Lochinvar Kight Xl 400 801 Users Manual OKBX I O Rev B

400-801 to the manual 80cf0bb2-9739-4377-a29c-de7b6c2efdd6

2015-02-09

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Outdoor Knight XL

Installation & Operation Manual

Models: 400 - 801

Save this manual for future reference.

This manual must only be used by

a qualiﬁ ed heating installer / service

technician. Read all instructions,

including this manual and the

Outdoor Knight XL Service Manual,

before installing. Perform steps in

the order given. Failure to comply

could result in severe personal

injury, death, or substantial property

damage.

 WARNING

OKBX-I-O Rev B

Contents

Hazard deﬁ nitions

The following deﬁ ned 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.

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE OUTDOOR KNIGHT XL -- HOW IT WORKS......... 4-6

RATINGS ........................................................................... 7

1. DETERMINE BOILER LOCATION

Flooring and Foundation .................................................... 9

Prevent Combustion Air Contamination ............................. 9

Corrosive Contaminants and Sources ................................9

2. PREPARE BOILER

Remove Boiler from Wood Pallet ..................................... 10

Install Flue Pipe Assembly .......................................... 10-11

Gas Conversions .............................................................. 12

Model 400 ....................................................................12

Model 501 ................................................................... 13

Models 601 - 801 ........................................................ 13

Leveling the Boiler ............................................................ 13

3. HYDRONIC PIPING

System Water Piping Methods ..........................................14

Low Water Cutoff Device ................................................. 14

Chilled Water System ........................................................ 14

Freeze Protection ............................................................. 14

General Piping Information ...............................................14

Flow Switch and Relief Valve Installation ....................... 15

Flow Switch Adjustment...............................................16

Circulator Sizing ............................................................... 17

4. GAS CONNECTIONS

Connecting Gas Supply Piping ......................................... 24

Natural Gas ...................................................................... 25

Pipe Sizing for Natural Gas ......................................... 25

Natural Gas Supply Pressure Requirements ............. 25

Propane Gas ..................................................................... 25

Pipe Sizing for Propane Gas ...................................... 25

Propane Supply Pressure Requirements ................... 25

Check Inlet Gas Supply ................................................... 26

Gas Pressure ................................................................... 27

Gas Valve Replacement ...................................................27

5. FIELD WIRING

Line Voltage Connections .................................................28

Low Voltage Connections ............................................28-29

Wiring of the Cascade ...................................................... 30

6. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 32

7. STARTUP .............................................................. 33-38

8. OPERATING INFORMATION

General ............................................................................. 39

Cascade ............................................................................42

Sequence of Operation ............................................... 43-44

Outdoor Knight XL Control Module .................................. 45

Status Display Screens ............................................... 46-48

9. MAINTENANCE

Maintenance and Annual Startup .................................49-53

10. DIAGRAMS

Wiring Diagram ........................................................... 54

Ladder Diagram ...........................................................55

Revision Notes .................................................. Back Cover

Outdoor Knight XL Installation & Operation Manual

Please read before proceeding

Installer – Read all instructions, including

this manual and the Outdoor Knight XL

Service Manual, before installing. Perform

steps in the order given.

User – This manual is for use only by

a qualified heating installer/service

technician. Refer to the User’s Information

Manual for your reference.

Have this boiler serviced/inspected by

a qualiﬁ ed service technician, at least

annually.

Failure to comply with the above could

result in severe personal injury, death or

substantial property damage.

Failure to adhere to the guidelines on this

page can result in severe personal injury,

death, or substantial property damage.

When servicing boiler –

• To avoid electric shock, disconnect electrical supply

before performing maintenance.

• To avoid severe burns, allow boiler to cool before

performing maintenance.

Boiler operation –

When calling or writing about the boiler

– Please have the boiler model and serial

number from the boiler rating plate.

Consider piping and installation when

determining boiler location.

Any claims for damage or shortage in

shipment must be ﬁ led immediately

against the transportation company by the

consignee.

Factory warranty (shipped with unit) does

not apply to units improperly installed or

improperly operated.

If the information in this manual is not

followed exactly, a ﬁ re or explosion may

result causing property damage, personal

injury or loss of life.

This appliance MUST NOT be installed in

any location where gasoline or ﬂ ammable

vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a near by phone. Follow the

gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the ﬁ re department.

• Installation and service must be

performed by a qualiﬁ ed installer,

service agency, or the gas supplier.

 WARNING

NOTICE

 WARNING

Do not use petroleum-based cleaning or

sealing compounds in the boiler system.

Gaskets and seals in the system may be

damaged. This can result in substantial

property damage.

 CAUTION

 CAUTION Do not use “homemade cures” or “boiler

patent medicines”. Serious damage to the

boiler, personnel, and/or property may

result.

• Do not block ﬂ ow of combustion or ventilation air to

the boiler.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location

external to the appliance.

• Do not use this boiler if any part has been under water.

The possible damage to a ﬂ ooded appliance can be

extensive and present numerous safety hazards. Any

appliance that has been under water must be replaced.

Boiler water –

• Thoroughly ﬂ ush the system (without boiler connected)

to remove sediment. The high-efﬁ ciency heat exchanger

can be damaged by build-up or corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life.

Mineral buildup in the heat exchanger reduces heat

transfer, overheats the stainless steel heat exchanger,

and causes failure. Addition of oxygen carried in by

makeup water can cause internal corrosion in system

components. Leaks in boiler or piping must be repaired

at once to prevent makeup water.

Freeze protection ﬂ uids –

• NEVER use automotive antifreeze. Use only inhibited

propylene glycol solutions, which are speciﬁ cally

formulated for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used in hydronic

systems.

The Outdoor Knight XL - How it works...

1. Stainless steel heat exchanger

Allows system water to ﬂ ow through specially designed

coils for maximum heat transfer, while providing protection

against ﬂ ue gas corrosion. The coils are encased in a jacket that

contains the combustion process.

2. Combustion chamber access cover

Allows access to the combustion side of the heat exchanger

coils.

3. Blower

The blower pulls in air and gas through the venturi (item 5).

Air and gas mix inside the blower and are pushed into the

burner, where they burn inside the combustion chamber.

4. Gas valve

The gas valve senses the negative pressure created by the

blower, allowing gas to ﬂ ow only if the gas valve is powered and

combustion air is ﬂ owing.

5. Venturi

The venturi controls air and gas ﬂ ow into the burner.

6. Flue gas sensor (limit rated - not shown)

This sensor monitors the ﬂ ue gas exit temperature. The

control module will modulate and shut down the boiler if the

ﬂ ue gas temperature gets too hot. This protects the ﬂ ue pipe from

overheating.

7. Boiler outlet temperature sensor (housed with the

high limit sensor)

This sensor monitors boiler outlet water temperature (system

supply). If selected as the controlling sensor, the control

module adjusts boiler ﬁ ring rate so the outlet temperature is

correct.

8. Boiler inlet temperature sensor

This sensor monitors return water temperature (system

return). If selected as the controlling sensor, the control

module adjusts the boiler ﬁ ring rate so the inlet temperature is

correct.

9. Temperature and pressure gauge (ﬁ eld installed, not

shown)

Monitors the outlet temperature of the boiler as well as the

system water pressure.

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial

and a multiple line liquid crystal display.

11. Flue pipe assembly

Factory-supplied components for complete venting

system.

12. Burner (not shown)

Made with metal ﬁ ber and stainless steel construction, the

burner uses pre-mixed air and gas and provides a wide range of

ﬁ ring rates.

13. Water outlet (system supply)

A 1-1/2" or 2" NPT (depending on the model) water

connection that supplies hot water to the system.

14. Water inlet (system return)

A 1-1/2" or 2" NPT (depending on the model) water connection

that returns water from the system to the heat exchanger.

15. Gas connection pipe

Threaded pipe connection of 1". This pipe should be connected

to the incoming gas supply for the purpose of delivering gas to

the boiler.

16. SMART SYSTEM Control Module

The SMART SYSTEM Control responds to internal and

external signals and controls the blower, gas valve, and pumps

to meet the heating demand.

17. Manual air vent

Designed to remove trapped air from the heat exchanger

coils.

18. Air intake

Provides combustion air to the appliance.

19. Air Intake Cover

Provides protection from outdoor elements.

20. High voltage junction box

The junction box contains the connection points for the line

voltage power and all pumps.

21. Boiler drain port

Location from which the heat exchanger can be drained.

22. Low voltage connection board

The connection board is used to connect external low voltage

devices.

23. Low voltage wiring connections (plugs)

Conduit connection points for the low voltage connection

board.

24. Condensate drain connection

Connects the condensate drain line to a 1/2” PVC union.

25. Access cover - front

Provides access to the gas train and the heat exchanger.

26. Ignition electrode

Provides direct spark for igniting the burner.

27. Flame inspection window

The quartz glass window provides a view of the burner surface

and ﬂ ame.

28. Gas shutoff valve

Manual valve used to isolate the gas valve from the gas supply.

29. Relief valve

Protects the heat exchanger from an over pressure condition.

The relief valve provided with the unit is set at 50 PSI.

30. Flame sensor

Used by the control module to detect the presence of burner

ﬂ ame.

31. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

32. Top panel

Removable panel to gain access to the internal components.

33. Power switch

Turns 120 VAC ON/OFF to the boiler.

34. Leveling legs

Used to allow the heat exchanger to be leveled. This is needed

for the proper draining of the condensate from the combustion

chamber.

35. Air shroud (Model 501 only)

The air shroud controls air and gas ﬂ ow into the burner.

36. Air pressure switch

The air pressure switch detects blocked ﬂ ue/inlet conditions.

break the control circuit, shutting the boiler down.

37. Pump relay board

The pump relay board is used to connect the boiler, system and

DHW pumps.

38. Transformer (not shown)

The transformer provides 24V power to the integrated control.

39. High limit sensor (housed with the outlet temperature

sensor)

Device that monitors the outlet water temperature. If the

temperature exceeds its setting, the integrated control will break

the control circuit, shutting the boiler down.

40. Over-temp switch (located underneath vent cover -

not shown)

An electrical switch designed to shut down boiler operation in

the event the outer back of the heat exchanger, directly above the

ﬂ ue connection exceeds 604°F (318°C). This is a one time

switch and could warrant a heat exchanger replacement. Check

the integrity of the rear refractory at the back of the upper coil if

the switch opens.

41. Vent Cover

Covers Over-temp switch and ﬂ ue collar with ﬂ ue sensor.

42. Flow switch

The ﬂ ow switch is a safety device that ensures ﬂ ow through

the heat exchanger during operation. This appliance is low

mass and should never be operated without ﬂ ow. The ﬂ ow

switch makes contact when ﬂ ow is detected and allows the unit

to operate. If ﬂ ow is discontinued during operation for any

reason the ﬂ ow switch will break the control circuit and the

unit wll shut down.

Outdoor Knight XL Installation & Operation Manual

Front View - Model 400

IMG00406

Left Side (inside unit) - Model 400

IMG00407

Right Side (inside unit) - Model 400

Rear View - Model 400

Model 400

IMG00405

IMG00404

The Outdoor Knight XL - How it works... (continued)

Outdoor Knight XL Installation & Operation Manual

IMG00408

Rear View - Model 501

23 31

IMG00323

Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801

Left Side (inside unit) - Model 501

Model 501

Models 601 - 801

IMG00409

IMG00324

The Outdoor Knight XL - How it works...

Outdoor Knight XL Installation & Operation Manual

Ratings

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net AHRI ratings are based on net installed radiation of sufﬁ cient quantity for the requirements of the building and nothing

need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3. Standard Outdoor Knight XL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler

will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

4. Ratings have been conﬁ rmed by the Hydronics Section of AHRI.

5. Outdoor Knight XL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation

control. The manual reset high limit provided with the Outdoor Knight XL is listed to UL353.

Maximum allowed working pressure is located on the rating plate.

NOTICE

Outdoor Knight XL Boiler

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Input

MBH

(Note 4)

Min Max

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

OKN400 80 399 370 322

OKN501 100 500 463 402

OKN601 120 600 566 493

OKN701 140 700 658 572

OKN801 160 800 748 651

Other Speciﬁ cations

Boiler Water

Content

Gallons

Water

Connections Gas

Connections Air Size

3.4 1-1/2" 1" 4"

4.2 1-1/2" 1" 4"

4.2 2" 1" 4"

5.0 2" 1" 4"

5.7 2" 1" 4"

Outdoor Knight XL Installation & Operation Manual

The Outdoor Knight XL gas manifold

and controls met safe lighting and other

performance criteria when the boiler

underwent tests speciﬁ ed in ANSI Z21.13

– latest edition.

Do not install the unit under a deck.

Do not install the unit in a well, stairwell,

alcove, courtyard or other recessed area.

Do not install outdoor units on stack

frames. Failure to comply with the above

may result in severe personal injury, death

or substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws,

regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Gas supply piping

• Electrical power

2. - Keep venting areas free of obstructions.

- Keep area clean and free of combustible and ﬂ ammable

materials.

- To avoid a blocked air inlet or blocked ﬂ ue condition,

keep the outdoor air inlet and ﬂ ue outlet clear or leaves,

debris, etc.

4. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger

cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• This unit is not intended for installations where

temperatures may reach below 32°F (0°C). Exposure to

freezing temperatures will cause the system and boiler

to freeze and leak.

 WARNING

NOTICE

1 Determine boiler location

Do not install outdoor models directly on

the ground. You must install the outdoor

unit on a level concrete, brick, block, or

pressure-treated wood platform.

Do not locate unit so that high winds

can deﬂ ect off of adjacent walls, buildings

or shrubbery causing recirculation.

Recirculation of ﬂ ue products may cause

operational problems, bad combustion or

damage to controls. Locate unit at least

3 feet (0.91m) from any wall or vertical

surface to prevent wind conditions from

affecting performance.

CAUTION

 CAUTION

3. Check area around the boiler. Remove any combustible

materials, gasoline and other ﬂ ammable liquids.

Outdoor Knight XL Installation & Operation Manual

Outdoor models must be installed outdoors

only and must use the outdoor vent

assembly supplied by the manufacturer.

Personal injury or product damage may

result if any other venting is used or if an

outdoor model is used indoors. All covers,

doors and jacket panels must be properly

installed to ensure proper operation and

prevent a hazardous condition.

 WARNING

The unit must not be installed in an area

that is enclosed by walls or a fence that

will block free wind movement around

the appliance. Free movement of wind

around the outdoor unit is required

to carry away the ﬂ ue products and

provide combustion air. The ﬂ ue outlet/

combustion air inlet of an outdoor unit

must not be installed closer than 10 feet

from an inside corner of an L-shaped

structure. Walls or enclosed fencing may

cause eddy currents which can recirculate

the ﬂ ue products into the combustion

air inlet. Recirculation of ﬂ ue products

may cause operational problems, bad

combustion or non-warrantable damage

to controls.

