Lochinvar KBN399 Service Manual

KBX-SER Rev F

Service Manual

Models: 399 - 800

WARNING	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.

Save this manual for future reference.

Contents

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2	2. MAINTENANCE
Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2	Maintenance and Annual Startup . . . . . . . . . . .	. . . . . . .	23-27
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . .	3	3. TROUBLESHOOTING
Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . . . . .	3	Before Troubleshooting . . . . . . . . . . . . . . . . . . .	. . . . . . .	28
When servicing boiler . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Check Control Module Fuses . . . . . . . . . . . . . .	. . . . . . .	28
Boiler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Table 3A - Troubleshooting Chart - No Display .	. . . . . . .	29
Boiler water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Checking Temperature Sensors . . . . . . . . . . . .	. . . . . . .	30
Freeze protection fluids . . . . . . . . . . . . . . . . . . . . . . . .	4	Table 3E - Troubleshooting Chart - Noisy System . . . . . 31
WHAT IS IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . .	5	Table 3F - Troubleshooting Chart - Fault Messages . . . .		32-39
1. SERVICE		Combustion Analysis Procedure . . . . . . . . . . . .	. . . . . . .	40
Near Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Table 3G - Troubleshooting Chart - Combustion Levels		40
The Knight Boiler Display . . . . . . . . . . . . . . . . . . . . . . . . .	7	Table 3H - Flue Products . . . . . . . . . . . . . . . . . .	. . . . . . .	40
Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8	Gas Valve Adjustment Procedure . . . . . . . . . . .	. . . . . . .	41
Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9	Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . .	Back Cover
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . .	11-12
Display Panel Menu Access . . . . . . . . . . . . . . . . . . . . . .	13
Display Panel Parameter Access . . . . . . . . . . . . . . . . . .	14
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15-16
Viewable and Changeable Control Parameters . . . . . . .	17-22

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.

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

										Service Manual
Please read before proceeding
	Installer –	Read		all	instructions,					When calling or writing about the boiler –
WARNING								NOTICE
	including this manual and the Knight XL									Please have the boiler model and serial
	Installation	and	Operation Manual,							number from the boiler rating plate.
	before installing.		Perform		steps in the					Consider piping and installation when
	order given.
										determining boiler location (see the Knight
	User – This manual is for use only by a									XL Installation and Operation Manual).
	qualified	heating		installer/service						Any claims for damage or shortage in
	technician. Refer to the Knight XL User’s
										shipment must be filed immediately against
	Information Manual for your reference.
										the transportation company by the
	Have this boiler serviced/inspected by a									consignee.
	qualified 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

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.

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

Service Manual

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.

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

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 Air Reset Curve

•G: Anti-cycling

•H: Control Modes

•I: Circulation Pumps

•J: Service Notification

Service Manual

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

1Service

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

DOMESTIC HOT

WATER PUMP

SYSTEM PUMP

FROM

TO

SYSTEM

TO

INDIRECT DOMESTIC HOT WATER TANK

BOILER PUMP

TO FLOOR

DRAIN

6

1Service (continued)

The Knight XL display

•Hold 5 seconds to enter code Input Mode (Menu Mode)

•Press to move up one level in Menu Mode or to exit

Menu Mode

MENU / EXIT

UP DOWN

•Press to change boiler water temperature set point during normal operation

•Press to change displayed data values in Menu Mode

•Press to navigate through menu listing in Menu Mode

Service Manual

• Press to turn boiler off or

	back on	SHUTDOWN
	• Press to select a menu item

•Press after parameter programming to store parameter data

• Press to exit Service Mode		ENTER / RESET

DISPLAY SCREEN

SERVICE

BUTTON

PC

CONNECTIO

PORT

PREVIOUS NEXT

•Press to toggle display during normal operation to show outlet and return temperatures, fan speed, and flame signal

•Press to toggle between digits when entering access code or between hour, minutes, etc., when entering date and time

7

1Service

Control inputs

GAS PRESSURE SWITCH (OPTIONAL)

DHW THERMOSTAT (OPTIONAL)

ROOM THERMOSTAT /

ZONE CONTROL

FLOW SWITCH

SYSTEM SENSOR

DHW TANK SENSOR (OPTIONAL)

OUTDOOR SENSOR (OPTIONAL)

SEQUENCER / BUILDING MANAGEMENT SYSTEM (OPTIONAL)

LOW WATER CUTOFF (OPTIONAL)

INLET TEMPERATURE

SENSOR

OUTLET TEMPERATURE

SENSOR

FLUE GAS SENSOR

AIR PRESSURE SWITCH

HIGH LIMIT

FLAME SENSOR

BLOCKED DRAIN SWITCH

DISPLAY PANEL

PC INTERFACE (OPTIONAL)

