model
Grundfos
TACO
Wilo
UP26-96 FC/VS
0013 IFC VS
Stratos 1.25 3 x 30
151
211
286
21
27
27
20
25
24
19
24
22
*The minimum temperature rise is derived from the chart in FIG. 3-3 with the firing rate and pump speed at 100% as shown in
the table above.
The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are
to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 3B to the boiler
high voltage terminal strip.)
Variable speed pump setup
Before operation, ensure the following:
- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control
- Pump is set for external signal control (if applicable)
- Pump is set for linear output (if applicable)
- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module
will be required from the vendor
Pump sizing and flow requirements are
NOTICE
based on 20 feet of piping, 4 - 90°
elbows, and 2 - fully ported ball valves.
It is required that near boiler piping
NOTICE
systems utilize the Primary/Secondary
configuration shown in FIG. 3-10 only.
The use of other near boiler piping
configurations could result in improper
building and system flow rates leading to
inadvertent boiler high limit shutdowns
and poor system performance.
SMART SYSTEM / Multi-temperature loop
control option
The outdoor boiler is capable of producing up to three (3) set
point temperatures to meet different space heating demands.
When using more than one temperature demand it is necessary
to protect the lower temperature loop from overheating. To
help aid with this protection, Lochinvar offers the Multi-
Temperature Loop Control Board Kit (RLY30086).
16
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-4 Single Boiler - Single Temperature Zoned with Circulators
ZONE #1
PRESSURE
GAUGE
PRESSURE
ZONE #2 ZONE #3 ZONE #4
REDUCING VALVE
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
(TYPICAL)
MAKE UP WATER
SYSTEM SUPPLY
SENSOR
ZONE CIRCULATORS
(TYPICAL)
(WHEN USED)
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
BALL VALVE
(TYPICAL)
Y-STRAINER
DRAIN POINT
(TYPICAL)
(RECOMMENDED)
BOILER
HOT
WATER
OUT
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
ANTI-SCALD
MIXING VALVE
COLD
WATER
IN
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
INDIRECT
DHW TANK
BOILER
IMG00370
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
17
Indoor tank shown for illustration purposes.
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
Figure 3-5 Multiple Boilers - Single Temperature Zoned with Circulators
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
151
211
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
3-1/2"
4"
5"
2" 2-1/2"
3"
3"
3"
3-1/2"
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
ZONE #1
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
ZONE #4
ZONE #2 ZONE #3
BACKFLOW
PREVENTER
FLOW CHECK
VALVE
SYSTEM SUPPLY
SENSOR
MAKE UP WATER
(TYPICAL)
AIR SEPARATOR
ZONE CIRCULATORS
(TYPICAL)
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
HOT
WATER
OUT
ANTI-SCALD
MIXING VALVE
BOILER
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
COLD
WATER
IN
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
UNION
TEMPERATURE /
(TYPICAL)
PRESSURE
GAUGE
DRAIN
BOILER 1
BOILER 2
INDIRECT
(LEADER)
(MEMBER 1)
DHW TANK
IMG00371
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.
NOTICE
Indoor tank shown for illustration purposes.
18
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-6 Single Boiler - Multiple Temperatures
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
WIRES TO
LOOP SENSORS
BACKFLOW
PREVENTER
PRESSURE
GAUGE
MAKE
UP
SYSTEM
WATER
MIXING VALVES
(TYPICAL)
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA
OR MAX. OF 12" APART
120VAC TO PUMPS
BALL VALVE
(TYPICAL)
24V SIGNALTO
MIXING VALVES
Y-STRAINER
(RECOMMENDED)
DRAIN POINT
(TYPICAL)
MULTI-TEMP
BOILER
LOOP CONTROL
CIRCULATOR
DOMESTIC
FLOW CHECK
VALVE
HOT WATER
CIRCULATOR
ANTI-SCALD
HOT WATER
OUT
MIXING VALVE
COLD
WATER
IN
SHIELDED CABLE TO
BOILER CONTROL
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE DRAIN
GAUGE
BOILER
Mixing valves are required for the protection of low temperature loops.
IMG00372
CAUTION
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.
Indoor tank shown for illustration purposes.
19
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
Figure 3-7 Multiple Boilers - Multiple Temperatures
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
151
211
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
3-1/2"
4"
5"
2" 2-1/2"
3"
3"
3"
3-1/2"
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
WIRES TO
LOOP
SENSORS
PRESSURE
TEMPERATURE
LOOP #1
TEMPERATURE
LOOP #2
TEMPERATURE
LOOP #3
REDUCING VALVE
BACKFLOW
PREVENTER
MIXING VALVES
(TYPICAL)
PRESSURE
GAUGE
SYSTEM
MAKE
UP
SUPPLY
SENSOR
WATER
AIR SEPARATOR
EXPANSION
TANK
24V
SIGNAL
TO MIXING
VALVES
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
120VAC TO PUMPS
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
MULTI-TEMP
LOOP CONTROL
(OPTIONAL)
BOILER
CIRCULATOR
SHIELDED CABLE TO
BOILER CONTROL
DOMESTIC
HOT WATER
CIRCULATOR
FLOW CHECK
VALVE
HOT
ANTI-SCALD
WATER
OUT
MIXING
VALVE
Y-STRAINER
COLD
WATER
IN
(RECOMMENDED)
TEMPERATURE /
PRESSURE
GAUGE
UNION
BOILER
BOILER
INDIRECT
DHW TANK
(TYPICAL)
DRAIN
IMG00373
Mixing valves are required for the protection of low temperature loops.
CAUTION
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.
Indoor tank shown for illustration purposes.
20
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-8 Single Boiler - Multiple Temperatures with DHW Piped as a Zone
PRESSURE
WIRES TO
LOOP
TEMPERATURE
LOOP #1
TEMPERATURE
TEMPERATURE
LOOP #3
REDUCING VALVE
LOOP #2
BACKFLOW
PREVENTER
SENSORS
PRESSURE
GAUGE
MAKE
UP
MIXING VALVES
(TYPICAL)
WATER
SYSTEM
SUPPLY
SENSOR
AIR SEPARATOR
EXPANSION
TANK
MAY SUBSTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
24V SIGNAL TO
MIXING VALVES
120VAC TO PUMPS
DRAIN POINT
(TYPICAL)
MULTI-TEMP TO
DOMESTIC
LOOP CONTROL
HOT WATER
CIRCULATOR
Y-STRAINER
(RECOMMENDED)
SHIELDED CABLE TO
BOILER CONTROL
FLOW
CHECK
VALVE
ANTI-SCALD
HOT WATER
MIXING VALVE
OUT
BOILER
CIRCULATOR
COLD
WATER
IN
PRESSURE
RELIEF
VALVE
TEMPERATURE /
PRESSURE GAUGE
UNION
DRAIN
(TYPICAL)
BOILER
BOILER
INDIRECT
DHW TANK
IMG00374
Mixing valves are required for the protection of low temperature loops.
