OKBX-I-O Rev B
Outdoor Knight XL
Installation & Operation Manual
Models: 400 - 801
This manual must only be used by
a qualified heating installer / service
ƽ WARNING
technician. Read all instructions,
including this manual and the
Outdoor Knight XL Service Manual,
before installing. Perform steps in
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.
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Outdoor Knight XL Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
When servicing boiler –
ƽ WARNING
this manual and the Outdoor Knight XL
Service Manual, before installing. Perform
steps in the order given.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
User – This manual is for use only by
• To avoid severe burns, allow boiler to cool before
performing maintenance.
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 the
ƽ CAUTION
WHAT TO DO IF YOU SMELL GAS
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.
Freeze protection fluids –
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• 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.
• 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.
3
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Outdoor Knight XL Installation & Operation Manual
The Outdoor Knight XL - How it works...
1. Stainless steel heat exchanger
21. Boiler drain port
Allows system water to flow through specially designed
coils for maximum heat transfer, while providing protection
against flue gas corrosion. The coils are encased in a jacket that
contains the combustion process.
Location from which the heat exchanger can be drained.
22. Low voltage connection board
The connection board is used to connect external low voltage
devices.
2. Combustion chamber access cover
Allows access to the combustion side of the heat exchanger
coils.
23. Low voltage wiring connections (plugs)
Conduit connection points for the low voltage connection
board.
3. Blower
24. Condensate drain connection
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.
Connects the condensate drain line to a 1/2” PVC union.
25. Access cover - front
Provides access to the gas train and the heat exchanger.
4. Gas valve
26. Ignition electrode
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.
Provides direct spark for igniting the burner.
27. Flame inspection window
The quartz glass window provides a view of the burner surface
and flame.
5. Venturi
The venturi controls air and gas flow into the burner.
28. Gas shutoff valve
6. Flue gas sensor (limit rated - not shown)
This sensor monitors the flue gas exit temperature. The
control module will modulate and shut down the boiler if the
flue gas temperature gets too hot. This protects the flue pipe from
overheating.
Manual valve used to isolate the gas valve from the gas supply.
29. Relief valve
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 50 PSI.
7. Boiler outlet temperature sensor (housed with the
high limit sensor)
30. Flame sensor
Used by the control module to detect the presence of burner
flame.
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.
31. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
8. Boiler inlet temperature sensor
32. Top panel
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.
Removable panel to gain access to the internal components.
33. Power switch
Turns 120 VAC ON/OFF to the boiler.
34. Leveling legs
9. Temperature and pressure gauge (field installed, not
shown)
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
Monitors the outlet temperature of the boiler as well as the
system water pressure.
35. Air shroud (Model 501 only)
10. Electronic LCD display
The air shroud controls air and gas flow into the burner.
The electronic display consists of 4 buttons, a navigation dial
and a multiple line liquid crystal display.
36. Air pressure switch
11. Flue pipe assembly
The air pressure switch detects blocked flue/inlet conditions.
break the control circuit, shutting the boiler down.
Factory-supplied components for complete venting
system.
37. Pump relay board
12. Burner (not shown)
The pump relay board is used to connect the boiler, system and
DHW pumps.
Made with metal fiber and stainless steel construction, the
burner uses pre-mixed air and gas and provides a wide range of
firing rates.
38. Transformer (not shown)
The transformer provides 24V power to the integrated control.
13. Water outlet (system supply)
A 1-1/2" or 2" NPT (depending on the model) water
connection that supplies hot water to the system.
39. High limit sensor (housed with the outlet temperature
sensor)
14. Water inlet (system return)
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.
A 1-1/2" or 2" NPT (depending on the model) water connection
that returns water from the system to the heat exchanger.
15. Gas connection pipe
40. Over-temp switch (located underneath vent cover -
not shown)
Threaded pipe connection of 1". This pipe should be connected
to the incoming gas supply for the purpose of delivering gas to
the boiler.
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.
16. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and
external signals and controls the blower, gas valve, and pumps
to meet the heating demand.
17. Manual air vent
41. Vent Cover
Designed to remove trapped air from the heat exchanger
coils.
Covers Over-temp switch and flue collar with flue sensor.
18. Air intake
42. Flow switch
Provides combustion air to the appliance.
The flow switch is a safety device that ensures flow through
the heat exchanger during operation. This appliance is low
mass and should never be operated without flow. The flow
switch makes contact when flow is detected and allows the unit
to operate. If flow is discontinued during operation for any
reason the flow switch will break the control circuit and the
unit wll shut down.
19. Air Intake Cover
Provides protection from outdoor elements.
20. High voltage junction box
The junction box contains the connection points for the line
voltage power and all pumps.
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4
Outdoor Knight XL Installation & Operation Manual
The Outdoor Knight XL - How it works...
(continued)
Model 400
32
31
19
10
4
040
IMG0
IMG00405
11
25
Front View - Model 400
Rear View - Model 400
20
22
4
33
26
20
36
37
16
8
4
1
30
2
39
3
7
39
34
13
27
IMG00406
17
21
24
IMG00407
Left Side (inside unit) - Model 400
Right Side (inside unit) - Model 400
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5
Outdoor Knight XL Installation & Operation Manual
The Outdoor Knight XL - How it works...
Model 501
15
32
35
19
33
15
28
17
4
29
7
39
09
IMG004
41
Rear View - Model 501
Left Side (inside unit) - Model 501
Models 601 - 801
31
16
20
23
22
15
3
4
18
5
10
29
11
18
8
2
1
34
IMG00323
30
21
IMG00324
14
24
41
Rear View - Models 601 - 801
Left Side (inside unit) - Models 601 - 801
6
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Outdoor Knight XL Installation & Operation Manual
Ratings
Outdoor Knight XL Boiler
AHRI Rating
Other Specifications
Net
AHRI
Input
MBH
Model Number
Gross
Boiler Water
Content
Gallons
Water
Gas
Output
MBH
Ratings
Water,
MBH
Air Size
Connections Connections
(Note 4)
Note: Change “N” to
“L” for L.P. gas models.
Min
80
Max
399
(Note 1)
370
(Note 2)
3.4
4.2
4.2
5.0
5.7
1-1/2"
1-1/2"
2"
1"
1"
1"
1"
1"
4"
4"
4"
4"
4"
OKN400
OKN501
OKN601
OKN701
OKN801
322
402
493
572
651
100
120
140
160
500
600
700
800
463
566
658
748
2"
2"
Maximum allowed working pressure is located on the rating plate.
NOTICE
Notes:
1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of 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.
3. Standard Outdoor Knight XL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler
will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.
4. Ratings have been confirmed by the Hydronics Section of AHRI.
5. Outdoor Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation
control. The manual reset high limit provided with the Outdoor Knight XL is listed to UL353.
7
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Outdoor Knight XL Installation & Operation Manual
1 Determine boiler location
Installation must comply with:
•
The unit must not be installed in an area
ƽ CAUTION
that is enclosed by walls or a fence that
will block free wind movement around
the appliance. Free movement of wind
around the outdoor unit is required
to carry away the 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.
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 Knight XL gas manifold
NOTICE
and controls met safe lighting and other
performance criteria when the boiler
underwent tests specified in ANSI Z21.13
– latest edition.
Outdoormodelsmustbeinstalledoutdoors
only and must use the outdoor vent
ƽ WARNING
assembly supplied by the manufacturer.
Personal injury or product damage may
result if any other venting is used or if an
outdoor model is used indoors. All covers,
doors and jacket panels must be properly
installed to ensure proper operation and
prevent a hazardous condition.
Locate the unit at least 3 feet (0.91m)
outside any overhang.
Do not install in locations where rain
from building runoff drains will spill onto
the unit.
CAUTION
This product contains a condensate
ƽ WARNING
Do not locate the unit so that water
from sprinklers may spray directly onto
it. Water may damage controls or other
electrical components.
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.
Do not install the unit under a deck.
ƽ WARNING
Do not install the unit in a well, stairwell,
alcove, courtyard or other recessed area.
Before locating the boiler, check:
Do not install outdoor units on stack
frames. Failure to comply with the above
may result in severe personal injury, death
or substantial property damage.
1. Check for nearby connection to:
• System water piping
• Gas supply piping
• Electrical power
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
2. - Keep venting areas free of obstructions.
- Keep area clean and free of combustible and flammable
materials.
Failure to keep boiler area clear and free
ƽ WARNING
of combustible materials, gasoline, and
- To avoid a blocked air inlet or blocked flue condition,
keep the outdoor air inlet and flue outlet clear or leaves,
debris, etc.
other flammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
Do not install outdoor models directly on
CAUTION
the ground. You must install the outdoor
4. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
unit on a level concrete, brick, block, or
pressure-treated wood platform.
• System leaks causing oxygen corrosion or heat exchanger
cracks from hard water deposits.
Do not locate unit so that high winds
ƽ CAUTION
can deflect off of adjacent walls, buildings
• Incorrectly-sized expansion tank.
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
• This unit is not intended for installations where
temperatures may reach below 32°F (0°C). Exposure to
freezing temperatures will cause the system and boiler
to freeze and leak.
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8
affecting performance.
Outdoor Knight XL Installation & Operation Manual
1 Determine boiler location
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6 mm) from combustible
materials.
2. Jacket—minimum of 0" from right side and 14" from rear
side for proximity from combustible materials.
3. Vent—minimum of 1" from combustible materials.
(continued)
Provide clearances:
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.
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.
Clearances for service access
1. If you do not provide the minimum clearances shown, it
may not be possible to service the boiler without removing
it from the space.
