Lochinvar Knight 51 - 106 Service Manual
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Lochinvar Knight 51 - 106 Service Manual

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WBII-SER Rev B
Service Manual
Models: 51 - 211
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read
all
instructions,
including this manual and the
Knight
Wall
Mount
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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Summary of Contents for Lochinvar Knight 51 - 106

  • Page 1 WBII-SER Rev B Service Manual Models: 51 - 211 This manual must only be WARNING used by a qualified heating installer / service technician. Read instructions, including this manual and the Knight Wall Mount Installation and Operation Manual, before installing. Perform steps in the order given.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ........2 Maintenance and Annual Startup .

  • Page 3: Please Read Before Proceeding

    Service Manual Please read before proceeding Installer – Read all instructions, When calling or writing about the boiler – WARNING NOTICE including this manual and the Knight Please have the boiler model and serial Wall Mount Installation and Operation number from the boiler rating plate. Manual, 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 wall mount boiler 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 wall mount boiler. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Knight Wall Mount Installation and Operation Manual for more detailed piping diagrams.

  • Page 7: The Knight Wall Mount Display

    Service Manual Service Service (continued) The Knight wall mount display NAVIGATION DIAL 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...

  • Page 8: Control Inputs

    Service Manual Service Service Control inputs SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL LOW VOLTAGE CONNECTION FLOW SWITCH BOARD SYSTEM SENSOR OUTDOOR SENSOR BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HIGH LIMIT SENSOR FLUE GAS SENSOR PRESSURE SWITCH...

  • Page 9: Control Outputs

    Service Manual Service Service (continued) Control outputs ALARM BELL LOW VOLTAGE AUX. DEVICE RELAY CONNECTION BOARD RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL PC INTERFACE...

  • Page 10: General Operation

    Service Manual Service Service General Operation How the boiler operates Access modes User The Knight wall mount boiler uses an advanced stainless steel The user can adjust space heating and tank target heat exchanger and an electronic control module that allows temperatures by pressing the NAVIGATION dial when fully condensing operation.

  • Page 11: Sequence Of Operation

    Service Manual Service Service (continued) Sequence of operation OPERATION DISPLAY 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, pump DHW).
  • Page 12 Service Manual Service Service Sequence of operation (continued) OPERATION DISPLAY 8. If the space heating call for heat is active, and the tank thermostat or sensor starts 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 boiler...

  • Page 13: Display Panel Menu Access

    Service Manual Service Service (continued) Display panel menu access Table 1-2 Use this procedure to access menus from the display panel SCREEN BUTTON OPERATION DISPLAY STATUS [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES]. Press and hold the LEFT SELECT soft key [MENU] [MENU] for five (5) seconds.

  • Page 14: Display Panel Parameter Access

    Service Manual Service Service Display panel parameter access Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN SH Setpt SCREEN BUTTON OPERATION DISPLAY STATUS This example shows how to access parameter Temperature Settings. The first display shown is at the beginning of the menu listings, after entering the installer access code.

  • Page 15: Parameter Table

    Service Manual Service Service (continued) Parameter table Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Item Page Display Modify Display Modify Date and Time Software Version (read only) Temperature Units (ºC/ºF) SH Night Setback Offset SH Night Setback On Times...

  • Page 16: Parameter Table

    Service Manual Service Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Item Page Display Modify Display Modify DHW Boiler Set Point DHW Tank Set Point Tank Set Point Differential Boiler Set Point Offset...
  • Page 17 Service Manual Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Item Page Display Modify Display Modify Boost Temperature Boost Time Anti-Cycling Time Anti-Cycling Override Differential Ramp Delay (Enable, Disable)
  • Page 18 Service Manual Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Item Page Display Modify Display Modify BMS Type (Power / Set Point) Volts at Min Volts at Max Rate at Min Volts...

  • Page 19: Viewable And Changeable Control Parameters

    Service Manual Service (continued) Viewable and changeable control parameters Before changing parameters, note the Space Heating (SH) and Domestic Hot Water (DHW) CAUTION settings so that the unit can be returned to Night Setback On Times its original operating parameters. This is the time in which the SH Night Setback Offset becomes active.
  • Page 20 Service Manual Service Display Timeout 3-Way Valve Time This is the time in which the display remains illuminated. Not used. The range is 10 seconds to 10 minutes. The default is 3 minutes. C: Data Logging Reset last 10 errors B: Temperature Settings The reset last 10 errors function clears the last 10 errors log.
  • Page 21 Service Manual Service E: DHW Settings DHW/SH Switching Time When a boiler has a DHW demand and it receives a space DHW Boiler Set Point heating demand, the SMART SYSTEM control will start a timer. Once the timer expires, it will stop the DHW demand and When a DHW call for heat becomes active, the control will service the space heating demand.
  • Page 22 Service Manual Service Service (continued) F: Outdoor Reset SH1 - SH3 Set Point at Low Outdoor Temperature When the outdoor air temperature drops below this point, the The option of controlling up to three (3) different outdoor water temperature will be at this setting (FIG. 1-1). However, resets for low outdoor temperatures is available.
  • Page 23 Service Manual Service Outdoor Air Shutdown Differential (SH1 - SH3) G: Anti-Cycling The outdoor air shutdown differential parameter is the Anti-Cycling Time number of degrees below parameters F5, F10 and F15 the outdoor air temperature must go before the boiler will Once a SH demand has been satisfied, a set amount of time must respond to a SH demand.
  • Page 24 Service Manual Service Service SH Ramp Delay H: Control modes Please note that the brackets ([]) Controlling Sensor NOTICE denote screen status. The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate. This parameter The SMART SYSTEM control can be programmed to limit is adjustable by the installer by accessing parameter H1.
  • Page 25 Service Manual Service Service (continued) ModBus (Active / Inactive) As the calculated load increases further and both boilers ramp up to 90%, it lowers the rate of the first two (2) boilers to 60% When BMS is set to ACTIVE (see BMS Active / Inactive) and brings the next boiler on at 60%.
  • Page 26 Service Manual Service I: Circulation pumps DHW Pump Anti-Seize Delay If the boiler pump does not run for 24 hours, it will be turned System Pump Delay on briefly to prevent it from seizing. The length of time it runs The system pump delay parameter sets the length of time the is determined by parameter I4.

