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Lochinvar 399 - 800 Boiler User Manual

1. 177 8 180 heating zone s and send it to the DHW tank instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point 11 Chae Service Manual 1 Service Sequence of operation continued Table 1A continued from previous page Sequence of operation space heating and DHW OPERATION DISPLAY 8 If the boiler is not part of a cascade and the DHW call for heat remains active for more than 30 minutes and the space heating call for heat is also active then the control will turn on the boiler pump turn off the DHW pump after 2 seconds and resume SH 41 RATE modulating based on the space heating set point As long as 123 0F 129 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 Once both calls for heat are satisfied the control will turn off the burner The blower will remain on for the 10 second postpurge POSTPURGE cycle Any pumps that are running will continue to run for their 127 4F 129 respective pump delay times then turn off Standby 124 7F 129 Standby 11 Syst ff 10 Boiler pump off system pump continues its delay if longer 12 1 Service continued Display panel menu access Service Manual Table 1B Use this procedure to access menus from the display panel BUTTON OPERATION ENTER RES Press 1 time in normal operati
2. 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Var Service Manual XL Cleaning boiler heat exchanger Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in the Knight XL Installation and Operation Manual Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside Remove the heat exchanger access cover cover gasket s and chamber insulation assembly A WARNING The boiler contains ceramic fiber materials Use care when handling these 10 11 12 13 materials per instructions on page 3 of this manual Failure to comply could result in severe personal injury Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent Finish cleaning using a clean cloth dampened with warm water Install access cover gasket chamber insulation assembly and cover Secure nuts on the studs DO NOT overtighten Re install the blower assembly gas air arm using the bolts set aside in Step 3 Close isol
3. BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL PC INTERFACE 9 1 Service General Operation How the boiler operates The Knight XL uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing operation The blower pulls in gas and air and pushes flue products out of the boiler through the heat exchanger and flue piping The control module regulates blower speed to control boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow How the control module operates The Knight XL control module receives input from boiler sensors The control module activates and controls the blower and gas valve to regulate heat input and switches boiler DHW and system pumps on and off as needed The user installer programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation 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 normal sequences of operation for space heating and DHW operation The combined operation sequence is for a typical application programmed to provide DHW priority 10 NSG Service Manual Au Access modes User The user can adjust
4. C Shift reset curve The shift reset curve parameter shifts the actual set point above the calculated set point the number of degrees in this parameter This parameter can be changed by the installer by accessing parameter F7 The temperature range of this parameter is 27 F 15 C to 27 F 15 C The default value is O F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C 19 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 O 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 inst
5. F 21 C Maximum SH set point When the outdoor temperature drops below its minimum setting F1 the water temperature will be at this point if the SH set point is set higher FIG 1 1 This parameter can be changed by the installer by accessing parameter F3 The temperature range of this parameter is 0 F 18 C to 190 F 88 C The default value is 180 F 82 C Minimum SH set point When the outdoor temperature rises to or above its maximum setting F2 the water temperature will be at this point 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 When the outdoor temperature rises above this point the control 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 18 C to 120 F 49 C The default value is 70 F 21 C Outdoor air shutdown differential The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before the boiler will respond to a SH demand This parameter can be changed by the user or the installer by accessing parameter F6 The temperature range of this parameter is 0 F 0 to 90 F 50 C The default value is 10 F 5
6. If an 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 1 on page 19 Minimum air temperature When the outdoor air temperature drops below this point the water temperature will be at its maximum setting FIG 1 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 34 C to 90 F 32 C The default value is 25 F 4 C 1 Service continued Figure 1 1 Outdoor Air Reset Curve WATER TEMPERATURE a SET POINT MAXIMUM RESET Default 180 F USER SET POINT Default 125 F MINIMUM RESET Default 70 F Default 25 F Default 70 F AT MINIMUM RESET OUTDOORAIR NSG Service Manual PCH OUTDOOR TEMPERATURE OUTDOOR AIR AT MAXIMUM RESET 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 1 This parameter can be changed by the installer by accessing parameter F2 The temperature range of this parameter is 30 F 34 C to 90 F 32 C The default value is 70
7. 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 Replace the fan Replace the main control board Replace fuse F4 on the control board see page 28 of this manual mE EH 35 Cost Service Manual XL 3 Troubleshooting Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Fan High Knight XL Installation and Operation Manual for OR proper lengths Fan Speed High Check for obstruction or blockage in the vent air will a A me The actual fan RPM is 30 higher than what intake pipes or at terminations reset once the condition is being called for has been corrected Press the RESET button on the SMART SYSTEM display to reset Check the wiring connections at the fan and at the main control board Replace the fan Replace the main control board Check the sensors and their associated wiring Sensor Open Repair or replace the sensor or wiring if damaged will require a manual Modo Either the inlet water or outlet water Ebay temperature sensor has been disconnected the RESET button on the SMART SYSTEM display to reset Measure the resistance of the sen