CAUTION
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.
Indoor tank shown for illustration purposes.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
NOTICE
Indoor tank shown for illustration purposes.
21
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
Figure 3-9 Multiple Boilers - Single Temperature Zoned with Valves
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
151
211
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
3-1/2"
4"
5"
2" 2-1/2"
3"
3"
3"
3-1/2"
ZONE #1
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
PRESSURE
REDUCING VALVE
ZONE #2
BACKFLOW
PREVENTER
ZONE #3 ZONE #4
PRESSURE
GAUGE
BALL VALVE
(TYPICAL)
ZONE VALVES
(TYPICAL)
SYSTEM SUPPLY
MAKE UP WATER
DIFFERENTIAL
SENSOR
PRESSURE BYPASS
VALVE (IF USED)
(WHEN USED)
AIR SEPARATOR
SYSTEM
CIRCULATOR
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
DRAIN POINT
(TYPICAL)
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
ANTI-SCALD
HOT
WATER
OUT
MIXING VALVE
BOILER
CIRCULATOR
DOMESTIC
HOT WATER
CIRCULATOR
COLD
WATER
IN
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
UNION
TEMPERATURE /
PRESSURE
GAUGE
(TYPICAL)
DRAIN
BOILER 2
BOILER 1
(LEADER)
INDIRECT
(MEMBER 1)
DHW TANK
IMG00375
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.
NOTICE
Indoor tank shown for illustration purposes.
22
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Outdoor Knight Boiler Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-10 Multiple Boilers - Non-Zoned Primary/Secondary Piping
Number of Units
Model
2
3
4
5
6
7
8
Required Pipe Sizes
151
211
2"
2"
2-1/2" 2-1/2"
3"
3"
4"
4"
3-1/2"
4"
5"
2" 2-1/2"
3"
3"
3"
3-1/2"
286 2-1/2" 2-1/2"
3-1/2" 3-1/2"
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
BACKFLOW
PREVENTER
MAKE UP WATER
SYSTEM SUPPLY
SENSOR
SYSTEM
AIR SEPARATOR
MAY SUBSTITUTE LOW LOSS HEADER
CIRCULATOR
TO
FROM
SYSTEM
SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
BALL VALVE
(TYPICAL)
EXPANSION
TANK
DRAIN POINT
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
HOT
ANTI-SCALD
WATER
MIXING VALVE
OUT
DOMESTIC
HOT WATER
COLD WATER
IN
CIRCULATOR
BOILER
CIRCULATOR
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
UNION
(TYPICAL)
BOILER 4
BOILER 3
BOILER 1
(LEADER)
BOILER 2
(MEMBER 1)
INDIRECT
(MEMBER 3)
(MEMBER 2)
DHW TANK
IMG00376
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.
NOTICE
Indoor tank shown for illustration purposes.
23
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Outdoor Knight Boiler Installation & Operation Manual
4 Gas connections
4. Purge all air from the gas supply piping.
Connecting gas supply piping
1. Remove the top access cover and refer to FIG. 4-1 to pipe
gas to the boiler.
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
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.
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
(3.5 kPa).
2. Install sediment trap / drip leg.
Figure 4-1 Gas Supply Piping
c. The appliance and its gas connection must be leak
tested before placing it in operation.
Do not check for gas leaks with an open
ƽ WARNING
UNION
flame – 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.
GAS SUPPLY
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 flow.
Failure to apply pipe sealing compound as
ƽ WARNING
DRIP
LEG
detailed in this manual can result in severe
personal injury, death, or substantial
property damage.
MANUAL
SHUTOFF VALVE
(FIELD SUPPLIED)
Outdoor boilers are typically shipped
ƽ WARNING
ready to fire 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 orifice
(see page 11). In order to operate on LP
gas, an orifice MUST BE installed. Failure
to comply could result in severe personal
injury, death, or substantial property
damage.
IMG00383
3. Support piping with hangers, not by the boiler or its
accessories.
The gas valve and blower will not support
the weight of the piping. Do not attempt
ƽ WARNING
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.
24
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Outdoor Knight Boiler Installation & Operation Manual
4 Gas connections
(continued)
Use two wrenches when tightening gas
piping at boiler (FIG. 4-2), 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.
Natural gas:
ƽ WARNING
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 specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.5 inches w.c.
Figure 4-2 Inlet Pipe with Backup Wrench
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. with no flow (lockup) or
with boiler on.
• Minimum 4 inches w.c. with gas flowing (verify during
boiler startup).
2. Install 100% lockup gas pressure regulator in supply line if
inlet pressure can exceed 14 inches w.c. at any time. Adjust
lockup regulator for 14 inches w.c. maximum.
Propane Gas:
Outdoor boilers are typically shipped ready
to fire on natural gas. Check boiler rating
ƽ WARNING
plate to determine which fuel the boiler is set
for. If set to natural gas, it may be converted
to LP by installing an orifice (see page 11).
In order to operate on LP gas, an orifice
MUST BE installed. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
IMG00384
USE BACKUP WRENCH
TO PREVENT PIPE FROM
ROTATING
Maximum inlet gas pressure must not
NOTICE
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
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. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with
boiler on.
• Minimum 8 inches w.c. with gas flowing (verify during
boiler startup).
Ensure that the high gas pressure regulator
is at least 6 - 10 feet upstream of the
appliance.
ƽ WARNING
25
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Outdoor Knight Boiler Installation & Operation Manual
4 Gas connections
Table 4A Natural Gas Pipe Size Chart
Single Unit
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet for 1/2 PSI
Nominal
Iron Pipe
Size (Inches)
10
20
30
97
40
50
60
70
80
90
100
125
150
N/A
175 200
N/A N/A
175
120
82
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1/2
3/4
1
369
697
256
477
974
205
384
789
174
328
677
155
292
595
923
141
267
543
830
128
246
502
769
121
236
472
707
113
210
441
666
106
200
410
636
95
86
79
74
179
369
564
164
333
513
974
149 138
308 287
472 441
871 820
1400
1-1/4
1-1/2
2
2150 1500 1210 1020
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100
6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300
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
Outdoor boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine
2-1/2
3
4
ƽ WARNING
which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page
11). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in severe
personal injury, death, or substantial property damage.
Check inlet gas supply
3. Loosen the set screw one (1) full turn from inside the
pressure tap on top of the gas valve. Place the tubing of
the manometer over the tap once the set screw is
loosened as shown in FIG. 4-3.
