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continued - Lochinvar

1. Press the LEFT SELECT soft key EXIT if all desired 18511 changes have been made HOME Press the LEFT SELECT soft key HOME SHUTDOWN GENERAL TEMPERATURE SETTINGS DATA LOGGING FUNCTIOHS HOME 49 SCROLL SHUTDOWN GENERAL gt TEMPERATURE SETTINGS DATA LOGGING FUNCTIOHS HOME 49 SCROLL SHUTDOWN 180 F MAKSETFT 180 F SHI OFFSET 10 F HOME 47 SCROLL MAA SETE SHi OFFSET HOME 44 SCROLL SHUTDOWN SHi SETFT 180 F MIN EE MHASETFT 1930 F SHLOFFSET 10 F ESITO 49 ADJUST SAVE SHUTDOWN SHi SETFT 180 F MIN se F MHASETFT 1930 F SHLOFFSET 10 F ESITO 49 ADIUSTO SAVE SHUTDOWN SH1 SETPT 180 F MIH SETFT se F MAA 190 F SH1 10 F ESITO S SCROLL SAVE SHUTDOWN SHi SETFT 180 F MIN s F MHASETFT 1930 F SHLOFFSET 10 F HOME 4 SCROLL WALL MOUNT BOILER Kaisa Service Manual 1 Service continued Parameter table Table 1 4 This table lists SMART SYSTEM control module parameters and where to access them e mene Bi Aten Torace o vm vee vm ve nigra oe TUE ve me ve vm stnasseaccontines fele me ve ve DES o we me vm ve omme fele me ve vm or wan ses on Te UO ve me vm ve or Mg sn of Te UO we me vm ve tele fm fvl ve sma EN oe fe e l lt OC LU Z Lu O SH1 Set Point eana fa e e e va sno Tefe fw re 5 essre Jofwm fmelfele fee eee ee oe Tele ve re eWervavetme a se se ve Reset Log Err
2. Gas Connections of the Knight Wall Mount Installation and Operation Manual 29 Kuce Service Manual WALL MOUNT BOILER 2 Maintenance Flue vent system and air piping l 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 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 l Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem 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 l 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 th
3. e Check ramp delay parameter settings e Turn ramp delay feature off See page 23 of this manual for instructions on how to turn this feature off Unit Does Boiler controlled by BMS e Check BMS parameter settings Not Modulate Above 50 No flue temperature change e Verify that the flue sensor is located in the flue outlet Check wiring connections at the flue sensor Check the resistance of the flue sensor and compare to Table 3 2D on page 35 of this manual Kuscer Service Manual WALL MOUNT BOILER 3 Troubleshooting continued 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 It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing These devices are designated as Sla S1b outlet sensor and S3a S3b flue sensor Please reference the wiring diagram in the Knight Wall Mount Installation and Operation Manual for correct terminal location Table 3 2A Inlet Water System Sensor Resistance vs Table 3 2B Outdoor Air Sensor Resistance vs Temperature Temperature 20 46218 30
4. lt lt General e Address reported problems e Inspect interior clean and vacuum if necessary e Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check control settings e Check ignition and flame sense electrodes sand off any deposits clean and reposition e Check wiring and connections e Perform start up checkout and performance verification per Section 10 in the Knight Wall Mount Installation and Operation Manual e Flame inspection stable uniform e Flame signal at least 10 microamps at high fire e Clean the heat exchanger if flue temperature is more than 54 F above return water temperature e Test low water flow conditions If combustion or performance indicate need Clean heat exchanger e Remove and clean burner compressed air only using e Clean the blower wheel Service Manual Owner maintenance see the Knight Wall Mount User s Information Manual for instructions Periodically Every 6 months End of season months e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system e Check air vents e Test low water cutoff if used e Reset button low
5. 0 44 DESCRIPTION Outlet water temperature has exceeded the maximum outlet water temperature 120 vac input to the main control board has dropped below 80 vac The control module has detected parameter settings that are out of range A lockout occurs at the same time as a power outage 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 Wall Mount Installation and Operation Manual the proper piping methods for the Knight wall mount boiler Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump 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 Wall Mount Boiler Installation and Operation Manual for boiler pump specifications Replace the main control board Check 120 vac supply to the transformer Check wiring connections at the low voltage terminal strip Check the wire size length to remote devices Replace the transformer Restore the parameter defaults from the optional PC software Replace the control
