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Service Manual

5

What is in this manual?

Service

Near boiler piping

• Typical system components

The Knight 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 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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Содержание 106

Страница 1: ...ian 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 result in severe personal injury death or substantial property damage WARNING Save this manual for future reference KBII SER Rev D ...

Страница 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 Knight Boiler Display 7 Control Inputs 8 Control Outputs 9 General Operation 10 Sequence of Operation...

Страница 3: ...ystalline 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 in this appliance is an ...

Страница 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...

Страница 5: ...n Knight 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 an...

Страница 6: ...TYPICAL TO SYSTEM FROM SYSTEM FROM TO SYSTEM SENSOR AIR SEPARATOR Near boiler piping This piping 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 Installation and Operation Manual for more detailed piping diagrams ...

Страница 7: ...N DIAL The Knight 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 ...

Страница 8: ...R BUILDING MANAGMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SWITCH 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 ...

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

Страница 10: ...ature 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 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...

Страница 11: ...rol starts a 15 second prepurge cycle by initiating the blower 5 The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve 6 If flame is not detected within 1 second after the sparking ends the control will perform a 10 second post purge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts ...

Страница 12: ...hen 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 blower will continue to r...

Страница 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...

Страница 14: ... 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 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...

Страница 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...

Страница 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...

Страница 17: ...dBus 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 25 No No Yes Yes Boiler Pump Delay 26 No No Yes Yes DHW Pump Del...

Страница 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...

Страница 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...

Страница 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...

Страница 21: ...and 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 Time parameter The minimum setting is 0 minutes and the maximum setting is 50 minutes ...

Страница 22: ...ue 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 instead Th...

Страница 23: ... Air 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...

Страница 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...

Страница 25: ...arameter 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 cycling th...

Страница 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...

Страница 27: ...er 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 alternate the standard boiler display text with the message SERVICE DUE every 5 seconds...

Страница 28: ...ht 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 Use...

Страница 29: ... 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 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 re...

Страница 30: ...t 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 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 natur...

Страница 31: ...ent 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 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 ...

Страница 32: ...low 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 through the water make up line to the b...

Страница 33: ...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 switch ...

Страница 34: ...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 actions Unit in Shutdown Mo...

Страница 35: ... It 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 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 R...

Страница 36: ...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 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 syste...

Страница 37: ...placed jumper on the Low 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 p...

Страница 38: ...H Applies to the 286 Model Only Inspect the back of the inner combustion chamber at burner level for refractory breakdown missing Replace heat exchanger 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 f...

Страница 39: ...s valve is not connected and will display the Gas Valve or Gas Valve Fail fault If 24 vac is present check the outlet of the valve to 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 doe...

Страница 40: ... 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 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 ...

Страница 41: ...isplay 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 Boiler Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the fan and at the main control board Rep...

Страница 42: ... 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 button ...

Страница 43: ...econnect repair wiring if 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...

Страница 44: ...n 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 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 s...

Страница 45: ...parameters from 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 i...

Страница 46: ...CO2 O2 8 0 10 3 0 6 5 9 0 11 4 1 6 9 8 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 9 Turn the main power off to the boiler and replace the flue temperature s...

Страница 47: ...ry Gas Valve Adjustment Refer to this page for the gas valve adjustment procedure Gas valve adjustment 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 leve...

Страница 48: ...eflects changes made to the Service Notification parameter Revision C ECO C07981 reflects changes made to the parameter table parameter descriptions updates to the troubleshooting chart and the addition of the O temp HEX switch Revision D ECO C09197 reflects updates made to the SMART SYSTEM control ECR R04523 KBII SER Rev D 11 11 ...

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