Table of Contents
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KBX-SER Rev E
Service Manual
Models: 399 - 800
This manual must only be
WARNING
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
Troubleshooting
Related Manuals for Lochinvar Knight XL 399 - 800
Summary of Contents for Lochinvar Knight XL 399 - 800
- Page 1 KBX-SER Rev E Service Manual Models: 399 - 800 This manual must only be WARNING used by a qualified heating installer / service technician. Read instructions, including this manual and the Knight XL Installation and Operation Manual, before installing. Perform steps in the order given.
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Page 2: Table Of Contents
Boiler operation ......4 Boiler water ....... . . 4 Freeze protection fluids . -
Page 3: Please Read Before Proceeding
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection. Apply enough water to the combustion chamber lining to prevent airborne dust. Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal. Wash potentially contaminated clothes separately from other clothing. -
Page 4: When Servicing Boiler
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. -
Page 5: What Is In This Manual
Service Manual Maintenance • Service and maintenance schedules • Address reported problems • Inspect boiler area and boiler interior • Clean condensate trap • Check all piping for leaks • Check air openings • Flue vent system and air piping •... -
Page 6: Service Near Boiler Piping
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 SYSTEM control. See the Knight XL Installation and Operation Manual for more detailed piping diagrams. -
Page 7: The Knight Xl Display
• Press to change displayed data values in Menu Mode • Press to navigate through menu listing in Menu Mode • Press to turn boiler off or back on • Press to select a menu item • Press after parameter programming to store parameter data •... -
Page 8: Control Inputs
Service Service Control inputs GAS PRESSURE SWITCH (OPTIONAL) DHW THERMOSTAT (OPTIONAL) ROOM THERMOSTAT / ZONE CONTROL FLOW SWITCH SYSTEM SENSOR DHW TANK SENSOR (OPTIONAL) OUTDOOR SENSOR (OPTIONAL) SEQUENCER / BUILDING MANAGEMENT SYSTEM (OPTIONAL) LOW WATER CUTOFF (OPTIONAL) INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR... -
Page 9: Control Outputs
Service (continued) Control outputs LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE Service Manual ALARM BELL AUX. DEVICE RELAY RUN TIME CONTACTS SEQUENCER / BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE... -
Page 10: General Operation
The control module regulates blower speed to control 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. -
Page 11: Sequence Of Operation
6. If the control detects a flame before the trial for ignition ends, it begins to modulate the burner in order to maintain the set point. If the boiler lights due to a space heating call for heat, and the ramp delay function is active (default is off), the modulation will be held to a series of increasing limits after the burner has lit. - Page 12 Table 1A (continued from previous page) Sequence of operation - space heating and DHW OPERATION 8. If the boiler is not part of a cascade, and the DHW call for heat remains active for more than 30 minutes, and the space heating...
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Page 13: Display Panel Menu Access
To select a highlighted menu, press the ENTER/RESET button one time. The display will change to the first parameter under that menu, with the first characters flashing. COMMENTS DISPLAY Boiler turns off (this ensures BLR:OFF uninterrupted programming) OUT:127.3ºF Enter Menu Code:... -
Page 14: Display Panel Parameter Access
Table 1C This is a typical example of accessing a parameter, shown for parameter I2, boiler pump delay BUTTON OPERATION This example shows how to access parameter I2, boiler pump delay. The first display shown is at the beginning of the menu listings, after entering the installer acess code. Beginning of menu listings... -
Page 15: Parameter Table
Hours Running SH Hours Running DHW Ignition Attempts Show Last 10 Errors Reset Last 10 Errors Service Mode Delay DHW Boiler Set Point SH/DHW Switching Time DHW Tank Set Point Minimum Air Temperature Maximum Air Temperature Maximum SH Set Point... -
Page 16: Parameter Table
DHW Pump Delay Service Notification in Month Service Notification Running Hours Service Notification Boiler Cycles Reset Service Notification Counter The parameters for Building Management System operation are not listed in this table. They are only NOTICE accessible using the PC interface software. See separate documentation for access information. See page 21 of this manual for a brief discussion. -
Page 17: Viewable And Changeable Control Parameters
For these features to work correctly, the clock must be set when the boiler is first installed or anytime the boiler has been powered off for more than 30 days. To set the clock, parameter A3 must be accessed. The date and time are displayed as “YY:MM:DD W hh:mm”. - Page 18 The delay sets the length of time the boiler will stay in the Service Mode if no keys have been pressed before going back to its original state.
- Page 19 The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before the boiler will respond to a SH demand. This parameter can be changed by the user or the installer by accessing parameter F6. The temperature range of this parameter is 0°F (0°) to 90°F (50°C).