CSA or UL listed flexible gas connections
NOTICE
are acceptable, but you must exercise
caution to ensure that the line has adequate
capacity to allow your boiler to fire at full
rate. Consult with local codes for proper
installation or service procedures.
4. Slowly turn on the gas supply at the field installed
manual gas valve.
5. Turn the power switch to the “ON” position.
DO NOT adjust gas valve outlet pressure.
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. 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.
ƽ WARNING
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 fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified 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.
The gas piping must be sized for the proper flow 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.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
If you experience a pressure drop greater than 1 inch w.c.,
the meter, regulator, or gas line is undersized or in need of
service. Perform the steps below when checking inlet gas
supply:
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.
1. Turn the main power switch to the “OFF” position.
13. Remove the manometer from the pressure tap on top of
the gas valve. Re-tighten the set screw inside the pressure
tap.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
26
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4 Gas connections
(continued)
When re-tightening the set screw, be sure
to tighten securely to prevent gas leaks.
Gas Pressure
ƽ WARNING
The gas pressure must remain between 4 inches w.c. (natural),
8 inches w.c. (LP) minimum and 14 inches w.c. (natural and
LP) maximum during stand-by (static) mode and while in
operating (dynamic) mode. If an in-line regulator is used, it
must be a minimum of 10 feet from the outdoor 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.
Do not check for gas leaks with an open
flame -- 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.
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.
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 flame characteristics.
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 flanged connection to the venturi
and blower.
Figure 4-3 Inlet Gas Supply Check
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP.
Failure to follow all precautions could
ƽ WARNING
result in fire, explosion, or death!
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. 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.
DETAIL
IMG00385
27
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Outdoor Knight Boiler Installation & Operation Manual
5 Field wiring
ELECTRICAL SHOCK HAZARD – For
your safety, turn off electrical power supply
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
ƽ WARNING
ƽ CAUTION
before making any electrical connections
to avoid possible electric shock hazard.
Failure to do so can cause severe personal
injury or death.
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
Wiring must be N.E.C. Class 1.
NOTICE
If original wiring as supplied with boiler
must be replaced, use only type 105°C wire
or equivalent.
Line voltage connections
Boiler must be electrically grounded as
required by National Electrical Code ANSI/
NFPA 70 – latest edition.
1. Connect 120 vac power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 5-1.
All wiring exterior to the appliance must be
enclosed in approved conduit.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 5-1).
In accordance with Section 303 of the 2007
Energy Act, this boiler is equipped with a
feature that saves energy by reducing the
boiler water temperature as the heating
load decreases. This feature is equipped
with an override, which is provided
primarily to permit the use of an external
energy management system that serves the
same function. This override MUST NOT
be used unless at least one of the following
conditions is true:
1. An external energy management
system is installed that reduces the
boiler water temperature as the heating
load decreases.
2. This boiler is not used for any space
heating.
NOTICE
3. The boiler pump is shipped loose. Wire the boiler pump
as shown in FIG. 5-1.
4. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 5-1.
5. To activate a system pump, wire as shown in FIG. 5-1.
If the motor is larger than 1/8 hp or 1.8 amps, you must
isolate with a relay.
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 5-2.
3. This boiler is part of a modular or
multiple boiler system having a total
input of 300,000 Btu/hr or greater.
4. This boiler is equipped with a tankless
coil.
2. Connect low voltage wiring to low voltage connection
board as shown in FIG. 5-3 on page 31 of this manual and
the boiler wiring diagram.
Figure 5-2 Routing Field Wiring
LOW VOLTAGE
CONNECTION
BOARD
Figure 5-1 Line Voltage Field Wiring Connections
LOW VOLTAGE
WIRING
KNOCKOUTS
LINE VOLTAGE
WIRING KNOCKOUTS
IMG00386
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28
Outdoor Knight Boiler Installation & Operation Manual
5 Field wiring
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.
(continued)
Thermostat
High gas pressure switch
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.
2. Install the thermostat on the inside wall away from 5-3).
influences of drafts, hot or cold water pipes, lighting
Low gas pressure switch
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).
fixtures, television, sunlight, or fireplaces.
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’ specifications
and thermostat instructions for details.
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).
Outdoor temperature sensor
Variable speed system pump
In the absence of an external energy management system, an
outdoor temperature sensor must be used.
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 0 - 10V
signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or
cascade) can modulate up and down as the primary flow
increases and decreases.
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow 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 boiler.
Boiler pump speed output
This 0 - 10V output is available to control the speed of a variable
speed boiler pump. The SMART SYSTEM control will vary the
speed of this pump in order to maintain a minimum T across
the heat exchanger, as well as prevent high limit lockouts when
the flow in the primary loop is extremely low. Connect this
output to the 0 - 10V input on the boiler pump speed control.
DHW thermostat
Connect storage indirect water heater (DHW) thermostat
(FIG. 5-3) to the DHW thermostat terminals on the
connection board. If a tank sensor is connected (see DHW
Tank Sensor below) the tank thermostat is ignored.
Rate output
This output provides a 0 - 10V signal that is proportional to the
firing rate of the boiler. This may be used by a BMS system to
monitor the actual rate of the boiler.
DHW tank sensor
1. By installing a tank sensor, the SMART SYSTEM control
can 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 drops 6°F (3°C) below the tank
set point and finishes the call for heat when the tank
temperature reaches the tank set point.
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.
2. The tank sensor included with the Lochinvar Squire
Indirect DHW tank (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).
Failure to use the correct sensor may result
in the tank temperature being either above
ƽ WARNING
or below the set point.
3. If the 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 manufacturers instructions and wired to the DHW
Thermostat terminals on the Low Voltage Connection
Board.
29
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5 Field wiring
1. A flow switch is used to guarantee flow through the
boiler before allowing it to fire. The flow switch must be
installed at the boiler outlet.
Flow switch
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
2. Remove the jumper wire from these terminals, and
connect these terminals to the normally open contacts on
the flow switch (FIG. 5-3).
responding to a call for heat.
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.
System supply sensor
1. By installing the system supply sensor into the supply
of the primary loop, the temperature of the primary
supply can be controlled. The SMART SYSTEM control
automatically detects the presence of this sensor, and
controls the boiler firing rate to maintain the system
supply temperature to the set point (if the outlet sensor
control is currently selected). If it is desired to control
the system return temperature, then program the
SMART SYSTEM control to use the inlet sensor as
the controlling sensor. See the Outdoor Knight Boiler
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.
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 38 “Configuration of the
Cascade” for a detailed explanation of this procedure.
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 3-5,
3-7, and 3-9). 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.
2. The TST2032 sensor provided with the boiler must be
used for the system sensor.
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). The Leader control will calculate the water
temperature set point based on the programmed reset curve
parameters.