8. Del 22 N N Ye Ye o z TE w 1 Service Notification in Month 22 No No Yes Yes 2 saa Notification Running 22 No No Yes Yes J x ra 3 Service Notification Boiler Cycles 22 No No Yes Yes g o 4 Reset Service Notification Counter 22 No No Yes Yes z NOTICE The parameters for Building Management System operation are not listed in this table They are only accessible using the PC interface software See separate documentation for access information See page 21 of this manual for a brief discussion 16 1 Service NS Service Manual PCH Viewable and changeable control parameters CAUTION Before changing parameters note the settings so that the unit can be returned to its original operating parameters A General Boiler model The control will display Knight Boiler as the model number because the same control is used on several models This will be displayed when parameter A1 has been accessed This parameter is not changeable User code The User Code allows the user to access and change a limited number of control parameters The access code can be changed by the user or the installer to a code of their choosing To change the code parameter A2 must be accessed The default code is 0704 The code can be changed one digit at a time by using the arrow keys on the display Date and time The control uses an internal clock for the night setback feature and for logging
9. This parameter is adjustable by the installer by accessing parameter H2 The control methods are as follows 1 Thermostat The control modulates the boiler based on the user set point and the temperature of the selected controlling sensor 2 BMS Building Management System The control modulates the boiler based on the 0 10 VDC signal delivered to the appropriate terminals on the connection board When BMS is selected additional parameters for BMS operation may need to be adjusted These can only be accessed by the optional PC software See the Knight Smart System PC Program Instructions Manual for additional BMS parameter information Service Manual 3 Cascade The boiler is part of a group of boilers sequenced together 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 Member boilers When Cascade is selected each boiler in the group requires a unique address see below The default control is Thermostat Boiler cascade address The boiler designated as the Leader needs to be programmed with address 0 All the Member boilers require addresses from 1 to 7 and the addresses must be different for each Member The addresses can be in any order regardless of the order in which the units are wired together This parameter is adjustable by the installer by accessing parameter H3 The o
10. and seals used in hydronic systems What is in this manual Service Near boiler piping Typical system components The Knight XL 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 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 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 Circulation Pumps eJ Service Notification ST Service Manual ZE 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 igniti
11. instructions a lt o m lt P Z lt x General Address reported problems Inspect interior clean and vacuum if necessary Clean condensate trap and fill with fresh water eCheck for leaks water gas flue condensate Verify flue and air lines in good condition and sealed tight eCheck system water pressure system piping expansion tank Check control settings Check ignition and flame sense electrodes sand off any deposits clean and reposition Check wiring and connections Perform start up checkout and performance verification per Section 10 in the Knight XL 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 30 C above return water temperature If combustion or performance indicate need Clean heat exchanger Remove and clean burner compressed air only using Clean the blower wheel Service Manual Owner maintenance see the Knight XL User s Information Manual for Monthly Periodically Every 6 months End of season months instructions Check boiler area Check pressure temperature gauge Check vent piping Check air piping Check air and vent termination screens Check relief valve Check condensate drain system Check automatic air vents Test low water cutoff if us
12. it must close The air pressure switch must be closed 3 The control then starts a 15 second prepurge cycle APAA prepurge cycle 123 9F 129 4 Once the prepurge cycle is complete and the blocked drain IGNITION switch is closed the control starts the 4 second trial for ignition by sending spark voltage to the spark electrode and opening 123 9F 129 the gas valve 5 If the control 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 POSTPURGE PREPURGE burner does not light after 4 trials on the 399 model the control 123 9F 129 will lock out for one hour and then try again On the 500 800 models the control will lock out indefinitely after the first trial for ignition fails 6 If the control detects a flame before the trial for ignition ends it begins to modulate the burner in order to maintain the set point SH 20 RATE If the boiler lights due to a space heating call for heat and the E ramp delay function is active default is off the modulation 124 8F 129 will be held to a series of increasing limits after the burner has lit 7 If the space heating call for heat is active and the DHW thermostat or sensor starts a DHW call for heat the control will turn on the DHW pump wait 2 seconds and then turn off the DHW 85 RATE boiler pump This will divert the hot water away from the
13. operation Section 10 Start up in the Knight Boiler Installation and Operation Manual after completing boiler service Gamer Service Manual XL 3 Troubleshooting continues Table 3A Troubleshooting Chart No Display CORRECTIVE ACTION No 120 VAC supplied to unit Check external line switch fuse or breaker Check position of ON OFF switch Turn switch to the ON position Check 120 VAC through the ON OFF switch Check wiring harness connection between display board and main control board Connect harness at both points No Display No voltage through the switch Replace switch Bad display board Replace board Bad main control board Replace the main control board Blown fuse Replace fuse F3 on the main control board see page 28 of this manual Main control board temperature set point Review temperature setting satisfied Remote thermostat satisfied Review remote thermostat setting Outside air temperature above Warm Check location of outside air sensor Check Weather Shutdown WWSD set point for resistance of outdoor air sensor and compare to Table main control board 3D on page 30 of this manual No Burner Operation Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 32 of this manual for corrective actions Ramp delay active Check ramp delay parameter settings Optional PC software required Turn ramp delay fea
14. KBX SER Rev E COMMERCIAL BOILER Service Manual Models 399 800 t Lochimar High EMcieacy Water Heaters Boiler und Pool Heaters This manual must only be used by a qualified heating installer service technician Read all instructions including this manual and the Knight XL Installation and Operation Manual before installing Perform steps in the order given Failure to 6 comply could result in severe personal injury death or substantial property damage CERTIFIED High Efficiency Water Heaters Boilers and Pool Heaters CONTENTS au ne h ros 2 2 MAINTENANCE Hazard Definitions 2 Maintenance and Annual Startup 23 27 PLEASE READ BEFORE PROCEEDING 3 3 TROUBLESHOOTING Handling Ceramic Fiber Materials 3 Before Troubleshooting 28 When servicing boiler 4 Check Control Module Fuses 28 Boiler operation 4 Table 3A Troubleshooting Chart No Display 29 Boiler water 4 Checking Temperature Sensors 30 Freeze protection fluids 4 Table 3E Troubleshooting Chart Noisy System 31 WHAT IS IN THIS MANUAL 5 Table 3F Troubleshooting Chart Fault Messages 32 39 1 SERVICE Combustion Analysi
