Home

Nikon 13216 Digital Camera User Manual

1. 4 The freeze protection set points may be lowered when freeze protection fluid is used see the Outdoor Knight 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 Outdoor Knight Boiler Installation amp Operation Manual Fill to correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING 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 l 3 Purge air from system a Connect a hose to the purge valve see purge drain valves in piping diagrams on pages 17 through 23 Route the hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time ope
2. TYPICAL LI l d UNION TEMPERATURE PRESSURE ICA pass BOILER 2 BOILER 1 I x INDIRECT MEMBER 1 LEADER a IMG00371 NOTICE 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 Indoor tank shown for illustration purposes 18 Klee Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping continued Figure 3 6 Single Boiler Multiple Temperatures PRESSURE REDUCING VALVE TEMPERATURE TEMPERATURE TEMPERATURE LOOP 1 LOOP 2 LOOP 3 WIRES TO f f 1 LOOP SENSORS BACKFLOW __ PREVENTER SRESSURE gt lt GAUGE MAKE a s UP lt T T 7 N SYSTEM 2 eee SUPPLY MIXING VALVES SENSOR TYPICAL Bir AIR SEPARATOR EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA BALL VALVE OR MAX OF 12 APART 120VAC TO PUMPS TYPICAL 24V SIGNALTO Y STRAINER MIXING VALVES RECOMMENDED DRAIN POINT MULTI TEMP TYPICAL nN CIRCULATOR LOOP CONTROL FLOW CHECK HOT WA TER HOT WATER FLOW ANTI SCALD CIRCULATOR a T MIXING VALVE COLD IIB WATER SHIELDED CABLE TO IN BOILER CONTROL UNION TYPICAL E s IBBT as TEMPERATURE i PRESSURE DRAIN K2 GAUGE BOILER IMG00372 CAUTION Mixing valves are required for the protection of low temperature loops NOTICE Please note that these illustra
3. 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Inspect fill condensate system Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate PVC fittings and condensate trap Fill condensate trap with water 1 Remove the PVC cap retaining screw from the PVC cap FIG 7 1 2 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 7 1 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 5 Replace the retaining screw The condensate trap FIG 7 1 must be 4 WARNING filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death F Start u D continued Final checks before starting the boiler Q Read the Outdoor Knight Boiler Service Manual to familiarize yourself with SMART SYSTEM control module operation Read this manual page 36 for proper steps to start boiler LI Verify the boiler and system are full of water and all system components are correctly set for operation 1 Verify the preparation procedures of Section 7 pages 33 and 34 have been completed Q Fill the vent condensate trap with water removing th
4. Tis 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 Outdoor Knight Boiler Installation amp Operation Manual 8 Operating information continued Monitor external limits Connections are provided on the connection board for external limits such as a flow 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 firing in the Space Heating Mode The other timer monitors the time the boiler is firing in the DHW Mode The control uses two 2 ignition counters to monitor the amount of boiler cycles The first 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 notification This notification 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
5. 8 _ Required Pipe Sizes PRESSURE REDUCING VALVE PRESSURE BACKFLOW ds c i PREVENTER jeg c Ly T SIS EI E MAKE UP WATER SYSTEM SUPPLY SENSOR AIR SEPARATOR __ MAY SUBSTITUTE LOW LOSS HEADER a FROM SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART SYSTEM CIRCULATOR TO W i SYSTEM 5 lt BALL VALVE TYPICAL EXPANSION Las DRAIN POINT TYPICAL Y STRAINER RECOMMENDED TYPICAL iS ANTI SCALD PA A MIXING VALVE ouf Gss DOMESTIC I HOT WATER CIRCULATOR CORE STER Se BOILER CIRCULATOR TEMPERATURE UNION ts Eon TYPICAL l O BOILER 4 BOILER 3 BOILER 2 BOILER 1 INDIRECT MEMBER 3 MEMBER 2 MEMBER 1 LEADER DHW TANK IMG00376 NOTICE 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 Indoor tank shown for illustration purposes 23 4 Gas connections Connecting gas supply piping 1 Remove the top access cover and refer to FIG 4 1 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 UNION GAS SUPPLY DRIP LEG MANUAL SHUTOFF VALVE FIELD SUPPLIED IMG00
6. Operation Manual General piping information Basic steps are listed in this section along with illustrations on the following pages FIG s 3 4 thru 3 10 which will guide you through the installation of the outdoor boiler reference FIG s 3 2A and 3 2B i pA 3 10 11 Connect the system return marked Inlet Connect the system supply marked Outlet Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone Install a backflow preventer on the cold feed make up water line Install a pressure reducing valve on the cold feed make up water line 15 psi nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi 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 Consult the factory for a pump and or pump cover If a field supplied pump is used install per the manufacturer s specifications in regard to indoor or outdoor location An outdoor rated pump is recommended Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity Install an air elimination device on the system supply Install a drain valve at the lowest point of the system Not
7. The coils are encased in a jacket that contains the combustion process Combustion chamber access cover Allows access to the combustion exchanger coils side of the heat 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 Gas valve The gas valve senses the negative pressure created by the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing Venturi The venturi controls air and gas flow into the burner Flue gas sensor limit rated This sensor monitors the flue gas exit temperature The control module will modulate and shut down the boiler if flue gas temperature gets too hot This protects the flue pipe from overheating 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 firing rate so the outlet temperature is correct Boiler inlet temperature sensor This sensor monitors return water temperature system return If selected as the controlling sensor the control module adjusts the boiler firing rate so the inlet temperature is correct Temperature and pressure gauge field installed not shown Monitors the outlet temperature of the boiler as well as the system water pressure Electr
8. 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 notification 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 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 firing and firing rate to achieve a target temperature The target temperature can be set between 32 F and 190 F Target temperature is calculated as described in the Outdoor Reset Operation section when the outdoor sensor is connected If the outdoor sensor is not connected the target temperature is fixed at SH 1 3 set points An outdoor sensor fault will remain on the display screen until the outdoor sensor is reconnected High limit operations The outdoor boiler is equipped with adjustable automatic reset and manual reset high limits The automatic reset high limit has
9. piping If you discover evidence of any gas leak ee 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 Q Propane boilers verify conversion l 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 field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Outdoor boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 11 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check flame and combustion 1 Turn the main power off to the boiler by placing the On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue pipe connection NOTE Combustion measurements will be made at this point 3 Turn the main power on
10. qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control Turn the power switch to the OFF position Shut off the gas supply at the manual gas valve in the gas piping to the appliance Remove the manometer from the pressure tap on top of the gas valve Re tighten the set screw inside the pressure tap 4 Gas connections continued When re tightening the set screw be sure A WARNING to tighten securely to prevent gas leaks Do not check for gas leaks with an open flame 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 flame characteristics Figure 4 3 Inlet Gas Supply Check LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP DETAIL IMG00385 Outdoor Knight Boiler Installation amp Operation
11. 286 ONLY w BLOCKED O TEMP HEX SW DRAIN SWITCH be SENSOR FA AIR PRESSURE L OPERATING SWITCH z u SENSOR O TO lt lt Le HIGH LIMIT GAS VALVE X2 2 SENSOR O lt lt 2 m FLUE ale SENSOR 6 X2 1 FLUE lt lt Z na Po SENSOR 13 CONNECTION L _ gt EBoARD h pre 1 CN5 1 gt gt lt X4 7 CONTACTS 2 CN5 8 gt X4 14 RUN TIME 3 mes gt gt lt lt CONTACTS 4 CN5 9 gt gt lt lt X4 13 SYSTEM S6 21 Le ENS gt lt lt x X1 7 SENSOR m A 22 5 23 FLAME ROD OUTDOOR SENSOR 24 ae TANK S4 26 t SENSOR 27 SHIELD 29 CAUTION HIGH VOLTAGE SPARK LEAD CASCADE S B 31 NOTES SHIELD 324 1 Where possible switches are shown without utilities gas water or BMS 33 electricity connected to the unit As such actual switch states may iN S 0 10V 34 vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present SYS PUMP oy 35 2 See wiring diagram for additional notes IN _ 36 BLR PUMP 37 our 38 BOX DEPICTS BATE 39 dk WA R N IN G OPTIONAL ITEMS OUT 40 B LOW VOLTAGE SHIELD 41 DISCONNECT POWER 120 VAC MODBUS te BEFORE SERVICING c HIGH VOLTAGE B SHIELD 44 LADDER DIAGRAM LBL20148 REV D 54 asf Outdoor Knight Boiler Installati