3. Connect these terminals to the system supply sensor
(FIG. 5-3).
Boiler management system
The United States Energy Policy and Conservation Act
requires residential heating boilers with inputs less than
300,000 Btu/hr be equipped with a control that automatically
adjusts boiler water temperature in relation to heat demand.
An external control may be connected to control the firing
rate or the set point of the boiler provided that either an
external energy management system is installed that reduces
the boiler water temperature as the heating load decreases,
the boiler is not used for any space heating, or the boiler is
part of a modular or multiple boiler system having a total
input of 300,000 Btu/hr or greater.
If a Thermostat, Zone Control enable output, or Building
Management System 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.
1. An external control may be connected to control either
the firing 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 0 - 10 Vdc terminal is connected to the 0 - 10 Vdc
terminal of the external control. Make sure the (-)
voltage is not below ground.
30
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Outdoor Knight Boiler Installation & Operation Manual
5 Field wiring
(continued)
Figure 5-3 Low Voltage Field Wiring Connections
31
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Outdoor Knight Boiler Installation & Operation Manual
6 Condensate disposal
Use materials approved by the authority
Condensate drain
NOTICE
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.
1. This boiler is a high efficiency appliance that produces
condensate.
2. The side of the boiler has a 1/2 inch PVC union for
connection of a 1/2 inch PVC pipe (FIG. 6-1).
To allow for proper drainage on large
NOTICE
3. Slope condensate tubing down and away from the
boiler into a drain or condensate neutralizing filter.
Condensate from the outdoor boiler will be slightly acidic
(typically with a pH from 3 to 5). Install a neutralizing
filter if required by local codes.
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch.
The condensate line must remain
unobstructed, allowing free flow 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.
A Neutralizer Kit (FIG. 6-1) is available from the factory
(Kit 3087).
4. Install the 1/2 inch PVC tee assembly (shipped with the
unit) as shown in FIG. 6-1.
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 overflow 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).
5. Leave the top of the 1/2 inch 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.
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)
1/2" PVC UNION
(FACTORY SUPPLIED)
NEUTRALIZER KIT
FLOOR DRAIN OR
DRAIN PAN
IMG00387
32
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
3. Fill to correct system pressure. Correct pressure will vary
with each application.
Check/control water chemistry
Do not use petroleum-based cleaning or
ƽ CAUTION
a. The minimum cold water fill pressure for
residential system is 12 psi.
a
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets
in the system could occur, resulting in
substantial property damage.
b. Pressure will rise when boiler is turned on and
system water temperature increases.
Hardness less than 7 grains
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Eliminate all system leaks. Continual
Chlorine concentration less than 200 ppm
ƽ WARNING
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.
1. Do not fill 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.
Purge air from water system
3. Do not use the boiler to directly heat swimming pool or
spa water.
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valves, in piping diagrams on pages 17 through 23).
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 fill connection to the system.
c. Close zone isolation valves.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids, follow fluid
manufacturer’s instructions.
2. Freeze protection fluid must be replaced periodically due
to degradation of inhibitors over time. Follow all fluid
manufacturer’s instructions.
d. Open quick-fill valve on cold water makeup line.
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 flow 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-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch
that system pressure rises to correct cold-fill
pressure.
Freeze protection (when used)
1. Determine freeze protection fluid quantity using
system water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 7.
Remember to include expansion tank water content.
2. Local codes may require a backflow preventer or actual
disconnect from city water supply.
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 floor. Close the vent when
water squirts out. Repeat with remaining vents.
3. When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid 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 fluid is used (see the Outdoor Knight
Service Manual).
2. Open automatic air vent (diaphragm-type or bladder-type
expansion tank systems only) one turn.
Fill and test water system
3. Open other vents:
1. Fill system only after ensuring the water meets the
requirements of this manual.
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
2. Close manual and automatic air vents and boiler drain
valve.
4. Refill to correct pressure.
33
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
Propane boilers only – Your propane
ƽ WARNING
Check for gas leaks
suppliermixesanodorantwiththepropane
Before starting the boiler, and during
initial operation, smell near the floor and
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.
ƽ WARNING
around the boiler for gas odorant or any
unusual odor. Remove the top access
cover 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.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to each
of the heat/loop demand terminals on the connection
board.
DO NOT adjust gas valve outlet pressure.
The gas valve is factory set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. 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.
ƽ WARNING
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.)
Figure 7-1 Condensate Trap
RETAINING
SCREW
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board.
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC
fittings and condensate trap.
Fill condensate trap with water
1. Remove the PVC cap retaining screw from the PVC cap
(FIG. 7-1).
CONDENSATE FROM
HEAT EXCHANGER
TO FLOOR
DRAIN
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.
The condensate trap (FIG. 7-1) must be
filled with water during all times of boiler
ƽ WARNING
operation to avoid flue gas emission from
the condensate drain line. Failure to fill
the trap could result in severe personal
injury or death.
34
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
(continued)
Final checks before starting the boiler
Check gas piping
Read the Outdoor Knight Boiler Service Manual to
familiarize yourself with SMART SYSTEM control
module operation. Read this manual, page 36 for proper
steps to start boiler.
1. Check around the boiler for gas odor following the
procedure on page 24 of this manual (connecting gas supply
piping).
If you discover evidence of any gas leak,
ƽ WARNING
shut down the boiler at once. Find the
Verify the boiler and system are full of water and all
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.
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.
Propane boilers – verify conversion
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
The gas valve is factory-set for the correct
Verify electrical connections are correct and securely
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. 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.
attached.
Verify air opening and vent opening are free of
obstruction.
Start the boiler
1. Read and follow the Operating instructions in FIG. 7-2,
page 36.
Outdoor boilers are typically shipped ready
to fire on natural gas. Check boiler rating
ƽ WARNING
plate to determine which fuel the boiler is set
for. If set to natural gas, it may be converted
to LP by installing an orifice (see page 11).
In order to operate on LP gas, an orifice
MUST BE installed. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
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?
3. Is thermostat set below the controlling sensor
temperature?
Check flame and combustion
1. Turn the main power off to the boiler by placing the “On/
Off” switch in the OFF position.
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches w.c.?
2. Remove the flue temperature sensor from the flue pipe
connection. NOTE: Combustion measurements will be
made at this point.
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Outdoor Knight Boiler
Service Manual.
3. Turn the main power on to the boiler by placing the “On/
Off” switch in the ON position.
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.
35
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
Figure 7-2 Operating Instructions
36
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
(continued)
Check flame and combustion (continued)
Set space heating operation
Please note that the brackets ([]) denote
screen status.
Determine controlling sensor
NOTICE
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 Boiler Service Manual for a detailed explanation of
this procedure.
