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Lochinvar 400 - 801 Boiler User Manual

1. e Check function of remote devices e Check for loose or misplaced jumper if auxiliary proving switch is not installed Sa 40 K 3 Troubleshooting continued Sein Service Manual AL Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAUT DESCRIPTION CORRECTIVE ACTION Inspect the heat exchanger Reference page 32 of this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and The stack temperature has exceeded the set compare to Table 3 2D on page 35 of this manual AUT K Ma lt parameters for the boiler Delta T High for the boiler Outlet Temp High Outlet water temperature has exceeded the maximum outlet water temperature The temperature rise across the heat exchanger has exceeded the set parameters Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace the main control board Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler Check for 120 vac to the boiler pu
2. 44 Near Boiler Piping 0 esse 6 Table 3 5 Troubleshooting Chart Combustion Levels 44 The Knight XL Display 0 00000 7 Table 3 6 Flue Products 44 Control Inputs i imua ker a thew ec VEE eevee 8 Gas Valve Adjustment Procedure 45 Control OUIPUuIS ccortedeske de hcusanuaseeeesns 9 Revision Notes 000 0c eee eae Back Cover General Operation 0 0 0 e eee 10 Sequence of Operation 00 0 eee eee 11 12 Display Panel Menu Access 13 Display Panel Parameter Access 14 Parameter Table ee ee eee 15 18 Viewable and Changeable Control Parameters 19 27 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate A CAUTION duy CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in
3. made at this point 3 Turn the main power on to the boiler by placing the 8 Once the combustion analysis is complete test the safety On Off switch in the ON position shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down 4 Place the boiler into the active position by pressing the and registers an alarm Open the manual shutoff valve RIGHT SELECT ON key see page 7 reset the control and return to Service Mode 5 Locate the pinhole button below the RESET button on 9 Turn the main power off to the boiler and replace the flue the display board see page 7 Insert a thin wire such as temperature sensor into the flue pipe connection a paper clip into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and TET You must replace the flue gas temperature will then modulate up to full fire sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 10 Place the boiler back into normal operation 6 Remove the flue temperature sensor Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 3 6 above The CO l
4. Anti cycling Control Modes Circulation Pumps Building Management System BMS Service Notification ASST OmMMOO o gt Service Manual KJ COMMERCIAL BOILER Maintenance 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 Check water system Check expansion tank Check boiler relief valve nspect ignition electrode Check ignition ground wiring Check all boiler wiring Check control settings Perform start up and checks Check burner flame Check flame signal e Check flue gas temperature General maintenance Review with owner e Cleaning boiler heat exchanger Oiled bearing circulators Troubleshooting Troubleshooting table No display Checking temperature sensors Sensor tables Troubleshooting table Fault messages displayed on boiler interface Combustion analysis procedure Gas valve adjustment procedure Ghee Service Manual AL 1 Service Near boiler piping 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 Kare eX DOMESTIC HOT WATER PUMP INDIRECT DIRT SEPARATOR SYST
5. Multiple start or stop triggers may be set within a single day if desired When a start trigger and a stop trigger are set to the same time the stop trigger has priority The installer may adjust the space heating night setback start triggers by accessing parameter A5 The DHW start triggers in parameter A8 This screen shows the start trigger number the day of the week and the time of day NOTICE Please note that the brackets denote screen status 1 When the screen is first accessed start trigger number 1 is shown If a different trigger number is desired the installer can rotate the NAVIGATION dial until the desired trigger number is displayed Once the desired trigger number is selected the installer can press the SCROLL knob and the day of the week will start to flash 2 The installer can adjust the day of the week to the one he wishes to set Once the day is set the installer can press the NAVIGATION dial and the hour will begin to flash 3 After setting the hour the installer can press the SCROLL knob and the minutes will flash Once all settings have been made the installer can press the RIGHT SELECT SAVE key The installer can now select a different trigger and adjust the settings for that trigger 4 Once all adjustments are made the installer can press the RIGHT SELECT SAVE key to save all of the new settings and return to the A menu or press the LEFT SELECT EXIT key to return to the A menu without savi
6. replace open fuse F3 is 80 amps F2 is 3 15 amps and F1 is 5 amps Note Fuses F1 F2 and F3 are all slow blow fuses A WARNING Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage 7 Install control module cover and top access cover after fuse inspection 8 Restore power to the boiler at the external line switch and verify boiler operation Section 10 Start up in the Knight XL Installation and Operation Manual after completing boiler service 33 Ghee Service Manual XKL 3 Troubleshooting Table 3 1 Troubleshooting Chart No Display CORRECTIVE ACTION No 120 vac supplied to unit Check external line switch fuse or breaker Check position of ON OFF switch Turn switch to the ON position Check 120 vac through the ON OFF switch Check wiring harness connection between display board and main control board Connect harness at both points No Display No voltage through the switch Replace switch Bad display board Replace board Bad main control board Replace the main control board Blown fuse Replace fuse F3 on the main control board see page 33 of this manual Main control board temperature set point e Review temperature setting satisfied Remote thermostat satisfied Review remote thermostat setting Outside air temperature above Warm Check lo
7. 12 VDC b Continuity checker c Contact thermometer Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground Make sure all external limit controls are installed and operating Check the following l Wire connectors to control module are securely plugged in at the module and originating control Gas pressures e Maximum 14 inches w c 3 5 kPa natural and LP with no flow lockup or with boiler on e Minimum 4 inches w c 1 0 kPa natural 8 inches w c 2 0 kPa LP with gas flowing verify during boiler startup Service Manual C COMMERCIAL BOILER I Check control module fuses NOTICE ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF the power to the boiler at the external line switch 2 Remove top access cover 3 Remove the control module cover 4 Inspect fuses F1 F2 and F3 see FIG 3 1 below Figure 3 1 Control Module Fuses F3 80 AMP FUSE 24V DC POWER SUPPLY F1 5AMP FUSE PUMPS 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
8. Blocked Drain SW will require a manual reset once condition has been corrected Press the RESET button on the e Check for loose wiring connection at wire harness SMART SYSTEM display plug to reset e Inspect condensate trap for blockage Clean if necessary Bad blocked drain switch Replace switch Check the wiring connections to switch Wires should be connected to the common and normally closed terminals Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual for proper lengths APS Open will reguire a manual reset once the condition has been corrected Press Check reference hoses connected to the air pressure the RESET button on the switch for blockage or obstruction SMART SYSTEM display Inspect the burner Reference page 31 of this manual to reset for removal and cleaning procedures Replace if necessary e Check for obstruction or blockage in the air intake pipes or at terminations Air pressure switch contacts are open e Inspect the heat exchanger Reference page 32 of this manual for removal and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch ESS 37 Gwe Service Manual XL 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The main
9. F Default 70 F OUTDOOR AIR Service Manual SH1 SH3 Set Point at Low Outdoor Temperature When the outdoor air temperature drops below this point the water temperature will be at this setting FIG 1 1 However if the user set point is set lower the water temperature will be limited by the user set point instead These parameters can be changed by the installer by accessing parameters F3 F8 and F13 The temperature range of this parameter is 40 F 40 C to 104 F 40 C The default value is 25 C 4 C SH1 SH3 Set Point at High Outdoor Temperature When the outdoor air temperature rises to or above this point the water temperature will be at this setting FIG 1 1 These parameters can be changed by the installer by accessing F4 F9 and F14 The temperature range of this parameter is 40 F 40 C to 104 F 40 C The default value is 70 F 21 C Outdoor Air Shutdown SH1 SH3 When the outdoor temperature rises above this point the control will block all SH demands DHW demands will still be active These parameters can be changed by the installer by accessing parameters F5 F10 and F15 The temperature range of this parameter is 32 F 0 C to 104 F 40 C The default value is 70 F 21 C OUTDOOR OUTDOOR AIR TEMPERATURE AT MINIMUM RESET AT MAXIMUM RESET 22 4 Service continued Outdoor Air Shutdown Differential SH1 SH3 The outdoor air shutdown differential parameter
