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1  

Service

20

Service Manual

1  

Service 

Boost temperature

If a SH demand lasts longer than the programmed time delay
setting (F9) and there have been no DHW demands, the
control will increase the water temperature set point by the
amount in this parameter.  If the SH demand continues
through another time period, the set point will be increased
again.  This will continue until either the SH demand ends, a
maximum of 20 increases has occurred, or the maximum set
point has been reached.  Once the SH demand has been
satisfied the set point will revert back to its calculated setting.
The boost temperature can be changed by the installer by
accessing parameter 

F8

.  The temperature range of this

parameter is 0°F (0°C) to 45°F (25°C).  The default value is
0°F (0°C).  This feature will be active if this parameter is set to
anything other than 0°F (0°C). 

Boost time

The boost time parameter sets the amount of time that must
elapse with a SH demand before the water temperature set
point will be increased.  This parameter can be changed by the
installer by accessing parameter 

F9

.  The time range for this

parameter is 1 minute to 60 minutes.  The default value is 20
minutes.

G: Anti-cycling

Anti-cycling time

Once a SH demand has been satisfied, a set amount of time
must elapse before the control will respond to a new SH
demand.  The control will block the new heat demand and
anti-cycling will be shown in the display until the time has
elapsed or the water temperature drops below parameter G2.
This parameter can be changed by the installer by accessing
parameter 

G1

.  The time range for this parameter is 0 minutes

to 40 minutes.  The default value is 1 minute.

Inlet temperature differential for ending anti-cycling

The control will bypass the anti-cycling time if the water
temperature drops too quickly.  The control will use the water
temperature the boiler was at when it shut off as the starting
point.  If the temperature drops below the temperature
parameter the control will abort anti-cycling and allow the
boiler to fire.  This parameter can be changed by the installer
by accessing parameter 

G2

.  The temperature range of this

parameter is 0°F (0°C) to 54°F (30°C).  The default value is
10°F (5°C).

Ramp delay on/off

When the ramp delay on/off parameter is active, the ramp
delay limits the boiler firing rate when a SH cycle has started.
There are six (6) limiting steps used to limit temperature
overshoot and short cycles, see FIG. 1-2 on page 21 of this
manual.  This feature can be turned on or off depending on
the installation.  This parameter can be changed by the
installer by accessing parameter 

G3

.  The control range of this

parameter is 0 = Off, 1 = Ramp Up Only, and 2 = Ramp Up
and Ramp Down.  The default value is 0.

When ramp delay is active, additional parameters for ramp
delay operation will have to be adjusted.  These can only be
accessed by the optional PC software.  See the Knight Smart
System PC Program Instructions Manual for additional ramp
delay parameter information.

Summary of Contents for KNIGHT 399 - 800

Page 1: ...ician Read all instructions including this manual and the Knight XL Installation and Operation Manual before installing Perform steps in the order given Failure to comply could result in severe person...

Page 2: ...t 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 Bo...

Page 3: ...product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crysta...

Page 4: ...ve 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 i...

Page 5: ...Knight XL operation A General B Temperature Setting C Data Logging D Functions E DHW Settings F Outdoor Air Reset Curve G Anti cycling H Control Modes I Circulation Pumps J Service Notification Mainte...

Page 6: ...P DOMESTIC HOT WATER PUMP SYSTEM PUMP Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight XL This piping scheme is important for proper operat...

Page 7: ...display during normal operation to show outlet and return temperatures fan speed and flame signal Press to toggle between digits when entering access code or between hour minutes etc when entering dat...

Page 8: ...OOR SENSOR OPTIONAL SEQUENCER BUILDING MANAGEMENT SYSTEM OPTIONAL LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR HIGH LIMIT FLAME SENSOR LOW WATER CUTO...

Page 9: ...tinued LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL AUX DEVICE RELAY RUN TIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DI...

Page 10: ...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 shows control module normal s...

Page 11: ...ntrol does not detect flame before the trial for ignition ends the control will perform a 10 second postpurge The 399 model will start another prepurge and trial for ignition If the burner does not li...