12. COVER 5 Slide the vent pipe through the wall strap and insert it into the elbow 6 Install the bird screen into the top of the flue pipe Gas conversions 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 7 of this manual Failure to comply could result in severe personal injury death or substantial property damage You must install a propane orifice to operate the outdoor boiler on propane gas Verify when installing that the orifice size marking matches boiler size Table 2A 1 Remove the top and front access covers from the unit tools required for removal 2 Remove the three screws securing the gas valve to the venturi FIG 2 3 3 Locate the propane orifice disk from the conversion kit bag Verify that the stamping on the orifice disk matches the boiler size see Table 2A Place the orifice into the black rubber grommet in the side of the gas valve and secure in the valve FIG 2 3 4 Reposition the gas valve against the venturi and replace the screws FIG 2 3 securing the valve to the venturi Kice Outdoor Knight Boiler Installation amp Operation Manual 2 Prepare boiler continueg 5 After installation is complete attach the propane Leveling the boiler conversion label in the conversion kit bag next to
13. Check boiler area e Check pressure temperature gauge e Check air and vent termination screens e Check relief valve Monthly e Check condensate drain system Periodically e Test low water cutoff if used e Reset button low water cutoff e Check boiler piping gas and water for leaks Every e Operate relief valve 6 months End of season months e Shut boiler down unless boiler used for domestic hot water 9 Maintenance Outdoor Knight Boiler Installation amp Operation Manual Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING l l l l l 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 A WARNING The boiler should be inspected annually only by a qualified 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 efficiency 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 A WARNING ee i noted otherwise in this Instruction manual Fail
14. Outdoor Knight Boiler Installation amp Operation Manual The control can be configured by the installer to use a 0 10 Vdc signal to either control set point or firing rate The outdoor boiler can also be programmed to accept a call for heat from a 0 10V signal reference the Outdoor Knight Boiler 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 firing 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 Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sens
15. System 12 Freeze Protection 12 General Piping Information 12 Relief Valve T amp P Installation 13 Near Boiler Piping Components 13 14 Near Boiler Piping Connections 14 Circulator Sizing 14 Variable Speed Pump Option 16 4 GAS CONNECTIONS Connecting Gas Supply Piping 24 25 Nalu alGl88 uuuuuuuu l u u nnne 25 Pipe Sizing for Natural Gas 25 Natural Gas Supply Pressure Requirements 25 POD ANC Gas a 25 Pipe Sizing for Propane Gas 25 Propane Supply Pressure Requirements 25 Check Inlet Gas Supply 26 Gas Pressure a a 27 Gas Valve Replacement 27 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important in
16. T Left Side inside unit Model 286 Right Side inside unit Model 286 gt Klee Outdoor Knight Boiler Installation amp Operation Manual Ratings DOE ENERGY STAR Saati CERTIFIED 3 i Outdoor Knight Boiler Other Specifications AHRI Rating Heating Capacity Model Number MBH Boiler Water Content Note Change N to L for L P gas models Gallons Note 2 5 Note 3 5 Note 1 5 ooon em or oa es 2 NOTICE Maximum allowed working pressure is located on the rating plate Notes 1 Asan Energy Star Partner Lochinvar has determined that outdoor boilers meet the Energy Star guidelines for energy efficiency 2 The ratings are based on standard test procedures prescribed by the United States Department of Energy 3 Net AHRI ratings are based on net installed radiation of sufficient 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 4 Standard outdoor 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 5 Ratings have been confirmed by the Hydronics Section of AHRI 6 Outdoor boilers temperature controls comply with the requirements of CSD 1 Section CW 400 requirements The manual reset high limit provided with the outdoor boiler is listed to
17. TANK DRAIN TYPICAL IMG00377 TO FLOOR DRAIN 14 Figure 3 2B Near Boiler Piping w Low Loss Header SYSTEM SENSOR A AIR SEPARATOR NN lt O NS lt LOW LOSS HEADER TYPICAL s 3 3 P gt SE FILL VALVE 2 a s DRAIN hA TYPICAL 5 seg EXPANSION TANK DRAIN VALVE RN ee INDIRECT DOMESTIC HOT WATER Y STRAINER RECOMMENDED BOLIER PUMP IMG00378 TO FLOOR DRAIN Kias Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping continea Figure 3 3 Pressure Drop vs Flow Pressure Drop vs Flow Includes Secondary Piping i 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Flow Rate GPM N o N oO on oO Sz QG Q L u O Q Q LL Q O m Q 0 V Q n J Table 3A Circulator Recommendations for Temperature Rise Applications 20 25 and 35 20 F Temperature Rise Applications Minimum Pipe Sasi TACO B amp G Armstrong 2 2 UPS26 99F 0011 NRF 36 UPS32 160 1400 50 PL 55 me UPS32 80 1400 20 PL 36 n These pumps are only slightly above 20 rise flows but are the closest available To reach a 20 rise or less an NOTICE upsized pump will be required 25 F Temperature Rise Applications Modei cpm Grundfos TACO B amp G _ ee ae ee ee ee ee om
18. UL353 Outdoor Knight Boiler Installation amp Operation Manual 1 Determine boiler location Installation must comply with Do not locate unit so that high winds can A CAUTION deflect off of adjacent walls buildings 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 NOTICE The Outdoor Knight gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition Outdoor models must be installed outdoors A WARNING only and must use the outdoor vent kit assembly supplied by the manufacturer Personal injury or product damage may result if any other cap 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 situation CAUTION 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 Before locating the boiler check or shrubbery causing recirculation Recirculation of flue products may ca
19. 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 NOTICE Please note that the brackets denote screen status 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 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 parameter will upload to the control 8 Ifthe 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 Ifthe 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 p
20. 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 38 Configuration 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 5 3 7 and 3 9 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 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 The Leader control will calculate the water temperature set point based on the programmed reset curve parameters If a Thermostat Zone Control enable output or Building Management System 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 wi
21. 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 NOTICE on the floor or pallet Damage to the boiler can result Figure 2 1 Boiler Mounted on Shipping Pallet LAG BOLTS QTY 2 LAG BOLTS FRONT mee REAR Install flue pipe assembly reference FIG 2 2 for flue pipe assembly The outdoor boiler is shipped with all the necessary vent components All components must be installed prior to operation Basic installation steps are as follows 1 Locate all venting components from the installation kit and carton 2 Before connecting the flue pipe sections or components verify the gasket is seated evenly inside the groove in the female end of the elbow and flue adapter 3 Remove the kit provided screws from the air cover and use them to install the wall strap 4 Insert the elbow into the flue adapter Do not use grease or other lubricant A CAUTION on the vent seals Only water may be used for this purpose Grease or other lubricant can make the seal brittle or it can result in tears in the surface of the seal this will result in flue gas leakage Outdoor Knight Boiler Installation amp Operation Manual Figure 2 2 Install Flue Pipe Assembly WALL STRAP SCREWS BIRD SCREEN WALL STRAP bs FLUE PIPE ELBOW NOTE VERIFY GASKETS ARE SEATED EVENLY INSIDE THE GROOVE IMG00443 FLUE ADAPTER AIR
22. detailed in this manual can result in severe personal injury death or substantial property damage ia Outdoor boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 11 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Klee Outdoor Knight Boiler Installation amp Operation Manual Use two wrenches when tightening gas l piping at boiler FIG 4 2 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 Figure 4 2 Inlet Pipe with Backup Wrench IMG00384 USE BACKUP WRENCH TO PREVENT PIPE FROM ROTATING NOTICE Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment 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 specific 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 o
23. exchanger door kit WTR3080 Oiled bearing circulators 1 The circulator shipped with the outdoor boiler is water lubricated No oiling is required 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 3 Replace the boiler front access cover 53 Klee Outdoor Knight Boiler Installation amp Operation Manual 10 Diagrams Figure 10 1 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP Q e 120V SUPPLY L 120V SUPPLY N V B eel INTEGRATED CONTROL KB ONLY 9 SWITCH Les T ies SYSTEM SYSTEM PUMP L PUMP N X BOILER PUMP L BOILER PUMP N TERMINAL Ao TERMINAL STRIP STRIP CONNECTION BOARD INTEGRATED CONTROL CN5 14 4 8 SWITCH CN5 10 X4 12 2 lt HEAT LOOP DEMAND CN5 7 X4 1 HEAT LOOP DEMAND HEAT LOOP DEMAND TANK THERMOSTAT LOW GAS HIGH GAS PRESSURE PRESSURE SWITCH SWITCH INTEGRATED CONTROL LOUVER RELAY COIL CN5 11 X4 11 gt CN5 3 X4 5 a 24VAC ata LOUVER PROVING SWITCH CN5 4 X4 4 2 gt lt Q RIBBON CABLE KB
24. provided with the unit 1 Install the tee with the 3 4 inch fitting positioned vertically and on the top as shown in FIG 3 1 2 Install the relief valve into the 3 4 inch fitting of the tee installed in Step 1 FIG 3 1 3 Install a field provided 5 inch long nipple and tee with the fitting positioned vertically on the top on the downstream side of the relief valve see FIG 3 1 4 Install the temperature and pressure gauge provided with the unit into the top fitting of the tee a bushing may be necessary installed in Step 3 FIG 3 1 Figure 3 1 Relief Valve T amp P Installation RELIEF VALVE TEMPERATURE amp PRESSURE GAUGE TEE W FITTING ON TOP D FIELD PROVIDED Se CLOSE NIPPLE FIELD PROVIDED IMG00369 TEE WITH 3 4 FITTING ON TOP CLOSE NIPPLE Outdoor Knight Boiler Installation amp Operation Manual Near boiler piping components 1 Boiler system piping Boiler system piping MUST be sized per the pipe requirements listed in Table 3A Reducing the pipe size can restrict the flow rate through the boiler causing inadvertent high limit shutdowns and poor system performance Flow rates are based on 20 feet of piping 4 90 elbows and 2 fully ported ball valves 2 Boiler system pump w pump cover A Grundfos UPS26 99F pump and pump cover will be provided by the factory for standard altitude models as the boiler circulation pump based on 20 feet of piping 4 90 elbows and 2 fully ported b