10. Point The SH maximum set point sets the maximum water temperature set point that can be used for space heating The user or installer will not be able to program the control with a higher SH set point This parameter can only be changed by the installer by accessing parameter B3 The temperature range of this parameter is 32 F 0 C to 190 F 88 C The default value is 185 F 85 C SH1 SH3 Offset Set Point The SH offset sets how many degrees above set point the temperature has to go before the boiler will shut off This parameter can only be changed by the installer by accessing parameters B4 B7 and B10 The temperature range of these parameters is O F to 20 F The default value is 10 F SH1 SH3 Differential Set Point The SH differential sets how many degrees below the offset the temperature has to drop before the boiler turns back on This parameter can only be changed by the installer by accessing parameters B5 B8 and B11 The range is O F to 60 F The default is 20 F 3 Way Valve Time Not used 20 PEET Service Manual AL 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 button on the front of the display for five 5 seconds the control will be placed in Service Mode This will override all other heat demands The Service Mode allows the installer to set the unit to either maximum firing rate or
11. The temperature range of this parameter is 0 F 0 C to 25 F 4 C The default value is O F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C Boost Time The boost time parameter sets the amount of time that must elapse with a SH demand before the water temperature set point will be increased This parameter can be changed by the installer by accessing parameter F19 The time range for this parameter is 0 minute to 50 minutes The default value is 0 minutes Service Manual G Anti Cycling Anti Cycling Time Once a SH demand has been satisfied a set amount of time must elapse before the control will respond to 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 water temperature drops below parameter G2 This parameter can be changed by the installer by accessing parameter G1 The time range for this parameter is 0 minutes to 10 minutes The default value is 1 minute Anti Cycling Override Differential 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 This parameter can be changed by the installer by accessing parameter G2 The temperat
12. heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion Leaks in boiler piping must be repaired at once to prevent the introduction of makeup water Freeze protection fluids e NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems What is in this manual Service Near boiler piping Typical system components The Knight XL display Display panel readout buttons and their functions Control module inputs Control module inputs and options Control module outputs Control module outputs and options General How the boiler operates How the control module operates Access modes user and installer Sequence of operation Domestic Hot Water DHW space heating Control panel menu access Accessing programming mode and locating menus See separate guide covering the interface Control panel parameter access Accessing and changing parameters from the display panel Quick table e An index of available adjustments and readouts where to access them and where to find detailed information start information parameter Knight XL operation General Temperature Setting Data Logging Functions DHW Settings Outdoor Reset
13. is the number of degrees below parameters F5 F10 and F15 the outdoor air temperature must go before the boiler will respond to a SH demand These parameters can be changed by the installer by accessing parameters F6 F11 and F16 The temperature range of this parameter is 0 F 09C to 90 F 50 C The default value is 10 F 6 C Shift Reset Curve SH1 SH3 There is a shift reset curve for each outdoor reset The shift reset curve parameter shifts the actual set point above the calculated set point the number of degrees in this parameter These parameters can be changed by the installer by accessing parameter F7 F12 and F17 The temperature range of this parameter is 17 F 27 C to 18 F 8 C The default value is O F 0 C This feature will be active if this parameter is set to anything other than OFF 0 C Boost Temperature If a SH demand lasts longer than the programmed time delay setting F19 and there have been no DHW demands the control will increase the water temperature set point by the amount in this parameter If the SH demand continues through another time period the set point will be increased again This will continue until either the SH demand ends a maximum of 20 increases has occurred or the maximum set point has been reached Once the SH demand has been satisfied the set point will revert back to its calculated setting The boost temperature can be changed by the installer by accessing parameter F18
14. minimum firing rate for the purpose of combustion analysis 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 This parameter can only be changed by the installer by accessing parameter D1 The time range of this parameter is 0 to 30 minutes The default value is 20 minutes Freeze Protection Pump On The SMART SYSTEM control will turn on the boiler and system pump outputs whenever the inlet temperature drops below this setting This is done to prevent the water in the heat exchanger from freezing Certain low temperature applications such as snow melt can operate at temperatures around freezing so this setting needs to be lowered in these cases The installer can adjust the temperature at which the pump outputs are turned on by accessing parameter D2 The minimum setting is 4 F 20 C and the maximum setting is 45 F 7 2 C The default setting is 45 F 7 2 C Freeze Protection Burner On If running the pumps does not prevent the inlet temperature from falling closer to freezing the SMART SYSTEM control will fire the burner at low fire The installer can adjust the temperature at which the burner fires by adjusting parameter D3 The minimum setting is 4 F 20 C and the maximum setting is 45 F 7 2 C The default setting is 37 F 2 8 C Freeze Protection Burner Differential Once the burner has started firing due to a low in
15. water sensors have two temperature sensing devices in one housing These devices are designated as Sla S1b outlet sensor and S3a S3b flue sensor Please reference the wiring diagram in the Knight XL Installation and Operation Manual for correct terminal location Table 3 2A Inlet Water System Sensor Resistance vs Table 3 2B Outdoor Air Sensor Resistance vs Temperature Temperature 20 30 40 50 70 HIEN oa 86 814 254196 40 165180 50 104 60 ERN NECI J i 118 018 85 362 Ga m 19 553 40 030 158 3 478 094 186 D m Resistance Resistancef Temperature Resistance 176 194 LL as sum a 8 6 369 Lm p m fn 35 iame Service Manual XKL 3 Troubleshooting Table 3 3 Troubleshooting Chart Noisy System CORRECTIVE ACTION Refer to Section 7 Gas Connections of the Knight XL Installation and Operation Manual for detailed information concerning the gas supply 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 e Refer to the Gas Valve Adjustment Procedure on page 45 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Knight XL Installation and Operation Manual Gas air mixture
16. wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring l Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings l Set the SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of this manual Adjust settings if necessary See Section 1 of this manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks l Start boiler and perform checks and tests specified in Section 10 Start up of the Knight XL Installation and Operation Manual Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame Inspect flame through observation window If the flame is unsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean burner if performed inside a building Remove the burner reference FIG s 2 2 thru 2 4 When replacing the burner ensure gasket is in good condition and positioned correctly FIG s 2 2 thru 2 4 si Service Manual AL Figure 2 2 Burner Assembly Model 400 Figure 2 3 Burner Assembly Model 501 Na AIR GAS ARM GASKET PA SCREWS OTY 5 Figur
