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  5. Installation & Operation Manual

Lochinvar Knight XL 400 Installation & Operation Manual

Manual is about: Lochinvar Boiler User Manual

Summary of Knight XL 400

  • Page 1

    Outdoor knight xl installation & operation manual models: 400 - 801 save this manual for future reference. This manual must only be used by a qualifi ed heating installer / service technician. Read all instructions, including this manual and the outdoor knight xl service manual, before installing. P...

  • Page 2: Contents

    2 contents hazard defi nitions the following defi ned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Danger warning caution caution notice danger indicates an imminently hazard...

  • Page 3

    Outdoor knight xl installation & operation manual 3 please read before proceeding installer – read all instructions, including this manual and the outdoor knight xl service manual, before installing. Perform steps in the order given. User – this manual is for use only by a qualified heating installe...

  • Page 4

    4 1. Stainless steel heat exchanger allows system water to fl ow through specially designed coils for maximum heat transfer, while providing protection against fl ue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Combustion chamber access cover allows acces...

  • Page 5

    Front view - model 400 img00406 30 26 20 36 8 7 21 24 4 4 29 13 43 39 33 left side (inside unit) - model 400 20 22 37 16 34 17 27 2 1 3 img00407 right side (inside unit) - model 400 rear view - model 400 5 model 400 25 32 10 img00405 the outdoor knight xl - how it works... (continued) outdoor knight...

  • Page 6

    6 img00408 19 15 41 32 28 rear view - model 501 rear view - models 601 - 801 left side (inside unit) - models 601 - 801 left side (inside unit) - model 501 model 501 models 601 - 801 img00409 35 4 33 17 43 7 39 29 15 img00324 img00324 20 16 22 3 5 10 30 43 2 24 21 34 8 1 4 18 the outdoor knight xl -...

  • Page 7: Ratings

    7 ratings notes: 1. The ratings are based on standard test procedures prescribed by the united states department of energy. 2. Net ahri ratings are based on net installed radiation of suffi cient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ra...

  • Page 8: Determine Boiler Location

    The outdoor knight xl gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specifi ed in ansi z21.13 – latest edition. Do not install the unit under a deck. Do not install the unit in a well, stairwell, alcove, courtyard or other recessed area. D...

  • Page 9: Determine Boiler Location

    1 determine boiler location (continued) products to avoid: spray cans containing chloro/fl uorocarbons permanent wave solutions chlorinated waxes/cleaners chlorine-based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varn...

  • Page 10: Prepare Boiler

    10 2 prepare boiler install fl ue pipe assembly this unit is provided with all of the necessary venting components. All components must be installed prior to operation. 1. Locate all venting components from the installation kit and carton. 2. Before connecting the vent pipe sections or components, v...

  • Page 11: Prepare Boiler

    2 prepare boiler (continued) outdoor knight xl installation & operation manual do not use grease or other lubricant on the vent seals. Only water may be used for this purpose. Grease or other lubricant can make the seal brittle or cause tearing of the seal surface which can result in fl ue gas leaka...

  • Page 12: Prepare Boiler

    12 outdoor knight xl installation & operation manual for a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under start-up, section 10 of thi...

  • Page 13: Prepare Boiler

    13 screwdriver slot lower raise figure 2-7 leveling legs on the boiler leveling the boiler 1. Set the boiler in place and check level. A) adjust legs if necessary to level boiler, see fig. 2-7 below. Allen wrench adjustment screw figure 2-5 gas valve adjustment - model 501 model 501 1. Remove the to...

  • Page 14: Hydronic Piping

    14 outdoor knight xl installation & operation manual 3 hydronic piping system water piping methods 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 tempe...

  • Page 15: Hydronic Piping

    15 notice be sure to install the fl ow switch so that the arrow on the fl ow switch is pointing in the direction of the fl ow (see fig. 3-3). Figure 3-2 flow switch, relief valve and temperature and pressure gauge installation_models 601 - 801 flow switch, relief valve and temperature and pressure g...

  • Page 16: Hydronic Piping

    16 outdoor knight xl installation & operation manual 3 hydronic piping figure 3-3 flow switch adjustment flow switch adjustment refer to table 3a for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a phillips driv...

  • Page 17: Hydronic Piping

    17 3 hydronic piping (continued) near boiler piping connections figure 3-4a near boiler piping w/y-strainer 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 thr...

