Lochinvar 50 Service Manual
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Lochinvar 50 Service Manual

Lochinvar 50 Service Manual

Knight wall mount boiler
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Download this manual See also: User's Information Manual, Operation & Installation Manual
WB-SER Rev D
Service Manual
Models: 50 - 210
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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  • Page 1 WB-SER Rev D Service Manual Models: 50 - 210 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.

  • 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...

  • Page 8: Control Inputs

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

  • Page 9: Control Outputs

    Service Manual Service Service (continued) Control outputs...

  • 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 heat exchanger and an electronic control module that allows The user can adjust space heating set point using the UP and fully condensing operation.

  • Page 11: Sequence Of Operation

    Service Manual Service Service (continued) Sequence of operation Table 1A Sequence of operation - space heating and DHW OPERATION DISPLAY 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 Service Service Sequence of operation (continued) Table 1A (continued from previous page) Sequence of operation - space heating and DHW OPERATION DISPLAY 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: Display Panel Menu Access

    Service Manual Service Service (continued) Display panel menu access Table 1B Use this procedure to access menus from the display panel...

  • Page 14: Display Panel Parameter Access

    Service Manual Service Service Display panel parameter access Table 1C This is a typical example of accessing a parameter, shown for parameter I2, boiler pump delay...

  • Page 15: Parameter Table

    Service Manual Service Service (continued) Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY Boiler Model User Code Date and Time Software Version Temperature Units Night Setback Temperature...

  • Page 16: Parameter Table

    Service Manual Service Service Parameter table (continued) Table 1D (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY Anti-cycling Time Return Temperature Differential for Ending Anti-Cycling Ramp Delay On/Off...

  • Page 17: Viewable And Changeable Control Parameters

    B1. The displayed as “YY:MM:DD W hh:mm”. YY = year, MM = month, temperature range of this parameter is 50°F to 190°F. The DD = date, W = day (1 = Sunday, 2 = Monday, etc.), hh = hour default value is 125°F.
  • Page 18 C: Data logging parameter E1. The temperature range of this parameter is 50°F to 190°F. The default value is 180°F. Hours running SH SH/DHW switching time The hours running SH parameter shows the total number of hours the boiler has been in the SH firing position.
  • Page 19 Service Manual Service Service (continued) Figure 1-1 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 Service Manual Service Service G: Anti-cycling Boost temperature If a SH demand lasts longer than the programmed time delay Anti-cycling time setting (F9) and there have been no DHW demands, the control will increase the water temperature set point by the Once a SH demand has been satisfied, a set amount of time amount in this parameter.
  • Page 21 Service Manual Service Service (continued) Figure 1-2 Ramp Delay Interval 3 - Cascade. The boiler is part of a group of boilers sequenced H: Control modes together. The designated Leader boiler determines the total SH controlling sensor output needed from the group based on the set point and controlling sensor reading.
  • Page 22 Service Manual Service Service 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: Maintenance

    Service Manual Maintenance Maintenance and annual startup Table 2A 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 24: Inspect Boiler Area

    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 25: 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 26: Check Control Settings

    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 27: Review With Owner

    1. Shut down boiler: CTN20005 Rear Refractory Cover • Follow the “To Turn Off Gas to Appliance” 50 - 105 KIT30062 MSC20083* Nylon 4" Wheel Brush* instructions for the boiler in Section 10 - Startup of the Installation and Operation Manual.

  • Page 28: Troubleshooting

    Service Manual Troubleshooting Label all wires prior to disconnection Check control module fuses WARNING when servicing controls. Wiring errors can cause improper and dangerous ALWAYS check control module fuses NOTICE operation. Always disconnect power to before replacing control module or any the boiler before servicing.

  • Page 29: Table 3A - Troubleshooting Chart - No Display

    Unit Does Not - Boiler controlled by BMS. software required. Modulate Above 50% - Flue sensor open. • Verify that the flue sensor is located in the flue outlet. • Check wiring connections at the flue sensor. • Check the resistance of the flue sensor and compare...

  • Page 30: 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 31: Table 3E - Troubleshooting Chart - Noisy System

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

  • Page 32: Table 3F - Troubleshooting Chart - Fault Messages

    Service Manual Troubleshooting Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Either the optional flow switch or the optional • Check boiler pump operation on a call for heat. low water cutoff is not making. •...

  • Page 33: Corrective Action

    Service Manual Troubleshooting (continued) Table 3F (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 34 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit was running and lost the flame • Inspect spark electrode and associated wiring for signal. This condition occurred four (4) damage and connection.
  • Page 35 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The outlet water temperature has exceeded • Verify that the system is full of water and that all air the fixed setting of the automatic reset high has been properly purged from the system.
  • Page 36 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The actual fan RPM is 30% higher than what • Vent/air intake lengths exceed the maximum allowed is being called for. lengths.
  • Page 37 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The stack temperature has exceeded the set • Inspect the heat exchanger. Reference page 27 of parameters for the boiler. this manual for the procedure on how to clean the flue side of the heat exchanger.
  • Page 38 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Temp O/Shoot • Verify that the boiler pump is set to the proper speed (continued) or that the boiler pump is the proper size. Reference (will require a manual Section 6 - Hydronic Piping of the Knight Wall Mount Outlet water temperature has exceeded the...
  • Page 39 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION While the unit is in Service Mode, the outlet • Establish a heating load to remove the heat from the temperature has exceeded 185°F.

  • Page 40: Combustion Analysis Procedure

    Service Manual Troubleshooting Combustion Analysis Procedure 1. Turn the main power off to the boiler by placing the Table 3H Flue Products “On/Off ” switch in the OFF position. Natural Gas Propane 2. Remove the flue temperature sensor from the flue pipe connection.

  • Page 41: 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 42 Service Manual Notes...
  • Page 43 Service Manual Notes...

  • Page 44: Revision Notes

    Revision Notes: Revision B (ECO #C02407) reflects air pressure switch changes, removal of references to the pocket pc, and changes made to the Circulation Pumps Section (page 22). Revision C (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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