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Knight 151-286 Installation & Operation Manual

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OKB-I-O Rev F
Outdoor Knight Boiler
Installation & Operation
Manual
Models: 151 - 286
This manual must only be used by
WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Knight Boiler Service
Manual, before installing. Perform
steps in the order given.
Failure
to comply could result in severe
personal injury, death, or substantial
property damage.
Save this manual for future reference.

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Summary of Contents for Knight 151-286

  • Page 1 This manual must only be used by WARNING a qualified heating installer / service technician. Read all instructions, including this manual and the Outdoor Knight Boiler Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

  • Page 2: Table Of Contents

    HAZARD DEFINITIONS ............ 2 5. FIELD WIRING PLEASE READ BEFORE PROCEEDING ......3 Line Voltage Connections ..........28 THE OUTDOOR KNIGHT BOILER -- HOW IT WORKS 4-6 Low Voltage Connections ..........28 RATINGS ................7 Wiring of the Cascade ............30 1.

  • Page 3: Please Read Before Proceeding

    Outdoor Knight Boiler Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including DO NOT install units in rooms or WARNING WARNING this manual and the Outdoor Knight environments that contain corrosive Boiler Service Manual, before installing.

  • Page 4: The Outdoor Knight Boiler - How It Works

    Outdoor Knight Boiler Installation & Operation Manual The Outdoor Knight Boiler - How it works... Stainless steel heat exchanger 17. Manual air vent Allows system water to flow through specially designed Designed to remove trapped air from the heat exchanger coils for maximum heat transfer, while providing coils.
  • Page 5 Outdoor Knight Boiler Installation & Operation Manual The Outdoor Knight Boiler - How it works... (continued) Models 151 - 211 IMG00365 IMG00365 Front View - Models 151 - 211 Rear View - Models 151 - 211 IMG00368 Right Side (inside unit) - Models 151 - 211...
  • Page 6 Outdoor Knight Boiler Installation & Operation Manual The Outdoor Knight Boiler - How it works... Model 286 IMG00379 Rear View - Model 286 Front View - Model 286 IMG00382 Left Side (inside unit) - Model 286 Right Side (inside unit) - Model 286...

  • Page 7: Ratings

    Outdoor Knight Boiler Installation & Operation Manual Ratings Outdoor Knight Boiler Other Specifications AHRI Rating Heating Input AFUE Capacity AHRI Model Number Boiler Ratings Water Water Water, Size Content Connections Connections (Note 4) Note: Change “N” to Gallons “L” for L.P. gas models.

  • Page 8: Determine Boiler Location

    Outdoor Knight Boiler Installation & Operation Manual Determine boiler location Installation must comply with: - To avoid a blocked air inlet or blocked flue condition, keep the outdoor air inlet and flue outlet clear of leaves, • Local, state, provincial, and national codes, laws, debris, etc.

  • Page 9: Flooring And Foundation

    4. If a new boiler will replace an existing boiler, check for and correct system problems, such as: Flooring • System leaks causing oxygen corrosion or heat exchanger The Outdoor Knight is approved for installation on combustible cracks from hard water deposits. flooring. • Incorrectly-sized expansion tank.

  • Page 10: Prepare Boiler

    Outdoor Knight Boiler Installation & Operation Manual Prepare boiler Remove boiler from wood pallet Figure 2-2 Install Flue Pipe Assembly 1. After removing the outer shipping carton from the boiler, remove the installation kit. 2. Remove the front access covers to access the lag bolts in front of the unit (FIG.

  • Page 11: Leveling The Boiler

    Outdoor Knight Boiler Installation & Operation Manual Prepare boiler (continued) Leveling the boiler 5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the Set the boiler in place and check level. boiler rating plate. Attach the LP caution label (in the a) Adjust legs if necessary to level boiler, see FIG.

  • Page 12: Hydronic Piping

    Outdoor Knight Boiler Installation & Operation Manual Hydronic piping System water piping methods General piping information The outdoor boiler is designed to function in a closed loop Basic steps are listed in this section along with illustrations on pressurized system not less than 12 psi. A temperature and the following pages (FIG.’s 3-4 thru 3-10), which will guide you...