Page 12: ...g based on the space heating set point As long as both the space heating and DHW calls for heat remain active the control will switch back and forth between the two modes until one of them is satisfie...

Page 13: ...ENU EXIT UP PREVIOUS UP PREVIOUS UP ENTER RES DOWN DOWN DOWN DOWN DOWN To select a highlighted menu press the ENTER RESET button one time The display will change to the first parameter under that menu...

Page 14: ...to return to normal operation OUT 123 7 F A General B Temp Settings I2 Postrun Time SH Pump 0 67 minutes I2 Postrun Time SH Pump 0 50 minutes I2 Postrun Time SH Pump I1 Postrun Time System Pump I Circ...

Page 15: ...7 No No Yes Yes 5 SH Differential 18 No No Yes Yes C 1 Hours Running SH 18 Yes No Yes No 2 Hours Running DHW 18 Yes No Yes No 3 Ignition Attempts 18 Yes No Yes No 4 Show Last 10 Errors 18 Yes No Yes N...

Page 16: ...turn Temperature Differential for Ending Anti Cycling 20 No No Yes Yes 3 Ramp Delay On Off 20 No No Yes Yes ANTI CYCLING H 1 SH Controlling Sensor Outlet System Inlet 21 No No Yes Yes 2 SH Source Ther...

Page 17: ...value is 125 F 52 C SH minimum set point The SH minimum set point sets the minimum water temperature set point that can be used for space heating operation The user or installer will not be able to p...

Page 18: ...W boiler set point When a DHW call for heat becomes active the control will use the DHW boiler set point to determine the firing rate of the boiler based on the actual water temperature This parameter...

Page 19: ...t FIG 1 1 This parameter can be changed by the installer by accessing parameter F4 The temperature range of this parameter is 0 F 18 C to 190 F 88 C The default value is 70 F 21 C Outdoor air shutdown...

Page 20: ...shown in the display until the time has elapsed or the water temperature drops below parameter G2 This parameter can be changed by the installer by accessing parameter G1 The time range for this param...

Page 21: ...needed from the group based on the set point and controlling sensor reading It assigns portions of this output to itself Leader and the Member boilers When Cascade is selected each boiler in the group...

Page 22: ...er is adjustable by the installer by accessing parameter I3 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds J Service Notification Service notification in m...

Page 23: ...lation 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 tempe...

Page 24: ...l the air and vent lines per this manual and the Knight XL Installation and Operation Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any...

Page 25: ...the Knight XL 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 in...

Page 26: ...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 con...

Page 27: ...revention 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 blower assembly gas air arm from the heat exchanger access cover Set b...

Page 28: ...Minimum 4 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...

Page 29: ...ote 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 resistanc...

Page 30: ...ble 3D Outdoor Air Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance 50 490 813 20 46 218 40 336 606 30 34 558 30 234 196 40 26 099 20 165 180 50 19 900 10 118 018 60 15 3...

Page 31: ...on procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for minimum flow r...

Page 32: ...full of water and all air has been purged from the system Check for loose or misplaced jumpers if flow switch or LWCO is not installed Blown fuse Replace fuse F2 on the control board see page 28 of t...

Page 33: ...and Operation Manual for detailed information concerning the gas supply 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...

Page 34: ...erify that the vent air intake pipes are installed correctly and 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 ig...

Page 35: ...at 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 either an inlet or sys...

Page 36: ...Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 30 of this manual Replace the sensor if necessary Sensor Shorte...

Page 37: ...t XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler Check for voltage to the boiler pump motor on a call for heat If voltage is not present check the wiring b...

Page 38: ...eset After downloading parameters from a laptop the main control board must be reset Press the ENTER RESET button on the SMART SYSTEM display panel APS Open will require a manual reset once the condit...

Page 39: ...ecessary 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 siz...

Page 40: ...and corrective actions Table 3G Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent Air Intake Length or Obstruction Refer to Section 3 General Venting of the Knight XL Insta...

Page 41: ...urn counterclockwise to increase CO2 levels or a 1 4 turn clockwise to decrease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measu...

Page 42: ...4 Notes 42 Service Manual...

Page 43: ...4 Notes Service Manual 43...

Page 44: ...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 Adjust...

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