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Service Manual

5

What is in this manual?

Service

Near boiler piping

• Typical system components

The Knight wall mount boiler display

• Display panel readout, buttons and their functions

Control module inputs

• Control module inputs and options

Control module outputs

• Control module outputs and options

General

• How the boiler operates
• How the control module operates
• Access modes -- user and installer
• Sequence of operation -- Domestic Hot Water
(DHW)/space heating

Control panel menu access

• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)

Control panel parameter access

• Accessing and changing parameters from the display panel

Quick start information -- parameter

table

• An index of available adjustments and readouts, where to
access them and where to find detailed information.

Knight wall mount boiler operation

• 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 water system
• Check expansion tank
• Check boiler relief valve
• Inspect ignition electrode
• Check ignition ground wiring
• Check all boiler wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
• Review with owner
• Cleaning boiler heat exchanger
• Oiled bearing circulators

Troubleshooting

• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on
boiler interface
• Combustion analysis procedure
• Gas valve adjustment procedure

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Summary of Contents for WH 399

Page 1: ...ian Read all instructions including this manual and the Knight Wall Mount 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 WH SER Rev G ...

Page 2: ...ut 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 Knight Wall Mount Display 7 Control Inputs 8 Control Outputs 9 General Operation 10 Sequence of Operati...

Page 3: ... Cancer 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 ...

Page 4: ...ove 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 result Conti...

Page 5: ...n Knight wall mount boiler operation 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 ven...

Page 6: ...ATER TANK TO FLOOR DRAIN AIR SEPARATOR EXPANSION TANK VENT OUTLET INLET Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight wall mount boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Knight Wall Mount Installation and Operation Manual for more detailed piping diagrams ...

Page 7: ...DIAL The Knight wall mount 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 ...

Page 8: ...W SWITCH SYSTEM SENSOR OUTDOOR SENSOR BUILDING MANAGEMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HIGH LIMIT SENSOR FLUE GAS SENSOR FLAME SENSOR LOW WATER CUTOFF DISPLAY PANEL PC INTERFACE SMART CONTROL MODULE PRESSURE SWITCH SYSTEM PUMP SPEED CONTROL Control inputs ...

Page 9: ...ce continued LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL AUX DEVICE RELAY RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE Control outputs ...

Page 10: ... user installer programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation can be based on boiler outlet water temperature boiler return water temperature or system supply temperature depending on the parameter setting Sequence of operation Table 1 1 shows control module normal sequences of operat...

Page 11: ...and blocked drain switch must close 4 The control starts the prepurge cycle by initiating 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 attem...

Page 12: ...nstead 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 them is satisfied 10 Once both calls for heat are satisfied the control will turn off the burner The ...

Page 13: ... the LEFT SELECT soft key 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 SE...

Page 14: ...e 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 dial to the desired temperature SAVE Press the RIGHT SELECT s...

Page 15: ...imes 19 No No Yes Yes DHW 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 Off...

Page 16: ...s Yes Outdoor 1 High 22 No 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...

Page 17: ...5 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 Pump Anti Seize Delay 26 No No Yes Yes Boiler Pump Min Voltage 26 No No Yes Yes System Pump Type 26 No No Yes...

Page 18: ...s 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 Yes Yes Service Name and Phone Number 27 No No Yes Yes SERVICE BMS Parameter table Table 1 4 continued from pre...

Page 19: ... set within a single day if 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 o...

Page 20: ...ze Protection Pump On parameter The minimum setting is 3 F 19 C and the maximum setting is 45 F 7 2 C The default setting is 45 F 7 2 C To save any changes and return to the Home Screen press the RIGHT 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 sec...

Page 21: ...ge is 0 F 0 C to 60 F 33 C The default setting is 20 F 13 C SH DHW Switching Time When a boiler has a space 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 ca...

Page 22: ...ture When the outdoor air temperature rises to or above this point the water temperature set point will be at Set point 1 3 at 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 Tem...

Page 23: ...ir Shutdown Differential 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 p...

Page 24: ...o 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 Ramp Settings The SMA...

Page 25: ...meter determines how much the 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 Off On Differential parameter The temperature range of this parameter is 0 F 0 C to 60 33 C The default value is 20 F 11 C In Cascade this parameter will override the boiler differential parameter ...

Page 26: ...ximum parameter is set by the Rate at Maximum 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 This parameter is adjustable by the installer by accessing the Boiler Pump Delay parameter The time ran...

Page 27: ...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 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 turn yellow and a new status screen will appear informing the installer t...

Page 28: ...nt 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 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 Knight Wal...

Page 29: ... reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections of the Knight Wall Mount Installation and Operation Manual Chec...

Page 30: ...t Wall Mount 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 n...

Page 31: ...nal 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 Wall Mount 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 ...

Page 32: ...severe personal injury WARNING Cleaning boiler heat exchanger 1 Shut down boiler Followthe ToTurnOffGastoAppliance instructions for the boiler in Section 10 Startup Do not drain the 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 nuts securing...

Page 33: ...lockup or with boiler on Minimum 4 inches 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 ...

Page 34: ...r 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 44 of this manual for corrective actions Unit in Shutdown Mode Take unit out of Shutdown Mode...

Page 35: ...t is important to note 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 Wall Mount Installation and Operation Manual for correct terminal location S1a Wire Color R BK and Y S1b Wire Color G and Y Temperature Resistance Temperature...

Page 36: ...n or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight Wall Mount 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 sys...

Page 37: ... been corrected Press the RESET button on the SMART SYSTEM display to reset The blocked drain jumper has been removed from the wire harness Check wire harness and replace jumper if necessary Check for loose wiring connection at wire harness plugs Air Pressure SW will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Air pressur...

Page 38: ...ply Verify that the plastic hose from the gas valve to the air 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 a...

Page 39: ...aged 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 control board and the gas valve Repla...

Page 40: ...ystem 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 Check resistance of water sensors and compare to Table 3 2A and 3 2C on page 35 of this manual Replace sensor if necessary Replace the main control board if necessary Outlet MRHL will require a manual reset once the condition has been corrected Press...

Page 41: ...ck for loose or misplaced jumper if auxiliary proving switch is not installed on the Low Voltage Connection Board Fan Speed 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 or higher than what is being called for Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 G...

Page 42: ...s an excessive temperature difference between the two sensors Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2C on page 35 of this manual Replace sensor if necessary Restore control parameter defaults from optional PC software Replace control module Flue Sensor F...

Page 43: ...exchanger Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3 2D on page 35 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace main control board Delta T High The temperature rise across the heat exchanger has exceeded the set parameters for...

Page 44: ...l 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 boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight Wall Mount Boiler Installation and Operation Manual for boiler pump specifications Replace the main contr...

Page 45: ...IVE ACTION Vent Air Intake Length or Obstruction Refer to Section 3 General Venting of the Knight Wall Mount Installation and Operation Manual for the proper venting and air intake methods for the Knight wall mount boiler Check for obstructions at the vent air intake terminals Gas Supply Pressure Refer to Section 7 Gas Connections of the Knight Wall Mount Installation and Operation Manual for the ...

Page 46: ...ise to increase CO2 levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 45 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the...

Page 47: ...47 NOTES ...

Page 48: ... made to the SMART SYSTEM control ECR R04523 Revision D ECO C09843 reflects the addition of the new condensate trap pipe R04984 Revision E ECO C10143 reflects the removal of the GV RELAY FAIL FAULT ECR R05239 and updates made to the ignition timing information Revision F ECO C10450 reflects changes made to Table 3 6 on page 45 Revision G ECO C11102 reflects outdoor air reset updates WH SER Rev G 0...

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