Lochinvar Power-Fin, Knight, Knight XL, Knight Wall Mount Installation Manual

This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual, the
Installation and Operation Manuals,
and the Service Manuals, before
installing. Perform steps in the
order given. Failure to comply could
result in severe personal injury,
death, or substantial property
damage.



WARNING

Save this manual for future reference.

PC PROGRAM INSTRUCTIONS

Models: Power-Fin, Knight, Knight XL,

Knight Wall Mount and Armor

SM-PCP REV B

2

PC Program Instructions

Contents

1. INSTALLATION

Program Installation ..................................................... 3

USB Installation............................................................ 3

Program Setup............................................................. 3

Starting the Program.................................................... 4-6

2. SMART SYSTEM Status Screen ................................. 5

3. SMART SYSTEM Graphics Screen............................. 7

4. SMART SYSTEM Fault History Screen....................... 8

5. SMART SYSTEM Cascade Screen............................. 9

6. POWER-FIN PARAMETERS

Parameter Information Screens ...................................10

Changeable Parameters ..............................................11

Set 2: Functional Data .................................................11

Set 4: Menu Values......................................................12-19

7. KNIGHT, KNIGHT XL, KNIGHT WALL MOUNT, and
ARMOR PARAMETERS

Parameter Information Screens ...................................20

Changeable Parameters ..............................................21

Set 1: System Setup ....................................................21

Set 2: Functional Data .................................................22

Set 4: Menu Values......................................................23-29

8. NOTES.........................................................................30-31

PC Program Instructions

3

1 Installation

Program installation

To begin installation of the program, please insert your Smart
System CD into the CD drive. If you have Autostart enabled,
the Smart System software screen will load. If not, navigate to
your CD drive and double-click on index.html. Once the
screen opens, select the program you wish to install. Follow
the prompts then restart your computer.

If you wish to have the PC program icon on your desktop,
click on START, and then Programs. Right click on SMART
SYSTEM PC. Place the cursor over Send to >, and then click
on Desktop. The icon will appear on the Desktop Screen.

USB installation

Your PC will communicate with the SMART SYSTEM control
through the USB cable adapter combo included with your kit.
This cable will require a specific USB driver. This driver may
be installed by starting the SMART SYSTEM PC program,
clicking on the Settings pull-down menu, and clicking on
Comport> item. In the next menu, you will have the option
of installing one of two USB drivers. Select the option
appropriate for the operating system used by your PC. The
necessary driver will install automaticall

y.

Program setup

The PC will assign a ComPort to your new adapter. You will
need to know the ComPort number it uses in order to tell the
Smart System PC program which one to communicate with:

1. Click on Start, then Control Panel, then on the System icon
(use the Classic View), then on the Hardware tab, and then
on the Device Manager button. You will see a list of the
hardware on your PC.

2. Double click on “Ports (COM&LPT)”. You will see an
entry called “USB Serial Port (COM4)”. The ComPort
number may be different on your computer but the device
description will be the same. The Smart System PC program
can communicate through Comports 1 – 16 on all models.
If the Comport assigned by your computer is a value larger
than what is available in the Smart System PC program, you
will need to manually reassign the ComPort on your
computer.

3. Go back to the “Ports (COM&LPT)” area referenced above
and take note of any unused ComPort between COM1 to
COM16. Double click on the “USB Serial Port”.

4. Click on the “Port Settings” tab, then on the “Advanced”
button. Select an unused Comport number (preferably
COM1) in the range of COM1 to COM16 Click on OK.
Click OK on the previous window and then close all of the
other windows.

5. Restart your PC to make sure the new ComPort number is
active. When you attach the USB cable to the PC, the PC
should recognize the cable. The first time you start up the
Smart System PC program, click on the “Settings” tab at
the top of the screen, then click on “Comport”. Select the
ComPort number assigned to the USB cable above.

The program displays temperatures in °F. If you wish to display
temperatures in °C, click on the Settings tab along the top of the
Main Screen window, and move the cursor over Temperature >
in the pull-down menu. A new menu will appear, click on
Celsius.

 CAUTION

DO NOT connect a phone line to the
phone jack on the front display.

4

PC Program Instructions

1 Installation

Figure 1-1_Main Screen

Starting the program

To start the program, double click on the icon (if you put it on
your desktop), or click on START, then Programs, then
SMART SYSTEM PC. See FIG. 1-1 on page 4.