15. Mode Tieme Service Manual XL Press to turn boiler off or back on Press to select a menu item SHUTDOWN Press after parameter programming to store parameter data Press to exit Service Mode ENTER RESET DISPLAY SCREEN SERVICE o BUTTON COMMERCIAL c PC m CONNECTIOI PORT High Efficiency Water Heaters Boilers and Pool Heaters _4 z E PREVIOUS NEXT Press to toggle 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 date and time 7 um 1 Service Control inputs GAS PRESSURE SWITCH OPTIONAL DHW THERMOSTAT OPTIONAL ROOM THERMOSTAT ZONE CONTROL FLOW SWITCH SYSTEM SENSOR DHW TANK SENSOR OPTIONAL OUTDOOR SENSOR OPTIONAL SEQUENCER BUILDING MANAGEMENT SYSTEM OPTIONAL LOW WATER CUTOFF OPTIONAL INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT FLAME SENSOR PC INTERFACE OPTIONAL ES Service Manual LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE NSG Service Manual 1 Service continued Control outputs ALARM BELL LOW VOLTAGE AUX DEVICE RELAY CONNECTION BOARD RUN TIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR
16. aller by accessing parameter F9 The time range for this parameter is 1 minute to 60 minutes The default value is 20 minutes 20 Service Manual 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 manua
17. at the system is full of water and that all air maximum outlet water temperature has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight 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 wiring back to the pump relay Replace the pump relay if necessary If 120 VAC is present on a call for heat and the boiler pump is not operating replace the pump EH 37 EM Bus 3 Troubleshooting Service Manual Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Temp O Shoot continued Rem Ctrl Fit Parameters Progr will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset APS Open will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset EM 55 EM Outlet water temperature has exceeded the maximum outlet water temperature External control is cycling too often After downloading parameters from a laptop the main control board must be reset Air pressure switch contacts are open Verify that the boiler pump is set to the p
18. ation 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 boiler When the boiler has been flushed restore boiler to operation Perform start up and check out procedures in the Knight XL Installation and Operation Manual 27 3 Troubleshooting A WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Always disconnect power to the boiler before servicing Failure to comply could result in severe personal injury death or substantial property damage Never jumper bypass any device except for momentary testing as outlined in the Troubleshooting chart Severe personal injury death or substantial property damage can result Before troubleshooting 1 Have the following items a Voltmeter that can check 120 VAC 24 VAC and 12 VDC b Continuity checker c Contact thermometer 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground 4 Make sure all external limit controls are installed and operating Check the following 1 Wire connectors to control module are securely plugged in at the module and ori
19. 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 18 Service Manual Gem 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 firi
20. ck times If parameter A6 is set to anything other than 32 F 0 C the night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures are required These times can be changed by the user or the installer by accessing parameter A7 Each day of the week Sunday through Saturday will have an on and off time Example Monday ON 22 30 Tuesday OFF 6 45 If you wish to skip a day and have no night setback leave the on and off times the same The default times for each day will be 00 00 midnight B Temperature settings SH set point user The SH set point user sets the water temperature set point for fixed operation or the maximum temperature set point when the outdoor air sensor is used This parameter can be changed by the user or the installer by accessing parameter Bl The temperature range of this parameter is 50 F 10 C to 190 F 88 C The default 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 program the control with a lower SH set point This parameter can only be changed by the installer by accessing parameter B2 The temperature range of this parameter is 32 F 0 C to 190 F 88 C The default value is 70 F 21 C SH Maximum set point The SH maximum set point sets the maximum water te
21. d more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3G on page 40 or replace the gas valve Service Manual Gog Figure 3 3 Gas Valve Adjustment Model 500 THROTTLE ADJUSTMENT SCREW Models 600 800 Locate the throttle adjustment screw on top of the gas valve see FIG 3 4 Using an Allen wrench turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 40 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 specified range revisit the possible causes in Table 3G on page 40 or replace the gas valve Figure 3 4 Gas Valve Adjustment Models 600 800 THROTTLE ADJUSTMENT SCREW REMOVE BLUE CAP NEC Service Manual 4 Notes 42 NSG Service Manual XL 4 Notes 43 Revision Notes Revision B ECO C02407 reflects air pressure switch changes changes made to the Circulation Pumps Section page 22 and removal of references to the pocket pc Revision C ECO C02545 reflects the addition of references to periodic c
22. dicates expansion tank sizing or performance problem 4 Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual before proceeding further eed Service Manual Safety relief valves should be re inspected A WARNING 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 naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not d
23. e Consider piping and installation when determining boiler location see the Knight XL Installation and Operation Manual Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection thoroughly NIOSH stated First Aid M Eye Irrigate immediately M Breathing Fresh air Wash potentially contaminated clothes separately from other clothing Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal Rinse clothes washer Service Manual Got Please read before proceeding When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should overheati
24. e temperature has exceeded 185 F 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 properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL boiler Service Bik Check voltage to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the pump relay Replace the pump relay 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 pump is the proper size Reference Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for boiler pump specifications 120 VAC input to the main control board has Check 120 VAC supply to the transformer dropped below 80 VAC Check wiring connections at the low voltage terminal Low 24 VAC strip Check the wire size length to remote devices Replace the transformer The main control board has detected Replace the main control board MEV Col Lele dela internal fault The main control board has detected Replace the main control board LLL CM sid internal fault The main control board has detected Replace the main control board ld L ETAT te internal fault The main control board has detected P