17. ECT soft key YES m Select Press and hold the LEFT SELECT soft key MENU MMENS for five 5 seconds Rotate the NAVIGATION dial clockwise until 5 is displayed first digit on the left Press the NAVIGATION dial to select the next digit Rotate the NAVIGATION dial clockwise until 3 is shown in the display Press the NAVIGATION dial 2 times to move to the last digit Rotate the NAVIGATION dial counterclockwise until 9 is displayed SAVE Press the RIGHT SELECT soft key SAVE Rotate the NAVIGATION dial counterclockwise to select a category STANDBY OUTLET IHLET MEHU JSETPOINTS SHOH STANDBY SHUT COMM STANDBY OUTLET IHLET MENU JSETPOIMNTS SHOH SHUTDOWN PASSWORD O000 ERIT HERT SHUE SHUTDOWN PASSWORD 2000 ERIT HEST SHUE SHUTDOWN PASSWORD 2300 ERIT HEST SHUE SHUTDOWN PASSWORD 2303 EMIT HEAT SHWE SHUTDOWN gt GENERAL TEMPERATURE SETTINGS DATA LOGGING FUMC TIONS HOME 427 SCROLL 13 1 Service Display panel parameter access Service Manual Table 1 3 This is a typical example of accessing a parameter shown for parameter Temperature Settings MIN SH Setpt SCREEN BUTTON STATUS OPERATION DISPLAY This example shows how to access parameter Temperature Settings The first display shown is at the beginning of the menu listings after entering the installer access code Rotate the NAVIGATION dial counterclockwise until the arrow g
18. EM SENSOR MS lt SYSTEM PUMP o Lv mt Y STRAINER b RECOMMENDED k BOILER PUMP TO FLOOR DRAIN ssi Service Manual AL 1 Service continued The Knight XL display t L E NAVIGATION DIAL PRESS OR TURN COMMER Ciad BOM Faut I RESET KEY LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY 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 Leit SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key si Service Manual XKL 1 Service Control inputs SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT ZONE CONTROL LOW VOLTAGE FLOW SWITCH CONNECTION BOARD 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 SMART CONTROL MODULE DISPLAY PANEL PC INTERFACE pec Ar Service Manual OMMERCIAL BOILER 1 Service continued Control outputs ALARM BELL LOW VOLTAGE CONNECTION BOARD Son Jy RUN TIME CONTACTS LOUVER RELAY BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER SMART CONTROL MODULE PC INTERFACE 9 1 Service Gen
19. KBXII SER Rev B COMMERCIAL BOILER Service Manual Models 400 801 A WARNING This manual must only be used by a gualified 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 High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference CONTENTS 223 6 Soee eb pease betes NERE SES 2 2 MAINTENANCE Hazard Definitions 00 c eee ee eee 2 Maintenance and Annual Startup 28 32 PLEASE READ BEFORE PROCEEDING 3 3 TROUBLESHOOTING Handling Ceramic Fiber Materials 3 Before Troubleshooting 1 355 ace loe meer ebore RR a 33 When servicing boiler llle 4 Check Control Module Fuses 33 Boiler operation xu ciuis eq Rb RE wo RES 4 Table 3 1 Troubleshooting Chart No Display 34 Boiler water llle 4 Checking Temperature Sensors lusus 35 Freeze protection fluids 00 00 cece eee 4 Table 3 3 Troubleshooting Chart Noisy System 36 WHAT IS IN THIS MANUAL 2cece eee 5 Table 3 4 Troubleshooting Chart Fault Messages 37 43 1 SERVICE Combustion Analysis Procedure
20. Yes Yes KN EN EN KN EN s joa EN alu e EN n Z O d o i N Vinse Service Manual XL 1 Service Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them SERVICE NOTIFICATION 18 Display moat ietay moar jsimmmmisarn 3 ve vee gt jossa 7000 fe C p pee T Dr eemumm a O O O O O O O O Z O 4 Service continued Service Manual K COMMERCIAL BOILER I Viewable and changeable control parameters CAUTION Before changing parameters note the settings so that the unit can be returned to its original operating parameters A General Date and Time 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 To set the clock parameter Al must be accessed The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Software Version The software version allows the user to view the software version in use by the control This software controls the operation of the boiler When a new software version becomes available the existing control can be replaced with a new control to update the software Software
21. adjust the length of time the boiler will service the DHW demand by accessing parameter E7 The minimum setting is 0 minutes and the maximum setting is 200 minutes The default setting is 30 minutes Tank Minimum Set Point This setting controls the minimum user set point for the tank temperature The installer can adjust this by accessing parameter E8 The minimum setting is 60 F 16 C and the maximum setting is the maximum tank set point parameter E9 Tank Maximum Set Point This setting controls the maximum user set point for the tank temperature The installer can adjust this by accessing parameter E9 The minimum setting is the minimum tank set point parameter E8 and the maximum setting is 185 F 85 C DHW Type This parameter determines whether the Knight XL treats the indirect 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 a zone the boiler will turn on the DHW pump leave the boiler pump on and raise the system set point to the DHW boiler set point parameter E1 if it is higher than the current SH set point This setting may be changed by the installer by accessing parameter E10 The choices are NORMAL and ZONE The default setting is NORMAL Fan Speed Limiting for Indirect DHW Tank This parameter determines the maximum fan speed and
22. ase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 44 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3 5 on page 44 or replace the gas valve Figure 3 4 Gas Valve Adjustment Models 601 801 CONN THROTTLE B SCREW Aul N REMOVE BLUE CAP F as Jalli di N I 1 KO m J E X W NOTES O NOTES N v Revision Notes Revision A ECO C05747 initial release Reflects Lo hinv r the new model numbers for the Knight XL upgrade High Efficienc Ci Boilers and ar 300 Maddox Simpson Parkway Revision B ECO C06234 reflects changes made to the Service Lebanon TN 37090 Notification parameter 615 889 8900 Fax 615 547 1000 www Lochinvar com KBXII SER Rev B 8 10
23. at maintenance is required This parameter is adjustable by the installer by accessing parameter K2 The time range for this parameter is 0 hours to 100 000 hours The default time is 8 760 hours jo COMMERCIAL BOILER I Service Manual Service Notification Cycles When the boiler control determines that a scheduled service is due based on the number of boiler cycles the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter K3 The range for this parameter is 0 cycles to 100 000 cycles The default is 50 000 cycles Reset Maintenance Reminder Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing parameter K4 Once accessed press the RESET key to reset the service notification counter Installer Name and Phone Number NOTICE Please note that the brackets denote screen status When a Maintenance Reminder timer or counter has expired a Maintenance Reminder screen will appear on the display By programming the installer s name and phone number this information will appear on the Maintenance Reminder Screen at that time This can be programmed by accessing parameter K5 When selected another menu will appear with PHONE and NAME 1 Rotate the NAVIGATION dial to point to the name phone number to program and press t
24. ation and Operation Manual e Flame inspection stable uniform e Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C above return water temperature If combustion or performance indicate need Clean heat exchanger e Remove and clean burner compressed air only using e Clean the blower wheel Service Manual Owner maintenance see the Knight XL User s Information Manual for Monthly Periodically Every 6 months End of season months instructions e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system e Check air vents e Test low water cutoff if used e Reset button low water cutoff e Check boiler piping gas and water for leaks e Operate relief valve e Shut boiler down unless boiler used for domestic hot water 2 Maintenance continued A WARNING KJ COMMERCIAL BOILER I Service Manual Follow the Service and maintenance procedures given throughout this manual and in component literature 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 a
25. cation of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual before proceeding further 30 JUS IN Service Manual OMMERCIAL BOILER Safety relief valves should be re inspected ey UN IISA AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever A WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposi
26. cation of outside air sensor Check Weather Shutdown WWSD set point for resistance of outdoor air sensor and compare to Table main control board 3 2B on page 35 of this manual No Burner Operation Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 37 of this manual for corrective actions Ramp delay active Check ramp delay parameter settings Optional PC software required Turn ramp delay feature off See page 23 of this manual for instructions on how to turn this feature off Check BMS parameter settings Optional PC software required Unit Does Not Modulate Above 50 Boiler controlled by BMS 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 to Table 3 2D on page 35 of this manual m 54 Em Ghee Service Manual AL 3 Troubleshooting continued 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 If the resistance of the sensor does not closely match its corresponding table replace the sensor It is important to note that the flue and outlet
