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Service Manual

Models: 51 - 211

This manual must only be used
by a qualified heating installer
/ service technician. 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.

WBII-SER Rev G

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Summary of Contents for 106

Page 1: ...ead 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 WBII 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: ...ll mount boiler operation A General B Temperature Setting C Data Logging D Functions E DHW Settings F Outdoor Reset G Anti cycling H Control Modes I Circulation Pumps J Building Management System BMS K 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 openin...

Page 6: ...OT WATER TANK TO FLOOR DRAIN AIR SEPARATOR EXPANSION TANK SYSTEM SENSOR 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: ...STEM 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 BLOCKED DRAIN SWITCH 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: ...er return water 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 ...

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: ...stead 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 b...

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: ...g 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 soft key SA...

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: ...o No Yes Yes BMS 24 No No Yes Yes ModBus 25 No No Yes Yes ModBus 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 256 No No Yes Yes Boiler Pum...

Page 18: ...s Volts at Max 26 No No Yes 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 Maint...

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: ...9 C and the maximum setting is 45 F 7 2 C The default setting is 37 F 2 8 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 seconds to 10 minutes The default is 3 minutes Temperature Sett...

Page 21: ...nd 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 Time parameter The minimum setting is 0 minutes and the maximum setting is 50 minutes The d...

Page 22: ...ault 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 parameters the calculated set point will be at this setting FIG 1 1 If the outdoor air temperature drops further the set point will continue to increase above this setting However if SH1 SH2 and SH3 are set lower the water temperature will be limited by these set points in...

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: ...ler 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 Control modes Controlling Sensor The SH controlling sensor parameter selects the sensor the control will use to regulate the boil...

Page 25: ...l This parameter 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 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 cy...

Page 26: ...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 Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing the Boiler...

Page 27: ...resented by the Volts at Minimum parameter is set by the Set Point at Maximum Volts parameter The minimum value is 32 F 0 C and the maximum is the Set Point at Maximum Volts setting The default value is 70 F 21 C Set Point at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts ...

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: ...ction 1 of the Knight Wall Mount Installation and Operation Manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight Wall Mount Installation and Operation Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sedimen...

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: ...t 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 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 windo...

Page 32: ...ll Extension 151 211 KIT30063 CTN20005 Rear Refractory Cover MSC20083 Nylon 4 Wheel Brush MSC20084 3mm Allen Wrench MSC20086 1 4 x 24 Drill Extension The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the Service Manual Failure to comply could result in severe personal injury WARNING 5 Remove the condensate hose from the heat exchanger end Connec...

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: ...ermostat 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 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 a...

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: ... Check for closed valves or obstructions in the boiler piping Verify system is 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 F3 on the control board see page 33 of this manual Blocked Drain SW will require a manual reset once condition has been corrected Press the RESET button on the SM...

Page 38: ... Boiler Installation 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 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 igniti...

Page 39: ...ge is not present check 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 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 co...

Page 40: ...sary 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 Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight Wall Mount Boiler Installation and Operation M...

Page 41: ...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 sensor and compare to the resistance in Table 3 2A on page 35 of 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 bu...

Page 42: ... 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 exceeded the Flue Temp Limit set parameters Inspect the heat exchanger Reference page 32...

Page 43: ...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 proper size Reference Section 6 Hydronic Piping of the Knight Wall Mount Boile...

Page 44: ...rom a laptop the main 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 prop...

Page 45: ...g connections at the low voltage terminal strip Check the wire size length to remote devices Replace the transformer Watch Dog Error The main control board has detected an internal fault Replace the main control board Write EEProm The main control board has detected an internal fault Replace the main control board CRC Parameters The main control board has detected an internal fault Replace the mai...

Page 46: ...CTION 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 prope...

Page 47: ...ls 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 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 spec...

Page 48: ...descriptions addition of the rope gasket and updates to the troubleshooting chart Revision D ECO C08632 reflects changes made to the Gas Valve Adjustment Procedure on page 47 Revision E ECO C09161 reflects updates made to the SMART SYSTEM control ECR R04523 Revision F ECO C10143 reflects the removal of the GV RELAY FAIL FAULT ECR R05239 and updates made to the ignition timing information Revision ...

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