25. ed Reset button low water cutoff Check boiler piping gas and water for leaks Operate relief valve Shut boiler down unless boiler used for domestic hot water 2 Maintenance WARNING ET Service Manual Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as WARNING nee i noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of the Knight XL Installation and Operation Manual If any of these are present in the boil
26. ensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 10 Place the boiler back into normal operation 6 Remove the flue temperature sensor Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 11 above The CO levels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the chart below for possible causes and corrective actions Table 3G Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual Vent Air Intake Length for the proper venting and air intake methods for the Knight XL boiler or Obstruction Check for obstructions at the vent air intake terminals Gas Supply Pressure Refer to Section 7 Gas Connections of the Knight XL Installation and Operation Manual for the proper gas supply for the Knight XL boiler Refer to page 26 of this manual for burner removal and cleaning procedures Dirty Damaged Burner PR ap Replace burner if necessary Gas Valve Adjustment Refer to page 41 of this manual for the gas valve adjustment procedure 40 3 Troubleshooting cont
27. er intake air vicinity they must be removed If they cannot be removed reinstall 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 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 retaining screw from the PVC cap FIG 2 1 3 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 2 1 4 Remove any sediment in the trap 5 Fill with fresh water until the water begins to pour out of the drain 6 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 7 Replace the retaining screw 24 A WARNING Lhe boiler should be inspected annually only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 2A and explained on the following pages must be performed to Figure 2 1 Condensate Trap RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH PVC TEE ASSEMBLY SUPPLIED 0 TO FLOOR CONDENSATE FROM vi HEAT EXCHANGER A A WARNING The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the tra
28. es Yes Yes 1 Minimum Air Temperature 18 No No Yes Yes 2 Maximum Air Temperature 19 No No Yes Yes z 3 Maximum SH Set Point 19 No No Yes Yes u 7 4 Minimum SH Set Point 19 No No Yes Yes 4 a F 5 Outdoor Air Shutdown 19 Yes Yes Yes Yes 5 6 ou oor 5 SUED 19 Yes Yes Yes Yes Differential 7 Shift Air Reset 19 No No Yes Yes 3 8 Boost Temperature 20 Yes Yes Yes Yes 9 Boost Time 20 Yes Yes Yes Yes 15 Service Manual 1 Service Parameter table continued Table 1D continued from previous page This table lists SMART SYSTEM control module parameters and where to access them o SEE USER ACCESS INSTALLER ACCESS z MENU SUB ITEM DESCRIPTION PAGE Lr DISPLAY MODIFY DISPLAY MODIFY o gt 1 Anti cycling Time 20 No No Yes Yes Q G 2 Return Temperature Differential 20 No No Yes Yes for Ending Anti Cycling 3 Ramp Delay On Off 20 No No Yes Yes SH Controlling Sensor 1 Outlet System Inlet 2l Ne Ne Tes Yes SH Source Thermostat BMS d 2 and Cascade 21 No No Yes Yes 4 0 3 Boiler Cascade Address 21 No No Yes Yes w EQ H ax Cascade Set Point o o es es S g 4 Max C de Set Poi 21 N N Y Ye o 5 Cascade Offset 22 No No Yes Yes ascade Differential o o es es 6 c de Diff ial 22 N N Ye Ye z o o 1 System Pump Delay 22 No No Yes Yes an q I 2 SH Pump Delay 22 No No Yes Yes 22 ump Delay o o es es a 3 DHW P
29. ess the RESET button on the SMART SYSTEM display to reset The actual fan RPM is 30 lower than what is being called for Fan Low le Fan Speed Low will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Blown fuse CORRECTIVE ACTION 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 properly into the heating system Refer to Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for the proper piping methods for the Knight XL Check voltage to boiler pump motor on a call for heat If voltage is not present check wiring back to the pump relay Replace the pump relay 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 either an inlet or system supply sensor check temperature setting of the main control board If the high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 3B on page 30 of this manual Replace sensor if necessary Replace high limit Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual for
30. etailed and 14 inches w c 3 5 kPa LP gas information concerning the gas supply pressures should be between 8 inches w c 2 0 kPa and 14 inches w c 3 2 kPa Gas air mixture problem Refer to the Gas Valve Adjustment Procedure on page 41 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Knight XL Installation and Operation Manual Dirty damaged burner Refer to page 26 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Noisy Operation Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight XL 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 system water pressure Verify system pressure is a minimum of 12 psi 82 7 kPa Replace fuse F5 on the control board see page 28 of Operation Boiler Pump Faulty pump id Replace pump System Pump or DHW Pump Internal fault on control board e Replace main control board Faulty pump relay Replace relay System pressure exceeds relief valve Lower the system pressure below the 50 psi setting 344 7 kPa rating of the supplied relief
31. etectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever A WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 25 2 Maintenance Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense elect
32. ginating control 2 Gas pressures Maximum 14 inches w c 3 5 kPa natural and LP with no flow lockup or with boiler on Minimum 4 inches w c 1 0 kPa natural 8 inches w c 2 0 kPa LP with gas flowing verify during boiler startup 28 Service Manual mg Check control module fuses NOTICE 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 2 Remove top access cover 3 Remove the control module cover 4 Inspect fuses F2 F3 F4 and F5 see FIG 3 1 below Figure 3 1 Control Module Fuses F3 1 25 AMP FUSE MAIN BOARD F4 3 15 AMP FUSE GAS VALVE F5 5AMP FUSE PUMPS F2 3 15 AMP FUSE 24V SUPPLY 5 The boiler is shipped with three 3 spare fuses in a plastic bag attached to the control module cover 6 Ifnecessary replace open fuse F3 is 1 25 amps F2 and F4 are 3 15 amps and F5 is 5 amps Note Fuses F2 F5 are all slow blow fuses Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage 7 Install control module cover and top access cover after fuse inspection 8 Restore power to the boiler at the external line switch and verify boiler
33. inued Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedures Note The procedures below are model specific CAUTION Under normal operating conditions this valve should not need adjusting Model 399 Locate the throttle adjustment screw on the top of the gas valve see FIG 3 2 Using a screwdriver turn the screw 1 8 turn counterclockwise to increase CO levels or 1 8 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 40 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 specified range revisit the possible causes in Table 3G on page 40 or replace the gas valve Figure 3 2 Gas Valve Adjustment Model 399 THROTTLE ADJUSTMENT SCREW Model 500 Locate the throttle adjustment screw on top of the gas valve see FIG 3 3 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performe