Table 1A Corrosive Contaminants and Sources
Recommended service clearances
Front: 30" (762mm)
Top: 24" (610mm)
Left side: 24" (610mm)
Rear: 24" (610mm)
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Outdoor vent / air intake location:
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
The flue products discharged from the
ƽ WARNING
flue outlet on the outdoor vent may be
very hot. Avoid touching or making other
direct contact with the flue gases or the
vent termination. These components are
hot and direct contact can result in burns.
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
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 or exterior building or unit surfaces
can be expected. Adjacent brick or masonry surfaces should
be protected with a rust resistant sheet metal plate.
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other
similar products
Maintain a minimum of 24" clearance to the air inlet.
Locate the outdoor vent termination at least 48" (1.22m)
below and 48" (1.22m) horizontally from any window, door,
walkway or gravity air intake.
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Locate the unit at least 10 feet (3.05m) away from any forced
inlet.
Metal fabrication plants
Beauty shops
Multiple unit outdoor installations require 24" (1.22m)
clearance between each vent termination.
Refrigeration repair shops
Photo processing plants
Auto body shops
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.
Plastic manufacturing plants
Furniture refinishing areas and establishments
Flooring and foundation
Flooring
The Outdoor Knight XL is approved for installation on
combustible flooring.
New building construction
Remodeling areas
Do not install the boiler on carpeting even
ƽ WARNING
Garages with workshops
if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
9
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Outdoor Knight XL Installation & Operation Manual
2 Prepare boiler
Remove boiler from wood pallet
Install flue pipe assembly
1. After removing the outer shipping carton from the
boiler, remove the parts box.
Models 400 - 601
This unit is provided with all of the necessary venting
components. All components must be installed prior to
operation.
2. Remove the front door to access the lag bolts in front
of the unit (FIG. 2-1).
1. Locate all venting components from the installation kit
and carton.
3. To remove the boiler from the pallet (after removing
the front door):
2. Before connecting the vent pipe sections or components,
verify that the gasket is seated evenly inside the groove in
the female end of the elbow and flue adaptor (FIG. 2-2).
a. Remove the two lag bolts from the wood pallet
inside the boiler (FIG. 2-1).
b. Detachtheboilerfromthelagboltsintherearofthe
unit, see FIG. 2-1.
3. Remove the provided screws from the vent cover and use
them to install the vent strap (FIG. 2-2).
Do not drop the boiler or bump the
NOTICE
4. Insert the elbow into flue adaptor (FIG. 2-2).
jacket on the floor or pallet. Damage to
Do NOT use grease or other lubricant
the boiler can result.
ƽ CAUTION
on the vent seals. Only water may be
used for this purpose. Grease or other
lubricant can make the seal brittle or
cause tearing of the seal surface which
can result in flue gas leakage.
Figure 2-1 Boiler Mounted on Shipping Pallet
5. Slide the vent pipe through the wall strap and insert it
into the elbow (FIG. 2-2).
6. Install the bird screen into the top of the vent.
Figure 2-2 Install flue pipe assembly - Models 400 -
601
. 2
WALL STRAP
AND SCREWS
BIRD SCREEN
VENT PIPE
ELBOW
IMG00444
FLUE
ADAPTER
NOTE: VERIFY THAT GASKET IS SEATED EVENLY
INSIDE THE GROOVE IN ELBOW AND ADAPTER
10
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Outdoor Knight XL Installation & Operation Manual
2 Prepare boiler
(continued)
Models 701 - 801
1. Locate all venting components from the installation kit and
carton.
2. Before connecting the vent pipe sections or components,
verify that the gasket is seated evenly inside the groove
in the female end of the elbow and flue adapter
(FIG. 2-3).
3. Remove the vent cover from the back of the unit as shown in
FIG. 2-3.
4. Insert the elbow into the flue adapter and tighten the clamp
using a 5/16" nut driver (FIG. 2-3).
5. Re-install the vent cover removed in Step 3.
6. Remove the provided screws from the vent cover and use
them to install the wall strap (FIG. 2-3).
Do NOT use grease or other lubricant on the
vent seals. Only water may be used for this
ƽ CAUTION
purpose. Grease or other lubricant can make
the seal brittle or cause tearing of the seal
surface which can result in flue gas leakage.
7. Slide the vent pipe through the wall strap and insert it into the
elbow. Tighten the clamp (FIG. 2-3).
8. Install the termination into the top of the vent and tighten the
clamp.
Figure 2-3 Install flue pipe assembly - Models 701 - 801
NOTE: VERIFY THAT GASKET IS SEATED EVENLY
INSIDE THE GROOVE IN ELBOW AND ADAPTER
VENT
TERMINATION
VENT PIPE
IMG00446
WALL
STRAP
CLAMP
VENT COVER
ELBOW
WALL STRAP
SCREWS
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11
Outdoor Knight XL Installation & Operation Manual
2 Prepare boiler
Gas conversions
For a boiler already installed, you must
After converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property damage.
ƽ WARNING
ƽ WARNING
turn off gas supply, turn off power and
allow boiler to cool before proceeding.
You must also completely test the boiler
after conversion to verify performance
as described under Start-up, Section 10
of this manual. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Model 400: Inspect the O-ring when the
blower is disassembled. The O-ring must
be in good condition and must be installed.
Failure to comply will cause a gas leak,
resulting in severe personal injury or death.
ƽ DANGER
For the 400 Model you must install a
propane orifice to operate the Outdoor
Knight XL on propane gas. Verify when
installing that the orifice size marking
matches boiler size (Model 400 - 8.0 LP
orifice stamping).
Figure 2-4 Installing Propane Orifice - Model 400
BLOWER
Models 501 - 801 do not require an orifice
installation for propane operation, but
they will require a valve adjustment.
O-RING
VENTURI
SCREWS
QTY. 3
Model 400
1. Remove the top and front access covers from the unit
(tools required for removal).
2. Remove the three screws securing the venturi to the
blower. Note: When separating the venturi from the
blower, take care not to damage the O-ring inside the
blower (FIG. 2-4).
SCREWS
QTY. 4
O-RING
BRASS ORIFICE
3. Remove the four star-drive screws securing the gas valve
to the venturi (FIG. 2-4).
GAS VALVE
4. Locate the propane orifice disk from the conversion kit
bag.Verify that the stamping on the orifice disk matches
the boiler size (Model 400 - 8.0 LP orifice stamping).
5. Remove the existing orifice from the O-ring in the side of
the gas valve and replace it with the orifice from the kit.
Position and secure the orifice in the valve as shown in
FIG. 2-4.
6. Reposition the gas valve against the venturi and replace
the star-drive screws (FIG. 2-4) securing the valve to the
venturi.
7. Inspect the O-ring inside the blower. Handle the O-ring
with care, do not damage. Reposition the venturi against
the blower and replace the screws securing the venturi to
the blower (FIG. 2-4).
8. After installation is complete, attach the propane
conversion label (in the conversion kit bag) next to the
boiler rating plate. Attach the LP caution label (in the
conversion kit bag) to the left side of the unit in the lower
left corner.
9. Replace the top and front access covers.
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12
Outdoor Knight XL Installation & Operation Manual
2 Prepare boiler
(continued)
Model 501
After converting to LP, check combustion
ƽ WARNING
per the Start-up procedure in Section
10 of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
1. Remove the top access cover from the unit (Philips Head
screwdriver required for removal).
2. Turn the adjustment screw on the gas valve clockwise until
it stops. Then turn the adjustment screw counterclockwise
four and three quarter (4 3/4) turns (see FIG. 2-5).
Figure 2-6 Gas Valve Adjustment - Models 601 - 801
3. Use a combustion analyzer to verify CO2 is within the range
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-5).
COVER
ALLEN WRENCH
4. After adjustment is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit bag)
to the left side of the unit in the lower left corner.
ADJUSTMENT SCREW
5. Replace the top access cover.
After converting to LP, check combustion
ƽ WARNING
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property
damage.
Figure 2-5 Gas Valve Adjustment - Model 501
Leveling the boiler
ALLEN WRENCH
1. Set the boiler in place and check level.
a) Adjust legs if necessary to level boiler, see FIG. 2-7
below.
Figure 2-7 Leveling Legs on the Boiler
SCREWDRIVER
SLOT
ADJUSTMENT SCREW
Models 601 - 801
1. Remove the top access cover from the unit (Philips Head
screwdriver required for removal).
2. Remove the cover on top of the gas valve (FIG. 2-6).
3. Turn the adjustment screw on top of the gas valve clockwise
one and three quarter (1 3/4) turns on the 601 Model, one
and a half (1 1/2) turns on the 701 Model, and one turn on
the 801 Model (see FIG. 2-6).
LOWER
RAISE
4. Use a combustion analyzer to verify CO2 is within the range
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-6).
5. After adjustment is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
plate. Attach the LP caution label (in the conversion kit
bag) to the left side of the unit in the lower left corner.
6. Replace the gas valve cover along with the top access cover.
13
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
System water piping methods
General piping information
Basic steps are listed below along with illustrations on the
following pages (FIG.’s 3-7 through 3-11), which will guide
you through the installation of the Outdoor Knight XL
(reference FIG.’s 3-4A and 3-4B).
The Outdoor Knight XL is designed to function in a closed
loop pressurized system not less than 12 psi (83 kPa).
A
temperature and pressure gauge is included to monitor
system pressure and outlet temperature and should be
located on the boiler outlet.
1. Connect the system return marked “Inlet”.
2. Connect the system supply marked “Outlet”.
It is important to note that the boiler has a minimal amount
of pressure drop which must be figured in when sizing
the circulators. Each boiler installation must have an air
elimination device, which will remove air from the system.
Install the boiler so the gas ignition system components
are protected from water (dripping, spraying, etc.) during
appliance operation or basic service of circulator replacement,
valves, and others.
