Knight 100 Series Service Manual Download Page 1

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Service Manual

Models:

55 - 399

Series 100 & 101

This manual must only be used
by a qualified heating installer
/ service technician. Read all
instructions, including this
manual and the Knight Fire Tube
Boiler 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.

Save this manual for future reference.

100305187_2000558071_Rev B

⚠

WARNING

Summary of Contents for 100 Series

Page 1: ...Read all instructions including this manual and the Knight Fire Tube Boiler 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 Save this manual for future reference 100305187_2000558071_Rev B WARNING ...

Page 2: ...tions 2 PLEASE READ BEFORE PROCEEDING 3 Handling Ceramic Fiber Materials 3 When servicing boiler 4 Boiler operation 4 Boiler water 4 Freeze protection fluids 4 WHAT IS IN THIS MANUAL 5 1 SERVICE The Knight Fire Tube Boiler Display 6 Control Inputs 7 Control Outputs 8 Temperature Control and Protection 9 10 Parameter Access Modes 10 Setup Wizard 10 Changing and Saving Parameters 10 General Operatio...

Page 3: ...lline silica inhaled 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 fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is...

Page 4: ...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 in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh ma...

Page 5: ... Settings Outdoor Reset Anti cycling Control Modes Building Management System BMS Circulation Pumps Service Notification Basic Setup USB Maintenance Service and maintenance schedules Address reported problems Inspect boiler area and boiler interior Clean condensate trap Check all piping for leaks Check air openings Flue vent system and air piping Check water system Check expansion tank Check boile...

Page 6: ...ombustion SHUTDOWN The unit has been placed in the OFF position SETPOINT MET The boiler has exceeded the target set point temperature and offset BLOCKED The unit has detected a condition that has interrupted the call for heat Call for Heat Indicators Room Thermostat 1 3 has a call for heat DHW tank thermostat or sensor has a call for heat Indicates which room thermostat demand has priority The uni...

Page 7: ... SENSOR OUTDOOR SENSOR SEQUENCER BUILDING MANAGEMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR AUX LOUVER PROVING SWITCH FLAME SENSOR LOW WATER CUTOFF BLOCKED DRAIN AIR PRESSURE SWITCH DISPLAY PANEL SMART CONTROL MODULE VARIABLE SPEED SYSTEM PUMP DHW RECIRCULATION SENSOR DHW TANK SENSOR ...

Page 8: ...anual 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 PANEL DHW RECIRCULATION PUMP RELAY DHW RECIRCULATION PUMP ...

Page 9: ...rence between the inlet and outlet sensor exceeds 55 F the control will reduce the fan speed If the difference exceeds 60 F the control will shut the unit down until the difference drops below 55 F and the minimum off time has expired Freeze Protection The control module provides freeze protection by operating the boiler and system pump constantly when the water temperature drops below 45 F If the...

Page 10: ...the NAVIGATION dial until the first digit of the password is displayed Press the NAVIGATION dial to keep this value and move to the next number When the full password 5309 is displayed press the RIGHT SELECT SAVE key The screen will now display the installer parameter menu Setup wizard The Knight Fire Tube boiler control has a Setup Wizard feature that is automatically accessed the first time the ...

Page 11: ... close 3 The control turns on power to the louver relay The louver proving switch and blocked drain switch must close 4 The control starts a prepurge cycle by starting the blower 5 The control starts a trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected after the sparking ends the control will perform a postpurge then start another prepurge cycle a...

Page 12: ...nit This will divert the boiler s outlet water from the heating system and send it to the tank coil instead The control will then 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 boiler will switch back and forth between the two heating modes until one of ...

Page 13: ...ey 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 NAVIGATION dial clockwise until 3 is shown in the display Press the NAVIGATION dial 2 times to move to the last digit Rotate the NAVIGATION dial counterclockwise until 9 is displayed SAVE Press the RIGHT SELECT soft key SAVE Serv...

Page 14: ...ameter Temperature Settings The first display shown is at the beginning of the menu listings after entering the installer access code Rotate the NAVIGATION dial counterclockwise until the arrow is 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 NAVIGATION d...

Page 15: ...ON DISPLAY This example shows how to access parameter Temperature Settings The first display shown is at the beginning of the menu listings after entering the installer access code SAVE Press the RIGHT SELECT soft key SAVE one time EXIT Press the LEFT SELECT soft key EXIT if all desired changes have been made HOME Press the LEFT SELECT soft key HOME Wait for the new settings to be saved Service Ma...

Page 16: ...et Point No Yes Maximum SH Set Point No Yes SH1 Offset Set Point No Yes SH1 Differential Set Point No Yes SH2 Set Point Yes Yes SH2 Offset Set Point No Yes SH2 Differential Set Point No Yes SH3 Set Point Yes Yes SH3 Offset Set Point No Yes SH3 Differential Set Point No Yes 3 Way Valve Time No Yes Reset Last 10 Errors No Yes Service Mode Delay No Yes Freeze Protection Pump On No Yes Freeze Protecti...