There are two access levels for this program. The user access
level allows only certain settings to be changed. The installer
access level allows more settings to be changed. The program
defaults to the user level when started. You will notice that a
lock symbol appears in the lower right-hand corner of the
window. To move to the installer level, a password must be
entered. This password is located on a label on the CD-ROM
case. You may enter the password by clicking on the “key”
button in the upper left-hand corner of the window. A
window opens in which you can type in the password (see
FIG. 1-2). Note that the password is case sensitive and is in all
CAPS. Click on the Ok button, or press the Enter key. You will
notice that the lock symbol at the lower right-hand corner of
the window has changed into a key symbol.

Figure 1-2_Password Window

There are some fields along the bottom of the window
(FIG. 1-1): The left field shows the location of the program.
The next field shows the status of the communication between
the PC and the SMART SYSTEM. This will say “No
connection” when the program is started. As soon as the
program sends or receives data from the SMART SYSTEM,
this field will show “Connected”. The right field shows the
filename of the parameter file in the program’s memory (see
the following parameters).

2 SMART SYSTEM Status screen

5

PC Program Instructions

Figure 2-1_SMART SYSTEM Status Screen

To monitor and record the operation of the heater, click on the
Status tab along the top of the Main Screen window (FIG. 1-1,
page 4). The SMART SYSTEM Status Screen will appear (see
FIG. 2-1 above). The screen is divided into several sections.

The Sensors section displays the current temperatures seen by
the Inlet, Outlet, System Inlet, System Outlet, Tank, Outdoor,
and Flue sensors. It also shows the delta T across the heat
exchanger and the voltage being applied to the 0-10Vdc input
(FIG. 2-1). The controlling sensor is shown below the items
mentioned above. The default controlling sensor is the Outlet
sensor. If a System Supply sensor is connected, the control will
automatically use it as the controlling sensor.

The SMART SYSTEM can be programmed to use the Inlet
sensor if desired. When so programmed, the Outlet sensor
will be displayed for the first 3 minutes after the burner lights,
and then the Inlet sensor will be displayed.

Power-fin Models Only: If a System Return sensor is
connected, the control will use it as the controlling sensor, and
display its reading instead.

Below the temperature readings are Derivative Flue and
Derivative Outlet. These show how quickly these
temperatures are changing. The control will take certain
actions based on these values. For instance, if the outlet
temperature rises too quickly, the control will force the heater
to run at low fire.

To the right of the sensor temperature readings are the
various setpoints. The SH setpoint is the setpoint the SMART
SYSTEM uses during a space heating call for heat. Note that
this setpoint will depend upon the outdoor temperature if the
outdoor air sensor is connected. When the 0-10Vdc input is
used, this setpoint will vary with the input voltage if it is used
to control the setpoint. The tank setpoint is the setpoint used
when a Tank sensor is connected. The DHW Mod Setpt is the
outlet temperature setpoint used when heating an indirect
DHW tank. The dSP setpoint is used when the inlet sensor is
programmed as the controlling sensor. Below these is a check
box indicating if Night Setback is active or not. Finally, the
HSI Current and Flame Current are shown.

Below the Sensors section is the Inputs section (FIG. 2-1).
This section displays the status of the Enable (Room
Thermostat) Input, DHW Thermostat, Manual Reset High
Limit, Flow Switch/Low Water Cutoff (optional), Gas Pressure
Switch (optional), Louver Proving Switch (optional), Air
Pressure Switch, Blocked Drain Switch, and Auto Reset High
Limit Switch.

Next to the Inputs section is the Outputs section (FIG. 2-1).
This section shows the status of the Boiler (secondary) pump,
System (primary) Pump, DHW Pump, Blower, Gas Valve (1),
Run-time Contacts, and Alarm Contacts.

2 SMART SYSTEM Status screen

6

PC Program Instructions

Power-fin Models Only: If a 3-way bypass valve is
installed, the display will indicate how much of the flow is not
bypassed. The Gas Valve 2 output is not used.

At the top right of the window is the Fan Speed status
information (FIG. 2-1). Included in the Fan Speed status are
Min., Max., and Ignition fan speeds. If Ramp Delay is
activated, the Ramp Delay limit is shown. The target and
actual fan speeds are displayed, and if the actual speed is
within acceptable limits. If the SMART SYSTEM is
programmed to be controlled by a Building Management
System (BMS), and programmed to have the BMS control the
power from the boiler, then the percent of max. power is
displayed. Finally, should select temperatures or the flame
current approach certain limits, the SMART SYSTEM will
force the fan speed up or down accordingly to prevent
exceeding those limits. When this happens, the box next to
the corresponding sensor is checked.

