Lochinvar Knight 80 - 285 Service Manual Download Page 9 | Manualshive

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Service

Service Manual

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Service

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LOW VOLTAGE

CONNECTION

BOARD

SMART CONTROL

MODULE

ALARM BELL

AUX. DEVICE RELAY

RUN TIME CONTACTS

SEQUENCER / BUILDING

MANAGMENT SYSTEM

BOILER PUMP

SYSTEM PUMP

DHW PUMP

IGNITOR

BLOWER

GAS VALVE

DISPLAY PANEL

PC INTERFACE

Control outputs

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Summary of Contents for Knight 80 - 285

Page 1: ...service technician Read all instructions including this manual and the Knight Boiler Installation and Operation Manual before installing Perform steps in the order given Failure to comply could resul...

Page 2: ...ant 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...

Page 3: ...n 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...

Page 4: ...ve 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 i...

Page 5: ...n Knight boiler 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...

Page 6: ...reference is included to specify the Near Boiler Piping specific to the Knight boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Knight Boiler Installati...

Page 7: ...1 Service Service Manual 7 1 Service continued The Knight boiler display...

Page 8: ...1 Service 8 Service Manual 1 Service AIR PRESSURE SWITCH Control inputs...

Page 9: ...tinued LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL AUX DEVICE RELAY RUN TIME CONTACTS SEQUENCER BUILDING MANAGMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DIS...

Page 10: ...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 norm...

Page 11: ...prepurge cycle is complete and the blocked drain switch and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and open...

Page 12: ...ng 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 0...

Page 13: ...1 Service Service Manual 13 1 Service continued Display panel menu access Table 2 Use this procedure to access menus from the display panel...

Page 14: ...1 Service 14 Service Manual 1 Service Display panel parameter access Table 3 This is a typical example of accessing a parameter shown for parameter I2 boiler pump delay...

Page 15: ...s Yes 4 SH Offset 17 No No Yes Yes 5 SH Differential 18 No No Yes Yes C 1 Hours Running SH 18 Yes No Yes No 2 Hours Running DHW 18 Yes No Yes No 3 Ignition Attempts 18 Yes No Yes No 4 Show Last 10 Err...

Page 16: ...turn Temperature Differential for Ending Anti Cycling 20 No No Yes Yes 3 Ramp Delay On Off 20 No No Yes Yes ANTI CYCLING H 1 SH Controlling Sensor Outlet System Inlet 21 No No Yes Yes 2 SH Source Ther...

Page 17: ...0 F to 190 F The default value is 125 F SH minimum set point The SH minimum set point sets the minimum water temperature set point that can be used for space heating operation The user or installer wi...

Page 18: ...installer by accessing parameter D2 The time range of this parameter is 0 to 40 minutes The default value is 20 minutes E DHW settings DHW boiler set point When a DHW call for heat becomes active the...

Page 19: ...trol will block all SH demands DHW demands will still be active This parameter can be changed by the user or the installer by accessing parameter F5 The temperature range of this parameter is 0 F to 1...

Page 20: ...in the display until the time has elapsed or the water temperature drops below parameter G2 This parameter can be changed by the installer by accessing parameter G1 The time range for this parameter...

Page 21: ...ther The designated Leader boiler determines the total output needed from the group based on the set point and controlling sensor reading It assigns portions of this output to itself Leader and the Me...

Page 22: ...s adjustable by the installer by accessing parameter I3 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds J Service Notification Service notification in month...

Page 23: ...allation and Operation Manual Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperat...

Page 24: ...l the air and vent lines per this manual and the Knight Boiler Installation and Operation Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum...

Page 25: ...night Boiler Installation and Operation Manual before proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized ins...

Page 26: ...attached Check control settings 1 Set the SMART SYSTEM control module display to Parameter Mode and check all settings See Section 1 of this manual Adjust settings if necessary See Section 1 of this...

Page 27: ...3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 5 Remove th...

Page 28: ...er on Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during boiler startup Check control module fuses ALWAYS check control module fuses before replacing control module or any maj...

Page 29: ...te thermostat satisfied Review remote thermostat setting Outside air temperature above Warm Weather Shutdown WWSD set point for main control board Check location of outside air sensor Check resistance...

Page 30: ...ble 7C Outdoor Air Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance 50 490 813 20 46 218 40 336 606 30 34 558 30 234 196 40 26 099 20 165 180 50 19 900 10 118 018 60 15 3...

Page 31: ...an or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for minimum flow rates Verify...

Page 32: ...for loose or misplaced jumpers if flow switch or LWCO is not installed Blown fuse Replace fuse F2 on the control board see page 28 of this manual Blocked Drain SW will require a manual reset once con...

Page 33: ...fy that the plastic hose from the gas valve to the air inlet is connected and is not damaged Verify that the vent air intake pipes are correctly installed and that there are no obstructions Check for...

Page 34: ...main control board If 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from th...

Page 35: ...sor check temperature setting of the main control board If the optional manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 7A on pag...

Page 36: ...g Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 30 of this manual Replace the sensor if necessary Sensor Shor...

Page 37: ...tion and Operation Manual for the proper piping methods for the Knight boiler Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the main...

Page 38: ...d or that the boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications Replace the main control board Re...

Page 39: ...ain control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump Verify that the boiler pump is set to the proper speed or that the boiler...

Page 40: ...ions Table 10 Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent Air Intake Length or Obstruction Refer to Section 3 General Venting of the Knight Boiler Installation and Op...

Page 41: ...s or a 1 4 turn clockwise to decrease CO2 levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measure the combustion If combustion...

Page 42: ...42 NOTES...

Page 43: ...43 NOTES...

Page 44: ...eferences to the pocket pc along with the removal of Models 399 500 Revision 6 ECO C02545 reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff te...

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