Lochinvar 399 - 800

Revision Notes: Revision B (ECO #C02407) reflects air pressure

switch changes, changes made to the Circulation Pumps Section (page

22) and removal of references to the pocket pc.

Revision C (ECO #C02545) reflects the addition of references to

periodic cleaning of screens in vent terminations and safety shutoff

testing and instructions.

Revision D (ECO #C02738) reflects the addition of the Gas Valve

Adjustment Procedure for a 399 model on page 41.

Revision E (ECO #CO2918) reflects the addition of Tank Sensor Open

on page 36 along with updating the condensate trap image on page 24.

KBX-SER Rev E

3/09

Contents

Main Service Manual Models: 399 - 800 Hazard definitions Contents DANGER WARNING CAUTION CAUTION NOTICE Please read before proceeding Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING NIOSH stated First Aid. Please read before proceeding When servicing boiler Boiler operation Boiler water Freeze protection fluids What is in this manual? Service Near boiler piping The Knight XL display Control module inputs Near boiler piping The Knight XL display LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE Control inputs LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE Control outputs General Operation How the boiler operates How the control module operates Sequence of operation Saving parameters Sequence of operation Sequence of operation Display panel menu access Table 1B Use this procedure to access menus from the display panel Display panel parameter access Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them OUTDOOR AIR RESET TEMPERATURE F Parameter table Viewable and changeable control parameters A: General B: Temperature settings NOTICE C: Data logging D: Functions E: DHW settings F: Outdoor air reset WATER TEMPERATURE SET POINT OUTDOOR TEMPERATURE G: Anti-cycling H: Control modes Cascade offset I: Circulation pumps J: Service Notification Maintenance and annual startup Service technician Owner maintenance Address reported problems Inspect boiler area Check all piping for leaks Inspect boiler interior Clean condensate trap 2 Flue vent system and air piping Check water system Check expansion tank Check boiler relief valve Inspect ignition and flame sense electrodes Check ignition ground wiring Check all boiler wiring Check control settings Perform start-up and checks 2 Check flame signal Review with owner Cleaning boiler heat exchanger Before troubleshooting: Check the following: Check control module fuses Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display No Burner Operation Unit Does Not Modulate Above 50% Checking temperature sensors FAULT CAUSE CORRECTIVE ACTION Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface Gas Pressure SW Flow Switch/LWCO Blocked Drain SW Flame Sequence Anti-cycling No Flame Ign No Flame Running Adjustable High Limit w/Manual Reset Fan Low OR Fan Speed Low Fan High OR Fan Speed High Tank Open Sensor Open Sensor Shorted Aux. Proving Temp O/Shoot Temp O/Shoot (continued) Rem Ctrl Flt Parameters Progr APS Open Service Blk No Error Stored CRC Parameters Watch Dog Error Low 24 VAC Combustion Analysis Procedure POSSIBLE CAUSE CORRECTIVE ACTION Gas valve adjustment procedure Model 500 Model 399 Models 600 - 800