34. ition attempt If no voltage is present replace the 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 the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the 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 does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Replace the main control board Bro 3 Troubleshooting continued Service Manual Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface The outlet water temperature has exceeded the setting of the high limit Adjustable High Limit w Manual Reset will require a manual reset once the condition has been corrected Pr
35. l 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 1 Service continued Figure 1 2 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 CALL FOR HEAT H Control modes SH controlling sensor The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate This parameter is adjustable by the installer by accessing parameter H1 The sensor selections are as follows The outlet sensor regulates the firing rate based on the outlet water temperature of the boiler and the inlet sensor regulates the firing rate based on the inlet water temperature of the boiler If the outlet sensor is selected and the optional system supply sensor is connected the control will regulate the firing rate based on the system supply sensor temperature The default sensor is the Outlet Sensor SH source The SH source parameter selects the method used to control the modulation of the boiler
36. leaning of screens in vent terminations and safety shutoff testing and instructions Revision D ECO C02738 reflects the addition of the Gas Valve Adjustment Procedure for a 399 model on page 41 Revision E ECO 4C02918 reflects the addition of Tank Sensor Open on page 36 along with updating the condensate trap image on page 24 KBX SER Rev E 3 09
37. ller acess code 14 Bain f listi gt A General The caret symbol gt highlights 2 eginning of menu listings B Temp Settings the selectable line W bow Press 1 time to highlight second listing Millen ee ama B Temp Settings the selectable line v DOWN Press 1 time to toggle menu listing gt C Data Logging The menu toggles to the next two D Functions menu options v BAN Press 2 times to toggle menu listing gt E DHW Settings The menu toggles to the next two F Heat Curve menu options s gt G Anti Cycling The menu toggles to the next two v DOWN Press 2 times to toggle menu listing eS mni optione I Circulation Pumps The menu toggles to the next two v pown Press 2 times to toggle menu listing bise Il P Ti o ENTER RES Press 1 time to list parameters 11 will flash System Pump A I2 Post Ti SH A UP Press 1 time to change parameter D AS I2 will flash Pump I2 P Ti H ing o ENTER RES Press 1 time to select parameter egi ZE E 12 will stop flashing parameter Pump 0 50 minutes value will appear UP I2 Postrun Time SH Parameter will increase or decrease Press to increase or decrease value 7 A or DOWN Pump 0 67 minutes depending on button pressed z Press 1 time to save A General Display will change to normal or press MENU EXIT to continue B Temp Settings display as you exit menu mode e ENTERRES Press 1 time to retur
38. moval and cleaning procedures Replace if necessary Replace the main control board mu 33 mm stacey Service Manual XL 3 Troubleshooting Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION The unit was running and lost the flame signal This condition occurred four 4 straight times on the 399 model or twice on the 500 800 models No Flame Running will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset H 34 CORRECTIVE ACTION e Inspect spark electrode and associated wiring for damage and connection Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Check for proper electrical grounding of unit Check incoming supply gas pressure Natural gas pressures should be between 4 14 inches w c 1 0 3 5 kPa and LP gas pressures should be between 8 14 inches w c 2 0 3 2 kPa Refer to Section 7 Gas Connections of the Knight XL 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 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 ign
39. mperature set point that can be used for space heating The user or installer will not be able to program the control with a higher SH set point This parameter can only be changed by the installer by accessing parameter B3 The temperature range of this parameter is 32 F 0 C to 190 F 88 C The default value is 185 F 85 C SH Offset The SH offset sets how many degrees above set point the temperature has to go before the boiler will shut off This parameter can only be changed by the installer by accessing parameter B4 The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 5 C 17 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 0 C to 54 F 30 C The default value is 20 F 11 C 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 Cl 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
40. n to normal BLR Pre Purge This display example assumes operation OUT 123 7 F a call for space heating is present 1 Service continued Parameter table Service Manual Table 1D This table lists SMART SYSTEM control module parameters and where to access them SEE USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Boiler Model 17 Yes No Yes No s 2 User Code re Yes Yes Yes Yes u 3 Date and Time 17 Yes Yes Yes Yes W o A 4 Software Version rf Yes No Yes No 5 Temperature Units 17 Yes Yes Yes Yes 6 Night Setback Temperature 17 Yes Yes Yes Yes 7 Night Setback Times 17 Yes Yes Yes Yes W 1 SH Set Point User AZ Yes Yes Yes Yes pa P o 2 SH Minimum Set Point 17 No No Yes Yes z E B S SH Maximum Set Point 17 No No Yes Yes u A U 4 SH Offset 17 No No Yes Yes u 5 SH Differential 18 No No Yes Yes 1 Hours Running SH 18 Yes No Yes No pa z 2 Hours Running DHW 18 Yes No Yes No 9 C a o 3 Ignition Attempts 18 Yes No Yes No zl 4 Show Last 10 Errors 18 Yes No Yes No 2 z 2 1 Reset Last 10 Errors 18 No No Yes Yes D E 2 Service Mode Delay 18 No No Yes Yes 2 4 1 DHW Boiler Set Point 18 Yes Yes Yes Yes E 2 SH DHW Switching Time 18 Yes Yes Yes Yes 3 DHW Tank Set Point 18 Yes Y
41. ness connection at the gas valve and at the main control board Replace the gas valve wire harness Replace the gas valve Replace the main control board am Service Manual gt 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has received a call The control board will release the call for heat after a for heat too quickly after the previous call for set time period heat has ended Anti cycling The control board will release the call for heat if the outlet temperature drops too quickly The unit has failed to prove main burner Inspect spark electrode and associated wiring for ignition after four 4 attempts on the 399 damage and connection Reference page 26 of this model or one 1 attempt on the 500 800 manual for removal and cleaning procedures models It will require a manual reset before Replace if necessary attempting to fire again Check for proper electrical grounding of the unit Check incoming supply gas pressure Natural gas pressures should be between 4 14 inches w c 1 0 3 5 kPa and LP gas pressures should be between 8 14 inches w c 2 0 3 2 kPa Refer to Section 7 Gas Connections of the Knight XL Installation and Operation Manual for detailed information concerning the gas supply Verify that the