6. Air Shutdown Differential SH1 SH2 and SH3 parameters The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Shift Reset Curve SH1 SH3 There is a shift reset curve for each outdoor reset The shift reset curve parameter shifts the actual set point above or below the calculated set point by the number of degrees in this parameter These parameters can be changed by the installer by accessing the Shift Reset Curve SH1 SH2 and SH3 parameters The temperature range of this parameter is 17 F 10 C to 18 F 10 C The default value is 0 F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C Boost Temperature If a SH demand lasts longer than the programmed time delay setting 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 SH1 SH2 SH3 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 the Boost Temperature parameter The temperature range of this parameter is 0 F 0 C to 25 F 14 C The default value is 0 F 0 C This
7. Burner On If running the pumps does not prevent the inlet temperature from falling closer to freezing the SMART SYSTEM control will fire the burner at low fire The installer can adjust the temperature at which the burner fires by adjusting the Freeze Protection Burner On parameter The minimum setting is 3 F 19 C and the maximum setting is 45 F 7 2 C The default setting is 37 F 2 8 C Freeze Protection Burner Differential Once the burner has started firing due to a low inlet temperature the inlet temperature must increase by this amount before the burner turns back off The installer can adjust this differential by accessing the Freeze Protection Burner Differential parameter The minimum setting is 0 F and the maximum is 20 F The default setting is 5 F 2 8 C DHW Settings DHW Boiler Set Point When a DHW call for heat becomes active the control will use the DHW boiler set point to determine the firing rate of the boiler based on the boiler outlet water temperature or system temperature when DHW is programmed as a zone This parameter can be changed by the installer by accessing the DHW Boiler Set point parameter The temperature range of this parameter is 68 F 20 C to 180 F 82 C The default value is 180 F 82 C 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 se
8. Please note that the brackets denote screen status When a Maintenance Reminder timer or counter has expired a Maintenance Reminder screen will appear on the display By programming the installer s name and phone number this information will appear on the Maintenance Reminder Screen at that time This can be programmed by accessing the Service Name and Phone Number parameter When selected another menu will appear with PHONE and NAME 1 Rotate the NAVIGATION dial to point to the name phone number to program and press the NAVIGATION dial The screen will now display the selected item either PHONE or NAME 2 Press the NAVIGATION dial again cursor will appear at the bottom of the screen By rotating the NAVIGATION dial various numbers and characters will appear When the desired number character is found press the NAVIGATION dial The cursor will move to the next position 3 Repeat this procedure until the entire message is entered If you make a mistake and wish to back up one character rotate the NAVIGATION dial until the back arrow character is displayed and press the NAVIGATION dial 4 When finished press the RIGHT SELECT SAVE key to return to the previous menu 27 2 Maintenance WALL MOUNT BOILER Maintenance and annual startup Table 2 1 Service and Maintenance Schedules Service technician see the following pages for instructions QA 7 H OC lt v l lt lt
9. demand and start a timer Once the timer has expired the boiler will switch back to the space heating demand and start another timer Once this timer expires it will switch back to the DHW demand The installer can adjust the length of time the boiler will service the space heating demand by accessing SH DHW Switching Time parameter The minimum setting is 0 minutes and the maximum setting is 50 minutes The default time is 30 minutes DHW SH Switching Time When a boiler has a DHW demand and it receives a space heating demand the SMART SYSTEM control will start a timer Once the timer expires it will stop the DHW demand and service the space heating demand The installer can adjust the length of time the boiler will service the DHW demand by accessing the DHW SW Switching Time parameter The minimum setting is 0 minutes and the maximum setting is 50 minutes The default setting is 30 minutes Tank Minimum Set Point This setting controls the minimum tank set point for the tank temperature The installer can adjust this by accessing the Tank Minimum Set point parameter The minimum setting is 60 F 16 C and the maximum setting is the maximum tank set point Tank Maximum Set point parameter The default value is 60 16 C Tank Maximum Set Point This setting controls the maximum tank set point for the tank temperature The installer can adjust this by accessing the Tank Maximum Set point parameter The minimum setting is the mi
