Lochinvar 400-801 service manual Combustion Analysis Procedure

Page 46

3 Troubleshooting

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.

3.Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

4.Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (see page 7).

5.Locate the pinhole button below the RESET button on the display board (see page 7). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire.

6.Remove the flue temperature sensor. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.

7.Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 3-5 above. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range, reference the chart below for possible causes and corrective actions.

Service Manual

Table 3-5Flue Products

Natural Gas

Propane

 

 

 

 

CO2

O2

CO2

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 valve to the OFF position and ensuring that the boiler shuts down and registers an alarm. Open the manual shutoff valve, reset the control, and return to Service Mode.

9.Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection.

10.Place the boiler back into normal operation.

WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into

the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

Table 3-6Troubleshooting Chart - Combustion Levels

POSSIBLE CAUSE

CORRECTIVE ACTION

 

 

Vent/Air Intake Length

• Refer to Section 3 - General Venting of the Knight XL Installation and Operation Manual

for the proper venting and air intake methods for the Knight XL boiler.

or Obstruction

• Check for obstructions at the vent/air intake terminals.

 

 

 

Gas Supply Pressure

• Refer to Section 7 - Gas Connections of the Knight XL Installation and Operation

Manual for the proper gas supply for the Knight XL boiler.

 

 

 

Dirty/Damaged Burner

• Refer to page 31 of this manual for burner removal and cleaning procedures.

• Replace burner if necessary.

 

 

 

Gas Valve Adjustment

• Refer to page 47 of this manual for the gas valve adjustment procedure.

 

 

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Contents Models 400 Contents Handling ceramic fiber materials Please read before proceedingNiosh stated First Aid When servicing boiler Maintenance What is in this manual?Service TroubleshootingService Near boiler pipingKnight XL display Navigation DialControl inputs LOW Voltage Connection BoardSmart Control Module Control outputsHow the boiler operates Access modesGeneral Operation How the control module operatesOperation Display From previous page Sequence of Operation Display panel menu access Button Screen Operation Display StatusDisplay panel parameter access Button Screen Status Operation DisplayParameter table Description See User Access Installer Access Display ModifyMenu Resetoutdoor ANTI-CYCLING See User Access Installer Access Display Modify DescriptionTime and Date Temperature units C / FViewable and changeable control parameters Software VersionData Logging Temperature SettingsFunctions DHW Settings Outdoor Reset Anti-Cycling Control modes Minimum On/Off Time Cascade OffsetCirculation pumps Boiler Pump Anti-Seize Delay Boiler Pump DelayDHW Pump Delay DHW Pump Anti-Seize DelayService Notification Service technician Maintenance Maintenance and annual startupOwner maintenance Maintenance Check water system Flue vent system and air pipingCheck expansion tank Check boiler relief valve Check control settings Check ignition ground wiringCheck all boiler wiring Inspect ignition and flame sense electrodesReview with owner Check flame signalCleaning boiler heat exchanger Model Kit Part Component Number DescriptionTest procedure Test low water flow conditionsCheck the following TroubleshootingBefore troubleshooting Check control module fusesOperation No DisplayNo Burner Unit DoesWire Color R/BK and Y Wire Color G and Y Checking temperature sensorsTemperature Resistance Temperature Resistance Resistance TemperatureBoiler Pump NoisyNo Pump System PumpTroubleshooting Anti-cycling Temp SwOpen Flame Fail IgnCont’d Flame SequenceOutlet Arhl Outlet MrhlHigh Fan Low/HighFan Speed Low GV/RelayLouver Proving FaultSensor Shorted Inlet SensorMemory Error Flue Sensor FaultFatal Error Flue Temp DiffDelta T High Flue Temp HighOutlet Temp No Error Stored Service BlkWatch Dog Error Rem Ctrl FltCombustion Analysis Procedure Model Gas valve adjustment procedureModels 601
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400-801 specifications

The Lochinvar 400-801 is a high-efficiency commercial boiler that embodies advanced engineering and cutting-edge technology. Designed for a variety of commercial applications, this boiler is known for its reliability, efficiency, and robust performance.

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Safety is paramount in the design of the Lochinvar 400-801. The boiler includes a comprehensive safety system that incorporates multiple safety interlocks and a venting system that prevents backflow and ensures safe exhaust. Moreover, the unit is designed to operate with minimal noise, making it suitable for environments where noise reduction is crucial.

Installation and maintenance of the Lochinvar 400-801 are straightforward, thanks to its compact design and multiple venting options. The low-profile construction allows for flexibility in placement, making it an ideal fit for tight spaces. Maintenance tasks are simplified with accessible components, minimizing downtime and ensuring the system operates efficiently over its lifespan.

In conclusion, the Lochinvar 400-801 stands out in the commercial boiler market with its blend of efficiency, reliability, and innovation. With its advanced technologies and features, businesses can achieve significant energy savings while ensuring comfortable and consistent heat for various applications. The Lochinvar 400-801 is an investment in quality and performance, backed by a well-established brand in the heating industry. Whether for a new installation or a replacement, this boiler offers a comprehensive solution for commercial heating needs.
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