42. ng occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water Thoroughly flush the system without boiler connected to remove 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 Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion Leaks in boiler piping must be repaired at once to prevent the introduction of makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets
43. ng rate of the boiler based on the actual water temperature This parameter can be changed by the installer by accessing parameter El The temperature range of this parameter is 50 F 10 C to 190 F 88 C The default value is 180 F 82 C 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 DHW tank set point By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6 F 3 5 C below the tank set point and finishes the call for heat when the tank temperature goes 4 F 2 C above the tank set point This parameter can be changed by the installer by accessing parameter E3 The temperature range of this parameter is 32 F 0 C to 212 F 100 C The default value is 125 F 52 C F Outdoor air reset Outdoor air reset operation
44. nsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean burner if performed inside a building 3 Remove the burner reference FIG s 2 2 thru 2 4 4 When replacing the burner ensure gasket is in good condition and positioned correctly FIG s 2 2 thru 2 4 Figure 2 2 Burner Assembly Model 399 oie QTY 5 Figure 2 3 Burner Assembly Model 500 SCREWS P QTY 5 2 Maintenance continued Figure 2 4 Burner Assembly Models 600 800 GASKET SCREWS QTY 5 Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps 2 A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode 3 See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner 1 Review the Knight XL Users Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the Knight XL User s Information Manual and in this manual as well 3 Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior
45. of events For these features to work correctly the clock must be set when the boiler is first installed or anytime the boiler has been powered off for more than 30 days To set the clock parameter A3 must be accessed The date and time are displayed as YY MM DD W hh mm YY year MM month DD date W day 1 Sunday 2 Monday etc hh hour 24 hour time 2 00 PM 14 00 mm minutes The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Software version The software version allows the user to view the software version in use by the control This software controls the operation of the boiler When a new software version becomes available the existing control can be replaced with a new control to update the software Temperature units The control can be configured to display temperature in either C or F This parameter can be changed by the user or the installer by accessing parameter A5 The default is F Night setback temperature Once the internal clock has been set correctly the night setback feature can be used to program a lower water temperature set point for space heating This parameter can be changed by the user or the installer by accessing parameter A6 The temperature range for this parameter is 32 F 0 C to 140 F 60 C The feature is turned off with a setting of 32 F 0 C The default value is 32 F 0 C Night setba
46. on iN MENU EXIT Hold for 5 seconds display will change A Press 9 times to change last digit UP k gt A in readout to 9 lt PREVIOUS Press 2 times to move to the second MGEN digit 4 UP Press 3 times to change second digit duri in readout to 3 f PREVIOUS Press 1 time to change to the first E digit A UP Press 5 times to change first digit in readout to 5 ENTER RES Press to enter the code 3 After 2 seconds display shows menus press ENTER RESET to select a menu at step 1 to enter the code LA DOWN Press 1 time to highlight second listing v DOWN Press 1 time to toggle menu listing LA DOWN Press 2 times to toggle menu listing LA DOWN Press 2 times to toggle menu listing Y DOWN Press 2 times to toggle menu listing DISPLAY COMMENTS Boiler turns off this ensures uninterrupted programming Enter Menu Code 0000 flashing Digit shown underlined at left will flash Enter Menu Code 0009 Digit shown underlined at left will flash Enter Menu Code 0009 Digit shown underlined at left will flash Digit shown underlined at left will flash Enter Menu Code 0309 Enter Menu Code 0309 Digit shown underlined at left will flash Enter Menu Code 5309 Digit shown underlined at left will flash If you enter a digit incorrectly you can move to the digit by using the NEXT and PREVIOUS b
47. on 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 amer Service Manual XL 1 Service 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 operation of the SMART SYSTEM control See the Knight XL Installation and Operation Manual for more detailed piping diagrams FROM p d SYSTEM DOMESTIC HOT WATER PUMP SYSTEM PUMP gN _ INDIRECT DOMESTIC HOT WATER TANK ro 27 SYSTEM P a 40 BOILER PUMP TO FLOOR DRAIN 1 Service continued The Knight XL display Hold 5 seconds to enter code Input Mode Menu Mode Press to move up one level in Menu Mode or to exit m Menu Mode MENU EXIT UP DOWN Press to change boiler water temperature set point during normal operation Press to change displayed data values in Menu Mode Press to navigate through menu listing in Menu
48. p could result in severe personal injury or death Check all piping for leaks Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free i Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections of the Knight XL Installation and Operation Manual 2 Maintenance continued Flue vent system and air piping 1 Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 82 7 kPa 3 Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise in
49. 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 No Flame Ign connection on the side of the main control board during will require a manual the ignition attempt If no voltage is present replace reset once the condition the main control board has been corrected Press the RESET button on the SMART SYSTEM display to reset 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 the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the 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 does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 26 of this manual for re
50. rature has exceeded the Set Inspect the heat exchanger Reference page 27 of parameters for the boiler this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3C on page 30 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace the main control board The temperature rise across the heat exchanger has exceeded the set parameters for the boiler 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 properly into the heating system Refer to Section 6 Hydronic Piping of the Knight 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 back to the pump relay Replace the pump relay if necessary Temp O Shoot 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 Boiler Installation and Operation Manual for boiler pump specifications Outlet water temperature has exceeded the Verify th
