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Lochinvar 399 - 800 manual

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Table of contents for the manual

  • Page 1

    Service Manual Models: 399 - 800 This manual must only be used by a qualified heating installer / ser vice technician. R ead all instructions, including this manual and the Knight XL Installation and Operation Manual, befor e installing. P erform steps in the order giv en. Failur e to comply c ould result in sev ere personal injur y , death, or sub[...]

  • Page 2

    2 Hazar d definitions The following defined terms are used thr oughout this manual to bring attention to the presenc e of hazards of var ious risk le vel s or to important information concerning the life of the product.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazar dous situation which, if not av oided, wi[...]

  • Page 3

    Service Manual Please r ead bef or e pr oceeding Installer – R ead all instructions, including this manual and the Knight XL Installation and Operation Man ual, before installing. P erform steps in the order given. Us e r – This manual is for use only by a qualified heating installer/serv ice technician. R efer to the K night XL U ser’ s Info[...]

  • Page 4

    4 Service Manual Please r ead bef or e pr oceeding When servicing boiler – • T o a v oid electric shock, disc onnect electrical supply before performing maintenance. • T o a vo id severe burns, allo w boiler to cool befor e performing maintenance. Boiler operation – • Do not block flow of combustion or ventilation air to the boiler . • [...]

  • Page 5

    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[...]

  • Page 6

    1 Ser vice 6 Service Manual FROM R TO INDIR ECT DOMES TI C HOT WA TE R TA N K TO F L O OR DRAIN TO SYSTEM FROM SYSTEM BOILER PUM P DOMES TI C HOT WA TE R PUM P SYSTEM PU MP Near boiler piping This piping referenc e is included to specify the N ear B oiler Piping specific to the Knight XL. This piping scheme is important for proper operation of the [...]

  • Page 7

    Service Manual 7 1 Ser vice (continued) • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level in Menu Mode or to exit Menu Mode • Press to turn boiler off or back on • Press to select a menu item • Press after parameter programming to store parameter data • Press to exit Service Mode • Press to toggle disp[...]

  • Page 8

    1 Ser vice 8 Service Manual 1 Ser vice GAS PRESSURE S W ITCH (OPTIONAL) DHW THERMOST A T (OPTIONAL) ROOM THER MOST A T / ZONE CONTROL FLOW SW ITCH SYSTEM SENSOR OUTDOOR SENSOR (OPTIONAL) SEQUE NCER / B UILDI NG MANAGEMENT SYSTEM (OPTIONAL) LOW VOL T AGE CONNECTION BOARD INLET TEMPERA TURE SENSOR OUTLET TEMPERA TURE SENSOR FLUE GAS SENSOR HIGH LIMIT[...]

  • Page 9

    1 Ser vice Service Manual 9 1 Ser vice (continued) LOW VOL T AGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL AUX . DEVICE RELA Y RUN TIME CO NT AC TS SEQUENCER / BUIL DING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PU MP DHW PUMP IGNITOR BLOW ER GAS V AL VE D I S P L AY PA N E L PC INTERF ACE Control outputs[...]

  • Page 10

    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 contr ol module that allows fully c ondensing operation. The blo wer pulls in gas and air and pushes flue products out of the boiler through the heat exchanger and flue piping. The c on[...]

  • Page 11

    1 Ser vice Service Manual 11 1 Ser vice (continued) Sequence of oper ation T able 1A Sequence of operation - space heating and DHW OPERATION DISPLAY 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for sp ace heating call; DHW pump for DHW call). BLR: Standby OUT: 123.8F(129) 2. The control connects 120 V[...]

  • Page 12

    1 Ser vice 12 Service Manual 1 Ser vice Sequence of oper ation (continued) T able 1A (continued from previous page) Sequence of operation - sp ace heating and DHW OPERATION DISPLAY 8. If the boiler is not part of a cascade, and the DHW call for heat remains active for more than 30 minutes, and the space heating call for heat is also active, then th[...]

  • Page 13

    1 Ser vice Service Manual 13 1 Ser vice (continued) Display panel menu access T able 1B Use this procedure to access menus from the display panel Press 1 time in normal operation Hold for 5 seconds -- display will change Press 9 times to change last digit in readout to “9” Press 2 times to move to the second digit Press 3 times to change second[...]