10. feature will be active if this parameter is set to anything other than 0 F 0 C Figure 1 2 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 CALL gt TIME FOR 1 HEAT gt TIME 3 TIME Service Manual WALL MOUNT BOILER Boost Time The boost time parameter sets the amount of time that must elapse with a SH demand before the water temperature calculated set point will be increased This parameter can be changed by the installer by accessing the Boost Time parameter The time range for this parameter is 0 minute to 50 minutes The default value is 0 minutes 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 the Anti Cycling Override Differential parameter This parameter can be changed by the installer by accessing the Anti Cycling Time parameter The time range for this parameter is 1 minute to 10 minutes The default value is 1 minute Anti Cycling Override Differential The control will bypass the anti cycling time if the inlet water temperature drops too much The control will use the inlet water temperature the boiler was at when it shut off as the starting point If the inlet temperature drops below the temperature parameter
11. module Reset control module us Service Manual WALL MOUNT BOILER 3 Troubleshooting continued Combustion Analysis Procedure Table 3 6 Flue Products 2 Remove the flue temperature sensor from the flue pipe mes an connection Note Combustion measurements will be CO CO Hon 8 0 10 5 2 8 6 5 10 0 11 4 1 5 4 3 Turn the main power on to the boiler 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm Turn the manual shutoff switch to the ON position reset the control and return to Service Mode 4 Place the boiler into the active position by pressing the RIGHT SELECT ON key see page 7 5 Locate the pinhole button below the RESET button on the display board see page 7 Insert a thin wire such as a paper clip into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode 9 Turn the main power off to the boiler and replace the flue In Service Mode the boiler will fire at ignition speed and temperature sensor into the flue pipe connection will then modulate up to full fire 10 Place the boiler back into normal operation 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor A WARNING You must replace the flue gas temperature sensor to prevent flue gas
12. removal and inspection procedure Clean or replace the burner as necessary Noisy Dirty damaged burner Operation Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight Wall Mount Boiler Installation and Operation Manual for minimum flow rates Verify that the boiler is piped in a primary secondary fashion and that the boiler and system pump are running on a call for heat Air in the piping system Properly purge all air from the piping system Low system water pressure Verify system pressure is a minimum of 12 psi Ni sati a Blown fuse e Replace fuse F1 on the control board see page 33 of Operation this manual Boiler Pump i Pump Note Make sure pump amperage does not exceed 1 8 amps HW Pump Faulty pump e Replace pump Internal fault on control board e Replace main control board System pressure exceeds relief valve Lower the system pressure below the 30 psi rating of setting the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger Relief Valve Opening Improperly sized expansion tank WALL MOUNT BOILER Kusi Service Manual 3 Troubleshooting continued Table 3 4 Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure SW will require a manual Check for a loose or mispla
13. see page 33 of Blown fuse this manual Inlet Sensor e Check wiring to sensor Make sure wiring is Fault connected and not damaged Reconnect repair will require a manual wiring if necessary reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Replace control module The control reads the inlet sensor as open Measure the resistance of the sensor and compare or shorted to the resistance in Table 3 2A on page 35 of this manual Replace sensor if necessary Service Manual WALL MOUNT BOILER 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet Sensor Fault will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The control reads the outlet sensor as open or shorted Outdoor Sensor Fault Models WH 55 285 will be displayed until condition has been corrected The control reads the outdoor sensor as open or shorted Outlet Temp Diff will require a manual reset once the condition i The control module reads an excessive has been corrected Press diff og the RESET button on the RA ure aimerence between the two SMART SYSTEM display to reset Flue Sensor Fault will require a manual reset once the condition has been corrected Press the
