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Outdoor Knight

Boiler

Service Manual

Models: 151 - 286

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



WARNING

Save this manual for future reference.

OKB-SER Rev A

1
2
3
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»

Summary of Contents for 151

Page 1: ...chnician Read all instructions including this manual and the Outdoor Knight 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 WARNING Save this manual for future reference OKB SER Rev A ...

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 Boiler water 4 Freeze protection fluids 4 WHAT IS IN THIS MANUAL 5 1 SERVICE Near Boiler Piping 6 The Outdoor Boiler Display 7 Control Inputs 8 Control Outputs 9 General Operation 10 Sequence of Operation...

Page 3: ...r IARC has concluded Crystalline 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 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 i...

Page 4: ...nected to remove 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 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...

Page 5: ...eration General Temperature Setting Data Logging Functions DHW Settings Outdoor Reset Anti cycling Control Modes Circulation Pumps Building Management System BMS Service Notification 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...

Page 6: ...M SYSTEM FROM TO IMG00377 Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the outdoor boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Outdoor Knight Boiler Installation and Operation Manual for more detailed piping diagrams Outdoor Knight Boiler Service Manual ...

Page 7: ...ht 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 SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key Outdoor Knight Boiler Service Manual ...

Page 8: ...GMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR FLAME SENSOR LOW WATER CUTOFF BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE SMART CONTROL MODULE AIR PRESSURE SWITCH SYSTEM PUMP SPEED CONTROL O TEMP HEAT EXCHANGER SWITCH IMG00006 Control inputs Outdoor Knight Boiler Service Manual ...

Page 9: ...OLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE Control outputs Outdoor Knight Boiler Service Manual ...

Page 10: ... 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 heating and DHW operation The combined operation sequence is for a typical application programmed to provide DHW priority Access modes User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION ...

Page 11: ...ng the blower 5 The control starts the 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 and try to light the burner again The control will perform a total of 4 attempts before locking out 7 If flame is detected it holds the firing rate steady for a few...

Page 12: ...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 them is satisfied 10 Once both calls for heat are satisfied the control will turn off the burner The blower will continue to run during the postpurge p...

Page 13: ...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 Rotate ...

Page 14: ...NGS 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 dial to the desired temperature 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 Table 1 3 This is a ...

Page 15: ...Night Setback Off Times 19 No No 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 Yes Maximum SH Set Point 20 No No Yes Yes SH1 Offset 20 No No Yes Yes SH1 Differential 20 No No Yes Yes SH2 Set Point 20 Yes Yes No No SH2 Offset 20 No No Yes Yes SH2 Differential 20 No No Yes Yes SH3 Set Point 20 Yes Yes No No SH3 Offset 20 No No Yes Yes SH3 D...

Page 16: ... 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 Shutdown Differential SH1 23 No No Yes Yes Shift Reset Curve SH1 23 No No Yes Yes Outdoor 2 Low 22 No No Yes Yes Outdoor 2 High 22 No No Yes Yes Set Point 2 at Low Outdoor Temp 2 22 No No Yes Yes Set Point 2 at High Outdoor Temp 2 ...

Page 17: ...us 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 Yes Cascade Offset 25 No No Yes Yes Cascade Differential 25 No No Yes Yes Min On Off Time 25 No No Yes Yes Min Next On Time 25 No No Yes Yes Boiler Size 25 No No Yes Yes System Pump Delay 25 No No Yes Yes Boiler Pump Delay 26 No No Yes Yes DHW Pump Delay 26 No No Yes Yes Boiler...

Page 18: ...s 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 Yes Yes Off Differential Volts 27 No No Yes Yes Service Notification Months 27 No No Yes Yes Service Notification Running Time 27 No No Yes Yes Service Notification Cycles 27 No No Yes Yes Reset Maintenance Reminder 27 No No Y...

Page 19: ...f 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 by accessing the SH Night Setback On Times parameter The DHW start triggers in the DHW Night Setback On Times parameter This screen shows the start trigger number the day of the week and the time of day 1 When the screen is...

Page 20: ...HT SELECT HOME key To return to the Status Screen without saving the changes press the LEFT SELECT EXIT key Display Timeout This is the time in which the display remains illuminated The range is 10 seconds to 10 minutes The default is 3 minutes Temperature Settings Space heating SH set point parameters limit boiler operating set point The exact boiler operating set point is calculated using the ou...

Page 21: ... heating demand and it receives a DHW demand it will immediately switch to the DHW demand and start a timer Once the timer has expired the boiler will switch back to the space heating demand and start another timer Once this timer expires it will switch back 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 ...