  • Page 18: Hydronic Piping

    18 outdoor knight xl installation & operation manual figure 3-5 pressure drop vs. Flow - models 400 and 501 table 3b sizing information for temperature rise applications_20°f, 25°f, 30°f and 35°f figure 3-6 pressure drop vs. Flow - models 601 thru 801 0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 20 25 30 3...

  • Page 19: Hydronic Piping

    19 3 hydronic piping (continued) figure 3-7 single boiler - multiple temperatures please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Notice caution mixing valves are required for the...

  • Page 20: Hydronic Piping

    20 outdoor knight xl installation & operation manual 3 hydronic piping figure 3-8 single boiler - primary/secondary piping notice system fl ow should always remain higher than the required fl ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues. Plea...

  • Page 21: Hydronic Piping

    21 3 hydronic piping (continued) figure 3-9 multiple boilers - multiple temperatures please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Notice caution mixing valves are required for ...

  • Page 22: Hydronic Piping

    22 outdoor knight xl installation & operation manual 3 hydronic piping figure 3-10 multiple boilers - primary/secondary piping model number of units 2 3 4 5 6 7 8 manifold pipe sizes in inches (mm) 400 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152) 501 3 (76) 3 1/2 (89) 4 (102) 5 (127)...

  • Page 23: Hydronic Piping

    23 3 hydronic piping (continued) figure 3-11 single boiler - multiple temperatures with dhw piped as a zone please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Notice please note that...

  • Page 24: Gas Connections

    24 outdoor knight xl installation & operation manual connecting gas supply piping 1. Remove the top access panel and refer to fig.’s 4-1 thru 4-3 to pipe gas to the boiler. A. Install ground joint union for servicing, when required. B. Install a manual shutoff valve in the gas supply piping outside ...

  • Page 25: Gas Connections

    25 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. Use two wrenches when tightening gas piping at boiler (fig. 4-4), using one wrench to prevent the boiler gas line connection...

  • Page 26: Gas Connections

    26 outdoor knight xl installation & operation manual 4 gas connections table 4a natural gas pipe size chart the gas piping must be sized for the proper fl ow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. ...

  • Page 27: Gas Connections

    27 warning when re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open fl ame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 14. Tur...

  • Page 28: Field Wiring

    28 outdoor knight xl installation & operation manual 5 field wiring electrical shock hazard – for your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be...

  • Page 29: Field Wiring

    29 5 field wiring (continued) thermostat 1. Connect the room thermostats or end switches (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in fig. 5-3. 2. Install the thermostat on the inside wall away from infl uences of drafts, hot or cold water pipes, lighting fi xtures, television...

  • Page 30: Field Wiring

    30 outdoor knight xl installation & operation manual 5 field wiring modbus when the optional modbus interface module is installed, the rs-485 modbus cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumpe...

  • Page 31: Field Wiring

    5 field wiring (continued) figure 5-3 low voltage field wiring connections flow sw itch t a nk ther m o st at r oom therm o stat 3 sy stem suppl y sensor bu ildin g m a na gem e nt sy st em com no low w a t e r cu t o ff outd oor sensor tank sens o r shield sh ield to ne x t boiler a b a b fr om pre...

  • Page 32: Condensate Disposal

    32 outdoor knight xl installation & operation manual 6 condensate disposal condensate drain 1. This boiler is a high effi ciency 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). 3. Slope conde...

  • Page 33: Start-Up

    33 7 start-up check/control water chemistry do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies...

  • Page 34: Start-Up

    34 7 start-up outdoor knight xl installation & operation manual check for gas leaks before starting the boiler, and during initial operation, smell near the fl oor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. D...

  • Page 35: Start-Up

    35 7 start-up (continued) final checks before starting the boiler read the outdoor knight xl service manual to familiarize yourself with smart system control module operation. Read this manual, page 33 for proper steps to start boiler. Verify the boiler and system are full of water and all system co...

  • Page 36: Start-Up

    36 7 start-up outdoor knight xl installation & operation manual for your safety read before operating warning: if you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is equ...

  • Page 37: Start-Up

    37 7 start-up (continued) check fl ame and combustion (continued) 4. Place the boiler into the active position by pressing the right select [on] key (fig. 8-1, page 43). 5. Locate the pinhole button below the reset button on the display board (fig. 8-1). Insert a thin wire (such as a paper clip) int...