14. set the DHW Blocks Sys Pump parameter to YES The default setting is NO DHW Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by the Boiler Pump Anti Seize Delay parameter The range of this setting is 0 seconds to 50 minutes The default setting is 20 seconds System Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by the Boiler Pump Anti Seize Delay parameter The range of this setting is 0 seconds to 50 minutes The default setting is 20 seconds BMS BMS Type When programmed for BMS control through the 0 10V BMS input or through ModBus the 0 10V signal can be interpreted as either a modulation command or a set point When the BMS Type parameter is set to POWER the 0 10V signal will control the modulation When set to SETPOINT the 0 10V signal will control the SH set point The default setting is SETPOINT Volts at Minimum When programmed for BMS control through the 0 10V BMS input or through ModBus the Volts at Minimum parameter should be set to the minimum voltage signal sent to the SMART SYSTEM control The range of this parameter is 0 0V to the Volts at Maximum The default setting is 2 0V Volts at Maximum When programmed for BMS control through the 0 10V BMS input or thro
15. then rotate the NAVIGATION dial to adjust that value If the installer presses the RIGHT SELECT SAVE key while the limit value is flashing the step value will flash again The installer can then select the next step and adjust the delay and limit values corresponding with that step When finished the installer can press the RIGHT SELECT SAVE key to store the new settings or the LEFT SELECT EXIT key to return to the Anti Cycling parameter list without saving the changes The delay value can be set between 0 minutes and 20 minutes The limit value can be set between 0 and 100 Control modes The United States Energy Policy and Conservation Act requires residential heating boilers with inputs less than 300 000 Btu hr be equipped with a control that automatically adjusts boiler water temperature in relation to heat demand An external control may be connected to control the firing rate or the set point of the boiler provided that either an external energy management system is installed that reduces the boiler water temperature as the heating load decreases the boiler is not used for any space heating or the boiler is part of a modular or multiple boiler system having a total input of 300 000 Btu hr or greater 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 the Controlling Sensor parameter T
16. water cutoff e Check boiler piping gas and water for leaks e Operate relief valve e Shut boiler down unless boiler used for domestic hot water 2 Maintenance continued Service Manual WALL MOUNT BOILER Follow the Service and maintenance procedures given throughout this manual and in component literature A WARNING l l l l l 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 A WARNING The boiler should be inspected annually only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 2 1 and explained on the following pages must be performed to 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 noted A WARNING iu l l i l 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 combus
17. 180 F 20 Service Manual WALL MOUNT BOILER SH1 SH3 Offset Set Point 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 SH1 2 and 3 Offset Set Point parameters The temperature range of these parameters is 0 F to 20 F The default value is 10 F SH1 SH3 Differential Set Point The SH Differential sets how many degrees below the offset the temperature has to drop before the boiler turns back on This parameter can only be changed by the installer by accessing the SH1 2 and 3 Differential Set Point parameters The range is 0 F to 60 F The default is 20 F 3 Way Valve Time The optional Lochinvar Multi Temperature Loop Control Board MTLCB can be used to control the supply temperature up to three 3 sub loops corresponding to each of the three 3 SH set points through the use of 3 way mixing valves To ensure the MTLCB will control these temperature properly it is necessary to let the control know how much time these mixing valves require to fully open and close Program this time into the 3 Way Valve Time parameter Since this parameter applies to all of the mixing valves used the actual open close time must be approximately the same for each one The minimum setting is 1 second and the maximum setting is 255 seconds The default setting is 20 seconds Data Logging Reset log errors Th
