Lochinvar 151-286 manual

OKB-I-O Rev C Outdoor Knight Boiler Installation & Operation Manual Models: 151 - 286 This manual must only be used by 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 [...]

2 Hazard definitions The following defined 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 hazardous situation which, if not avoided, will result [...]

3 Outdoor Knight Boiler Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including this manual and the Outdoor Knight Boiler Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/ service technician. Refer to th[...]

The Outdoor Knight Boiler - How it works... 1. Stainless steel heat exchanger 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. 2. Combustion chamber access cover Allows access to the c[...]

5 IMG00365 30 10 24 23 31 IMG00365 Front View - Models 151 - 211 10 25 28 33 15 8 14 27 13 32 22 39 1 IM G003 67 19 Left Side (inside unit) - Models 151 - 211 Right Side (inside unit) - Models 151 - 211 The Outdoor Knight Boiler - How it works... (continued) 21 29 11 6 IM G003 66 38 Rear View - Models 151 - 211 Models 151 - 211 4 5 36 7 35 2 26 18 [...]

6 The Outdoor Knight Boiler - How it works... IMG00380 15 37 21 29 38 6 11 39 Model 286 Left Side (inside unit) - Model 286 Right Side (inside unit) - Model 286 Front View - Model 286 Rear View - Model 286 IMG003 79 24 23 10 31 30 IM G003 81 4 33 25 28 5 36 2 22 32 19 13 27 14 8 15 18 20 10 IM G00382 34 16 17 3 1 Outdoor Knight Boiler Installation [...]

7 Ratings A S M E H Notes: 1. As an Energy Star Partner, Lochinvar has determined that outdoor boilers meet the Energy Star guidelines for energy efficiency. 2. The ratings are based on standard test procedures prescribed by the United States Department of Energy. 3. Net AHRI ratings are based on net installed radiation of sufficient quantity for t[...]

8 1 Determine boiler location The Outdoor Knight gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition. Installation must comply with: • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, ANSI [...]

9 1 Determine boiler location (continued) Table 1A Corrosive Contaminants and Sources Provide clearances: Clearances from combustible materials 1. Hot water pipes—at least 1/4" (6 mm) from combustible materials. 2. Vent pipes—minimum of 14" (356mm) from the rear and 0" on the right side from combustible materials. Clearances for [...]

10 Remove boiler from wood pallet 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. 2-1). 3. To remove the boiler from the pallet (after removing the front access covers): a. Remove the two lag bolts from the wood pallet insi[...]

5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner. 6. Replace the top and front access covers. 11 2 Prepare boiler (continued) Figure 2-3 Installing Propane O[...]

12 3 Hydronic piping System water piping methods The outdoor boiler is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet. It is important to note that the boiler has a minimal amount [...]

13 *See the piping illustrations included in this section, FIG.’s 3-4 thru 3-10 for suggested guidelines in piping the outdoor boiler with either zone valves or circulator pumps. *Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.[...]

14 3 Hydronic piping 12. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature. 13. Indirect water heaters:[...]

15 0 5 10 15 20 25 3 4 5 6 7 8 9 1 01 11 21 31 41 51 61 71 81 92 02 12 22 32 42 5 151 211 286 Flow Rate (GPM) Pressure Drop vs. Flow (Includes Secondary Piping) Pressure Drop (Feet of Head) Figure 3-3 Pressure Drop vs. Flow 20°F Temperature Rise Applications Model GPM FT/HD Minimum Pipe Size Pump Grundfos TACO B & G Armstrong 151 14 20 1"[...]

16 It is required that near boiler piping systems utilize the Primary/Secondary configuration shown in FIG. 3-10 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance. NOTICE Pump sizing and flow requirements are[...]

17 3 Hydronic piping (continued) BOILER INDIRE CT DHW TAN K DOMESTIC HOT WATER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VAL VE PRESSURE GAUGE ANTI-SCALD MIXING VAL VE COLD WATE R IN TEMPERATUR E / PRESSURE GAUGE AIR SEPARATO R EXPAN SION TANK ZONE #1 ZONE #2 ZONE #3 ZONE #4 BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN DRAIN POIN T (TYPICAL) MA[...]