25. 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 Boiler 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 Boiler Service Manual for a detailed explanation of this procedure Set clock NOTICE Please note that the brackets denote screen status 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 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 7 Turn the NAVIGATION dial to adjust the minutes Press the NAVIGATION dial 38 PASSWORD Outdoor Knight Boiler Installation amp Operation Manual 8 Turn the NAVIGATION dial to adjust th
26. to the boiler by placing the On Off switch in the ON position 35 Kleer Outdoor Knight Boiler Installation amp Operation Manual r Start up Figure 7 2 Operating Instructions This appliance does not have a pilot Itis Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department 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 move by hand don t try to repair it call a floor qualified service technician Force or attempted WHAT TO DO IF YOU SMELL GAS repair may result in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building to replace any part of the control system and any gas control which has been under water C Use only your hand to move the gas control switch Never use tools If the switch will not OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Move the switch to the ON position above on this label 9 Install front door 2 Set the thermostat to lowes
27. up to take its place The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its firing rate to maintain this Once the DHW call has been satisfied 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 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 Boiler Service Manual for information regarding Night Setback Ramp Delay operation of the boilers as described in the Outdoor Knight Boiler Service Manual is available when the boilers are part of a Cascade system Kleer Outdoor Knight Boiler Installation amp Operation Manual 8 Operating information continued Sequence of operation OPERATION DISPLAY Upon a call for heat the gas pressure switch es must be closed 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 flow switch and or LWCO must close The air pressure sw
28. 383 3 Support piping with hangers not by the boiler or its accessories 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 Outdoor Knight Boiler Installation amp Operation Manual 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 JARNING Do not check for gas leaks with an open flame 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 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 flow inc Failure to apply pipe sealing compound as
29. ATER SYSTEM SUPPLY D amp a SENSOR WHEN USED ZONE CIRCULATORS TYPICAL AIR SEPARATOR EXPANSION _ TANK MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE TYPICAL Z Y STRAINER DRAIN POINT Lik RECOMMENDED TYPICAL BOILER CIRCULATOR HOT WATER OUT DOMESTIC HOT WATER CIRCULATOR ANTI SCALD MIXING VALVE T DN lt d J ii p l l UNION TYPICAL Ill l O TEMPERATURE PRESSURE DRAIN G BOILER INDIRECT DHW TANK IMG00370 NOTICE 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 Indoor tank shown for illustration purposes 17 Kler Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping Figure 3 5 Multiple Boilers Single Temperature Zoned with Circulators Number of Units Model 2 3 4 5 6 7 8 _ Required Pipe Sizes Spe near ey EE PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE E PREVENTER O gt 2 SISI FLOW CHECK MAKE UP WATER SYSTEM SUPPLY VALVE SENSOR TYPICAL AIR SEPARATOR ZONE CIRCULATORS TYPICAL MAY SUBSTITUTE LOW LOSS HEADER E BALL VALVE NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL Z DRAIN POINT z TYPICAL l ANTI SCALD BOILER MIXING VALVE CIRCULATOR 1 DOMESTIC HOT WATER P CIRCULATOR Y STRAINER a lt RECOMMENDED g A b
30. Boiler water e Thoroughly flush the system without boiler connected to remove sediment The high efficiency 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 Gaskets and seals in the system may be damaged This can result in substantial property damage A CAUTION 2 not use petroleum based cleaning or sealing compounds in the boiler system Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Freeze protection fluids e NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems Outdoor Knight Boiler Installation amp Operation Manual The Outdoor Knight Boiler How it works 1 10 11 12 13 14 15 16 Stainless steel heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer while providing protection against flue gas corrosion
31. CE SWITCH BOILER SYSTEM 120V SUPPLY PUMP PUMP LINE GROUND NEUTRAL Lg didi kee boy boy Faik D b i Label all wires prior to disconnection A CAUTION eee u when servicing controls Wiring errors can cause improper and dangerous operation 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 The boiler pump is shipped loose Wire the boiler pump as shown in FIG 5 1 4 When connecting a domestic hot water DHW pump connect the wiring to the line voltage terminal strip as shown in FIG 5 1 5 To activate a system pump wire as shown in FIG 5 1 If the motor is larger than 1 8 hp or 1 8 amps you must isolate with a relay 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 low voltage connection board as shown in FIG 5 3 on page 31 of this manual and the boiler wiring diagram Figure 5 2 Routing Field Wiring LOW VOLTAGE CONNECTION BOARD LOW VOLTAGE WIRING KNOCKOUTS LINE VOLTAGE IMG00386 WIRING KNOCKOUTS Klee
32. ECT 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 8 Operating information General How the boiler operates The outdoor boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping The control module regulates blower speed to control the boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow 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 The
33. ICE 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 NOTICE A WARNING A WARNING Klee Outdoor Knight Boiler Installation amp Operation Manual Please read before proceeding A WARNING Installer Read all instructions including this manual and the Outdoor Knight Boiler 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 qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage 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 filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in se
34. Manual Gas Pressure The gas pressure must remain between 4 inches w c natural 8 inches w c LP minimum and 14 inches w c natural and LP maximum during stand by static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the outdoor 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 flanged connection to the venturi and blower A WARNING Failure to follow all precautions could result in fire explosion or death A WARNING DO NOT adjust gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage 27 Kissel Outdoor Knight Boiler Installation amp Operation Manual 5 F
35. NING The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Check all piping for leaks 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 9 Maintenance continued Flue vent system and air piping l Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system l Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi Watch the system pressure as the boiler heats up during testing to ensure pressure does
36. NVA ONIAG1NG l ONYWAT aoo 1 1YSH ON WAo dOO 1 Ly dH ONYWSd doo 1 1YSH LYLSOWYSAL AN YL IP TT H m mj m is HOLIMS SHNSSsayd SYI HOLIMS SNIAOYA HAAS MOD AY aH HAAN IYAPE SLOYLNDS SWIL Nita SLIYINOD Wav Ty Fa A 553 he 4IAOLNO YSLVM MOJ G7 IHS t t qT3IHS TY 7 E yg1109g lt lt lt gt lt lt s snolA3 d b V wows L LVLSOWYSAHL NOOt 09900 IVISOWYSHL NOOt ooo LV LSONW I3H1 WOOti IVLSOWYSHL ANVL HOLIMS MO 1A 31 6 Condensate disposal Condensate drain 1 This boiler is a high efficiency appliance that produces condensate 2 The side of the boiler has a 1 2 inch PVC union for connection of a 1 2 inch PVC pipe FIG 6 1 3 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the outdoor boiler will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes A Neutralizer Kit FIG 6 1 is available from the factory Kit 3087 4 Install the 1 2 inch PVC tee assembly shipped with the unit as shown in FIG 6 1 5 Leave the top of the 1 2 inch 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
37. Natural Gas Pipe Size Chart Nominal lron Pipe Size Inches Outdoor Knight Boiler Installation amp Operation Manual Single Unit Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1 2 PSI to 20 so 40 so so 70 f 80 90 100 15 160 175 200 34 s 256 205 174 155 141 128 121 119 106 95 se 79 74 iue arse ioo 1210 1020 023 80 760 707 oee oxo soa s18 are ast A WARNING Outdoor boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 11 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check inlet gas supply NOTICE CSA or UL listed flexible gas connections are acceptable but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate Consult with local codes for proper installation or service procedures A WARNING DO NOT adjust gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal in
38. OKB I O Rev C HEATING BOILER Outdoor Knight Boiler Installation amp Operation Manual Models 151 286 s s IMG00363 fp K A WARNING This manual must only be used by a qualified heating installer service ENERGY STAR technician Read all instructions including this manual and the Outdoor Knight Boiler Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage High Efficiency Water Heaters Boilers and Pool Heaters e this manual fo HAZARD DEFINITIONS 2 PLEASE READ BEFORE PROCEEDING 3 THE OUTDOOR KNIGHT BOILER HOW IT WORKS 4 6 RATINGS 0 0 cece cccccccceceeceeeeesseceeeeeeeeeseeeseaeeeeeeeeeseeeaeens 7 1 DETERMINE BOILER LOCATION Provide Clearances 9 Corrosive Contaminants and Sources 9 2 PREPARE BOILER Remove Boiler from Wood Pallet 10 Gas Conversions 10 11 Leveling the Boiler 11 3 HYDRONIC PIPING System Water Piping Methods 12 Low Water Cutoff Device 12 Chilled Water
