Lochinvar Knight XL 100 Series Service Manual
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Also See for Knight XL 100 Series:
- Installation & operation manual (80 pages) ,
- User's information manual (12 pages)
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100332296_2000589042_Rev C
Service Manual
Models: 400 - 1000
Series 100 & 101
⚠ WARNING
This manual must only be used
by a qualified heating installer
/ service technician. Read all
instructions, including this manual
and the Knight XL Installation and
Operation 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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Table of Contents
Related Manuals for Lochinvar Knight XL 100 Series
Summary of Contents for Lochinvar Knight XL 100 Series
- Page 1 100332296_2000589042_Rev C Service Manual Models: 400 - 1000 Series 100 & 101 ⚠ WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight XL Installation and Operation Manual, before installing.
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Page 2: Table Of Contents
Contents 2. MAINTENANCE CONTENTS ............... 2 Maintenance and Annual Startup ........ 29-34 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ..... 3 Before Troubleshooting ............ 35 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 35 When servicing boiler ........... -
Page 3: Please Read Before Proceeding
Service Manual Please read before proceeding Installer – Read instructions, ⚠ WARNING When calling or writing about the boiler NOTICE including this manual and the Knight – Please have the boiler model and serial XL Installation and Operation Manual, number from the boiler rating plate. before installing. -
Page 4: When Servicing Boiler
Service Manual Please read before proceeding When servicing boiler – • To avoid electric shock, disconnect electrical supply before performing maintenance. • To avoid severe burns, allow boiler to cool before performing maintenance. Boiler operation – • Do not block flow of combustion or ventilation air to the boiler. -
Page 5: What Is In This Manual
Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior • Clean condensate trap The Knight XL display •... -
Page 6: Service Near Boiler Piping
Service Manual Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight XL. This piping scheme is important for proper operation of the SMART TOUCH control. See the Knight XL Installation and Operation Manual for more detailed piping diagrams. -
Page 7: The Knight Xl Display
Service Manual Service (continued) The Knight XL display HOME VIEW SETUP INFORMATION SETTINGS... -
Page 8: Control Inputs
Service Manual Service Service Control inputs GAS PRESSURE SWITCH DHW THERMOSTAT LOW VOLTAGE FLOW SWITCH CONNECTION BOARD TANK SENSOR SEQUENCER / BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH SMART SYSTEM... -
Page 9: Control Outputs
Service Manual Service Service (continued) Control outputs ALARM BELL LOW VOLTAGE LOUVER RELAY CONNECTION BOARD RUN TIME CONTACTS SEQUENCER / BUILDING MANAGEMENT SYSTEM BUILDING RECIRCULATION PUMP BOILERR PUMP IGNITOR BLOWER SMART SYSTEM GAS VALVE CONTROL BOARD DISPLAY PANEL DIR #2000596354... -
Page 10: General Operation
Service Manual Service Service General Operation How the boiler operates Adjust set point temperature(s) During normal operation, set point temperatures can be The Knight XL uses an advanced stainless steel heat adjusted from the Home Screen by pressing the DETAILS exchanger and an electronic control module that allows button on the bottom of the screen (see FIG. -
Page 11: Sequence Of Operation
Service Manual Service Service (continued) Table 1-1 Sequence of Operation OPERATION 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). -
Page 12: Display Panel Menu Access
Service Manual Service Service (continued) Display panel menu access... -
Page 13: Parameter Table
Service Manual Service Service (continued) Parameter table Table 1-4 This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display/Modify Display/Modify Time and Date Software Version (read only) Yes/No Temperature Units (ºC/ºF) SH Night Setback Offset SH Night Setback On Times SH Night Setback Off Times... - Page 14 Service Manual Service Service Parameter table Table 1-4 (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display/Modify Display/Modify Outdoor 1 Low Outdoor 1 High Set Point 1 at Low Outdoor Temp 1 Set Point 1 at High Outdoor Temp 1 Outdoor Air Shutdown SH1 Outdoor Air Shutdown Differential SH1...