18 3 Hydronic piping INDIRE CT DHW TAN K BACKFLOW PREVENTER PRESSURE REDUCING VA LVE PRESSURE GAUGE ANTI-SCALD MIX ING VALVE AIR SEPARATO R EXPAN SION TANK ZONE #1 ZONE #2 ZONE #3 ZONE #4 BALL VALVE (TYPICAL) DRAIN POI NT (TYPICAL) MAKE UP W A TER ZONE CIRCULA TORS (TYPICAL) FLOW CHECK VALVE (TYPICAL) NOT TO EXCEED 4 PIPE DIA OR MA X. OF 12" A[...]

19 3 Hydronic piping (continued) Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Indoor tank shown for illustration purposes. NOTICE BOILER INDIRE CT DHW TAN K DOMESTIC HOT W A TER CIRCULAT OR ANTI-SCALD MIX ING VALVE COLD WATE R[...]

20 DOMESTIC HOT WATER CIRCULATOR ANTI-SCALD MIXING VALVE COLD WATE R IN AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POI NT (TYPICAL) MAK E UP WAT E R HOT WATE R OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALV E PRESSURE GAUGE EXPANSIO N TANK MIX ING VALVES (TYPICAL) FLOW CHECK VALVE SYSTEM SUPPLY SENSOR MAY SUBSTITUT E LOW LOSS HEADE R[...]

21 3 Hydronic piping (continued) DOMESTIC HOT WA TER CIRCULATOR ANTI-SCALD MIXING VAL VE COLD WATE R IN AIR SEPARATOR BALL VALVE (TYPICAL) DRAIN POI NT (TYPICAL) MA KE UP WATE R HOT WA TER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALV E PRESSURE GAUGE EXPAN SION TANK MIX ING VALVES (TYPICAL) FLOW CHECK VALVE SYSTEM SUPPLY SENSOR M[...]

22 3 Hydronic piping INDIRE CT DHW TAN K BACKFLOW PREVENTER PRESSURE REDUCING VA LVE PRESSURE GAUGE ANTI-SCALD MIX ING VALVE TEMPERAT URE / PRESSURE GAUGE AIR SEPARATO R EXPAN SION TANK ZONE #1 ZONE #2 BALL VALVE (TYPICAL) DRAIN POI NT (TYPICAL) MAKE UP W A TER ZONE VALVES (TYPICAL) BOILER CIRCULAT OR BOILER 2 (MEMBE R 1) DOMESTIC HOT WA TER CIRCUL[...]

23 3 Hydronic piping (continued) BOILER 1 (LEADER) INDI RECT DHW T ANK DOMESTIC HOT WATER CIRCULAT OR BACKFLOW PREVENTER PRESSURE REDUCING VAL VE PRESSURE GAUGE ANTI-SCALD MIXING VAL VE COLD WATER IN TEMPERATURE / PRESSURE GAUGE AIR SE PARATO R EXPANSION TANK BALL VALVE (TYPICAL) UNION (TYPICAL) DRAIN POI NT (TYPICAL) MAKE UP WATER FROM SYSTEM TO S[...]

24 4 Gas connections Connecting gas supply piping 1. Remove the top access cover and refer to FIG. 4-1 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 [...]

25 4 Gas connections (continued) Use two wrenches when tightening gas piping at boiler (FIG. 4-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components. IMG00 38 4 USE BACKUP W RENCH TO PREVENT PIP E FROM ROTATI NG Figur[...]

26 4 Gas connections Nominal Iron Pipe Size (Inches) Single Unit Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 267 246 236 210 200 179 16[...]

27 4 Gas connections (continued)  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 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 supp[...]

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 N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 105°C wi[...]