39. Outdoor Knight Boiler Installation amp Operation Manual 5 Field wiring continues 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 influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces 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 specifications and thermostat instructions for details Outdoor temperature sensor In the absence of an external energy management system an outdoor temperature sensor must be used 1 Mount the sensor on an exterior wall shielded from direct sunlight or flow 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 boiler DHW 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 1 By installing a tank sen
40. SENSOR J SPARK G ROD 07N HIGH VOLTAGE SPARK LEAD SHIELD GROUNDING JUMPER Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using WIRING DIAGRAM diagrams to troubleshoot unit LBL20127 REV E Revision Notes Revision A ECO C11234 initial release or Revision B ECO C11235 reflects updates made to the freezing aus 4 O hinva conditions warnings W High Effici ecn Boilers and Pool Ar x 300 Maddox Simpson Parkway Revision C ECO C11736 reflects changes made to the ratings page Lebanon TN 37090 page 7 615 889 8900 Fax 615 547 1000 www Lochinvar com OKB I O Rev C 11 12
41. al codes Indoor tank shown for illustration purposes 20 Klee Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping continued Figure 3 8 Single Boiler Multiple Temperatures with DHW Piped as a Zone PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE WIRES TO BACKFLOW REDUCING VALVE LOOP 2 LOOP 3 LOOP PREVENTER SENSORS L PRESSURE Sa GAUGE MAKE E UP LANA Ly LI MIXING VALVES WATER TYPICAL SYSTEM SUPPLY SENSOR AIR SEPARATOR EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE OR MAX OF 12 APART 24V SIGNAL TO TYPICAL MIXING VALVES DRAIN POINT 420VAC TO PUMP here TYPICAL OAG TO POME N MULTI TEMP TO DOMESTIC LOOP CONTROL HOT WATER Y STRAINER RECOMMENDED CIRCULATOR SHIELDED CABLE TO FLOW a BOILER CONTROL HOT WATER ANTI SCALD OUT MIXING VALVE COLD WATER IN PRESSURE RELIEF VALVE TEMPERATURE IS ae DRAIN PRESSURE GAUGE N BOILER BOILER INDIRECT DHW TANK IMG00374 CAUTION Mixing valves are required for the protection of low temperature loops NOTICE 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 Indoor tank shown for illustration purposes NOTICE Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone Indoor tank
42. all valves Outdoor boilers are capable of controlling a variable speed boiler circulator Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG 3 3 on page 15 at full speed 3 Domestic hot water circulating pump Field supplied The pump MUST be sized to meet the specified minimum flow requirements listed in FIG 3 3 Consult the indirect water heater operating guide to determine flow characteristics for the selected product used 4 Boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 5 Check valves Field supplied Check valves are recommended for installation as shown in FIG s 3 4 thru 3 10 Failure to install check valves could result in a reverse flow condition during pump s off cycle 6 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 flow rate through the boiler 7 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above LI5 h 8 Unions Field supplied Recommended for unit serviceability 9 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 press
43. an and free of combustible and flammable materials To avoid a blocked air inlet or blocked flue condition keep the outdoor air inlet and flue outlet clear of leaves debris etc Do not install outdoor models directly CAUTION on the ground You must install the outdoor unit on a concrete brick block or pressure treated wood platform water from sprinklers may spray directly onto it Water may damage controls or other electrical components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep the boiler area clear and free LAINIE of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 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 Lack of freeze protection in boiler water causing system and boiler to freeze and leak Klee Outdoor Knight Boiler Installation amp Operation Manual 1 Determine boiler location continued Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 4 6 mm from combustible materials 2 Vent pipes minimum of 14 356mm from the rear and 0 on the right side from combustible materials Clearances for servi
44. anel NAVIGATION DIAL PRESS OR TURN RESET KEY LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY 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 Access modes Savin arameters reference the Parameter Table in g p User the Outdoor Knight Boiler Service Manual The user can adjust space heating and tank target temperatures NOTICE Please note that the brackets denote by pressing the NAVIGATION dial when SETPOINTS is SEAU flashing at the bottom of the display The date and time and To save parameters and exit programming the temperature units can also be changed see page 38 Press the RIGHT SELECT SAVE key and then press the Installer RIGHT SELECT HOME key Most parameters are available only to the installer accessible To enter a parameter and continue programming by entering the installer password see the Outdoor Knight Press the RIGHT SELECT SAVE key 1 time to return to the Boiler Service Manual parameter listings press again to return to the menu listings Remember to press the RIGHT SELECT HOME key when finished programming in order to save the changes made See the Outdoor Knight Boiler Service Manual for a detailed description of parameters and access modes Kias Outdoor Knight Boiler I
45. aper clip into the hole and press the button continuously for five 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire 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 5 If needed press the RIGHT SELECT STOP key to exit Service Mode The new 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 flow 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 flow 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 41 8 Operating information Outdoor reset operation Target temperature with outdoor reset This feature improves the system s efficiency by decreasing set point as the outdoor temperature warms up Energy Efficiency Standar
46. ce access 1 If you do not provide the minimum clearances it may not be possible to service the boiler without removing it from the space Recommended service clearances Front 24 610mm Top 24 610mm Left side 24 610mm Rear 24 610mm Outdoor vent air intake location The flue products discharged from the flue outlet on the outdoor vent may be very hot Avoid touching or other direct contact with the flue gases or the vent termination assembly These components are hot and direct contact can result in burns To prevent recirculation of the flue 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 to 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 610mm clearance to the side of 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 outdoor unit at least 10 feet 3 05m away from any forced air inlet Multiple outdoor unit installations require 24 61m 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 o
47. 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 flow 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 heat exchanger 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 fluid 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 Use only inhibited propylene glycol AMIN solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 12 Outdoor Knight Boiler Installation amp
48. ctory at either high fire or low fire 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 9 2 below 4 When replacing the burner ensure gasket is in good condition and positioned correctly FIG 9 2 Figure 9 2 Burner Assembly INSULATION HEAT EXCHANGER ACCESS DOOR BURNER ai S GASKET J SCREWS QTY 5 IMG00447 Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps 2 A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode 3 See Section 3 Troubleshooting of the Outdoor Knight Boiler Service Manual for other procedures to deal with low flame signal 9 Maintenance continued Review with owner 1 Review the Outdoor Knight Boiler User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the Outdoor Knight Boiler 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 p
49. d Low voltage connection board The connection board is used to connect external low voltage devices Low voltage wiring connections Conduit connection points for connection board Condensate drain connection Connects the condensate drain line to a 1 2 PVC union Access cover top front Provides protection of the control panel display from outside elements Access cover bottom front Provides access to the burner Ignition electrode Provides direct spark for igniting the burner Flame inspection window The quartz glass window provides a view of the burner surface and flame Relief valve Protects the heat exchanger from an over pressure condition The relief valve provided with the unit is set at 30 psi Flame sensor Used by the control module to detect the presence of burner flame Line voltage wiring connections Conduit connection points for the high voltage junction box Top access cover Provides access to the internal components Power switch Turns 120 VAC ON OFF to the boiler 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 Air pressure switch The air pressure switch detects blocked inlet conditions the low voltage Transformer The transformer provides 24V power to the integrated control High limit sensor housed with the outlet temperature sensor Device that monitors the outlet water temperatu