Locate the unit at least 3 feet (0.91m)

outside any overhang.

 CAUTION

CAUTION Do not install in locations where rain

from building runoff drains will spill onto

the unit.

Do not locate the unit so that water

from sprinklers may spray directly onto

it. Water may damage controls or other

electrical components.

Failure to keep boiler area clear and free

of combustible materials, gasoline, and

other ﬂ ammable liquids and vapors can

result in severe personal injury, death, or

substantial property damage.

 WARNING

This product contains a condensate

management and disposal system that

may be subject to freezing if exposed

to sustained temperatures below 32°F.

Precautions should be taken to protect the

condensate trap and drain lines during

extended periods of outdoor temperatures

below 32°F.

1 Determine boiler location (continued)

Products to avoid:

Spray cans containing chloro/ﬂ uorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other

similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture reﬁ nishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" (6 mm) from combustible

materials.

2. Jacket—minimum of 0" from right side and 14" from rear

side for proximity from combustible materials.

3. Vent—minimum of 1" from combustible materials.

Clearances for service access

1. If you do not provide the minimum clearances shown, it

may not be possible to service the boiler without removing

it from the space.

Do not install the boiler on carpeting even

if foundation is used. Fire can result,

causing severe personal injury, death, or

substantial property damage.

Flooring and foundation

Flooring

The Outdoor Knight XL is approved for installation on

combustible ﬂ ooring.

 WARNING

Prevent combustion air contamination

Do not install unit in locations that can allow contamination

of combustion air. Refer to Table 1A for products and areas

which may cause contaminated combustion air.

Under no circumstances is the manufacturer to be held

responsible for water damage in connection with this

appliance, or any of its components. If ﬂ ooding is possible,

elevate the boiler sufﬁ ciently to prevent water from reaching

the boiler.

Recommended service clearances

Front: 30" (762mm)

Top: 24" (610mm)

Left side: 24" (610mm)

Rear: 24" (610mm)

Outdoor Knight XL Installation & Operation Manual

Outdoor vent / air intake location:

The ﬂ ue products discharged from the

ﬂ ue outlet on the outdoor vent may be

very hot. Avoid touching or making other

direct contact with the ﬂ ue gases or the

vent termination. These components are

hot and direct contact can result in burns.

 WARNING

To prevent recirculation of the ﬂ ue products into the

combustion air inlet, follow all instructions in this section.

Flue gas condensate can condense on exterior walls or on the

vent. Some discoloration or exterior building or unit surfaces

can be expected. Adjacent brick or masonry surfaces should

be protected with a rust resistant sheet metal plate.

Maintain a minimum of 24" clearance to the air inlet.

Locate the outdoor vent termination at least 48" (1.22m)

below and 48" (1.22m) horizontally from any window, door,

walkway or gravity air intake.

Locate the unit at least 10 feet (3.05m) away from any forced

inlet.

Multiple unit outdoor installations require 24" (1.22m)

clearance between each vent termination.

Clearances around outdoor installations can change with

time. Do not allow the growth of trees, shrubs or other plants

to obstruct the proper operation of the outdoor vent system.

2 Prepare boiler

Install ﬂ ue pipe assembly

This unit is provided with all of the necessary venting

components. All components must be installed prior to

operation.

1. Locate all venting components from the installation kit

and carton.

2. Before connecting the vent pipe sections or components,

verify that the gasket is seated evenly inside the groove in

the female end of the elbow and ﬂ ue adaptor (FIG. 2-2).

3. Remove the provided screws from the vent cover and use

them to install the vent strap (FIG. 2-2).

4. Insert the elbow into ﬂ ue adaptor (FIG. 2-2).

Outdoor Knight XL Installation & Operation Manual

Do NOT use grease or other lubricant

on the vent seals. Only water may be

used for this purpose. Grease or other

lubricant can make the seal brittle or

cause tearing of the seal surface which

can result in ﬂ ue gas leakage.

 CAUTION

5. Slide the vent pipe through the wall strap and insert it

into the elbow (FIG. 2-2).

6. Install the bird screen into the top of the vent.

Figure 2-2 Install ﬂ ue pipe assembly - Models 400 -

601

FLUE

ADAPTER

ELBOW

VENT PIPE

BIRD SCREEN

WALL STRAP

AND SCREWS

IMG00444

NOTE: VERIFY THAT GASKET IS SEATED EVENLY

INSIDE THE GROOVE IN ELBOW AND ADAPTER

Models 400 - 601

Remove boiler from wood pallet

1. After removing the outer shipping carton from the

boiler, remove the parts box.

2. Remove the front door to access the lag bolts in front

of the unit (FIG. 2-1).

3. To remove the boiler from the pallet (after removing

the front door):

a. Remove the two lag bolts from the wood pallet

inside the boiler (FIG. 2-1).

b. Detach the boiler from the lag bolts in the rear of the

unit, see FIG. 2-1.

Do not drop the boiler or bump the

jacket on the ﬂ oor or pallet. Damage to

the boiler can result.

. 2

Figure 2-1 Boiler Mounted on Shipping Pallet

NOTICE

2 Prepare boiler (continued)

Outdoor Knight XL Installation & Operation Manual

Do NOT use grease or other lubricant on the

vent seals. Only water may be used for this

purpose. Grease or other lubricant can make

the seal brittle or cause tearing of the seal

surface which can result in ﬂ ue gas leakage.

 CAUTION

Models 701 - 801

Figure 2-3 Install ﬂ ue pipe assembly - Models 701 - 801

CLAMP

VENT COVER

WALL STRAP

SCREWS

WALL

STRAP

ELBOW

VENT PIPE

VENT

TERMINATION

IMG00446

NOTE: VERIFY THAT GASKET IS SEATED EVENLY

INSIDE THE GROOVE IN ELBOW AND ADAPTER

1. Locate all venting components from the installation kit and

carton.

2. Before connecting the vent pipe sections or components,

verify that the gasket is seated evenly inside the groove

in the female end of the elbow and ﬂ ue adapter

(FIG. 2-3).

3. Remove the vent cover from the back of the unit as shown in

FIG. 2-3.

4. Insert the elbow into the ﬂ ue adapter and tighten the clamp

using a 5/16" nut driver (FIG. 2-3).

5. Re-install the vent cover removed in Step 3.

6. Remove the provided screws from the vent cover and use

them to install the wall strap (FIG. 2-3).

7. Slide the vent pipe through the wall strap and insert it into the

elbow. Tighten the clamp (FIG. 2-3).

8. Install the termination into the top of the vent and tighten the

clamp.

Outdoor Knight XL Installation & Operation Manual

For a boiler already installed, you must

turn off gas supply, turn off power and

allow boiler to cool before proceeding.

You must also completely test the boiler

after conversion to verify performance

as described under Start-up, Section 10

of this manual. Failure to comply could

result in severe personal injury, death, or

substantial property damage.

For the 400 Model you must install a

propane oriﬁ ce to operate the Outdoor

Knight XL on propane gas. Verify when

installing that the oriﬁ ce size marking

matches boiler size (Model 400 - 8.0 LP

oriﬁ ce stamping).

Models 501 - 801 do not require an oriﬁ ce

installation for propane operation, but

they will require a valve adjustment.

Gas conversions

 WARNING

Model 400

1. Remove the top and front access covers from the unit

(tools required for removal).

2. Remove the three screws securing the venturi to the

blower. Note: When separating the venturi from the

blower, take care not to damage the O-ring inside the

blower (FIG. 2-4).

3. Remove the four star-drive screws securing the gas valve

to the venturi (FIG. 2-4).

4. Locate the propane oriﬁ ce disk from the conversion kit

bag.Verify that the stamping on the oriﬁ ce disk matches

the boiler size (Model 400 - 8.0 LP oriﬁ ce stamping).

5. Remove the existing oriﬁ ce from the O-ring in the side of

the gas valve and replace it with the oriﬁ ce from the kit.

Position and secure the oriﬁ ce in the valve as shown in

FIG. 2-4.

6. Reposition the gas valve against the venturi and replace

the star-drive screws (FIG. 2-4) securing the valve to the

venturi.

7. Inspect the O-ring inside the blower. Handle the O-ring

with care, do not damage. Reposition the venturi against

the blower and replace the screws securing the venturi to

the blower (FIG. 2-4).

8. After installation is complete, attach the propane

conversion label (in the conversion kit bag) next to the

boiler rating plate. Attach the LP caution label (in the

conversion kit bag) to the left side of the unit in the lower

left corner.

9. Replace the top and front access covers.

 DANGER Model 400: Inspect the O-ring when the

blower is disassembled. The O-ring must

be in good condition and must be installed.

Failure to comply will cause a gas leak,

resulting in severe personal injury or death.

 WARNING After converting to LP, check combustion

per the Start-up procedure in Section 10

of this manual. Failure to check and verify

combustion could result in severe personal

injury, death, or substantial property damage.

BLOWER

O-RING VENTURI

SCREWS

QTY. 3

GAS VALVE

BRASS ORIFICE

O-RING

SCREWS

QTY. 4

Figure 2-4 Installing Propane Oriﬁ ce - Model 400

2 Prepare boiler

SCREWDRIVER

SLOT

LOWER

RAISE

Figure 2-7 Leveling Legs on the Boiler

Leveling the boiler

1. Set the boiler in place and check level.

a) Adjust legs if necessary to level boiler, see FIG. 2-7

below.

ALLEN WRENCH

ADJUSTMENT SCREW

Figure 2-5 Gas Valve Adjustment - Model 501

Model 501

1. Remove the top access cover from the unit (Philips Head

screwdriver required for removal).

2. Turn the adjustment screw on the gas valve clockwise until

it stops. Then turn the adjustment screw counterclockwise

four and three quarter (4 3/4) turns (see FIG. 2-5).

3. Use a combustion analyzer to verify CO2 is within the range

of 9.6 – 10.5%. If not, adjust the screw counterclockwise

incrementally to raise CO2 and clockwise to lower CO2

(FIG. 2-5).

4. After adjustment is complete, attach the propane conversion

label (in the conversion kit bag) next to the boiler rating

plate. Attach the LP caution label (in the conversion kit bag)

to the left side of the unit in the lower left corner.

5. Replace the top access cover.

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

Figure 2-6 Gas Valve Adjustment - Models 601 - 801

Models 601 - 801

1. Remove the top access cover from the unit (Philips Head

screwdriver required for removal).

2. Remove the cover on top of the gas valve (FIG. 2-6).

3. Turn the adjustment screw on top of the gas valve clockwise

one and three quarter (1 3/4) turns on the 601 Model, one

and a half (1 1/2) turns on the 701 Model, and one turn on

the 801 Model (see FIG. 2-6).

4. Use a combustion analyzer to verify CO2 is within the range

of 9.6 – 10.5%. If not, adjust the screw counterclockwise

incrementally to raise CO2 and clockwise to lower CO2

(FIG. 2-6).

5. After adjustment is complete, attach the propane conversion

label (in the conversion kit bag) next to the boiler rating

plate. Attach the LP caution label (in the conversion kit

bag) to the left side of the unit in the lower left corner.

6. Replace the gas valve cover along with the top access cover.

 WARNING After converting to LP, check combustion

per the Start-up procedure in Section 10

of this manual. Failure to check and verify

combustion could result in severe personal

injury, death, or substantial property

damage.

 WARNING After converting to LP, check combustion

per the Start-up procedure in Section

10 of this manual. Failure to check and

verify combustion could result in severe

personal injury, death, or substantial

property damage.

2 Prepare boiler (continued)

Outdoor Knight XL Installation & Operation Manual

3 Hydronic piping

System water piping methods

The Outdoor Knight XL is designed to function in a closed

loop pressurized system not less than 12 psi (83 kPa). A

temperature and pressure gauge is included to monitor

system pressure and outlet temperature and should be

located on the boiler outlet.

It is important to note that the boiler has a minimal amount

of pressure drop which must be ﬁ gured in when sizing

the circulators. Each boiler installation must have an air

elimination device, which will remove air from the system.

Install the boiler so the gas ignition system components

are protected from water (dripping, spraying, etc.) during

appliance operation or basic service of circulator replacement,

valves, and others.

Observe a minimum of 1/4 inch (6 mm) clearance around all

un-insulated hot water pipes when openings around the pipes

are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and

local codes require a low water cutoff device at the time of

installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler

units, ﬂ ow control valves or other devices must be installed to

prevent gravity circulation of heater water in the coils during

the cooling cycle. A chilled water medium must be piped in

parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use

glycol that is specially formulated for this purpose. This

includes inhibitors, which prevent the glycol from attacking

the metallic system components. Make certain to check that

the system ﬂ uid is correct for the glycol concentration and

inhibitor level. The system should be tested at least once

a year and as recommended by the producer of the glycol

solution. Allowance should be made for the expansion of the

glycol solution in the system piping.

General piping information

Basic steps are listed below along with illustrations on the

following pages (FIG.’s 3-7 through 3-11), which will guide

you through the installation of the Outdoor Knight XL

(reference FIG.’s 3-4A and 3-4B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain

on system return to purge air out of each zone.

4. Install a backﬂ ow preventer on the cold feed make-up

water line.

5. Install a pressure reducing valve on the cold feed make-up

water line, (15 psi (103 kPa) nominal). Check temperature

and pressure gauge (shipped separately), which should

read a minimum pressure of 12 psi (83 kPa).

6. Consult the factory for a pump and/or pump cover. If a

ﬁ eld-supplied pump is used, install per the manufacturer’s

speciﬁ cations in regard to indoor or outdoor location. An

outdoor rated pump is recommended.

7. Install a circulator as shown on the piping diagrams in this

section. Make sure the circulator is properly sized for the

system and friction loss.

8. Install an expansion tank on the system supply. Consult the

tank manufacturer’s instruction for speciﬁ c information

relating to tank installation. Size the expansion tank for the

required system volume and capacity.

9. Install an air elimination device on the system supply.

10. Install a drain valve at the lowest point of the system.

Note: The boiler cannot be drained completely of water

without purging the unit with an air pressure of 15 psi

(103 kPa).

11. This appliance is supplied with a relief valve sized in

accordance with ASME Boiler and Pressure Vessel Code,

Section IV (“Heating Boilers”). Pipe the discharge of the

safety relief valve to prevent injury in the event of pressure

relief. Pipe the discharge to a drain. Provide piping that is

the same size as the safety relief valve outlet. Never block

the outlet of the safety relief valve.

See the piping illustrations included in this section, FIG.’s

3-7 and 3-11 for suggested guidelines in piping the Outdoor

Knight XL.

Please note that these illustrations are

meant to show system piping concept only,

the installer is responsible for all equipment

and detailing required by local codes.

Use only inhibited propylene glycol

solutions, which are speciﬁ cally formulated

for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used

in hydronic systems.

