Lochinvar Knight 81 - 286 Service Manual Download Page 6

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Service

Service Manual

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

DOMESTIC HOT

WATER PUMP

BOILER

PUMP

SYSTEM

PUMP

Y-STRAINER

(RECOMMENDED)

DRAIN

(TYPICAL)

SYS

TEM

FRO

M S

YST

FRO

SYSTEM SENSOR

AIR SEPARATOR

Near boiler piping

This piping 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 Installation and Operation Manual for more
detailed piping diagrams.

Summary of Contents for Knight 81 - 286

Page 1: ...an 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 result in severe perso...

Page 2: ...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 Boil...

Page 3: ...stalline silica 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...

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: ...Knight boiler operation General Temperature Setting Data Logging Functions DHW Settings Outdoor Reset Anti cycling Control Modes Circulation Pumps Building Management System BMS Service Notification...

Page 6: ...YPICAL TO SYSTEM FROM SYSTEM FROM TO SYSTEM SENSOR AIR SEPARATOR Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight boiler This piping scheme...

Page 7: ...DIAL The Knight boiler 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 the center MENU Left SELECT Key SETP...

Page 8: ...BUILDING MANAGMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SWITCH FLAME SENSOR LOW WATER CUTOFF BLOCKED DRAIN SW...

Page 9: ...ice continued LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL LOUVER RELAY RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY P...

Page 10: ...ture boiler return water temperature or system supply temperature depending on the parameter setting Sequence of operation Table 1 1 shows control module normal sequences of operation for space heatin...

Page 11: ...ol starts a 15 second prepurge cycle by initiating the blower 5 The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected with...

Page 12: ...en 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 boil...

Page 13: ...the LEFT SELECT soft key MENU for five 5 seconds Rotate the NAVIGATION dial clockwise until 5 is displayed first digit on the left Press the NAVIGATION dial to select the next digit Rotate the NAVIGAT...

Page 14: ...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 NAVIGATIO...

Page 15: ...9 No No Yes Yes DHW Night Setback Off Times 19 No No Yes Yes Night Setback Override 19 Yes Yes Yes Yes Display Timeout 20 No No Yes Yes SH1 Set Point 20 Yes Yes No No Minimum SH Set Point 20 No No Yes...

Page 16: ...Yes Outdoor 1 High 22 No No Yes Yes Set Point 1 at Low Outdoor Temp 1 22 No No Yes Yes Set Point 1 at High Outdoor Temp 1 22 No No Yes Yes Outdoor Air Shutdown SH1 22 No No Yes Yes Outdoor Air Shutdo...

Page 17: ...tat Input 24 No No Yes Yes BMS 24 No No Yes Yes ModBus 25 No No Yes Yes ModBus T O 25 No No Yes Yes Cascade Address 25 No No Yes Yes Cascade Type 25 No No Yes Yes Max Cascade Set Point 25 No No Yes Ye...

Page 18: ...Volts at Max 26 No No Yes Yes Rate at Min Volts 26 No No Yes Yes Rate at Max Volts 26 No No Yes Yes Set Point at Min Volts 27 No No Yes Yes Set Point at Max Volts 27 No No Yes Yes On Volts 27 No No Y...

Page 19: ...t within a single day if desired When a start trigger and a stop trigger are set to the same time the stop trigger has priority The installer may adjust the space heating night setback start triggers...

Page 20: ...is 0 F and the maximum is 20 F The default setting is 5 F 2 8 C Rotate the NAVIGATION dial to select the trigger you wish to skip and press the NAVIGATION dial SK will appear next to that trigger You...

Page 21: ...to the DHW demand The installer can adjust the length of time the boiler will service the space heating demand by accessing SH DHW Switching Time parameter The minimum setting is 0 minutes and the max...

Page 22: ...value is 70 F 21 C Set Point 1 3 at Low Outdoor Temperature When the outdoor air temperature drops to the Outdoor 1 3 Low parameters the calculated set point will be at this setting FIG 1 1 If the out...

Page 23: ...r Shutdown Differential SH1 SH2 and SH3 parameters The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Shift Reset Curve SH1 SH3 There is a shift reset curve...

Page 24: ...he 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE When finished the installer can press the RIGHT SELECT SAVE key to store...

Page 25: ...lated load increases further and both boilers ramp up to 90 it lowers the rate of the first two 2 boilers to 60 and brings the next boiler on at 60 The three 3 boilers then modulate together As the ca...

Page 26: ...um value is the Rate at Minimum Volts setting and the maximum is 100 The default value is 100 Circulation pumps System Pump Delay The system pump delay parameter sets the length of time the system pum...

Page 27: ...r by accessing the Service Notification Running Time parameter The time range for this parameter is 0 hours to 17 500 hours The default time is 8 760 hours Service Notification Cycles When the boiler...

Page 28: ...t Installation 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 te...

Page 29: ...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 a...

Page 30: ...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 inspecti...

Page 31: ...nt procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks 1 Start boiler and perform checks and tests specified in Section 10 Start up of the...

Page 32: ...ow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 11 Close isolation valves on pip...

Page 33: ...r with boiler 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...

Page 34: ...emote thermostat setting Outside air temperature above Warm Weather Shutdown WWSD set point for main control board Check location of outside air sensor Check resistance of outdoor air sensor and compa...

Page 35: ...It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing These devices are designated as S1a S1b outlet sensor and S3a S3b flue sensor Please...

Page 36: ...r 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 that...

Page 37: ...laced jumper on the Low Voltage Connection Board Check for the addition of a device wired across the gas pressure switch terminals on the Low Voltage Connection Board Flow Switch LWCO will require a m...

Page 38: ...Applies to the 286 Model Only Inspect the back of the inner combustion chamber at burner level for refractory breakdown missing Replace heat exchanger if refractory is broken and unit has fired Check...

Page 39: ...valve is not connected and will display the Gas Valve or Gas Valve Fail fault If 24 vac is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the o...

Page 40: ...pump is a variable speed pump ensure that the system flow is not less than the boiler flow If operating on something other than an outlet sensor check temperature setting of the main control board If...

Page 41: ...splay to reset The actual fan RPM is 30 lower than what is being called for Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight Boiler Installat...

Page 42: ...sensor as open or shorted Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance i...

Page 43: ...connect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2D on page 35 of this manual Replace sensor if necessary Restore control parameter defa...

Page 44: ...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 cont...

Page 45: ...arameters from a laptop the main control board must be reset Press the ENTER RESET button on the SMART SYSTEM display panel Service Blk While the unit is in Service Mode the outlet temperature has exc...

Page 46: ...O2 O2 8 0 10 3 0 6 5 9 0 11 4 1 6 9 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shut...

Page 47: ...y Gas Valve Adjustment Refer to this page for the gas valve adjustment procedure Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedure Locate th...

Page 48: ...he Knight upgrade Revision B ECO C06234 reflects changes made to the Service Notification parameter Revision C ECO C07981 reflects changes made to the parameter table parameter descriptions updates to...

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