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Outdoor Knight XL
Installation & Operation Manual
Models: 400 - 801
This manual must only be used by
WARNING
a qualifi ed heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Knight XL Service Manual,
before installing. Perform steps in
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.
OKBX-I-O Rev F
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Table of Contents
Related Manuals for Lochinvar Knight XL 601
Summary of Contents for Lochinvar Knight XL 601
- Page 1 OKBX-I-O Rev F Outdoor Knight XL Installation & Operation Manual Models: 400 - 801 This manual must only be used by WARNING a qualifi ed heating installer / service technician. Read all instructions, including this manual and the Outdoor Knight XL Service Manual, before installing.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS ............ 2 Pipe Sizing for Natural Gas ......... 25 PLEASE READ BEFORE PROCEEDING ......3 Natural Gas Supply Pressure Requirements ..... 25 THE OUTDOOR KNIGHT XL -- HOW IT WORKS..4-6 Propane Gas ..............25 RATINGS ................7 Pipe Sizing for Propane Gas ........ -
Page 3: Please Read Before Proceeding
Outdoor Knight XL Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including When servicing boiler – WARNING this manual and the Outdoor Knight XL • To avoid electric shock, disconnect electrical supply Service Manual, before installing. Perform before performing maintenance. -
Page 4: The Outdoor Knight Xl - How It Works
Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... Stainless steel heat exchanger 22. Low voltage connection board Allows system water to fl ow through specially designed The connection board is used to connect external low voltage coils for maximum heat transfer, while providing protection devices. - Page 5 Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... (continued) Model 400 Front View - Model 400 Rear View - Model 400 Left Side (inside unit) - Model 400 Right Side (inside unit) - Model 400...
- Page 6 Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... Model 501 IMG00408 IMG00409 Rear View - Model 501 Left Side (inside unit) - Model 501 Models 601 - 801 IMG00324 IMG00324 Left Side (inside unit) - Models 601 - 801 Rear View - Models 601 - 801...
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Page 7: Ratings
Outdoor Knight XL Installation & Operation Manual Ratings Outdoor Knight XL Boiler Other Specifi cations AHRI Rating Input Model Number Gross AHRI Boiler Water Water Output Ratings Content Air Size Connections Connections (Note 4) Water, Gallons Note: Change “N” to “L”... -
Page 8: Determine Boiler Location
Outdoor Knight XL Installation & Operation Manual Determine boiler location Installation must comply with: Do not install outdoor models directly on CAUTION • Local, state, provincial, and national codes, laws, regulations, the ground. You must install the outdoor and ordinances. unit on a level concrete, brick, block, or pressure-treated wood platform. -
Page 9: Flooring And Foundation
Outdoor Knight XL Installation & Operation Manual Determine boiler location (continued) Flooring and foundation • This unit is not intended for installations where temperatures may reach below 32°F (0°C). Exposure to Flooring freezing temperatures will cause the system and boiler to freeze and leak. -
Page 10: Prepare Boiler
Outdoor Knight XL Installation & Operation Manual Prepare boiler Remove boiler from wood pallet Install fl ue pipe assembly Models 400 - 601 1. After removing the outer shipping carton from the boiler, remove the parts box. This unit is provided with all of the necessary venting components. - Page 11 Outdoor Knight XL Installation & Operation Manual Prepare boiler (continued) Models 701 - 801 1. Locate all venting components from the installation kit and carton. 2. Before connecting the vent pipe sections or components, verify that the gasket is seated evenly inside the groove in the female end of the elbow and fl...