 WARNING

NOTICE

 WARNING The relief valve, tee and any other necessary

ﬁ ttings are shipped in the install kit with the

boiler and are to be ﬁ eld installed (FIG.’s

3-1 and 3-2).

12. On any pre-existing system, it is good practice to install

a ﬁ eld supplied strainer to prevent damage to the heat

exchanger.

RELIEF VALVE

FLOW SWITCH

PADDLE

TEMPERATURE &

PRESSURE GAUGE

TEE WITH FITTING

(FIELD PROVIDED)

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 1" FITTING

ON TOP

CLOSE NIPPLE

TEE WITH 3/4"

FITTING ON TOP

IMG00389

NOTICE Be sure to install the ﬂ ow switch so

that the arrow on the ﬂ ow switch is

pointing in the direction of the ﬂ ow

(see FIG. 3-3).

Figure 3-2 Flow Switch, Relief Valve and Temperature and

Pressure Gauge Installation_Models 601 - 801

Flow switch, relief valve and temperature

and pressure gauge installation

Basic steps are listed below to guide you through the

installation of the ﬂ ow switch, relief valve, and temperature

and pressure gauge provided with the unit.

1. For Models 400 - 501 install the close nipple on the

outlet connection of the heat exchanger. Install the tee

with the 3/4 inch ﬁ tting positioned vertically and on

the top as shown in FIG. 3-1. For Models 601 - 801

install the tee directly to the outlet connection of the

heat exchanger with the 3/4 inch ﬁ tting positioned

vertically and on the top (see FIG. 3-2).

2. For Models 701 - 801 install the 3/4 inch close nipple

in the tee. Install the relief valve on the 3/4 inch close

nipple (FIG. 3-2). For Models 400 - 601 install the

relief valve directly into the 3/4 inch ﬁ tting on the tee

(FIG. 3-1).

3. Install the close nipple on the downstream side of

the relief valve tee (FIG. 3-1).

4. Install the tee with the 1 inch ﬁ tting positioned

vertically and on the top (FIG. 3-1).

5. Attach paddle #3 to the ﬂ ow switch per the

manufacturer’s instructions.

6. Install the assembled ﬂ ow switch into the 1 inch ﬁ tting

of the tee installed in Step 4 (see FIG. 3-1).

7. Install a ﬁ eld provided close nipple on the downstream

side of the ﬂ ow switch (see FIG.’s 3-1 and 3-2).

8. Install a ﬁ eld provided tee with the gauge ﬁ tting

positioned vertically and on the top (FIG.’s 3-1 and

3-2)

9. Install the temperature and pressure gauge provided

with the unit into the top ﬁ tting of the tee (a bushing

may be necessary) installed in Step 8 (FIG.’s 3-1 and

3-2).

RELIEF VALVE

FLOW SWITCH

PADDLE

TEMPERATURE &

PRESSURE GAUGE

TEE WITH FITTING

ON TOP

(FIELD PROVIDED)

CLOSE NIPPLE

(FIELD PROVIDED)

TEE WITH 1" FITTING ON TOP

CLOSE NIPPLE

TEE WITH 3/4"

FITTING ON TOP

8' NIPPLE

(REQUIRED FOR MODELS 400 - 701)

IMG00390

Figure 3-1 Flow Switch, Relief Valve and Temperature and

Pressure Gauge Installation_Models 400 - 501

3 Hydronic piping (continued)

Outdoor Knight XL Installation & Operation Manual

3 Hydronic piping

Figure 3-3 Flow Switch Adjustment

Flow switch adjustment

Refer to Table 3A for the proper setting of the sensitivity

screw. For reference, the position of the screw prior to setting

should be turned clockwise with a Phillips driver until it stops

(FIG. 3-3). Proceed to turn the screw counterclockwise the

amount of turns listed in Table 3A based on the model.

Consult the manufacturer’s instructions for wiring the ﬂ ow

switch to your system.

NORMALLY

OPEN

SENSITIVITY

ADJUSTMENT

NORMALLY

CLOSED

COMMON

GROUND

NOTICE Turn the sensitivity screw clockwise to

increase the ﬂ ow rate required to activate

the switch. Turn the sensitivity screw

counterclockwise to decrease the ﬂ ow rate

required to activate the switch.

MODEL PADDLE SIZE SENSITIVITY SCREW

ADJUSTMENT

Note: Paddles are included with the ﬂ ow switch.

400 #3 7½ turns

501 #3 5½ turns

601 #3 7¼ turns

701 #3 5¼ turns

801 #3 3¼ turns

Table 3A Paddle Size / Sensitivity Screw Adjustment

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe

requirements listed in Table 3B. Reducing the pipe size

can restrict the ﬂ ow rate through the boiler, causing

inadvertent high limit shutdowns and poor system

performance. Flow rates are based on 20 feet (6 m) of

piping, 4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler system circulating pump:

(Field supplied.) The boiler circulating pump should be

based on 20 feet (6 m) of piping, 4 - 90° elbows, and

2 - fully ported ball valves.

3. Domestic hot water circulating pump:

(Field supplied.) The pump MUST be sized to meet

the speciﬁ ed minimum ﬂ ow requirements listed in

FIG.’s 3-5 and 3-6. Consult the indirect water heater

operating guide to determine ﬂ ow characteristics for the

selected product used.

4. Variable speed boiler system circulator:

Outdoor Knight XL boilers are capable of controlling

a variable speed boiler system circulator. Variable speed

circulators MUST be sized to meet the speciﬁ ed minimum

ﬂ ow requirements listed in FIG.’s 3-5 and 3-6 on page 16

at full speed.

5. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure

to use full port ball valves could result in a restricted ﬂ ow

rate through the boiler.

6. Check valves:

Field supplied. Check valves are recommended for

installation as shown in FIG.’s 3-7 through 3-11. Failure

to install check valves could result in a reverse ﬂ ow

condition during pump(s) off cycle.

7. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are required. Failure

to use full port ball valves could result in a restricted ﬂ ow

rate through the boiler.

8. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is

recommended when storing domestic hot water above

115°F (46°C).

9. Unions:

Field supplied. Recommended for unit serviceability.

10. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is

shipped loose. It is the responsibility of the contractor to

install the temperature and pressure gauge on the boiler

water outlet.

11. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to

ASME speciﬁ cations.

3 Hydronic piping (continued)

Near boiler piping connections

Y-STRAINER

(RECOMMENDED)

BOILER PUMP

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

FROM

SYSTEM

DOMESTIC HOT

WATER PUMP

AIR SEPARATOR

SYSTEM SENSOR

IMG00413

SYSTEM PUMP

Figure 3-4A Near Boiler Piping w/Y-Strainer

Circulator sizing

The Outdoor Knight XL heat exchanger does have a pressure

drop, which must be considered in your system design. Refer

to the graphs in FIG’s 3-5 and 3-6 for pressure drop through

the Outdoor Knight XL heat exchanger.

DRAIN

(TYPICAL)

AIR SEPARATOR

AIR VENT VALVE

EXPANSION TANK

LOW LOSS HEADER

(TYPICAL)

Y-STRAINER

(RECOMMENDED)

DRAIN

VALVE

FAST FILL VALVE

INDIRECT

DOMESTIC

HOT WATER

TANK

SYSTEM SENSOR

SYSTEM PUMP

TO FLOOR

DRAIN

FROM

SYSTEM

BOILER PUMP

IMG00391

Figure 3-4B Near Boiler Piping w/Low Loss Header

12. Boiler purge valve:

Field supplied. The boiler purge valve is used to

remove entrapped air from the heat exchanger during

start-up.

13. System temperature sensor:

Lochinvar supplies a system temperature sensor. The

sensor is to be installed in the heating loop downstream

from the boiler hot water piping and heating loop

junction. The sensor should be located far enough

downstream to sense system diluted water temperature.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose

strainer is recommended at the inlet of the heat exchanger

to remove system particles from older hydronic systems

and protect newer systems.

Variable speed pump option

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10VDC

by the dip switches on the pump control

- Pump is set for external signal control

(if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a

0 - 10 VDC input option, an optional module

will be required from the vendor

SMART SYSTEM / Multi-temperature

loop control option

The Outdoor Knight XL boiler is capable of producing

up to three (3) set point temperatures to meet different

space heating demands. When using more than one

temperature demand it is necessary to protect the

lower temperature loop from overheating. To help

aid with this protection, Lochinvar offers the Multi-

Temperature Loop Control Board Kit (RLY30086).

Outdoor Knight XL Installation & Operation Manual

Figure 3-5 Pressure Drop vs. Flow - Models 400 and 501

Table 3B Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F

Figure 3-6 Pressure Drop vs. Flow - Models 601 thru 801

0 5 10 15 20 25 30 35 40 45

KBN501

KBN400

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Flow Rate (GPM)

Pressure Drop (Feet of Head)

0 102030405060708090

KBN801

KBN701

KBN601

Pressure Drop vs Flow

(Includes Boiler Secondary Piping)

Flow Rate (GPM)

Pressure Drop (Feet of Head)

TEMPERATURE RISE APPLICATIONS

Model MINIMUM

PIPE

SIZE

20°F 25°F 30°F 35°F

GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD

400 1 1/2" 37 21 30 14 26 11 21 8

501 1 1/2" 46 23 37 16 32 13 26 10

601 2" 55 31 44 22 38 18 32 13

701 2" 65 30 52 20 45 16 37 11

801 2" 74 33 60 23 51 18 42 12

3 Hydronic piping

3 Hydronic piping (continued)

Figure 3-7 Single Boiler - Multiple Temperatures

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

EXPANSION

TANK

AIR SEPARATOR

PRESSURE

REDUCING

VALVE

BALL VALVE

(TYPICAL)

UNION (TYPICAL)

PRESSURE

RELIEF

VALVE

FLOW CHECK VALVE

(TYPICAL)

INDIRECT DHW

TANK

PRESSURE

GAUGE

BOILER CIRCULATOR

COLD WATER IN

ANTI-SCALD

MIXING VALVE DOMESTIC

HOT WATER

CIRCULATOR

HOT WATER OUT

MAKE UP WATER

Y-STRAINER (RECOMMENDED)

TEMPERATURE

LOOP 1

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 3

BACK FLOW

PREVENTER

LOOP SENSOR (3X)

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

WIRES TO LOOP SENSORS

24V SIGNAL TO

MIXING VALVES

FROM

SYSTEM

120VAC

TO PUMPS

BOILER

SHIELDED CABLE

TO BOILER CONTROL

SYSTEM

IMG00392

Outdoor Knight XL Installation & Operation Manual

Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

Outdoor Knight XL Installation & Operation Manual

3 Hydronic piping

Figure 3-8 Single Boiler - Primary/Secondary Piping

NOTICE System ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in

operation to prevent short cycling and high limit issues.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler

output does not not exceed indirect water heater transfer capabilities.

EXPANSION TANK

AIR SEPARATOR

PRESSURE REDUCING

VALVE

BACK FLOW

PREVENTER

BALL VALVE

(TYPICAL)

UNION (TYPICAL)

PRESSURE RELIEF

VALVE

FLOW CHECK

VALVE (TYPICAL)

INDIRECT DHW

TANK

BOILER

DRAIN

DRAIN POINT

(TYPICAL)

BOILER CIRCULATOR

COLD WATER IN

ANTI-SCALD

MIXING VALVE

SYSTEM SUPPLY SENSOR

(WHEN USED)

SYSTEM CIRCULATOR

TOSYSTEM

FROMSYSTEM

DOMESTIC

HOT WATER

CIRCULATOR

HOT WATER OUT

MAKE UP WATER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE

LOW LOSS HEADER

IMG00393

Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

3 Hydronic piping (continued)

Figure 3-9 Multiple Boilers - Multiple Temperatures

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

CAUTION

Model

Number of Units

2 3 4 5678

Manifold Pipe Sizes in Inches (mm)

400 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

501 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)

601 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

701 3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

801 4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler

output does not not exceed indirect water heater transfer capabilities.

EXPANSION

TANK

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION (TYPICAL)

PRESSURE

RELIEF

VALVE

FLOW CHECK

VALVE (TYPICAL)

INDIRECT DHW

TANK

BOILER 1

PRESSURE

GAUGE

DRAIN POINT

(TYPICAL)

ANTI-SCALD

MIXING VALVE

DOMESTIC

HOT WATER

CIRCULATOR

MAKE UP WATER

Y-STRAINER

(RECOMMENDED)

TEMPERATURE

LOOP 1

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 3

BOILER 2

BOILER CIRCULATOR

TEMPERATURE/PRESSURE

GAUGE

COLD WATER IN

WIRES TO

LOOP SENSORS

120VAC

TO PUMPS

24V SIGNAL TO

MIXING VALVES

SHIELDED CABLE

TO BOILER CONTROL

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

LOOP SENSOR (3X)

BACK FLOW

PREVETER

SYSTEM

FROM

SYSTEM

IMG00394

Outdoor Knight XL Installation & Operation Manual

Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

Outdoor Knight XL Installation & Operation Manual

3 Hydronic piping

Figure 3-10 Multiple Boilers - Primary/Secondary Piping

Model

Number of Units

2345678

Manifold Pipe Sizes in Inches (mm)

400 2 1/2 (64) 3 (76) 3 1/2 (89) 4 (102) 4 (102) 5 (127) 6 (152)

501 3 (76) 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152)

601 3 1/2 (89) 4 (102) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203)

701 3 1/2 (89) 5 (127) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203)

801 4 (102) 5 (127) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203)

EXPANSION

TANK

AIR SEPARATOR

PRESSURE REDUCING

VALVE

BACK FLOW

PREVENTER

BALL VALVE

(TYPICAL)

UNION (TYPICAL)

PRESSURE RELIEF

VALVE

FLOW CHECK

VALVE (TYPICAL)

INDIRECT DHW

TANK

BOILER 1

(LEADER)

TEMPERATURE /

PRESSURE GAUGE

DRAIN

DRAIN POINT

(TYPICAL)

BOILER CIRCULATOR

(TYPICAL)

ANTI-SCALD

MIXING VALVE

SYSTEM SUPPLY SENSOR

(WHEN USED)

SYSTEM CIRCULATOR

NOT TOEXCEED4PIPEDIAOR MAX.OF12"APART

BOILER 2

(MEMBER 1)

BOILER 3

(MEMBER 2)

BOILER 4

(MEMBER 3)

DOMESTIC

HOT WATER

CIRCULATOR

COLD WATER IN

HOT WATER OUT

MAKE UP WATER

Y-STRAINER

(TYPICAL)

(RECOMMENDED)

MAY SUBSTITUTE

LOW LOSS HEADER

FROMSYSTEM

TO SYSTEM

IMG00417

NOTICE System ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in

operation to prevent short cycling and high limit issues.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler

output does not not exceed indirect water heater transfer capabilities.

Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

3 Hydronic piping (continued)

Figure 3-11 Single Boiler - Multiple Temperatures with DHW Piped as a Zone

EXPANSION

TANK

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION (TYPICAL)

FLOW CHECK

VALVE (TYPICAL)

INDIRECT DHW

TANK

TEMPERATURE / PRESSURE

GAUGE

PRESSURE

GAUGE

DRAIN

DRAIN POINT

(TYPICAL)

BOILER CIRCULATOR

COLD WATER IN

ANTI-SCALD

MIXING VALVE DOMESTIC

HOT WATER

CIRCULATOR

HOT WATER OUT

MAKE UP WATER

Y-STRAINER

(RECOMMENDED)

TEMPERATURE

LOOP 1

TEMPERATURE

LOOP 2

TEMPERATURE

LOOP 3

PRESSURE RELIEF

VALVE

BACK FLOW

PREVENTER

FROM

SYSTEM

SHIELDED CABLE

TO BOILER CONTROL

LOOP SENSOR (3X)

MULTI-TEMP

LOOP CONTROL

(OPTIONAL)

WIRES TO

LOOP SENSORS

120VAC TO

PUMPS

24VAC SIGNAL

TO MIXING VALVES

PRESSURE

REDUCING

VALVE

BOILER

IMG00412

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

CAUTION Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler

output does not not exceed indirect water heater transfer capabilities.

Outdoor Knight XL Installation & Operation Manual

Please note that these illustrations show an indoor tank to demonstrate piping concept only.

NOTICE

Outdoor Knight XL Installation & Operation Manual

Connecting gas supply piping

1. Remove the top access panel and refer to FIG.’s 4-1 thru

4-3 to pipe gas to the boiler.

a. Install ground joint union for servicing, when

required.

b. Install a manual shutoff valve in the gas supply

piping outside boiler jacket when required by local

codes or utility requirements.

2. Install sediment trap / drip leg.

Figure 4-1 Gas Supply Piping - Model 400

3. Support piping with hangers, not by the boiler or its

accessories.

Do not check for gas leaks with an open

ﬂ ame – use the bubble test. Failure to

use the bubble test or check for gas leaks

can cause severe personal injury, death, or

substantial property damage.

UNION

(FACTORY INSTALLED)

MANUAL

SHUTOFF VALVE

(FACTORY SUPPLIED)

GAS SUPPLY

SEDIMENT TRAP/

DRIP LEG

IMG00410

Figure 4-3 Gas Supply Piping - Models 601 - 801

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler

and its gas connection for leaks.

a. The appliance must be disconnected from the gas

supply piping system during any pressure testing of

that system at a test pressure in excess of 1/2 PSIG

(3.5 kPa).

b. The appliance must be isolated from the gas supply

piping system by closing a manual shutoff valve

during any pressure testing of the gas supply piping

system at test pressures equal to or less than 1/2 PSIG

(3.5 kPa).

c. The appliance and its gas connection must be leak

tested before placing it in operation.

The gas valve and blower will not support

the weight of the piping. Do not attempt

to support the weight of the piping with

the boiler or its accessories. Failure to

comply could result in severe personal

injury, death, or substantial property

damage.

 WARNING

6. Use pipe sealing compound compatible with propane

gases. Apply sparingly only to male threads of the pipe

joints so that pipe dope does not block gas ﬂ ow.

IMG00411

UNION

GAS SUPPLY

SEDIMENT TRAP /

DRIP LEG

MANUAL

SHUTOFF

VALVE

(FIELD SUPPLIED)

Figure 4-2 Gas Supply Piping - Model 501

GAS SUPPLY

MANUAL SHUTOFF VALVE

(FACTORY SUPPLIED)

SEDIMENT TRAP

/ DRIP LEG

IMG00328

4 Gas connections

4 Gas connections (continued)

Failure to apply pipe sealing compound

as detailed in this manual can result

in severe personal injury, death, or

substantial property damage.

Use two wrenches when tightening gas

piping at boiler (FIG. 4-4), using one

wrench to prevent the boiler gas line

connection from turning. Failure to

support the boiler gas connection pipe

to prevent it from turning could damage

gas line components.

USE BACKUP WRENCH

TO PREVENT PIPE FROM

ROTATING

IMG00420

Figure 4-4 Inlet Pipe with Backup Wrench

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 4A for pipe length and diameter. Based on

rated boiler input (divide by 1,000 to obtain cubic feet per

hour).

a. Table 4A is only for natural gas with speciﬁ c gravity

0.60 inches, with a pressure drop through the gas

piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.5 kPa) with no ﬂ ow

(lockup) or with boiler on.

• Minimum 4 inches w.c. (.99 kPa) with gas ﬂ owing (verify

during boiler startup).

2. Install 100% lockup gas pressure regulator in supply line

if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any

time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa)

maximum.

Propane Gas:

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup

gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas

supplier for 14 inches w.c. (3.2 kPa) maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.2 kPa) with no ﬂ ow (lockup)

or with boiler on.

• Minimum 8 inches w.c. (1.9 kPa) with gas ﬂ owing (verify

during boiler startup).

Maximum inlet gas pressure must not

exceed the value speciﬁ ed. Minimum

value listed is for the purposes of input

adjustment.

 WARNING

NOTICE

 WARNING Ensure that the high gas pressure regulator

is at least 10 feet (3 m) upstream of the

appliance.

 WARNING Outdoor Knight XL boilers are typically

shipped ready to ﬁ re 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

oriﬁ ce or by making a gas valve adjustment

(see page 12). In order to operate on LP

gas, an oriﬁ ce 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.

Outdoor Knight XL Installation & Operation Manual

Nominal

Iron Pipe

Size

(inches)

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet

Maximum

Capacity of Pipe

in Thousands of

Btu/hr per hour

for gas pressures

of 14 Inches

Water Column

(0.5 PSIG) or less

and a pressure

drop of 0.5 Inch

Water Column

(Based on NAT

GAS, 1025 Btu/

hr per Cubic Foot

of Gas and 0.60

Speciﬁ c Gravity)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74

1697 477 384 328 292 267 246 236 210 200 179 164 149 138

1-1/4 1400 974 789 677 595 543 502 472 441 410 369 333 308 287

1-1/2 2150 1500 1210 1020 923 830 769 707 666 636 564 513 472 441

24100 2820 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 871 820

2-1/2 6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300

311200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340

423500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720

4 Gas connections

Table 4A Natural Gas Pipe Size Chart

The gas piping must be sized for the proper ﬂ ow and length of

pipe, to avoid excessive pressure drop. Both the gas meter and

the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c.

(249 Pa), the meter, regulator, or gas line is undersized or in

need of service. Perform the steps below when checking inlet

gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas

piping to the appliance.

3. On Models 400 - 501 loosen the set screw one (1) full turn

from inside the pressure tap on top of the gas valve. On

Models 601 - 801 remove the 1/8" (3 mm) pipe plug on the

inlet ﬂ ange to the valve and install a suitable 1/8" (3 mm)

ﬁ tting (ﬁ eld supplied) for the manometer tubing. Place

the tubing of the manometer over the tap once the set

screw is loosened or the 1/8" (3 mm) ﬁ tting is installed

(depending on model) as shown in FIG.’s 4-5 thru 4-7 on

page 27.

4. Slowly turn on the gas supply at the ﬁ eld installed

manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of

the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner ﬁ res at

100% of rated input. Percent of burner input will be

displayed on the control panel.

8. Ensure inlet pressure is within speciﬁ ed range.

Minimum and maximum gas supply pressures are

speciﬁ ed in this section of the manual.

9. If gas supply pressure is within normal range and no

adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility,

gas supplier, qualiﬁ ed installer or service agency to

determine the necessary steps to provide proper gas

pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas

piping to the appliance.

13. Remove the manometer from the pressure tap on top of

the gas valve. On Models 400 - 501 re-tighten the set

screw inside the pressure tap. On Models 601 - 801

remove the 1/8" (3 mm) ﬁ eld supplied ﬁ tting and

reinstall the pipe plug removed in Step 3.

Check inlet gas supply

NOTICE CSA or UL listed ﬂ exible gas connections

are acceptable, but you must exercise

caution to ensure that the line has adequate

capacity to allow your boiler to ﬁ re at full

rate. Consult with local codes for proper

installation or service procedures.

DO NOT adjust gas valve outlet pressure.

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.

 WARNING

 WARNING When 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 bubble test. Failure to

use the bubble test or check for gas leaks

can cause severe personal injury, death, or

substantial property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of

the SMART SYSTEM control module to the desired

water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while

you observe burner response. The burner should ignite

promptly. Flame pattern should be stable. Turn system

off and allow burner to cool, then cycle burner again to

ensure proper ignition and ﬂ ame characteristics. Gas pressure

The gas pressure must remain between 4 inches w.c. (.99

kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for

Natural gas and between 8 inches w.c. (1.9 kPa) minimum

and 14 inches w.c. (3.2 kPa) maximum for LP gas during

standby (static) mode and while in operating (dynamic)

mode. If an in-line regulator is used, it must be a minimum

of 10 feet (3 m) from the Outdoor Knight XL boiler. It is

very important that the gas line is properly purged by the gas

supplier or utility company. Failure to properly purge the

lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations

and also in empty tank situations. This can also occur when

a utility company shuts off service to an area to provide

maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional

gas valve under any circumstances. As an additional safety

feature, this gas valve has a ﬂ anged connection to the venturi

and blower.

Figure 4-5 Inlet Gas Supply Check - Model 400

DETAIL

IMG00414

LOOSEN THE SET SCREW ONE (1) FULL TURN

ND PLACE THE MANOMETER TUBING OVER

THE PRESSURE TAP

Figure 4-6 Inlet Gas Supply Check - Model 501

DETAIL

IMG00415

LOOSEN THE SET SCREW ONE (1) FULL TURN

ND PLACE THE MANOMETER TUBING OVER

THE PRESSURE TAP

Figure 4-7 Inlet Gas Supply Check - Models 601 - 801

DO NOT adjust gas valve outlet pressure.

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.

Failure to follow all precautions could

result in ﬁ re, explosion, or death!

 WARNING

DETAIL

REMOVE THE 1/8” (3 MM) PIPE PLUG ON

THE INLET FLANGE TO THE VALVE AND

INSTALL A SUITABLE 1/8” (3 MM) FITTING

(FIELD SUPPLIED) FOR THE MANOMETER

TUBING.

4 Gas connections (continued)

Outdoor Knight XL Installation & Operation Manual

5 Field wiring

ELECTRICAL SHOCK HAZARD – For

your safety, turn off electrical power

supply before making any electrical

connections to avoid possible electric

shock hazard. Failure to do so can cause

severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler

must be replaced, use only type 105°C

wire or equivalent.

Boiler must be electrically grounded as

required by National Electrical Code

ANSI/NFPA 70 – latest edition.

Ensure that all wiring external to the

unit is enclosed in approved conduit.

Installation must comply with:

1. National Electrical Code and any other national, state,

provincial, or local codes, or regulations.

Line voltage connections

1. Connect 120 VAC power wiring to the line voltage terminal

strip in the junction box, as shown in FIG.5-1.

2. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code (see

FIG. 5-1).

3. When connecting a domestic hot water (DHW) pump,

connect the wiring to the line voltage terminal strip as

shown in FIG. 5-1.

4. To activate a system pump, wire as shown in FIG. 5-1. Dry

contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.

DOMESTIC

HOT WATER

PUMP

BOILER

PUMP

SYSTEM

PUMP

120V SUPPLY

LINE

GROUND

NEUTRAL

SERVICE

SWITCH

L2/N GL1

Figure 5-1 Line Voltage Field Wiring Connections

Label all wires prior to disconnection

when servicing controls. Wiring errors

can cause improper and dangerous

operation.

 WARNING

NOTICE

 CAUTION

Low voltage connections

1. Route all low voltage wires through the knockouts in the

rear of the boiler, as shown in FIG. 5-2.

2. Connect low voltage wiring to the low voltage connection

board as shown in FIG. 5-3 on page 29 of this manual and

the boiler wiring diagram.

LINE VOLTAGE

JUNCTION BOX

LOW VOLTAGE

CONNECTION

BOARD

LOW VOLTAGE

WIRING

KNOCKOUT

PLUGS

LINE VOLTAGE

WIRING KNOCKOUT

PLUGS

IMG00329

Figure 5-2 Routing Field Wiring

5 Field wiring (continued)

Thermostat

1. Connect the room thermostats or end switches (isolated

contact only) to heat/loop demand 1, 2, or 3, as shown in

FIG. 5-3.

2. Install the thermostat on the inside wall away from

inﬂ uences of drafts, hot or cold water pipes, lighting

ﬁ xtures, television, sunlight, or ﬁ replaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps.

b. If connected to relays or other devices, set to match

total electrical power requirements of connected

devices. See device manufacturers’ speciﬁ cations

and thermostat instructions for details.

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from

direct sunlight or ﬂ ow of heat or cooling from other

sources.

2. Route sensor wires through a knockout at the rear of the

boiler (see FIG. 5-2).

3. Connect the outdoor temperature sensor (FIG. 5-3) to

the outdoor sensor terminals on the connection board

to enable outdoor reset operation of the Outdoor Knight

XL. If ﬁ xed temperature operation is required, do not

install outdoor sensor.

DHW (Domestic Hot Water)

thermostat

Connect storage indirect water heater (DHW) thermostat

(FIG. 5-3) to the DHW thermostat terminals on the

connection board. If a tank sensor is connected (see DHW

Tank Sensor below) the tank thermostat is ignored.

DHW tank sensor

By installing a tank sensor, the SMART SYSTEM control can

perform the tank thermostat function. The SMART SYSTEM

control automatically detects the presence of this sensor, and

generates a DHW call for heat when the tank temperature

drops 6°F (3°C) below the tank set point, and ﬁ nishes the call

for heat when the tank temperature reaches the tank set point.

The tank sensor included with the Lochinvar Squire® indirect

DHW tanks (TST20015) is the only sensor suitable for use

with the SMART SYSTEM control. Connect the sensor leads

to the Tank Sensor terminals on the low voltage connection

board (FIG. 5-3).

High gas pressure switch

1. If a switch is provided to detect excessive gas pressure,

remove the jumper wire from the terminals on the

connection board, and then connect them to its normally

closed contacts (FIG. 5-3).

Low gas pressure switch

1. If a switch is provided to detect low gas pressure, remove

the jumper wire from the terminals on the connection

board and connect them to its normally open contacts

(FIG. 5-3).

2. If both a high and low gas pressure switch is used, connect

their respective contacts in series, and connect them to the

terminals on the connection board (FIG. 5-3).

Failure to use the correct sensor may

result in the tank temperature being either

above or below the set point.

 WARNING

If TST20015 is not compatible with the indirect tank, a

tank thermostat can be used to control the boiler. The

tank thermostat should be installed per the manufacturer’s

instructions and wired to the DHW Thermostat terminals on

the low voltage connection board (FIG. 5-3).

