Lochinvar 400-801 operation manual Contents

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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	25
1. DETERMINE BOILER LOCATION		Propane Supply Pressure Requirements	25
Flooring and Foundation	9	Check Inlet Gas Supply	26
Prevent Combustion Air Contamination	9	Gas Pressure	27
Corrosive Contaminants and Sources	9	Gas Valve Replacement	27
2. PREPARE BOILER		5. FIELD WIRING
Remove Boiler from Wood Pallet	10	Line Voltage Connections	28
Install Flue Pipe Assembly	10-11	Low Voltage Connections	28-29
Gas Conversions	12	Wiring of the Cascade	30
Model 400	12	6. CONDENSATE DISPOSAL
Model 501	13	Condensate Drain	32
Models 601 - 801	13	7. STARTUP	33-38
Leveling the Boiler	13	8. OPERATING INFORMATION
3. HYDRONIC PIPING		General	39
System Water Piping Methods	14	Cascade	42
Low Water Cutoff Device	14	Sequence of Operation	43-44
Chilled Water System	14	Outdoor Knight XL Control Module	45
Freeze Protection	14	Status Display Screens	46-48
General Piping Information	14	9. MAINTENANCE
Flow Switch and Relief Valve Installation	15	Maintenance and Annual Startup	49-53
Flow Switch Adjustment	16	10. DIAGRAMS
Circulator Sizing	17	Wiring Diagram	54
4. GAS CONNECTIONS		Ladder Diagram	55
Connecting Gas Supply Piping	24	Revision Notes	Back Cover
Natural Gas	25

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 in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

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Contents

Outdoor Knight XL Models 400 Contents When servicing boiler Please read before proceedingOutdoor Knight XL How it works Stainless steel heat exchangerModel Models 601 Ratings Outdoor Knight XL Boiler Ahri RatingBefore locating the boiler, check Installation must comply withDetermine boiler location Flooring and foundation Provide clearancesOutdoor vent / air intake location Prevent combustion air contaminationRemove boiler from wood pallet Install ﬂue pipe assembly Models 400Prepare boiler 3Install ﬂue pipe assembly Models 701 Models 7014Installing Propane Oriﬁce Model Gas conversions ModelModels 601 Leveling the boilerHydronic piping TEE with 1 Fitting on TOP Nipple Close Nipple Flow switch adjustment Near boiler piping componentsVariable speed pump option Near boiler piping connectionsCirculator sizing 20F 25F 30F 35F Model Head FeetPressure 7Single Boiler Multiple Temperatures 8Single Boiler Primary/Secondary Piping Number of Units Manifold Pipe Sizes in Inches mm10Multiple Boilers Primary/Secondary Piping Temperature Wires to Loop Sensors 120VAC to Connecting gas supply piping Gas connectionsNatural gas Propane GasCheck inlet gas supply InchesGas valve replacement Gas pressureLine voltage connections Field wiringInstallation must comply with Low voltage connectionsLow gas pressure switch Outdoor temperature sensorHigh gas pressure switch ThermostatWiring of the cascade Flow switchAlarm contacts ModBus3Low Voltage Field Wiring Connections Condensate disposal Condensate drainCheck/control water chemistry Freeze protection when usedStart-up Fill and test water systemInspect/ﬁll condensate system Check for gas leaksCheck thermostat circuits Inspect/check condensate lines and ﬁttingsIf boiler does not start correctly Final checks before starting the boilerStart the boiler Check system and boilerFor Your Safety Read Before Operating Set space heating operation Natural Gas PropaneConﬁguration of the cascade Verify DHW modeSet domestic hot water DHW operation How the boiler operates Operating informationGeneral How the control module operatesTemperature control Protection featuresBoiler temperature regulation Outdoor reset operation, if used CascadeSequence of operation Operation DisplayStandby, ready to start a new cycle Outdoor Knight XL control module Access modesInstaller UserCall for Heat Information Dial Function Owner maintenance Maintenance Maintenance and annual startupService technician Maintenance Check expansion tank Flue vent system and air pipingCheck water system Check boiler relief valveCheck control settings Check ignition ground wiringCheck all boiler wiring Inspect ignition and ﬂame sense electrodesReview with owner Check ﬂame signalCleaning boiler heat exchanger Model Kit Part Component Number DescriptionDiagrams High Voltage2Ladder Diagram