Instruction/ maintenance manual of the product KNIGHT 400 Lochinvar
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Service Manual Models: 400 - 801 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.
2 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.
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.
4 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.
5 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.
1 Service 6 Y- S T R A I N E R (RECOMMENDED) BOILER PUMP INDIREC T DOM ESTIC HOT WA T ER T ANK SYSTEM PUMP TO FLOOR DRAIN T O F R O M F R O M S Y S T E M T O S Y S T E M DOMESTIC HOT WA TER P UM P SYSTEM SENSOR DIRT SEP ARA TOR Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight XL.
7 1 Service (continued) NA VIGA TION DIAL The Knight XL display The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in .
1 Service 8 1 Service GAS PRESSURE SW ITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CO NTROL FLOW SW ITCH SYSTEM SENSOR OUTDOOR SENSO R SEQUENCER / BUILDING MANAGMENT SY STEM LOW VOLTAGE CONNECT ION BOAR.
1 Service 9 1 Service (continued) LOW VOL T AGE CONNECT ION BOARD SMAR T CONTROL MODULE ALARM BELL LOUVER RELA Y RUN TI ME CONT ACTS BUILDING M ANAGEM ENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNIT.
1 Service 10 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.
1 Service 1 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).
1 Service 12 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.
1 Service 13 1 Service (continued) Display panel menu access Table 1-2 Use this procedure to access menus from the display panel BUTTON SCREEN STATUS OPERATION DISPLAY [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES].
1 Service 14 1 Service 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 SCREEN STATUS OPERATION DISPLAY This example shows how to access parameter Temperature Settings.
1 Service 15 1 Service (continued) Parameter table Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them Service Manual Menu Description See Page User Access Insta.
1 Service 16 1 Service Parameter table Service Manual Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Menu Description See Pag.
1 Service (continued) 17 Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Service Manual Menu Description See P.
1 Service 18 Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Service Manual Menu Description See Page User Acc.
19 1 Service (continued) Viewable and changeable control parameters Service Manual General Time and Date The control uses an internal clock for the night setback feature and for logging of events.
20 1 Service Service Manual SH1 - SH3 Differential Set Point The SH differential sets how many degrees below the offset the temperature has to drop before the boiler turns back on. This parameter can only be changed by the installer by accessing the SH1, 2 and 3 Differential Set point parameters .
21 1 Service (continued) Service Manual DHW Settings DHW Boiler Set Point When a DHW call for heat becomes active, the control will use the DHW boiler set point to determine the firing rate of the boiler based on the boiler outlet water temperature, or system temperature when DHW is programmed as a zone.
22 1 Service Service Manual SET POINT A T LOW OUTDOOR TEMPERA TURE (SH1, SH2, SH3) SET POINT SET POINT A T HIGH OUTDOOR TEMPERA TURE LOW OUTDOOR TEMPERA TURE HIGH OUTDOOR TEMPERA TURE Figure 1-1 Outdoor Air Reset Curve Outdoor Reset The option of controlling up to three (3) different outdoor resets for low outdoor temperatures is available.
23 1 Service (continued) Service Manual Anti-Cycling Anti-Cycling Time Once a SH demand has been satisfied, a set amount of time must elapse before the control will respond to a new SH demand.
24 1 Service Service Manual Figure 1-2 Ramp Delay Interval Control modes Controlling Sensor The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate. This parameter is adjustable by the installer by accessing the Controlling Sensor parameter .
25 1 Service (continued) Service Manual ModBus When BMS is set to ACTIVE (see BMS Active / Inactive) and the boiler is being controlled through ModBus, set ModBus parameter to ACTIVE. Otherwise, set the ModBus parameter to INACTIVE. Note that the boiler can still be monitored by ModBus with this parameter set to INACTIVE.
26 1 Service Service Manual DHW Pump Anti-Seize Delay If the boiler pump does not run for 24 hours, it will be turned on briefly to prevent it from seizing. The length of time it runs is determined by the DHW Pump Anti-Seize Delay parameter. The range of this setting is 0 seconds to 50 minutes.
27 1 Service (continued) Service Manual Service Name and Phone Number When a Maintenance Reminder timer or counter has expired, a Maintenance Reminder screen will appear on the display. By programming the installer’s name and phone number, this information will appear on the Maintenance Reminder Screen at that time.
2 Maintenance 28 Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Ins.
2 Maintenance (continued) 29 Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.
2 Maintenance 30 Flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.
2 Maintenance (continued) 31 Inspect ignition and flame sense electrodes 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper.
2 Maintenance 32 Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode.
3 Troubleshooting 33 Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage.
3 Troubleshooting 34 Table 3-1 Troubleshooting Chart - No Display Service Manual FAULT CAUSE CORRECTIVE ACTION No Display - No 120 vac supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position.
3 Troubleshooting (continued) 35 Table 3-2A - Inlet Water/System Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance 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 Table 3-2B - Outdoor Air Sensor Resistance vs.
3 Troubleshooting 36 Table 3-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w.c. and 14 inches w.c. LP gas pressures should be between 8 inches w.
3 Troubleshooting (continued) 37 Table 3-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure SW (will require a manual reset once the condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.
3 Troubleshooting 38 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION APS / HEX Temp Sw Open (will require a manual reset once the condition has been corrected.
3 Troubleshooting (continued) 39 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION Flame Fail Ign (cont’d) (will require a manual reset once the condition has been corrected.
3 Troubleshooting 40 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION Outlet ARHL The outlet water temperature has exceeded the setting of the automatic reset high limit.
3 Troubleshooting (continued) 41 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION Outlet MRHL (cont’d) (will require a manual reset once the condition has been corrected.
3 Troubleshooting 42 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Service Manual FAULT DESCRIPTION CORRECTIVE ACTION Sensor Shorted (will require a manual reset once the condition has been corrected.
3 Troubleshooting (continued) 43 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flue Sensor Fault (will require a manual reset once the condition has been corrected.
3 Troubleshooting 44 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flue Temp High The stack temperature has exceeded the set parameters for the boiler.
3 Troubleshooting (continued) 45 Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Rem Ctrl Flt External control is cycling too often. • Check set point of the external control.
3 Troubleshooting 46 Service Manual Combustion Analysis Procedure 1. Turn the main power off to the boiler by placing the “On/ Off” switch in the OFF position. 2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point.
47 3 Troubleshooting (continued) Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: ( Note: The procedures below are model specific.) Figure 3-3 Gas Valve Adjustment: Model 501 Model 501 Locate the throttle adjustment screw on top of the gas valve, see FIG.
Revision Notes: Revision A (ECO #C05747) initial release. Reflects the new model numbers for the Knight XL upgrade. Revision B (ECO #C06234) reflects changes made to the Service Notification parameter.
An important point after buying a device Lochinvar KNIGHT 400 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lochinvar KNIGHT 400 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lochinvar KNIGHT 400 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lochinvar KNIGHT 400 you will learn all the available features of the product, as well as information on its operation. The information that you get Lochinvar KNIGHT 400 will certainly help you make a decision on the purchase.
If you already are a holder of Lochinvar KNIGHT 400, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lochinvar KNIGHT 400.
However, one of the most important roles played by the user manual is to help in solving problems with Lochinvar KNIGHT 400. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lochinvar KNIGHT 400 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