  • Page 38: Start-Up

    38 7 start-up outdoor knight xl installation & operation manual 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 b...

  • Page 39: Operating Information

    39 8 operating information general how the boiler operates the outdoor knight xl uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes fl ue products out of the boiler through the heat exchanger and fl...

  • Page 40: Operating Information

    40 8 operating information outdoor knight xl installation & operation manual temperature control modulation the outdoor knight xl is capable of modulating its fi ring rate from a minimum of 20% to a maximum of 100%. The fi ring rate is dictated by the call for heat (i.E., space heating or domestic h...

  • Page 41: Operating Information

    41 8 operating information (continued) monitor external limits connections are provided on the connection board for external limits such as fl ow switch, low water cutoff and gas pressure switches. The smart system will shut off the burner and inhibit relighting whenever any of these external limits...

  • Page 42: Operating Information

    42 8 operating information outdoor knight xl installation & operation manual outdoor reset operation, if used target temperature with outdoor reset this feature improves the system’s effi ciency as the outdoor temperature warms up. See the outdoor knight xl service manual to change the settings. Res...

  • Page 43: Operating Information

    43 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)...

  • Page 44: Operating Information

    44 8 operating information outdoor knight xl installation & operation manual 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)...

  • Page 45: Operating Information

    45 access modes user the user can adjust space heating and tank target temperatures by pressing the navigation dial when “ setpoints” is fl ashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 36). Installer most parameters are available onl...

  • Page 46: Operating Information

    46 8 operating information status display screens section display description a (boiler status bar) standby the unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a dhw thermostat. Start the unit has begun a burn cycle and is checking all safety c...

  • Page 47: Operating Information

    47 8 operating information (continued) status display screens (cont’d) section display description c (operational information) 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 o...

  • Page 48: Operating Information

    48 8 operating information status display screens (cont’d) section display description d (left select key function) menu press and hold the left select key for 5 seconds to enter the menu screen. Exit press the left select key to exit the current screen or setting. Yes press the left select key to c...

  • Page 49: Owner Maintenance

    49 maintenance and annual startup table 9a service and maintenance schedules owner maintenance (see the outdoor knight xl user’s information manual for instructions) daily • check boiler area • check pressure/temperature gauge monthly • check air and vent termination screens • check relief valve • c...

  • Page 50: Maintenance

    50 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 componen...

  • Page 51: Maintenance

    51 9 maintenance (continued) flue vent system and air piping 1. Visually inspect the entire fl ue gas venting system for blockage, deterioration or leakage. 2. Verify that boiler vent discharge and air intake openings are clean and free of obstructions. Failure to inspect for the above conditions an...

  • Page 52: Maintenance

    52 img00439 screws (5) air / gas arm burner gasket figure 9-4 burner assembly - models 601 - 801 9 maintenance inspect ignition and fl ame sense electrodes 1. Remove the ignition and fl ame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the igniti...

  • Page 53: Maintenance

    53 9 maintenance (continued) check fl ame signal 1. At high fi re the fl ame signal shown on the display should be at least 10 microamps. 2. A lower fl ame signal may indicate a fouled or damaged fl ame sense electrode. If cleaning the fl ame sense electrode does not improve, ground wiring is in goo...

  • Page 54: Diagrams

    54 figure 10-1 wiring diagram 10 diagrams x1-7 or or br pr or br br pr pr cn2-4 cn2-1 cn1-5 cn1-6 cn1-3 cn1-4 cn1-1 cn1-2 k1 k2 k3 relay board on/off switch junction box bk w 1 2 3 4 5 g r r w 3.5a r t w bk y bl kb 801 only blower -t high limit sensor s1b operating sensor s1a inlet sensor s2 flue se...

  • Page 55: Diagrams

    55 figure 10-2 ladder diagram box depicts optional items ladder diagram lbl20400 rev a 24 vac cn5-6 cn5-12 cn5-11 x4-2 x4-10 x4-11 integrated control louver relay coil 24vac louver proving switch cn5-4 x4-4 x2-1 gas valve gas valve relay x5-7 x5-16 x5-8 x5-15 1 2 4 5 tr2 x1-7 flame rod spark rod cau...

  • Page 56

    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 ...