Lochinvar KBL501 Service Manual
KBXII-SER Rev I
Service Manual
Models: 400 - 801
WARNING
Save this manual for future reference.
This manual must only be used
by a qualified heating installer /
service technician. Read all
instructions, including this manual
and the Knight XL Installation and
Operation Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Contents
CONTENTS ........................................................................ 2
Hazard Definitions .............................................................. 2
PLEASE READ BEFORE PROCEEDING ........................ 3
Handling Ceramic Fiber Materials ...................................... 3
When servicing boiler ................................................... 4
Boiler operation ............................................................ 4
Boiler water ................................................................... 4
Freeze protection fluids ................................................ 4
WHAT IS IN THIS MANUAL .............................................. 5
1. SERVICE
Near Boiler Piping .............................................................. 6
The Knight XL Display ....................................................... 7
Control Inputs ............................................................... 8
Control Outputs ............................................................. 9
General Operation ...................................................... 10
Sequence of Operation ............................................... 11-12
Display Panel Menu Access ............................................ 13
Display Panel Parameter Access ..................................... 14
Parameter Table.......................................................... 15-17
Viewable and Changeable Control Parameters .......... 18-26
Hazard definitions
2. MAINTENANCE
Maintenance and Annual Startup ................................ 27-32
3. TROUBLESHOOTING
Before Troubleshooting .................................................... 33
Check Control Module Fuses .......................................... 33
Table 3-1 - Troubleshooting Chart - No Display .............. 34
Checking Temperature Sensors ...................................... 35
Table 3-3 - Troubleshooting Chart - Noisy System ......... 36
Table 3-4 - Troubleshooting Chart - Fault Messages . 37-46
Combustion Analysis Procedure ...................................... 46
Table 3-5 - Flue Products ................................................ 46
Table 3-6 - Troubleshooting Chart - Combustion Levels 46
Gas Valve Adjustment Procedure .................................... 47
Revision Notes .................................................. Back Cover
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.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
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
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
2
Please read before proceeding
Service Manual
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 qualified service technician at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
NOTICE
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
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 cristobalite.
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.
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.
Apply enough water to the combustion chamber lining to prevent airborne dust.
Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
3
Please read before proceeding
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• 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.
Service Manual
Boiler water –
• 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 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 –
• 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.
4
What is in this manual?
Service 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 start information -- parameter
table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
Knight XL operation
• A: General
• B: Temperature Setting
• C: Data Logging
• D: Functions
• E: DHW Settings
• F: Outdoor Reset
• G: Anti-cycling
• H: Control Modes
• I: Circulation Pumps
• J: Building Management System (BMS)
• K: Service Notification
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
• Inspect ignition electrode
• Check ignition ground wiring
• Check all boiler wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
• Review with owner
• 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
5
Service Manual
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.
FROM
SYSTEM
AIR SEPARATOR
SYSTEM SENSOR
SYSTEM PUMP
TO
SYSTEM
Y-STRAINER
(RECOMMENDED)
BOILER PUMP
DOMESTIC HOT
WATER PUMP
FROM
TO
INDIRECT
DOMESTIC
HOT WATER
TANK
TO FLOOR
IMG00852
DRAIN
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1 Service (continued)
The Knight XL display
Service Manual
NAVIGATION DIAL
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
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1 Service
1 Service
Control inputs
SYSTEM PUMP SPEED CONTROL
GAS PRESSURE SWITCH
DHW THERMOSTAT
ROOM THERMOSTAT /
ZONE CONTROL
SYSTEM SENSOR
OUTDOOR SENSOR
FLOW SWITCH
Service Manual
LOW VOLTAGE
CONNECTION
BOARD
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
LOW WATER CUTOFF
O-TEMP
HEAT EXCHANGER SWITCH
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE /
HI-LIMIT SENSOR
FLUE GAS SENSOR
AIR PRESSURE SWITCH
LOUVER PROVING SWITCH
FLAME SENSOR
BLOCKED DRAIN SWITCH
DOOR TEMPERATURE SWITCH
SMART CONTROL
MODULE
DISPLAY PANEL
IMG00006
PC INTERFACE
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1 Service
1 Service (continued)
Control outputs
Service Manual
ALARM BELL
LOW VOLTAGE
CONNECTION
BOARD
LOUVER RELAY
RUN TIME CONTACTS
BUILDING MANAGEMENT
SYSTEM
BOILER PUMP
SYSTEM PUMP
DHW PUMP
SMART CONTROL
MODULE
IGNITOR
BLOWER
GAS VALVE
DISPLAY PANEL
PC INTERFACE
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1 Service
1 Service
Service Manual
General 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.
Access modes
User
The user can adjust space heating and tank target temperatures
by pressing the NAVIGATION dial when “SETPOINTS” is
flashing 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
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.
Please note that the brackets ([]) denote
screen status.