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 influences of drafts, hot or cold water pipes, lighting fixtures, television, sunlight, or fireplaces. 3. Thermostat anticipator[...]

30 5 Field wiring System supply sensor 1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if [...]

31 5 Field wiring (continued) FLOW SW ITCH TANK THERMOSTAT ROOM THERM OSTAT 3 SYSTEM SUPPLY SENSOR BUILDING MANAGEME NT SYSTEM COM NO LOW W ATER CUTOFF OUTDOOR SENSOR TANK SENSOR SHIELD SHIELD TO NEX T BOILER A B A B FROM PREVIOUS BOILER ROOM THERM OSTAT 1 ROOM THERM OSTAT 2 A B NOTE: CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES WI R E AS NEEDE[...]

6 Condensate disposal Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The side of the boiler has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 6-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the outdoor boile[...]

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 for hard water areas (above 7 grains hardness). C[...]

34 7 Start-up Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access cover and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection s[...]

35 7 Start-up (continued) Final checks before starting the boiler  Read the Outdoor Knight Boiler Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, page 36 for proper steps to start boiler.  Verify the boiler and system are full of water and all system components are correctly set for operati[...]

36 7 Start-up Figure 7-2 Operating Instructions Outdoor Knight Boiler Installation & Operation Manual[...]

37 Check flame and combustion (continued) Set space heating operation 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 wil[...]

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[...]

39 8 Operating information General How the boiler operates The outdoor boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed t[...]

40 8 Operating information Temperature control Modulation The outdoor boiler is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations. Ramp del[...]

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. High limit test procedure Monitor external limit[...]

42 8 Operating information 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 progra[...]

43 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.[...]

44 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 [...]

45 Outdoor Knight boiler control module Figure 8-1 Control Panel Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor boiler operation. 8 Operating information (continued) 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 cen[...]

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 circuits. PREPURGE The unit has initiated a prepurg[...]

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 outdoor sensor. INLET TEMP: The temperature read [...]

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 confirm that the boiler needs to shutdown. LIMITS[...]

9 Maintenance Maintenance and annual startup Table 9A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (water, gas, flue, condensate) • V[...]

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, [...]

9 Maintenance (continued) Flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. 2. Verify that boiler vent discharge and air intake are clean and free of obstructions. Failure to inspect for the above conditions and [...]

9 Maintenance Inspect ignition and flame sense 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. 3. Replace ignition/flame sense [...]

Review with owner 1. Review the Outdoor Knight Boiler User’s Information Manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the Outdoor Knight Boiler User’s Information Manual (and in this manual as well). 3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit[...]

10 Diagrams BOX DEPI CTS OPTIONAL ITEMS LADDER DIAG RAM LBL201 48 REV D 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPLY "L" ON / OFF SW ITC H X1- 6 F2 NEUTRAL CN5-6 CN5-12 CN5-11 X4- 2 X4-1 0 X4- 1 1 INTEGRATED CONTROL LOUVER RELAY COIL 24VAC LOUVER PROVING SWITCH CN5-4 X4-4 X2-1 GAS VALVE GAS VALVE RELAY X5-7 X5-1 6 X5-8 X5-1 5 1 2 4 5 [...]

55 X1- 7 ON/OFF SWITCH 1 2 3 4 5 G R R W R T W BK Y BL BLO WE R -T HIGH LIMIT SENSOR S1b OPERATING SENSOR S1a INLET SENSOR S2 FLUE SENSO R S3a FLUE SENSOR S3b INTEG RATE D CONTROL BK Y GAS VALVE @24VAC SPARK ROD TRANSFORMER TR 2 G HIGH VOLTAGE SPARK LEAD CAUTI ON FLAME SENSOR ALARM CONTACTS RUN-TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING [...]

Revision Notes: Revision A (ECO C11234) initial release. Revision B (ECO #C11235) reflects updates made to the freezing conditions warnings. Revision C (ECO #C11736) reflects changes made to the ratings page (page 7). OKB-I-O Rev C 11/12[...]