Variable speed system pump

If a variable speed pump is used in the primary loop, and

a 0-10V signal is available from the pump speed control,

this signal can be used by the SMART SYSTEM control to

anticipate changes in the building heat load. By connecting this

0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler

(or cascade) can modulate up and down as the primary ﬂ ow

increases and decreases.

Boiler pump speed output

This 0 - 10V output is available to control the speed of a variable

speed boiler pump. The SMART SYSTEM control will vary the

speed of this pump in order to maintain a minimum T across

the heat exchanger, as well as prevent high limit lockouts when

the ﬂ ow in the primary loop is extremely low. Connect this

output to the 0 - 10V input on the boiler pump speed control.

Rate output

This output provides a 0 - 10V signal that is proportional to the

ﬁ ring rate of the boiler. This may be used by a BMS system to

monitor the actual rate of the boiler.

Outdoor Knight XL Installation & Operation Manual

5 Field wiring

ModBus

When the optional ModBus interface module is installed, the

RS-485 ModBus cable is connected to these terminals. Use

shielded, 2-wire twisted pair cable. If desired, the shield can

be connected to ground by installing a jumper wire between

terminals 1 and 3 on connector X5 on the optional ModBus

interface module.

Flow switch

1. A ﬂ ow switch is used to guarantee ﬂ ow through the boiler

before allowing it to ﬁ re. The ﬂ ow switch must be installed

at the boiler outlet.

2. Remove the jumper wire from the terminals on the

connection board and connect these terminals to the

normally open contacts on the ﬂ ow switch (FIG. 5-3).

System supply sensor

1. By installing the system supply sensor into the supply of

the primary loop, the temperature of the system supply can

be controlled. The SMART SYSTEM control automatically

detects the presence of this sensor, and controls the boiler

ﬁ ring rate to maintain the system supply temperature to the

set point (if the outlet sensor control is currently selected).

See the Outdoor Knight XL Service Manual for instructions

on how to use the inlet sensor as the controlling sensor.

When the inlet sensor is programmed as the controlling

sensor, it is vital that the SYSTEM SUPPLY sensor be

installed. DO NOT INSTALL THE SYSTEM SUPPLY

SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be used

for the system sensor.

3. Connect these terminals to the system supply sensor

(FIG. 5-3).

Alarm contacts

The SMART SYSTEM control closes another set of contacts

whenever the boiler is locked out or the power is turned off.

This can be used to turn on an alarm, or signal a Building

Management System that the boiler is down.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one

boiler as the Leader boiler. The remaining boilers will be

designated as Members. See page 36 “Conﬁ guration of the

Cascade” for a detailed explanation of this procedure.

Connect the system supply sensor and outdoor air sensor (if

used) to the Leader boiler. For the Cascade system to work

properly the system supply sensor must be installed. The

location of the system supply sensor should be downstream

of the boiler connections in the main system loop (FIG.’s 3-7

through 3-11). The system supply sensor should be wired to

the Low Voltage Connection Board at the terminals marked

for the system sensor (see FIG. 5-3). The Leader control will

use the water temperature at the system supply sensor to

control the operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be

wired to the Low Voltage Connection Board at the terminals

marked for the outdoor air sensor (FIG. 5-3). If the outdoor

air sensor is connected, the Leader control will calculate the

water temperature set point based on the programmed reset

curve parameters. If the outdoor air sensor is not connected,

the Leader control will maintain the ﬁ xed water temperature

set point that is programmed into the control.

If a Thermostat or Zone Control enable output is available,

it should be wired to the Low Voltage Connection Board

on the Leader boiler at the terminals marked for one of the

heat/loop demands 1-3 (FIG. 5-3). If the boilers are to run

continuously, connect a jumper wire between the R and W

terminals for the heat/loop demand input. This will initiate a

call for heat on the Cascade.

Communication between the Leader boiler and the Member

boilers is accomplished by using shielded, 2-wire twisted pair

communication cable. Connect one of the twisted pair wires

to Cascade terminal A on each of the Low Voltage Connection

boards, and the other wire of the twisted pair to Cascade

terminal B on each of the Low Voltage Connection Boards.

Connect the shield wires to one of the shield terminals on

the Low Voltage Connection Boards (FIG. 5-3). If more than

two boilers are on the Cascade, daisy chain the wiring from

the Cascade terminals on the second boiler to the Cascade

terminals on the third boiler, then from the third to the forth,

and so on. The connections between boilers can be made in

any order, regardless of the addresses of the boilers. Try to

keep each cable as short as possible.

Boiler management system

1. An external control may be connected to control either

the ﬁ ring rate or the set point of the boiler. If the

external control uses a set of contacts to enable the boiler,

connect the contacts to the heat/loop demand 1 terminals.

Otherwise, the SMART SYSTEM control will be enabled by

the 0-10V signal.

2. Make sure the (-) terminal is connected to the (-) or

common output terminal of the external control, and

the (+) terminal is connected to the 0 - 10 VDC or (+)

terminal of the external control. Make sure that the (-)

voltage is not below ground.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts

whenever the burner is running. This is typically used by

Building Management Systems to verify that the boiler is

responding to a call for heat.

5 Field wiring (continued)

Figure 5-3 Low Voltage Field Wiring Connections

FLOW SWITCH

TANK THERMOSTAT

ROOM THERMOSTAT 3

SYSTEM SUPPLY SENSOR

BUILDING

MANAGEMENT

SYSTEM

COM

LOW WATER

CUTOFF OUTDOOR SENSOR

TANK SENSOR

SHIELD SHIELD

BOILER

FROM

BOILER

ROOM THERMOSTAT 1

ROOM THERMOSTAT 2

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

WIRE AS

NEEDED

SYSTEM PUMP

SPEED

CONTROL

BOILER

PUMP

IMG00127

Outdoor Knight XL Installation & Operation Manual

6 Condensate disposal

Condensate drain

1. This boiler is a high efﬁ ciency appliance that produces

condensate.

2. The side of the boiler has a 1/2 inch (12.7 mm) PVC

union for connection of a 1/2 inch (12.7 mm) PVC pipe

(FIG. 6-1).

3. Slope condensate tubing down and away from the boiler

into a drain or condensate neutralizing ﬁ lter. Condensate

from the Outdoor Knight XL will be slightly acidic

(typically with a pH from 3 to 5). Install a neutralizing

ﬁ lter if required by local codes.

A Neutralizer Kit (FIG. 6-1) is available from the factory

(KIT3087 for Models 400 - 501 and KIT3046 for Models

601 - 801).

4. Install the 1/2 inch (12.7 mm) PVC tee assembly (shipped

with the unit) as shown in FIG. 6-1.

5. Leave the top of the 1/2 inch (12.7 mm) tee OPEN. This

is needed as a vacuum break.

6. Do not expose condensate line to freezing temperatures.

Precautions should be taken to protect the condensate

management and disposal system during extended

periods of outdoor temperatures below 32°F.

7. Use only plastic tubing or piping as a condensate drain

line (FIG. 6-1).

Use materials approved by the authority

having jurisdiction. In the absence of other

authority, PVC and CPVC pipe must comply

with ASTM D1785 or D2845. Cement and

primer must comply with ASME D2564 or

F493.

8. A condensate removal pump is required if the boiler is

below the drain. When installing a condensate pump, select

one approved for use with condensing boilers and furnaces.

The pump should have an overﬂ ow switch to prevent

property damage from condensate spillage. The switch

should be wired in series with the blocked drain switch

inside the boiler (see FIG. 7-1 on page 34).

NOTICE

NOTICE To allow for proper drainage on large

horizontal runs, a second line vent may

be required and tubing size may need to

increase to 1 inch (25 mm).

The condensate line must remain

unbstructed, allowing free ﬂ ow of condensate.

If condensate is allowed to freeze in the line

or if the line is obstructed in any other

manner, condensate can exit from the boiler

tee, resulting in potential water damage to

property.

1/2" PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

NEUTRALIZER KIT

FLOOR DRAIN OR

DRAIN PAN 1/2" PVC UNION

(FACTORY SUPPLIED)

IMG00331

Figure 6-1 Condensate Disposal

KIT3087 shown for illustration purposes.

7 Start-up

Check/control water chemistry

Do not use petroleum-based cleaning or

sealing compounds in the boiler system.

Damage to elastomer seals and gaskets

in the system could occur, resulting in

substantial property damage.

Hardness less than 7 grains

1. Consult local water treatment companies for hard water

areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not ﬁ ll boiler or operate with water containing

chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable

since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or

spa water.

Test/replace freeze protection ﬂ uid

1. For systems using freeze protection ﬂ uids, follow ﬂ uid

manufacturer’s instructions.

2. Freeze protection ﬂ uid must be replaced periodically due

to degradation of inhibitors over time. Follow all ﬂ uid

manufacturer’s instructions.

Freeze protection (when used)

1. Determine freeze protection ﬂ uid quantity using

system water content, following ﬂ uid manufacturer’s

instructions. Boiler water content is listed on page 7.

Remember to include expansion tank water content.

2. Local codes may require a backﬂ ow preventer or actual

disconnect from city water supply.

3. When using freeze protection ﬂ uid with automatic ﬁ ll,

install a water meter to monitor water makeup. Freeze

protection ﬂ uid may leak before the water begins to

leak, causing concentration to drop, reducing the freeze

protection level.

4. The freeze protection set points may be lowered when

freeze protection ﬂ uid is used (see the Outdoor Knight

XL Service Manual).

Fill and test water system

1. Fill system only after ensuring the water meets the

requirements of this manual.

2. Close manual and automatic air vents and boiler drain

valve.

Eliminate all system leaks. Continual

fresh makeup water will reduce boiler life.

Minerals can build up in the heat exchanger,

reducing heat transfer, overheating the heat

exchanger, and causing heat exchanger

failure.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve (see purge/drain

valves, in piping diagrams on page 22). Route the

hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between

the purge valve and ﬁ ll connection to the system.

c. Close zone isolation valves.

d. Open quick-ﬁ ll valve on cold water makeup line.

e. Open purge valve.

f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air.

Run until no noticeable air ﬂ ow is present. Close the

zone isolation valves and proceed with the next zone.

Follow this procedure until all zones are purged.

g. Close the quick-ﬁ ll water valve and purge valve and

remove the hose. Open all isolation valves. Watch

that system pressure rises to correct cold-ﬁ ll

pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located

throughout the system.

i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time,

beginning with the lowest ﬂ oor. Close the vent when

water squirts out. Repeat with remaining vents.

2. Open automatic air vent (diaphragm-type or bladder-

type expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest ﬂ oor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Reﬁ ll to correct pressure.

3. Fill to correct system pressure. Correct pressure will vary

with each application.

a. The minimum cold water ﬁ ll pressure for a

commercial system is 12 psi (82.7 kPa).

b. Pressure will rise when boiler is turned on and

system water temperature increases.

4. At initial ﬁ ll and during boiler startup and testing, check

system thoroughly for any leaks. Repair all leaks before

proceeding further.

 WARNING

 CAUTION

Outdoor Knight XL Installation & Operation Manual

7 Start-up

Outdoor Knight XL Installation & Operation Manual

Check for gas leaks

Before starting the boiler, and during

initial operation, smell near the ﬂ oor 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 ﬁ eld 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.

Propane boilers only – Your propane

supplier mixes an odorant with the propane

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

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/ﬁ ll condensate system

Inspect/check condensate lines and ﬁ ttings

1. Inspect the condensate drain line, condensate PVC

ﬁ ttings 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.

The condensate trap (FIG. 7-1) must be

ﬁ lled with water during all times of boiler

operation to avoid ﬂ ue gas emission from

the condensate drain line. Failure to ﬁ ll

the trap could result in severe personal

injury or death.

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

TO FLOOR

DRAIN

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

Figure 7-1 Condensate Trap

 WARNING

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

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.

 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

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)?

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 gas piping

1. Check around the boiler for gas odor following the

procedure on page 46 of this manual (connecting gas

supply piping).

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.

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the

Propane Conversion instructions.

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 ﬁ eld 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.

Check ﬂ ame 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.

 WARNING

 WARNING Outdoor Knight XL boilers are typically

shipped ready to ﬁ re 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 oriﬁ ce or by making a gas

valve adjustment (see page 12). In order

to operate on LP gas, an oriﬁ ce 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.

Outdoor Knight XL Installation & Operation Manual

7 Start-up

Outdoor Knight XL Installation & Operation Manual

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury, or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which

automatically lights the burner. Do not try

to light the burner by hand.

B. BEFORE OPERATING smell all around

the appliance area for gas. Be sure to

smell next to the floor because some gas

is heavier than air and will settle on the

floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do

not use any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

C. Use only your hand to turn the gas control knob.

Never use tools. If the handle will not turn by

hand, don’t try to repair it, call a qualified service

technician. Force or attempted repair may result

in a fire or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified

service technician to inspect the appliance and

to replace any part of the control system and

any gas control which has been under water.

• If you cannot reach your gas supplier, call

the fire department.

1. STOP! Read the safety information

above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the

appliance.

4. This appliance is equipped with an

ignition device which automatically lights

the burner. Do not try to light the burner

by hand.

5. Remove top cover.

6. Turn gas shutoff valve counterclockwise

to “OFF”. Handle will be perpendicular to

pipe. Do not force.

7. Wait five (5) minutes to clear out any gas.

If you then smell gas, STOP! Follow “B”

in the safety information above on this label.

If you don’t smell gas, go to next step.

8. Turn gas shutoff valve clockwise to “ON”.

Handle will be parallel to pipe.

9. Install top cover.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and

call your service technician or gas supplier.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance

if service is to be performed.

3. Remove top cover.

4. Turn gas shut off valve counterclockwise to

“OFF”. Handle will be perpendicular to pipe.

Do not force.

5. Install top cover.

LBL2284 REV -

TO TURN OFF GAS TO APPLIANCE

OPERATING INSTRUCTIONS

Figure 7-2 Operating Instructions

7 Start-up (continued)

Check ﬂ ame and combustion (continued)

4. Place the boiler into the active position by pressing the

RIGHT SELECT [ON] key (FIG. 8-1, page 43).

5. Locate the pinhole button below the RESET button on

the display board (FIG. 8-1). Insert a thin wire (such as

a paper clip) into the hole and press the button once

and hold for 5 seconds to place the boiler into Service

Mode. In Service Mode the boiler will ﬁ re at ignition

speed and will then modulate up to full ﬁ re.

6. Once the boiler has modulated up to full ﬁ re, measure

the combustion. The values should be in the range

listed in Table 7A below. The CO levels should be less

than 150 ppm for a properly installed unit.

If the combustion is not within the speciﬁ ed range,

reference the Troubleshooting Section of the Outdoor

Knight XL Service Manual for possible causes and

corrective actions.

Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be

based on one of three sensors; the inlet, outlet, or system

supply sensor. The SMART SYSTEM control is programmed

at the factory to control the temperature of the outlet

sensor. The control will automatically switch to the system

supply sensor once it is connected. If it is desired to base

the temperature control on the inlet sensor, the appropriate

parameter must be changed in the control. See the Outdoor

Knight XL Service Manual for a detailed explanation of this

procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system pump

(if connected), and the boiler pump. When the SMART

SYSTEM control receives a space heating call for heat, it turns

on the system pump. If the boiler is not heating an indirect

DHW (Domestic Hot Water) tank, and the set point is not

met, it also turns on the boiler pump. After the space heating

call for heat ends, the system pump continues to run for a

short period of time. The system pump can be programmed

to run continuously, except during outdoor shutdown. If

the boiler pump was running, it continues to run for a short

period of time as well. These pump delays are factory set to

30 seconds. If different delays are desired, the appropriate

parameters in the control must be changed. See the Outdoor

Knight XL Service Manual for a detailed explanation of this

procedure.

Adjust set point temperature(s)

Table 7A Flue Products Chart

7. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff

valve to the OFF position and ensuring that the boiler

shuts down and registers an alarm. Turn the manual

shutoff switch to the ON position and reset the control.

8. Place the boiler back into normal operation.

Natural Gas Propane

CO2O2CO2O2

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

Please note that the brackets ([]) denote

screen status.

NOTICE

The NAVIGATION dial may be used during normal

operation to adjust the space heating and tank set point

temperatures.

1. From the Status Screen press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select

the appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the

RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to

additional set points.

6. Press the RIGHT SELECT [HOME[ key to upload the

changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the

new settings will be discarded.

Outdoor Knight XL Installation & Operation Manual

7 Start-up

Outdoor Knight XL Installation & Operation Manual

Set domestic hot water (DHW) operation

Verify DHW mode

There are two (2) modes of operation for DHW. In Normal

Mode, when a DHW demand begins, the control will start

the DHW pump, turn off the boiler pump (if running), and

modulate to bring the outlet temperature to the DHW boiler

set point. The maximum ﬁ ring rate may be limited in this

mode if desired.

In Zone Mode it is assumed that the indirect DHW tank is

piped as a zone on the primary loop. When a DHW demand

begins, the control will turn on the DHW pump output, and

raise the system temperature set point to the DHW boiler set

point (if higher). The boiler pump will be turned on. The

system pump may be forced on, forced off, or not changed,

depending on the System Pump Mode selected (reference

the Outdoor Knight XL Service Manual for details). In this

mode, any low temperature zones (such as radiant heating)

may need additional controls to limit the water temperature

sent to those zones.

Set DHW boiler target temperature

When in the DHW Mode, the control will modulate to

maintain the boiler outlet temperature or system supply

temperature to a set point. This set point is set at the factory

to 180°F. If a different set point is desired, the appropriate

parameter in the control must be changed. See the Outdoor

Knight XL Service Manual for a detailed explanation of this

procedure.

Set maximum DHW fan speed

If the rated input of the indirect tank is less than the maximum

output of the boiler, change the maximum DHW fan speed

setting to limit the boiler output accordingly, see the Outdoor

Knight XL Service Manual for a detailed explanation of this

procedure.

NOTICE The internal clock does not adjust for

Daylight Savings Time and therefore, will

require a manual adjustment.

Conﬁ guration of the cascade

7. Turn the NAVIGATION dial to adjust the minutes. Press

the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press

the NAVIGATION dial.

9. Turn the NAVIGATION dial to adjust the date. Press the

NAVIGATION dial.

10. Turn the NAVIGATION dial to adjust the year. Press the

RIGHT SELECT [SAVE] key.

11. Press the RIGHT SELECT [HOME] key.

Please note that the brackets ([]) denote

screen status.

NOTICE

Set clock

When installed in a Cascade system, the individual controls must

be programmed for cascade operation. This is accomplished by

accessing the control parameters.

Press the [MENU] key for at least ﬁ ve (5) seconds. Input the

Installer code as described in the Outdoor Knight XL Service

Manual. Once the control parameters have been accessed,

use the NAVIGATION DIAL to select the Control Mode

parameters. Press the NAVIGATION DIAL to access these

parameters.

Rotate the NAVIGATION dial to select the parameter “Cascade

Address”. Press the NAVIGATION dial to access this parameter.

Each appliance in the Cascade system must be programmed

with its own address. The boiler designated as the Leader will

have an address of 0. The remaining boilers in the Cascade

will be Members and have addresses from 1 - 7. Rotate the

NAVIGATION dial to select the appropriate address. Press the

RIGHT SELECT [SAVE] key.

Press the RIGHT SELECT [HOME] key to upload the address

into the control. Repeat this procedure for all boilers in the

Cascade, designating the Leader control and the Member

controls.

Please note that the brackets ([]) denote

screen status.

NOTICE

The SMART SYSTEM control has a built-in clock that it

uses for its night setback feature and for logging events. This

clock must be set when the boiler is installed, and anytime the

boiler has been powered off for more than 4 hours. Use the

following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at

least 5 seconds.

2. The display changes to read [PASSWORD],

with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and

date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press

the NAVIGATION dial.

The clock is automatically updated whenever a PC is connected

and the Win_Pro-Installer program is started.

8 Operating information

General

How the boiler operates

The Outdoor Knight XL uses an advanced stainless steel heat

exchanger and electronic control module that allows fully

condensing operation. The blower pulls in air and pushes ﬂ ue

products out of the boiler through the heat exchanger and

ﬂ ue piping. The control module regulates blower speed to

control the boiler ﬁ ring rate. The gas valve senses the amount

of air ﬂ owing into the boiler and allows only the right amount

of gas to ﬂ ow.

How the control module operates

The SMART SYSTEM control module receives inputs from

boiler sensors and external devices. The control module

activates and controls the blower and gas valve to regulate

heat input and switches the boiler, Domestic Hot Water

(DHW), and system pumps on and off as needed. The user

programs the module to meet system needs by adjusting

control parameters. These parameters set operating

temperatures and boiler operating modes. Boiler operation

can be based on boiler outlet water temperature, boiler inlet

water temperature, system temperature, a 0 - 10V signal, or

Modbus, depending on the parameter settings.

Control inputs and outputs

Room thermostat

There are three (3) heat/loop demand connections available

on this control. These inputs tell the boiler to provide water

for space heating. Each demand connection has its own set

point and outdoor air reset curve. When multiple demands

have a call for heat the control will give priority to the demand

with the highest set point.

Example: Assume that both heat/loop demand 1 and heat/

loop demand 2 have a call for heat. Demand 1 has a set point

of 110°F. Demand 2 has a set point of 140°F. The boiler will

regulate the system temperature to 140°F until Demand 2 has

been satisﬁ ed. Once Demand 2 has been satisiﬁ ed the boiler

will provide 110°F water to the system.

SMART SYSTEM Multi-temp loop control

The Outdoor Knight XL boiler is capable of producing up

to three (3) set point temperatures to meet different space

heating demands. This device controls the temperatures

of up to three (3) separate loops, based on the settings for

the three (3) heat/loop demands (reference Lochinvar kit

RLY30086).

0 - 10V input (set point or power)

The Outdoor Knight XL can be controlled by a Building

Management System (BMS) using a 0 - 10 VDC signal. The

control can be conﬁ gured by the installer to use this signal to

either control set point or ﬁ ring rate.

The Outdoor Knight XL can also be programmed to accept a

call for heat from a 0 - 10V signal, reference the Outdoor Knight

XL Service Manual for a detailed explanation of this procedure.

DHW priority

The SMART SYSTEM control allows the connection of a DHW

thermostat or tank sensor to the low voltage connection board.

When a tank sensor is connected, the DHW thermostat input

is ignored. When a boiler is programmed for DHW Normal

Mode, the maximum ﬁ ring rate can be limited to match the

input rating of the indirect tank coil.

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is

in progress, and the DHW is in Normal Mode, the control will

start the DHW pump and shut the boiler pump off. The system

pump will remain on. For stand-alone boilers, if the space

heating call is still active while the DHW call is in operation, the

control will wait for 30 minutes (time adjustable by installer)

then it will switch back to the space heating demand. There is

a timer to switch from space heating to DHW and a timer to

switch from DHW to space heating. The control will switch

back and forth until one of the heat demands end. This function

does not apply to cascade systems.

Programmable controlling sensor

The control module is programmed to use the outlet sensor

as the control sensor by default. If a system supply sensor is

connected, the control automatically uses it as the control

sensor. For stand-alone boilers, the control sensor can be

changed by the installer to the inlet sensor. If the inlet sensor

is chosen as the controlling sensor, it is recommended that the

system supply sensor be installed in the system supply in order

to provide the best control of the inlet temperature.

Anti-cycling

After the burner turns off, the control will delay the next burner

cycle for a set time period (time is adjustable by the installer).

The time delay will be bypassed if the inlet water temperature

drops too far during the delay.

Boiler and system pump control

The boiler pump will run whenever the burner is ﬁ ring, unless

the DHW is programmed for Normal Mode and the boiler is

heating the DHW tank. The boiler pump will run during Freeze

Protection Mode as well. It will continue to run for a short time

after the burner turns off or the Freeze Protection Mode ends.

The system pump will run whenever there is a space heating call

for heat, or the boiler goes into Freeze Protection Mode. It may

be programmed to run during a DHW call for heat when the

DHW is programmed for Zone Mode. It will continue to run

for a short time after the end of the heat demand or the Freeze

Protection Mode. The system pump can be programmed to run

continuously if desired, except during outdoor shutdown and/

or a DHW call for heat.

 CAUTION When multiple temperature loops are

used, mixing valves are required for the

protection of any low temperature loops.

Outdoor Knight XL Installation & Operation Manual

8 Operating information

Outdoor Knight XL Installation & Operation Manual

Temperature control

Modulation

The Outdoor Knight XL is capable of modulating its ﬁ ring

rate from a minimum of 20% to a maximum of 100%. The

ﬁ ring rate is dictated by the call for heat (i.e., space heating

or domestic hot water), the heating load, ramp delay (if

enabled), and various other temperature limitations.

Ramp delay

For systems with lower ﬂ ow, the SMART SYSTEM can

limit the ﬁ ring rate (when enabled) when a space heating

call for heat starts, or when switching from a DHW call for

heat to a space heating call for heat. There are six (6) limits

that can be programmed, as well as six (6) time intervals

corresponding to each limit. The sixth limit will also limit

the ﬁ ring rate for the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature

is rising too quickly, the control will reduce the ﬁ ring rate

to its lowest setting.

Outdoor air reset

If an outdoor air sensor is connected, the control module

will calculate the set points of the three (3) space heating

demands based on the programmed reset curves. The

installer can change the slope of the reset curves by several

adjustable parameters. The user can limit the maximum

set point for the system using the space heating set points.

Boost function

If outdoor air reset is active, and any space heating

demand has been active continuously for a set period of

time (time adjustable by installer) and there has been no

DHW demands, the control will increase the set point of

that demand by a ﬁ xed number of degrees (adjustable by

installer). This process will continue until the space heating

demand ends, the set point reaches the programmed set

point or a maximum of 20 increases has occurred. Once the

system heat demand is satisﬁ ed, the set point will revert to

the value determined by the reset curve.

Night setback

The controller may be programmed to reduce the space

heating and DHW set points during certain times each week.

Seven different start and stop times may be programmed

for the space heating setback and seven start and stop times

for the DHW setback.

Flame current support

To prevent nuisance shutdowns when the boiler is ﬁ ring

at minimum rates, the control will increase the ﬁ ring rate

when the ﬂ ame signal drops too low.

Protection features

Outlet temperature, ﬂ ue temperature, and temperature

rise limiting

The outlet temperature is monitored by the boiler outlet

temperature sensor. When the outlet temperature exceeds

185°F, the unit will reduce the fan speed. If the outlet water

temperature exceeds 195°F (90°C) the control will shut the unit

down until it cools off.

The control module monitors the ﬂ ue temperature by a sensor

located in the ﬂ ue exhaust. If the ﬂ ue temperature exceeds

215°F (102°C) the control will reduce the maximum fan speed.

If the ﬂ ue temperature exceeds 240°F (115°C) the control will

shut the unit down. The unit will restart automatically once the

ﬂ ue temperature drops 25°F (-4°C) and the minimum off time

has expired.

The control monitors the temperature difference between

the inlet and the outlet sensor. If this difference exceeds 55°F

(13°C) the control will reduce the maximum fan speed. If the

temperature difference exceeds 60°F (15°C) the control will

shut the unit down. The unit will restart automatically once the

temperature difference has dropped below 55°F (13°C) and the

minimum off time has expired.

Freeze protection

DO NOT install the boiler in a location where it is likely to

freeze.

The following integral feature of the SMART SYSTEM control

module provides some protection for the boiler only -- not for

the system.

• The SMART SYSTEM control module provides

freeze-up protection as follows when the boiler

water temperature drops below 45°F (7°C):

• Below 45°F (7°C), the boiler and system pumps

operate constantly.

• Below 37°F (3°C), the boiler turns on.

• Boiler and pumps turn off if boiler water

temperature rises above 45°F (7°C).

• Lower temperatures may be programmed for systems

with anti-freeze solutions.

This feature of the SMART SYSTEM

control module does not eliminate the

possibility of freezing. The installation must

still use recognized design, installation and

maintenance practice to prevent freeze

potential for the boiler and system.

 CAUTION

NOTICE When system return temperatures

are maintained below the dew point,

condensation will form on the inside of the

boiler jacket causing some internal sheet

metal components to rust.

8 Operating information (continued)

Monitor external limits

Connections are provided on the connection board for

external limits such as ﬂ ow switch, low water cutoff and

gas pressure switches. The SMART SYSTEM will shut off

the burner and inhibit relighting whenever any of these

external limits open.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the

boiler is running, and when it is unable to operate.

Run-time and cycle counting

The control uses two timers to monitor the total hours of

burner operation. One timer monitors the time the boiler

is in the Space Heating Mode. The other timer monitors

the time the boiler is ﬁ ring in the DHW Mode.

The control uses two (2) ignition counters to monitor

the amount of boiler cycles. The ﬁ rst counter counts all

ignitions of the control. The second counter counts only

ignition attempts that have failed.

Service reminder

The control can be programmed for service reminder

notiﬁ cation. This notiﬁ cation will become active when

either a set time frame has expired, or a set amount of

running hours or cycles has expired (all adjustable by the

installer). The display will show a Maintenance Required

screen. The installer’s name and phone number can be

programmed into the control. This information will appear

on the Maintenance Required screen. The service reminder

notiﬁ cation can be reset or disabled by the installer.