50. ds require the use of a control that automatically adjusts set point in relation to heat demand In the absence of an external energy management system this feature MUST BE used See the Outdoor Knight Boiler Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point in relation to heat demand 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 Efficiency 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 Boiler Service Manual to program the reset curve If outdoor air reset is not desired do not connect the outdoor air sensor A fixed temperature set point can be programmed into the control See page 37 of this manual to program the set point If the water temperature at the system supply sensor is less than the set
51. e The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi 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 Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve 3 Hydronic piping continued The relief valve tee and any necessary fittings A WARNING are shipped in the install kit with the boiler and are to be field installed FIG 3 1 See the piping illustrations included in this section FIG s 3 4 thru 3 10 for suggested guidelines in piping the outdoor boiler with either zone valves or circulator pumps l NOTICE 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 The outdoor boiler is capable of servicing multiple temperature loop systems It is the responsibility of the installer to protect the loops with lower temperature requirements from higher temperatures that may be required by other loops Relief valve and temperature and pressure gauge installation Basic steps are listed below to guide you through the installation of the relief valve and the temperature and pressure T amp P gauge
52. e 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 LI Verify electrical connections are correct and securely attached Q Verify air opening and vent opening are free of obstruction 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 3 Is thermostat set below the controlling sensor temperature 4 Is gas turned on at meter or boiler 5 Is incoming gas pressure less than 4 inches w c If none of the above corrects the problem refer to the Troubleshooting Section of the Outdoor Knight Boiler Service Manual Check system and boiler Q 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 Outdoor Knight Boiler Installation amp Operation Manual Q Check gas piping 1 Check around the boiler for gas odor following the procedure on page 24 of this manual connecting gas supply
53. e the temperature control on the inlet sensor the appropriate parameter must be changed in the control See the Outdoor Knight Boiler 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 Boiler Service Manual for a detailed explanation of this procedure Adjust set point temperature s NOTICE Please note that the brackets denote screen status 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 Turn the NAVIGATION dial counterclockwise to select the appropriate set point 3 Press the NAVIGATION dial to adjust the
54. e 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 The internal clock does not adjust for I Daylight Savings Time and therefore will require a manual adjustment The clock is automatically updated whenever a PC is connected and the Win Pro Installer program is started Configuration of the cascade NOTICE Please note that the brackets denote screen status 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 five 5 seconds Input the Installer code as described in the Outdoor Knight Boiler 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 SEL
55. esigned to control and balance the space heating demand by switching between DHW and space heating Near boiler piping connections Outdoor Knight Boiler Installation amp Operation Manual Lochinvar offers the Squire which is a series of indirect water heaters The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger CAUTION minimum system flow is not less than the minimum boiler flow at any time A WARNING The National Standard Plumbing Code and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum Also the heat transfer fluid must be water or other non toxic fluid having a toxicity of Class 1 as listed in Clinical Toxicology of Commercial Products 5 Edition It is up to the installer to ensure the 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 Circulator sizing The outdoor boiler heat exchanger does have a pressure drop which must be considered in your system design Refer to the graph in FIG 3 3 for pressure drop through the outdoor boiler heat exchanger Figure 3 2A Near Boiler Piping w Y Strainer Y STRAINER RECOMMENDED DOMESTIC HOT WATER PUMP ow ee INDIRECT DOMESTIC HOT WATER
56. formation concerning the life of the product A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury 5 FIELD WIRING Line Voltage Connections 28 Low Voltage Connections 28 Wiring of the Cascade 30 6 CONDENSATE DISPOSAL Condensate Drain 32 f STARTUP u uuu Lu uuu eri 33 38 8 OPERATING INFORMATION CGO n uu u uuu E A E E 39 Cascada uuu eee nee eee ane eect TET 42 Sequence Of Operation 43 44 Outdoor Knight Boiler Control Module 45 Status Display Screens 46 48 9 MAINTENANCE Maintenance and Annual Startup 49 53 10 DIAGRAMS Ladder DAG iN LLL aaausasassashasaywwaskhkaqkua 54 Wiring Diagram 55 Revision Notes Back Cover A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION NOT
57. ias Outdoor Knight Boiler Installation amp Operation Manual 8 Operating information Status Display Screens cont d Section Display _ Description Press and hold the LEFT SELECT key for 5 seconds to enter the Menu MENU Screen EXIT Press the LEFT SELECT key to exit the current screen or setting D YES Press the LEFT SELECT key to confirm that the boiler needs to shutdown deti eee P he LEFT SELECT k h hat all ress the ey to enter the screen that allows you to key function ene 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 Turning the NAVIGATION dial will select the next or previous Status 4I SCREEN me Pressing the NAVIGATION dial will show the next fault NSB Night HEST Setback trigger or ramp delay setting E 4 SELECT Pressing the NAVIGATION dial will select the setting indicated by the cursor NAVIGATION Dial Function 5ETPOINTS Pressing the NAVIGATION dial will display the Set Points Screen ga SC ROLL Turning the NAVIGATION dial will move the cursor up or down Turning the NAVIGATION dial will increase or decrease the current g SHDN Press the RIGHT SELECT key to turn the boiler OFF Press the RIGHT SELECT key to turn the boiler ON F RIGHT SELECT NO Press the RIGHT SELECT key to cancel the shutdown operation key function SAVE P
58. ield wiring A WARNING 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 NOTICE 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 All wiring exterior to the appliance must be enclosed in approved conduit NOTICE In accordance with Section 303 of the 2007 Energy Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function This override MUST NOT be used unless at least one of the following conditions is true l An external energy management system is installed that reduces the boiler water temperature as the heating load decreases 2 This boiler is not used for any space heating 3 This boiler is part of a modular or multiple boiler system having a total input of 300 000 Btu hr or greater 4 This boiler is equipped with a tankless coil Figure 5 1 Line Voltage Field Wiring Connections DOMESTIC HOT WATER PUMP 28 SERVI
59. if connected The temperature read by the tank sensor if connected The temperature read by the outdoor sensor INLET TEMP The temperature read at the inlet to the heat exchanger The temperature read at the outlet of the heat exchanger The temperature difference between the inlet and the outlet of the heat exchanger FLUE TEMP The temperature read by the flue sensor FLAME CURRENT The current measured by the flame sense circuit FAN SPEED The speed of the combustion blower BOILER PUMP The status of the boiler pump output C SYSTEM PUMP The status of the system pump output Operational Information DHW PUMP The status of the DHW pump output g Ola 2 a Ciel amp p a Z 5 gt E O ee gt Fri eo Z z y 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 firing rate of the boiler 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 N T c Z T K
60. ire at ignition speed and will then modulate up to full fire 6 Insert the probe from a combustion analyzer into the flue outlet opening 7 Once the boiler has modulated up to full fire 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 specified range reference the Troubleshooting Section of the Outdoor Knight Boiler Service Manual for possible causes and corrective actions Table 7A Flue Products Chart O ranas Pope 8 0 10 3 0 6 5 9 0 11 4 1 6 9 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch 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 9 Turn the main power off to the boiler 10 Place the boiler back into normal operation Outdoor Knight Boiler Installation amp Operation Manual 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 bas
61. itch and blocked drain switch must close The control starts the prepurge cycle by initiating the blower The control starts the trial for ignition by firing the spark electrode and opening the gas valve If flame is not detected after the sparking ends the control will perform a post purge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts before locking out If flame is detected it holds the firing rate steady for a few seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal START SYSTEM 116 F TAHE 12e Foles3 OUTDOOR 26 F MENU et SCREEH SHDH START amp Sus TEM 1167 TAHE 1Ze F oles OUTDOOR 26 MEHO ea SCREEH SHDH START amp SYSTEM 1167 TAHE 126 F 0125 OUTDOOR D67 MEHO et SCREEH SHDH PRE PURGE t SYSTEM TAHE HHE OUTDOOR MEHU 478CREEN SHOH IGNITIUH A oro TEH lir DHW TAHKE 126 OUTDOOR a6 MEHL aI SCEEEH HDH PUST PURGE tit SYSTEM TANK OUTDOOR MENU amp 7SCREEN SHOH 4246 m SYSTEM llr 7 Fells TAHE Fi 13B OUTDOOR a6 F MEHO oa SCREEHM SHDH Kler Outdoor Knight Boiler Installation amp Operation Manual 8 Operating information Sequence of operation continued OPERATION DISPLAY 8 If the space heating call for heat is active and the tank thermostat or sensor start