27. check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail fault If 24 vac is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not Opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Replace the main control board EH 55 N o COMMERCIAL BOILER I 3 Troubleshooting continued Service Manual Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION Flame Sequence will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The flame detector circuit is seeing a flame signal while no flame is present The outlet wate
28. 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 heat has ended Anti cycling The control board will release the call for heat if the outlet temperature drops too quickly The unit has failed to prove main burner ignition after four 4 attempts Inspect spark electrode and associated wiring for damage and connection Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Check for proper electrical grounding of the unit Check incoming supply gas pressure Natural gas pressures should be between 4 14 inches w c and LP gas pressures should be between 8 14 inches w c Refer to Section 7 Gas Connections of the Knight XL 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 Verify that the vent air intake pipes are correctly installed and that there are no obstructions Check for 24 vac to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board Flame Fail Ign will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset If 24 vac is present at the main control board
29. djustment on the valve follow the Combustion Analysis Procedure on page 44 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3 5 on page 44 or replace the gas valve Figure 3 2 Gas Valve Adjustment Model 400 THROTTLE ADJUSTMENT SCREW Model 501 Locate the throttle adjustment screw on top of the gas valve see FIG 3 3 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 44 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3 5 on page 44 or replace the gas valve jo COMMERCIAL BOILER I Service Manual Figure 3 3 Gas Valve Adjustment Model 501 THROTTLE ADJUSTMENT SCREW Models 601 801 Locate the throttle adjustment screw on top of the gas valve see FIG 3 4 Using an Allen wrench turn the screw a 1 4 turn counterclockwise to incre
30. e 2 4 Burner Assembly Models 601 801 SCREWS OTY 5 mu 37 Em 2 Maintenance Check flame signal At high fire the flame signal shown on the display should be at least 10 microamps A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner Review the Knight XL User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Knight XL User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed instructions see Table 2 2 Heat Exchanger Cleaning Kits iB 4 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup of the Installation and Operation Manual e Do not drain the boiler unless it will be exposed to fre
31. e and opening the gas valve If flame is not detected within 1 second after the sparking ends the control will perform a 10 second post purge then start another prepurge cycle and try to light the burner again On the 501 and larger models the control will lock out if this second attempt also fails On the 400 model the control will perform a total of 4 attempts before locking out If flame is detected it holds the firing rate steady for 5 seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal START d SYSTEM TAHE OUTDOOR MEHO eat SCREEH SHDH START SYSTEM Lib F TAHE 1287FG1252 OUTDOOR 26 F MEHU et SCEEEHM SHDH START o SYSTEM 16 F Mboo 2158 MENU 23 SsCREEH SHOH PRE PURGE t SYSTEM TAHE OUTDOOR MEHU YHSLEEEN SHOH IENITION SYSTEM DHW TAME OUTDOOR MEHU q SLEEEHM SHOH POST PURGE fii SYSTEM TANK OUTDOOR MEHU 425CREEM SHOH Lib F l2e Folesa gb SYSTEM TAHE OUTDOOR MEHU sa SCREEH SHDH KaT Service Manual XL 1 Service Table 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 starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW 1 operation not as a zone the DHW pump will turn on
32. e risk of temperature overshoot with a Cascade this parameter defines the minimum time delay from starting one unit until the next unit may be started The installer can adjust this time delay by accessing parameter H12 The minimum setting is 0 minutes and the maximum setting is 10 minutes The default is 60 seconds Boiler Size Not used 25 1 Service I Circulation pumps System Pump Delay The system pump delay parameter sets the length of time the system pump if connected will run after a SH demand has been satisfied Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing parameter I1 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds Boiler Pump Delay The SH pump delay parameter sets the length of time the boiler pump will run after a SH demand has been satisfied Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing parameter I2 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds DHW Pump Delay The DHW pump delay parameter sets the length of time the DHW pump if connected will run after a DHW demand has been satisfied Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing parameter 13 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 sec
33. ed for has been corrected Press the RESET button on the SMART SYSTEM display to reset e Check for obstruction or blockage in the ventair intake pipes or at terminations Check the wiring connections at the fan and at the main control board Replace the fan Replace the main control board Sensor Open will require a manual reset once the condition lEFN J3 8 02 29 2 592 219 Either the inlet water or outlet water 104 M MTT IMO MIsta temperature sensor has been disconnected SMART SYSTEM display to reset e Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged e Measure the resistance of the sensors and compare the resistance to the tables on page 35 of this manual e Replace the sensor if necessary e Check the sensors and their associated wiring Sensor Shorted mM Repair or replace the sensor or wiring if damaged will require a manual reset once the condition Either the inlet water or outlet water hasibeenicorrected Press temperature sensor has been shorted the RESET button on the P SMART SYSTEM display to reset Measure the resistance of the sensors and compare the resistance to the tables on page 35 of this manual Replace the sensor if necessary Louver Proving Sw will require a manual SIA MONIKSI An optional remote proving switch is not lE MUSS NeUNIU S MAakKINg the RESET button on the SMART SYSTEM display to reset
34. eed or that the boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for boiler pump specifications mu 42 um Kue Service Manual XL 3 Troubleshooting continued Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION CORRECTIVE ACTION 120 vac input to the main control board has Check 120 vac supply to the transformer dropped below 80 vac e Check wiring connections at the low voltage Low 24 vac terminal strip Check the wire size length to remote devices Replace the transformer The main control board has detected Replace the main control board UE Eor E ddl internal fault The main control board has detected Replace the main control board LL dC SC internal fault The main control board has detected Replace the main control board fed lol ley tee internal fault The main control board has detected Replace the main control board hE dd MS 1123 a internal fault mu 4 3 m Vase Service Manual XL 3 Troubleshooting Combustion Analysis Procedure Table 3 6 Flue Products 1 Turn the main power off to the boiler by placing the NaturalGas Propane On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue pipe a n CO connection Note Combustion measurements will be 80 10 3 0 6 5 9 0 11 4 195 6 9
35. eral Operation How the boiler operates The Knight XL uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing operation 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 How the control module operates The Knight XL control module receives input from boiler sensors The control module activates and controls the blower and gas valve to regulate heat input and switches boiler DHW and system pumps on and off as needed The user installer programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation can be based on boiler outlet water temperature boiler return water temperature or system supply temperature depending on the parameter setting Sequence of operation Table 1 1 shows control module normal sequences of operation for space heating and DHW operation The combined operation sequence is for a typical application programmed to provide DHW priority 10 dicen Service Manual XL Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when LSETPOINTS is flashi
