Lochinvar 400-801 manual

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. Perform steps in the order given. Failure to c[...]

2 Contents Hazard de fi 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 hazardous situation which, if not avoided[...]

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 installer/service technician. Refer to the User’[...]

4 The Outdoor Knight XL - How it works... 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 access to the[...]

Front View - Model 400 30 26 20 36 8 7 21 24 4 4 39 13 IMG00406 39 33 Left Side (inside unit) - Model 400 20 22 37 16 34 17 27 2 1 3 IMG00 407 Right Side (inside unit) - Model 400 Rear View - Model 400 5 Model 400 25 32 10 IMG00405 19 31 11 IMG00404 The Outdoor Knight XL - How it works... (continued) Outdoor Knight XL Installation & Operation M[...]

6 19 28 15 IMG00408 32 41 Rear View - Model 501 18 29 14 15 23 31 IMG00323 41 11 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801 Left Side (inside unit) - Model 501 Model 501 Models 601 - 801 35 4 IMG00409 33 15 29 17 7 39 IMG0 0324 4 8 1 34 21 24 30 2 10 5 3 22 16 20 IMG00324 18 The Outdoor Knight XL - How it works... Outdo[...]

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. Ratings are based on a piping and pickup allowance [...]

8 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. Do not install outdoor units on stack frames. [...]

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 varnish removers Hydrochloric acid/muriatic acid Ceme[...]

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, verify that the gasket is seated evenly inside the[...]

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 leakage.  CAUTION 11 Models 701 - 801 Figure 2-[...]

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 this manual. Failure to comply could result in se[...]

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 top access cover from the unit (Philips Head screwdr[...]

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 temperature and should be located on the boiler out[...]

15 RELIEF VALVE FLOW SW ITCH PADDLE TEMPERATURE & PRESSURE GAUGE TEE WITH FITTIN G (FIELD PROVIDED) CLOSE NIPPLE (FIELD PROVIDED) TEE W ITH 1" FIT TING ON TOP CLOSE NIPPLE TEE W ITH 3/4" FITTING ON T OP IMG0 038 9 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[...]

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 driver until it stops (FIG. 3-3). Proceed to turn [...]

17 3 Hydronic piping (continued) Near boiler piping connections Y-STRAINER (RECOMMENDED) BOILER PUMP INDIRECT DOMESTIC HOT W A TER TANK TO FLOOR DRAIN T O F R O M F R O M S Y S T E M T O S Y S T E M DOMESTIC HOT WAT ER P U M P AIR SEPARATOR SYSTEM SENSOR IMG00413 SYSTEM PUMP Figure 3-4A Near Boiler Piping w/Y-Strainer Circulator sizing The Outdoor [...]

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 35 40 45 KBN501 KBN400 Pressure Drop vs Flo[...]

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 protection of low temperature loops. EXPANSION TA[...]

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. Please note that these illustrations are meant t[...]

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 the protection of low temperature loops. CAUTION M[...]

22 Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping Figure 3-10 Multiple Boilers - Primary/Secondary Piping Model Number of Units 23 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) 5 (127) 6 (152) 6 (152) 601 3 1/2 (89) 4 (102)[...]

23 3 Hydronic piping (continued) Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone EXPANSION TANK AIR SEPARATOR BALL VALVE (TYPICAL) UNION (TYPICAL) FLOW CHECK VALVE (TYPICAL) INDIRE CT DHW TANK TEMPERATURE / PRESSURE GAUGE PRESSURE GAUGE DRAIN DRAIN POINT (TYPICAL) BOILER CIRCULAT OR COLD WATER IN ANTI-SCALD MIX ING VALVE [...]

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 boiler jacket when required by local codes o[...]

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 from turning. Failure to support the boiler gas c[...]

26 Outdoor Knight XL Installation & Operation Manual Nominal Iron Pipe Size (inches) Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet Maximum 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 [...]

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. Turn on the gas supply at the manual gas valve. [...]

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 N.E.C. Class 1. If original wiring as suppl[...]

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, sunlight, or fi replaces. 3. Thermostat antic[...]

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 jumper wire between terminals 1 and 3 on connector [...]

5 Field wiring (continued) Figure 5-3 Low Voltage Field Wiring Connections FLOW SW ITCH TANK THERMOSTAT ROOM THERM OSTAT 3 SYSTEM SUPPLY SENSOR BUILDING MANAGEM ENT SYSTEM COM NO LOW W A TER 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 S[...]

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 condensate tubing down and away from the boiler in[...]

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 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. Do not proceed with startup if there is any in[...]

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 components are correctly set for operation. [...]

36 7 Start-up Outdoor Knight XL Installation & Operation Manual FOR YOUR SAFETY READ BEFORE OPERA TING W ARNING: 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 equipped with an ignition device which automa[...]

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) into the hole and press the button once and hold for[...]

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 bring the outlet temperature to the DHW boiler [...]

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 ue piping. The control module regulates blower [...]

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 hot water), the heating load, ramp delay (if [...]

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 open. Run-time and alarm outputs The boiler prov[...]

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. Reset curve The reset curves look at outdoor a[...]

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). The fl ow switch and/or LWCO must close. 3. The[...]

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), the DHW pump will turn on fi rst, then the [...]

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 only to the installer, accessible by enterin[...]

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 (if connected). INLET TEMP: The te[...]

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 confi rm that the boiler needs to shutdown. LIMI[...]

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 • Check condensate drain system Periodica[...]

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 component literature could result in severe personal injur[...]

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 and have them repaired can result in severe persona[...]

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 ignition/fl ame sense electrode using sandpaper. If t[...]

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 good condition, and ground continuity is satisf[...]

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 BLO WE R -T HIGH LIMIT SENSOR S1b OPERATING SENSOR S1a INLET SENSOR S2 FLUE SENSOR S3a FLUE SENSOR S3b INTEG RA TED CONTROL B[...]

55 Figure 10-2 Ladder Diagram BOX DEPI CTS OPTIONAL ITEMS LADDER DIAG RAM LBL201 41 REV D 24 VAC 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 TR2 X1-7 FLAME ROD SPARK ROD CAUT ION HIGH VOLTAGE SPARK LE AD BLOWER CONNE[...]

Revision Notes: Revision A (ECO #C11234) initial release. Revision B (ECO #C11235) re fl ects updates made to the freezing conditions warnings. OKBX-I-O Rev B 10/12[...]