The time dependent feature has been disabled by the

manufacturer. To enable this feature change the parameter

to the desired time interval, reference the Outdoor Knight

XL Service Manual for details regarding parameters.

Error logging

The control will hold in memory the last 10 lockouts as

well as the last 10 blockings. The date and time of the

occurrence will be recorded as well. Only the 10 most

current occurrences of each will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water

temperature and regulates boiler ﬁ ring and ﬁ ring rate to

achieve a target temperature. The target temperature can

be set between 70°F (21°C) and 190°F (88°C).

• Target temperature is ﬁ xed when the outdoor

sensor is not installed.

• Target temperature is calculated as described

on this page under “Outdoor Reset Operation”

and “Target Temperature Boost” when the

outdoor sensor is connected.

High limit operations

The Outdoor Knight XL is equipped with adjustable automatic

reset and manual reset high limits. The automatic reset high

limit has a maximum set point of 200°F and the manual reset

high limit has a maximum set point of 210°F.

When the outlet temperature exceeds 200°F, the automatic

high limit action occurs. The boiler shuts down until the outlet

water temperature cools below 190°F, and a 60 second timer

has expired. If the outlet temperature continues to increase, the

manual reset high limit action will occur at 210°F.

High limit test procedure

1. Turn ON the main power to the boiler by placing the

ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to

access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating

the NAVIGATION dial counterclockwise, then press

the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current

outlet temperature (or to its minimum setting, whichever

is higher) by turning the NAVIGATION dial

counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new

parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL

set point, the MRHL will function causing boiler lockout.

If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL

set point, locate the pinhole (SERVICE button) below the

RESET button on the display board. Insert a thin probe

(such as a paper clip) into the hole and press the button

continuously for ﬁ ve (5) seconds to place the boiler into

Service Mode. In Service Mode, the boiler will ﬁ re at

ignition speed and will then modulate up to full ﬁ re.

10. Once the outlet temperature rises up to the MRHL set

point, the MRHL will function, causing the boiler to shut

down and lock out.

11. Repeat Steps 2, 3 and 4.

12. Set the MRHL to the appropriate set point by turning the

NAVIGATION dial clockwise.

13. Repeat Steps 6 and 7.

14. Press the RESET button to clear the lockout.

15. If needed, press the RIGHT SELECT [STOP] key to exit

Service Mode.

Please note that the brackets ([]) denote

screen status.

NOTICE

Outdoor Knight XL Installation & Operation Manual

8 Operating information

Outdoor Knight XL Installation & Operation Manual

Outdoor reset operation, if used

Target temperature with outdoor reset

This feature improves the system’s efﬁ ciency as the outdoor

temperature warms up.

See the Outdoor Knight XL Service Manual to change the

settings.

Reset curve

The reset curves look at outdoor air temperature and adjusts

the set points.

Cascade

When multiple boilers are installed, they can be wired

together in a cascade sequence. A maximum of eight boilers

can be controlled from a single control. In this application

one boiler would be designated as the Leader control and all

others would be designated as Member controls. The Leader

control can be programmed to use Lead/Lag or Efﬁ ciency

Optimization control methods.

Once the Leader boiler receives a call for heat from a room

thermostat, BMS, or Modbus, the control will determine what

the set point will be. If outdoor air reset is desired, connect

the outdoor air sensor to the terminals on the Low Voltage

Connection Board on the Leader boiler. The set point will be

calculated based on the programmed reset curve parameters.

See the Outdoor Knight XL Service Manual to program the

reset curve. If outdoor air reset is not desired, do not connect

the outdoor air sensor. A ﬁ xed temperature set point can be

programmed into the control. See page 59 of this manual to

program the set point.

If the water temperature at the system supply sensor is less

than the set point + the turn-off offset - the off-on differential,

then the control will initiate a call for heat on the Cascade

(see the Outdoor Knight XL Service Manual for an explanation

of the offset and differential). The Leader will energize the

lead boiler on the Cascade. For a new startup this will be the

Leader boiler.

DHW, Night Setback, and Ramp Delay operation with

cascade

For normal mode DHW operation any boiler(s) in the Cascade

can be selected to provide heat for a DHW call. Select a boiler to

be designated as the DHW boiler. Connect the DHW thermostat

or sensor to the terminals on the Low Voltage Connection

Board marked for the corresponding device. When the boiler

receives a DHW call, the Leader control will take that boiler

out of the Cascade sequence. If another boiler is available, the

Leader will start it up to take its place.

The DHW boiler will adjust its set point to the programmed

DHW boiler set point and will adjust its ﬁ ring rate to maintain

this. Once the DHW call has been satisﬁ ed, the Leader control

will place that boiler back into the Cascade sequence.

Switching of the boiler between DHW operation and SH

operation when there is a call for both does not occur in Cascade

Mode.

When DHW is programmed for Zone Mode, connect the DHW

thermostat or tank sensor to the Leader boiler. When a DHW

call is received, the Leader will modulate the entire Cascade to

bring the system supply temperature up to the DHW boiler set

point (if higher).

Night Setback operation of the boilers within the Cascade is

available. Programming of the Night Setback will be done

through the Leader boiler. Refer to the Outdoor Knight XL

Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the Outdoor

Knight XL Service Manual is available when the boilers are part

of a Cascade system.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the ﬁ ring

sequence will automatically be changed at set intervals.

The sequence will be changed once every 24 hours. The

switching on/off sequence will be as follows:

TIME SWITCHING ON SEQUENCE

Start L-M1-M2-M3-M4-M5-M6-M7

1 hour M1-M2-M3-M4-M5-M6-M7-L

2 hours M2-M3-M4-M5-M6-M7-L-M1

If a boiler locks out or is used to heat an indirect DHW tank,

it will automatically be given the lowest priority for the rest of

that 24 hour period.

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature

sensing of both supply and return areas of the heat

exchanger. If the ﬂ ow rate is too low or the outlet

temperature too high, the control module modulates and

shuts the boiler down. This ensures boiler shutdown in

the event of low water or low ﬂ ow conditions.

2. Some codes and jurisdiction may accept these integral

features of the control in lieu of requiring an additional

limit control or low water cutoff. Consult local jurisdiction

to determine. A low water cutoff is available from the

factory (WTR30024).

8 Operating information (continued)

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns

on the appropriate pumps (system and boiler pumps for space

heating, DHW pump for DHW). The ﬂ ow switch and/or LWCO

must close.

3. The air pressure switch and blocked drain switch must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by ﬁ ring the spark

electrode and opening the gas valve.

6. If ﬂ ame is not detected after the sparking ends, the control will

perform a postpurge, then start another prepurge cycle and try

to light the burner again. On the 501 and larger models, the control

will lock out if this second attempt also fails. On the 400 model,

the control will perform a total of 4 attempts before locking out.

7. If ﬂ ame is detected, it holds the ﬁ ring rate steady for a few

seconds to let the ﬂ ame stabilize, then it begins to modulate the

ﬁ ring rate based on a set point or some other command (such

as a 0-10V BMS signal).

Outdoor Knight XL Installation & Operation Manual

8 Operating information

Outdoor Knight XL Installation & Operation Manual

OPERATION DISPLAY

8. If the space heating call for heat is active, and the tank thermostat

or sensor starts a DHW call for heat, the boiler will switch to the

DHW mode. If programmed for normal DHW operation (not as a

zone), the DHW pump will turn on ﬁ rst, then the boiler pump will

turn off (boiler and DHW pump operation brieﬂ y overlap to ensure

ﬂ ow is maintained through the unit). This will divert the boiler’s

outlet water from the heating system and send it to the tank coil

instead. The control will then modulate to maintain the outlet

temperature to the DHW boiler set point.

9. If the boiler is not part of a Cascade, and both the space heating

and DHW calls for heat remain active long enough, the boiler will

switch back and forth between the two heating modes until one of

them is satisﬁ ed.

10. Once both calls for heat are satisﬁ ed, the control will turn off

the burner.The blower will continue to run during the postpurge

period.

11. Any pumps that are running will continue to run for their respective

pump delay times before turning off, unless programmed to

remain on continuously. A 60 second anti-cycle period will start,

which will delay any new call for heat until it times out.

12. In Standby, ready to start a new cycle.

Sequence of operation (continued)

Access modes

User

The user can adjust space heating and tank target temperatures

by pressing the NAVIGATION dial when “SETPOINTS” is

ﬂ ashing at the bottom of the display. The date and time, and

the temperature units can also be changed (see page 36).

Installer

Most parameters are available only to the installer, accessible

by entering the installer password, see the Outdoor Knight XL

Service Manual.

Saving parameters (reference the Parameter Table in

the Outdoor Knight XL Service Manual)

8 Operating information (continued)

Please note that the brackets ([]) denote

screen status.

NOTICE

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the

RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the

parameter listings; press again to return to the menu listings.

Remember to press the RIGHT SELECT [HOME] key when

ﬁ nished programming in order to save the changes made.

See the Outdoor Knight XL Service Manual for a detailed

description of parameters and access modes.

Outdoor Knight XL control module

NAVIGATION DIAL

Figure 8-1 Control Panel

Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor boiler operation.

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the

NAVIGATION dial (in the center):

MENU = Left SELECT Key

SETPOINTS = NAVIGATION Dial - Pressing Down

SHDN = Right SELECT Key

Outdoor Knight XL Installation & Operation Manual

8 Operating information

Status Display Screens

Section Display Description

(Boiler Status

Bar)

STANDBY The unit has not received a call for heat from a remote thermostat nor

has it received a call for heat from a DHW thermostat.

START The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE The unit has initiated a prepurge period on a call for heat.

IGNITION The unit has begun a spark period to ignite the main burner.

The unit has ﬁ red and is running at the displayed percentage.

POSTPURGE

The call for heat has been satisﬁ ed and the unit runs the fan for an

additional postpurge period to clear the combustion chamber and

vent system of residual ﬂ ue products.

SHUTDOWN The unit has been placed in the OFF position.

The controlled temperature has exceeded its set point and its offset.

BLOCKED The unit has detected a condition that has temporarily interrupted

the current call for heat.

(Call for Heat

Indicators)

Room Thermostat 1 has a call for heat.

Room Thermostat 2 has a call for heat.

Room Thermostat 3 has a call for heat.

The tank thermostat or sensor has a call for heat.

Indicates which room thermostat demand shows priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

(BOILER

STATUS)

(OPERATIONAL

INFORMATION)

(LEFT SELECT

KEY)

(RIGHT SELECT KEY)

(NAVIGATION DIAL)

(CALL FOR

HEAT)

Figure 8-2 Status Display Screen

Outdoor Knight XL Installation & Operation Manual

8 Operating information (continued)

Status Display Screens (cont’d)

Section Display Description

(Operational

Information)

SYSTEM: The temperature read by the system supply sensor (if connected).

TANK: The temperature read by the tank sensor (if connected).

OUTDOOR: The temperature read by the outdoor sensor (if connected).

INLET TEMP: The temperature read at the inlet to the heat exchanger.

OUTLET TEMP: The temperature read at the outlet of the heat exchanger.

DELTA T: The temperature difference between the inlet and the outlet of the

heat exchanger.

FLUE TEMP: The temperature read by the ﬂ ue sensor.

FLAME CURRENT: The current measured by the ﬂ ame sense circuit.

FAN SPEED: The speed of the combustion blower.

BOILER PUMP: The status of the boiler pump output.

SYSTEM PUMP: The status of the system pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT: The speed signal received from a variable speed system pump control.

RATE OUTPUT: A 0 - 10V signal indicating the ﬁ ring rate of the boiler.

SH RUN HOURS: The total hours of operation in the Space Heating Mode.

SH CYCLES: The total burner cycles in the Space Heating Mode.

DHW RUN HOURS: The total hours of operation in the DHW Mode.

DHW CYCLES: The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:* The last 10 lockouts.

NIGHT SETBACK Shows the next Night Setback trigger (if active).

Outdoor Knight XL Installation & Operation Manual

8 Operating information

Status Display Screens (cont’d)

Section Display Description

(LEFT SELECT

key function)

MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu

Screen.

EXIT Press the LEFT SELECT key to exit the current screen or setting.

YES Press the LEFT SELECT key to conﬁ rm that the boiler needs to

shutdown.

LIMITS Press the LEFT SELECT key to enter the screen that allows you to

adjust the limit settings.

HOME Press the LEFT SELECT key to return to the Status Screen and upload

parameter changes.

SKIP Press the LEFT SELECT key when in the Night Setback Screen to

access the Night Setback Skip Screen.

(NAVIGATION

Dial Function)

Turning the NAVIGATION dial will select the next or previous Status

Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night

Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by

the cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current

setting.

(RIGHT SELECT

key function)

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME Press the RIGHT SELECT key to return to the Status Screen and

upload parameter changes.

Outdoor Knight XL Installation & Operation Manual

Maintenance and annual startup

Table 9A Service and Maintenance Schedules

Owner maintenance

(see the Outdoor Knight XL User’s Information

Manual for instructions)

Daily • Check boiler area

• Check pressure/temperature

gauge

Monthly

• Check air and vent termination

screens

• Check relief valve

• Check condensate drain system

Periodically

• Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check boiler piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

• Shut boiler down (unless boiler

used for domestic hot water)

9 Maintenance

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if

necessary;

• Clean condensate trap and ﬁ ll with fresh

water

• Check for leaks (water, gas, ﬂ ue,

condensate)

• Verify ﬂ ue and air passage ways in good

condition and sealed tight

• Check system water pressure/system

piping/expansion tank

• Check control settings

• Check ignition and flame sense

electrodes (sand off any deposits; clean

and reposition)

• Check wiring and connections

• Perform start-up checkout and performance

veriﬁ cation per Section 7.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at

high ﬁ re)

• Clean the heat exchanger if ﬂ ue temperature

is more than 54°F (30°C) above return water

temperature.

If combustion or performance

indicate need:

• Clean heat exchanger

• Remove and clean burner using

compressed air only

• Clean the blower wheel

ANNUAL START-UP

Outdoor Knight XL Installation & Operation Manual

9 Maintenance

Follow the Service and maintenance procedures given throughout this manual and in component literature

shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler

or system. Failure to follow the directions in this manual and component literature could result in severe

personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualiﬁ ed service technician. In addition, the maintenance

and care of the boiler designated in Table 9A and explained on the following pages must be performed to

assure maximum boiler efﬁ ciency and reliability. Failure to service and maintain the boiler and system could

result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as

noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,

causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct

before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials,

gasoline and other ﬂ ammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants

listed in Section 1 of this manual. If any of these are

present in the boiler intake air vicinity, they must be

removed.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of

the boiler.

2. Vacuum any sediment from inside the boiler and

components. Remove any obstructions.

Clean condensate trap

1. Inspect the condensate drain line, condensate PVC

ﬁ ttings, and condensate trap.

2. Remove the PVC cap retaining screw from the PVC cap

(FIG. 9-1).