10
1 Service1 Service (continued)
Table 1-1 Sequence of Operation
OPERATION DISPLAY
1. Upon a call for heat, the gas pressure switch(es) must be closed.
2. Once the gas pressure switch(es) are closed, the control turns
on the appropriate pumps (system and boiler pumps for space
heating, DHW pump for DHW). The flow switch and/or LWCO
must close.
Service Manual
3. The control turns on power to the louver relay. The louver
proving switch, air pressure switch, and blocked drain switch
must close.
4. The control starts a prepurge cycle by initiating the blower.
5. The control starts a trial for ignition by firing the spark
electrode and opening the gas valve.
6. If flame is not detected after the sparking ends, the control will
perform a postpurge, 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.
7. If flame is detected, it holds the firing rate steady for a few
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).
a
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1 Service
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 operation (not as
a zone), the DHW pump will turn on first, then the boiler pump
will turn off (boiler and DHW pump operation briefly overlap to
ensure flow is maintained through the unit). This will divert the
boiler’s outlet water from the heating system and send it to the
tank coil instead. The control will then modulate to maintain the
outlet temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one
of them is satisfied.
Service Manual
10. Once both calls for heat are satisfied, the control will turn off
the burner. The blower will continue to run during the postpurge
period.
11. Any pumps that are running will continue to run for their
respective pump delay times before turning off, unless
programmed to remain on continuously. A 60 second anti-cycle
period will start, which will delay any new call for heat until it
times out.
12. In Standby, ready to start a new cycle.
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1 Service
1 Service (continued)
Display panel menu access
Table 1-2 Use this procedure to access menus from the display panel
Service Manual
BUTTON
SCREEN
STATUS
[SHDN] Press the RIGHT SELECT soft key [SHDN].
[YES] Press the LEFT SELECT soft key [YES].
[MENU]
Press and hold the LEFT SELECT soft key [MENU]
for five (5) seconds.
Rotate the NAVIGATION dial clockwise until 5 is
displayed (first digit on the left).
OPERATION DISPLAY
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.
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1 Service
1 Service
Service Manual
Display panel parameter access
Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN
SH Setpt
BUTTON
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.
SCREEN
STATUS
OPERATION DISPLAY
Rotate the NAVIGATION dial counterclockwise until
the arrow (>) is next to TEMPERATURE SETTINGS.
Press the NAVIGATION dial one time.
Rotate the NAVIGATION dial counterclockwise until
the arrow (>) is next to MIN SETPT.
Press the NAVIGATION dial one time.
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Rotate the NAVIGATION dial to the desired
temperature.
[SAVE] Press the RIGHT SELECT soft key [SAVE] one time.
[EXIT]
[HOME] Press the LEFT SELECT soft key [HOME].
Press the LEFT SELECT soft key [EXIT] if all desired
changes have been made.
1 Service
1 Service (continued)
Service Manual
Parameter table
Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them
Menu Description
Time and Date 18 Yes Yes Yes Yes
Software Version (read only) 18 No No Yes No
Temperature Units (ºC/ºF) 18 Yes Yes Yes Yes
SH Night Setback Offset 18 No No Yes Yes
SH Night Setback On Times 18 No No Yes Yes
SH Night Setback Off Times 18 No No Yes Yes
DHW Night Setback Offset 18 No No Yes Yes
GENERAL
DHW Night Setback On Times 18 No No Yes Yes
DHW Night Setback Off Times 18 No No Yes Yes
Display Timeout 19 No No Yes Yes
SH1 Set Point 19 Yes Yes No No
Minimum SH Set Point 19 No No Yes Yes
Maximum SH Set Point 19 No No Yes Yes
SH1 Offset 19 No No Yes Yes
SH1 Differential 19 No No Yes Yes
SH2 Set Point 19 Yes Yes No No
SH2 Offset 19 No No Yes Yes
SH2 Differential 19 No No Yes Yes
SH3 Set Point 19 Yes Yes No No
SH3 Offset 19 No No Yes Yes
TEMPERATURE SETTINGS
SH3 Differential 19 No No Yes Yes
3-Way Valve Time 19 No No Yes Yes
See
Page
User Access Installer Access
Display Modify Display Modify
DATA
DHW SETTINGS
Reset Log Errors 19 No No Yes Yes
LOGGING
Service Mode Delay 19 No No Yes Yes
Freeze Protection Pump On 19 No No Yes Yes
Freeze Protection Burner On 19 No No Yes Yes
Freeze Protection Burner Differential 20 No No Yes Yes
FUNCTIONS
DHW Boiler Set Point 20 No No Yes Yes
Tank Set Point 20 Yes Yes Yes Yes
Tank Set Point Differential 20 No No Yes Yes
DHW Boiler Offset 20 No No Yes Yes
DHW Boiler Differential 20 No No Yes Yes
SH/DHW Switching Time 20 No No Yes Yes
DHW/SH Switching Time 20 No No Yes Yes
Tank Minimum Set Point 20 No No Yes Yes
Tank Maximum Set Point 20 No No Yes Yes
DHW Type 20 No No Yes Yes
Fan Speed Limiting for DHW 20 No No Yes Yes
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