18. 40 50 70 490813 20 46218 336606 30 3458 234196 40 26 09 ME das 118 018 60 15311 85 362 70 11 888 e 10 62 466 80 929 Table 3 2C Outlet Water Sensor Resistance vs Temperature 19 553 30 4000 158 3478 50 gt 86 16 09 L816 10 610 1 344 12 7166 __ Oow ee II Table 3 2D Flue Sensor Resistance vs Temperature 40 030 3 478 258 500 16 870 68 2500 176 242 f 68 125500 176 1200 __ 86 16090 194 1816 fi 86 80200 194 864 12 z PE an 350 LO odo 498 pg 1 280 gt 35 WALL MOUNT BOILER Kuscer Service Manual 3 Troubleshooting Table 3 3 Troubleshooting Chart Noisy System FAULT CAUSE CORRECTIVE ACTION Supply gas problem Natural gas Refer to Section 7 Gas Connections of the Knight Wall pressures should be between 4 inches w c Mount Boiler Installation and Operation Manual for and 14 inches w c LP gas pressures detailed information concerning the gas supply should be between 8 inches w c and 14 inches w c e Refer to the Gas Valve Adjustment Procedure on page 46 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 Wall Mount Installation and Operation Manual Gas air mixture problem e Refer to page 31 in this manual for the burner
19. Bus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Maximum parameter is set by the Set point at Maximum Volts parameter The minimum value is the Set Point at Minimum Volts setting and the maximum is 180 F 82 C The default value is 180 F 82 C On Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE the On Volts parameter determines the 0 10V BMS input voltage at which the boiler is enabled The minimum value is 0 5V and the maximum is 10 0V The default value is 2 0V Off Differential Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE the Off Differential Volts parameter determines how far below the On Volts setting the 0 10V BMS input voltage must be in order to disable the boiler The minimum value is 0 2V and the maximum is the On Volts setting The default value is 1 0V 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 turn yellow and a new status screen will appear informing the installer that maintenance is required This parameter is adjustable by the installer by accessing the Service Notification in Months parameter The time range for this parameter is 0 months to 100 months The default t
20. ITOR BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL SN PC INTERFACE 9 1 Service General Operation How the boiler operates The Knight wall mount boiler 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 wall mount 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 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 Service Manual WALL MOUNT BOILER Access mo
21. MESTIC HOT WATER PUMP INDIRECT CONDENSATE DOMESTIC DRAIN HOT WATER FLOW CHECK VALVE TO FLOOR DRAIN SYSTEM PUMP BOILER PUMP Y STRAINER RECOMMENDED AIR SEPARATOR IS EXPANSION TANK we IMG00656 Kuce Service Manual WALL MOUNT BOILER 1 Service continued The Knight wall mount display NAVIGATION DIAL RESET KEY PRESS OR TURN LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key us Service Manual WALL MOUNT BOILER 1 Service Control inputs SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT ZONE CONTROL LOW VOLTAGE FLOW SWITCH E CONNECTION BOARD SYSTEM SENSOR P OUTDOOR SENSOR BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HIGH LIMIT SENSOR FLUE GAS SENSOR PRESSURE SWITCH Ga La A FLAME SENSOR 7 N ee SMART CONTROL MODULE DISPLAY PANEL PC INTERFACE Kusi Service Manual WALL MOUNT BOILER 1 Service continued Control outputs ALARM BELL LOW VOLTAGE CONNECTION BOARD AUX DEVICE RELAY RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGN
22. ON BURNER DOOR BURNER GASKET BURNER At high fire the flame signal shown on the display should be at least 10 microamps 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 See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner l Review the Knight Wall Mount User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Knight Wall Mount User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 31 2 Maintenance Ze 4 A WARNING 10 Allow time for the boiler to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cov
23. RESET button on the SMART SYSTEM display to reset The control reads the flue sensor as open or shorted Flue Temp Diff will require a manual Koamelamitmeoteisem The control module reads an excessive KES ds temperature difference between the two er Mm uiacesmeemintal SENSOrS SMART SYSTEM display to reset Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2C on page 35 of this manual Replace sensor if necessary Replace control module Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2B on page 35 of this manual Replace sensor if necessary Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2C on page 35 of this manual Replace sensor if necessary Restore control parameter defaults from optional PC software Replace control module Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2D on page 35 of this manual Replace sensor if necessary Replace c
