Lochinvar 400-801 operation manual Diagrams, High Voltage

Page 54

Outdoor Knight XL Installation & Operation Manual

10 Diagrams

Figure 10-1Wiring Diagram

 

LOW VOLTAGE

BOX DEPICTS

 

120 VAC

 

OPTIONAL ITEMS

 

HIGH VOLTAGE

BOX DEPICTS

 

 

 

 

DUAL SENSOR

 

 

SINGLE HOUSING

CONNECTION BOARD

INTEGRATED

 

CONTROL

 

 

 

 

 

ALARM

1

 

ALARMBELL

BELLJUMPER

CONTACTS

2

 

LOUVER

7

 

 

 

RUN-TIME

3

 

 

 

CONTACTS

4

 

 

 

24 VAC LOUVER

5

 

 

 

RELAY COIL

6

 

 

 

PROVING SWITCH

8

CN5-1

 

 

CN5-8

 

 

GAS PRESSURE

9

 

 

CN5-2

 

 

SWITCH

10

 

 

CN5-9

 

 

 

 

 

 

SWITCH

 

 

 

 

 

CN5-3

 

 

 

 

 

CN5-11

 

 

 

 

 

 

CN5-10

SILENCING

 

 

TANK

13

CN5-4

 

 

CN5-12

 

 

FLOW

11

CN5-5

 

 

SWITCH

12

CN5-14

 

 

THERMOSTAT

14

CN5-6

 

 

HEAT/LOOP

3

15

CN5-13

 

 

DEMAND

16

CN5-7

 

 

HEAT/LOOP

2

17

 

 

 

DEMAND

18

 

 

 

HEAT/LOOP

1

19

 

 

 

DEMAND

20

 

 

 

SYSTEM

 

 

21

 

 

 

SENSOR

 

 

22

 

 

 

OUTDOOR

 

 

23

 

 

 

SENSOR

 

 

24

 

 

 

 

 

 

25

 

 

 

TANK

 

 

26

 

 

 

SENSOR

 

 

27

 

 

 

 

 

 

28

 

 

 

SHIELD

 

 

29

 

 

 

A

 

 

30

 

 

 

CASCADE

 

 

31

 

 

 

B

 

 

 

 

 

SHIELD

 

 

32

 

 

 

 

 

 

 

CN6

 

 

BMS

+

0-10V

33

 

 

 

IN

-

34

 

 

 

SYS PUMP

+

0-10V

35

 

 

 

IN

-

36

 

 

 

BLR PUMP

+

0-10V

37

 

 

 

OUT

-

38

 

 

 

RATE

+

0-10V

39

 

 

 

OUT

-

40

 

 

 

SHIELD

 

41

 

 

 

MODBUS

A

 

42

 

 

 

OPTION

B

 

43

 

 

 

SHIELD

 

44

 

 

 

LOW

 

24 VAC

CN7-1

 

 

 

CUT-OFF

 

COM

CN7-2

CN8-1 CN8-2 CN8-3

 

 

 

 

CN7-4

 

 

WATER

 

 

CN7-3

 

 

 

 

 

 

 

 

 

 

 

 

 

R BLG

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

X-7

X4-7

X4-14

X4-6

X4-13

X4-5

X4-12

X4-11

X4-4

X4-3

X4-8

X4-10

X4-2

X4-9

X4-1

X6

 

RELAY

 

L

N

 

 

JUNCTION

 

 

BOARD

 

BOX

DHW

 

 

 

 

PUMP

X1-3

OR CN2-4

CN1-5

OR

 

 

K1

 

 

 

 

BR CN2-2

CN1-6

OR

BOILER

X1-4

CN1-3

BR

PUMP

 

K2

 

 

 

X1-2

PR CN2-3

CN1-4

BR

 

CN1-1

PR

 

 

K3

 

 

SYSTEM

 

CN2-1

CN1-2

PR

 

PUMP

 

ON/OFF

 

 

 

 

SWITCH

 

L

 

X1-6

BK

 

120V

 

GND

X1-5

W

 

N

SUPPLY

X1-8

G

 

 

 

X1-1

R

 

 

 

 

 

 

TRANSFORMER

 

 

R W G

3.5A

 

 

KB 801

 

 

1 2 3

ONLY

 

 

 

 

 

BLOWER

 

 

 

1 2 3 4 5

 

 

 

X5-7

R

 

 

 

X5-16

T

 

 

 

X5-8

W

 

 

 

X5-15

BK

 

 

 

X5-9

Y

 

 

 

X5-1

BL

 

 

 

X5-2

O

 

O-TEMP HEX SW

 

 

BLOCKED DRAIN SWITCH

 

X5-10

P

 

 

 

X5-11

AIR PRESSURE SWITCH

 

O/BK

 

 

 

 

-T

 

 

 

X5-4

R/BK

OPERATING SENSOR S1a

X5-12

-T

HIGH LIMIT SENSOR S1b

 

GY

 

X5-6

-T

INLET SENSOR S2

 

P/BK

 

X5-5

-T

FLUE SENSOR S3a

 

W/BK

 

X5-13

-T

FLUE SENSOR S3b

 

PR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X5-14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X6-3

X6-2 X6-1 X6-4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X2-2

 

 

BK

 

 

 

 

 

GAS VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X4-1

 

 

 

O

 

 

 

X9-1

 

X2-1

 

 

 

Y

 

 

 

 

 

 

@24VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X4-2

 

 

 

GY

 

 

X9-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MODBUS BOARD

 

 

 

 

X4-3

 

 

 

G

 

 

 

X9-3

 

X1-7

 

W/R

 

 

FLAME SENSOR

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X4-4

 

 

 

 

 

 

 

 

X9-4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MTR-01

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TR2

 

 

 

 

 

 

 

 

 

SPARK

 

 

 

 

 

 

 

 

SHIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ROD

 

 

 

 

 

 

 

GROUNDING

 

 

 

 

 

 

 

X5-1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

HIGH VOLTAGE SPARK LEAD

 

 

 

 

 

 

 

 

 

X5-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

JUMPER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X1-1

 

 

 

BK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X1-2

 

 

 

W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X1-3

 

 

 

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Notes:

1.All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2.If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using

WIRING DIAGRAM

diagrams to troubleshoot unit.

LBL20116 REV E

54

Page 53 Page 55
Image 54
Page 53 Page 55
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 RatingInstallation must comply with Determine boiler locationBefore locating the boiler, check Flooring and foundation Provide clearancesOutdoor vent / air intake location Prevent combustion air contaminationInstall flue pipe assembly Models 400 Prepare boilerRemove 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 componentsNear boiler piping connections Circulator sizingVariable speed pump option Head Feet Pressure20F 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 PropaneVerify DHW mode Set domestic hot water DHW operationConfiguration 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 Maintenance Maintenance and annual startup Service technicianOwner 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