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3  

Troubleshooting

32

Service Manual

Table 9

Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT

DESCRIPTION

CORRECTIVE ACTION

Gas Pressure SW

(will require a manual

reset once the condition

has been corrected.  Press

the RESET button on the
SMART SYSTEM display

to reset.)

Either the optional manual reset low gas
pressure switch or the optional manual reset
high gas pressure switch tripped.  

• Reset the pressure switches.

• Measure the supply gas pressure to determine cause 

of failure.  Natural gas pressures should be between           
4 - 14 inches w.c. and LP gas pressures 
should be between 8 - 14 inches w.c.

• Refer to Section 7 - Gas Connections of the Knight  

Boiler Installation and Operation Manual for detailed 
information concerning the gas supply.

• Correct the supply gas pressure if necessary.

• Check for a loose or misplaced jumper if pressure 

switches are not installed.

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 pump operation on a call for heat. 

• 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 F2 on the control board, see page 28 of 

this manual.

Blocked Drain SW

(will require a manual

reset once condition has

been corrected.  Press the

RESET button on the

SMART SYSTEM display

to reset.)

The blocked drain switch has detected
excessive condensate build up inside the
unit.

• Check condensate tube from unit to floor drain for 

proper installation and obstructions.

• Inspect condensate trap for blockage.  Clean if 

necessary.

• Check for loose wiring connection at wire harness 

plug.

• Bad blocked drain switch.  Replace switch.

APS

Open

(will require a manual

reset once the condition

has been corrected.  Press

the RESET button on the
SMART SYSTEM display

to reset.)

Air pressure switch contacts are open.

• Check the wiring connections to switch.  Wires should 

be connected to the common and normally closed 
terminals.

• Air intake lengths exceed the maximum allowed 

lengths.  Refer to Section 3 - General Venting of the 
Knight Installation and Operation Manual for 
proper lengths.

• Check for obstruction or blockage in the air 

intake pipes or at terminations.

• Check reference hoses connected to the air pressure 

switch for blockage or obstruction.

• Inspect the burner.  Reference page 26 of this manual 

for removal and cleaning procedures.  Replace if 
necessary.

• Inspect the heat exchanger.  Reference page 27 of 

this manual for removal and cleaning procedures.  
Replace if necessary.

• Faulty air pressure switch.  Replace switch.

Содержание Knight 80 - 285

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 42: ...42 NOTES...

Страница 43: ...43 NOTES...

Страница 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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