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
4. Install a backflow preventer on the cold feed make-up
water line.
5. Install a pressure reducing valve on the cold feed make-up
water line, (15 psi (103 kPa) nominal). Check temperature
and pressure gauge (shipped separately), which should
read a minimum pressure of 12 psi (83 kPa).
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. 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.
Low water cutoff device
7. Install a circulator as shown on the piping diagrams in this
section. Make sure the circulator is properly sized for the
system and friction loss.
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
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.
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.
9. Install an air elimination device on the system supply.
10. Install a drain valve at the lowest point of the system.
Note: The boiler cannot be drained completely of water
without purging the unit with an air pressure of 15 psi
(103 kPa).
Freeze protection
11. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). Pipe the discharge of the
safety relief valve to prevent injury in the event of pressure
relief. Pipe the discharge to a drain. Provide piping that is
the same size as the safety relief valve outlet. Never block
the outlet of the safety relief valve.
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.
The relief valve, tee and any other necessary
ƽ WARNING
fittings are shipped in the install kit with the
boiler and are to be field installed (FIG.’s
3-1 and 3-2).
Use only inhibited propylene glycol
ƽ WARNING
12. On any pre-existing system, it is good practice to install
a field supplied strainer to prevent damage to the heat
exchanger.
solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
See the piping illustrations included in this section, FIG.’s
3-7 and 3-11 for suggested guidelines in piping the Outdoor
Knight XL.
Please note that these illustrations are
NOTICE
meant to show system piping concept only,
the installer is responsible for all equipment
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14
Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
(continued)
Flowswitch,reliefvalveandtemperature
and pressure gauge installation
Figure 3-1 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 400 - 501
Basic steps are listed below to guide you through the
installation of the flow switch, relief valve, and temperature
and pressure gauge provided with the unit.
1. For Models 400 - 501 install the close nipple on the
outlet connection of the heat exchanger. Install the tee
with the 3/4 inch fitting positioned vertically and on
the top as shown in FIG. 3-1. For Models 601 - 801
install the tee directly to the outlet connection of the
heat exchanger with the 3/4 inch fitting positioned
vertically and on the top (see FIG. 3-2).
RELIEF VALVE
FLOW SWITCH
PADDLE
TEMPERATURE &
PRESSURE GAUGE
2. For Models 701 - 801 install the 3/4 inch close nipple
in the tee. Install the relief valve on the 3/4 inch close
nipple (FIG. 3-2). For Models 400 - 601 install the
relief valve directly into the 3/4 inch fitting on the tee
(FIG. 3-1).
TEE WITH FITTING
ON TOP
(FIELD PROVIDED)
CLOSE NIPPLE
3. Install the close nipple on the downstream side of
the relief valve tee (FIG. 3-1).
(FIELD PROVIDED)
IMG00390
TEE WITH 1" FITTING ON TOP
8' NIPPLE
(REQUIRED FOR MODELS 400 - 701)
CLOSE NIPPLE
TEE WITH 3/4"
4. Install the tee with the 1 inch fitting positioned
vertically and on the top (FIG. 3-1).
FITTING ON TOP
5. Attach paddle #3 to the flow switch per the
manufacturer’s instructions.
Figure 3-2 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 601 - 801
6. Install the assembled flow switch into the 1 inch fitting
of the tee installed in Step 4 (see FIG. 3-1).
7. Install a field provided close nipple on the downstream
side of the flow switch (see FIG.’s 3-1 and 3-2).
RELIEF VALVE
8. Install a field provided tee with the gauge fitting
positioned vertically and on the top (FIG.’s 3-1 and
3-2)
FLOW SWITCH
PADDLE
9. 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 8 (FIG.’s 3-1 and
3-2).
TEMPERATURE &
PRESSURE GAUGE
TEE WITH FITTING
(FIELD PROVIDED)
Be sure to install the flow switch so
NOTICE
that the arrow on the flow switch is
pointing in the direction of the flow
(see FIG. 3-3).
CLOSE NIPPLE
(FIELD PROVIDED)
TEE WITH 1" FITTING
ON TOP
IMG00389
CLOSE NIPPLE
TEE WITH 3/4"
FITTING ON TOP
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15
Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
Flow switch adjustment
Near boiler piping components
Refer to Table 3A for the proper setting of the sensitivity
screw. For reference, the position of the screw prior to setting
should be turned clockwise with a Phillips driver until it stops
(FIG. 3-3). Proceed to turn the screw counterclockwise the
amount of turns listed in Table 3A based on the model.
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe
requirements listed in Table 3B. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on 20 feet (6 m) of
piping, 4 - 90° elbows, and 2 - fully ported ball valves.
Consult the manufacturer’s instructions for wiring the flow
switch to your system.
2. Boiler system circulating pump:
(Field supplied.) The boiler circulating pump should be
based on 20 feet (6 m) of piping, 4 - 90° elbows, and
2 - fully ported ball valves.
Table 3A Paddle Size / Sensitivity Screw Adjustment
SENSITIVITY SCREW
MODEL
PADDLE SIZE
ADJUSTMENT
Note: Paddles are included with the flow switch.
3. Domestic hot water circulating pump:
(Field supplied.) The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG.’s 3-5 and 3-6. Consult the indirect water heater
operating guide to determine flow characteristics for the
selected product used.
400
501
601
701
801
#3
#3
#3
#3
#3
7½ turns
5½ turns
7¼ turns
5¼ turns
3¼ turns
Turn the sensitivity screw clockwise to
increase the flow rate required to activate
the switch. Turn the sensitivity screw
counterclockwise to decrease the flow rate
required to activate the switch.
4. Variable speed boiler system circulator:
Outdoor Knight XL boilers are capable of controlling
a variable speed boiler system circulator. Variable speed
circulators MUST be sized to meet the specified minimum
flow requirements listed in FIG.’s 3-5 and 3-6 on page 16
at full speed.
NOTICE
Figure 3-3 Flow Switch Adjustment
NORMALLY
OPEN
5. 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.
SENSITIVITY
ADJUSTMENT
6. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 3-7 through 3-11. Failure
to install check valves could result in a reverse flow
condition during pump(s) off cycle.
GROUND
7. Domestic indirect hot water isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
NORMALLY
CLOSED
COMMON
8. Anti-scald mixing valve:
Field supplied. An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F (46°C).
9. Unions:
Field supplied. Recommended for unit serviceability.
10. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
11. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
16
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
(continued)
12. Boiler purge valve:
Figure 3-4B Near Boiler Piping w/Low Loss Header
Field supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
SYSTEM PUMP
SYSTEM SENSOR
AIR SEPARATOR
DRAIN
(TYPICAL)
13. System temperature sensor:
AIR VENT VALVE
Lochinvar supplies a system temperature sensor. The
sensor is to be installed in the heating loop downstream
from the boiler hot water piping and heating loop
junction. The sensor should be located far enough
downstream to sense system diluted water temperature.
LOW LOSS HEADER
(TYPICAL)
FAST FILL VALVE
EXPANSION TANK
INDIRECT
DOMESTIC
DRAIN
14. Y-Strainer:
HOT WATER
VALVE
TANK
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.
Y-STRAINER
(RECOMMENDED)
BOILER PUMP
Circulator sizing
The Outdoor Knight XL heat exchanger does have a pressure
drop, which must be considered in your system design. Refer
to the graphs in FIG’s 3-5 and 3-6 for pressure drop through
the Outdoor Knight XL heat exchanger.
Near boiler piping connections
IMG00391
Figure 3-4A Near Boiler Piping w/Y-Strainer
TO FLOOR
DRAIN
Variable speed pump option
Variable speed pump setup
SYSTEM SENSOR
DOMESTIC HOT
AIR SEPARATOR
WATER PUMP
Before operation, ensure the following:
INDIRECT
SYSTEM PUMP
-
Pump is set for an input signal of 0 - 10VDC
by the dip switches on the pump control
DOMESTIC
HOT WATER
TANK
-
Pump is set for external signal control
(if applicable)
-
-
Pump is set for linear output (if applicable)
Y-STRAINER
(RECOMMENDED)
If pump does not come equipped with a
0 - 10 VDC input option, an optional module
will be required from the vendor
BOILER PUMP
SMART SYSTEM / Multi-temperature
loop control option
The Outdoor Knight XL boiler is capable of producing
up to three (3) set point temperatures to meet different
space heating demands. When using more than one
temperature demand it is necessary to protect the
lower temperature loop from overheating. To help
aid with this protection, Lochinvar offers the Multi-
Temperature Loop Control Board Kit (RLY30086).
