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Lochinvar KNIGHT 400 - 801 User Manual

Lochinvar KNIGHT 400 - 801
48 pages
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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. Failure to comply
could result in severe personal
injury, death, or substantial
property damage.
WARNING
Save this manual for future reference.
KBXII-SER Rev B

Table of Contents

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Lochinvar KNIGHT 400 - 801 Specifications

General IconGeneral
CategoryBoiler
BrandLochinvar
ModelKNIGHT 400 - 801
TypeCondensing Boiler
EfficiencyUp to 98%
AFUE95%
Heat Exchanger MaterialStainless Steel
Vent TypeDirect Vent
Vent MaterialPVC/CPVC
Modulation Ratio5:1
Gas TypeNatural Gas or Propane
Input Capacity400, 000 - 800, 000 BTU/hr
BTU Input (KNIGHT 400)400, 000 BTU/hr
BTU Input (KNIGHT 801)800000 BTU/hr
DimensionsVaries by model
WeightVaries by model

Summary

Service

Please read before proceeding

Important instructions and warnings before operating or servicing the boiler.

Handling ceramic fiber materials

Guidelines for safely handling ceramic fiber materials used in the boiler.

What is in this manual?

Summary of the manual's content and structure.

Near boiler piping

Describes the piping configuration around the boiler for proper operation.

The Knight XL display

Details the functions of the boiler's display panel and its controls.

Control inputs

Lists and illustrates the various inputs to the boiler's control module.

Control outputs

Lists and illustrates the various outputs controlled by the boiler's module.

General Operation

Explains how the boiler operates and how the control module functions.

Display panel menu access

Procedure for navigating and accessing menus on the boiler's display panel.

Display panel parameter access

Steps for accessing and modifying parameters via the boiler's display panel.

Parameter table

Comprehensive list of SMART SYSTEM control module parameters and access levels.

Maintenance

Maintenance and annual startup

Schedules and procedures for routine maintenance and annual startup.

Address reported problems

Steps to identify and correct issues reported by the owner.

Inspect boiler area

Checks for safety and cleanliness in the area surrounding the boiler.

Inspect boiler interior

Procedure for inspecting the internal components of the boiler.

Clean condensate trap

Instructions for cleaning and refilling the boiler's condensate trap.

Check all piping for leaks

Procedure for checking all system and boiler piping for leaks.

Flue vent system and air piping

Inspection of the flue gas venting and air piping for blockages or damage.

Check water system

Verification of system components, pressure, and air vents.

Check expansion tank

Inspection and understanding of the boiler's expansion tank function.

Check boiler relief valve

Inspection and testing procedures for the boiler's safety relief valve.

Inspect ignition and flame sense electrodes

Procedure for inspecting and cleaning ignition and flame sense electrodes.

Check ignition ground wiring

Verifies the condition and continuity of the ignition ground wiring.

Check all boiler wiring

General check of all boiler wiring for condition and security.

Check control settings

Review and adjustment of SMART SYSTEM control module and external limit settings.

Perform start-up and checks

Instructions for performing boiler start-up and operational checks.

Check burner flame

Visual inspection of the burner flame for proper operation.

Check flame signal

Verifies the flame signal strength for proper burner operation.

Review with owner

Discusses manual operation, maintenance schedules, and system behavior with the owner.

Cleaning boiler heat exchanger

Detailed steps for cleaning the boiler's heat exchanger.

Troubleshooting

Before troubleshooting

Lists necessary tools and pre-checks before starting troubleshooting.

Check control module fuses

Procedure to check and replace control module fuses.

Troubleshooting Chart - No Display

Identifies causes and corrective actions for a 'No Display' fault.

Checking temperature sensors

Explains how to check boiler temperature sensors using resistance tables.

Troubleshooting Chart - Noisy System

Identifies causes and corrective actions for noisy operation.

Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

Lists fault messages and their corresponding corrective actions.

Combustion Analysis Procedure

Step-by-step guide for performing a combustion analysis.

Troubleshooting Chart - Combustion Levels

Lists possible causes and corrective actions for incorrect combustion levels.

Gas valve adjustment procedure

Procedures for adjusting the gas valve on different boiler models.

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