Lochinvar OKL501 Service Manual

OKBX-SER Rev C

Outdoor Knight XL

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 Outdoor 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 Outdoor 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.

Please read before proceeding

Outdoor Knight XL Service Manual

 WARNING

Installer – Read all instructions, including this manual and the Outdoor 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 Outdoor 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

 WARNING

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 Outdoor 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.

Do NOT install the appliance where it will be exposed to freezing temperatures.

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.

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.

Outdoor Knight XL 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.

What is in this manual?

Outdoor Knight XL Service Manual

Service

Near boiler piping

• Typical system components

The Outdoor 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.

Outdoor 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

Outdoor Knight XL Service Manual

1 Service

Near boiler piping

This piping reference is included to specify the Near Boiler Piping specific to the Outdoor Knight XL. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Outdoor Knight XL Installation and Operation Manual for more detailed piping diagrams.

SYSTEM SENSOR

AIR SEPARATOR

SYSTEM PUMP

(RECOMMENDED)

BOILER PUMP

Y-STRAINER

DOMESTIC HOT WATER PUMP

INDIRECT

DOMESTIC

HOT WATER

TANK

IMG00413

TO FLOOR DRAIN

1 Service (continued)

The Outdoor Knight XL display

Outdoor Knight XL 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

1 Service

Control inputs

SYSTEM PUMP SPEED CONTROL

GAS PRESSURE SWITCH

DHW THERMOSTAT

ROOM THERMOSTAT /

ZONE CONTROL

SYSTEM SENSOR

OUTDOOR SENSOR

FLOW SWITCH

Outdoor Knight XL 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

1 Service

1 Service (continued)

Control outputs

LOW VOLTAGE

CONNECTION

BOARD

Outdoor Knight XL Service Manual

ALARM BELL

RUN TIME CONTACTS

BUILDING MANAGEMENT

SYSTEM

SMART CONTROL

MODULE

BOILER PUMP

SYSTEM PUMP

DHW PUMP

IGNITOR

BLOWER

GAS VALVE

DISPLAY PANEL

PC INTERFACE

1 Service

Outdoor Knight XL Service Manual

General Operation

How the boiler operates

The Outdoor 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 Outdoor 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

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.

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.

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.

Outdoor Knight XL Service Manual

3. The 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).

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.

Outdoor Knight XL 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.

1 Service

1 Service (continued)

Display panel menu access

Table 1-2 Use this procedure to access menus from the display panel

Outdoor Knight XL 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.

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.

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.

Outdoor Knight XL Service Manual

1 Service

1 Service (continued)

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

DHW Night Setback On Times 18 No No Yes Yes

GENERAL

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

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

DHW SETTINGS

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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