Lochinvar 80 - 285 Service Manual
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Lochinvar 80 - 285 Service Manual

Heating boiler
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See also: User's Information Manual
KB-SER-07
Service Manual
Models: 80 - 285
Starting Serial #H07H10040039
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read
all
instructions,
including this manual and the
Knight Boiler 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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  • Page 1 KB-SER-07 Service Manual Models: 80 - 285 Starting Serial #H07H10040039 This manual must only be WARNING used by a qualified heating installer / service technician. Read instructions, including this manual and the Knight Boiler Installation and Operation Manual, before installing. Perform steps in the order given.

  • Page 2: Table Of Contents

    Table 11 - Flue Products ......40 The Knight Boiler Display ......7 Gas Valve Adjustment Procedure .
  • Page 3 Service Manual 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 Boiler Installation Operation number from the boiler rating plate. Manual, before installing. Perform steps Consider piping and installation when in the order given.

  • Page 4: When Servicing Boiler

    Service Manual 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: Sequence Of Operation

    Service Manual • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior • Clean condensate trap • Check all piping for leaks • Display panel readout, buttons and their functions •...
  • Page 6 Service Manual This piping reference is included to specify the Near Boiler Piping specific to the Knight boiler. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Knight Boiler Installation and Operation Manual for more...
  • Page 7 Service Manual (continued)
  • Page 8 Service Manual AIR PRESSURE SWITCH...
  • Page 9 Service Manual (continued) ALARM BELL LOW VOLTAGE AUX. DEVICE RELAY CONNECTION BOARD RUN TIME CONTACTS SEQUENCER / BUILDING MANAGMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL PC INTERFACE...
  • Page 10 Service Manual Access modes User The Knight boiler uses an advanced stainless steel heat exchanger and an electronic control module that allows fully The user can adjust space heating set point using the UP and condensing operation. The blower pulls in gas and air and DOWN buttons at any time during normal operation.
  • Page 11 Service Manual (continued) Table 1 Sequence of operation - space heating and DHW BLR: Standby 1. Upon a call for heat, the control turns on the appropriate pumps OUT: 123.8F(129) (system and boiler pumps for space heating call; DHW pump for DHW call).
  • Page 12 Service Manual (continued) Table 1 (continued from previous page) Sequence of operation - space heating and DHW 8. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 BLR: SH 41% RATE seconds, and resume modulating based on the space heating...
  • Page 13 Service Manual (continued) Table 2 Use this procedure to access menus from the display panel...
  • Page 14 Service Manual Table 3 This is a typical example of accessing a parameter, shown for parameter I2, boiler pump delay...
  • Page 15 Service Manual (continued) Table 4 This table lists SMART SYSTEM control module parameters and where to access them Boiler Model User Code Date and Time Software Version Temperature Units Night Setback Temperature Night Setback Times SH Set Point User SH Minimum Set Point SH Maximum Set Point SH Offset SH Differential...
  • Page 16 Service Manual (continued) Table 4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Anti-cycling Time Return Temperature Differential for Ending Anti-Cycling Ramp Delay On/Off SH Controlling Sensor (Outlet/System, Inlet) SH Source (Thermostat, BMS, and Cascade) Boiler Cascade Address Max.
  • Page 17 A7. Each day of the week (Sunday through Saturday) will have an on and off time. The control will display “Knight Boiler” as the model number because the same control is used on several models. This will be Example: Monday ON: 22:30, Tuesday OFF: 6:45.
  • Page 18 Service Manual SH Differential The SH differential sets how many degrees below the turn off DHW boiler set point temperature the temperature has to go before the boiler will turn on. This parameter can only be changed by the installer When a DHW call for heat becomes active, the control will by accessing parameter B5.
  • Page 19 Service Manual (continued) Figure 1 Outdoor Air Reset Curve Maximum SH set point Outdoor air shutdown differential When the outdoor temperature drops to or below its The outdoor air shutdown differential parameter is the minimum setting (F1) the water temperature will be at this number of degrees below parameter F5 the outdoor air point, if the SH set point is set higher (FIG.
  • Page 20 When ramp delay is active, additional parameters for ramp delay operation will have to be adjusted. These can only be accessed by the optional PC software. See the Knight Boiler Smart System PC Program Instructions Manual for additional ramp delay parameter information.
  • Page 21 These can only be accessed by the cascade set point. Therefore, this parameter can be used to optional PC software. See the Knight Boiler Smart System PC limit the outlet temperatures of all the boilers in a Cascade.
  • Page 22 Service Manual Cascade offset Service notification running hours When the boiler control determines that a scheduled service is This parameter determines how much the temperature must due based on the hours of actual operation, the boiler display go above set point before the lead boiler will turn off. This will alternate the standard boiler display text with the message parameter can be adjusted by the installer by accessing SERVICE DUE every 5 seconds.
  • Page 23 Service Manual Table 5 Service and Maintenance Schedules (see the Knight User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area • Inspect interior; clean and vacuum if Daily necessary;...
  • Page 24 2. Verify that air intake area is free of any of the contaminants listed in Section 1 of the Knight Boiler Installation and Operation Manual. If any of these are present in the boiler intake air vicinity, they must be removed.
  • Page 25 Tanks may be open, closed or diaphragm or bladder type. disposal. Otherwise severe personal injury See Section 6 - Hydronic Piping of the Knight Boiler may result. If no water flows, valve is Installation and Operation Manual for suggested best inoperative.
  • Page 26 2. Check settings of external limit controls (if any) and adjust if necessary. 1. Start boiler and perform checks and tests specified in Section 10 - Start-up of the Knight Boiler Installation and Operation Manual. 2. Verify cold fill pressure is correct and that operating...
  • Page 27 Boiler Installation and Operation Manual. 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance” instructions 1. The circulator shipped with the Knight boiler is water- for the boiler in the Knight Boiler Installation and lubricated. No oiling is required.

