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OKBX-I-O Rev B
Outdoor Knight XL
Installation & Operation Manual
Models: 400 - 801
This manual must only be used by
WARNING
a qualifi ed heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Knight XL Service Manual,
before installing. Perform steps in
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.
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Contents HAZARD DEFINITIONS .................................................... 2 Pipe Sizing for Natural Gas .........................................25 PLEASE READ BEFORE PROCEEDING ........................ 3 Natural Gas Supply Pressure Requirements ............. 25 THE OUTDOOR KNIGHT XL -- HOW IT WORKS......... 4-6 Propane Gas .....................................................................25 RATINGS ........................................................................... 7
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Outdoor Knight XL Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including When servicing boiler – WARNING this manual and the Outdoor Knight XL • To avoid electric shock, disconnect electrical supply Service Manual, before installing. Perform before performing maintenance. steps in the order given. User – This manual is for use only by • To avoid severe burns, allow boiler to cool before a qualified heating installer/service per
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Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... 1. Stainless steel heat exchanger 21. Boiler drain port Allows system water to fl ow through specially designed Location from which the heat exchanger can be drained. coils for maximum heat transfer, while providing protection 22. Low voltage connection board against fl ue gas corrosion. The coils are encased in a jacket that The connection board is used to connect external low voltage contai
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4 33 20 36 26 8 4 30 39 7 39 13 IMG00406 21 24 Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... (continued) Model 400 31 19 IMG00405 11 Front View - Model 400 Rear View - Model 400 IMG00407 Left Side (inside unit) - Model 400 Right Side (inside unit) - Model 400 5 32 10 25 20 22 37 16 1 2 3 34 27 17 IMG00404
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31 23 15 18 29 11 IMG00323 14 41 15 32 19 28 41 IMG00324 Outdoor Knight XL Installation & Operation Manual The Outdoor Knight XL - How it works... Model 501 35 33 15 17 4 29 7 39 Left Side (inside unit) - Model 501 Rear View - Model 501 Models 601 - 801 IMG00324 Rear View - Models 601 - 801 Left Side (inside unit) - Models 601 - 801 6 IMG00409 16 20 22 3 4 5 10 18 8 2 1 34 30 21 24 IMG00408
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Outdoor Knight XL Installation & Operation Manual Ratings Outdoor Knight XL Boiler Other Specifi cations AHRI Rating Input Net Model Number Gross AHRI MBH Boiler Water Water Gas Output Ratings Content Air Size Connections Connections (Note 4) MBH Water, Note: Change “N” to Gallons MBH “L” for L.P. gas models. Min Max (Note 1) (Note 2) OKN400 80 399 370 322 3.4 1-1/2" 1" 4" 4.2 1-1/2" 1" 4" OKN501 100 500 463 402 4.2 2" 1" 4" OKN601 120 600 566 493 5.0 2" 1
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Outdoor Knight XL Installation & Operation Manual 1 Determine boiler location Installation must comply with: The unit must not be installed in an area CAUTION that is enclosed by walls or a fence that • Local, state, provincial, and national codes, laws, regulations, and ordinances. will block free wind movement around the appliance. Free movement of wind • National Fuel Gas Code, ANSI Z223.1 – latest edition. around the outdoor unit is required • Standard for Controls and Safet
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Outdoor Knight XL Installation & Operation Manual 1 Determine boiler location (continued) Provide clearances: Under no circumstances is the manufacturer to be held responsible for water damage in connection with this Clearances from combustible materials appliance, or any of its components. If fl ooding is possible, 1. Hot water pipes—at least 1/4" (6 mm) from combustible elevate the boiler suffi ciently to prevent water from reaching materials. the boiler. 2. Jacket—minimum of 0" from
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Outdoor Knight XL Installation & Operation Manual 2 Prepare boiler Remove boiler from wood pallet Install fl ue pipe assembly 1. After removing the outer shipping carton from the Models 400 - 601 boiler, remove the parts box. This unit is provided with all of the necessary venting components. All components must be installed prior to 2. Remove the front door to access the lag bolts in front operation. of the unit (FIG. 2-1). 1. Locate all venting components from the installation kit