Page 22: ...t High Outdoor Temp 1 3 parameters FIG 1 1 This parameter can be changed by the installer by accessing the Outdoor 1 3 High parameters The temperature range is low outdoor air temperature set point to 104 F 40 C The default 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 parameter the set point will be at this setting FIG 1 ...

Page 23: ... SH1 SH3 The outdoor air shutdown differential parameter is the number of degrees below Outdoor Air Shutdown SH1 SH2 and SH3 parameters the outdoor air temperature must go before the boiler will respond to a SH demand These parameters can be changed by the installer by accessing the Outdoor Air Shutdown Differential SH1 SH2 and SH3 parameters The temperature range of this parameter is 0 F 0 C to 5...

Page 24: ... rate of the next to last boiler to 40 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 20 minutes The limit value can be set between 0 and 100 Co...

Page 25: ... temperature must go below the turn off temperature Set point Offset before the lead boiler turns on This parameter can be adjusted by the installer by accessing the Cascade Differential parameter The temperature range of this parameter is 0 F to 60 F 33 C The default value is 20 F 11 C Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum...

Page 26: ...mum Volts parameter The minimum value is the Rate at Minimum Volts setting and the maximum is 100 The default value is 100 Boiler Pump Delay The SH pump delay parameter sets the length of time the boiler pump will run after a SH demand has been satisfied Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing the Boiler Pump Delay parameter The ...

Page 27: ...e 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 control determines that a scheduled service is due based on the number of boiler cycles the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjusta...

Page 28: ...on 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 temperature If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ANNUAL START UP Owner maintenance see the Outdoor Knight User s Information Man...

Page 29: ...e removed Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 2 Remove the PVC cap retaining screw from the PVC cap FIG 2 1 3 Remove the 2 inch PVC cap with the switch loc...

Page 30: ...ler 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 inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally ...

Page 31: ...just if necessary Perform start up and checks 1 Start boiler and perform checks and tests specified in Section 7 Start up of the Outdoor Knight Boiler Installation and Operation Manual 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame 1 Inspect flame through observation window 2 If the flame is unsatisfactory at either high fire or low fire ...

Page 32: ...n severe personal injury WARNING 9 Allow 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 piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow th...

Page 33: ...ches 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 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 top access cover 3 Re...

Page 34: ...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 on page 35 of this manual Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 37 of this manual for corrective actions Unit in Shutdown Mode Take unit out of Shutdo...

Page 35: ...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 Outdoor Knight 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 Temperature ...

Page 36: ...ng of the Outdoor Knight Boiler Installation and Operation Manual for minimum flow rates Verify that the boiler is piped in a primary secondary fashion and 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 P...

Page 37: ...ow 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 manual reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Either the optional flow switch or the optional low water cutoff is not making Check boiler pump operation on a cal...

Page 38: ...nger if refractory is broken and unit has fired Check continuity across two contacts Wires should be connected at both poles of the normally closed switch Faulty O Temp HEX Switch Replace switch Anti cycling The main control board has received a call for heat too quickly after the previous call for heat has ended The control board will release the call for heat after a set time period The control ...

Page 39: ...ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 31 of this ma...

Page 40: ...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 the optional manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 3 2A on page 35 of this manual Replace sensor if necessary Replace high limit Outlet MRHL wil...

Page 41: ...pare to Table 3 2A on page 35 of this manual Replace sensor if necessary Replace high limit Fan Low High OR Fan Speed Low High will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The actual fan RPM is 30 lower than what is being called for Check for obstruction or blockage in the vent air intake pipes or at terminations Chec...

Page 42: ... this manual Replace sensor if necessary Replace control module Outlet Sensor Fault will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The control reads the inlet 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 ...

Page 43: ...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 defaults from optional PC software Replace control module Flue Temp Limit will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The stack temperature has exc...

Page 44: ...per piping methods for the outdoor 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 control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump Verify that the boiler pump is set to the proper speed or that the pump is the prop...

Page 45: ...ain 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 exceeded 185 F Establish a heating load to remove the heat from the boiler loop Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heat...

Page 46: ...Natural Gas Propane CO2 O2 CO2 O2 8 0 10 3 0 6 5 9 0 11 4 1 6 9 7 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 shuts down and registers an alarm Turn the manual shutoff switch to the ON position reset the control and return to Service Mode 8 Turn the main power off to the boiler 9 Place...

Page 47: ...t procedure If adjustment of the gas valve is deemed necessary use the following procedure Locate the throttle adjustment screw on the side of the venturi valve FIG 3 2 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO2 levels or a 1 4 turn clockwise to decrease CO2 levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 46 o...

Page 48: ...Revision Notes Revision A ECO C11234 initial release OKB SER Rev A 10 12 ...

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