Lochinvar Kight XL 400-801 User Manual Page 1

Outdoor Knight XL Installation & Operation ManualModels: 400 - 801Save this manual for future reference.This manual must only be used by a quali

102 Prepare boilerInstall fl ue pipe assembly This unit is provided with all of the necessary venting components. All components must be installed pri

2 Prepare boiler (continued) Outdoor Knight XL Installation & Operation ManualDo NOT use grease or other lubricant on the vent seals. Only wa

12 Outdoor Knight XL Installation & Operation ManualFor a boiler already installed, you must turn off gas supply, turn off power and allow boi

13SCREWDRIVERSLOTLOWERRAISEFigure 2-7 Leveling Legs on the BoilerLeveling the boiler1. Set the boiler in place and check level. a) Adjust legs if n

14 Outdoor Knight XL Installation & Operation Manual3 Hydronic pipingSystem water piping methodsThe Outdoor Knight XL is designed to function

15RELIEF VALVEFLOW SWITCHPADDLETEMPERATURE &PRESSURE GAUGETEE WITH FITTING(FIELD PROVIDED)CLOSE NIPPLE(FIELD PROVIDED)TEE WITH 1" FITTINGON T

16 Outdoor Knight XL Installation & Operation Manual3 Hydronic piping Figure 3-3 Flow Switch AdjustmentFlow switch adjustmentRefer to Tabl

173 Hydronic piping (continued)Near boiler piping connectionsY-STRAINER(RECOMMENDED)BOILER PUMP INDIRECT DOMESTICHOT WATER TANKTO FLOOR DRAINT

18 Outdoor Knight XL Installation & Operation ManualFigure 3-5 Pressure Drop vs. Flow - Models 400 and 501Table 3B Sizing Information for Tem

193 Hydronic piping (continued)Figure 3-7 Single Boiler - Multiple TemperaturesPlease note that these illustrations are meant to show system piping c

2ContentsHazard defi nitionsThe following defi ned terms are used throughout this manual to bring attention to the presence of hazards of various risk l

20 Outdoor Knight XL Installation & Operation Manual3 Hydronic piping Figure 3-8 Single Boiler - Primary/Secondary Piping NOTICESystem fl ow

213 Hydronic piping (continued)Figure 3-9 Multiple Boilers - Multiple Temperatures Please note that these illustrations are meant to show system pip

22 Outdoor Knight XL Installation & Operation Manual3 Hydronic piping Figure 3-10 Multiple Boilers - Primary/Secondary Piping ModelNumber o

233 Hydronic piping (continued)Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a ZoneEXPANSIONTANKAIR SEPARATORBALL VALVE(TYPICAL

24 Outdoor Knight XL Installation & Operation ManualConnecting gas supply piping1. Remove the top access panel and refer to FIG.’s 4-1 thru 4

254 Gas connections (continued)Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or subs

26 Outdoor Knight XL Installation & Operation ManualNominalIron PipeSize (inches)Natural Gas Pipe Capacity ChartLength of Pipe in Straight Fee

27 WARNINGWhen 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

28 Outdoor Knight XL Installation & Operation Manual5 Field wiringELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply

295 Field wiring (continued)Thermostat1. Connect the room thermostats or end switches (isolated contact only) to heat/loop demand 1, 2, or 3, as sho

Outdoor Knight XL Installation & Operation Manual3Please read before proceedingInstaller – Read all instructions, including this manual and t

30 Outdoor Knight XL Installation & Operation Manual5 Field wiring ModBusWhen the optional ModBus interface module is installed, the RS-485

5 Field wiring (continued)Figure 5-3 Low Voltage Field Wiring ConnectionsFLOW SWITCHTANK THERMOSTATROOM THERMOSTAT 3SYSTEM SUPPLY SENSORBUILDINGMANAG

32 Outdoor Knight XL Installation & Operation Manual6 Condensate disposalCondensate drain1. This boiler is a high effi ciency appliance that