8

Service Manual

LOW VOLTAGE

CONNECTION

BOARD

SMART CONTROL MODULE

Service Manual

1Service (continued)

Control outputs

ALARM BELL

AUX. DEVICE RELAY

LOW VOLTAGE

CONNECTION

BOARD

RUN TIME CONTACTS

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

BOILER PUMP

SYSTEM PUMP

DHW PUMP

IGNITOR

BLOWER

SMART CONTROL

MODULE

GAS VALVE

DISPLAY PANEL

PC INTERFACE

9

Service Manual

1Service

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 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

Access modes

User

The user can adjust space heating set point using the UP and DOWN buttons at any time during normal operation. By entering the USER code (0704), the user can also change temperature units, time and date, and night setback settings. In user mode, the following parameters can be viewed but not changed: Boiler outlet water temperature in DHW mode; boiler model number; software version; total operating hours, and total cycles.

Installer

Most parameters are available only to the installer, accessible only by entering the installer access code (5309).

Saving parameters

To save parameters:

Press the ENTER/RESET button.

To keep parameter settings only for a current operating cycle:

Press the MENU/EXIT button 1 time to return to the parameter listings; press again to return to the menu listings.

Service Manual

1Service (continued)

Sequence of operation

Table 1A Sequence of operation - space heating and DHW

	OPERATION	DISPLAY
	1. Upon a call for heat, the control turns on the appropriate pumps	BLR: Standby
	(system and boiler pumps for space heating call; DHW pump	OUT: 123.8F(129)
	for DHW call).
	2. The control connects 120 VAC to the blower. The blower
	does not run at this time.	BLR: Standby
	• The manual reset high limit must be closed and reset.
	• Once the pumps are turned on, the flow switch must close.	OUT: 123.8F(129)
	• If the unit is equipped with gas pressure switches, they must
	close.
	• If an auxiliary limit is connected to the unit, it must close.
	• The air pressure switch must be closed.
	3. The control then starts a 15 second prepurge cycle.	BLR: PREPURGE
		OUT: 123.9F(129)
	4. Once the prepurge cycle is complete, and the blocked drain	BLR: IGNITION
	switch is closed, the control starts the 4 second trial for ignition
	by sending spark voltage to the spark electrode and opening	OUT: 123.9F(129)
	the gas valve.
	5. If the control does not detect flame before the trial for ignition
	ends, the control will perform a 10 second postpurge. The 399	BLR: POSTPURGE, PREPURGE
	model will start another prepurge and trial for ignition. If the
	burner does not light after 4 trials on the 399 model, the control	OUT: 123.9F(129)
	will lock out for one hour and then try again.
	On the 500 - 800 models, the control will lock out indefinitely
	after the first trial for ignition fails.
	6. If the control detects a flame before the trial for ignition ends, it	BLR: SH 20% RATE
	begins to modulate the burner in order to maintain the set point.
	If the boiler lights due to a space heating call for heat, and the
	ramp delay function is active (default is off), the modulation	OUT: 124.8F(129)
	will be held to a series of increasing limits after the burner has
	lit.
	7. If the space heating call for heat is active, and the DHW
	thermostat or sensor starts a DHW call for heat, the control will	BLR: DHW 85% RATE
	turn on the DHW pump, wait 2 seconds, and then turn off the
	boiler pump. This will divert the hot water away from the	OUT: 177.8(180)
	heating zone(s) and send it to the DHW tank instead. The
	control will then modulate to maintain the outlet temperature to
	the DHW boiler set point.

11

Service Manual

1Service

Sequence of operation (continued)

Table 1A (continued from previous page) Sequence of operation - space heating and DHW

	OPERATION	DISPLAY
8. If the boiler is not part of a cascade, and the DHW call for heat
	remains active for more than 30 minutes, and the space heating
	call for heat is also active, then the control will turn on the boiler	BLR: SH 41% RATE
	pump, turn off the DHW pump after 2 seconds, and resume
	modulating based on the space heating set point. As long as	OUT: 123.0F(129)
	both the space heating and DHW calls for heat remain active,
	the control will switch back and forth between the two modes
	until one of them is satisfied.
9. Once both calls for heat are satisfied, the control will turn off the		BLR: POSTPURGE
	burner. The blower will remain on for the 10 second postpurge
	cycle. Any pumps that are running will continue to run for their	OUT: 127.4F(129)
	respective pump delay times, then turn off.
10.	Boiler pump off, system pump continues its delay if longer.	BLR: Standby
		OUT: 124.7F(129)
11.	System pump off.	BLR: Standby
		OUT: 122.9F(129)