IMG00413
TO FLOOR
DRAIN
17
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
Figure 3-5 Pressure Drop vs. Flow - Models 400 and 501
Pressure Drop vs Flow
(Includes Boiler Secondary Piping)
20
18
16
14
12
10
8
KBN501
KBN400
O
O
6
4
2
0
0
5
10
15
20
25
30
35
40
45
Flow Rate (GPM)
Figure 3-6 Pressure Drop vs. Flow - Models 601 thru 801
Pressure Drop vs Flow
(Includes Boiler Secondary Piping)
60
50
40
30
20
10
0
KBN801
O
O
KBN701
O
KBN601
0
10
20
30
40
50
60
70
80
90
Flow Rate (GPM)
Table 3B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F
TEMPERATURE RISE APPLICATIONS
20°F
25°F
30°F
35°F
MINIMUM
PIPE
Model
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
SIZE
400
501
601
701
801
1 1/2"
1 1/2"
2"
37
46
55
65
74
21
23
31
30
33
30
37
44
52
60
14
16
22
20
23
26
32
38
45
51
11
13
18
16
18
21
26
32
37
42
8
10
13
11
12
2"
2"
18
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-7 Single Boiler - Multiple Temperatures
RE
TEMPERATU
RE
TEMPERATU
LOOP 3
RE
TEMPERATU
S
OP SENSOR
WIRES TO LO
LOOP 2
LOOP 1
(3X)
LOOP SENSOR
120VAC
TO PUMPS
TER
MAKE UP WA
AIR SEPARAT
PRESSURE
OR
MULTI-TEMP
LOOP CONTROL
(OPTIONAL)
GAUGE
TO
SYSTEM
BACK FLOW
PREVENTER
O
24V SIGNAL T
FROM
SYSTEM
S
MIXING VALVE
NDED)
(RECOMME
Y-STRAINER
BALL VALVE
(TYPICAL)
K VALVE
FLOW CHEC
(TYPICAL)
CULATOR
BOILER CIR
EXPANSION
TANK
PRESSURE
ABLE
SHIELDED C
REDUCING
VALVE
NTROL
TO BOILER CO
HW
INDIRECT D
TANK
BOILER
PRESSURE
RELIEF
VALVE
UT
HOT WATER O
ANTI-SCALD
ICAL)
UNION (TYP
MIXING VALVE
DOMESTIC
N
COLD WATER I
HOT WATER
R
CIRCULATO
IMG00392
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.
Please note that these illustrations show an indoor tank to demonstrate piping concept only.
NOTICE
19
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
Figure 3-8 Single Boiler - Primary/Secondary Piping
AIR SEPARATOR
MAY SUBSTITUTE
LOW LOSS HEADE
R
DRAIN POINT
(TYPICAL)
NOT TO EXCEED 4
PIPE DIA OR MA
X. OF 12" APART
SYSTEM SUPPLY
SENSOR
(WHEN USED)
BALL VALVE
(TYPICAL)
SYSTEM CIRCULA
TOR
Y-STRAINER
EXPANSION TANK
(RECOMMENDED)
BOILER CIRCULAT
OR
MAKE UP WATER
BACK FLOW
PREVENTER
PRESSURE REDU
CING
VALVE
INDIRECT DHW
TANK
ANTI-SCALD
MIXING VALVE
HOT WATER OUT
DOMESTIC
HOT WATER
CIRCULATOR
UNION (TYPICAL)
BOILER
COLD WATER IN
PRESSURE RELIEF
VALVE
DRAIN
IMG00393
FLOW CHECK
VALVE (TYPICAL)
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not not exceed indirect water heater transfer capabilities.
CAUTION
NOTICE
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.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
Please note that these illustrations show an indoor tank to demonstrate piping concept only.
NOTICE
20
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-9 Multiple Boilers - Multiple Temperatures
Number of Units
2
3
4
5
6
7
8
Model
Manifold Pipe Sizes in Inches (mm)
2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)
3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)
3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)
400
501
601
3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)
4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)
701
801
WIRES TO
LOOP SENSORS
TEMPERATURE
LOOP 3
TEMPERATURE
LOOP 2
120VAC
MULTI-TEMP
LOOP CONTRO
(OPTIONAL)
TO PUMPS
TEMPERATURE
LOOP 1
L
24V SIGNAL TO
MIXING VALVES
LOOP SENSOR
(3X)
TO
SYSTEM
AIR SEPARATOR
SHIELDED CABLE
TO BOILER CON
TROL
FROM
SYSTEM
Y-STRAINER
MAKE UP WATER
(RECOMMENDED)
FLOW CHECK
VALVE (TYPICAL)
BALL VALVE
(TYPICAL)
BACK FLOW
PREVETER
PRESSURE
GAUGE
EXPANSION
DRAIN POINT
(TYPICAL)
TANK
INDIRECT DHW
TANK
ANTI-SCALD
BOILER 2
PRESSURE
RELIEF
MIXING VALVE
VALVE
DOMESTIC
TEMPERATURE/PRESS
GAUGE
URE
COLD WATER IN
HOT WATER
CIRCULATOR
UNION (TYPICAL
)
BOILER CIRCUL
ATOR
BOILER 1
IMG00394
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not not exceed indirect water heater transfer capabilities.
CAUTION
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.
Please note that these illustrations show an indoor tank to demonstrate piping concept only.
21
NOTICE
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Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
Figure 3-10 Multiple Boilers - Primary/Secondary Piping
Number of Units
2
3
4
5
6
7
8
Model
Manifold Pipe Sizes in Inches (mm)
2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)
3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)
3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)
400
501
601
701
801
3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)
4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)
BALL VALVE
(TYPICAL)
MAY SUBSTITUTE
LOW LOSS HEADER
AIR SEPARATOR
DRAIN POINT
(TYPICAL)
SYSTEM SUPPLY SENSOR
(WHEN USED)
SYSTEM CIRCULATOR
MAKE UP WATER
Y-STRAINER
(TYPICAL)
(RECOMMENDED)
EXPANSION
TANK
BACK FLOW
PREVENTER
PRESSURE REDUCING
VALVE
BOILER 4
PRESSURE GAUGE
(MEMBER 3)
INDIRECT DHW
TANK
BOILER 3
(MEMBER 2)
ANTI-SCALD
MIXING VALVE
BOILER 2
(MEMBER 1)
HOT WATER OUT
IMG00417
BOILER 1
DOMESTIC
HOT WATER
CIRCULATOR
(LEADER)
BOILER CIRCULATOR
PRESSURE RELIEF
VALVE
(TYPICAL)
COLD WATER IN
DRAIN
FLOW CHECK
UNION (TYPICAL)
TEMPERATURE /
VALVE (TYPICAL)
PRESSURE GAUGE
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not not exceed indirect water heater transfer capabilities.
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.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
NOTICE
Please note that these illustrations show an indoor tank to demonstrate piping concept only.
NOTICE
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22
Outdoor Knight XL Installation & Operation Manual
3 Hydronic piping
(continued)
Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone
WIRES TO
TEMPERATURE
LOOP SENSORS
LOOP 3
TEMPERATURE
LOOP 2
TEMPERATURE
LOOP 1
LOOP SENSOR (3X)
120VAC TO
PUMPS
MAKE UP WATER
AIR SEPARATOR
BACK FLOW
PREVENTER
TO
SYSTEM
PRESSURE
BALL VALVE
GAUGE
FROM
SYSTEM
(TYPICAL)
MULTI-TEMP
LOOP CONTROL
(OPTIONAL)
Y-STRAINER
24VAC SIGNAL
TO MIXING VALVES
(RECOMMENDED)
FLOW CHECK
VALVE (TYPICAL)
BOILER CIRCULATOR
PRESSURE
REDUCING
VALVE
DRAIN POINT
(TYPICAL)
EXPANSION
SHIELDED CABLE
TO BOILER CONTROL
TANK
INDIRECT DHW
TANK
HOT WATER OUT
BOILER
ANTI-SCALD
MIXING VALVE
DOMESTIC
HOT WATER
CIRCULATOR
UNION (TYPICAL)
DRAIN
COLD WATER IN
TEMPERATURE / PRESSURE
PRESSURE RELIEF
VALVE
IMG00412
GAUGE
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not not exceed indirect water heater transfer capabilities.
CAUTION
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.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
Please note that these illustrations show an indoor tank to demonstrate piping concept only.
NOTICE
NOTICE
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23
Outdoor Knight XL Installation & Operation Manual
4 Gas connections
Connecting gas supply piping
Figure 4-3 Gas Supply Piping - Models 601 - 801
GAS SUPPLY
1. Remove the top access panel and refer to FIG.’s 4-1 thru
4-3 to pipe gas to the boiler.
a. Install ground joint union for servicing, when
required.
b. Install a manual shutoff valve in the gas supply
piping outside boiler jacket when required by local
codes or utility requirements.
2. Install sediment trap / drip leg.
Figure 4-1 Gas Supply Piping - Model 400
MANUAL SHUTOFF VALVE
(FACTORY SUPPLIED)
UNION
GAS SUPPLY
IMG00328
SEDIMENT TRAP
/ DRIP LEG
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
SEDIMENT TRAP /
DRIP LEG
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.
MANUAL
SHUTOFF
VALVE
(FIELD SUPPLIED)
4. Purge all air from the gas supply piping.
IMG00411
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
Figure 4-2 Gas Supply Piping - Model 501
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).
UNION
(FACTO
RY INST
ALLED)
GAS SU
PPLY
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).
SEDIME
NT TRAP/
DRIP LE
G
c. The appliance and its gas connection must be leak
tested before placing it in operation.
MANUAL
Do not check for gas leaks with an open
ƽ WARNING
SHUTOFF VAL
VE
(FACTOR
Y SUPPLI
ED)
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.
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.
IMG00410
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24
Outdoor Knight XL Installation & Operation Manual
4 Gas connections
(continued)
Failure to apply pipe sealing compound
as detailed in this manual can result
in severe personal injury, death, or
substantial property damage.
Natural gas:
Pipe sizing for natural gas
ƽ WARNING
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).
Use two wrenches when tightening gas
piping at boiler (FIG. 4-4), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
ƽ WARNING
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.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Figure 4-4 Inlet Pipe with Backup Wrench
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
USE BACKUP WRENCH
TO PREVENT PIPE FROM
ROTATING
• Maximum 14 inches w.c. (3.5 kPa) with no flow
(lockup) or with boiler on.
• Minimum 4 inches w.c. (.99 kPa) 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. (3.5 kPa) at any
time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa)
maximum.
Propane Gas:
Outdoor Knight XL boilers are typically
shipped ready to fire on natural gas. Check
ƽ WARNING
IMG00420
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 or by making a gas valve adjustment
(see page 12). In order to operate on LP
gas, an orifice MUST BE installed or a gas
valve adjustment MUST BE made. Failure
to comply could result in severe personal
injury, death, or substantial property
damage.
