Gebruiksaanwijzing /service van het product Knight XL 399 - 800 van de fabrikant Lochinvar
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Service Manual Models: 399 - 800 This manual must only be used by a qualified heating installer / ser vice technician. R ead all instructions, including this manual and the Knight XL Installation and Operation Manual, befor e installing. P erform steps in the order giv en.
2 Hazar d definitions The following defined terms are used thr oughout this manual to bring attention to the presenc e of hazards of var ious risk le vel s or to important information concerning the life of the product.
Service Manual Please r ead bef or e pr oceeding Installer – R ead all instructions, including this manual and the Knight XL Installation and Operation Man ual, before installing. P erform steps in the order given. Us e r – This manual is for use only by a qualified heating installer/serv ice technician.
4 Service Manual Please r ead bef or e pr oceeding When servicing boiler – • T o a v oid electric shock, disc onnect electrical supply before performing maintenance. • T o a vo id severe burns, allo w boiler to cool befor e performing maintenance.
Service Manual 5 W ha t is in this manual? Ser vice Near boiler piping • T y pical system components T he Knight XL display • Display panel r eadout, buttons and their functions Control module inp.
1 Ser vice 6 Service Manual FROM R TO INDIR ECT DOMES TI C HOT WA TE R TA N K TO F L O OR DRAIN TO SYSTEM FROM SYSTEM BOILER PUM P DOMES TI C HOT WA TE R PUM P SYSTEM PU MP Near boiler piping This piping referenc e is included to specify the N ear B oiler Piping specific to the Knight XL.
Service Manual 7 1 Ser vice (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.
1 Ser vice 8 Service Manual 1 Ser vice GAS PRESSURE S W ITCH (OPTIONAL) DHW THERMOST A T (OPTIONAL) ROOM THER MOST A T / ZONE CONTROL FLOW SW ITCH SYSTEM SENSOR OUTDOOR SENSOR (OPTIONAL) SEQUE NCER / .
1 Ser vice Service Manual 9 1 Ser vice (continued) LOW VOL T AGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL AUX . DEVICE RELA Y RUN TIME CO NT AC TS SEQUENCER / BUIL DING MANAGEMENT SYSTEM BOILE.
1 Ser vice 10 Service Manual 1 Ser vice General Oper ation How the boiler operates The Knight XL uses an advanced stainless st eel heat ex changer and an electronic contr ol module that allows fully c ondensing operation. The blo wer pulls in gas and air and pushes flue products out of the boiler through the heat exchanger and flue piping.
1 Ser vice Service Manual 11 1 Ser vice (continued) Sequence of oper ation T able 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 sp ace heating call; DHW pump for DHW call).
1 Ser vice 12 Service Manual 1 Ser vice Sequence of oper ation (continued) T able 1A (continued from previous page) Sequence of operation - sp ace heating and DHW OPERATION DISPLAY 8.
1 Ser vice Service Manual 13 1 Ser vice (continued) Display panel menu access T able 1B Use this procedure to access menus from the display panel Press 1 time in normal operation Hold for 5 seconds --.
1 Ser vice 14 Service Manual 1 Ser vice Display panel parameter access T able 1C This is a typical example of accessing a parameter , shown for parameter I2, boiler pump delay BLR:Pre-Purge BUT TO N OPERA TION DISPLA Y COMMENTS This example shows how to access parameter I2, boiler pump delay .
1 Ser vice Service Manual 15 1 Ser vice (continued) Parameter table T able 1D This table list s SMAR T SYSTEM control module parameters and where to access them MENU SUB ITEM DESCRIPTION SEE PAGE USER.
1 Ser vice 16 Service Manual 1 Ser vice Parameter table (continued) T able 1D (continued from previous page) This t able lists SMAR T SYSTEM control module p arameters and where to access them The parameters for Building Management S ystem operation are not list ed in this table.
1 Ser vice Service Manual 17 Viewable and changeable contr ol par ameter s A: General Boiler model The control will displa y “Knight Boiler” as the model number because the same contr ol is used on several models. This will be display ed when parameter A1 has been accessed.
18 Service Manual 1 Ser vice SH Differential The SH differential sets ho w many degrees belo w the turn off temperature the te mperature has to go before the boiler will turn on. This parameter can only be changed by the installer b y accessing paramet er B5 .
1 Ser vice Service Manual 19 1 Ser vice (continued) WA T E R TEMPERA TURE SET POINT MAXIMUM RESET Default = 180°F USER SET POINT Default = 125°F MINIMUM RESET Default = 70°F Default = 25°F Default.