Below the Fan Speed status is the Boiler Configuration. This
indicates the application to which the SMART SYSTEM is
programmed to be used (water heater or boiler with indirect
DHW), and the source of control (thermostat, BMS, or
cascade depending on the model). The ID plug information
is used in production to verify the correct programming of
the control on Power-fin models.

Finally, the General status of the boiler is shown. Included in
the General status is the active call for heat (if any), the active
limits (if any), the last active limit, the burner status, the last
fault, and the date and time as stored in the SMART SYSTEM.

While in the SMART SYSTEM Status Screen, you can generate
a log file of the readings as the heater operates. Click on the
Options button at the bottom right-hand corner of the screen
(FIG. 2-1). Press the LogFile button and define a log file
name and the directory you want it to be located in. Click
OK. When you want to start logging data, click the Log
button. The Log button will turn green to indicate that it is
logging. You will also notice the filename at the top of the
window, and will see the size increase as data is logged to the
file. To stop logging, click on the Options button, then click
on the Log button again. The Log button will turn back to
gray to indicate that logging has stopped. If you desire to log
data over an extended period of time, you may want to select
a longer Log every time so the log file doesn’t grow too large.

You can also produce a bitmap of the window. Click on the
Options button, then the Bitmap button. A bitmap of the
window will be saved into the ENCONFLS directory below
the directory in which the SMART SYSTEM program resides.

7

3 SMART SYSTEM Graphics screen

PC Program Instructions

The SMART SYSTEM Graphics Screen allows you to observe
the changes in various readings while the heater operates (see
FIG. 3-1). By default, the Outlet Temperature, Inlet
Temperature, System Supply Temperature (if connected),
Outdoor Temperature (if connected), Tank Sensor
Temperature (if connected), Space Heating setpoint, Tank
setpoint, 0-10Vdc input voltage, System Inlet Temperature (if
connected), fan speed, and 3-way Bypass Valve (Power- fin
Models Only) are plotted.

In addition, the status of the Gas Valve Output, Flame
Current, and Pump Outputs are indicated by horizontal lines.
When these readings are off, the line is thin; when on, the line
is wide. Any of these readings can be removed from the graph
by deselecting them at the bottom of the window. The
current values of these readings are also displayed at the
bottom of the window as depicted in FIG. 3-1.

The time scale and vertical (Y) scale can be changed by
clicking on the Options button to get the Options window,
and then the Up or Down buttons for the desired scale. Note
that the vertical scale has two numbers for each division. The
top number represents °F, and the bottom number represents
°C. Press the Ok button to close the Options window. The
background color of the Graphics Screen can be changed by
pressing the Display button on the Options window.

Figure 3-1_SMART SYSTEM Graphics Screen

As with the SMART SYSTEM Status Screen, a log file can be
generated to record the performance of the appliance. Click
on the Options button to open the Options window. Click on
the LogFile button to create a file name and define the folder
in which to put it. Once a Log File is defined, click on the Log
button to start logging the readings. The Log button will turn
green to indicate that the program is logging, and the log file
size will appear at the top of the Graphics Screen window.
Note that the file size will increase as more readings are
logged. Click on the Log button again to stop logging of the
readings. The Log button will turn gray again to indicate that
logging has stopped.

A bitmap can also be generated of the SMART SYSTEM
Graphics Screen. Click on the Options button, and then the
Bitmap button. A bitmap of the window will be saved into
the C:/program files/SMART SYSTEM PC/enconfls directory.

8

4 SMART SYSTEM Fault history screen

PC Program Instructions

Figure 4-1_Fault History Screen

The Fault History Screen provides historical data about the
operation of the SMART SYSTEM. Click on the Fault history
button along the top of the Main Screen window (FIG. 1-1),
and then click on Read from Control in the pull-down menu.
After uploading data from the SMART SYSTEM, a window
will appear with the status of numerous counters and lists of
the most recent events (see FIG. 4-1 above). Included are
details of the control board serial number, software version,
default parameters, production date, and last service date.
The number of times various faults have occurred is also
shown. The last 10 faults are listed, as well as the last 10
blockings (a blocking is an event that causes the burner to
shut off). In addition, the number of hours the control has
operated in various states is shown, as well as the number of
successful and failed ignition attempts. Finally, a count of
internal checks is shown.

The total number of occurrences of certain faults are also
stored in the control and shown on the left side of the screen.
The column on the right shows the total occurrences since the
control was built. The column on the left shows the total
occurrences since the table was reset. Press the Erase table
button at the bottom of the window to clear the totals in the
column on the left. This will also clear the Last 10 faults and
the Last 10 blockings.