36. erature at the system supply sensor to the user set point If any of the boiler outlet temperatures reach the maximum cascade set point the boiler will then modulate down on its own in order to keep its outlet temperature within the maximum cascade set point Therefore this parameter can be used to limit the outlet temperatures of all the boilers in a Cascade Note that this parameter does not apply when the boiler is heating an indirect DHW tank This parameter is adjustable by the installer by accessing parameter H8 The default maximum cascade set point is 185 F 85 C Cascade Offset 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 H9 The default value is 10 F 6 C Cascade Off On Differential This parameter determines how much the temperature must go below the turn off temperature Set point Offset before the lead boiler turns on This parameter can be adjusted by the installer by accessing parameter H10 The default value is 20 F 11 C Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum ON and OFF time for each unit The installer can adjust this time by accessing parameter H11 The minimum setting is 0 seconds and the maximum setting is 10 minutes The default is 30 seconds Minimum Next On Time In order to reduce th
37. ermostat 1 input With parameter H2 set to INACTIVE the boiler will be enabled by the voltage level on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE BMS Active Inactive The set point or modulation of the boiler may be controlled through the 0 10V BMS input or through Modbus When parameter H3 is set to INACTIVE the 0 10V input will be ignored When set to ACTIVE the set point or modulation will be controlled by the voltage on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE lt TIME gt TIME TIME 5 MINUTES 1 Service continued Modbus Active Inactive When BMS is set to ACTIVE see BMS Active Inactive and the boiler is being controlled through Modbus set parameter H4 to ACTIVE Otherwise set the Modbus parameter to INACTIVE Note that the boiler can still be monitored by ModBus with this parameter set to INACTIVE The default value is INACTIVE Modbus T O Timeout The amount of time the unit controls will wait to receive a communication string from the BMS controller before reverting back to its own internal parameters This parameter is adjustable by the installer by accessing parameter H5 The default value is 10 seconds Cascade Address The boiler designated as the Leader needs to be programmed with address 0 A
38. evels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the chart below for possible causes and corrective actions Table 3 5 Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual Vent Air Intake Length for the proper venting and air intake methods for the Knight XL boiler or Obstruction e Check for obstructions at the vent air intake terminals Gas Supply Pressure M Refer to Section 7 Gas Connections of the Knight XL Installation and Operation Manual for the proper gas supply for the Knight XL boiler Refer to page 31 of this manual for burner removal and cleaning procedures Dirty Damaged Burner Replace burner if necessary Gas Valve Adjustment W Refer to page 45 of this manual for the gas valve adjustment procedure 44 3 Troubleshooting continued Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the The procedures below are following procedures Note model specific CAUTION Under normal operating conditions this valve should not need adjusting Model 400 Locate the throttle adjustment screw on the top of the gas valve see FIG 3 2 Using a screwdriver turn the screw 1 8 turn counterclockwise to increase CO levels or 1 8 turn clockwise to decrease CO levels After one a
39. ezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside Remove the heat exchanger access cover burner and gas air arm assembly A WARNING The boiler contains ceramic fiber materials Use care when handling these materials per instructions on page 3 of this manual Failure to comply could result in severe personal injury 32 K COMMERCIAL BOILER I I5 Service Manual Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan Using field supplied means cover the refractory in the back of the combustion chamber of the heat exchanger Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply Allow the heat exchanger to thoroughly dry Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flu
40. f the trap FIG 2 1 4 Remove any sediment in the trap 5 Fill with fresh water until the water begins to pour out of the drain 6 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 7 Replace the retaining screw CONDENSATE FROM A WARNING 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 Figure 2 1 Condensate Trap RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH Oy PVC TEE ASSEMBLY FACTORY SUPPLIED HEAT EXCHANGER J TO FLOOR DRAIN A WARNING The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Check all piping for leaks Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage m Inspect all water and gas piping and verify to be leak free E Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections of the Knig
41. first then SUSTEN 117 the boiler pump will turn off 2 seconds later d This will divert the boiler s outlet water from the heating system OUTDOOR 26 and send it to the tank coil instead MEHI 425CREEM SHON The control will then modulate to maintain the outlet temperature to the DHW boiler set point 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 CUSTENM switch back and forth between the two heating modes until one arbos of them is satisfied MEHU SdSCREEHX SHEH POST cae 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during a 10 second 2 postpurge OUTDOOR MEHU q SCREEM SHOH 11 Any pumps that are running will continue to run for their BLOCKED respective pump delay times before turning off unless eee programmed to remain on continuously A 60 second anti cycle period will start which will delay any OUTDOOR new call for heat until it times out HEHU 42 S5CREEH SHOH STANDBY 12 In Standby ready to start a new cycle S NN I 1385 F OUTDOOR MEHU SETPOINTS SHOH 12 K COMMERCIAL BOILER I 1 Service continued Display panel menu access Service Manual Table 1 2 Use this procedure to access menus from the display panel BUTTON STATUS OPERATION DISPLAY SHDN Press the RIGHT SELECT soft key SHDN p Select YES Press the LEFT SEL
42. he NAVIGATION dial The screen will now display the selected item either PHONE or NAME 2 Press the NAVIGATION dial again A cursor will appear at the bottom of the screen By rotating the NAVIGATION dial various numbers and characters will appear When the desired number character is found press the NAVIGATION dial The cursor will move to the next position 3 Repeat this procedure until the entire message is entered If you make a mistake and wish to back up one character select the back arrow character and press the NAVIGATION dial 4 When finished press the RIGHT SELECT SAVE key to return to the previous menu 27 2 Maintenance o COMMERCIAL BOILER I Maintenance and annual startup Table 2 1 Service and Maintenance Schedules Service technician see the following pages for instructions aB H lt H o lt lt General e Address reported problems e Inspect interior clean and vacuum if necessary e Clean condensate trap and fill with fresh water Check for leaks water flue condensate gas e Verify flue and air lines in good condition and sealed tight eCheck system water pressure system piping expansion tank e Check control settings e Check ignition and flame sense electrodes sand off any deposits clean and reposition e Check wiring and connections ePerform start up checkout and performance verification per Section 10 in the Knight XL Install
43. he device Check resistance of water sensors and compare to Table 3 2A on page 35 of this manual Replace sensor if necessary Replace high limit Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the fan and at the main control board Replace the fan Replace the main control board Replace fuse F2 on the control board see page 33 of this manual Choe Service Manual XL 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION GV Relay Fail will require a manual NNN PPP HP The main control board did not detect the Ea en gas valve the RESET button on the SMART SYSTEM display to reset e Check wiring harness connection at the gas valve and at the main control board e Replace the gas valve wire harness e Replace the gas valve e Replace the main control board e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual for Fan High proper lengths OR Fan Speed High E euE ETUE The actual fan RPM is 30 higher than what reset once the condition is being call
44. he pressure switches e Measure the supply gas pressure to determine cause Gas Pressure SW of failure Natural gas pressures should be between 4 14 inches w c and LP gas pressures will require a manual should be between 8 14 inches w c Tuy shissuiisym Either the optional manual reset low gas ETIKETTI LIS pressure switch or the optional manual reset Refer to Section 7 Gas Connections of the Knight a oun high gas pressure switch tripped XL Installation and Operation Manual for detailed SMART SYSTEM display information concerning the gas supply to reset Correct the supply gas pressure if necessary Check for a loose or misplaced jumper if pressure switches are not installed e Check boiler pump operation on a call for heat e 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 Flow SIS M 19 Either the optional flow switch or the optional MEZE ente low water cutoff is not making reset once condition has been corrected Press the e Check for loose or misplaced jumpers if flow switch or RESET button on the LWCO is not installed SMART SYSTEM display to reset Replace fuse F3 on the control board see page 33 BIOWIN ISE of this manual The blocked drain switch has detected Check condensate tube from unit to floor drain for excessive condensate build up inside the proper installation and obstructions unit