51. ress the ENTER RESET button on the SMART HE 4018 1016 B internal fault SYSTEM display panel 39 EM Chae Service Manual XL 3 Troubleshooting Combustion Analysis Procedure able 3H Flue Products 1 Turn the main power off to the boiler by placing the NaturalGas Propane On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue pipe EEE CO connection Note Combustion measurements will be g0 10 3 0 6 5 9 0 11 4 1 6 9 made at this point 3 Turn the main power on to the boiler by placing the 8 Once the combustion analysis is complete test the safety On Off switch in the ON position shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down 4 Place the boiler into the active position by pressing the and registers an alarm Open the manual shutoff valve SHUTDOWN button on the display board see page 7 reset the control and return to Service Mode ES m the diya anew 9 Turn the main power off to the boiler and replace the flue 5 Locate the pinhole button above the T in the Knight temperature sensor into the flue pipe connection logo on the display board see page 7 Press the button once and hold for 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at You must replace the flue gas temperature ignition speed and will then modulate up to full fire s
52. rodes from the boiler heat exchanger access cover 2 Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones 3 Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip 2 Verify all wiring is in good condition and securely attached 3 Check ground continuity of wiring using continuity meter 4 Replace ground wires if ground continuity is not satisfactory Check all boiler wiring 1 Inspect all boiler wiring making sure wires are in good condition and securely 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 manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks l Start boiler and perform checks and tests specified in Section 10 Start up of the Knight XL Installation and Operation Manual 2 Verify cold fill pressure is correct and that operating pressure does not go too high EN 26 MM Service Manual iem Check burner flame 1 Inspect flame through observation window 2 Ifthe flame is u
53. roper speed or that the boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight XL Installation and Operation Manual for boiler pump specifications Replace the main control board Check set point of the external control Check the wiring between the external control and the unit Replace the control Press the ENTER RESET button on the SMART SYSTEM display panel Check the wiring connections to switch Wires should be connected to the common and normally closed terminals Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight XL Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent 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 Usta Service Manual XL 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION While the unit is in Service Mode the outlet Establish a heating load to remove the heat from th
54. s This parameter is adjustable by the installer by accessing parameter J1 The time range for this parameter is 0 months to 36 months The default time is 12 months 22 NSG Service Manual Service notification running hours When the boiler control determines that a scheduled service is due based on the hours of actual operation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter J2 The time range for this parameter is 0 hours to 100 000 hours The default time is 10 000 hours Service notification boiler 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 This parameter is adjustable by the installer by accessing parameter J3 The range for this parameter is 0 cycles to 100 000 cycles The default is 10 000 cycles Reset service notification counter Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing parameter J4 Once accessed press the RESET key to reset the service notification counter 2 Maintenance Bros Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician see the following pages for
55. s Procedure 40 Near Boiler Piping 6 Table 3G Troubleshooting Chart Combustion Levels 40 The Knight Boiler Display 7 Table 3H Flue Products 40 Control Inputss 222222 2er ae 8 Gas Valve Adjustment Procedure 41 Control Outputs wsio ka Lea rein Luis 9 Revision Notes Back Cover General Operation 10 Sequence of Operation 11 12 Display Panel Menu Access 13 Display Panel Parameter Access 14 Parameter Table saure a eee Bae ARS 15 16 Viewable and Changeable Control Parameters 17 22 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may re
56. sors and compare the resistance to the tables on page 30 of this manual Replace the sensor if necessary Check the sensors and their associated wiring nsor Shor gsx penso ted Repair or replace the sensor or wiring if damaged will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Either the inlet water or outlet water Measure the resistance of the sensors and compare temperature sensor has been shorted the resistance to the tables on page 30 of this manual Replace the sensor if necessary Aux Proving will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Check function of remote devices An optional remote proving switch is not making Check for loose or misplaced jumper if auxiliary proving switch is not installed Sensors equipped with an internal limit such Check the tank temperature as the Lochinvar Squire Indirect Tank the limit has opened due to temperature 195 F or the sensor has become disconnected Replace the sensor if necessary Tank Open Repair or replace the sensor wiring if damaged EH 36 MM Chace Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The stack tempe
57. space heating set point using the UP and DOWN buttons at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In user mode the following parameters can be viewed but not changed Boiler outlet water temperature in DHW mode boiler model number software version total operating hours and total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code 5309 Saving parameters To save parameters Press the ENTER RESET button To keep parameter settings only for a current operating cycle Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Gamer Service Manual XL 1 Service continued Sequence of operation Table 1A Sequence of operation space heating and DHW OPERATION DISPLAY 1 Upon a call for heat the control turns on the appropriate pumps BLR Standby system and boiler pumps for space heating call DHW pump 123 8F 129 for DHW call 2 The control connects 120 VAC to the blower The blower does not run at this time The manual reset high limit must be closed and reset Standby Once the pumps are turned on the flow switch must close 123 8F 129 If the unit is equipped with gas pressure switches they must close If an auxiliary limit is connected to the unit