Page 17: ...s Low Outdoor Temperature 2 No Yes High Outdoor Temperature 2 No Yes SH2 Set Point at Low Outdoor Temp No Yes SH2 Set Point at High Outdoor Temp No Yes Outdoor Air Shutdown SH2 No Yes Outdoor Air Shutdown Differential SH2 No Yes Shift Reset Curve SH2 No Yes Low Outdoor Temperature 3 No Yes High Outdoor Temperature 3 No Yes SH3 Set Point at Low Outdoor Temp No Yes SH3 Set Point at High Outdoor Temp...

Page 18: ...Input kBtuh No Yes BMS ACTIVE i BMS Type POWER 1 Rate at Minimum Volts 2 Rate at Maximum Volts ii BMS Type SETPOINT 1 Set Point at Minimum Volts 2 Set Point at Maximum Volts iii Volts at Minimum iv Volts at Maximum v BMS Thermostat Input INACTIVE 1 On Volts 2 Off Differential Volts vi ModBus BACnet ACTIVE INACTIVE vii BAS T O No Yes System Pump Delay No Yes Boiler Pump Delay No Yes DHW Pump Delay ...

Page 19: ...door Temperature v Outdoor Air Shutdown SH1 vi Outdoor Air Shutdown Differential SH1 No Yes Cascade Address 0 i Maximum Cascade Set Point ii Cascade Offset iii Cascade Differential iv Cascade Type No Yes BMS ACTIVE i BMS Type POWER 1 Rate at Minimum Volts 2 Rate at Maximum Volts ii BMS Type SETPOINT 1 Set Point at Minimum Volts 2 Set Point at Maximum Volts iii Volts at Minimum iv Volts at Maximum ...

Page 20: ... The DHW night setback will not work without a tank sensor installed The installer may adjust the space heating night setback offset by accessing the SH Night Setback Offset parameter and the DHW night setback offset by accessing the DHW Night Setback Offset parameter The minimum setting is 0 F 0 C and the maximum setting is 90 F 50 C Space Heating SH and Domestic Hot Water DHW Night Setback On an...

Page 21: ...et point that can be used for space heating The user or installer will not be able to program the control with a higher SH set point This parameter can only be changed by the installer by accessing Maximum SH Set point parameter The temperature range of this parameter is the space heating minimum set point to 190 F 88 C The default value is 185 F 85 C SH1 SH3 Offset Set Point The SH offset sets ho...

Page 22: ... turn on the boiler and system pump outputs whenever the inlet temperature drops below this setting This is done to prevent the water in the heat exchanger from freezing Certain low temperature applications such as snow melt can operate at temperatures around freezing so this setting needs to be lowered in these cases The installer can adjust the temperature at which the pump outputs are turned on...

Page 23: ...set the DHW Forces Sys Pump parameter to YES the parameter DHW Blocks Sys Pump must be set to NO If this parameter and the DHW Blocks Sys Pump parameter are both set to NO the system pump operation will be based strictly on the System Pump Type parameter setting The default setting of this parameter is YES DHW Blocks System Pump When the indirect DHW tank is connected as a zone on the primary loop...

Page 24: ...s 68 F 20 C to 190 F 88 C The default value is 70 F 21 C Outdoor Air Shutdown SH1 SH3 When the outdoor temperature rises above this point the control will block the corresponding SH demand DHW demands will still be active These parameters can be changed by the installer by accessing the Outdoor Air Shutdown SH1 SH2 and SH3 parameters The temperature range of this parameter is 32 F 0 C to 104 F 40 ...

Page 25: ...llows the installer to reduce the responsiveness of the temperature control function for situations where for example redundant heating capacity is installed The values that are available are 40 50 60 70 80 90 and 100 with 100 being the most responsive The default value is 100 Boost Temperature If a SH demand lasts longer than the programmed time delay setting and there have been no DHW demands th...

Page 26: ...te for the decreased load thus eliminating the sudden drop in total output of the Cascade When finished the installer can press the RIGHT SELECT SAVE key to store the new settings or the LEFT SELECT EXIT key to return to the Anti Cycling parameter list without saving the changes The delay value can be set between 0 minutes and 40 minutes The limit value can be set between 0 and 100 Control modes C...

Page 27: ...8 The default value is 0 Alternate Leader This parameter allows the Member 1 boiler to automatically assume control of the Cascade should it lose communication with the Leader boiler When programmed to YES it is recommended that the Member 1 boiler have its own set of external sensors installed such as the system supply sensor to maintain the same level of temperature control as with the Leader bo...

Page 28: ...ogrammed for BMS control through the 0 10V BMS input or through ModBus BACnet and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Minimum parameter is set by the Rate at Minimum Volts parameter The minimum value is 0 and the maximum is the Rate at Maximum Volts setting The default value is model dependant Rate at Maximum Volts When programmed for BMS contr...

Page 29: ...emands go into Outdoor Shutdown To program the system pump to operate only with a space heating call for heat set the System Pump Type parameter to CFH To program the system pump to run continuously until outdoor shutdown starts set the System Pump Type parameter to WWSD The default setting is CFH Boiler Pump Type This parameter determines how the control turns the boiler circulating pump on and o...