24. W Settings e Outdoor Reset Anti cycling e Control Modes e Circulation Pumps Building Management System BMS e Service Notification Service Manual WALL MOUNT BOILER Maintenance Service and maintenance schedules e Address reported problems Inspect boiler area and boiler interior e Clean condensate trap e Check all piping for leaks e Check air openings Flue vent system and air piping e Check water system e Check expansion tank e Check boiler relief valve Inspect ignition electrode e Check ignition ground wiring e Check all boiler wiring e Check control settings Perform start up and checks e Check burner flame e Check flame signal e Check flue gas temperature e General maintenance e Review with owner e Cleaning boiler heat exchanger e Oiled bearing circulators Troubleshooting e Troubleshooting table No display e Checking temperature sensors e Sensor tables e Troubleshooting table Fault messages displayed on boiler interface e Combustion analysis procedure Gas valve adjustment procedure us Service Manual WALL MOUNT BOILER 1 Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight wall mount boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Knight Wall Mount Installation and Operation Manual for more detailed piping diagrams AIR De TS DO
25. WH SER Rev J KNIGHT WALL MOUNT BOILER Service Manual Models WH 55 399 A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions including p this manual and the Knight nurg Wall Mount Installation and Operation Manual before E R NERGY STA installing Perform steps in the order given Failure to comply 4 I f Lochinv could result in severe personal Ar property damage injury death or substantial High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference Contents CONTENTS 2 sid aiar 2 Hazard Definitions n n anaa aaa aaa 2 PLEASE READ BEFORE PROCEEDING 3 Handling Ceramic Fiber Materials 3 When servicing boiler 00 ccc eee eee 4 Boiler operation sesso 4 Boiler Walter ae i e ni 4 Freeze protection fluids 4 WHAT IS IN THIS MANUAL 5 1 SERVICE Near Boiler Piping serre ina 6 The Knight Wall Mount Display 7 Control Inputs n on naana aaan w see ee on 8 Control Outputs cos anaa anaana ss 9 General Operation nnana anaana aaa 10 Sequence of Operation 11 12 Display Panel Menu Access _ 13 Display Panel Parameter Access 14 Parameter Table 0 000 ce eee eee 15 18 Viewable and Chan
26. Wall Mount Installation and Operation Manual Air Pressure SW for proper lengths will require a manual e Check for obstruction or blockage in the air reset once the condition intake pipes or at terminations Eee Ge Air pressure switch contacts are open the RESET button on the SMART SYSTEM display to reset Inspect the burner Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Check reference hoses connected to the air pressure switch for blockage or obstruction Inspect the heat exchanger Reference page 32 of this manual for removal and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch The main control board has received a call The control board will release the call for heat after a Anti cycling for heat too quickly after the previous call set time period for heat has ended o e The control board will release the call for heat if the inlet temperature drops too quickly 7 WALL MOUNT BOILER Kuscer Service Manual 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION e Check wiring harness connection at the gas valve and at the main control board e Inspect spark electrode and associated wiring for damage and connection Reference page 31 of this manual for removal and cleaning procedures Replace if n
27. a screwdriver turn the screw a 1 4 turn clockwise to decrease CO levels or a 1 4 turn counterclockwise to increase CO levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 45 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 3 5 on page 45 or replace the gas valve Figure 3 2 Gas Valve Adjustment THROTTLE ADJUSTMENT 1 degna gt gt I I ee i f DI A VA _ Ti Ky 44 A ji a f WIL ZI 0 an DI a El m y um AN a of m f I 4 IMG00160 m 44 WALL MOUNT BOILER Service Manual NOTES vt Revision Notes Revision A ECO C06854 initial release Revision B ECO C08645 reflects additional cleaning and inspection instructions for the condensate trap page 29 Revision C ECO C09197 reflects updates made to the SMART SYSTEM control ECR R04523 Revision D ECO C 09843 reflects the addition of the new condensate trap pipe R04984 Revision E ECO C10143 reflects the removal of the GV RELAY FAIL FAULT ECR R05239 and updates made to the ignition timing information Revision F ECO 010450 reflects c