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VENT TERMINATION VENT PIPE IMG00446 WALL STRAP CLAMP ELBOW VENT COVER WALL STRAP SCREWS Outdoor Knight XL Installation & Operation Manual 2 Prepare boiler (continued) Models 701 - 801 1. Locate all venting components from the installation kit and carton. 2. Before connecting the vent pipe sections or components, verify that the gasket is seated evenly inside the groove in the female end of the elbow and fl ue adapter (FIG. 2-3). 3. Remove the vent cover from the back of the unit as sho
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Outdoor Knight XL Installation & Operation Manual 2 Prepare boiler Gas conversions For a boiler already installed, you must After converting to LP, check combustion WARNING WARNING turn off gas supply, turn off power and per the Start-up procedure in Section 10 allow boiler to cool before proceeding. of this manual. Failure to check and verify You must also completely test the boiler combustion could result in severe personal after conversion to verify performance injury, dea
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Outdoor Knight XL Installation & Operation Manual 2 Prepare boiler (continued) Model 501 After converting to LP, check combustion WARNING per the Start-up procedure in Section 1. Remove the top access cover from the unit (Philips Head 10 of this manual. Failure to check and screwdriver required for removal). verify combustion could result in severe 2. Turn the adjustment screw on the gas valve clockwise until personal injury, death, or substantial it stops. Then turn the adjustme
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping System water piping methods General piping information Basic steps are listed below along with illustrations on the The Outdoor Knight XL is designed to function in a closed following pages (FIG.’s 3-7 through 3-11), which will guide loop pressurized system not less than 12 psi (83 kPa). A you through the installation of the Outdoor Knight XL temperature and pressure gauge is included to monitor (reference FIG.’s 3
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping (continued) Flow switch, relief valve and temperature Figure 3-1 Flow Switch, Relief Valve and Temperature and and pressure gauge installation Pressure Gauge Installation_Models 400 - 501 Basic steps are listed below to guide you through the installation of the fl ow switch, relief valve, and temperature and pressure gauge provided with the unit. 1. For Models 400 - 501 install the close nipple on the outlet connecti
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping Flow switch adjustment Near boiler piping components Refer to Table 3A for the proper setting of the sensitivity 1. Boiler system piping: screw. For reference, the position of the screw prior to setting Boiler system piping MUST be sized per the pipe should be turned clockwise with a Phillips driver until it stops requirements listed in Table 3B. Reducing the pipe size (FIG. 3-3). Proceed to turn the screw cou
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping (continued) 12. Boiler purge valve: Figure 3-4B Near Boiler Piping w/Low Loss Header Field supplied. The boiler purge valve is used to SYSTEM PUMP remove entrapped air from the heat exchanger during SYSTEM SENSOR start-up. AIR SEPARATOR DRAIN (TYPICAL) 13. System temperature sensor: AIR VENT VALVE Lochinvar supplies a system temperature sensor. The LOW LOSS HEADER (TYPICAL) sensor is to be installed in the
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping Figure 3-5 Pressure Drop vs. Flow - Models 400 and 501 Pressure Drop vs Flow (Includes Boiler Secondary Piping) 20 18 16 14 12 OKBN501 10 KBN400 O 8 6 4 2 0 0 5 10 15 20 25 30 35 40 45 Flow Rate (GPM) Figure 3-6 Pressure Drop vs. Flow - Models 601 thru 801 Pressure Drop vs Flow (Includes Boiler Secondary Piping) 60 50 40 KBN801 O 30 KBN701 O OKBN601 20 10 0 0 10 203040 506070 8090 Flow Rate (GPM) Table 3B Sizing Info
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Outdoor Knight XL Installation & Operation Manual 3 Hydronic piping (continued) Figure 3-7 Single Boiler - Multiple Temperatures Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes. Please note that these illustrations show an indoor tank to demonstrate piping concept only. NOTICE 19 T
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AIR SEPARATOR MAY SUBSTITUTE LOW LOSS HEADER DRAIN POINT (TYPICAL) NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART SYSTEM SUPPLY SENSOR (WHEN USED) BALL VALVE (TYPICAL) SYSTEM CIRCULATOR Y-STRAINER EXPANSION TANK (RECOMMENDED) BOILER CIRCULATOR MAKE UP WATER BACK FLOW PREVENTER PRESSURE REDUCING VALVE INDIRECT DHW TANK ANTI-SCALD M X NG VALVE I I HOT WATER OUT DOMESTIC HOT WATER CIRCULATOR BOILER UNION (TYPICAL) COLD WATER IN PRESSURE RELIEF VALVE DRAIN IMG00393 FLOW CHECK VA
