Lochinvar XL 399 - 800 User Manual

Service Manual

Models: 399 - 800

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.

 WARNING

Save this manual for future reference.

KBX-SER Rev E

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.

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 Boiler 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Viewable and Changeable Control Parameters . . . . . . . 17-22

2. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 23-27

3. TROUBLESHOOTING

Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Check Control Module Fuses . . . . . . . . . . . . . . . . . . . . . 28

Table 3A - Troubleshooting Chart - No Display . . . . . . . . 29

Checking Temperature Sensors . . . . . . . . . . . . . . . . . . . 30

Table 3E - Troubleshooting Chart - Noisy System . . . . . 31

Table 3F - Troubleshooting Chart - Fault Messages . . . . 32-39

Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 40

Table 3G - Troubleshooting Chart - Combustion Levels 40

Table 3H - Flue Products . . . . . . . . . . . . . . . . . . . . . . . . . 40

Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 41

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

Service Manual

Please read before proceeding

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.

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.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber door insulation in this product 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).”:

 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 boiler 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.

 WARNING

NOTICE

 WARNING

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.

Service Manual

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

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

1 Service

Service Manual

FROM

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

SYSTEM

FROM

SYSTEM

BOILER PUMP

DOMESTIC HOT WATER PUMP

SYSTEM PUMP

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.

Service Manual

1 Service (continued)

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

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

• Press to turn boiler off or back on

• Press to select a menu item

• Press after parameter programming to store parameter data

• Press to exit Service Mode

• 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

• 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

DISPLAY SCREEN

MENU / EXIT

SHUTDOWN

ENTER / RESET

SERVICE

BUTTON

CONNECTION

PORT

DOWNUP

The Knight XL display

1 Service

Service Manual

1 Service

Control inputs

GAS PRESSURE SWITCH

(OPTIONAL)

DHW THERMOSTAT

(OPTIONAL)

ROOM THERMOSTAT /

ZONE CONTROL

FLOW SWITCH

SYSTEM SENSOR

DHW TANK SENSOR

(OPTIONAL)

OUTDOOR SENSOR

(OPTIONAL)

LOW VOLTAGE

CONNECTION

BOARD

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 SW ITCH

SMART CONTROL

MODULE

PC INTERFACE

(OPTIONAL)

DISPLAY PANEL

1 Service

Service Manual

1 Service (continued)

Control outputs

ALARM BELL

LOW VOLTAGE

CONNECTION

BOARD

AUX. DEVICE RELAY

RUN TIME CONTACTS

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

BOILER PUMP

SYSTEM PUMP

DHW PUMP

SMART CONTROL

MODULE

IGNITOR

BLOWER

GAS VALVE

DI SP LAY PANEL

PC INTERFACE

1 Service

Service Manual

1 Service

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.

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.

1 Service

Service Manual

1 Service (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 (system and boiler pumps for space heating call; DHW pump for DHW call).

BLR: Standby OUT: 123.8F(129)

2. The control connects 120 VAC to the blower. The blower does not run at this time.

• The manual reset high limit must be closed and reset.

• Once the pumps are turned on, the flow switch must close.

• 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.

BLR: Standby OUT: 123.8F(129)

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 switch is closed, the control starts the 4 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve.

BLR: IGNITION OUT: 123.9F(129)

5. If the control does not detect flame before the trial for ignition ends, the control will perform a 10 second postpurge. The 399 model will start another prepurge and trial for ignition. If the burner does not light after 4 trials on the 399 model, the control 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.

BLR: POSTPURGE, PREPURGE OUT: 123.9F(129)

6. If the control detects a flame before the trial for ignition ends, it 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 will be held to a series of increasing limits after the burner has lit.

BLR: SH 20% RATE OUT: 124.8F(129)

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 turn on the DHW pump, wait 2 seconds, and then turn off the boiler pump. This will divert the hot water away from the 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.

BLR: DHW 85% RATE OUT: 177.8(180)

1 Service

Service Manual

1 Service

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 pump, turn off the DHW pump after 2 seconds, and resume modulating based on the space heating set point. As long as 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.

BLR: SH 41% RATE OUT: 123.0F(129)

9. Once both calls for heat are satisfied, the control will turn off the burner. The blower will remain on for the 10 second postpurge cycle. Any pumps that are running will continue to run for their respective pump delay times, then turn off.

BLR: POSTPURGE OUT: 127.4F(129)

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)

1 Service

Service Manual

1 Service (continued)

Display panel menu access

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

BUTTON

ENTER/RES

MENU/EXIT

ENTER/RES

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

OPERATION

Press 1 time in normal operation

Hold for 5 seconds -- display will change

Press 9 times to change last digit in readout to “9”

Press 2 times to move to the second digit

Press 3 times to change second digit in readout to “3”

Press 1 time to change to the first digit

Press 5 times to change first digit in readout to “5”

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.

Press to enter the code

After 2 seconds, display shows menus (press ENTER/RESET to select a menu)

Press 1 time to highlight second listing

Press 1 time to toggle menu listing

Press 2 times to toggle menu listing

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.

>I Circulation Pumps J Service Notification

DISPLAY

BLR:OFF OUT:127.3ºF

Enter Menu Code:

0000

Enter Menu Code:

>A General B Temp Settings

A General >B Temp Settings

>C Data Logging D Functions

>E DHW Settings F Outdoor Reset

>G Anti-cycling H Control Modes

0009

0309

5309

INSTALLER CODE

flashing

COMMENTS

Boiler turns off (this ensures uninterrupted programming)

Digit shown underlined at left will flash

The words, “INSTALLER CODE” will flash while displayed

The caret symbol, “>” highlights the selectable line

The menu toggles to the next two menu options

1 Service

Service Manual

1 Service

Display panel parameter access

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

BUTTON

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.

DOWN

ENTER/RES

(or DOWN)

ENTER/RES

OPERATION

Beginning of menu listings

Press 1 time to highlight second listing

Press 1 time to toggle menu listing

Press 2 times to toggle menu listing

Press 1 time to list parameters

Press 1 time to change parameter

Press 1 time to select parameter

Press to increase (or decrease) value

Press 1 time to save (or press MENU/EXIT to continue)

Press 1 time to return to normal operation

DISPLAY

>A General B Temp Settings

>C Data Logging D Functions

>E DHW Settings F Heat Curve

>G Anti-Cycling H Control Modes

I Circulation Pumps J Service Notification

I1 Postrun Time System Pump

I2 Postrun Time SH Pump

I2 Postrun Time SH Pump 0.50 minutes

I2 Postrun Time SH Pump 0.67 minutes

A General B Temp Settings

BLR:Pre-Purge

OUT:123.7ºF

COMMENTS

The caret symbol, “>” highlights the selectable line

The menu toggles to the next two menu options

I1 will flash

I2 will flash

I2 will stop flashing; parameter

value will appear

Parameter will increase or decrease, depending on button pressed

Display will change to normal display as you exit menu mode

This display example assumes a call for space heating is present

+ 30 hidden pages