  • Page 13: Relief Valve / T & P Installation

    Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Near boiler piping components The relief valve, tee and any necessary fittings WARNING are shipped in the install kit with the boiler 1. Boiler system piping: and are to be field installed (FIG. 3-1).

  • Page 14: Near Boiler Piping Connections

    Outdoor Knight Boiler Installation & Operation Manual Hydronic piping 12. System temperature sensor: Lochinvar offers the Squire which is a series of indirect Lochinvar supplies a system temperature sensor. water heaters. The Squire features a stainless steel vessel The sensor is to be installed in the heating loop with a single wall stainless steel heat exchanger.
  • Page 15 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Figure 3-3 Pressure Drop vs. Flow Pressure Drop vs. Flow (Includes Secondary Piping) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Flow Rate (GPM) Table 3A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°...

  • Page 16: Variable Speed Pump Option

    Outdoor Knight Boiler Installation & Operation Manual Hydronic piping Variable speed pump option Table 3B Recommended Variable Speed Pumps Minimum Temperature Rise* Pump Model Grundfos TACO Wilo UP26-96 FC/VS 0013 IFC VS Stratos 1.25 3 x 30 *The minimum temperature rise is derived from the chart in FIG. 3-3 with the firing rate and pump speed at 100% as shown in the table above.
  • Page 17 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Figure 3-4 Single Boiler - Single Temperature Zoned with Circulators ZONE 1 PRESSURE PRESSURE GAUGE REDUCING VALVE ZONE 2 ZONE 3 ZONE 4 BACKFLOW FLOW CHECK PREVENTER VALVE (TYPICAL) MAKE UP WATER...
  • Page 18 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping Figure 3-5 Multiple Boilers - Single Temperature Zoned with Circulators Number of Units Model Required Pipe Sizes 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2" 2" 2-1/2" 3" 3" 3-1/2" 4" 4"...
  • Page 19 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Figure 3-6 Single Boiler - Multiple Temperatures PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE REDUCING VALVE LOOP #1 LOOP #2 LOOP #3 WIRES TO LOOP SENSORS BACKFLOW PREVENTER PRESSURE GAUGE MAKE SYSTEM WATER...
  • Page 20 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping Figure 3-7 Multiple Boilers - Multiple Temperatures Number of Units Model Required Pipe Sizes 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2" 2" 2-1/2" 3" 3" 3-1/2" 4" 4" 2-1/2" 2-1/2" 3"...
  • Page 21 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Figure 3-8 Multiple Boilers - Multiple Temperatures with DHW Piped as a Zone PRESSURE TEMPERATURE TEMPERATURE WIRES TO TEMPERATURE REDUCING VALVE LOOP #1 LOOP #2 LOOP LOOP #3 BACKFLOW SENSORS...
  • Page 22 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping Figure 3-9 Multiple Boilers - Single Temperature Zoned with Valves Number of Units Model Required Pipe Sizes 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2" 2" 2-1/2" 3" 3" 3-1/2" 4" 4"...
  • Page 23 Outdoor Knight Boiler Installation & Operation Manual Hydronic piping (continued) Figure 3-10 Multiple Boilers - Non-Zoned Primary/Secondary Piping Number of Units Model Required Pipe Sizes 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2" 2" 2-1/2" 3" 3" 3-1/2" 4" 4" 2-1/2" 2-1/2"...

  • Page 24: Gas Connections

    Outdoor Knight Boiler Installation & Operation Manual Gas connections Connecting gas supply piping 4. Purge all air from the gas supply piping. 1. Remove the top access cover and refer to FIG. 4-1 to pipe 5. Before placing the boiler in operation, check the boiler gas to the boiler.

  • Page 25: Natural Gas

    Outdoor Knight Boiler Installation & Operation Manual Gas connections (continued) Natural gas: Use two wrenches when tightening gas WARNING piping at boiler (FIG. 4-2), using one Pipe sizing for natural gas wrench to prevent the boiler gas line connection from turning.