45. ht XL Installation and Operation Manual 29 2 Maintenance Flue vent system and air piping 1 Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verity 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 Excessive pressure rise indicates expansion tank sizing or performance problem 4 Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for suggested best lo
46. ing The length of time it runs is determined by parameter I4 The range of this setting is 0 seconds to 40 minutes The default setting is 20 seconds System Pump Anti Seize Delay 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 The range of this setting is 0 seconds to 40 minutes The default setting is 20 seconds J BMS BMS Type Power Set Point When programmed for BMS control through the 0 10V BMS input or through ModBus the 0 10V signal can be interpreted as either a modulation command or a set point When parameter J1 is set to POWER the 0 10V signal will control the modulation When set to SETPOINT the 0 10V signal will control the SH set point The default setting is POWER Volts at Minimum When programmed for BMS control through the 0 10V BMS input or through ModBus parameter J2 should be set to the minimum voltage signal sent to the SMART SYSTEM control The range of this parameter is 0 0V to the Volts at Minimum value parameter J3 The default setting is 2 0V Volts at Maximum When programmed for BMS control through the 0 10V BMS input or through ModBus parameter J3 should be set to the maximum voltage signal sent to the SMART SYSTEM control The range of this parameter is the Minimum value parameter J2 to 10 0V The default value is 10 0V Rate at Minimum Volts When programmed fo
47. let temperature the inlet temperature must increase by this amount before the burner turns back off The installer can adjust this differential by accessing parameter D4 The minimum setting is 0 F and the maximum is 20 F The default setting is 5 F 2 8 C 1 Service continued E DHW Settings DHW Boiler Set Point When 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 temperature This parameter can be changed by the installer by accessing parameter E1 The temperature range of this parameter is 60 F 16 C to 190 F 88 C The default value is 180 F 82 C DHW Tank Set Point By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops below the tank set point differential parameter E3 and finishes the call for heat when the tank temperature reaches tank set point This parameter can be changed by the installer by accessing parameter E2 The temperature range of this parameter is 68 F 20 C to 190 F 88 C The default value is 125 F 52 C Tank Set Point Differential When a tank sensor is installed the tank temperature must drop this amount below the tank set point parameter E2 before the heater will turn on The installe
48. lite NOTICE 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 Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines H Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection thoroughly NIOSH stated First Aid H Eye Irrigate immediately H Breathing Fresh air Wash potentially contaminated clothes separately from other clothing Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the ap
49. ll the Member boilers require addresses from 1 to 7 and the addresses must be different for each Member The addresses can be in any order regardless of the order in which the units are wired together This parameter is adjustable by the installer by accessing parameter H6 The outdoor air if used and system supply sensor must be connected to the Leader boiler The default address is 1 If installing the boilers in an existing system the new boilers should be programmed as the Leader and or the higher number addresses Cascade Type L L EFF There are two 2 options for the way a Cascade divides the load between its heaters The first is Lead Lag designated at L L in the menu This method is used when it is desired to have the least amount of total flow through the boilers This method works much like the current Cascade except it will modulate the last two 2 boilers instead of just the last boiler This change provides for smoother transitions when a boiler turns on or off When the last boiler reaches 100 and the calculated load is still increasing it will start the next boiler at 20 and reduce the previous boiler to 80 thus eliminating the sudden jump in total output of the Cascade Therefore the dead zone we had in the original Cascade is no longer necessary When the calculated load is decreasing and the last boiler gets down to 20 fire it will hold it there and start lowering the firing rate on the next to last boile
50. mp motor on a call for heat If voltage is not present check the wiring back to the main control board 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 Reference Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for boiler pump specifications Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler e Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board 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 Chet Service Manual XL 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size Reference Outlet Temp Section 6 Hydronic Piping of the Knight XL High Outlet water temperature ha
51. ng at the bottom of the display The date and time and the temperature units can also be changed Installer Most parameters are available only to the installer accessible by entering the installer password 5309 Saving parameters reference the Parameter Table Table 1 4 on pages 15 18 of this manual NOTICE Please note that the brackets denote screen status To save parameters and exit programming Press the RIGHT SELECT SAVE key and then press the RIGHT SELECT HOME key To enter a parameter and continue programming Press the RIGHT SELECT SAVE key 1 time to return to the parameter listings press again to return to the menu listings Remember to press the RIGHT SELECT HOME key when finished programming in order to save the changes made Service Manual K COMMERCIAL BOILER I 1 Service continued Table 1 1 Sequence of Operation OPERATION DISPLAY Upon a call for heat the gas pressure switch es must be closed Once the gas pressure switch es are closed the control turns on the appropriate pumps system and boiler pumps for space heating DHW pump for DHW The flow switch and or LWCO must close The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch must close The control starts a 15 second prepurge cycle by initiating the blower The control starts a 4 second trial for ignition by firing the spark electrod
52. ng the changes Space Heating SH and Domestic Hot Water DHW Night Setback Off Times The corresponding space heating night setback stop triggers are set by accessing parameter A6 The stop triggers for the DHW night setback feature can be adjusted by accessing parameter A9 The adjustment procedure for these parameters is identical to the space heating start triggers described above 19 1 Service Display Timeout This is the time in which the display remains illuminated The range is 10 seconds to 10 minutes The default is 3 minutes B Temperature Settings Space Heating SH1 SH2 SH3 Set Point CAUTION Mixing valves are reguired for the protection of any low temperature loops There are three 3 individual user set points for better zone control These are listed as SHI Set Point through SH3 Set Point If multiple set points are calling for heat the highest set point has priority The range is 32 F 0 C to 190 F 88 C The default is 125 F 52 C Space Heating SH Minimum Set Point The SH minimum set point sets the minimum water temperature set point that can be used for space heating operation The user or installer will not be able to program the control with a lower SH set point This parameter can only be changed by the installer by accessing parameter B2 The temperature range of this parameter is 32 F 0 C to 190 F 88 C The default value is 70 F 21 C Space Heating SH Maximum Set
53. ogrammed for BMS control through the 0 10V BMS input or through 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 Off Differential Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE parameter J9 determines how far below the On Volts setting J8 the 0 10V BMS input voltage must be in order to disable the boiler The minimum value is 0 2V and the maximum is the On Volts setting J8 The default value is 1 0V K Service Notification Service Notification in Months When the boiler control determines that a scheduled service is due based on days of installation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter K1 The time range for this parameter is 0 months to 36 months The default time is 0 months This feature has been disabled by the manufacturer To enable this feature change parameter K1 to the desired time range Service Notification Running Time When the boiler control determines that a scheduled service is due based on the hours of actual operation the boiler display will turn yellow and a new status screen will appear informing the installer th