337 Start-up Check/control water chemistryDo not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals a

347 Start-up Outdoor Knight XL Installation & Operation ManualCheck for gas leaksBefore starting the boiler, and during initial operation, sm

357 Start-up (continued)Final checks before starting the boiler Read the Outdoor Knight XL Service Manual to familiarize yourself with SMART SYSTEM

367 Start-up Outdoor Knight XL Installation & Operation ManualFOR YOUR SAFETY READ BEFORE OPERATINGWARNING: If you do not follow these ins

377 Start-up (continued)Check fl ame and combustion (continued)4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FI

387 Start-up Outdoor Knight XL Installation & Operation ManualSet domestic hot water (DHW) operationVerify DHW modeThere are two (2) modes o

398 Operating information GeneralHow the boiler operatesThe Outdoor Knight XL uses an advanced stainless steel heat exchanger and electronic control

4The Outdoor Knight XL - How it works...1. Stainless steel heat exchanger Allows system water to fl ow through specially designed coils for maximu

408 Operating information Outdoor Knight XL Installation & Operation ManualTemperature controlModulationThe Outdoor Knight XL is capable o

418 Operating information (continued)Monitor external limitsConnections are provided on the connection board for external limits such as fl ow switch,

428 Operating information Outdoor Knight XL Installation & Operation ManualOutdoor reset operation, if usedTarget temperature with outdoor

438 Operating information (continued)Sequence of operationOPERATION DISPLAY1. Upon a call for heat, the gas pressure switch(es) must be closed. 2.

448 Operating information Outdoor Knight XL Installation & Operation ManualOPERATION DISPLAY8. If the space heating call for heat is active

45Access modesUserThe user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is fl ashing at the

468 Operating information Status Display ScreensSection Display DescriptionA(Boiler Status Bar)STANDBYThe unit has not received a call for heat from

478 Operating information (continued)Status Display Screens (cont’d)Section Display DescriptionC(Operational Information)SYSTEM: The temperature read

488 Operating information Status Display Screens (cont’d)Section Display DescriptionD(LEFT SELECT key function)MENUPress and hold the LEFT SELECT key

49Maintenance and annual startupTable 9A Service and Maintenance SchedulesOwner maintenance(see the Outdoor Knight XL User’s Information Manual for in

Front View - Model 40030262036872124443913IMG004063933Left Side (inside unit) - Model 40020223716341727213IMG00407Right Side (inside unit) - Model 400

509 MaintenanceFollow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failu

519 Maintenance (continued)Flue vent system and air piping1. Visually inspect the entire fl ue gas venting system for blockage, deterioration or leak

52IMG00439SCREWS(5)AIR / GASARMBURNERGASKETFigure 9-4 Burner Assembly - Models 601 - 8019 MaintenanceInspect ignition and fl ame sense electrodes1.

539 Maintenance (continued)Check fl ame signal1. At high fi re the fl ame signal shown on the display should be at least 10 microamps.2. A lower fl ame

54Figure 10-1 Wiring Diagram10 Diagrams X1-7ORORBRPRORBRBRPRPRCN2-4CN2-1CN1-5CN1-6CN1-3CN1-4CN1-1CN1-2K1K2K3RELAYBOARDON/OFFSWITCHJUNCTIONBOXBKW1 2

55Figure 10-2 Ladder DiagramBOX DEPICTSOPTIONAL ITEMSLADDER DIAGRAMLBL20141 REV D24 VACCN5-6CN5-12CN5-11X4-2X4-10X4-11INTEGRATEDCONTROLLOUVERRELAY COI

Revision Notes: Revision A (ECO #C11234) initial release. Revision B (ECO #C11235) refl ects updates made to the freezing conditions warnings.OKBX-I-

6192815IMG004083241Rear View - Model 501182914152331IMG003234111Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801Left Side (insi

7RatingsNotes:1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.2. Net AHRI ratings are base

8The Outdoor Knight XL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specifi ed in ANSI Z2

1 Determine boiler location (continued)Products to avoid:Spray cans containing chloro/fl uorocarbonsPermanent wave solutionsChlorinated waxes/cleaners