  • Page 26: Check Inlet Gas Supply

    Outdoor Knight Boiler Installation & Operation Manual Gas connections Table 4A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe...

  • Page 27: Gas Pressure

    Outdoor Knight Boiler Installation & Operation Manual Gas connections (continued) Gas Pressure When re-tightening the set screw, be sure WARNING to tighten securely to prevent gas leaks. The gas pressure must remain between 4 inches w.c. (natural), Do not check for gas leaks with an open 8 inches w.c.

  • Page 28: Field Wiring

    Outdoor Knight Boiler Installation & Operation Manual Field wiring ELECTRICAL SHOCK HAZARD – For Label all wires prior to disconnection WARNING CAUTION your safety, turn off electrical power supply when servicing controls. Wiring errors before making any electrical connections can cause improper and dangerous to avoid possible electric shock hazard.

  • Page 29: Outdoor Temperature Sensor

    Outdoor Knight Boiler Installation & Operation Manual Field wiring (continued) Thermostat High gas pressure switch 1. Connect the room thermostats or end switches (isolated If a switch is provided to detect excessive gas pressure, remove contact only) to Heat/Loop Demand 1, 2, or 3, as shown the jumper wire from the terminals on the connection board, in FIG.

  • Page 30: Flow Switch

    SMART SYSTEM control to use the inlet sensor as Connect the system supply sensor and outdoor air sensor (if the controlling sensor. See the Outdoor Knight Boiler used) to the Leader boiler. For the Cascade system to work Service Manual for instructions on how to use the inlet properly the system supply sensor must be installed.
  • Page 31 Outdoor Knight Boiler Installation & Operation Manual Field wiring (continued) Figure 5-3 Low Voltage Field Wiring Connections...

  • Page 32: Condensate Disposal

    Outdoor Knight Boiler Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of 1. This boiler is a high efficiency appliance that produces other authority, PVC and CPVC pipe condensate.

  • Page 33: Startup

    Close the vent when 4. The freeze protection set points may be lowered when water squirts out. Repeat with remaining vents. freeze protection fluid is used (see the Outdoor Knight Service Manual). 2. Open automatic air vent (diaphragm-type or bladder-type expansion tank systems only) one turn.

  • Page 34: Check For Gas Leaks

    Outdoor Knight Boiler Installation & Operation Manual Start-up Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the propane Before starting the boiler, and during to make its presence detectable. In some WARNING...

  • Page 35: Start The Boiler

    (continued) Final checks before starting the boiler  Check gas piping  Read the Outdoor Knight Boiler Service Manual to 1. Check around the boiler for gas odor following the familiarize yourself with SMART SYSTEM control procedure on page 24 of this manual (connecting gas supply module operation.
  • Page 36 Outdoor Knight Boiler Installation & Operation Manual Start-up Figure 7-2 Operating Instructions...

  • Page 37: Set Space Heating Operation

    5 seconds to place the boiler into Service Mode. parameter must be changed in the control. See the Outdoor In Service Mode the boiler will fire at ignition speed and Knight Boiler Service Manual for a detailed explanation of will then modulate up to full fire. this procedure.
  • Page 38 Press the [MENU] key for at least five (5) seconds. Input to 180°F. If a different set point is desired, the appropriate the Installer code as described in the Outdoor Knight Boiler parameter in the control must be changed. See the Outdoor Service Manual.

  • Page 39: Operating Information

    The outdoor boiler can also be programmed to accept a call for exchanger and electronic control module that allows fully heat from a 0 - 10V signal, reference the Outdoor Knight Boiler condensing operation. The blower pulls in air and pushes flue Service Manual for a detailed explanation of this procedure.