Maximum inlet gas pressure must not
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
NOTICE
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100% lockup
gas pressure regulator.
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. (3.2 kPa) maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.2 kPa) with no flow (lockup)
or with boiler on.
• Minimum 8 inches w.c. (1.9 kPa) with gas flowing (verify
during boiler startup).
Ensure that the high gas pressure regulator
is at least 10 feet (3 m) upstream of the
ƽ WARNING
appliance.
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25
Outdoor Knight XL Installation & Operation Manual
4 Gas connections
Table 4A Natural Gas Pipe Size Chart
Maximum
Nominal
Iron Pipe
Size
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet
Capacity of Pipe
in Thousands of
Btu/hr per hour
for gas pressures
of 14 Inches
Water Column
(0.5 PSIG) or less
and a pressure
drop of 0.5 Inch
Water Column
(Based on NAT
GAS, 1025 Btu/
hr per Cubic Foot
of Gas and 0.60
Specific Gravity)
(inches)
10
20
30
40
50
60
70
80
90 100 125 150 175 200
175
369
697
120
256
477
97
82
N/A
155
292
595
N/A N/A N/A N/A N/A N/A N/A N/A N/A
1/2
3/4
1
205
384
789
174
328
677
141 128 121 113 106
95
86
79
74
267 246 236 210 200 179 164 149 138
543 502 472 441 410 369 333 308 287
830 769 707 666 636 564 513 472 441
1400 974
1-1/4
1-1/2
2
2150 1500 1210 1020 923
4100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820
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
2-1/2
3
4
Check inlet gas supply
CSA or UL listed flexible gas connections
4. Slowly turn on the gas supply at the field installed
manual gas valve.
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.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to call for heat.
7. Observe the gas supply pressure as the burner fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
DO NOT adjust gas valve outlet pressure.
Attempting to alter the gas valve outlet
pressure could result in damage to the valve,
causing potential severe personal injury,
death, or substantial property damage.
ƽ WARNING
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
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.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, 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.
(249 Pa), 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.
1. Turn the main power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
13. Remove the manometer from the pressure tap on top of
the gas valve. On Models 400 - 501 re-tighten the set
screw inside the pressure tap. On Models 601 - 801
remove the 1/8" (3 mm) field supplied fitting and
reinstall the pipe plug removed in Step 3.
3. On Models 400 - 501 loosen the set screw one (1) full turn
from inside the pressure tap on top of the gas valve. On
Models 601 - 801 remove the 1/8" (3 mm) pipe plug on the
inlet flange to the valve and install a suitable 1/8" (3 mm)
fitting (field supplied) for the manometer tubing. Place
the tubing of the manometer over the tap once the set
screw is loosened or the 1/8" (3 mm) fitting is installed
(depending on model) as shown in FIG.’s 4-5 thru 4-7 on
page 27.
26
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Outdoor Knight XL Installation & Operation Manual
4 Gas connections
(continued)
When re-tightening the set screw, be sure
to tighten securely to prevent gas leaks.
Figure 4-7 Inlet Gas Supply Check - Models 601 - 801
ƽ WARNING
REMOVE THE 1/8” (3 MM) PIPE PLUG ON
THE INLET FLANGE TO THE VALVE AND
INSTALL A SUITABLE 1/8” (3 MM) FITTING
(FIELD SUPPLIED) FOR THE MANOMETER
TUBING.
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.
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.
DETAIL
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 pressure
Figure 4-5 Inlet Gas Supply Check - Model 400
The gas pressure must remain between 4 inches w.c. (.99
kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for
Natural gas and between 8 inches w.c. (1.9 kPa) minimum
and 14 inches w.c. (3.2 kPa) maximum for LP gas during
standby (static) mode and while in operating (dynamic)
mode. If an in-line regulator is used, it must be a minimum
of 10 feet (3 m) from the Outdoor Knight XL boiler. It is
very important that the gas line is properly purged by the gas
supplier or utility company. Failure to properly purge the
lines or improper line sizing, will result in ignition failure.
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP
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.
DETAIL
IMG00414
Figure 4-6 Inlet Gas Supply Check - Model 501
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.
LOOSEN THE SET SCREW ONE (1) FULL TURN
AND PLACE THE MANOMETER TUBING OVER
THE PRESSURE TAP
Failure to follow all precautions could
result in fire, explosion, or death!
ƽ WARNING
DO NOT adjust gas valve outlet pressure.
ƽ WARNING
DETAIL
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.
IMG00415
27
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Outdoor Knight XL Installation & Operation Manual
5 Field wiring
ELECTRICAL SHOCK HAZARD – For
Installation must comply with:
ƽ WARNING
your safety, turn off electrical power
supply before making any electrical
connections to avoid possible electric
shock hazard. Failure to do so can cause
severe personal injury or death.
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG.5-1.
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.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 5-1).
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
3. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 5-1.
Ensure that all wiring external to the
unit is enclosed in approved conduit.
4. To activate a system pump, wire as shown in FIG. 5-1. Dry
contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
ƽ CAUTION
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 5-2.
Figure 5-1 Line Voltage Field Wiring Connections
2. Connect low voltage wiring to the low voltage connection
board as shown in FIG. 5-3 on page 29 of this manual and
the boiler wiring diagram.
120V SUPPLY
NEUTRAL
W
GROUND
G
Figure 5-2 Routing Field Wiring
LINE
BK
LINE VOLTAGE
LOW VOLTAGE
SERVICE
SWITCH
JUNCTION BOX
CONNECTION
BOARD
BK
SYSTEM
PUMP
G
W
LOW VOLTAGE
WIRING
KNOCKOUT
PLUGS
BK
G
W
BOILER
PUMP
IMG00329
LINE VOLTAGE
WIRING KNOCKOUT
PLUGS
BK
G
W
DOMESTIC
HOT WATER
PUMP
L2/N
G
L1
28
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Outdoor Knight XL Installation & Operation Manual
5 Field wiring
(continued)
If TST20015 is not compatible with the indirect tank, a
tank thermostat can be used to control the boiler. The
tank thermostat should be installed per the manufacturer’s
instructions and wired to the DHW Thermostat terminals on
the low voltage connection board (FIG. 5-3).
Thermostat
1. Connect the room thermostats or end switches (isolated
contact only) to heat/loop demand 1, 2, or 3, as shown in
FIG. 5-3.
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
High gas pressure switch
1. If a switch is provided to detect excessive gas pressure,
remove the jumper wire from the terminals on the
connection board, and then connect them to its normally
closed contacts (FIG. 5-3).
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.
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).
Outdoor temperature sensor
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow of heat or cooling from other
sources.
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).
2. Route sensor wires through a knockout at the rear of the
boiler (see FIG. 5-2).
Variable speed system pump
3. Connect the outdoor temperature sensor (FIG. 5-3) to
the outdoor sensor terminals on the connection board
to enable outdoor reset operation of the Outdoor Knight
XL. If fixed temperature operation is required, do not
install outdoor sensor.
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.
DHW
(Domestic
Hot
Water)
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.
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 tank sensor
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.
The tank sensor included with the Lochinvar Squire® indirect
DHW tanks (TST20015) is the only sensor suitable for use
with the SMART SYSTEM control. Connect the sensor leads
to the Tank Sensor terminals on the low voltage connection
board (FIG. 5-3).
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.
Failure to use the correct sensor may
ƽ WARNING
result in the tank temperature being either
above or below the set point.
29
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Outdoor Knight XL Installation & Operation Manual
5 Field wiring
ModBus
Alarm contacts
When the optional ModBus interface module is installed, the The SMART SYSTEM control closes another set of contacts
RS-485 ModBus cable is connected to these terminals. Use whenever the boiler is locked out or the power is turned off.
shielded, 2-wire twisted pair cable. If desired, the shield can This can be used to turn on an alarm, or signal a Building
be connected to ground by installing a jumper wire between
terminals 1 and 3 on connector X5 on the optional ModBus
interface module.
Management System that the boiler is down.
Wiring of the cascade
Flow switch
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.
When wiring the boilers for Cascade operation, select one
boiler as the Leader boiler. The remaining boilers will be
designated as Members. See page 36 “Configuration of the
Cascade” for a detailed explanation of this procedure.
2. Remove the jumper wire from the terminals on the
connection board and connect these terminals to the
normally open contacts on the flow switch (FIG. 5-3).
Connect the system supply sensor and outdoor air sensor (if
used) to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
location of the system supply sensor should be downstream
of the boiler connections in the main system loop (FIG.’s 3-7
through 3-11). The system supply sensor should be wired to
the Low Voltage Connection Board at the terminals marked
for the system sensor (see FIG. 5-3). The Leader control will
use the water temperature at the system supply sensor to
control the operation of the Cascade.
System supply sensor
1. By installing the system supply sensor into the supply of
the primary loop, the temperature of the system supply can
be controlled. The SMART SYSTEM control automatically
detects the presence of this sensor, and controls the boiler
firing rate to maintain the system supply temperature to the
set point (if the outlet sensor control is currently selected).
See the Outdoor Knight XL Service Manual for instructions
on how to use the inlet sensor as the controlling sensor.
When the inlet sensor is programmed as the controlling
sensor, it is vital that the SYSTEM SUPPLY sensor be
installed. DO NOT INSTALL THE SYSTEM SUPPLY
SENSOR INTO THE SYSTEM RETURN.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 5-3). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature
set point that is programmed into the control.
2. The TST2032 sensor provided with the boiler must be used
for the system sensor.