3. Remove the 2 inch PVC cap with the switch located at the

top of the trap (FIG. 9-1).

4. Remove any sediment in the trap.

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

the drain.

6. Replace the cap. Press the cap onto the trap until the cap

makes contact with the drain.

7. Replace the retaining screw.

Eliminate all system or boiler leaks.

Continual fresh makeup water will reduce

boiler life. Minerals can build up in sections,

reducing heat transfer, overheating heat

exchanger, and causing heat exchanger

failure. Leaking water may also cause severe

property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems

found.

3. Check gas line using the procedure found in Section 4 -

Gas Connections.

Check all piping for leaks

The condensate trap must be ﬁ lled with

water during all times of boiler operation to

avoid ﬂ ue gas emission from the condensate

drain line. Failure to ﬁ ll the trap could result

in severe personal injury or death.

 WARNING

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

TO FLOOR

DRAIN

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

Figure 9-1 Condensate Trap

Outdoor Knight XL Installation & Operation Manual

9 Maintenance (continued)

Flue vent system and air piping

1. Visually inspect the entire ﬂ ue gas venting system for

blockage, deterioration or leakage.

2. Verify that boiler vent discharge and air intake openings

are clean and free of obstructions.

Failure to inspect for the above conditions

and have them repaired can result in

severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold ﬁ ll pressure for the system. Verify it is

correct (must be a minimum of 12 psi (82.7 kPa)).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high.

Excessive pressure rise indicates expansion tank sizing or

performance problem.

4. Inspect automatic air vents and air separators. Remove

air vent caps and brieﬂ y press push valve to ﬂ ush vent.

Replace caps. Make sure vents do not leak. Replace any

leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in

and out as the heating system water expands due to

temperature increase or contracts as the water cools.

Tanks may be open, closed or diaphragm or bladder

type. See Section 3 - Hydronic Piping for suggested best

location of expansion tanks and air eliminators.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify ﬂ ow.

Before operating any relief valve, ensure that it is piped

with its discharge in a safe area to avoid severe scald

potential. Read Section 3 - Hydronic Piping before

proceeding further.

Safety relief valves should be re-inspected

AT LEAST ONCE EVERY THREE YEARS,

by a licensed plumbing contractor or

authorized inspection agency, to ensure

that the product has not been affected by

corrosive water conditions and to ensure

that the valve and discharge line have not

been altered or tampered with illegally.

Certain naturally occurring conditions may

corrode the valve or its components over

time, rendering the valve inoperative. Such

conditions are not detectable unless the valve

and its components are physically removed

and inspected. This inspection must only

be conducted by a plumbing contractor

or authorized inspection agency – not by

the owner. Failure to re-inspect the boiler

relief valve as directed could result in

unsafe pressure buildup, which can result in

severe personal injury, death, or substantial

property damage.

Following installation, the valve lever must

be operated AT LEAST ONCE A YEAR to

ensure that waterways are clear. Certain

naturally occurring mineral deposits may

adhere to the valve, rendering it inoperative.

When manually operating the lever, water

will discharge and precautions must be

taken to avoid contact with hot water and

to avoid water damage. Before operating

lever, check to see that a discharge line is

connected to this valve directing the ﬂ ow

of hot water from the valve to a proper

place of disposal. Otherwise severe personal

injury may result. If no water ﬂ ows, valve

is inoperative. Shut down the boiler until a

new relief valve has been installed.

2. After following the above warning directions, if the relief

valve weeps or will not seat properly, replace the relief

valve. Ensure that the reason for relief valve weeping is

the valve and not over-pressurization of the system due to

expansion tank waterlogging or undersizing.

 WARNING

Outdoor Knight XL Installation & Operation Manual

IMG00439

SCREWS

(5)

AIR / GAS

ARM

BURNER

GASKET

Figure 9-4 Burner Assembly - Models 601 - 801

9 Maintenance

Inspect ignition and ﬂ ame sense

electrodes

1. Remove the ignition and ﬂ ame sense electrodes from the

boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/ﬂ ame

sense electrode using sandpaper. If the electrodes cannot

be cleaned satisfactorily, replace with new ones.

3. Replace ignition/ﬂ ame sense electrode, making sure

gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger

access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely

attached.

3. Check ground continuity of wiring using continuity

meter.

4. Replace ground wires if ground continuity is not

satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good

condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to

Parameter Mode and check all settings. See Section 1 of

the Outdoor Knight XL Service Manual. Adjust settings

if necessary. See Section 1 of the Outdoor Knight XL

Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and

adjust if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests speciﬁ ed in

Section 7 - Start-up.

2. Verify cold ﬁ ll pressure is correct and that operating

pressure does not go too high.

Check burner ﬂ ame

1. Inspect ﬂ ame through observation window.

2. If the ﬂ ame is unsatisfactory at either high ﬁ re or low ﬁ re,

turn off boiler and allow boiler to cool down. Remove

the burner and clean it thoroughly using a vacuum

cleaner or compressed air. Do not use compressed air to

clean burner if performed inside a building.

3. Remove the burner, reference FIG.’s 9-2 thru 9-4.

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG.’s 9-2 thru 9-4).

IMG00437

BURNER

GASKET

SCREWS

(5)

AIR / GAS

ARM

Figure 9-2 Burner Assembly - Model 400

IMG00438

SCREWS

(5)

AIR / GAS

ARM

BURNER

GASKET

Figure 9-3 Burner Assembly - Model 501

Outdoor Knight XL Installation & Operation Manual

9 Maintenance (continued)

Check ﬂ ame signal

1. At high ﬁ re the ﬂ ame signal shown on the display should

be at least 10 microamps.

2. A lower ﬂ ame signal may indicate a fouled or damaged

ﬂ ame sense electrode. If cleaning the ﬂ ame sense electrode

does not improve, ground wiring is in good condition,

and ground continuity is satisfactory, replace the ﬂ ame

sense electrode.

3. See Section 3 - Troubleshooting in the Outdoor Knight

XL Service Manual for other procedures to deal with low

ﬂ ame signal.

Review with owner

1. Review the Outdoor Knight XL User’s Information

Manual with the owner.

2. Emphasize the need to perform the maintenance schedule

speciﬁ ed in the Outdoor Knight XL User’s Information

Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor

should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown

procedure and to schedule an annual start-up at the

beginning of the next heating season.

The boiler contains ceramic fiber

materials. Use care when handling these

materials per instructions in the Service

Manual. Failure to comply could result in

severe personal injury.

 WARNING

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate

extension(s), refractory cover, and detailed instructions see

Table 9B - Heat Exchanger Cleaning Kits.

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions

for the boiler in Section 7 - Startup.

• Do not drain the boiler unless it will be exposed to

freezing temperatures. If using freeze prevention ﬂ uid

in system, do not drain.

2. Allow time for the boiler to cool to ambient temperature

if it has been ﬁ ring.

3. Remove the nuts securing the heat exchanger access cover

to the heat exchanger and set aside.

4. Remove the heat exchanger access cover, burner, and

gas/air arm assembly.

6. Use a vacuum cleaner to remove any accumulation on the

boiler heating surfaces. Do not use any solvent.

7. Brush the heat exchanger while dry using a nylon bristle

brush. Caution: DO NOT use a metal brush. Re-vacuum

the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm

water. Rinse out debris with a low pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the ﬁ eld supplied rear refractory cover from the

back of the combustion chamber of the heat exchanger and

reassemble.

11. Close isolation valves on piping to isolate boiler from

system. Attach a hose to the boiler drain and ﬂ ush boiler

thoroughly with clean water by using purging valves to

allow water to ﬂ ow through the water make-up line to the

boiler.

12. Perform start-up and check-out procedures in the Check

Flame and Combustion - Section 7 - Startup on pages 35

and 37 of this manual.

13. Replace the access cover and restore boiler to operation.

Table 9B Heat Exchanger Cleaning Kits

Model

Kit

Number Part

Number Component

Description

400 KIT30063

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20084 3mm Allen Wrench

MSC20086 1/4" x 24" Drill Extension

501 - 801 KIT30064

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20085 1/4" x 12" Drill Extension

MSC20086 1/4" x 24" Drill Extension

* Do NOT use a metal brush. Only use

the kit provided brush or an equivalent

replacement nylon brush.

 CAUTION

NOTICE Rope gasket is intended for sealing combustion

(FIG. 9-5). If damaged DO NOT reuse, the

heat exchanger door must be replaced. Consult

factory for replacement heat exchanger door

(kit WTR3080 and WTR3086).

ROPE GASKET

CAUTION: IF GASKET IS DAMAGED

DO NOT REUSE, THE HEAT EXCHANGER DOOR

MUST BE REPLACED.

Figure 9-5 Rope Gasket - Heat Exchanger Door

5. Remove the condensate hose from the heat exchanger

end. Connect a ﬁ eld supplied 3/4" diameter hose to

a drain pan. Using ﬁ eld supplied means, cover the

refractory in the back of the combustion chamber of the

heat exchanger.

Outdoor Knight XL Installation & Operation Manual

Figure 10-1 Wiring Diagram

10 Diagrams

X1-7

CN2-4

CN2-1

CN1-5

CN1-6

CN1-3

CN1-4

CN1-1

CN1-2

RELAY

BOARD

ON/OFF

SWITCH

JUNCTION

BOX

1 2 3 4 5

RW3.5A

KB 801

ONLY

BLOWER

-T

HIGH LIMIT SENSOR S1b

OPERATING SENSOR S1a

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

INTEGRATED

CONTROL

GAS VALVE

@24VAC

SPARK

ROD

TRANSFORMER

TR2 G

HIGH VOLTAGE SPARK LEAD

CAUTION

FLAME SENSOR

P/BK

W/R

X1-3

X1-4

X1-2

X1-6

X1-5

X1-8

X1-1

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

O-TEMP HEX SW

BLOCKED DRAIN SWITCH

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

diagrams to troubleshoot unit. WIRING DIAGRAM

LBL20116 REV E

BOX DEPICTS

OPTIONAL ITEMS

CN2-2

CN2-3

DHW

PUMP

BOILER

PUMP

SYSTEM

PUMP

120V

SUPPLY

GND

X-7

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

MODBUS BOARD

MTR-01

X6-3

X6-2

X6-1

X6-4

X9-1

X9-2

X9-3

X9-4

X4-1

X4-2

X4-3

X4-4

X5-1

X5-2

X1-1

X1-2

X1-3

RBLG

-T

SHIELD

GROUNDING

JUMPER

R/BK

W/BK

1 2

HIGH VOLTAGE

LOW VOLTAGE

120 VAC

AIR PRESSURE SWITCH

O/BK

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

CASCADE A

SHIELD

0-10V

BMS

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS

OPTION

SHIELD

LOW

WATER

CUT-OFF

24 VAC

COM

CN7-1

CN7-2

CN7-3

CN7-4

CONNECTION BOARD

CN8-1

CN8-2

CN8-3

RBLG

BELL JUMPER

ALARM BELL

SILENCING SWITCH

HEAT/LOOP

DEMAND 3

HEAT/LOOP

DEMAND 2

HEAT/LOOP

DEMAND 1

CN5-1

CN5-8

CN5-2

CN5-9

CN5-3

CN5-10

CN5-11

CN5-4

CN5-5

CN5-14

CN5-12

CN5-6

CN5-13

CN5-7

CN6 X6

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

Outdoor Knight XL Installation & Operation Manual

Figure 10-2 Ladder Diagram

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM

LBL20141 REV D

24 VAC

CN5-6

CN5-12

CN5-11

X4-2

X4-10

X4-11

INTEGRATED

CONTROL

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH CN5-4 X4-4

X2-1

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

TR2

X1-7

FLAME ROD

SPARK

ROD

CAUTION HIGH VOLTAGE SPARK LEAD

BLOWER

CONNECTION

BOARD

INLET

SENSOR

OPERATING

SENSOR

FLUE

SENSOR

INTEGRATED

CONTROL

RUN-TIME

CONTACTS

RIBBON CABLE

SYSTEM

SENSOR

TANK

SENSOR

OUTDOOR

SENSOR

0-10V

CASCADE A

SHIELD

SILENCING

SWITCH

ALARM

BELL

BMS

CN6 X6

CN5-2 X4-6

CN5-9 X4-13

CN5-1 X4-7

CN5-8 X4-14

CN6 X6

HIGH LIMIT

SENSOR

FLUE

SENSOR

X5-4

X5-12

X5-5

X5-13

X5-14

X5-6

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS A

SHIELD

CN6 X6

CN8-1 X6-1

CN8-2 X6-2

CN8-3 X6-3

X4-1 X9-2

X4-2 X9-1

X4-3 X9-3

PC INTERFACE

S1a

S1b

S3a

S3b

ALARM

CONTACTS

X2-2

NOTES:

1. Where possible, switches are shown without utilities (gas, water or

electricity) connected to the unit. As such, actual switch states may

vary from those shown on diagrams depending upon whether utilities

are connected or a fault condition is present.

2. See wiring diagram for additional notes.

CN5-3 X4-5

3.5A

KB 801

ONLY

CN5-13 X4-9

CN5-7 X4-1

CN5-10 X4-12

CN5-14 X4-8

CN5-5

X4-3

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

X5-2

X5-11

X5-10

AIR PRESSURE

SWITCH

BLOCKED

DRAIN SWITCH

O-TEMP HEX SW

CONNECTION BOARD

LWCO

CN7-3

CN7-2

CN7-4

CN7-1

24 VAC

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOW GAS

PRESSURE

SWITCH

FLOW

SWITCH

120 VAC

120VAC

TERMINAL STRIP

120V SUPPLY "L"

ON / OFF

SWITCH

X1-6

X1-2

NEUTRAL

TERMINAL STRIP

120V SUPPLY "N"

3.15A

INTEGRATED CONTROL

GROUND

JUNCTION BOX

BOILER

PUMP

DHW

PUMP

SYSTEM

PUMP

BOILER

PUMP

CONTACTS

DHW

PUMP

CONTACTS

SYSTEM

PUMP

CONTACTS

OUT

RELAY BOARD

X1-1 12

BLOWER

SYSTEM PUMP

RELAY

DHW PUMP

RELAY

BOILER PUMP

RELAY

SYSTEM PUMP

RELAY

DHW PUMP

RELAY

BOILER PUMP

RELAY

24V DC

SUPPLY

.8A

X5-1

X5-9

X1-3

X1-4

10 Diagrams (continued)

Outdoor Knight XL Installation & Operation Manual

Revision Notes: Revision A (ECO #C11234) initial release.

Revision B (ECO #C11235) reﬂ ects updates made to the freezing

conditions warnings.

OKBX-I-O Rev B

10/12

Lochinvar Kight Xl 400 801 Users Manual OKBX I O Rev B

400-801 to the manual 80cf0bb2-9739-4377-a29c-de7b6c2efdd6

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