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Lochinvar Knight 50-210 Service Manual
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Lochinvar Knight 50-210 Service Manual

Lochinvar Knight 50-210 Service Manual

Lochinvar wall mount boiler service manual
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This manual must only be
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 50-210

  • Page 1 This manual must only be 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. Failure to comply could result in severe personal injury, death, or substantial property damage.
  • Page 2 Boiler operation ......4 Boiler water ....... . . 4 Freeze protection fluids .
  • Page 3 • 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 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 • I: Circulation Pumps • J: Service Notification • 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 Manual 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...
  • Page 7 Service Manual...
  • Page 8 GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL FLOW SWITCH 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 FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE...
  • Page 9 Service Manual...
  • Page 10 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. The Knight wall mount control module receives input from boiler sensors.
  • Page 11 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 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 seconds, and resume modulating based on the space heating set point.
  • Page 13 Service Manual Table 1B...
  • Page 14 Service Manual Table 1C...
  • Page 15 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 Minimum Air Temperature Maximum Air Temperature Maximum SH Set Point Minimum SH Set Point...
  • Page 16 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 accessible using the PC interface software. See separate documentation for access information. See page 21 of this manual for a brief discussion.
  • Page 17 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 C1. The hours running DHW parameter shows the total number of hours the boiler has been in the DHW firing position. This parameter can be viewed by the user and the installer by accessing parameter C2.
  • 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 to 90°F.
  • 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 System PC Program Instructions Manual for additional BMS parameter information. 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.
  • Page 22 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. This parameter determines how much the temperature must go below the turn off temperature (Set point + Offset) before the lead boiler turns on.
  • Page 23 • 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 Failure to service and maintain the boiler and system could result in equipment failure. Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.
  • Page 25 2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi). 3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high.
  • Page 26 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 27 • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in the Knight Wall Mount 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 PUMPS F2 - 3.15 AMP FUSE 24V SUPPLY 5. The boiler is shipped with three (3) spare fuses in a plastic bag provided with the unit. 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 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 30 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 Clean or replace the burner as necessary. Knight Wall Mount 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 SMART SYSTEM display to reset.) Service Manual • Check boiler pump operation on a call for heat. • Check for closed valves or obstructions in the boiler piping. • Verify system is full of water and all air has been purged from the system.
  • Page 33 Table 3F 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 34 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. • Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged.
  • Page 35 • 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 36 Table 3F The actual fan RPM is 30% higher than what is being called for. (will require a manual reset once the condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) Either the inlet water or outlet water temperature sensor has been disconnected.
  • Page 37 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 38 SMART SYSTEM display to reset.) Service Manual • Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size. Reference Section 6 - Hydronic Piping of the Knight Wall Mount Installation and Operation Manual for boiler pump specifications.
  • 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. • Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size.
  • Page 40 • Refer to Section 3 - General Venting of the Knight Wall Mount Installation and Operation Manual for the proper venting and air intake methods for the Knight wall mount boiler. • Check for obstructions at the vent/air intake terminals.
  • Page 41 Service Manual 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 levels.
  • Page 42 Service Manual...
  • Page 43 Service Manual...
  • Page 44 Revision Notes:...