Lochinvar 400-801 operation manual Final checks before starting the boiler, Start the boiler

Page 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

Outdoor Knight XL Installation & Operation Manual

Check gas piping

1.Check around the boiler for gas odor following the procedure on page 46 of this manual (connecting gas supply piping).

steps to start boiler.

Verify the boiler and system are full of water and all

system components are correctly set for operation.

Verify the preparation procedures of Section 7, pages 33

and 34 have been completed.

￿WARNING

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap

with the switch located at the top of the trap). Replace

the cap. Press the cap onto the trap until the cap makes

Propane boilers – verify conversion

1.Verify propane conversion has been completed per the Propane Conversion instructions.

contact with the drain. Replace the retaining screw.

Verify electrical connections are correct and securely

attached.

Start the boiler

1.Read and follow the Operating instructions in FIG. 7-2, page 36.

If boiler does not start correctly

1.Check for loose connections, blown fuse or service switch off?

2.Is boiler water temperature above 200°F (93°C)?

3.Is thermostat set below controlling sensor temperature?

4.Is gas turned on at meter or boiler?

5.Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?

￿WARNING

￿WARNING

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.

Outdoor Knight XL boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice or by making a gas valve adjustment (see page 12). In order to operate on LP gas, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

If none of the above corrects the problem, refer to the Troubleshooting Section of the Outdoor Knight XL Service Manual.

Check system and boiler

Check water piping

1.Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 33 and 34 (startup) regarding failure to repair leaks.)

2.Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

Check flame and combustion

1.Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.

2.Combustion measurements will be made from exhaust opening.

3.Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

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Contents
Outdoor Knight XL Models 400 Contents Please read before proceeding When servicing boilerStainless steel heat exchanger Outdoor Knight XL How it worksModel Models 601 Outdoor Knight XL Boiler Ahri Rating RatingsBefore locating the boiler, check Installation must comply withDetermine boiler location Prevent combustion air contamination Provide clearancesOutdoor vent / air intake location Flooring and foundationRemove boiler from wood pallet Install flue pipe assembly Models 400Prepare boiler Models 701 3Install flue pipe assembly Models 701Gas conversions Model 4Installing Propane Orifice ModelLeveling the boiler Models 601Hydronic piping TEE with 1 Fitting on TOP Nipple Close Nipple Near boiler piping components Flow switch adjustmentVariable speed pump option Near boiler piping connectionsCirculator sizing 20F 25F 30F 35F Model Head FeetPressure 7Single Boiler Multiple Temperatures 8Single Boiler Primary/Secondary Piping Manifold Pipe Sizes in Inches mm Number of Units10Multiple Boilers Primary/Secondary Piping Temperature Wires to Loop Sensors 120VAC to Gas connections Connecting gas supply pipingPropane Gas Natural gasInches Check inlet gas supplyGas pressure Gas valve replacementLow voltage connections Field wiringInstallation must comply with Line voltage connectionsThermostat Outdoor temperature sensorHigh gas pressure switch Low gas pressure switchModBus Flow switchAlarm contacts Wiring of the cascade3Low Voltage Field Wiring Connections Condensate drain Condensate disposalFill and test water system Freeze protection when usedStart-up Check/control water chemistryInspect/check condensate lines and fittings Check for gas leaksCheck thermostat circuits Inspect/fill condensate systemCheck system and boiler Final checks before starting the boilerStart the boiler If boiler does not start correctlyFor Your Safety Read Before Operating Natural Gas Propane Set space heating operationConfiguration of the cascade Verify DHW modeSet domestic hot water DHW operation How the control module operates Operating informationGeneral How the boiler operatesProtection features Temperature controlBoiler temperature regulation Cascade Outdoor reset operation, if usedOperation Display Sequence of operationStandby, ready to start a new cycle User Access modesInstaller Outdoor Knight XL control moduleCall for Heat Information Dial Function Owner maintenance Maintenance Maintenance and annual startupService technician Maintenance Check boiler relief valve Flue vent system and air pipingCheck water system Check expansion tankInspect ignition and flame sense electrodes Check ignition ground wiringCheck all boiler wiring Check control settingsModel Kit Part Component Number Description Check flame signalCleaning boiler heat exchanger Review with ownerHigh Voltage Diagrams2Ladder Diagram