If a Thermostat or Zone Control enable output is available,
it should be wired to the Low Voltage Connection Board
on the Leader boiler at the terminals marked for one of the
heat/loop demands 1-3 (FIG. 5-3). If the boilers are to run
continuously, connect a jumper wire between the R and W
terminals for the heat/loop demand input. This will initiate a
call for heat on the Cascade.
3. Connect these terminals to the system supply sensor
(FIG. 5-3).
Boiler management system
1. An external control may be connected to control either
the 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.
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.
2. Make sure the (-) terminal is connected to the (-) or
common output terminal of the external control, and
the (+) terminal is connected to the 0 - 10 VDC or (+)
terminal of the external control. Make sure that the (-)
voltage is not below ground.
Runtime contacts
The SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
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30
Outdoor Knight XL Installation & Operation Manual
5 Field wiring
(continued)
Figure 5-3 Low Voltage Field Wiring Connections
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31
Outdoor Knight XL Installation & Operation Manual
6 Condensate disposal
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493.
Condensate drain
NOTICE
NOTICE
1. This boiler is a high efficiency appliance that produces
condensate.
2. The side of the boiler has a 1/2 inch (12.7 mm) PVC
union for connection of a 1/2 inch (12.7 mm) PVC pipe
(FIG. 6-1).
To allow for proper drainage on large
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch (25 mm).
3. Slope condensate tubing down and away from the boiler
into a drain or condensate neutralizing filter. Condensate
from the Outdoor Knight XL will be slightly acidic
(typically with a pH from 3 to 5). Install a neutralizing
filter if required by local codes.
The condensate line must remain
unbstructed, allowingfreeflowofcondensate.
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
(KIT3087 for Models 400 - 501 and KIT3046 for Models
601 - 801).
4. Install the 1/2 inch (12.7 mm) 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 (12.7 mm) tee OPEN. This
is needed as a vacuum break.
6. Do not expose condensate line to freezing temperatures.
Precautions should be taken to protect the condensate
management and disposal system during extended
periods of outdoor temperatures below 32°F.
7. Use only plastic tubing or piping as a condensate drain
line (FIG. 6-1).
Figure 6-1 Condensate Disposal
BLY
TEE ASSEM
1/2" PVC
)
Y SUPPLIED
(FACTOR
IMG00331
IN OR
FLOOR DRA
UNION
1/2" PVC
AN
DRAIN P
)
Y SUPPLIED
(FACTOR
IT
LIZER K
NEUTRA
32
KIT3087 shown for illustration purposes.
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Outdoor Knight XL 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 a
commercial system is 12 psi (82.7 kPa).
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 page 22). Route the
hose to an area where water can drain and be seen.
b. Close the boiler or system isolation valve between
the purge valve and 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
XL 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:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close manual and automatic air vents and boiler drain
valve.
4. Refill to correct pressure.
33
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Outdoor Knight XL Installation & Operation Manual
7 Start-up
Propane boilers only – Your propane
Check for gas leaks
ƽ WARNING
suppliermixesanodorantwiththepropane
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.
Before starting the boiler, and during
ƽ WARNING
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the top access
panel and smell the interior of the boiler
enclosure. Do not proceed with startup
if there is any indication of a gas leak.
Use an approved leak detection solution.
Repair any leaks at once.
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. Allow the boiler to
cycle.
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 XL Installation & Operation Manual
7 Start-up
(continued)
Check gas piping
Final checks before starting the boiler
1. Check around the boiler for gas odor following the
procedure on page 46 of this manual (connecting gas
supply piping).
Read the Outdoor Knight XL Service Manual to
familiarize yourself with SMART SYSTEM control
module operation. Read this manual, page 33 for proper
steps to start boiler.
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.
Propane boilers – verify conversion
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.
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.
Start the boiler
1. Read and follow the Operating instructions in FIG. 7-2,
page 36.
If boiler does not start correctly
Outdoor Knight XL boilers are typically
ƽ WARNING
shipped 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 or by making a gas
valve adjustment (see page 12). In order
to operate on LP gas, an orifice MUST
BE installed or a gas valve adjustment
MUST BE made. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
1. Check for loose connections, blown fuse or service switch
off?
2. Is boiler water temperature above 200°F (93°C)?
3. Is thermostat set below controlling sensor temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Outdoor Knight XL Service
Manual.
Check flame and combustion
1. Turn the main power off to the boiler by placing the
“On/Off” switch in the OFF position.
Check system and boiler
2. Combustion measurements will be made from exhaust
opening.
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.)
3. Turn the main power on to the boiler by placing the
“On/Off” switch in the ON position.
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 XL Installation & Operation Manual
7 Start-up
Figure 7-2 Operating Instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury, or loss of life.
• Immediately call your gas supplier from a
A. This appliance does not have a pilot. It is
neighbor’s phone. Follow the gas supplier’s
instructions.
equipped with an ignition device which
automatically lights the burner. Do not try
• If you cannot reach your gas supplier, call
the fire department.
to light the burner by hand.
B. BEFORE OPERATING smell all around
the appliance area for gas. Be sure to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
C. Use only your hand to turn the gas control knob.
Never use tools. If the handle will not turn by
hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result
in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
• Do not try to light any appliance.
service technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
• Do not touch any electric switch; do
not use any phone in your building.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
8. Turn gas shutoff valve clockwise to “ON”.
Handle will be parallel to pipe.
2. Set the thermostat to lowest setting.
9. Install top cover.
10. Turn on all electric power to appliance.
11. Set thermostat to desired setting.
3. Turn off all electric power to the
appliance.
4. This appliance is equipped with an
ignition device which automatically lights
the burner. Do not try to light the burner
by hand.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.
5. Remove top cover.
6. Turn gas shutoff valve counterclockwise
to “OFF”. Handle will be perpendicular to
pipe. Do not force.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B”
in the safety information above on this label.
If you don’t smell gas, go to next step.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
4. Turn gas shut off valve counterclockwise to
“OFF”. Handle will be perpendicular to pipe.
Do not force.
2. Turn off all electric power to the appliance
if service is to be performed.
5. Install top cover.
3. Remove top cover.
LBL2284 REV -
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36
Outdoor Knight XL Installation & Operation Manual
7 Start-up
(continued)
Check flame and combustion (continued)
Set space heating operation
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 8-1, page 43).
Determine controlling sensor
For space heating systems, the temperature control can be
based on one of three sensors; the inlet, outlet, or system
supply sensor. The SMART SYSTEM control is programmed
at the factory to control the temperature of the outlet
sensor. The control will automatically switch to the system
supply sensor once it is connected. If it is desired to base
the temperature control on the inlet sensor, the appropriate
parameter must be changed in the control. See the Outdoor
Knight XL Service Manual for a detailed explanation of this
procedure.
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. 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.
Verify space heat circulator mode
If the combustion is not within the specified range,
reference the Troubleshooting Section of the Outdoor
Knight XL Service Manual for possible causes and
corrective actions.
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 XL Service Manual for a detailed explanation of this
procedure.
Table 7A Flue Products Chart
Natural Gas
CO2 O2
Propane
CO2
O2
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
7. Once the combustion analysis is complete, test the
safety shutoff device by turning the manual shutoff
valve to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Turn the manual
shutoff switch to the ON position and reset the control.
Adjust set point temperature(s)
Please note that the brackets ([]) denote
screen status.
NOTICE
8. Place the boiler back into normal operation.
The NAVIGATION dial may be used during normal
operation to adjust the space heating and tank set point
temperatures.
1. From the Status Screen press the NAVIGATION dial.
2. Turn the NAVIGATION dial counterclockwise to select
the appropriate set point.
3. Press the NAVIGATION dial to adjust the temperature.
4. Once the desired temperature is displayed, press the
RIGHT SELECT [SAVE] key.
5. If necessary repeat Steps 3 and 4 to make adjustments to
additional set points.
6. Press the RIGHT SELECT [HOME[ key to upload the
changes.
7. If the RIGHT SELECT [SAVE] key is not pressed, the
new settings will be discarded.
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37
Outdoor Knight XL Installation & Operation Manual
7 Start-up
Set domestic hot water (DHW) operation
Verify DHW mode
There are two (2) modes of operation for DHW. In Normal
Mode, when a DHW demand begins, the control will start
the DHW pump, turn off the boiler pump (if running), and
modulate to bring the outlet temperature to the DHW boiler
set point. The maximum firing rate may be limited in this
mode if desired.
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
8. Turn the NAVIGATION dial to adjust the month. Press
the NAVIGATION dial.
9. Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
In Zone Mode it is assumed that the indirect DHW tank is
piped as a zone on the primary loop. When a DHW demand
begins, the control will turn on the DHW pump output, and
raise the system temperature set point to the DHW boiler set
point (if higher). The boiler pump will be turned on. The
system pump may be forced on, forced off, or not changed,
depending on the System Pump Mode selected (reference
the Outdoor Knight XL Service Manual for details). In this
mode, any low temperature zones (such as radiant heating)
may need additional controls to limit the water temperature
sent to those zones.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
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
Set DHW boiler target temperature
Please note that the brackets ([]) denote
screen status.
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 XL Service Manual for a detailed explanation of this
procedure.
NOTICE
When installed in a Cascade system, the individual controls must
be programmed for cascade operation. This is accomplished by
accessing the control parameters.
Press the [MENU] key for at least five (5) seconds. Input the
Installer code as described in the Outdoor Knight XL Service
Manual. Once the control parameters have been accessed,
use the NAVIGATION DIAL to select the Control Mode
parameters. Press the NAVIGATION DIAL to access these
parameters.
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 XL 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
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:
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.
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.
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38
Outdoor Knight XL Installation & Operation Manual
8 Operating information
The Outdoor Knight XL can also be programmed to accept a
call for heat from a 0 - 10V signal, reference the Outdoor Knight
XL Service Manual for a detailed explanation of this procedure.