  • Page 14

    1 Ser vice 14 Service Manual 1 Ser vice Display panel parameter access T able 1C This is a typical example of accessing a parameter , shown for parameter I2, boiler pump delay BLR:Pre-Purge BUT TO N OPERA TION DISPLA Y COMMENTS This example shows how to access parameter I2, boiler pump delay . The first display shown is at the beginning of the menu[...]

  • Page 15

    1 Ser vice Service Manual 15 1 Ser vice (continued) Parameter table T able 1D This table list s SMAR T SYSTEM control module parameters and where to access them MENU SUB ITEM DESCRIPTION SEE PAGE USER ACCESS INSTALLER ACCESS DISPLAY MODIFY DISPLAY MODIFY A 1 Boiler Model 17 Ye s No Ye s No 2 User Code 17 Ye s Ye s Ye s Ye s 3 Date and T ime 17 Ye s[...]

  • Page 16

    1 Ser vice 16 Service Manual 1 Ser vice Parameter table (continued) T able 1D (continued from previous page) This t able lists SMAR T SYSTEM control module p arameters and where to access them The parameters for Building Management S ystem operation are not list ed in this table. They are only accessible using the PC int erface softwar e. See separ[...]

  • Page 17

    1 Ser vice Service Manual 17 Viewable and changeable contr ol par ameter s A: General Boiler model The control will displa y “Knight Boiler” as the model number because the same contr ol is used on several models. This will be display ed when parameter A1 has been accessed. This par ameter is not changeable. User code The U ser Code allo ws the[...]

  • Page 18

    18 Service Manual 1 Ser vice SH Differential The SH differential sets ho w many degrees belo w the turn off temperature the te mperature has to go before the boiler will turn on. This parameter can only be changed by the installer b y accessing paramet er B5 . The temperature range of this parameter is 0°F (0°C) to 54°F (30°C). The default valu[...]

  • Page 19

    1 Ser vice Service Manual 19 1 Ser vice (continued) WA T E R TEMPERA TURE SET POINT MAXIMUM RESET Default = 180°F USER SET POINT Default = 125°F MINIMUM RESET Default = 70°F Default = 25°F Default = 70°F OUTDOOR AIR A T MAXIMUM RESET OUTDOOR AIR A T MINIMUM RESET OUTDOOR TEMPERA TURE Figure 1-1 Outdoor Air Reset Curve Maximum air temperature W[...]

  • Page 20

    1 Ser vice 20 Service Manual 1 Ser vice Boost temperature If a SH demand lasts longer than the programmed time delay setting (F9) and there ha ve been no DHW demands, the control will increase the wat er temperature set point b y the amount in this parameter . I f the SH demand continues through another time period, the set point will be increased [...]

  • Page 21

    1 Ser vice Service Manual 21 1 Ser vice (continued) H: Control modes SH controlling sensor The SH controlling sensor paramet er selects the sensor the control will use to r egulate the boiler firing rate. This parameter is adjustable by the installer by ac cessing parameter H1 . The sensor selections ar e as follows: The outlet sensor regulates the[...]

  • Page 22

    1 Ser vice 22 Service Manual 1 Ser vice Cascade offset This parameter determines how m uch the temperature m ust go abov e set point before the lead boiler will turn off. This parameter can be adjusted b y the installer by acc essing parameter H5 . The default value is 9.9°F (5°C). Cascade off-on differential This parameter determines how m uch t[...]

  • Page 23

    2 Maintenance Service Manual 23 Maintenance and annual star tup T able 2A 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,[...]

  • Page 24

    2 Maintenance 24 Service Manual Follo w the Serv ice and maintenance pr ocedur es given thr oughout this manual and in component lit erature shipped with the boiler . Failur e to perform the serv ice and maintenanc e could result in damage t o the boiler or system. Failur e to follo w the directions in this manual and component lit erature could r [...]

  • Page 25

    2 Maintenance (continued) Service Manual 25 Flue vent system and air piping 1. V isually inspect the entire flue gas ve nting system and air piping for blockage, deterioration or leakage. R epair any joints that show signs of leakage. V er ify that air inlet pipe is connected and pr operly sealed. 2. V erify that boiler vent disc harge and air inta[...]