  • Page 40: Temperature Control

    Outdoor Knight Boiler Installation & Operation Manual Operating information Temperature control Protection features Modulation Outlet temperature, flue temperature, The outdoor boiler is capable of modulating its firing rate temperature rise limiting from a minimum of 20% to a maximum of 100%. The The outlet temperature is monitored by the boiler outlet firing rate is dictated by the call for heat (i.e., space heating...
  • Page 41 To enable this feature change the parameter continuously for five (5) seconds to place the boiler into to the desired time interval, reference the Outdoor Knight Service Mode. In Service Mode, the boiler will fire at Service Manual for details regarding parameters.

  • Page 42: Cascade

    In the absence of an 24 hours. The switching on/off sequence will be as follows: external energy management system, this feature MUST BE used. TIME SWITCHING ON SEQUENCE See the Outdoor Knight Boiler Service Manual to change the Start L-M1-M2-M3-M4-M5-M6-M7 settings. 1 hour M1-M2-M3-M4-M5-M6-M7-L...

  • Page 43: Sequence Of Operation

    Outdoor Knight Boiler Installation & Operation Manual 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).
  • Page 44 Outdoor Knight Boiler Installation & Operation Manual 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.

  • Page 45: Outdoor Knight Boiler Control Module

    Remember to press the RIGHT SELECT [HOME] key when finished programming in order to save the changes made. See the Outdoor Knight Boiler Service Manual for a detailed description of parameters and access modes.

  • Page 46: Status Display Screens

    Outdoor Knight Boiler Installation & Operation Manual Operating information Figure 8-2 Status Display Screen (CALL FOR (BOILER HEAT) STATUS) (OPERATIONAL INFORMATION) (RIGHT SELECT KEY) (LEFT SELECT KEY) (NAVIGATION DIAL) Status Display Screens Section Display Description The unit has not received a call for heat from a remote thermostat nor STANDBY has it received a call for heat from a DHW thermostat.
  • Page 47 Outdoor Knight Boiler Installation & Operation Manual 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). OUTDOOR: The temperature read by the outdoor sensor.
  • Page 48 Outdoor Knight Boiler Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen. EXIT Press the LEFT SELECT key to exit the current screen or setting.

  • Page 49: Maintenance

    Outdoor Knight Boiler Installation & Operation Manual Maintenance Maintenance and annual startup Table 9A Service and Maintenance Schedules Owner maintenance Service technician (see the Outdoor Knight User’s Information Manual (see the following pages for instructions) for instructions) • Check boiler area General: •...

  • Page 50: Inspect Boiler Area

    Outdoor Knight Boiler Installation & Operation Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.

  • Page 51: Check Expansion Tank

    Outdoor Knight Boiler Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage.

  • Page 52: Check Burner Flame

    Parameter Mode and check all settings. See Section 1 of IMG00447 Outdoor Knight Boiler Service Manual. Adjust settings if necessary. See Section 1 of the Outdoor Knight Boiler Check flame signal Service Manual for adjustment procedures. 1. At high fire the flame signal shown on the display should be 2.

  • Page 53: Review With Owner

    11. Close isolation valves on piping to isolate boiler from system. Attach a hose to the boiler drain and flush boiler 1. Review the Outdoor Knight Boiler User’s Information thoroughly with clean water by using purging valves to Manual with the owner.

  • Page 54: Diagrams

    Outdoor Knight Boiler Installation & Operation Manual Diagrams Figure 10-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" INTEGRATED CONTROL BLOWER ON / OFF KB ONLY SWITCH SYSTEM SYSTEM X1-1 X1-6 PUMP "L"...

  • Page 55: Wiring Diagram

    Outdoor Knight Boiler Installation & Operation Manual Diagrams (continued) Figure 10-2 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONNECTION BOARD BOX DEPICTS CONTROL JUNCTION OPTIONAL ITEMS ALARM X1-3...

  • Page 56: Revision Notes

    Revision Notes: Revision A (ECO C11234) initial release. Revision B (ECO #C11235) reflects updates made to the freezing conditions warnings. Revision C (ECO #C11654) reflects updates made to the Ratings page. Revision D (ECO #C12102) reflects the addition of condensate kit option information for areas that may reach below 32°F and Table 1A on page 8.

This manual is also suitable for:

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