54. onds Boiler Pump Anti Seize Delay 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 14 The range of this setting is 0 seconds to 40 minutes The default setting is 20 seconds Boiler Pump Minimum Voltage The speed of the boiler pump can be controlled by the SMART SYSTEM control in order to maintain a minimum AT through the heat exchanger Thus as the firing rate decreases the speed of the boiler pump can decrease as well The SMART SYSTEM control outputs a 0 10V signal to the boiler pump to control its speed Parameter I5 determines the minimum voltage given to the boiler pump thereby setting its minimum speed The range of this setting is 2 5V to 10V The default setting is 3 5V System Pump Type CFH WWSD CFH Call for Heat WWSD Warm Weather Shutdown The system pump can be programmed to operate in response to any of the Room Thermostat inputs or to run continuously until the boiler goes into Outdoor Shutdown To program the system pump to operate only with a space heating call for heat set parameter 16 to CFH To program the system pump to run continuously until outdoor shutdown starts set parameter 16 to WWSD The default setting is CFH 26 Service Manual K COMMERCIAL BOILER I DHW Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seiz
55. p EN Reset Last 10 Errors Service Mode Delay Freeze Protection Pump On No Yes Yes Freeze Protection Burner Differential DATA LOGGING Choe Service Manual AL 1 Service Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them menu TAI Los Installer Access pwssessma at ne m m m o pense Lt 9 9 3 sanoma fa w ve ow s jose s 9 9o e eeemmmen fa o9 o9 o9 s meemesumm ow o9 s pee samoina a ne ww s esarion w 9 o9 ee s sesaran onone a ne ow a IN INIM Bo ee SH3 Set Point at Low Outdoor Temp EXE EIE OUTDOOR RESET Outdoor Air Shutdown SH3 Outdoor Air Shutdown Differential SH3 Shift Reset Curve SH3 16 Vias Service Manual XL 4 Service continued Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them Installer Access Modify Description Hu Z 5 o O es ae ZI Z O O d o i DHW Pump Anti Seize Delay System Pump Anti Seize Delay 2 N N N O alz ZIZ ali o o p o o N N AB Z O alz O g os n Yes O es es CIRCULATION PUMPS o N N Yes Yes O N N es N O Z 5 o 5 o ec F 3 BMS Active Inactive Yes Yes alu 9 29 29 18 Boiler Size N No
56. pliance and place it in a plastic bag for disposal Rinse clothes washer JUS IN Service Manual OMMERCIAL BOILER Please read before proceeding When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance e 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 Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator 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 Boiler water e Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces
57. problem Refer to page 31 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Noisy Dirty damaged burner Operation Refer to Section 6 Hydronic Piping of the 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 Air in the piping system Properly purge all air from the piping system Low system water pressure e Verify system pressure is a minimum of 12 psi No Pump Blown fuse Replace fuse F1 on the control board see page 33 of Operation this manual Boiler Pump NOI NOE System Pump ote ake sure pump amperage does not excee 1 8 amps DHW Pump Faulty pump e Replace pump Internal fault on control board e Replace main control board e Lower the system pressure below the 30 psi rating of the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger Low water flow through the heat exchanger System pressure exceeds relief valve setting Relief Valve Opening e Improperly sized expansion tank 36 Chee Service Manual AL 3 Troubleshooting continued Table 3 4 Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Reset t
58. property damage NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE K COMMERCIAL BOILER I Please read before proceeding A WARNING Installer Read all instructions including this manual and the Knight XL Installation and Operation Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the Knight XL User s Information Manual for your reference Have this boiler serviced inspected by a gualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristoba
59. r 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 The other Cascade divider method is Efficiency Optimization designated as EFF in the menu This method is used as the name implies when it is desired to have the most efficient system When the first boiler reaches a certain rate default 90 it lowers its rate to 45 and turns on the next boiler at 45 The two 2 boilers then modulate at the same rate Service Manual KJ COMMERCIAL BOILER I As the calculated load increases further and both boilers ramp up to 90 it lowers the rate of the first two 2 boilers to 60 and brings the next boiler on at 60 The three 3 boilers then modulate together As the calculated load decreases the boilers will reach a lower threshold default 35 at which time the last boiler the third in our example will turn off and the Cascade will increase the rates of the remaining boilers to provide the equivalent total output as before 3 x 35 2 52 5 in our example Maximum Cascade Outlet Set Point This parameter determines the set point used by the individual boilers in a Cascade When a boiler is commanded to fire by the Leader boiler it will attempt to achieve this temperature at its outlet The Leader boiler will limit the modulation of the last boiler to fire in order to hold the temp
60. r BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Minimum parameter J2 is set by parameter J4 The minimum value is 0 and the maximum is the Power at Maximum Volts setting J5 The default value is 2096 Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Maximum parameter J3 is set by parameter J5 The minimum value is the Power at Minimum Volts setting J4 and the maximum is 100 The default value is 100 1 Service continued Set Point at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Minimum parameter J2 is set by parameter J6 The minimum value is 32 F 0 C and the maximum is the Set Point at Maximum Volts setting J7 The default value is 70 F 21 C Set Point at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Maximum parameter J4 is set by parameter J7 The minimum value is the Set Point at Minimum Volts setting J6 and the maximum is 190 F 88 C The default value is 180 F 82 C On Volts When pr
61. r can adjust this setting by accessing parameter E3 The minimum setting is 0 0 C and the maximum is 40 F 22 C The default setting is 6 F 3 C Boiler Set Point Offset This parameter reflects the degrees above DHW boiler set point the temperature has to go before the boiler will shut off The range is 0 F 0 C to 20 F 13 C The default setting is 10 F 6 C Boiler Set Point Differential This parameter reflects the degrees below DHW boiler offset the temperature has to go before the boiler shuts off The range is 0 F 0 C to 60 F 33 C The default setting is 20 F 13 C SH DHW Switching Time When a boiler has a space heating demand and it receives a DHW demand it will immediately switch to the DHW demand and start a timer Once the timer has expired the boiler will switch back to the space heating demand and start another timer Once this timer expires it will switch back to the DHW demand The installer can adjust the length of time the boiler will service the space heating demand by accessing parameter E6 The minimum setting is 0 minutes and the maximum setting is 200 minutes The default time is 30 minutes Service Manual K COMMERCIAL BOILER I DHW SH Switching Time When a boiler has a DHW demand and it receives a space heating demand the SMART SYSTEM control will start a timer Once the timer expires it will stop the DHW demand and service the space heating demand The installer can
62. r temperature has exceeded the setting of the automatic reset high limit Auto Reset High Limit The actual fan RPM is 30 lower than what is being called for Fan Low OR Fan Speed Low will reguire a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Blown fuse CORRECTIVE ACTION e Check supply voltage for proper polarity Check external wiring for voltage feedback Check the flame rod and make sure it is clean Check the internal wiring for bad connections Replace main control board Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler Check 120 vac to boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board 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 If operating on something other than an outlet sensor check temperature setting of the main control board If the optional manual reset high limit has tripped check setting of t
