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Service

18

Service Manual

1  

Service 

SH Differential

The SH differential sets how many degrees below the turn off
temperature the temperature has to go before the boiler will
turn on.  This parameter can only be changed by the installer
by accessing parameter 

B5

.  The temperature range of this

parameter is 0°F to 86°F.  The default value is 20°F.

C: Data logging

Hours running SH

The hours running SH parameter shows the total number of
hours the boiler has been in the SH firing position.  This
parameter can be viewed by the user and the installer by
accessing parameter 

C1

.

Hours running DHW

The hours running DHW parameter shows the total number
of hours the boiler has been in the DHW firing position.  This
parameter can be viewed by the user and the installer by
accessing parameter 

C2

.

Ignition attempts

The ignition attempts parameter shows the total number of
times the boiler has attempted to fire.  This parameter can be
viewed by the user and the installer by accessing parameter

C3

.

Show last 10 errors

The control will log the 10 most current errors with the date
and time the error occurred.  This parameter can be viewed
by the user and the installer by accessing parameter 

C4

.

D: Functions

Reset last 10 errors

The reset last 10 errors parameter allows the error counter to
be reset to 0.  This parameter can only be cleared by the
installer by accessing parameter 

D1

.  Once accessed, press the

RESET key to clear the counter.

Service mode delay

By pressing the pin button on the front of the display for five
(5) seconds, the control will be placed in Service Mode.  This
will override all other heat demands.  The Service Mode
allows the installer to set the unit to either maximum firing
rate or minimum firing rate for the purpose of combustion
analysis.  The delay sets the length of time the boiler will stay
in the Service Mode if no keys have been pressed before going
back to its original state.  This parameter can only be changed
by the installer by accessing parameter 

D2

.  The time range of

this parameter is 0 to 40 minutes.  The default value is
20 minutes.

E: DHW settings

DHW 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 can be changed by the installer by accessing
parameter 

E1

.  The temperature range of this parameter is

50°F to 190°F.  The default value is 180°F.

SH/DHW switching time

The SH/DHW switching time parameter sets the length of
time the control will stay in DHW Mode when a SH call has
been received.  After this time period has expired the control
will revert to SH Mode.  If a DHW call is still active the timer
will reset.  After the time period has expired the control will
revert back to DHW Mode.  This will continue until one of
the demands has been satisfied.  This parameter can be
changed by the installer by accessing parameter 

E2

.  The time

range of this parameter is 10 minutes to 240 minutes.  The
default value is 30 minutes.

F: Outdoor air reset  

Outdoor air reset operation

When the outdoor air sensor is installed, the control will
calculate the water temperature set point based on the
outdoor air temperature.  As the outdoor air temperature
drops the water temperature set point increases.  This feature
allows the boiler to be more efficient in periods of mild
weather, see FIG. 1 on page 19.

Minimum air temperature

When the outdoor air temperature drops to or below this
point, the water temperature will be at its maximum setting
(FIG. 1).  However, if the user set point is set lower, the water
temperature will be limited by the user set point instead.  This
parameter can be changed by the installer by accessing
parameter 

F1

.  The temperature range of this parameter is -

30°F to 90°F.  The default value is 25°F.

Maximum air temperature

When the outdoor air temperature rises to or above this
point, the water temperature will be at its minimum setting
(FIG. 1).  This parameter can be changed by the installer by
accessing parameter 

F2

.  The temperature range of this

parameter is -30°F to 90°F.  The default value is 70°F.

Summary of Contents for Knight 80 - 285

Page 1: ...service technician Read all instructions including this manual and the Knight Boiler Installation and Operation Manual before installing Perform steps in the order given Failure to comply could resul...

Page 2: ...ant 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...

Page 3: ...n this 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...

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: ...n Knight boiler 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...

Page 6: ...reference is included to specify the Near Boiler Piping specific to the Knight boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Knight Boiler Installati...

Page 7: ...1 Service Service Manual 7 1 Service continued The Knight boiler display...

Page 8: ...1 Service 8 Service Manual 1 Service AIR PRESSURE SWITCH Control inputs...

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

Page 10: ...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 shows control module norm...

Page 11: ...prepurge cycle is complete and the blocked drain switch and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and open...

Page 12: ...ng 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 satisfied BLR SH 41 RATE OUT 123 0...

Page 13: ...1 Service Service Manual 13 1 Service continued Display panel menu access Table 2 Use this procedure to access menus from the display panel...

Page 14: ...1 Service 14 Service Manual 1 Service Display panel parameter access Table 3 This is a typical example of accessing a parameter shown for parameter I2 boiler pump delay...

Page 15: ...s Yes 4 SH Offset 17 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 Err...

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: ...0 F to 190 F The default value is 125 F 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 wi...

Page 18: ...installer by accessing parameter D2 The time range of this parameter is 0 to 40 minutes The default value is 20 minutes E DHW settings DHW boiler set point When a DHW call for heat becomes active the...

Page 19: ...trol will block all SH demands DHW demands will still be active This parameter can be changed by the user or the installer by accessing parameter F5 The temperature range of this parameter is 0 F to 1...

Page 20: ...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...

Page 21: ...ther The designated Leader boiler determines the total output needed from the group based on the set point and controlling sensor reading It assigns portions of this output to itself Leader and the Me...

Page 22: ...s 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 month...

Page 23: ...allation 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 temperat...

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

Page 25: ...night Boiler 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 ins...

Page 26: ...attached Check control settings 1 Set the SMART SYSTEM 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...

Page 27: ...3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 5 Remove th...

Page 28: ...er 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 maj...

Page 29: ...te 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...

Page 30: ...ble 7C 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: ...an or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for minimum flow rates Verify...

Page 32: ...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 this manual Blocked Drain SW will require a manual reset once con...

Page 33: ...fy 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...

Page 34: ...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 Replace the wiring if necessary Do not disconnect the wiring from th...

Page 35: ...sor 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 7A on pag...

Page 36: ...g 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 Shor...

Page 37: ...tion and Operation Manual for the proper piping methods for the Knight 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...

Page 38: ...d or that the boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications Replace the main control board Re...

Page 39: ...ain 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...

Page 40: ...ions Table 10 Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent Air Intake Length or Obstruction Refer to Section 3 General Venting of the Knight Boiler Installation and Op...

Page 41: ...s or a 1 4 turn clockwise to decrease CO2 levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measure the combustion If combustion...

Page 42: ...42 NOTES...

Page 43: ...43 NOTES...

Page 44: ...eferences to the pocket pc along with the removal of Models 399 500 Revision 6 ECO C02545 reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff te...

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