Page 30: ...es that a scheduled service is due based on the hours of actual operation the boiler display will turn yellow and a new status screen will appear informing the user that maintenance is required This parameter is adjustable by the installer 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 Figure...

Page 31: ...the display will return to the Main Status Screen Reset Maintenance Reminder Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing the Reset Maintenance Reminder parameter Once accessed press the RESET key to reset the service notification counter Service Name and Phone Number When a Maintenance Reminder timer o...

Page 32: ... per Section 10 in the Knight Fire Tube Boiler 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 30 C above return water temperature Test low water flow conditions If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air ...

Page 33: ...ent from inside the boiler and components Remove any obstructions Service Manual Inspect condensate trap 1 Inspect the condensate trap and drain line monthly to ensure it is properly installed and there are no obstructions in the drain line 2 Inspect the neutralizing kit if installed monthly to ensure the condensate is draining properly and there is an adequate amount of neutralizing agent availab...

Page 34: ... result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing Service Man...

Page 35: ...M 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 manual for adjustment 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 Knight Fire Tube Boiler Installati...

Page 36: ...e boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow time for the boiler to cool to room temperature if it has been firing 3 Remove the top and front access panels no tools required for removal along with the bezel 4 Remove the wiring from the ignitor flame rod and the fan Remove the reference tubing from the air intake 5 Loose...

Page 37: ...atch the behavior of the boiler These screens allow you to monitor the inlet temperature outlet temperature and T 6 When the T reaches 55 F 13 C the control will attempt to modulate the firing rate down to protect it from low flow conditions 7 When the T reaches 60 F 16 C the control module will turn off the burner If the control module shuts down the test was successful 8 Completely open the isol...

Page 38: ... inches w c 1 0 kPa natural 8 inches w c 2 0 kPa LP with gas flowing verify during boiler startup Check control module fuses ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF the power to the boiler at the external line switch 2 Remove fr...

Page 39: ... Remote 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 of outdoor air sensor and compare to Table 3 2B Unit locked out on fault Consult display for specific fault Refer to fault descriptions for corrective actions Unit in Shutdown Mode Take unit out...

Page 40: ...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 reference the wiring diagram in the Knight Fire Tube Boiler Installation and Operation Manual for correct terminal location S1a Wire Color R BK and Y S1b Wire Color G and Y Temperature Resistance Temperature Resistance Tempe...

Page 41: ...fy that the boiler and system pump are running on a call for heat Air in the piping system Properly purge all air from the piping system Low system water pressure Verify system pressure is a minimum of 12 psi No Pump Operation Boiler Pump System Pump or DHW Pump Blown fuse Replace fuse F1 on the control board Note Make sure pump amperage does not exceed 1 8 amps Faulty pump Replace pump Internal f...

Page 42: ...e control board Air Pressure SW will require a manual reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The air pressure switch contacts are open Check the wiring connections to switch Wires should be connected to the common and normally closed terminals Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the...

Page 43: ...r 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 24 vac to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board If 24 vac is present at the main control board check the wiring between the main co...

Page 44: ...mp motor on a call for heat If voltage is not present check wiring back to the main control board If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump If the system 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 bo...

Page 45: ...ted Press the RESET button on the SMART SYSTEM display to reset The actual fan RPM is 30 lower or higher than the fan speed target Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight Fire Tube Boiler Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the...

Page 46: ...esistance of the sensor and compare to the resistance in Table 3 2C of this manual Replace sensor if necessary Restore control parameter defaults from optional PC software Replace control module Fatal Error The control module has detected parameter settings that are corrupted Restore the parameter defaults from the optional PC software Replace control module Memory Error A lockout occurs at the sa...

Page 47: ... or that the pump is the proper size Reference Section 6 Hydronic Piping of the Knight Fire Tube Boiler Installation and Operation Manual for boiler pump specifications Outlet Temp High Outlet Temp Limit Outlet water temperature has exceeded the maximum outlet water temperature Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler ...

Page 48: ...length to remote devices Replace the transformer Watch Dog Error The main control board has detected an internal fault Cycle power to the boiler Replace the main control board Write EEProm The main control board has detected an internal fault Cycle power to the boiler Replace the main control board CRC Parameters The main control board has detected an internal fault Cycle power to the boiler Repla...

Page 49: ...acing the On Off switch in the OFF position 2 Remove the combustion plug from the vent connector provided on the unit Insert the probe from a combustion analyzer into the opening on the vent connector 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 Place the boiler into the active position by pressing th...

Page 50: ...e of this manual to measure the combustion Low Fire Locate the bias offset adjustment screw on the gas valve FIG 3 3 Using a 4 mm hex key wrench turn the screw 1 10 to 1 8 turn clockwise to increase CO2 levels or 1 10 to 1 8 turn counterclockwise to decrease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure of this manual to measure the combustion NOTE The low f...

Page 51: ...51 Service Manual Notes ...

Page 52: ...vision Notes Revision A PCP 3000024795 CN 500014734 initial release Revision B PCP 3000034309 CN 500022970 reflects an update to the gas valve adjustment procedure MM 100305187_DIR 2000558071_Rev B 08 19 ...

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