  • Page 26

    2 Maintenance 26 Service Manual Inspect ignition and flame sense electrodes 1. R emov e the ignition and flame sense electrodes from the boiler heat ex changer acc ess cov er . 2. R emov e an y deposits accumulated on the ignition/flame sense electrode using sandpaper . I f the electrodes cannot be cleaned satisfactorily , r eplace with new ones. 3[...]

  • Page 27

    2 Maintenance (continued) Service Manual 27 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, g round wiring is in good condition, and g round contin uity is[...]

  • Page 28

    3 T roubleshooting 28 Service Manual Label all wires prior to disconnection when serv icing controls. W iring errors can cause improper and danger ous operation. Alwa ys disc onnect power t o the boiler before serv icing. Failur e to comply c ould result in sever e personal injur y , death, or substantial proper ty damage. Nev er jumper (bypass) an[...]

  • Page 29

    3 T roubleshooting (continued) Service Manual 29 T able 3A T roubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 V AC 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 V AC through the ON/OFF switch. • Check wirin[...]

  • Page 30

    3 T roubleshooting 30 Service Manual T able 3B - Inlet/Outlet System Sensor Resistance vs. T emperature T emperature Resist ance 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 3C - Flue T emperature Sensor Resistance vs. T emperature T emperature Resist anc[...]

  • Page 31

    3 T roubleshooting (continued) Service Manual 31 T able 3E T roubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w .c. (1.0 kPa) and 14 inches w .c. (3.5 kPa). LP gas pressures should be between 8 inches w .c. (2.0 kPa) and 14 inches w .c. (3.2 kPa)[...]

  • Page 32

    3 T roubleshooting 32 Service Manual T able 3F 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. Press the RESET butt on on the SMAR T SYSTEM display to reset.) Either the optional manual reset low gas press[...]

  • Page 33

    3 T roubleshooting (continued) Service Manual 33 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Anti-cy c ling The main control board has received a call for heat too quickly after the previous call for heat has ended. • The control board will rele[...]

  • Page 34

    3 T roubleshooting 34 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION No Flam e Running (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 unit was r[...]

  • Page 35

    3 T roubleshooting (continued) Service Manual 35 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Adjustable High Limit w/Manual Reset (will require a manual reset once the c ondition has been correct ed. P ress the RESET button on the SMAR T SYSTEM di[...]

  • Page 36

    3 T roubleshooting 36 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION F an High OR F an Speed High (will require a manual reset once the c ondition has been correct ed. P ress the RESET button on the SMAR T SYSTEM display to reset.) The[...]

  • Page 37

    3 T roubleshooting (continued) Service Manual 37 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION T emp O/Shoot The stack temperature has exceeded the set parameters for the boiler . • Inspect the heat exchanger . Reference page 27 of this manual for[...]

  • Page 38

    3 T roubleshooting 38 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION T emp O/Shoot (continued) Outlet water temperature has exceeded the maximum outlet water temperature. • V erify that the boiler pump is set to the proper speed or t[...]

  • Page 39

    3 T roubleshooting (continued) Service Manual 39 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Ser vice Blk While the unit is in Service Mode, the outlet temperature has exceeded 185°F . • Establish a heating load to remove the heat from the boil[...]

  • Page 40

    3 T roubleshooting 40 Service Manual Combustion Analysis Pr ocedur e 1. T urn the main power off to the boiler by placing the “On/Off ” switch in the OFF position. 2. Remov e the flue temperatur e sensor from the flue pipe connection. No t e : Combustion measurements will be made at this point. 3. T urn the main power on to the boiler b y placi[...]

  • Page 41

    3 T roubleshooting (continued) Service Manual 41 Gas valv e adjustment procedur e If adjust ment of the gas valve is deemed nec essary , use the following procedur es: ( Not e : The procedures belo w are model specific.) Figure 3-3 Gas V alve Adjustment: Model 500 Model 500 Locate the throttle adjustment scr ew on top of the gas valve, see FIG. 3-3[...]

  • Page 42

    4 Notes 42 Service Manual[...]

  • Page 43

    4 Notes Service Manual 43[...]

  • Page 44

    Revision Notes: Revision B (ECO #C02407) reflects air pressure switch changes, changes made to the Circulation Pumps Section (page 22) and removal of references to the pocket pc. Revision C (ECO #C02545) reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff testing and instructions. Revision D ([...]