12

Service Manual

1Service (continued)

Display panel menu access

Table 1B Use this procedure to access menus from the display panel

	BUTTON	OPERATION	DISPLAY	COMMENTS

				ENTER/RES		Press 1 time in normal operation	BLR:OFF		Boiler turns off (this ensures
							OUT:127.3ºF		uninterrupted programming)
				MENU/EXIT		Hold for 5 seconds -- display will change	Enter Menu Code:		Digit shown underlined at left will
							0000	flashing	flash
				UP		Press 9 times to change last digit	Enter Menu Code:		Digit shown underlined at left will
						in readout to “9”	0009		flash
				PREVIOUS		Press 2 times to move to the second	Enter Menu Code:		Digit shown underlined at left will
						digit	0009		flash
				UP		Press 3 times to change second digit	Enter Menu Code:		Digit shown underlined at left will
						in readout to “3”	0309		flash
				PREVIOUS		Press 1 time to change to the first	Enter Menu Code:		Digit shown underlined at left will
						digit	0309		flash
				UP		Press 5 times to change first digit	Enter Menu Code:		Digit shown underlined at left will
						in readout to “5”	5309		flash

If you enter a digit incorrectly, you can move to the digit by using the NEXT and PREVIOUS buttons as needed until the digit you want is flashing. Then use UP and/or DOWN buttons to change the value.

		ENTER/RES	Press to enter the code	Enter Menu Code:	The words, “INSTALLER CODE”
				INSTALLER CODE	will flash while displayed
			After 2 seconds, display shows menus	>A General	The caret symbol, “>” highlights
			(press ENTER/RESET to select a menu)	B Temp Settings	the selectable line
		If the code is entered incorrectly, the display will return to its previous mode. You will have to start over
		at step 1 to enter the code.
		DOWN	Press 1 time to highlight second listing	A General	The caret symbol, “>” highlights
					the selectable line
				>B Temp Settings
		DOWN	Press 1 time to toggle menu listing	>C Data Logging	The menu toggles to the next two
				D Functions	menu options
		DOWN	Press 2 times to toggle menu listing	>E DHW Settings	The menu toggles to the next two
				F Outdoor Reset	menu options
		DOWN	Press 2 times to toggle menu listing	>G Anti-cycling	The menu toggles to the next two
				H Control Modes	menu options
		DOWN	Press 2 times to toggle menu listing	>I Circulation Pumps	The menu toggles to the next two
				J Service Notification	menu options

To select a highlighted menu, press the ENTER/RESET button one time. The display will change to the first parameter under that menu, with the first characters flashing.

13

Service Manual

1Service

Display panel parameter access

Table 1C This is a typical example of accessing a parameter, shown for parameter I2, boiler pump delay

BUTTON	OPERATION	DISPLAY	COMMENTS

This example shows how to access parameter I2, boiler pump delay. The first display shown is at the beginning of the menu listings, after entering the installer acess code.

			Beginning of menu listings	>A General	The caret symbol, “>” highlights
				B Temp Settings	the selectable line
		DOWN	Press 1 time to highlight second listing	>A General	The caret symbol, “>” highlights
				B Temp Settings	the selectable line
		DOWN	Press 1 time to toggle menu listing	>C Data Logging	The menu toggles to the next two
				D Functions	menu options
		DOWN	Press 2 times to toggle menu listing	>E DHW Settings	The menu toggles to the next two
				F Heat Curve	menu options
		DOWN	Press 2 times to toggle menu listing	>G Anti-Cycling	The menu toggles to the next two
				H Control Modes	menu options
		DOWN	Press 2 times to toggle menu listing	I Circulation Pumps	The menu toggles to the next two
				J Service Notification	menu options
		ENTER/RES	Press 1 time to list parameters	I1 Postrun Time	I1 will flash
				System Pump
		UP	Press 1 time to change parameter	I2 Postrun Time SH	I2 will flash
				Pump
		ENTER/RES	Press 1 time to select parameter	I2 Postrun Time SH	I2 will stop flashing; parameter
				Pump 0.50 minutes	value will appear

UP	Press to increase (or decrease) value	I2 Postrun Time SH	Parameter will increase or decrease,
(or DOWN)		Pump 0.67 minutes	depending on button pressed

	ENTER/RES	Press 1 time to save	A	General	Display will change to normal
		(or press MENU/EXIT to continue)	B	Temp Settings	display as you exit menu mode
	ENTER/RES	Press 1 time to return to normal	BLR:Pre-Purge		This display example assumes
		operation	OUT:123.7ºF		a call for space heating is present

14