Lochinvar 400-801 Check for gas leaks, Check thermostat circuits, Inspect/fill condensate system

Page 34

7 Start-up

Outdoor Knight XL Installation & Operation Manual

Check for gas leaks

￿WARNING

Propane boilers only – Your propane supplier mixes an odorant with the propane

￿WARNING

￿WARNING

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 panel 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 solution. Repair any leaks at once.

DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1.

Disconnect the two external wires connected to each

 

of the heat/loop demand terminals on the connection

 

board.

2.

Connect a voltmeter across these two incoming wires.

 

Close each thermostat, zone valve, and relay in the

 

external circuit one at a time and check the voltmeter

 

reading across the incoming wires.

3.

There should NEVER be a voltage reading.

4.

If a voltage does occur under any condition, check and

 

correct the external wiring. (This is a common problem

Figure 7-1Condensate Trap

RETAINING

SCREW

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

PVC TEE ASSEMBLY (FACTORY SUPPLIED)

CONDENSATE FROM

HEAT EXCHANGER TO FLOOR

DRAIN

34

when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and

corrected if necessary, reconnect the external thermostat

circuit wires to the connection board. Allow the boiler to

cycle.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1.Inspect the condensate drain line, condensate PVC fittings and condensate trap.

Fill condensate trap with water

1.Remove the PVC cap retaining screw from the PVC cap (FIG. 7-1).

2.Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 7-1).

3.Fill with fresh water until the water begins to pour out of the drain.

4.Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

5.Replace the retaining screw.

￿WARNING The condensate trap (FIG. 7-1) must be filled with water during all times of boiler

operation to avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

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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 RatingDetermine boiler location Installation must comply withBefore locating the boiler, check Flooring and foundation Provide clearancesOutdoor vent / air intake location Prevent combustion air contaminationPrepare boiler Install flue pipe assembly Models 400Remove boiler from wood pallet 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 componentsCirculator sizing Near boiler piping connectionsVariable speed pump option Pressure Head Feet20F 25F 30F 35F Model 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 PropaneSet domestic hot water DHW operation Verify DHW modeConfiguration of the cascade 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 Service technician Maintenance Maintenance and annual startupOwner maintenance 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