General
How the boiler operates
The Outdoor Knight XL uses an advanced stainless steel heat
exchanger and electronic control module that allows fully DHW priority
condensing operation. The blower pulls in air and pushes flue
The SMART SYSTEM control allows the connection of a DHW
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.
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
DHW / space heating (SH) cycling
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.
If a DHW call for heat is received while a space heating call is
in progress, and the DHW is in Normal Mode, the control will
start the DHW pump and shut the boiler pump off. The system
pump will remain on. For stand-alone boilers, if the space
heating call is still active while the DHW call is in operation, the
control will wait for 30 minutes (time adjustable by installer)
then it will switch back to the space heating demand. There is
a timer to switch from space heating to DHW and a timer to
switch from DHW to space heating. The control will switch
back and forth until one of the heat demands end. This function
does not apply to cascade systems.
Control inputs and outputs
Room thermostat
Programmable controlling sensor
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.
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.
Example: Assume that both heat/loop demand 1 and heat/
loop demand 2 have a call for heat. Demand 1 has a set point
of 110°F. Demand 2 has a set point of 140°F. The boiler will
regulate the system temperature to 140°F until Demand 2 has
been satisfied. Once Demand 2 has been satisified 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
Boiler and system pump control
protection of any low temperature loops.
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.
SMART SYSTEM Multi-temp loop control
The Outdoor Knight XL boiler is capable of producing up
to three (3) set point temperatures to meet different space
heating demands.
This device controls the temperatures
of up to three (3) separate loops, based on the settings for
the three (3) heat/loop demands (reference Lochinvar kit
RLY30086).
The 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 Knight XL can be controlled by a Building
Management System (BMS) using a 0 - 10 VDC signal. The
control can be configured by the installer to use this signal to
either control set point or firing rate.
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39
Outdoor Knight XL Installation & Operation Manual
8 Operating information
Temperature control
Protection features
Modulation
Outlettemperature, fluetemperature, andtemperature
The Outdoor Knight XL 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.
rise limiting
The outlet temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F (90°C) the control will shut the unit
down until it cools off.
Ramp delay
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 module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F (102°C) the control will reduce the maximum fan speed.
If the flue temperature exceeds 240°F (115°C) the control will
shut the unit down. The unit will restart automatically once the
flue temperature drops 25°F (-4°C) and the minimum off time
has expired.
Gradient limiting
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds 55°F
(13°C) the control will reduce the maximum fan speed. If the
temperature difference exceeds 60°F (15°C) the control will
shut the unit down. The unit will restart automatically once the
temperature difference has dropped below 55°F (13°C) and the
minimum off time has expired.
Ifduringoperationoftheboilertheoutletwatertemperature
is rising too quickly, the control will reduce the firing rate
to its lowest setting.
Outdoor air reset
If an outdoor air sensor is connected, the control module
will calculate the set points of the three (3) space heating
demands based on the programmed reset curves. The
installer can change the slope of the reset curves by several
adjustable parameters. The user can limit the maximum
set point for the system using the space heating set points.
Freeze protection
DO NOT install the boiler in a location where it is likely to
freeze.
The following integral feature of the SMART SYSTEM control
module provides some protection for the boiler only -- not for
the system.
Boost function
If outdoor air reset is active, and any space heating
demand has been active continuously for a set period of
time (time adjustable by installer) and there has been no
DHW demands, the control will increase the set point of
that demand by a 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.
•
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F (7°C):
Below 45°F (7°C), the boiler and system pumps
operate constantly.
•
•
Below 37°F (3°C), the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F (7°C).
•
Lower temperatures may be programmed for systems
with anti-freeze solutions.
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.
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.
Flame current support
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
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 XL Installation & Operation Manual
8 Operating information
(continued)
Monitor external limits
High limit operations
Connections are provided on the connection board for
external limits such as 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.
The Outdoor Knight XL is equipped with adjustable automatic
reset and manual reset high limits. The automatic reset high
limit has a maximum set point of 200°F and the manual reset
high limit has a maximum set point of 210°F.
When the outlet temperature exceeds 200°F, the automatic
high limit action occurs. The boiler shuts down until the outlet
water temperature cools below 190°F, and a 60 second timer
has expired. If the outlet temperature continues to increase, the
manual reset high limit action will occur at 210°F.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
High limit test procedure
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler
is in the Space Heating Mode. The other timer monitors
the time the boiler is firing in the DHW Mode.
Please note that the brackets ([]) denote
screen status.
NOTICE
1. Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
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.
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.
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.
5. Decrease the set point of the MRHL to below the current
outlet temperature (or to its minimum setting, whichever
is higher) by turning the NAVIGATION dial
counterclockwise.
6. Press the RIGHT SELECT [SAVE] key.
7. Press the RIGHT SELECT [HOME] key. The new
parameter will upload to the control.
8. If the current outlet temperature is above the new MRHL
set point, the MRHL will function causing boiler lockout.
If this occurs, skip to Step 11.
The time dependent feature has been disabled by the
manufacturer. To enable this feature change the parameter
to the desired time interval, reference the Outdoor Knight
XL Service Manual for details regarding parameters.
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.
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.
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.
Boiler temperature regulation
Operating temperature (target)
11. Repeat Steps 2, 3 and 4.
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 70°F (21°C) and 190°F (88°C).
12. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
13. Repeat Steps 6 and 7.
14. Press the RESET button to clear the lockout.
•
Target temperature is fixed when the outdoor
sensor is not installed.
15. If needed, press the RIGHT SELECT [STOP] key to exit
Service Mode.
•
Target temperature is calculated as described
on this page under “Outdoor Reset Operation”
and “Target Temperature Boost” when the
outdoor sensor is connected.
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41
Outdoor Knight XL Installation & Operation Manual
8 Operating information
Low water cutoff protection
Sequence of the cascade
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the 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.
To equalize the run time of all boilers on the Cascade, the firing
sequence will automatically be changed at set intervals.
The sequence will be changed once every 24 hours. The
switching on/off sequence will be as follows:
TIME
Start
SWITCHING ON SEQUENCE
L-M1-M2-M3-M4-M5-M6-M7
M1-M2-M3-M4-M5-M6-M7-L
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).
1 hour
2 hours
M2-M3-M4-M5-M6-M7-L-M1
Outdoor reset operation, if used
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.
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
DHW, Night Setback, and Ramp Delay operation with
cascade
See the Outdoor Knight XL Service Manual to change the
settings.
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.
Reset curve
The reset curves look at outdoor air temperature and adjusts
the set points.
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.
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.
Once the Leader boiler receives a call for heat from a room
thermostat, BMS, or Modbus, the control will determine what
the set point will be. If outdoor air reset is desired, connect
the outdoor air sensor to the terminals on the Low Voltage
Connection Board on the Leader boiler. The set point will be
calculated based on the programmed reset curve parameters.
See the Outdoor Knight XL Service Manual to program the
reset curve. If outdoor air reset is not desired, do not connect
the outdoor air sensor. A fixed temperature set point can be
programmed into the control. See page 59 of this manual to
program the set point.
When DHW is programmed for Zone Mode, connect the DHW
thermostat or tank sensor to the Leader boiler. When a DHW
call is received, the Leader will modulate the entire Cascade to
bring the system supply temperature up to the DHW boiler set
point (if higher).
Night Setback operation of the boilers within the Cascade is
available. Programming of the Night Setback will be done
through the Leader boiler. Refer to the Outdoor Knight XL
Service manual for information regarding Night Setback.
If the water temperature at the system supply sensor is less
than the set point + the turn-off offset - the off-on differential,
then the control will initiate a call for heat on the Cascade
(see the Outdoor Knight XL Service Manual for an explanation
of the offset and differential). The Leader will energize the
lead boiler on the Cascade. For a new startup this will be the
Leader boiler.
Ramp Delay operation of the boilers as described in the Outdoor
Knight XL Service Manual is available when the boilers are part
of a Cascade system.
42
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Outdoor Knight XL 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 postpurge, then start another prepurge cycle and try
to light the burner again. On the 501 and larger models, the control
will lock out if this second attempt also fails. On the 400 model,
the control will perform a total of 4 attempts before locking out.
7. If 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 XL 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 (boiler and DHW pump operation briefly overlap to ensure
flow is maintained through the unit). This will divert the boiler’s
outlet water from the heating system and send it to the tank coil
instead. The control will then modulate to maintain the outlet
temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one of
them is 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 XL Installation & Operation Manual
8 Operating information
(continued)
Outdoor Knight XL control module
Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor boiler operation.
Figure 8-1 Control Panel
NAVIGATION DIAL
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
Access modes
Please note that the brackets ([]) denote
screen status.
NOTICE
User
To save parameters and exit programming:
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 36).
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
To enter a parameter and continue programming:
Installer
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.
Most parameters are available only to the installer, accessible
by entering the installer password, see the Outdoor Knight XL
Service Manual.
See the Outdoor Knight XL Service Manual for a detailed
description of parameters and access modes.
Saving parameters (reference the Parameter Table in
the Outdoor Knight XL Service Manual)
45
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Outdoor Knight XL 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
Room Thermostat 1 has a call for heat.
Room Thermostat 2 has a call for heat.
Room Thermostat 3 has a call for heat.
B
The tank thermostat or sensor has a call for heat.
(Call for Heat
Indicators)
Indicates which room thermostat demand shows priority.
The unit is being controlled by a 0 - 10V BMS signal.
The member unit is supplying heat while in Cascade Mode.
46
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Outdoor Knight XL 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 (if connected).
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.
DHW RUN HOURS:
DHW CYCLES:
LAST 10 FAULTS NO:* The last 10 lockouts.