58. sted by the installer by accessing parameter H6 The default value is 19 8 F 11 C I Circulation pumps System pump delay The system pump delay parameter sets the length of time the system pump if connected 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 parameter I1 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds SH 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 parameter I2 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds DHW pump delay The DHW pump delay parameter sets the length of time the DHW pump if connected will run after a DHW demand has been satisfied Setting the delay time to 0 will disable the pump This parameter 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 months When the boiler control determines that a scheduled service is due based on days of installation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 second
59. sult in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Please read before proceeding Installer Read all instructions including this manual and the Knight XL Installation and Operation Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the Knight XL User s Information Manual for your reference Have this boiler serviced inspected by a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING The combustion chamber door insulation in 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 Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 NOTICE M Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 Service Manual When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plat
60. ture off See page 20 of this manual for instructions on how to turn this feature off Check BMS parameter settings Optional PC software required Unit Does Not Modulate Above 50 Flue sensor open Verify that the flue sensor is located in the flue outlet Boiler controlled by BMS Check wiring connections at the flue sensor Check the resistance of the flue sensor and compare to Table 3C on page 30 of this manual 29 NEC Service Manual XL 3 Troubleshooting Checking temperature sensors The boiler temperature sensors inlet water outlet water system water flue and outdoor air are all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its corresponding table replace the sensor Table 3B Inlet Outlet System Sensor Resistance vs Temperature Table 3C Flue Temperature Sensor Resistance vs Temperature WZ W KA Low oom o9 Table 3D Outdoor Air Sensor Resistance vs Temperature 30 tame Service Manual XL 3 Troubleshooting continued Table 3E Troubleshooting Chart Noisy System CORRECTIVE ACTION Supply gas problem Natural gas pressures Refer to Section 7 Gas Connections of the Knight should be between 4 inches w c 1 0 kPa XL Installation and Operation Manual for d
61. utdoor air if used and system supply sensor must be connected to the Leader boiler The default address is 1 Max cascade set point This parameter determines the set point used by the individual boilers in a Cascade When a boiler is commanded to fire by the Leader boiler it will attempt to achieve this temperature at its outlet The Leader boiler will limit the modulation of the last boiler to fire in order to hold the temperature at the system supply sensor to the user set point If any of the boiler outlet temperatures reach the max cascade set point the boiler will then modulate down on its own in order to keep its outlet temperature within the max cascade set point Therefore this parameter can be used to limit the outlet temperatures of all the boilers in a Cascade Note that this parameter does not apply when the boiler is heating an indirect DHW tank This parameter is adjustable by the installer by accessing parameter H4 The default max cascade set point is 185 F 85 C 21 1 Service Cascade offset This parameter determines how much the temperature must go above set point before the lead boiler will turn off This parameter can be adjusted by the installer by accessing parameter H5 The default value is 9 9 F 5 C Cascade off on differential 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 adju
62. uttons as needed until the digit you want is flashing Then use UP and or DOWN buttons to change the value The words INSTALLER CODE will flash while displayed Enter Menu Code INSTALLER CODE gt A General B Temp Settings The caret symbol gt highlights the selectable line If the code is entered incorrectly the display will return to its previous mode You will have to start over The caret symbol gt highlights the selectable line A General gt B Temp Settings gt C Data Logging D Functions The menu toggles to the next two menu options The menu toggles to the next two menu options gt E DHW Settings F Outdoor Reset gt G Anti cycling H Control Modes The menu toggles to the next two menu options gt I Circulation Pumps J Service Notification The menu toggles to the next two menu options To select a highlighted menu press the ENTER RESET button one time The display will change to the first parameter under that menu with the first characters flashing 13 1 Service Beer Display panel parameter access Service Manual Table 1C This is a typical example of accessing a parameter shown for parameter I2 boiler pump delay BUTTON OPERATION DISPLAY COMMENTS This example shows how to access parameter I2 boiler pump delay The first display shown is at the beginning of the menu listings after entering the insta
63. valve or replace Relief Valve the standard relief valve with a higher rated valve up to Opening the maximum pressure of the heat exchanger Improperly sized expansion tank 31 Usta Service Manual XL 3 Troubleshooting Table 3F Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped not available on 399 models 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 flow switch or the optional low water cutoff is not making Flow Switch LWCO will require a manual reset once condition has been corrected Press the RESET button on the SMART SYSTEM 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 1 0 3 5 kPa and LP gas pressures should be between 8 14 inches w c 2 0 3 2 kPa Refer to Section 7 Gas Connections of the Knight XL 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 Check boiler pump operation on a call for heat Check for closed
64. 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 GEE uses Blown fuse Replace fuse F2 on the control board see page 28 of this manual The blocked drain switch has detected j fotos CE TEE excessive condensate build up inside the MUSSCZECWNEJW unit reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Flame The flame detector circuit is seeing a flame Sequence signal while no flame is present will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset GV Relay The main control board did not detect the gas Fail valve will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Check condensate tube from unit to floor drain for proper installation and obstructions e Inspect condensate trap for blockage Clean if necessary Check for loose wiring connection at wire harness plug Bad blocked drain switch Replace switch Check supply voltage for proper polarity Check external wiring for voltage feedback Check the flame rod and make sure it is clean Check the internal wiring for bad connections Replace main control board Check wiring har

Lochinvar 399 - 800 Boiler User Manual

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