- Page 15 Service Manual Service (continued) Parameter table Table 1-4 (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display/Modify Display/Modify System Pump Delay Boiler Pump Delay DHW Pump Delay Boiler Pump Anti-Seize Delay Boiler Pump Min Voltage System Pump Demand...
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Page 16: Initial Setup
(4) hours. This parameter must be accessed to set the clock. If the unit is connected to the internet, the Press the SETTINGS button under the Lochinvar logo time will adjust based on the time zone selected. -
Page 17: Viewable And Changeable Control Parameters
Service Manual Service Viewable and changeable control parameters Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. Set Point Screens Figure 1-2 Set Points HW Screen Space Heating (SH) and Domestic Hot Water (DHW) Space Heating (SH) and Domestic Hot Water (DHW) Night Setback Offset Night Setback On &... - Page 18 (continued) Display Timeout 3-Way Valve Time The optional Lochinvar Multi-Temperature Loop Control This is the time in which the display remains illuminated. Board (MTLCB) can be used to control the supply temperature The range is 10 seconds to 10 minutes. The default is 3 up to three (3) sub-loops, corresponding to each of the three minutes.
- Page 19 Service Manual Service Freeze Protection Burner Differential Once this timer expires, it will switch back to the DHW demand. The installer can adjust the length of time the boiler will service Once the burner has started firing due to a low inlet the space heating demand by accessing SH/DHW Switching temperature, the inlet temperature must increase by this Time parameter.
- Page 20 Service Manual Service (continued) Outdoor Reset Set Point (1 - 3) at Low Outdoor Temperature When the outdoor air temperature drops to the Outdoor The option of controlling up to three (3) different outdoor (1 - 3) Low parameters, the calculated set point will be at resets for low outdoor temperatures is available.
- Page 21 Service Manual Service Outdoor Air Shutdown Differential (SH1 - SH3) Boost Time The outdoor air shutdown differential parameter is the The boost time parameter sets the amount of time that must number of degrees below Outdoor Air Shutdown SH1, SH2, elapse with a SH demand before the water temperature and SH3 parameters the outdoor air temperature must calculated set point will be increased.
- Page 22 Service Manual Service (continued) Ramp Settings The SMART TOUCH control can be programmed to limit Note, however, that the 6th limit will also limit the rate for the the firing rate for a fixed period of time at the start of a space rest of that heat demand.
- Page 23 Service Manual Service The other Cascade divider method is Efficiency Optimization, designated as EFF in the menu. This method is used, as the The set point or modulation of the boiler may be controlled name implies, when it is desired to have the most efficient through the 0 - 10V BMS input or through ModBus.
- Page 24 Service Manual Service Figure 1-6 Cascade Setup Figure 1-7 Cascade Leader Setup...
- Page 25 TOUCH Controls for Multiple Size Units & Front End Loading installer can adjust this time delay by accessing the Minimum Instruction Sheet provided on the Lochinvar website). Next On Time parameter. The minimum setting is 0 minutes and the maximum setting is 10 minutes. The default is 60...
- Page 26 Service Manual Service Circulation pumps Boiler Pump Maximum Voltage The SMART SYSTEM control outputs a 0 - 10V signal to Boiler Pump Mode control the speed of the boiler circulator. The Boiler Pump The parameter determines how the control turns the boiler Maximum Voltage parameter sets the maximum voltage signal circulating pump on and off.
- Page 27 Service Manual Service (continued) Volts at Maximum Force On When programmed for BMS control through the 0 - 10V BMS The Force On parameter tells the system pump it must run input or through ModBus, the Volts at Maximum parameter when there is a DHW demand.
- Page 28 Service Manual Service Figure 1-9 Service Notification Screen Table 1-5 Service Notification (This table lists control module parameters; use the sub-tab under the Setup tab to access them. Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Maintenance Notice By: Months Maintenance Notice By: Running Hours...