62. jury death or substantial property damage The gas piping must be sized for the proper flow 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 the meter regulator or gas line is undersized or in need of Perform the steps below when checking inlet gas 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 26 10 11 12 15 Loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG 4 3 Slowly turn on the gas supply at the field installed manual gas valve Turn the power switch to the ON position Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat Observe the gas supply pressure as the burner fires at 100 of rated input Percent of burner input will be displayed on the control panel Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in this section of the manual If gas supply pressure is within normal range and no adjustments are needed proceed on to Step 11 If the gas pressure is out of range contact the gas utility gas supplier
63. leaning 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 fill 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 fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used 1 Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 7 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level
64. low switch is used to guarantee flow through the boiler before allowing it to fire The flow switch must be installed at the boiler outlet 2 Remove the jumper wire from these terminals and connect these terminals to the normally open contacts on the flow 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 primary supply can be controlled The SMART SYSTEM control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point if the outlet sensor control is currently selected If it is desired to control the system return temperature then program the SMART SYSTEM control to use the inlet sensor as the controlling sensor See the Outdoor Knight Boiler 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 Boiler management system The United States Energy Policy and Conservation Act requires residential heating boilers with inputs less than 300 000 Btu hr be equipped with a control that automaticall
65. m te 19 i UPS26 99F 0013 NR36 E7 rn 35 F Temperature Rise Applications woe T or no as size Grundfos _ TACO B amp G _ Armstrong ee ee ee ese 008 0010 NRE 36 _ 2 li 9 J r _UPSI5 58FC 0010 NRF 36 1 1 4 UP26 64F 008 0010 NRFE 36 NOTICE Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude models NOTICE Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude models NOTICE _ The temperature rise provided by a pump model combination will decrease by 3 per 1000 feet of elevation 15 Klee Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping Variable speed pump option Table 3B Recommended Variable Speed Pumps Minimum Temperature Rise Grundfos TACO Wilo UP26 96 FC VS 0013 IFC VS Stratos 1 25 3 x 30 286 The minimum temperature rise is derived from the chart in FIG 3 3 with the firing rate and pump speed at 100 as shown in the table above The shaded regions of pump coverage are only available for applications with 230V 60 Hz supply voltage all others are to be 115V A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 3B to the boiler high voltage terminal strip Variable speed pump setup Before operation ensure the following Pump is set for an input signal of 0 10Vdc by the dip s
66. n the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow 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 fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill 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 floor Close the vent when water squirts out Repeat with remaining vents 7 Fb m an Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 4 Refill to correct pressure 33 r Start up Check for gas leaks Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the top access cover 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 o
67. nd 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 A WARNING 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 flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed 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 51 9 Maintenance Inspect ignition and flame sense electrodes Remove the ignition and flame sense electrodes from the boiler heat excha
68. nformation Temperature control Modulation The outdoor boiler is capable of modulating its firing rate from a minimum of 20 to a maximum of 100 The firing 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 flow the SMART SYSTEM can limit the firing 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 firing 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 firing rate to its lowest setting Outdoor air reset With the outdoor air sensor 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
69. nger access cover Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring l Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring l Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings l Set the SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of Outdoor Knight Boiler Service Manual Adjust settings if necessary See Section 1 of the Outdoor Knight Boiler Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks l Start boiler and perform checks and tests specified in Section 7 Start up Verify cold fill pressure is correct and that operating pressure does not go too high 52 Outdoor Knight Boiler Installation amp Operation Manual Check burner flame 1 Inspect flame through observation window 2 If the flame is unsatisfa
70. no DHW demands the control will increase the set point of that demand by a fixed 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 satisfied 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 Any night setback event scheduled within the next seven 7 days can be temporarily bypassed if desired Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low 40 Outdoor Knight Boiler Installation amp Operation Manual Protection features Outlet temperature flue temperature rise limiting temperature and 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 the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the fl
71. not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank l 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 Inspect the relief valve and lift the lever to verify flow 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 Outdoor Knight Boiler Installation amp Operation Manual Safety relief valves should be re inspected Le 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 a
72. nstallation amp Operation Manual 8 Operating information Figure 8 2 Status Display Screen BOILER STATUS C OPERATIONAL INFORMATION D LEFT SELECT KEY A Boiler Status Bar B Call for Heat Indicators S TEM TAHE ODT DOOR B CALL FOR RIGHT SELECT KEY NAVIGATION DIAL Status Display Screens Section Display Description STANDBY START PREPURGE IGNITION POSTPURGE SETPOINT MET BLOCKED 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 The unit has begun a burn cycle and is checking all safety circuits The unit has initiated a prepurge period on a call for heat The unit has begun a spark period to ignite the main burner The unit has fired and is running at the displayed percentage The call for heat has been satisfied and the unit runs the fan for an additional postpurge period to clear the combustion chamber and vent system of residual flue products The unit has been placed in the OFF position the current call for heat Indicates which Heat Loop Demand has priority The unit is being controlled by a 0 10V BMS signal The unit is supplying heat while in Cascade Mode Kias Outdoor Knight Boiler Installation amp Operation Manual 8 Operating information continea Status Display Screens cont d Description The temperature read by the system supply sensor
73. of outdoor temperatures below 32 F 7 Use only plastic tubing or piping as a condensate drain line FIG 6 1 Outdoor Knight Boiler Installation amp Operation Manual NOTICE 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 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 The condensate line must remain unobstructed allowing free flow 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 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 overflow 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 Figure 6 1 Condensate Disposal 1 2 PVC TEE ASSEMBLY FACTORY SUPPLIED 1 2 PVC UNION FACTORY SUPPLIED NEUTRALIZER KIT FLOOR DRAIN OR 32 DRAIN PAN IMG00387 r Start up Check control water chemistry A CAUTION Do not use petroleum based c
74. on amp Operation Manual 10 Dia grams continued Figure 10 2 Wiring Diagram LOW VOLTAGE Foes TEA 120 VAC OPTIONAL ITEMS EER aa aS HIGH VOLTAGE DISCONNECT POWER i DUAL BEFORE SERVICING CONTROL JUNCTION eae BOX L_ ITEMS _ hes a DHW G PUMP A E eae ALARM CONTACTS RUN TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH G PUMP do mm S ese D Pe BELL JUMPER e ANI aneh DWOOWOO WOODY OO Z N ALARM BELL KB ONLY ON OFF Swen L 120V sare SUPPLY FLOW SWITCH TANK O OF THERMOSTAT HEATILOOP 3 oO DEMAND HEATILOOP 5 oo DEMAND HEATLOCE 4 oa oO EES DEMAND SILENCING SWITCH SYSTEM SENSOR gt gt K2 OUTDOOR SENSOR gt KL BLOWER SENSOR L_N_ kK SHIELD T P a CASCADE D SHIELD TANK BMS IN SYS ne 10V 2am BLR PUMP OUT RATE OUT 010V KB 286 ONLY BLOCKED DRAIN SWITCH O TEMP HEX SW AIR PRESSURE SWITCH L eS SHIELD MODBUS a__fA___ _ OPTION a UJ SHIELD OPERATING SENSOR S1a HIGH LIMIT SENSOR S1b LOW WATER INLET SENSOR S2 CUT OFF FLUE SENSOR S3a FLUE SENSOR S3b BK GAS VALVE 9 24VAC WIR FLAME
75. onic LCD display The electronic display consists of 4 buttons a navigation dial and a multiple line liquid crystal display Flue pipe adapter Allows for the connection of the vent system to the boiler Burner not shown Made with metal fiber and stainless steel construction the burner uses pre mixed air and gas and provides a wide range of firing rates Water outlet system supply NPT water connection that supplies hot water to the system either 1 or 1 1 4 depending on the model Water inlet system return NPT water connection that returns water from the system to the heat exchanger either 1 or 1 1 4 depending on the model Gas connection pipe Threaded pipe connection either 1 2 or 3 4 depending on the model This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler 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 4 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Manual air vent Designed to remove trapped air from the heat exchanger coils High voltage junction box The junction box contains the connection points for the line voltage power and all pumps Boiler drain port Location from which the heat exchanger can be draine