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Page 12: Gas Conversions
Outdoor Knight XL Installation & Operation Manual Prepare boiler Gas conversions For a boiler already installed, you must After converting to LP, check combustion WARNING WARNING turn off gas supply, turn off power and per the Start-up procedure in Section 10 allow boiler to cool before proceeding. -
Page 13: Model 501
Outdoor Knight XL Installation & Operation Manual Prepare boiler (continued) Model 501 After converting to LP, check combustion WARNING per the Start-up procedure in Section 1. Remove the top access cover from the unit (Philips Head 10 of this manual. Failure to check and screwdriver required for removal). -
Page 14: Hydronic Piping
Outdoor Knight XL Installation & Operation Manual Hydronic piping System water piping methods General piping information Basic steps are listed below along with illustrations on the The Outdoor Knight XL is designed to function in a closed following pages (FIG.’s 3-7 through 3-11), which will guide loop pressurized system not less than 12 psi (83 kPa). -
Page 15: Flow Switch And Relief Valve Installation
Outdoor Knight XL Installation & Operation Manual Hydronic piping (continued) Flow switch, relief valve and temperature Figure 3-1 Flow Switch, Relief Valve and Temperature and and pressure gauge installation Pressure Gauge Installation_Models 400 - 501 Basic steps are listed below to guide you through the installation of the fl... -
Page 16: Flow Switch Adjustment
Outdoor Knight XL Installation & Operation Manual Hydronic piping Flow switch adjustment Near boiler piping components Refer to Table 3A for the proper setting of the sensitivity 1. Boiler system piping: screw. For reference, the position of the screw prior to setting Boiler system piping MUST be sized per the pipe should be turned clockwise with a Phillips driver until it stops requirements listed in Table 3B. -
Page 17: Circulator Sizing
(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). - Page 18 Outdoor Knight XL Installation & Operation Manual Hydronic piping Figure 3-5 Pressure Drop vs. Flow - Models 400 and 501 Pressure Drop vs Flow (Includes Boiler Secondary Piping) KBN501 KBN400 Flow Rate (GPM) Figure 3-6 Pressure Drop vs. Flow - Models 601 thru 801 Pressure Drop vs Flow (Includes Boiler Secondary Piping) KBN801...
- Page 19 Outdoor Knight XL Installation & Operation Manual Hydronic piping (continued) Figure 3-7 Single Boiler - Multiple Temperatures Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 20 Outdoor Knight XL Installation & Operation Manual Hydronic piping Figure 3-8 Single Boiler - Primary/Secondary Piping Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION output does not not exceed indirect water heater transfer capabilities. Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 21 Outdoor Knight XL Installation & Operation Manual Hydronic piping (continued) Figure 3-9 Multiple Boilers - Multiple Temperatures Number of Units 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)
- Page 22 Outdoor Knight XL Installation & Operation Manual Hydronic piping Figure 3-10 Multiple Boilers - Primary/Secondary Piping Number of Units 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)
- Page 23 Outdoor Knight XL Installation & Operation Manual Hydronic piping (continued) Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION output does not not exceed indirect water heater transfer capabilities.
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Page 24: Gas Connections
Outdoor Knight XL Installation & Operation Manual Gas connections Connecting gas supply piping Figure 4-3 Gas Supply Piping - Models 601 - 801 1. Remove the top access panel and refer to FIG.’s 4-1 thru 4-3 to pipe gas to the boiler. Install ground joint union for servicing, when required. -
Page 25: Natural Gas
Outdoor Knight XL Installation & Operation Manual Gas connections (continued) Natural gas: Failure to apply pipe sealing compound WARNING as detailed in this manual can result Pipe sizing for natural gas in severe personal injury, death, or substantial property damage. 1. -
Page 26: Check Inlet Gas Supply
Outdoor Knight XL 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 specifi c gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size... -
Page 27: Gas Pressure
Outdoor Knight XL Installation & Operation Manual Gas connections (continued) When re-tightening the set screw, be sure Figure 4-7 Inlet Gas Supply Check - Models 601 - 801 WARNING to tighten securely to prevent gas leaks. REMOVE THE 1/8” (3 MM) PIPE PLUG ON Do not check for gas leaks with an open THE INLET FLANGE TO THE VALVE AND fl... -
Page 28: Field Wiring
Outdoor Knight XL Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply before making any electrical 1. National Electrical Code and any other national, state, connections to avoid possible electric provincial, or local codes, or regulations. -
Page 29: Outdoor Temperature Sensor
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. -
Page 30: Wiring Of The Cascade
Outdoor Knight XL Installation & Operation Manual 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. - Page 31 Outdoor Knight XL Installation & Operation Manual Field wiring (continued) Figure 5-3 Low Voltage Field Wiring Connections...