  • Page 28: Check Control Module Fuses

    7. Install control module cover and top access cover after fuse inspection. 8. Restore power to the boiler at the external line switch and verify boiler operation (Section 10 - Start-up in the Knight Boiler Installation and Operation Manual) after completing boiler service.
  • Page 29 Service Manual (continued) Table 6 Troubleshooting Chart - No Display - 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. • Check 120 vac through the ON/OFF switch. •...
  • Page 30 Service Manual 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 (continued) Table 8 Troubleshooting Chart - Noisy System - Supply gas problem. Natural gas pressures • Refer to Section 7 - Gas Connections of the Knight should be between 4 inches w.c. and Boiler Installation and Operation Manual for detailed 14 inches w.c.
  • Page 32 Either the optional manual reset low gas has been corrected. Press pressure switch or the optional manual reset • Refer to Section 7 - Gas Connections of the Knight the RESET button on the high gas pressure switch tripped. Boiler Installation and Operation Manual for detailed information concerning the gas supply.
  • Page 33 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 7 - Gas Connections of the Knight Boiler Installation and Operation Manual for detailed information concerning the gas supply.
  • Page 34 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 7 - Gas Connections of the Knight Boiler Installation and Operation Manual for detailed information concerning the gas supply.
  • Page 35 Refer to Section 6 - Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler. • Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.
  • Page 36 Table 9 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface • Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting of the Knight Boiler Installation and Operation Manual for proper lengths. • Check for obstruction or blockage in the vent/air...
  • Page 37 Refer to Section 6 - Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler. • Check for 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board.
  • Page 38 • Verify that the boiler pump is set to the proper speed maximum outlet water temperature. or that the boiler pump is the proper size. Reference Section 6 - Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications.
  • Page 39 Knight Boiler Installation Operation Manual for the proper piping methods for the Knight boiler. • Check 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board. Replace the main control board if necessary.
  • Page 40 Table 10 Troubleshooting Chart - Combustion Levels • Refer to Section 3 - General Venting of the Knight Boiler Installation and Operation Manual for the proper venting and air intake methods for the Knight boiler. Vent/Air Intake Length or Obstruction •...
  • Page 41 Service Manual (continued) If adjustment of the gas valve is deemed necessary, use the following procedure: Locate the throttle adjustment screw on the side of the venturi valve (FIG. 6). Using a screwdriver, turn the screw a 1/4 turn counterclockwise to increase CO levels or a 1/4 turn clockwise to decrease CO levels.
  • Page 42 NOTES...
  • Page 43 NOTES...
  • Page 44 Revision Notes: Revision 4 (KB-SER-04) reflects the addition of the Dungs information to the manual. Revision 5 (ECO #C02407) reflects air pressure switch addition, removal of references to the pocket pc, along with the removal of Models 399 - 500. Revision 6 (ECO #C02545) reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff testing and instructions.

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