76. or 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 firing 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 39 8 Operating i
77. 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 Boiler 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 42 Outdoor Knight Boiler Installation amp Operation Manual Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically be changed at set intervals During the first 24 hours of operation the sequence will change every hour After that the sequence will change every 24 hours The switching on off sequence will be as follows TIME SWITCHING ON SEQUENCE L M1 M2 M3 M4 M5 M6 M7 M1 M2 M3 M4 M5 M6 M7 L EATE 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 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
78. r 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 with no flow lockup or with boiler on e Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane Gas ING Outdoor boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 11 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage 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 maximum pressure 2 Pressure required at gas valve inlet pressure port e Maximum 14 inches w c with no flow lockup or with boiler on e Minimum 8 inches w c with gas flowing verify during boiler startup Ensure that the high gas pressure regulator is at least 6 10 feet upstream of the appliance 55 mms 4 Gas connections Table 4A
79. r respective contacts in series and connect them to the terminals on the 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 flow 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 AT across the heat exchanger as well as prevent high limit lockouts when the flow 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 firing rate of the boiler This may be used by a BMS system to monitor the actual rate of the boiler 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 29 5 Field wiring Flow switch 1 A f
80. re If the temperature exceeds its setting the integrated control will break the control circuit shutting the boiler down Gas shutoff switch An electrical switch designed to cut power to the gas valve to prevent releasing any gas Over temp switch Model 286 Only located underneath access cover An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger directly above the flue 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 Air cover Covers the over temp switch and the flue collar with flue sensor Flue pipe assembly Factory supplied components for a complete venting system eT Outdoor Knight Boiler Installation amp Operation Manual The Outdoor Knight Boiler How it works continued Models 151 211 IMG00365 Front View Models 151 211 Rear View Models 151 211 cO O Ol N NI J N N IMG00368 IMG00367 Left Side inside unit Models 151 211 Right Side inside unit Models 151 211 aseP Outdoor Knight Boiler Installation amp Operation Manual The Outdoor Knight Boiler How it works Model 286 IMG00379 Front View Model 286 Hear View Model 286 Z 1MG00381 IMG00382 lt N
81. re 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 Outdoor Knight Boiler Installation amp Operation Manual T Ke ac BOILER 5 Field wiring continues Figure 5 3 Low Voltage Field Wiring Connections ZcLOOOWI SASOdaNd NOILVYLSNTI1 YO4 Lids GUYVOd NOILOANNOO TSTHS NOILAG g snsacl Y gJ TSTHS LNO SLYH A I Lit diitd 4 18 A BI O NI ditd SAS ADI OTSIHS a qqvasvo ly g IdIHS uosN3s Z o PINV 1 HOSNAS WALSAS YOSNAS AlddNS WALSAS c YOSNIS YOOGLNO i E YOSNAS YNYVL x11009 1X3N 8 ol Y WALSAS LINANASV
82. ress the RIGHT SELECT key to save the current change Press the RIGHT SELECT key to return to the Status Screen and HOME upload parameter changes 48 9 Maintenance Outdoor Knight Boiler Installation amp Operation Manual Maintenance and annual startup Table 9A Service and Maintenance Schedules Service technician see the following pages for instructions QO u oc lt P V l lt lt lt lt General e Address reported problems e Inspect interior clean and vacuum if necessary e Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate e Verify flue and air openings in good condition and free of obstruction e Check system water pressure system piping expansion tank e Check control settings eCheck ignition and flame sense electrodes sand off any deposits clean and reposition e Check wiring and connections e Perform start up checkout and performance verification per Section 7 of this manual e Flame inspection stable uniform e Flame signal at least 10 microamps at high fire eClean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need e Clean heat exchanger e Remove and clean burner compressed air only using e Clean the blower wheel Owner maintenance see the Outdoor Knight User s Information Manual for instructions e
83. roper shutdown procedure and to schedule an annual start up at the beginning of the next heating season 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 e Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow time for the boiler to cool to ambient temperature if it has been firing 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 A WARNING 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 5 Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan Using field supplied means cover the refractory in the back of the combustion chamber of the heat exchanger 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 vacu
84. s 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 first then the boiler pump will SYSTEM turn off 2 seconds later This will divert the boilers outlet water ae from the heating system and send it to the tank coil instead The ee control will then modulate to maintain the outlet temperature to HEHU Se SCREEH SHOH the DHW boiler set point 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 SUCTEHM switch back and forth between the two heating modes until one of Hire elie them is satisfied MENU oa SCREEH sHDH POST PURGE 10 Once both calls for heat are satisfied the control will turn off the SYSTEM burner The blower will continue to run during the postpurge period OUTOCOOR MEHU ge SCREEH SHOH 11 Any pumps that are running will continue to run for their respective pump delay times before turning off unless programmed to Sv TEM remain on continuously A 60 second anti cycle period will start TAHE pas OUTOCOOR which will delay any new call for heat until it times out E MEHO s SCREEH SHEH STANDBY 12 In Standby ready to start a new cycle S OK H ESE 136 a F OUTDOOR MEHO SETPOINTS SHOH 44 Use the control panel FIG 8 1 to set temperatures operating conditions and monitor boiler operation Figure 8 1 Control P
85. se 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 satisfied Once Demand 2 has been satisfied the boiler will provide 110 F water to the system A CAUTION When multiple temperature loops are used mixing valves are required for the protection of any low temperature loops SMART SYSTEM Multi temp loop control The outdoor 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 boiler can be controlled by a Building Management System BMS provided that either an external energy management system is installed that reduces the boiler water temperature as the heating load decreases the boiler is not used for any space heating or the boiler is part of a modular or multiple boiler system having a total input of 300 000 Btu hr or greater
86. shown for illustration purposes 21 Kase Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping Figure 3 9 Multiple Boilers Single Temperature Zoned with Valves Number of Units Model 2 3 4 5 6 7 8 _ Required Pipe Sizes 5 cr TT en I PRESSURE BACKELOW A SOINS VANE ZONE 2 ZONE 3 ZONE 4 Pee eee PRESSURE a eee a BALL VALVE Sk GAUGE 7 E 7 ZONE VALVES TYPICAL pal lt S TYPICAL I j wa E il MAKE UP WATER SYSTEM SUPPLY SENSOR WHEN USED DIFFERENTIAL PRESSURE BYPASS VALVE IF USED AIR SEPARATOR SYSTEM RCULATOR EXPANSION TANK MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART TYPICAL x S I ANTI SCALD Since MIXING VALVE 4 CIRCULATOR QO DOMESTIC HOT WATER CIRCULATOR Y STRAINER lt RECOMMENDED WV TYPICAL UNION TEMPERATURE TYPICAL Ke E DRAIN BOILER 2 BOILER 1 INDIRECT MEMBER 1 LEADER DHW TANK IMG00375 NOTICE 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 Indoor tank shown for illustration purposes 22 Kase Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping continea Figure 3 10 Multiple Boilers Non Zoned Primary Secondary Piping Number of Units Model 2 3 4 5 6 7
87. sor 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 finishes the call for heat when the tank temperature reaches the tank set point 2 The tank sensor included with the Lochinvar Squire Indirect DHW tank 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 Failure to use the correct sensor may result in the tank temperature being either above or below the set point 3 If the 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 manufacturers instructions and wired to the DHW Thermostat terminals on the Low Voltage Connection Board High gas pressure switch 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 Ifa 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 thei
88. t setting 10 Turn on all electric power to appliance 3 Turn off all electric power to the 11 Set thermostat to desired setting apPianCe 12 lf the appliance will not operate follow the 4 This appliance is equipped with an instructions To Turn Off Gas To Appliance and ignition device which automatically lights call your service technician or gas supplier the burner Do not try to light the burner by hand 5 Remove front door Move switch to the OFF position 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step gt TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Move switch the OFF position Turn off all electric power to the appliance 5 Install front door if service is to be performed Remove front door LBL2339 REV B 36 f Start u D continuea Check flame and combustion continued NOTICE Please note that the brackets denote screen status 4 Place the boiler into the active position by pressing the RIGHT SELECT ON key FIG 8 1 page 45 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 f