Some of this information may be needed by a service
technician to diagnose a problem, so provision is made to
create a file in which to save this data. Click on Save file, and
define a file name and the folder in which to save it. A bitmap
can also be saved by clicking on the Bitmap button at the
bottom of the Fault History Screen (FIG. 4-1). The bitmap
file will be saved to the folder ENCONFLS located below the
file in which the SMART SYSTEM program resides.

9

5 SMART SYSTEM Cascade screen

PC Program Instructions

Figure 5-1_Cascade Screen

The Cascade Screen provides the status of the cascade system.
The PC must be connected to the Leader (address 0)
appliance. Click on the Cascade button along the top of the
Main Screen window (FIG. 1-1).

The Cascade System area shows the power demand and
setpoint, the boiler pump status, the boiler status, and the
priority of each heater in the cascade. If a tank sensor (water
heaters) or system supply sensor (boilers) is connected to the
Leader heater, the cascade control will send a fixed setpoint of
215°F (102°C) (Power-fin boiler only); 185°F (85°C) (Knight
boilers only) or a setpoint equal to the tank setpoint +27°F
(15°C) (water heaters) and a power (% modulation)
command to all the heaters as required to maintain the
controlled temperature at the setpoint. On boilers, if a system
supply sensor is not connected (NOT recommended), the
Leader will send the space heating setpoint to all of the boilers
in the cascade and each boiler will fire as required to hold their
outlet sensors to this setpoint.

The Priority column indicates the order in which the heaters
will fire to meet the load. This order changes every hour
during the first day of operation, andevery24 hours thereafter.

The Sensors area displays the system supply or tank sensor
temperature, and space heating or tank setpoint (see FIG. 5-1).

Power-Fin Models Only: Beneath this area is a check box
indicating if Night Setback is active. Beneath that is a check
box indicating if the Dead zone is active.

The Dead zone is active whenever the actual temperature is
near the setpoint and the target modulation rate for the last
boiler to fire is below its minimum firing rate. In this zone, the
calculated total firing rate is held steady. Once the actual
temperature goes too far above or below the setpoint, the total
firing rate is adjusted accordingly.

The Status area displays several important parameters. The
Cascade Pump gives the status of the system pump output,
and the type of heat demand (Space Heating or DHW). The
Cascade power shows the power target for the cascade, and
the total power available. This target power may not be the
same as the total power shown in the Cascade System area,
due to the various time delays described below. The Cascade
Max and Cascade Min values show the maximum and
minimum fan speed percentages available in all of the heaters.
The Off Timer and On Timer are used to force each boiler to
have a minimum off and on time, to prevent short cycling.
The Block Switch on the timer is started whenever a heater is
commanded to start, and the next heater is prevented from
starting until this timer times out. This allows time for the
system supply or tank sensor to read the temperature change
resulting from firing the last heater, before starting the next
heater.

By clicking on the Options button, a log file can be defined,
and logging can be started and stopped in the same way as
with the Status and Graphics Screens previously described. A
bitmap of the current screen can also be saved if desired.

6 Power-fin Parameters

10

PC Program Instructions

Parameter information screens

By accessing the Parameter Information Screens, the installer
can view all of the SMART SYSTEM parameters. The installer
can also change certain specific parameters to fine tune the
operation of the heater to the installation.

To access the parameter list, click on the Parameters button
along the top of the Main Screen window (FIG. 6-1). Next
click on Retrieve Parameters from Controller in the pull
down menu (see FIG. 6-1). This will upload the current
parameters in the SMART SYSTEM to the PC.

Figure 6-1_Parameters Pull-Down Menu Screen

Adjustable parameters are located in:

Set 2: Functional Data

Set 4: Menu Values

While many parameters are viewable in each set, only select
parameters are adjustable. To make an adjustment to a
parameter, select the parameter to be changed from the
appropriate set. Click on the box next to the parameter and
type in the value for the parameter.

Once an adjustment has been made to a parameter, it must be
programmed into the SMART SYSTEM.

On the Parameters pull down menu, click on the Program
Parameters into Control button. This will bring up another
pull down menu. If a parameter was changed in just one set,
select the set from the menu and click on it. If changes were
made in multiple sets, select the Store Parameter Set 0-6 from
the menu and click on it. This will program the new
parameters into the SMART SYSTEM.

While the programming is taking place, the SMART SYSTEM
will go into a lockout mode. It requires the Enter/Reset
button on the display to be pressed after the programming has
been completed before the appliance will be allowed to
operate.