  • Page 27: Service Notification

    Service Manual Service Set Point at Minimum Volts Service Notification Cycles When programmed for BMS control through the 0 - 10V BMS When the boiler control determines that a scheduled input or through ModBus and the BMS Type is programmed as service is due based on the number of boiler cycles, the SETPOINT, the set point represented by the Volts at Minimum boiler display will alternate the standard boiler display text...

  • Page 28: Maintenance

    Service Manual Maintenance Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Owner maintenance Service technician (see the Knight Wall Mount User’s Information (see the following pages for instructions) Manual for instructions) General: • Address reported problems • Check boiler area •...

  • Page 29: Address Reported Problems

    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 30: Check Expansion Tank

    Service Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage. Repair any authorized inspection agency, to ensure joints that show signs of leakage.

  • Page 31: Check Burner Flame

    Service Manual Maintenance Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from the 2. If the flame is unsatisfactory at either high fire or low fire, boiler heat exchanger access cover.

  • Page 32: Review With Owner

    Service Manual Maintenance (continued) Review with owner 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. 1. Review the Knight Wall Mount User’s Information Manual with the owner.

  • Page 33: Troubleshooting

    Service Manual Troubleshooting Label all wires prior to disconnection Check control module fuses WARNING when servicing controls. Wiring errors can cause improper and ALWAYS check control module fuses NOTICE dangerous operation. Always before replacing control module or any disconnect power to the boiler before major components (blower, etc.).
  • Page 34 Service Manual Troubleshooting (continued) Table 3-1 Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - No 120 vac supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position.

  • Page 35: Checking Temperature Sensors

    Service Manual Troubleshooting 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 36: Noisy System Troubleshooting Chart

    Service Manual Troubleshooting (continued) Table 3-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply problem. Natural • Refer to Section 7 - Gas Connections of the Knight Wall pressures should be between 4 inches w.c. Mount Boiler Installation and Operation Manual for and 14 inches w.c.

  • Page 37: Fault Messages Displayed On Boiler Interface

    Service Manual Troubleshooting 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 Gas Pressure SW 4 - 14 inches w.c.
  • Page 38 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has received a call • The control board will release the call for heat after a for heat too quickly after the previous call for set time period.
  • Page 39 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence • Check supply voltage for proper polarity. (will require a manual • Check external wiring for voltage feedback. reset once the condition The flame detector circuit is seeing a flame •...
  • Page 40 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION GV/Relay • Check wiring harness connection at the gas valve and Fail at the main control board. (will require a manual The main control board did not detect the •...
  • Page 41 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 page 32 of this manual for the procedure on how to clean the flue side of the heat exchanger.
  • Page 42 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 boiler pump is set to the proper speed or that the boiler pump is the proper size. Reference Outlet Temp Section 6 - Hydronic Piping of the Knight Wall Mount High...
  • Page 43 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION 120 vac input to the main control board has • Check 120 vac supply to the transformer. dropped below 80 vac. •...

  • Page 44: Combustion Analysis Procedure

    Service Manual Troubleshooting Combustion Analysis Procedure 1. Turn the main power off to the boiler. Table 3-6 Flue Products 2. Remove the flue temperature sensor from the flue pipe Natural Gas Propane connection. Note: Combustion measurements will be made at this point. 3.

  • Page 45: Gas Valve Adjustment Procedure

    Service Manual Troubleshooting (continued) Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: Locate the throttle adjustment screw on the side of the venturi valve (FIG. 3-2). Using a screwdriver, turn the screw a 1/4 turn clockwise to increase CO levels or a 1/4 turn counterclockwise to decrease CO...
  • Page 46 NOTES...
  • Page 47 NOTES...

  • Page 48: Revision Notes

    Revision Notes: Revision A (ECO #C05747) initial release. Reflects the new model numbers for the Knight Wall Mount upgrade. Revision B (ECO #C06234) reflects changes made to the Service Notification parameter. WBII-SER-Rev B 8/10...

This manual is also suitable for:

Knight 151 - 211

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