- Page 20 The control will bypass the anti-cycling time if the water temperature drops too quickly. The control will use the water temperature the boiler was at when it shut off as the starting point. If the temperature drops below the temperature parameter the control will abort anti-cycling and allow the boiler to fire.
- Page 21 TIME TIME TIME 3 - Cascade. The boiler is part of a group of boilers sequenced together. The designated Leader boiler determines the total output needed from the group based on the set point and controlling sensor reading. It assigns portions of this output to itself (Leader) and the Member boilers.
- Page 22 Service Cascade offset This parameter determines how much the temperature must go above set point before the lead boiler will turn off. This parameter can be adjusted by the installer by accessing parameter H5. The default value is 9.9°F (5°C).
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Page 23: Maintenance
• Check condensate drain system • Check automatic air vents • Test low water cutoff (if used) • Reset button (low water cutoff) • Check boiler piping (gas and water) for leaks • Operate relief valve • Shut boiler down (unless boiler... -
Page 24: Address Reported Problems
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance WARNING and care of the boiler designated in Table 2A 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. -
Page 25: Check Expansion Tank
2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi (82.7 kPa)). 3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high. -
Page 26: Check Burner Flame
4. Replace ground wires if ground continuity is not satisfactory. Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. -
Page 27: Cleaning Boiler Heat Exchanger
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in the Knight XL Installation and Operation Manual. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. -
Page 28: Troubleshooting
F2 - 3.15 AMP FUSE 24V SUPPLY 5. The boiler is shipped with three (3) spare fuses in a plastic bag attached to the control module cover. 6. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4 are 3.15 amps, and F5 is 5 amps). -
Page 29: Table 3A - Troubleshooting Chart - No Display
Operation Weather Shutdown (WWSD) set point for main control board. - Unit locked out on fault. - Ramp delay active. Unit Does Not - Boiler controlled by BMS. Modulate Above 50% - Flue sensor open. (continued) CAUSE • Check external line switch, fuse, or breaker. -
Page 30: Checking Temperature Sensors
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 31: Table 3E - Troubleshooting Chart - Noisy System
Clean or replace the burner as necessary. Knight XL Installation and Operation Manual for minimum flow rates. Verify that the boiler is piped in a primary/secondary fashion and that the boiler and system pump are running on a call for heat. -
Page 32: Table 3F - Troubleshooting Chart - Fault Messages
Troubleshooting Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped (not available on 399 models). Gas Pressure SW... -
Page 33: Corrective Action
Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION The main control board has received a call for heat too quickly after the previous call for Anti-cycling heat has ended. The unit has failed to prove main burner... - Page 34 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION The unit was running and lost the flame signal. This condition occurred four (4) straight times on the 399 model or twice on the 500 - 800 models .
- Page 35 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT The outlet water temperature has exceeded the setting of the high limit. Adjustable High Limit w/Manual Reset (will require a manual reset once the condition has been corrected.
- Page 36 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT Fan High Fan Speed High (will require a manual The actual fan RPM is 30% higher than what reset once the condition is being called for.
- Page 37 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION The stack temperature has exceeded the set parameters for the boiler. The temperature rise across the heat exchanger has exceeded the set parameters for the boiler.
- Page 38 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT Outlet water temperature has exceeded the maximum outlet water temperature. Temp O/Shoot (continued) External control is cycling too often. Rem Ctrl Flt After downloading parameters from a laptop, Parameters the main control board must be reset.
- Page 39 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT While the unit is in Service Mode, the outlet temperature has exceeded 185°F. Service Blk 120 VAC input to the main control board has dropped below 80 VAC.
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Page 40: Combustion Analysis Procedure
Table 3G Troubleshooting Chart - Combustion Levels POSSIBLE CAUSE • Refer to Section 3 - General Venting of the Knight XL Installation and Operation Manual for the proper venting and air intake methods for the Knight XL boiler. Vent/Air Intake Length or Obstruction •... -
Page 41: Gas Valve Adjustment Procedure
Troubleshooting Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.) Under normal operating conditions this CAUTION valve should not need adjusting. Model 399 Locate the throttle adjustment screw on the top of the gas valve, see FIG. - Page 42 Service Manual Notes...
- Page 43 Service Manual Notes...
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Page 44: Revision Notes
Revision Notes: Revision B (ECO #C02407) reflects air pressure switch changes, changes made to the Circulation Pumps Section (page 22) and removal of references to the pocket pc. Revision C (ECO #C02545) reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff testing and instructions.