63. s exceeded the Installation and Operation Manual for boiler pump continued maximum outlet water temperature specifications Replace the main control board Check set point of the external control Check the wiring between the external control and the External control is cycling too often unit Rem Ctrl Fit A Replace the control Parameters Progr will reguire a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Press the ENTER RESET button on the SMART After downloading parameters from a laptop SYSTEM display panel the main control board must be reset While the unit is in Service Mode the outlet Establish a heating load to remove the heat from the temperature has exceeded 185 F boiler loop Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler Service Bik Check 120 vac to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the main control board 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 sp
64. sh boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler Perform start up and check out procedures in the Check Flame and Combustion Section 10 Startup of the Installation and Operation Manual Replace the access cover and restore boiler to operation Table 2 2 Heat Exchanger Cleaning Kits Part Number Component Description CTN20005 Rear Refractory Cover MSC20083 KIT30063 MSC20084 Nylon 4 Wheel Brush 3mm Allen Wrench 4 4 x 24 Drill Extension x 24 Drill Extension Rear Refractory Cover Nylon 4 Wheel Brush 1 4 x 12 Drill Extension 1 4 x 24 Drill Extension KIT30064 Do NOT use a metal brush Only use the A CAUTION kit provided brush or an equivalent replacement nylon brush 3 Troubleshooting A WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Always disconnect power to the boiler before servicing Failure to comply could result in severe personal injury death or substantial property damage A WARNING Never jumper bypass any device except for momentary testing as outlined in the Troubleshooting chart Severe personal injury death or substantial property damage can result Before troubleshooting l ps gt 4 Have the following items a Voltmeter that can check 120 VAC 24 VAC and
65. ssure maximum boiler efficiency and reliability 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 A WARNING AP OMA l l noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liguids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of the Knight XL Installation and Operation Manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight XL Installation and Operation Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 2 Remove the PVC cap retaining screw from the PVC cap FIG 2 1 3 Remove the 2 inch PVC cap with the switch located at the top o
66. t is next to TEMPERATURE SETTINGS Press the NAVIGATION dial one time Rotate the NAVIGATION dial counterclockwise until the arrow gt is next to MIN SETPT Press the NAVIGATION dial one time Rotate the NAVIGATION dial to the desired temperature Press the RIGHT SELECT soft key SAVE one time Press the LEFT SELECT soft key EXIT if all desired changes have been made Press the LEFT SELECT soft key HOME SHUTDOWN gt GENERAL TEMPERATURE SETTINGS PATA LOGGING FUMCTIOWS HOME 47 SCROLL SHUTDOWN GEHEFHL gt TEMPERATURE SETTINGS DATA LOGGING FUMCTIOWS HOME 47 SCROLL SHUTDOWN 150 F MAA SETPT 130 F SH1 OFFSET 10 F HOME 47 SCROLL MAA SETP SH1 OFFSET HOME 44 SCROLL SHUTDOWN SH1 SETFT 150 F MIN SETPT J F HAs SETFT 130 F SHL OFFSET 10 F HOME 44 SCROLL SHUTDOWN SH1 SETFT 150 F MIH SETFT 22r MAA SHI HOME 44 SCROLL SHUTDOWN SH1 SETFT 120 F MIM SETFT MAA 150 F MAA SETP 1904F SH1 OFFSET 10 F HOME SHWE Ciel Service Manual AL 1 Service continued Parameter table Table 1 4 This table lists SMART SYSTEM control module parameters and where to access them See Installer Access s emen o o9 ve pemensaenones o me o9 ve pwns s ow ow O9 ve Pe fewer fm fm me eonan m ow me o9 sen o e e e o poas m ow e e Pe pemememma af w e 9 e wawe pm po e e o0 O 15 o0 QJ ES E w am
67. the brackets denote screen status When finished the installer can press the RIGHT SELECT SAVE key to store the new settings or the LEFT SELECT EXIT key to return to the G parameter list without saving the changes The delay value can be set between 0 minutes and 120 minutes The limit value can be set between 0 and 100 Figure 1 2 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 CALL TIME FOR 1 HEAT 3 TIME 3 gt 2 24 TIME Service Manual K COMMERCIAL BOILER I H Control modes Controlling Sensor The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate This parameter is adjustable by the installer by accessing parameter H1 The sensor selections are as follows The outlet sensor regulates the firing rate based on the outlet water temperature of the boiler and the inlet sensor regulates the firing rate based on the inlet water temperature of the boiler If the outlet sensor is selected and the optional system supply sensor is connected the control will regulate the firing rate based on the system supply sensor temperature The default sensor is the Outlet Sensor BMS Thermostat Input Active Inactive 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 Th
68. therefore the maximum rate to be used when heating an indirect DHW tank This setting may be used when the tank is unable to accept all of the BTU s available from the boiler This parameter may be adjusted by the installer by accessing parameter E11 The default value is the maximum fan speed for that model 21 1 Service F Outdoor Reset The option of controlling up to three 3 different outdoor resets for low outdoor temperatures is available Low Outdoor Temperature 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 This parameter can be changed by the installer by accessing parameter F1 The temperature range of this parameter is 40 F 40 C to 104 F 40 C The default value is 25 F 4 C High Outdoor Temperature When the outdoor air temperature rises to or above this point the water temperature will be at parameters F4 F9 and F14 FIG 1 1 This parameter can be changed by the installer by accessing parameter F2 The temperature range of this parameter is 40 F 40 C to 104 F 40 C The default value is 70 F 21 C Figure 1 1 Outdoor Air Reset Curve WATER TEMPERATURE SET POINT MAXIMUM RESET Default 180 F USER SET POINT Default 125 F MINIMUM RESET Default 70 F Default 25
69. ts may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 2 Maintenance continued Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover 2 Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones 3 Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring l Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of
70. ure range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Ramp Delay Enable Disable This parameter allows the installer to enable or disable the SH ramp delay by accessing parameter G4 23 1 Service SH Ramp Delay NOTICE The SMART SYSTEM control can be programmed to limit the firing rate for a fixed period of time at the start of a space heating demand There are six 6 possible limits each with their own time delay The first limit applies as soon as the burner starts Once its time delay expires the second limit is applied and its timer begins The control steps through these limits until the 6th sixth limit expires Note however that the rate can be held to less than 100 if so desired The installer can adjust the firing limits and time delays by accessing parameter G4 Once this parameter is selected the screen will show the step number the time delay for that step and the limit value corresponding with that step If the installer wishes to adjust one of the values in that step he can press the NAVIGATION dial until the value he wishes to change is flashing The installer can then rotate the NAVIGATION dial to adjust that value If the installer presses the RIGHT SELECT SAVE key while the limit value is flashing the step value will flash again The installer can then select the next step and adjust the delay and limit values corresponding with that step Please note that
71. version is read only Temperature units C F The control can be configured to display temperature in either C or F This parameter can be changed by the user or the installer by accessing parameter A3 The default is F Space Heating SH and Domestic Hot Water DHW Night Setback Offset The unit s internal clock can be set up to run at a lower set point temperature during unoccupied times Both the space heating and DHW can be programmed for night setback When in night setback the control reduces the set point by a fixed amount For space heating it subtracts the space heating night setback offset from each of the SH user set points parameters B1 B6 and B9 or the calculated outdoor reset set point if lower For DHW it subtracts the DHW night setback offset from the tank set point parameter E2 NOTE The DHW night setback will not work without a tank sensor installed The installer may adjust the space heating night setback offset by accessing A4 and the DHW night setback offset by accessing parameter A7 The minimum setting is 0 F 0 C and the maximum setting is 90 F 50 C Space Heating SH and Domestic Hot Water DHW Night Setback On Times This is the time in which the SH Night Setback Offset becomes active There are 7 start times and 7 stop times each for the space heating and DHW night setback features Both may be set to any time within a 7 day week These settings are referred to as triggers

Lochinvar 400 - 801 Boiler User Manual

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