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 8-1, page 45).
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 fire at ignition speed and
will then modulate up to full fire.
6. Insert the probe from a combustion analyzer into the flue
outlet opening.
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
Knight Boiler Service Manual for a detailed explanation of
this procedure.
7. Once the boiler has modulated up to full fire, 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 specified range,
reference the Troubleshooting Section of the Outdoor
Knight Boiler Service Manual for possible causes and
corrective actions.
Table 7A Flue Products Chart
Natural Gas
CO2 O2
Propane
CO2
O2
Adjust set point temperature(s)
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
Please note that the brackets ([]) denote
screen status.
NOTICE
8. Once the combustion analysis is complete, test the safety
shutoff device by turning the manual shutoff switch 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.
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.
9. Turn the main power off to the boiler.
10. Place the boiler back into normal operation.
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
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Outdoor Knight Boiler Installation & Operation Manual
7 Start-up
Set domestic hot water (DHW) operation
Verify DHW mode
8. Turn the NAVIGATION dial to adjust the month. Press the
NAVIGATION dial.
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 firing rate may be limited in this
mode if desired.
9. Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
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 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.
11. Press the RIGHT SELECT [HOME] key.
The internal clock does not adjust for
NOTICE
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.
Configuration of the cascade
Please note that the brackets ([]) denote
screen status.
NOTICE
Set DHW boiler target temperature
When installed in a Cascade system, the individual controls
must be programmed for cascade operation. This is
accomplished by accessing the control parameters.
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
Knight Boiler Service Manual for a detailed explanation of
this procedure.
Press the [MENU] key for at least five (5) seconds. Input
the Installer code as described in the Outdoor Knight Boiler
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.
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 Knight Boiler Service Manual for a detailed
explanation of this procedure.
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 RIGHT SELECT [SAVE] key.
Set clock
Please note that the brackets ([]) denote
screen status.
NOTICE
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.
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.
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
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38
Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
How the boiler operates
General
The control can be configured by the installer to use a 0 - 10
Vdc signal to either control set point or firing rate.
The outdoor boiler uses an advanced stainless steel heat
exchanger and electronic control module that allows fully
condensing operation. The blower pulls in air and pushes flue
products out of the boiler through the heat exchanger and flue
piping. The control module regulates blower speed to control
the boiler firing rate. The gas valve senses the amount of air
flowing into the boiler and allows only the right amount of gas
to flow.
The outdoor boiler can also be programmed to accept a call for
heat from a 0 - 10V signal, reference the Outdoor Knight Boiler
Service Manual for a detailed explanation of this procedure.
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 firing rate can be limited to match the
input rating of the indirect tank coil.
How the control module operates
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.
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.
Control inputs and outputs
Room thermostat
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
have call for heat.
1
and heat/loop demand
2
a
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 satisfied. Once Demand 2 has
been satisfied the boiler will provide 110°F water to the system.
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.
When multiple temperature loops are
ƽ CAUTION
used, mixing valves are required for the
protection of any low temperature loops.
Boiler and system pump control
SMART SYSTEM Multi-temp loop control
The boiler pump will run whenever the burner is firing, 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.
The outdoor 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 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.
0 - 10V input (set point or power)
The outdoor boiler can be controlled by a Building
Management System (BMS) provided that either an external
energy management system is installed that reduces the boiler
water temperature as the heating load decreases, the boiler
is not used for any space heating, or the boiler is part of a
modular or multiple boiler system having a total input of
300,000 Btu/hr or greater.
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39
Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Temperature control
Protection features
Modulation
Outlet temperature, flue temperature, and
temperature rise limiting
The outdoor boiler is capable of modulating its firing rate
from a minimum of 20% to a maximum of 100%. The
firing 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.
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 the control will shut the unit
down until it cools off.
Ramp delay
The control module monitors the flue temperature by a
sensor located in the flue exhaust. If the flue temperature
exceeds 215°F the control will reduce the maximum fan
speed. If the flue temperature exceeds 240°F the control will
shut the unit down. The unit will restart automatically once
the flue temperature drops 25°F and the minimum off time
has expired.
For systems with lower flow, the SMART SYSTEM can limit
the firing 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 firing rate for
the rest of the call for heat.
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds
55°F the control will reduce the maximum fan speed. If
the temperature difference exceeds 60°F the control will
shut the unit down. The unit will restart automatically once
the temperature difference has dropped below 55°F and the
minimum off time has expired.
Gradient limiting
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate to
its lowest setting.
Outdoor air reset
With the outdoor air sensor 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.
Freeze protection
DO NOT install the boiler 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.
Boost function
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F:
Below 45°F, the boiler and system pumps operate
constantly.
Below 37°F, the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F.
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 fixed 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 satisfied, the set point will revert to the value
determined by the reset curve.
•
•
•
•
Lower temperatures may be programmed for
systems with anti-freeze solutions.
When system return temperatures
NOTICE
are maintained below the dew point,
condensation will form on the inside of
the boiler jacket causing some internal
sheet metal components to rust.
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. Any night setback event scheduled
within the next seven (7) days can be temporarily bypassed
if desired.
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.
ƽ CAUTION
Flame current support
To prevent nuisance shutdowns when the boiler is firing at
minimum rates, the control will increase the firing rate when
the flame signal drops too low.
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40
Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Connections are provided on the connection board for
external limits such as a flow 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.
(continued)
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.
Monitor external limits
High limit test procedure
Run-time and alarm outputs
Please note that the brackets ([]) denote
screen status.
NOTICE
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
1. Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
Run-time and cycle counting
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.
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler is
firing in the Space Heating Mode. The other timer monitors
the time the boiler is firing in the DHW Mode.
The control uses two (2) ignition counters to monitor the
amount of boiler cycles. The first counter counts all ignitions
of the control. The second counter counts only ignition
attempts that have failed.
Service reminder
The control can be programmed for service reminder
notification. This notification 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
notification can be reset or disabled by the installer.
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 five (5) seconds to place the boiler into
Service Mode. In Service Mode, the boiler will fire at
ignition speed and will then modulate up to full fire.
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.
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
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.
11. Repeat Steps 2, 3 and 4.
12. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
Boiler temperature regulation
Operating temperature (target)
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
Service Mode.
The SMART SYSTEM control module senses water
temperature and regulates boiler firing and firing rate to
achieve a target temperature. The target temperature can be
set between 32°F and 190°F.
Low water cutoff protection
•
Target temperature is calculated as described in the
“Outdoor Reset Operation” section, when the
outdoor sensor is connected.
If the outdoor sensor is not connected, the target
temperature is fixed at SH (1 - 3) set points. An
outdoor sensor fault will remain on the display
screen until the outdoor sensor is reconnected.