NIGHT SETBACK
Shows the next Night Setback trigger (if active).
47
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Outdoor Knight XL 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
YES
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.
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 XL Installation & Operation Manual
9 Maintenance
Maintenance and annual startup
Table 9A Service and Maintenance Schedules
Owner maintenance
Service technician
(see the Outdoor Knight XL User’s Information
Manual for instructions)
(see the following pages for instructions)
General:
• Check boiler area
• Address reported problems
Daily
• Inspect interior; clean and vacuum if
necessary;
• Check pressure/temperature
gauge
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air passage ways in good
condition and sealed tight
• Check air and vent termination
screens
• Check system water pressure/system
piping/expansion tank
Monthly
• Check control settings
• Check relief valve
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check condensate drain system
• Check wiring and connections
• Perform start-up checkout and performance
•Test low water cutoff (if used)
verification per Section 7.
• Flame inspection (stable, uniform)
Periodically
• Reset button (low water cutoff)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue temperature
is more than 54°F (30°C) above return water
temperature.
• Check boiler piping (gas and
water) for leaks
Every
6 months
If combustion or performance
indicate need:
• Operate relief valve
• 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 XL 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
1. Inspect any problems reported by the owner and correct
before proceeding.
RETAINING
SCREW
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
Eliminate all system or boiler leaks.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 9-1).
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.
2. Look for signs of leaking lines and correct any problems
found.
6. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
3. Check gas line using the procedure found in Section 4 -
Gas Connections.
7. Replace the retaining screw.
50
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Outdoor Knight XL Installation & Operation Manual
9 Maintenance
(continued)
Safety relief valves should be re-inspected
Flue vent system and air piping
ƽ WARNING
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions may
corrode the valve or its components over
time, rendering the valve inoperative. Such
conditions are not detectable unless the valve
and its components are physically removed
and inspected. This inspection must only
be conducted by a plumbing contractor
or authorized inspection agency – not by
the owner. Failure to re-inspect the boiler
relief valve as directed could result in
unsafe pressure buildup, which can result in
severe personal injury, death, or substantial
property damage.
1. Visually inspect the entire flue gas venting system for
blockage, deterioration or leakage.
2. Verify that boiler vent discharge and air intake openings
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 (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be
taken to avoid contact with hot water and
to avoid water damage. Before operating
lever, check to see that a discharge line is
connected to this valve directing the 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.
ƽ WARNING
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.
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.
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.
Check boiler relief valve
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 XL Installation & Operation Manual
9 Maintenance
Inspect ignition and flame sense
Figure 9-2 Burner Assembly - Model 400
electrodes
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
AIR / GAS
ARM
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
SCREWS
(5)
IMG00437
Check ignition ground wiring
BURNER
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
GASKET
2. Verify all wiring is in good condition and securely
attached.
Figure 9-3 Burner Assembly - Model 501
3. Check ground continuity of wiring using continuity
meter.
4. Replace ground wires if ground continuity is not
satisfactory.
AIR / GAS
ARM
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
SCREWS
(5)
condition and securely attached.
IMG00438
Check control settings
BURNER
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the Outdoor Knight XL Service Manual. Adjust settings
if necessary. See Section 1 of the Outdoor Knight XL
Service Manual for adjustment procedures.
GASKET
Figure 9-4 Burner Assembly - Models 601 - 801
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
AIR / GAS
ARM
Section 7 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
IMG0043
9
Check burner flame
1. Inspect flame through observation window.
BURNER
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.
GASKET
SCREWS
(5)
3. Remove the burner, reference FIG.’s 9-2 thru 9-4.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG.’s 9-2 thru 9-4).
52
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Outdoor Knight XL Installation & Operation Manual
9 Maintenance
(continued)
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
7. Brush the heat exchanger while dry using a nylon bristle
brush. Caution: DO NOT use a metal brush. Re-vacuum
the heat exchanger.
8. Finish cleaning using a clean cloth dampened with warm
water. Rinse out debris with a low pressure water supply.
9. Allow the heat exchanger to thoroughly dry.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
reassemble.
11. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
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.
3. See Section 3 - Troubleshooting in the Outdoor Knight
XL Service Manual for other procedures to deal with low
flame signal.
Review with owner
1. Review the Outdoor Knight XL User’s Information
Manual with the owner.
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.
2. Emphasize the need to perform the maintenance schedule
specified in the Outdoor Knight XL User’s Information
Manual (and in this manual as well).
13. Replace the access cover and restore boiler to operation.
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
Table 9B Heat Exchanger Cleaning Kits
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.
Kit
Part
Component
Description
Model
Number Number
CTN20005
Rear Refractory Cover
Nylon 4" Wheel Brush*
MSC20083*
Cleaning boiler heat exchanger
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 9B - Heat Exchanger Cleaning Kits.
400
KIT30063
MSC20084
3mm Allen Wrench
1/4" x 24" Drill Extension
Rear Refractory Cover
Nylon 4" Wheel Brush*
1/4" x 12" Drill Extension
1/4" x 24" Drill Extension
MSC20086
CTN20005
MSC20083*
KIT30064
1. Shut down boiler:
501 - 801
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in Section 7 - Startup.
MSC20085
MSC20086
• 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 9-5 Rope Gasket - Heat Exchanger Door
3. Remove the nuts securing the heat exchanger access cover
to the heat exchanger and set aside.
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
ROPE GASKET
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. 9-5). If damaged DO NOT reuse, the
NOTICE
heat exchanger door must be replaced. Consult
factory for replacement heat exchanger door
(kit WTR3080 and WTR3086).
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53
Outdoor Knight XL Installation & Operation Manual
10 Diagrams
Figure 10-1 Wiring Diagram
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
CONTROL
CONNECTION BOARD
L
N
ALARM
CONTACTS
1
2
JUNCTION
BOX
RELAY
BOARD
X-7
DHW
PUMP
RUN-TIME
3
CN2-4
CN2-2
CN1-5
OR
BR
PR
OR
CONTACTS
X1-3
X1-4
X1-2
4
K1
K2
K3
24 VAC LOUVER
5
CN1-6
CN1-3
OR
BR
RELAY COIL
BOILER
PUMP
6
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
CN1-4
CN1-1
8
BR
PR
CN2-3
9
SYSTEM
PUMP
10
CN2-1
CN1-2
PR
X4-13
X4-5
BK
BK
BK
BK
BK
X4-12
X4-11
X4-4
ON/OFF
SWITCH
L
X1-6
X1-5
BK
W
120V
GND
N
FLOW
SWITCH
11
12
13
14
15
16
17
18
19
20
X4-3
SUPPLY
BK
X4-8
BK
BK
BK
BK
TANK
X4-10
X4-2
THERMOSTAT
HEAT/LOOP
X4-9
G
R
X1-8
X1-1
3
2
1
DEMAND
X4-1
HEAT/LOOP
DEMAND
HEAT/LOOP
TRANSFORMER
3.5A
DEMAND
RW G
3
SYSTEM
SENSOR
OUTDOOR
SENSOR
21
22
23
24
25
26
27
28
29
30
31
32
KB 801
ONLY
1
2
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
33
34
35
36
37
38
39
40
41
42
43
44
+
0-10V
X5-15
X5-9
IN
-
SYS PUMP
+
0-10V
IN
-
BLR PUMP
X5-1
BL
O
+
0-10V
OUT
-
X5-2
RATE
+
O-TEMP HEX SW
0-10V
BLOCKED DRAIN SWITCH
OUT
-
X5-10
X5-11
X5-4
P
SHIELD
AIR PRESSURE SWITCH
A
O/BK
R/BK
GY
MODBUS
-T
-T
-T
-T
-T
OPTION
B
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
SHIELD
X5-12
X5-6
24 VAC
LOW
CN7-1
COM
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
P/BK
W/BK
PR
CN7-2
CN7-3
CN7-4
WATER
CUT-OFF
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
SPARK
ROD
G
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
LBL20116 REV E
54
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Outdoor Knight XL Installation & Operation Manual
10 Diagrams
(continued)
Figure 10-2 Ladder Diagram
JUNCTION BOX
120VAC
NEUTRAL
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
L
IN
L
OUT
GROUND
SYSTEM
PUMP
CONTACTS
INTEGRATED CONTROL
ON / OFF
SWITCH
BLOWER
2
1
X1-1
X1-2
X1-6
F2
3.15A
SYSTEM
PUMP
3
BOILER
F1
5A
PUMP
CONTACTS
SYSTEM PUMP
RELAY
SYSTEM PUMP
RELAY
X1-3
BOILER
PUMP
DHW PUMP
RELAY
DHW PUMP
RELAY
DHW
PUMP
X1-4
CONTACTS
BOILER PUMP
RELAY
BOILER PUMP
RELAY
F3
DHW
PUMP
.8A
24V DC
SUPPLY
RELAY BOARD
X5-9
X5-1
120 VAC
24 VAC
3.5A
X4-3
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
CN5-13
CN5-6
X4-1
X4-9
20
18
16
14
19
HEAT/LOOP
DEMAND 2
17
HEAT/LOOP
DEMAND 3
X4-2
15
13
TANK
THERMOSTAT
CN5-12
X4-10
LOW GAS
PRESSURE
SWITCH
HIGH GAS
PRESSURE
SWITCH
CN5-11
CN5-3
X4-11
X4-5
9
10
INTEGRATED
CONTROL
LOUVER
RELAY COIL
5
6
7
24VAC
LOUVER
PROVING SWITCH
CN5-4
X4-4
X7
8
RIBBON CABLE
X5-2
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
LBL20141 REV D
SHIELD
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.
OKBX-I-O Rev B
10/12
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