89. 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 37 r Start up 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 firing 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 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
90. 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 1 Set the boiler in place and check level a Adjust legs if necessary to level boiler see FIG 2 4 below 6 Replace the top and front access covers Figure 2 4 Leveling Legs on the Boiler SCREWDRIVER Table 2A LP Conversion Table LP Conversion Table Model LP Orifice Stamping 210 W150 26 25 _ A WARNING After converting to LP check combustion cen LOWER per the Start up procedure in Section 7 of this manual Failure to check and verify combustion could result in severe personal injury death or substantial property damage Figure 2 3 Installing Propane Orifice GAS VALVE GROMMET BRASS ORIFICE 17 3 Hydronic piping System water piping methods The outdoor boiler is designed to function in a closed loop pressurized system not less than 12 psi 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 and must be figured 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 for basic service of
91. tions are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes Indoor tank shown for illustration purposes 19 Kias Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping Figure 3 7 Multiple Boilers Multiple Temperatures Number UN Model 2 3 4 5 6 7 58 _ Required Pipe Sizes WIRES TO LOOP SENSORS PRESSURE TEMPERATURE TEMPERATURE TEMPERATURE BACKFLOW REDUCING VALVE LOOP 1 LOOP 2 LOOP 3 PREVENTER pod ar ns MIXING VALVES PRESSURE TYPICAL GAUGE MAKE SYSTEM N UP SUPPLY 2 lt T cJ Bik Br F A T rl j C ll rl j EXPANSION 24V SIGNAL TO MIXING VALVES TANK Cc D SHIELDED CABLE TO BOILER CONTROL di J MAY SUBSTITUTE si V w LOSS HEADER R T Nor TO EXCEED 4 PIPE DIA OR MAX OF 12 APART 120VAC TO PUMPS BALL VALVE TYPICAL DRAIN POINT 1 TYPICAL BOILER MULTI TEMP CIRCULATOR LOOP CONTROL OPTIONAL DOMESTIC HOT HOT WATER ANTI SCALD WATER CIRCULATOR MIXING OUT Y STRAINER VAVE A8 coLp RECOMMENDED WATER IN Q l TEMPERATURE l ER PRESSURE IMG00373 CAUTION Mixing valves are required for the protection of low temperature loops NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by loc
92. ue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F 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 the control will reduce the maximum fan speed If the temperature difference exceeds 60 F the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 55 F and the minimum off time has expired Freeze protection DO NOT install the boiler 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 Below 45 F the boiler and system pumps operate constantly Below 37 F the boiler turns on Boiler and pumps turn off if boiler water temperature rises above 45 F Lower temperatures may be programmed for systems with anti freeze solutions When system return temperatures NOTICE oe Eee are maintained below the dew point condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust A caution
93. um 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 field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble Outdoor Knight Boiler Installation amp Operation Manual 11 Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow 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 Part Component Number Description CTN20005 Rear Refractory Cover 151 MSC20083 Nylon 4 Wheel Brush ragg MSC20083 Ny 286 MSC20084 3mm Allen Wrench MSC20086 1 4 x 24 Drill Extension A CAUTION Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush CAUTION IF GASKET IS DAMAGED UU DO NOT REUSE THE HEAT EXCHANGER DOOR MUST BE REPLACED NOTICE Rope gasket is intended for sealing combustion FIG 9 3 If damaged DO NOT reuse the heat exchanger door must be replaced Consult factory for replacement heat
94. ure gauge on the boiler water outlet 10 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 11 Boiler purge valve Field supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up 13 3 Hydronic piping 12 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 Typically the sensor will be located far enough downstream to sense system diluted water temperature 13 Indirect water heaters The outdoor boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium As depicted on pages 17 through 23 there are two options when utilizing an indirect water heater A The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater B The indirect water heater is connected to the system supply piping A pump controlled by the outdoor boiler s control will regulate the flow of water through the indirect water heater The indirect water heater s temperature will be regulated by the outdoor boiler s control The outdoor boiler is pre configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming The DHW programming is d
95. ure 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 flammable 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 fittings 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 50 CONDENSATE ou J HEAT EXCHANGER Figure 9 1 Condensate Trap RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN A WAR
96. use 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 The outdoor unit must not be installed in an area that is enclosed by walls or a fence that will block free wind movement around the unit Free movement of wind around the outdoor unit is required to carry away the flue products and provide combustion air The flue 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 flue products into the combustion air inlet Recirculation of flue products may cause operational problems bad combustion or non warrantable damage to controls Do not install the outdoor unit under a A WARNING Fea Do not install an outdoor 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 could result in severe personal injury death or substantial property damage 1 Check for nearby connection to e Water piping Do not install outdoor units in locations Gas supply piping CAUTION where rain from building runoff drains e Electrical power will spill onto the unit 2 Keep venting areas free of obstructions Do not locate the outdoor unit so that Keep area cle
97. utdoor vent system Flooring and foundation Flooring The Outdoor Knight is approved for installation on combustible flooring A WARNING Do not install the boiler on carpeting even if foundation is used Fire can result causing severe personal injury death or substantial property damage Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler 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 Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons 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 9 2 Prepare boiler Remove boiler from wood pallet 1 After removing the outer shipping carton from the boiler remove the installation kit 2 Remove the front access covers 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 access covers a Remove the two lag bolts from the wood pallet inside the
98. utlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 7 1 Condensate Trap RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH PVC TEE ASSEMBLY TO FLOOR DRAIN CONDENSATE aS HEAT EXCHANGER 34 FACTORY SUPPLIED Outdoor Knight Boiler Installation amp Operation Manual 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 Ifa voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves
99. vere personal injury death or substantial property damage If the information in this manual is not followed exactly a fire 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 flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e 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 fire department Installation and service must be performed by a qualified installer service agency or the gas supplier When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e Do not block flow 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 flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced
100. witches 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 Pump sizing and flow requirements are DOGE based on 20 feet of piping 4 90 elbows and 2 fully ported ball valves It is required that near boiler piping systems utilize the Primary Secondary configuration shown in FIG 3 10 only The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance SMART SYSTEM Multi temperature loop control option The outdoor 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 16 Kice Outdoor Knight Boiler Installation amp Operation Manual 3 Hydronic piping continea Figure 3 4 Single Boiler Single Temperature Zoned with Circulators 7 PRESSURE PRESSURE REDUCING VALVE GAUGE ZONE 2 ZONE 3 ZONE 4 f a f 1 f L jJ L 4i L 4i L qi BACKFLOW PREVENTER Le a ag Sy f TYPICAL IIB NN IIB IIB MAKE UP W
101. y adjusts boiler water temperature in relation to heat demand An external control may be connected to control the firing rate or the set point of the boiler provided that either an external energy management system is installed that reduces the boiler water temperature as the heating load decreases the boiler is not used for any space heating or the boiler is part of a modular or multiple boiler system having a total input of 300 000 Btu hr or greater 1 An external control may be connected to control either the firing 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 0 10 Vdc terminal is connected to the 0 10 Vdc terminal of the external control Make sure the voltage is not below ground 30 Outdoor Knight Boiler Installation amp Operation Manual 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 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

Nikon 13216 Digital Camera User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents