Lochinvar 400 - 801 manual

Service Manual Models: 400 - 801 This manual must only be used by a qualified heating installer / serv ice technician. Read all instructions, including this manual and the Knight XL Installation and Operation Manual, before installing. P erform steps in the order given. Failur e to comply could result in sev ere personal injur y , death, or substan[...]

2 Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention t o the presence of hazards of various r isk level s or to important information concerning the life of the product.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazardous situation whic h, if not avoided, wil[...]

Service Manual Please r ead bef or e proceeding Installer – R ead all instructions, including this manual and the Knight XL Installation and Operation Man ual, before installing. Pe rfor m steps in the order given. Us e r – This manual is for use only by a qualified heating installer/serv ice technician. Refer t o the Knight XL User’ s Inform[...]

4 Service Manual Please r ead bef or e proceeding When servicing boiler – • T o av oid electric shock, disconnect electrical supply before performing maintenance. • T o av oid severe burns, allow boiler to c ool before performing maintenance. Boiler operation – • Do not block flow of combustion or v entilation air to the boiler . • Shou[...]

Service Manual 5 W hat is in this manual? Ser vice Near boiler piping • T y pical system components T he Knight XL display • Display panel r eadout, buttons and their functions Control module inputs • Control module inputs and options Control module outputs • Control module outputs and options General • Ho w the boiler operates • Ho w t[...]

1 Ser vice 6 Service Manual Y -STRAINER (RECOMMEND ED) BOILER PUM P INDIRECT DOM ESTIC HOT WA T ER T ANK SYSTEM PUM P TO FLOOR DRAIN T O F R O M F R O M S Y S T E M T O S Y S T E M DOMEST IC HO T WA TE R P UM P SYSTEM SENSOR DIRT SEP ARA TOR Near boiler piping This piping referenc e is included to specify the N ear Boiler Piping specific to the Kni[...]

Service Manual 7 1 Ser vice (continued) NA VIGA TION DIAL T he Knight XL display The information on the bottom of the display sho ws the functions of the two SELECT keys (on either c or ner), and the N A VIGA TION dial (in the center): MENU = Left SELECT K e y SETPOINTS = N A VIGA TION Dial - Pr essing Down SHDN = Right SELECT K ey[...]

1 Ser vice 8 Service Manual 1 Ser vice GAS PRESSURE SW ITCH DHW T HERMOSTA T ROOM THERMOST A T / ZONE CONTRO L FLO W SW ITCH SYSTEM SENSOR OUTDOOR SENSOR BUILDING MANAG EMENT SYSTEM LOW VOL T AGE CONNECTION BOARD INLET TEMPERA TUR E SENSOR OUTLET TEMPERA TURE / HI-LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SW ITCH FLAME SENSOR LOW WA TER CUTOFF BL[...]

1 Ser vice Service Manual 9 1 Ser vice (continued) LOW VOL T AGE CONNECT ION BOARD SMAR T CONTROL MODULE ALARM BELL LOUVER RELA Y RUN TI ME CONT ACTS BUILDING M ANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW P UMP IGNITOR BLOW ER GAS V AL VE DISPLA Y P ANEL PC INTERF ACE Control outputs[...]

1 Ser vice 10 Service Manual 1 Ser vice General Oper ation How the boiler operates The Knight XL uses an advanced stainless st eel heat ex changer and an electronic control module that allo ws fully condensing operation. The blower pulls in gas and air and pushes flue products out of the boiler through the heat ex changer and flue piping. The contr[...]

1 Ser vice Service Manual 1 Ser vice (continued) T able 1-1 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 pump s for space heating, DHW pump for DHW). The flow switch and/or L W[...]

1 Ser vice 12 Service Manual 1 Ser vice T able 1-1 (continued from previous page) Sequence of Operation OPERATION DISPLAY 8. If the space heating call for heat is active, and the tank thermostat or sensor st arts 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 tu[...]

1 Ser vice Service Manual 13 1 Ser vice (continued) Display panel menu access T able 1-2 Use this procedure to access menus from the display panel B UTTON SCREEN ST A TUS OPERA TION DISPLA Y [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES]. [MENU] Press and hold the LEFT SELECT soft key [MENU] for five (5) s[...]

1 Ser vice 14 Service Manual 1 Ser vice Display panel parameter access T able 1-3 This is a typical example of accessing a parameter , shown for parameter T emperature Settings, MIN SH Setpt B UTTON SCREEN ST A TUS OPERA TION DISPLA Y This example shows how to access parameter T emperature Settings. The first display shown is at the beginning of th[...]

1 Ser vice Service Manual 15 1 Ser vice (continued) Parameter table T able 1-4 This table lists SMAR T SYSTEM control module parameters and where to access them Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify A 1 Date and T ime 19 Ye s Ye s Ye s Ye s 2 Software V ersion (read only) 19 No No Ye s No 3 T[...]

1 Ser vice 16 Service Manual 1 Ser vice Parameter table T able 1-4 (continued from previous page) This table list s SMART SYSTEM control module parameters and where to access them Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify E 1 DHW Boiler Set Point 21 No No Ye s Ye s 2 DHW T ank Set Point 21 Ye s Y[...]

1 Ser vice (continued) Service Manual 17 Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify F 18 Boost T emperature 23 No No Ye s Ye s 19 Boost T ime 23 No No Ye s Ye s G 1 Anti-Cycling T ime 23 No No Ye s Ye s 2 Anti-Cycling Override Differential 23 No No Ye s Ye s 3 Ramp Delay (Enable, Disable) 23 No No[...]

1 Ser vice Service Manual 18 Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify J 1 BMS T ype (Power / Set Point) 26 No No Ye s Ye s 2 V olts at Min 26 No No Ye s Ye s 3 V olts at Max 26 No No Ye s Ye s 4 Rate at Min V olts 26 No No Ye s Ye s 5 Rate at Max V olts 26 No No Ye s Ye s 6 Set Point at Min V ol[...]

Service Manual 19 1 Ser vice (continued) Viewable and changeable contr ol parameter s A: General Date and Time The control uses an int ernal clock for the nig ht setback feature and for logging of events. For these featur es to work correctly , the clock must be set when the boiler is first installed or anytime the boiler has been powe red off for [...]

20 Service Manual 1 Ser vice C: Data Logging Reset last 10 errors The reset last 10 errors function clears the last 10 errors log. D: Functions Service Mode Delay By pressing the pin butt on on the front of the display for fi ve (5) seconds, the control will be placed in Serv ice M ode. This will override all other heat demands. The Service Mode al[...]

Service Manual 21 1 Ser vice (continued) E: DHW Settings DHW Boiler Set Point W hen a DHW call for heat becomes active, the control will use the DHW boiler set point to determine the firing rate of the boiler based on the boiler outlet water temperatur e. This parameter can be changed by the installer b y accessing parameter E1 . The temperature ra[...]

22 Service Manual 1 Ser vice Figure 1-1 Outdoor Air Reset Curve F: Outdoor R eset The option of contr olling up to three (3) different outd oor resets for lo w outdoor temperatures is a vailable. Low Out door T emperature W hen the outdoor air temperature drops belo w this point, the water te mper ature will be at parameters F3 , F8 and F13 (FIG. 1[...]

Service Manual 23 1 Ser vice (continued) G: Anti-Cyc ling Anti-Cycling Time Once a SH demand has been satisfied, a set amount of time must elapse before the co ntrol w ill respond t o a new SH demand. The control will block the new heat demand and anti-cycling will be shown in the display until the time has elapsed or the wat er temperature dr ops [...]

Service Manual 24 1 Ser vice H: Control modes Controlling Sensor The SH controlling sensor paramet er selects the sensor the control will use to r egulate the boiler firing r ate. This par ameter is adjustable by the installer by ac cessing parameter H1 . T he sensor selections are as follo ws: The outlet sensor regulates the firing rate based on t[...]

Service Manual 25 1 Ser vice (continued) Modbus (Active / Inactive) W hen BMS is set to A CTIVE (see BMS Acti ve / Inactiv e) and the boiler is being controlled thr ough Modbus, set parameter H4 to A CTIVE. Otherwise, set the M odbus parameter to IN A CTIVE. N ote that the boiler can still be monitored b y ModBus with this parameter set to IN ACTIV[...]

26 Service Manual 1 Ser vice DHW Pump Anti-Seize Delay If the boiler pump does not r un for 24 hours, it will be tur ned on briefly to prevent it fr om seizing . The length of time it runs is determined by parameter I4 . The r ange of this setting is 0 seconds t o 40 minutes. The default setting is 20 seconds. System Pump Anti-Seize Delay If the bo[...]

Service Manual 27 1 Ser vice (continued) Inst aller Name and Phone Number W hen a Maintenance R eminder timer or counter has expired, a Maintenance R eminder screen will appear on the display . By pr og ramming the installer’ s name and phone number , this information will appear on the Maintenanc e Re minder Screen at that time. This can be pr o[...]

2 Maintenance Service Manual 28 Maintenance and annual star tup T able 2-1 Service and Maintenance Schedules Ser vice tec hnician (see the following p ages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (water , gas[...]

2 Maintenance (continued) 29 Service Manual Follo w the Ser vice and maintenance pr ocedures given thr oughout this manual and in component literature shipped with the boiler . F ailure to perform the serv ice and maintenanc e could result in damage to the boiler or system. Failure to follo w the directions in this manual and component literatur e [...]

2 Maintenance Service Manual 30 Flue vent system and air piping 1. V isually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. R epair any joints that show signs of leakage. V erify that air inlet pipe is connected and pr operly sealed. 2. V er ify that boiler vent disc harge and air intake are clean [...]

2 Maintenance (continued) 31 Service Manual Inspect ignition and flame sense electrodes 1. R emove the ignition and flame sense electrodes fr om the boiler heat ex changer access co ver . 2. R emove an y deposits accumulated on the ignition/flame sense electrode using sandpaper . I f the electrodes cannot be cleaned satisfactorily , r eplace with n[...]

2 Maintenance Service Manual 32 Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not impro ve, ground wir ing is in good condition, and g round c ontinuity is satisfactor[...]

3 T r oubleshooting 33 Service Manual Label all wires prior to disconnection when serv icing controls. W iring errors can cause improper and dangerous operation. Alwa ys disconnect po wer to the boiler before serv icing. Failur e to comply c ould result in sever e personal injur y , death, or substantial property damage. Nev er jumper (bypass) any [...]

3 T r oubleshooting Service Manual 34 T able 3-1 T roubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 vac supplied to unit. • Check external line switch, fuse, or breaker . • Check position of ON/OFF switch. T urn switch to the ON position. • Check 120 vac through the ON/OFF switch. • Check wiring harness co[...]

3 T r oubleshooting (continued) 35 Service Manual T able 3-2A - Inlet Water/System Sensor Resistance vs. T emperature T emperature Resistance T emperature Resistance 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 140 2,760 T able 3-2B - Outdoor Air Sensor Resistance vs. T emperature T emperature Resist ance T[...]

3 T r oubleshooting Service Manual 36 T able 3-3 T roubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w .c. and 14 inches w .c. LP gas pressures should be between 8 inches w .c. and 14 inches w .c. • Refer to Section 7 - Gas Connections of the Kn[...]

3 T r oubleshooting (continued) 37 Service Manual T able 3-4 T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressur e SW (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM display to reset.) Either the optional manual reset[...]

3 T r oubleshooting Service Manual 38 T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Anti-cy cling The main control board has received a call for heat too quickly after the previous call for heat has ended. • The control board will release the cal[...]

3 T r oubleshooting (continued) 39 Service Manual T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence (will require a manual reset once the c ondition has been correct ed. Press the RESET butt on on the SMAR T SYSTEM display to reset.) The[...]

3 T r oubleshooting Service Manual 40 T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION GV/Relay F ail (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM display to reset.) The main contro[...]

3 T r oubleshooting (continued) 41 Service Manual T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flue T emp High The stack temperature has exceeded the set parameters for the boiler . • Inspect the heat exchanger . Reference page 32 of this manual[...]

3 T r oubleshooting Service Manual 42 T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet T emp High (continued) Outlet water temperature has exceeded the maximum outlet water temperature. • V erify that the boiler pump is set to the proper spee[...]

3 T r oubleshooting (continued) 43 Service Manual T able 3-4 (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Low 24 vac 120 vac input to the main control board has dropped below 80 vac. • Check 120 vac supply to the transformer . • Check wiring connections [...]

3 T r oubleshooting Service Manual 44 Combustion Analysis Pr ocedur e 1. T urn the main power off to the boiler b y placing the “On/Off ” sw itch in the OFF position. 2. Remov e the flue temperature sensor from the flue pipe connection. No t e : Combustion measur ements w ill be made at this point. 3. T urn the main power on to the boiler b y p[...]

45 Service Manual 3 T r oubleshooting (continued) Gas valv e adjustment pr ocedure If adjust ment of the gas valve is deemed necessary , use the following procedur es: ( No te : The procedur es below are model specific.) Figure 3-3 Gas V alve Adjustment: Model 501 Model 501 Locate the throttle adjustment scr ew on top of the gas valv e, see FIG. 3-[...]

46 NOTES[...]

47 NOTES[...]

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