Lochinvar KNIGHT 400 - 801 Service Manual
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Lochinvar KNIGHT 400 - 801 Service Manual

Lochinvar boiler user manual
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See also: User's Information Manual
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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Summary of Contents for Lochinvar KNIGHT 400 - 801

  • Page 1 This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Installation Operation Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, substantial...
  • Page 2 Boiler operation ......4 Boiler water ....... . . 4 Freeze protection fluids .
  • Page 3 Eye: Irrigate immediately. Breathing: Fresh air. Service Manual When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate. Consider piping and installation when determining boiler location (see the Knight XL Installation and Operation Manual).
  • Page 4 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 • K: Service Notification Service Manual • 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 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 Service Manual 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 SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL FLOW SWITCH SYSTEM SENSOR OUTDOOR SENSOR BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HI-LIMIT SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH...
  • Page 9 Service Manual ALARM BELL LOW VOLTAGE LOUVER 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 The blower pulls in gas and air and pushes flue products out of the boiler through the heat exchanger and flue piping. 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 Table 1-1 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 The flow switch and/or LWCO must close.
  • Page 12 The control will then modulate to maintain the outlet temperature to the DHW boiler set point. 9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisfied.
  • Page 13 Service Manual Table 1-2 [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. Rotate the NAVIGATION dial clockwise until 5 is displayed (first digit on the left).
  • Page 14 Service Manual Table 1-3 Rotate the NAVIGATION dial counterclockwise until the arrow (>) is next to TEMPERATURE SETTINGS. Press the NAVIGATION dial one time. Rotate the NAVIGATION dial counterclockwise until the arrow (>) is next to MIN SETPT. Press the NAVIGATION dial one time. Rotate the NAVIGATION dial to the desired temperature.
  • Page 15 Table 1-4 Date and Time Software Version (read only) Temperature Units (ºC/ºF) SH Night Setback Offset SH Night Setback On Times SH Night Setback Off Times DHW Night Setback Offset DHW Night Setback On Times DHW Night Setback Off Times Display Timeout SH1 Set Point Minimum SH Set Point...
  • Page 16 Table 1-4 DHW Boiler Set Point DHW Tank Set Point Tank Set Point Differential Boiler Set Point Offset Boiler Set Point Differential SH/DHW Switching Time DHW/SH Switching Time Tank Minimum Set Point Tank Maximum Set Point DHW Type (Normal, Zone)
  • Page 17 Min On/Off Time Min Next On Time Boiler Size System Pump Delay Boiler Pump Delay DHW Pump Delay Boiler Pump Anti-Seize Delay Boiler Pump Min Voltage System Pump Type (CFH/WWSD) DHW Pump Anti-Seize Delay System Pump Anti-Seize Delay Service Manual...
  • Page 18 Table 1-4 BMS Type (Power / Set Point) Volts at Min Volts at Max Rate at Min Volts Rate at Max Volts Set Point at Min Volts Set Point at Max Volts On Volts Off Differential Volts Service Notification Months Service Notification Running Time Service Notification Cycles Reset Maintenance Reminder...
  • Page 19 The control uses an internal clock for the night setback feature and for logging of events. 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 four (4) hours.
  • Page 20 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 21 DHW tank as a separate load, or as a zone on the primary loop. When programmed as a separate load, the boiler will turn on the DHW pump and then turn off the boiler pump when an indirect DHW demand begins. When programmed as...
  • Page 22 The option of controlling up to three (3) different outdoor resets for low outdoor temperatures is available. When the outdoor air temperature drops below this point, the water temperature will be at parameters F3, F8 and F13 (FIG. 1-1). However, if the user set point is set lower, the water temperature will be limited by the user set point instead.
  • Page 23 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 24 The default sensor is the Outlet Sensor. Once this When controlling the boiler through the 0 - 10V BMS input or through ModBus, the boiler can be enabled one of two ways. With parameter H2 set to ACTIVE, the boiler will enabled by closing the Room Thermostat 1 input.
  • Page 25 20% fire, it will hold it there and start lowering the firing rate on the next-to-last boiler. When the next-to-last boiler reaches 35%, it will turn the last boiler off and raise the rate of the next-to-last boiler to 55%, thus eliminating the sudden drop in total output of the Cascade.
  • Page 26 I3. The time range for this parameter is 0 minutes to 40 minutes. The default time is 30 seconds. If the boiler pump does not run for 24 hours, it will be turned on briefly to prevent it from seizing. The length of time it runs is determined by parameter I4.
  • Page 27 ModBus and the BMS Thermostat Input is set to INACTIVE, parameter J8 determines the 0 - 10V BMS input voltage at which the boiler is enabled. The minimum value is 0.5V and the maximum is 10.0V. The default value is 2.0V.
  • Page 28 • Check condensate drain system • Check 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 29 The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 2-1 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 30 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 31 4. Replace ground wires if ground continuity is not satisfactory. 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of this manual.
  • Page 32 • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the 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 33 F2 - 3.15 AMP FUSE BLOWER 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 .80 amps, F2 is 3.15 amps and F1 is 5 amps).
  • Page 34 Weather Shutdown (WWSD) set point for main control board. - Unit locked out on fault. - Ramp delay active. - Boiler controlled by BMS. - Flue sensor open. Service Manual • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position.
  • Page 35 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 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 37 • Correct the supply gas pressure if necessary. • Check for a loose or misplaced jumper if pressure switches are not installed. • Check boiler pump operation on a call for heat. • Check for closed valves or obstructions in the boiler piping.
  • Page 38 Table 3-4 The main control board has received a call for heat too quickly after the previous call for heat has ended. The unit has failed to prove main burner ignition after four (4) attempts. (will require a manual reset once the condition has been corrected.
  • Page 39 • 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. • If the system pump is a variable speed pump, ensure that the system flow is not less than the boiler flow.
  • Page 40 Table 3-4 (will require a manual The main control board did not detect the reset once the condition gas valve. has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) (will require a manual The actual fan RPM is 30% higher than what reset once the condition is being called for.
  • Page 41 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. • Verify that the boiler pump is set to the proper speed or that the pump is the proper size.
  • Page 42 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. • Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size.
  • Page 43 Table 3-4 120 vac input to the main control board has dropped below 80 vac. The main control board has detected an internal fault. The main control board has detected an internal fault. The main control board has detected an internal fault.
  • Page 44 Table 3-5 • 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. • Check for obstructions at the vent/air intake terminals.
  • Page 45 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 valve should not need adjusting. Locate the throttle adjustment screw on the top of the gas valve, see FIG.
  • Page 48 Revision Notes:...

This manual is also suitable for:

Knight xl 400-801

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