1 Ser vice 20 Service Manual 1 Ser vice Boost temperature If a SH demand lasts longer than the programmed time delay setting (F9) and there ha ve been no DHW demands, the control will increase the wat er temperature set point b y the amount in this parameter .
1 Ser vice Service Manual 21 1 Ser vice (continued) H: Control modes SH controlling sensor The SH controlling sensor paramet er selects the sensor the control will use to r egulate the boiler firing rate. This parameter is adjustable by the installer by ac cessing parameter H1 .
1 Ser vice 22 Service Manual 1 Ser vice Cascade offset This parameter determines how m uch the temperature m ust go abov e set point before the lead boiler will turn off. This parameter can be adjusted b y the installer by acc essing parameter H5 . The default value is 9.
2 Maintenance Service Manual 23 Maintenance and annual star tup T able 2A Service and Maintenance Schedules Ser vice tec hnician (see the following p ages for instructions) General: • Address report.
2 Maintenance 24 Service Manual Follo w the Serv ice and maintenance pr ocedur es given thr oughout this manual and in component lit erature shipped with the boiler . Failur e to perform the serv ice and maintenanc e could result in damage t o the boiler or system.
2 Maintenance (continued) Service Manual 25 Flue vent system and air piping 1. V isually inspect the entire flue gas ve nting system and air piping for blockage, deterioration or leakage. R epair any joints that show signs of leakage. V er ify that air inlet pipe is connected and pr operly sealed.
2 Maintenance 26 Service Manual Inspect ignition and flame sense electrodes 1. R emov e the ignition and flame sense electrodes from the boiler heat ex changer acc ess cov er . 2. R emov e an y deposits accumulated on the ignition/flame sense electrode using sandpaper .
2 Maintenance (continued) Service Manual 27 Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2.
3 T roubleshooting 28 Service Manual Label all wires prior to disconnection when serv icing controls. W iring errors can cause improper and danger ous operation. Alwa ys disc onnect power t o the boiler before serv icing. Failur e to comply c ould result in sever e personal injur y , death, or substantial proper ty damage.
3 T roubleshooting (continued) Service Manual 29 T able 3A T roubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 V AC supplied to unit. • Check external line switch, fuse, or breaker . • Check position of ON/OFF switch.
3 T roubleshooting 30 Service Manual T able 3B - Inlet/Outlet System Sensor Resistance vs. T emperature T emperature Resist ance T emperature Resist ance 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 -- -- 140 2,760 -- -- T able 3C - Flue T emperature Sensor Resistance vs.
3 T roubleshooting (continued) Service Manual 31 T able 3E T roubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w .c. (1.0 kPa) and 14 inches w .c. (3.
3 T roubleshooting 32 Service Manual T able 3F T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressur e SW (will require a manual reset once the c ondition has been correct ed. Press the RESET butt on on the SMAR T SYSTEM display to reset.
3 T roubleshooting (continued) Service Manual 33 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Anti-cy c ling The main control board has received a call for heat too quickly after the previous call for heat has ended.
3 T roubleshooting 34 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION No Flam e Running (will require a manual reset once the c ondition has been correct ed.
3 T roubleshooting (continued) Service Manual 35 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Adjustable High Limit w/Manual Reset (will require a manual reset once the c ondition has been correct ed.
3 T roubleshooting 36 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION F an High OR F an Speed High (will require a manual reset once the c ondition has been correct ed.
3 T roubleshooting (continued) Service Manual 37 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION T emp O/Shoot The stack temperature has exceeded the set parameters for the boiler .
3 T roubleshooting 38 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION T emp O/Shoot (continued) Outlet water temperature has exceeded the maximum outlet water temperature.
3 T roubleshooting (continued) Service Manual 39 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Ser vice Blk While the unit is in Service Mode, the outlet temperature has exceeded 185°F .
3 T roubleshooting 40 Service Manual Combustion Analysis Pr ocedur e 1. T urn the main power off to the boiler by placing the “On/Off ” switch in the OFF position. 2. Remov e the flue temperatur e sensor from the flue pipe connection. No t e : Combustion measurements will be made at this point.
3 T roubleshooting (continued) Service Manual 41 Gas valv e adjustment procedur e If adjust ment of the gas valve is deemed nec essary , use the following procedur es: ( Not e : The procedures belo w are model specific.) Figure 3-3 Gas V alve Adjustment: Model 500 Model 500 Locate the throttle adjustment scr ew on top of the gas valve, see FIG.
4 Notes 42 Service Manual.
4 Notes Service Manual 43.
Revision Notes: Revision B (ECO #C02407) reflects air pressure switch changes, changes made to the Circulation Pumps Section (page 22) and removal of references to the pocket pc. Revision C (ECO #C02545) reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff testing and instructions.
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