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Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
THE OUTDOOR KNIGHT XL -- HOW IT WORKS......... 4-6
RATINGS ........................................................................... 7
1. DETERMINE BOILER LOCATION
Flooring and Foundation .................................................... 9
Prevent Combustion Air Contamination ............................. 9
Corrosive Contaminants and Sources ................................ 9
2. PREPARE BOILER
Remove Boiler from Wood Pallet ..................................... 10
Install Flue Pipe Assembly .......................................... 10-11
Gas Conversions .............................................................. 12
Model 400 .................................................................... 12
Model 501 ................................................................... 13
Models 601 - 801 ........................................................ 13
Leveling the Boiler............................................................ 13
3. HYDRONIC PIPING
System Water Piping Methods .......................................... 14
Low Water Cutoff Device ................................................. 14
Chilled Water System........................................................ 14
Freeze Protection ............................................................. 14
General Piping Information ............................................... 14
Flow Switch and Relief Valve Installation ....................... 15
Flow Switch Adjustment............................................... 16
Circulator Sizing ............................................................... 17
4. GAS CONNECTIONS
Connecting Gas Supply Piping ......................................... 24
Natural Gas ...................................................................... 25
Pipe Sizing for Natural Gas ......................................... 25
Natural Gas Supply Pressure Requirements ............. 25
Propane Gas ..................................................................... 25
Pipe Sizing for Propane Gas ...................................... 25
Propane Supply Pressure Requirements ................... 25
Check Inlet Gas Supply ................................................... 26
Gas Pressure ................................................................... 27
Gas Valve Replacement ................................................... 27
5. FIELD WIRING
Line Voltage Connections ................................................. 28
Low Voltage Connections ............................................28-29
Wiring of the Cascade ...................................................... 30
6. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 32
7. STARTUP .............................................................. 33-38
8. OPERATING INFORMATION
General............................................................................. 39
Cascade ............................................................................ 42
Sequence of Operation ............................................... 43-44
Outdoor Knight XL Control Module .................................. 45
Status Display Screens ............................................... 46-48
9. MAINTENANCE
Maintenance and Annual Startup .................................49-53
10. DIAGRAMS
Wiring Diagram ........................................................... 54
Ladder Diagram ........................................................... 55
Revision Notes .................................................. Back Cover
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 information concerning the life of the product.
 DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
 WARNING injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
 CAUTION injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
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