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the flow 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 flow conditions.
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).
•
High limit operations
The outdoor boiler 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 setDpoowinnlotaodffr2o1m0W°Fw.w.Somanuals.com. All Manuals Search And Download.
41
Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Outdoor reset operation
Sequence of the cascade
Target temperature with outdoor reset
To equalize the run time of all boilers on the Cascade, the
firing sequence will automatically be changed at set intervals.
This feature improves the system's efficiency by decreasing set
point as the outdoor temperature warms up. Energy Efficiency
Standards require the use of a control that automatically adjusts
set point in relation to heat demand. In the absence of an
external energy management system, this feature MUST BE
used.
During the first 24 hours of operation, the sequence will
change every hour. After that, the sequence will change every
24 hours. The switching on/off sequence will be as follows:
TIME
Start
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
See the Outdoor Knight Boiler Service Manual to change the
settings.
1 hour
Reset curve
2 hours
M2-M3-M4-M5-M6-M7-L-M1
The reset curve looks at outdoor air temperature and adjusts
the set point in relation to heat demand.
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.
Cascade
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 Efficiency Optimization
control methods.
DHW, Night Setback, and Ramp Delay operation
with 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.
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 Boiler Service Manual to program the
reset curve. If outdoor air reset is not desired, do not connect
the outdoor air sensor. A fixed temperature set point can be
programmed into the control. See page 37 of this manual to
program the set point.
The DHW boiler will adjust its set point to the programmed
DHW boiler set point and will adjust its firing rate to maintain
this. Once the DHW call has been satisfied, 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.
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 Boiler 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.
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.
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 Boiler
Service Manual for information regarding Night Setback.
Ramp Delay operation of the boilers as described in the
Outdoor Knight Boiler Service Manual is available when the
boilers are part of a Cascade system.
42
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Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
(continued)
Sequence of operation
OPERATION
DISPLAY
1. Upon a call for heat, the gas pressure switch(es) must be closed.
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 flow 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 firing the spark electrode
and opening the gas valve.
6. If flame is not detected after the sparking ends, the control will
perform a post-purge, then start another prepurge cycle and try to
light the burner again. The control will perform a total of 4
attempts before locking out.
7. If flame is detected, it holds the firing rate steady for a few
seconds to let the flame stabilize, then it begins to modulate the
firing rate based on a set point or some other command (such
as a 0-10V BMS signal).
43
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Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Sequence of operation (continued)
OPERATION
DISPLAY
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 first, then the boiler pump will
turn off 2 seconds later. 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 satisfied.
10. Once both calls for heat are satisfied, 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
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Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
(continued)
Outdoor Knight boiler 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
(PRESS OR TURN)
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
Saving parameters (reference the Parameter Table in
the Outdoor Knight Boiler Service Manual)
Please note that the brackets ([]) denote
screen status.
NOTICE
The user can adjust space heating and tank target temperatures
by pressing the NAVIGATION dial when “SETPOINTS” is
flashing at the bottom of the display. The date and time, and
the temperature units can also be changed (see page 38).
To save parameters and exit programming:
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
Installer
To enter a parameter and continue programming:
Most parameters are available only to the installer, accessible
by entering the installer password, see the Outdoor Knight
Boiler Service Manual.
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
finished programming in order to save the changes made.
See the Outdoor Knight Boiler Service Manual for a detailed
description of parameters and access modes.
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45
Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Figure 8-2 Status Display Screen
B
A
(CALL FOR
HEAT)
(BOILER
STATUS)
C
(OPERATIONAL
INFORMATION)
F
D
(LEFT SELECT
KEY)
(RIGHT SELECT KEY)
E
(NAVIGATION DIAL)
Status Display Screens
Section
Display
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.
STANDBY
START
The unit has begun a burn cycle and is checking all safety circuits.
The unit has initiated a prepurge period on a call for heat.
PREPURGE
IGNITION
The unit has begun a spark period to ignite the main burner.
The unit has fired and is running at the displayed percentage.
A
%
(Boiler Status
Bar)
The call for heat has been satisfied and the unit runs the fan for an
additional postpurge period to clear the combustion chamber and
vent system of residual flue products.
POSTPURGE
SHUTDOWN
The unit has been placed in the OFF position.
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.
BLOCKED
Heat/Loop Demand 1 has a call for heat.
Heat/Loop Demand 2 has a call for heat.
Heat/Loop Demand 3 has a call for heat.
B
The tank thermostat or sensor has a call for heat.
Indicates which Heat/Loop Demand has priority.
The unit is being controlled by a 0 - 10V BMS signal.
The unit is supplying heat while in Cascade Mode.
(Call for Heat
Indicators)
46
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Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
(continued)
Status Display Screens (cont’d)
Section
Display
Description
SYSTEM:
The temperature read by the system supply sensor (if connected).
TANK:
The temperature read by the tank sensor (if connected).
The temperature read by the outdoor sensor.
OUTDOOR:
INLET TEMP:
OUTLET TEMP:
DELTA T:
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.
FLUE TEMP:
The temperature read by the flue sensor.
FLAME CURRENT:
The current measured by the flame sense circuit.
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.
C
(Operational
Information)
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 firing rate of the boiler.
The total hours of operation in the Space Heating Mode.
The total burner cycles in the Space Heating Mode.
The total hours of operation in the DHW Mode.
The total burner cycles in the DHW Mode.
The last 10 lockouts.
DHW RUN HOURS:
DHW CYCLES:
LAST 10 FAULTS NO:
NIGHT SETBACK
Shows the next Night Setback trigger (if active).
47
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Outdoor Knight Boiler Installation & Operation Manual
8 Operating information
Status Display Screens (cont’d)
Section
Display
Description
Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
MENU
EXIT
Press the LEFT SELECT key to exit the current screen or setting.
Press the LEFT SELECT key to confirm that the boiler needs to
shutdown.
YES
D
(LEFT SELECT
key function)
Press the LEFT SELECT key to enter the screen that allows you to
adjust the limit settings.
LIMITS
HOME
SKIP
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.
E
(NAVIGATION
Dial Function)
Pressing the NAVIGATION dial will display the Set Points Screen.
Turning the NAVIGATION dial will move the cursor up or down.
Turning the NAVIGATION dial will increase or decrease the current
setting.
SHDN
ON
Press the RIGHT SELECT key to turn the boiler OFF.
Press the RIGHT SELECT key to turn the boiler ON.
F
NO
Press the RIGHT SELECT key to cancel the shutdown operation.
Press the RIGHT SELECT key to save the current change.
(RIGHT SELECT
key function)
SAVE
HOME
Press the RIGHT SELECT key to return to the Status Screen and
upload parameter changes.
48
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Outdoor Knight Boiler Installation & Operation Manual
9 Maintenance
Maintenance and annual startup
Table 9A Service and Maintenance Schedules
Owner maintenance
Service technician
(see the Outdoor Knight User’s Information Manual
for instructions)
(see the following pages for instructions)
• Check boiler area
General:
• Address reported problems
• Check pressure / temperature
gauge
• Inspect interior; clean and vacuum if
necessary;
Daily
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air openings in good
condition and free of obstruction
• Check air and vent termination
screens
• Check system water pressure/system
piping/expansion tank
• Check relief valve
Monthly
• Check control settings
• Check condensate drain system
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 7
of this manual.
Periodically
•Test low water cutoff (if used)
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Reset button (low water cutoff)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Check boiler piping (gas and
water) for leaks
Every
6 months
• Operate relief valve
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
End
of season
months
•Shut boiler down (unless boiler
used for domestic hot water)
• Clean the blower wheel
49
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Outdoor Knight Boiler Installation & Operation Manual
9 Maintenance
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.
ƽ WARNING
The boiler should be inspected annually only by a qualified 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 efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
ƽ 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.
ƽ WARNING
Address reported problems
Figure 9-1 Condensate Trap
RETAINING
SCREW
1. Inspect any problems reported by the owner and correct
before proceeding.
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
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
CONDENSATE FROM
HEAT EXCHANGER
1. Remove the front access cover and inspect the interior of
the boiler.
TO FLOOR
DRAIN
The condensate trap must be filled with
water during all times of boiler operation
to avoid flue gas emission from the
condensate drain line. Failure to fill the
trap could result in severe personal injury
or death.
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
ƽ WARNING
Clean condensate trap
1. Inspect the condensate drain line, condensate PVC
fittings, and condensate trap.
Check all piping for leaks
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 9-1).
Eliminate all system or boiler leaks.
ƽ WARNING
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.
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.
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
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Outdoor Knight Boiler Installation & Operation Manual
9 Maintenance
(continued)
Safety relief valves should be re-inspected
ƽ WARNING
Flue vent system and air piping
AT LEAST ONCE EVERY THREE YEARS,
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage.
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.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
ƽ WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi).
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.
Following installation, the valve lever
must be operated AT LEAST ONCE
ƽ WARNING
A YEAR to ensure that waterways are
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
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 flow of hot
water from the valve to a proper place of
disposal. Otherwise severe personal injury
may result. If no water flows, valve is
inoperative. Shut down the boiler until a
new relief valve has been installed.
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.
Check boiler relief valve
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.
1. Inspect the relief valve and lift the lever to verify flow.
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.
51
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Outdoor Knight Boiler Installation & Operation Manual
9 Maintenance
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
2. If the flame is unsatisfactory at either high fire or low fire,
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.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Remove the burner, reference FIG. 9-2 below.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 9-2).
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
Figure 9-2 Burner Assembly
2. Verify all wiring is in good condition and securely
attached.
3. Check ground continuity of wiring using continuity
meter.
AIR / GAS ARM
4. Replace ground wires if ground continuity is not
satisfactory.
INSULATION
Check all boiler wiring
HEAT EXCHANGER
ACCESS DOOR
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
BURNER
GASKET
Check control settings
SCREWS
(QTY. 5)
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
Outdoor Knight Boiler Service Manual. Adjust settings
if necessary. See Section 1 of the Outdoor Knight Boiler
Service Manual for adjustment procedures.
IMG00447
Check flame signal
1. At high fire the flame signal shown on the display should be
at least 10 microamps.
2. Check settings of external limit controls (if any) and
adjust if necessary.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition, and
ground continuity is satisfactory, replace the flame sense
electrode.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 7 - Start-up.
3. See Section 3 - Troubleshooting of the Outdoor Knight
Boiler Service Manual for other procedures to deal with
low flame signal.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
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Outdoor Knight Boiler Installation & Operation Manual
9 Maintenance
(continued)
11. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
Review with owner
1. Review the Outdoor Knight Boiler User’s Information
Manual with the owner.
2. Emphasize the need to perform the maintenance
schedule specified in the Outdoor Knight Boiler User’s
Information Manual (and in this manual as well).
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.
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
13. Replace the access cover and restore boiler to operation.
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.
Table 9B Heat Exchanger Cleaning Kits
Kit
Part
Component
Description
Model
Cleaning boiler heat exchanger
Number Number
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 9B - Heat Exchanger Cleaning Kits.
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
151
-
286
KIT30063
MSC20084
3mm Allen Wrench
1. Shut down boiler:
MSC20086 1/4" x 24" Drill Extension
• 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 fluid
in system, do not drain.
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
replacement nylon brush.
ƽ CAUTION
2. Allow time for the boiler to cool to ambient temperature
if it has been firing.
Figure 9-3 Rope Gasket - Heat Exchanger Door
3. Remove the nuts securing the heat exchanger access
cover to the heat exchanger and set aside.
ROPE GASKET
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
The boiler contains ceramic fiber
ƽ WARNING
materials. Use care when handling these
materials per instructions in the Service
Manual. Failure to comply could result in
severe personal injury.
CAUTION: IF GASKET IS DAMAGED
DO NOT REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
5. Remove the condensate hose from the heat exchanger
end. Connect a field supplied 3/4" diameter hose to
a drain pan. Using field supplied means, cover the
refractory in the back of the combustion chamber of the
heat exchanger.
Rope gasket is intended for sealing combustion
(FIG. 9-3). If damaged DO NOT reuse, the
heat exchanger door must be replaced. Consult
factory for replacement heat exchanger door
(kit WTR3080).
NOTICE
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
Oiled bearing circulators
1. The circulator shipped with the outdoor boiler is water-
lubricated. No oiling is required.
7. Brush the heat exchanger while dry using a nylon bristle
brush. Caution: DO NOT use a metal brush. Re-vacuum
the heat exchanger.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
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.
3. Replace the boiler front access cover.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger
and reassemble.