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Page 29: Maintenance
Service Manual Maintenance Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Owner maintenance Service technician (see the Knight XL User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Inspect interior; clean and vacuum if •... - Page 30 Service Manual Maintenance Follow the Service and maintenance procedures given throughout this manual and in component literature ⚠ WARNING 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.
- Page 31 Service Manual Maintenance (continued) Check boiler relief valve Flue vent system and air piping Visually inspect the entire flue gas venting system and air 1. Inspect the relief valve and lift the lever to verify flow. piping for blockage, deterioration or leakage. Repair any Before operating any relief valve, ensure that it is piped joints that show signs of leakage.
- Page 32 Service Manual Maintenance Inspect ignition and flame sense Figure 2-2 Burner Assembly - Model 400 - 1000 electrodes 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper.
- Page 33 Service Manual Maintenance (continued) Check flame signal 7. Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum 1. At high fire the flame signal shown on the display should the heat exchanger. be at least 10 microamps.
- Page 34 Service Manual Maintenance Test low water flow conditions While slowly shutting off the isolation valve, refer to the Status Screens to watch the behavior of the boiler. These screens allow you to monitor the inlet temperature, outlet This test is to be carried out once the NOTICE temperature, and ΔT.
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Page 35: Troubleshooting
Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection ⚠ WARNING when servicing controls. Wiring errors can cause improper and dangerous ALWAYS check control module fuses before NOTICE operation. Always disconnect power replacing control module or any major to the boiler before servicing. - Page 36 Service Manual Troubleshooting Table 3-1 Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. - No 120 vac supplied to unit. • Check position of ON/OFF switch. Turn switch to the ON position. •...
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Page 37: Checking Temperature Sensors
Service Manual Troubleshooting (continued) Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. - Page 38 Service Manual Troubleshooting Table 3-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Supply problem. Natural pressures should be between 4 inches • Refer to the Gas Connections section of the Knight XL w.c. and 14 inches w.c. LP gas pressures Installation and Operation Manual for detailed should be between 8 inches w.c.
- Page 39 Service Manual Troubleshooting (continued) Table 3-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Reset the pressure switches. • Measure the supply gas pressure to determine cause of failure. Natural gas pressures should be between 4 - 14 inches w.c.
- Page 40 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION APS: • Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals.
- Page 41 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged. •...
- Page 42 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference the Knight XL Installation and Operation Manual for adjusting procedures.
- Page 43 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Replace the main control board if necessary. • If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.
- Page 44 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check the sensors and their associated wiring. Sensor Shorted Repair or replace the sensor or wiring if damaged. (will require a manual reset once the condition has been Either the inlet water or outlet water...
- Page 45 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check wiring to sensor. Make sure wiring is connected and not damaged. Reconnect / repair Flue Sensor Fault wiring if necessary.
- Page 46 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect the heat exchanger. Reference this manual for the procedure on how to clean the flue side of the heat exchanger.
- Page 47 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check set point of the external control. • Check the wiring between the external control and the Rem Ctrl Flt External control is cycling too often.
- Page 48 Service Manual Troubleshooting Check flame and combustion 7. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in 1. Turn the main power off to the boiler by placing the “On/ Table 11B below.
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Page 49: Gas Valve Adjustment Procedure
Service Manual Troubleshooting (continued) Gas valve adjustment procedure 1. For Models 400-500: Remove the front panel from the unit (no tools required for removal). For Models 650-1000: Remove the top access cover from the unit (no tools required for removal). 2. - Page 50 Service Manual NOTES...
- Page 51 Service Manual NOTES...
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Page 52: Revision Notes
Revision Notes: Revision A (PCP #3000042117 / CN #500030025) initial release. Revision B (PCP #3000042688 / CN # 500030426) reflects an update from SMART SYSTEM to SMART TOUCH. Revision C (PCP #3000059169 / CN #500045359) reflects updates to Table 1-4, page 26, and page 27. 100332296_2000589042_Rev C 01/24...