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Page 32: Condensate Disposal
Outdoor Knight XL Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. This boiler is a high effi ciency appliance that produces authority, PVC and CPVC pipe must comply condensate. -
Page 33: Startup
Outdoor Knight XL Installation & Operation Manual Start-up Check/control water chemistry 3. Fill to correct system pressure. Correct pressure will vary with each application. Do not use petroleum-based cleaning or CAUTION The minimum cold water fi ll pressure for a sealing compounds in the boiler system. -
Page 34: Check For Gas Leaks
Outdoor Knight XL 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 initial operation, smell near the fl... -
Page 35: Start The Boiler
Outdoor Knight XL Installation & Operation Manual Start-up (continued) Final checks before starting the boiler Check gas piping 1. Check around the boiler for gas odor following the Read the Outdoor Knight XL Service Manual to procedure on page 46 of this manual (connecting gas familiarize yourself with SMART SYSTEM control supply piping). -
Page 36: For Your Safety Read Before Operating
Outdoor Knight XL Installation & Operation Manual 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. •... -
Page 37: Set Space Heating Operation
Outdoor Knight XL Installation & Operation Manual Start-up (continued) Check fl ame and combustion Set space heating operation (continued) 4. Place the boiler into the active position by pressing the Determine controlling sensor RIGHT SELECT [ON] key (FIG. 8-1, page 43). For space heating systems, the temperature control can be 5. - Page 38 Outdoor Knight XL Installation & Operation Manual Start-up Set domestic hot water (DHW) operation Verify DHW mode There are two (2) modes of operation for DHW. In Normal Turn the NAVIGATION dial to adjust the minutes. Press Mode, when a DHW demand begins, the control will start the NAVIGATION dial.
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Page 39: Operating Information
Freeze Protection Mode ends. of up to three (3) separate loops, based on the settings for the three (3) heat/loop demands (reference Lochinvar kit The system pump will run whenever there is a space heating call RLY30086). -
Page 40: Temperature Control
Outdoor Knight XL Installation & Operation Manual Operating information Temperature control Protection features Modulation Outlet temperature, fl ue temperature, and temperature The Outdoor Knight XL is capable of modulating its fi ring rise limiting rate from a minimum of 20% to a maximum of 100%. The fi... - Page 41 Outdoor Knight XL Installation & Operation Manual Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for The Outdoor Knight XL is equipped with adjustable automatic external limits such as fl ow switch, low water cutoff and reset and manual reset high limits.
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Page 42: Cascade
Outdoor Knight XL Installation & Operation Manual Operating information Low water cutoff protection Sequence of the cascade The SMART SYSTEM control module uses temperature To equalize the run time of all boilers on the Cascade, the fi ring sensing of both supply and return areas of the heat sequence will automatically be changed at set intervals. -
Page 43: Sequence Of Operation
Outdoor Knight XL 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 XL 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.
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Page 45: Outdoor Knight Xl Control Module
Outdoor Knight XL Installation & Operation Manual 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... -
Page 46: Status Display Screens
Outdoor Knight XL 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 XL 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 (if connected). INLET TEMP: The temperature read at the inlet to the heat exchanger.
- Page 48 Outdoor Knight XL 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. Press the LEFT SELECT key to confi...
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Page 49: Maintenance
Outdoor Knight XL Installation & Operation Manual Maintenance Maintenance and annual startup Table 9A Service and Maintenance Schedules Owner maintenance Service technician (see the Outdoor Knight XL User’s Information (see the following pages for instructions) Manual for instructions) General: • Address reported problems •... -
Page 50: Address Reported Problems
Outdoor Knight XL 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 XL 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 fl ue gas venting system for by a licensed plumbing contractor or blockage, deterioration or leakage. -
Page 52: Check Control Settings
Outdoor Knight XL Installation & Operation Manual Maintenance Inspect ignition and fl ame sense Figure 9-2 Burner Assembly - Model 400 electrodes 1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/fl ame sense electrode using sandpaper. -
Page 53: Review With Owner
Outdoor Knight XL Installation & Operation Manual Maintenance (continued) Check fl ame signal 6. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent. 1. At high fi re the fl ame signal shown on the display should 7. -
Page 54: Diagrams
Outdoor Knight XL Installation & Operation Manual Diagrams Figure 10-1 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONNECTION BOARD CONTROL ALARM JUNCTION RELAY CONTACTS BOARD PUMP RUN-TIME CONTACTS X1-3 CN2-4 CN1-5... -
Page 55: Ladder Diagram
Outdoor Knight XL Installation & Operation Manual Diagrams (continued) Figure 10-2 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" GROUND SYSTEM INTEGRATED CONTROL PUMP ON / OFF CONTACTS SWITCH BLOWER X1-6 X1-1 3.15A SYSTEM PUMP... -
Page 56: Revision Notes
Revision Notes: Revision A (ECO #C11234) initial release. Revision B (ECO #C11235) refl ects updates made to the freezing conditions warnings. Revision C (ECO #C12102) refl ects the addition of condensate kit option information for areas that may reach below 32°F as well as a warning not to install OK 400 in these areas and Table 1A on page 8.
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