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Outdoor Knight Boiler Installation & Operation Manual
10 Diagrams
Figure 10-1 Ladder Diagram
JUNCTION BOX
120VAC
NEUTRAL GROUND
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
1
2
INTEGRATED CONTROL
BLOWER
3
ON / OFF
SWITCH
GND
KB ONLY
SYSTEM
PUMP "L"
SYSTEM
PUMP "N"
X1-1
X1-6
F2
X1-2
3.15A
GND
F1
5A
SYSTEM
PUMP
BOILER
BOILER
PUMP "N"
SYSTEM PUMP
RELAY
PUMP "L"
X1-4
X1-3
BOILER PUMP
RELAY
GND
BOILER
PUMP
DHW
PUMP "L"
DHW
PUMP "N"
DHW PUMP
RELAY
F3
TERMINAL
STRIP
TERMINAL
STRIP
DHW
PUMP
.8A
24V DC
SUPPLY
X5-9
X5-1
120 VAC
24 VAC
X4-3
3.5A
KB 801
ONLY
CONNECTION BOARD
INTEGRATED
CONTROL
LWCO
CN5-5
FLOW
CN5-14 X4-8
CN7-3
CN7-4
CN7-2
SWITCH
11
12
CN5-10
X4-12
24 VAC
CN7-1
HEAT/LOOP
DEMAND
1
CN5-7
X4-1
20
18
16
14
19
HEAT/LOOP
DEMAND 2
CN5-13 X4-9
17
HEAT/LOOP
DEMAND 3
CN5-6
X4-2
15
13
TANK
THERMOSTAT
CN5-12
X4-10
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
X4-11
X4-5
CN5-11
CN5-3
9
10
INTEGRATED
CONTROL
LOUVER
RELAY COIL
5
6
7
24VAC
LOUVER
PROVING SWITCH
CN5-4
X4-4
X7
8
RIBBON CABLE
X5-2
KB 286 ONLY
PC INTERFACE
BLOCKED
X5-10
X5-11
X2-2
O-TEMP HEX SW
DRAIN SWITCH
X5-6
X5-4
S2
INLET
SENSOR
AIR PRESSURE
SWITCH
S1a
S1b
S3a
OPERATING
SENSOR
1
X5-12
X5-5
HIGH LIMIT
SENSOR
GAS VALVE
2
FLUE
SENSOR
GAS VALVE
RELAY
X2-1
6
X5-13
X5-14
S3b
FLUE
SENSOR
BLOWER
1
2
4
5
X5-7
X5-16
X5-8
13
CONNECTION
BOARD
CN5-1
CN5-8
X4-7
1
2
ALARM
CONTACTS
X4-14
X5-15
CN5-2
CN5-9
X4-6
3
4
RUN-TIME
CONTACTS
X4-13
TR2
CN6
CN6
CN6
X6
X6
X6
S6
21
22
X1-7
SYSTEM
SENSOR
S5
FLAME ROD
23
24
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
OUTDOOR
SENSOR
SPARK
ROD
CN6
CN6
X6
X6
S4
TANK
SENSOR
SHIELD
CAUTION HIGH VOLTAGE SPARK LEAD
CN6
X6
A
CASCADE
B
CN6
CN6
X6
X6
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.
SHIELD
CN6
CN6
CN6
X6
X6
X6
BMS
+
0-10V
IN
-
+
-
SYS PUMP
IN
2. See wiring diagram for additional notes.
0-10V
0-10V
0-10V
CN6
CN6
X6
X6
+
-
BLR PUMP
OUT
CN6
CN6
X6
X6
BOX DEPICTS
OPTIONAL ITEMS
+
-
RATE
OUT
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
M
O
D
B
U
S
SHIELD
CN8-1
CN8-2
CN8-3
X6-1
X6-2
X4-1
X9-2
X9-1
X9-3
A
MODBUS
X4-2
X4-3
B
X6-3
LADDER DIAGRAM
LBL20148 REV D
SHIELD
54
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Outdoor Knight Boiler Installation & Operation Manual
10 Diagrams
(continued)
Figure 10-2 Wiring Diagram
LOW VOLTAGE
BOX DEPICTS
120 VAC
OPTIONAL ITEMS
HIGH VOLTAGE
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
BOX DEPICTS
CONTROL
CONNECTION BOARD
JUNCTION
BOX
OPTIONAL
ITEMS
ALARM
CONTACTS
1
2
X1-3
X1-4
X1-2
X-7
OR
BR
PR
L
DHW
G
G
G
PUMP
RUN-TIME
3
W
W
W
N
L
CONTACTS
4
24 VAC LOUVER
BOILER
PUMP
5
RELAY COIL
6
N
L
LOUVER
PROVING SWITCH
GAS PRESSURE
SWITCH
7
BK
BK
BK
BK
X4-7
X4-14
X4-6
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
SYSTEM
PUMP
8
9
N
10
X4-13
X4-5
BK
KB ONLY
ON/OFF
SWITCH
BK
BK
BK
BK
X4-12
X4-11
X4-4
L
120V
SUPPLY
X1-6
X1-5
L
N
BK
W
GND
N
FLOW
SWITCH
11
12
13
14
15
16
17
18
19
20
X4-3
BK
X4-8
BK
BK
BK
BK
X4-10
X4-2
TANK
THERMOSTAT
HEAT/LOOP
X4-9
X1-8
X1-1
G
R
3
2
1
DEMAND
X4-1
HEAT/LOOP
DEMAND
HEAT/LOOP
TRANSFORMER
DEMAND
RW G
SYSTEM
SENSOR
OUTDOOR
SENSOR
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
BLOWER
TANK
SENSOR
1
2
3
4
5
SHIELD
A
CASCADE
B
SHIELD
X5-7
X5-16
X5-8
R
T
CN6
X6
W
BK
Y
BMS
IN
33
34
35
36
37
38
39
40
41
42
43
44
+
0-10V
X5-15
X5-9
-
SYS PUMP
+
0-10V
IN
-
BLR PUMP
X5-1
BL
O
+
0-10V
OUT
-
KB 286 ONLY
X5-2
RATE
+
O-TEMP HEX SW
0-10V
BLOCKED DRAIN SWITCH
AIR PRESSURE SWITCH
OUT
-
X5-10
X5-11
X5-4
P
SHIELD
A
O/BK
R/BK
GY
MODBUS
-T
-T
OPTION
B
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
SHIELD
X5-12
X5-6
-T
-T
-T
24 VAC
LOW
WATER
CUT-OFF
CN7-1
CN7-2
CN7-3
CN7-4
COM
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
P/BK
W/BK
PR
X5-5
X5-13
X5-14
RBLG
Y
X2-2
BK
Y
GAS VALVE
@24VAC
O
GY
G
X4-1
X9-1
X9-2
X9-3
X9-4
X2-1
X1-7
TR2
X4-2
X4-3
X4-4
MODBUS BOARD
MTR-01
W/R
FLAME SENSOR
G
SPARK
ROD
SHIELD
GROUNDING
JUMPER
X5-1
X5-2
CAUTION HIGH VOLTAGE SPARK LEAD
BK
W
G
X1-1
X1-2
X1-3
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
LBL20127 REV
E
55
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Revision Notes: Revision A (ECO C11234) initial release.
Revision B (ECO #C11235) reflects updates made to the freezing
conditions warnings.
Revision C (ECO #C11736) reflects changes made to the ratings page
(page 7).
OKB-I-O Rev C
11/12
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