28. adequate gas and water flow Once the test is completed ensure that the isolation valve is opened up to allow full water flow Test procedure l Set the SH1 SETPOINT set point to the max user set point reference Section 10 of the Knight Wall Mount Installation and Operation Manual Max user set point will allow the boiler to operate without reaching this set point The boiler will require a load large enough to dissipate a large portion of the heat it is generating Simulate a call for heat by placing a jumper wire across the enable contacts 19 and 20 on the low voltage terminal strip FIG 2 3 32 WALL M 10 LI Service Manual OUNT BOILER Allow the unit to progress through its normal diagnostics and pre purge programming Allow the unit to fire and operate until the temperatures stabilize Thisoccurswhen the inlet and outlet temperatures are rising together and the Delta T A T is maintained When the unit stabilizes begin to slowly shut off the isolation valve on the outlet piping of the boiler see FIG 4 This will begin to restrict the flow and simulate a low flow condition While slowly shutting off the isolation valve refer to the Status Screen to watch the behavior of the boiler This screen allows you to monitor the inlet temperature outlet temperature and AT When the A T reaches 55 F the control will attempt to modulate the firing rate down to protect it from low flow conditions Whe
29. ader boiler has to know the size of each boiler in that Cascade The Boiler Size parameters allow the installer to program the size based on the Cascade address This screen shows the Cascade address and the size of the boiler with that address in BTU hr 1 When the Boiler Size screen is first accessed Cascade Address 0 Leader is shown 2 Press the NAVIGATION dial to access the first digit of the boiler size Rotate the NAVIGATION dial to adjust the first digit To access the next digit press the NAVIGATION dial again Continue this process until the correct boiler size to the nearest 1000 BTU hr is shown Press the RIGHT SELECT SAVE key 3 Rotate the NAVIGATION dial to select the address of the next boiler in the Cascade Repeat Step 2 4 Once the size of the last boiler in the Cascade has been entered and saved press the LEFT SELECT EXIT key to return to the Control Modes menu 5 Ifno other parameters are to be adjusted press the RIGHT SELECT HOME key to save the new settings and return to the Status screens The SMART SYSTEM control automatically uses the Efficiency Optimization Cascade type when controlling boilers of different sizes 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 This parameter is adjustable by the installer by accessing the System Pump Delay parameter The time range
30. ameters compare to Table 3 2D on page 35 of this manual SMART SYSTEM display Replace the sensor if necessary to reset Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace main control board e 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 Wall Mount Installation and Operation Manual for the proper piping methods for the Knight wall mount boiler e Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the main control board Replace the main control board if necessary The temperature rise across the Bedia L bulle heat exchanger has exceeded the set parameters for the boiler e If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump e Verify that the boiler pump is set to the proper speed or that the pump is the proper size Reference Section 6 Hydronic Piping of the Knight Wall Mount Boiler Installation and Operation Manual for boiler pump specifications WALL MOUNT BOILER Kuscer Service Manual 3 Troubleshooting Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface Outlet Temp High Low 24 vac Fatal Error Memory Error
31. and both the space heating and DHW calls for heat remain active long enough the boiler will SYSTEM switch back and forth between the two heating modes until one ee of them is satisfied n i n HEHU S4SASCREEH SHDH 10 Once both calls for heat are satisfied the control will turn off SYSTEM the burner The blower will continue to run during the postpurge TORK i period OUTDOOR MEHU ga5SLKEEN SHOH 11 Any pumps that are running will continue to run for their respective pump delay times before turning off unless programmed to remain on continuously A 60 second FG anti cycle period will start which will delay any new call for heat OUTDOOR NE UEO MENU amp SCREEH SHOH STANDBY 12 In Standby ready to start a new cycle SE ul 1385 JATF OUTDOOR MEHL SETPOINTS SHOH 12 Service Manual WALL MOUNT BOILER 1 Service continued Display panel menu access Table 1 2 Use this procedure to access menus from the display panel SCREEN BUTTON STATUS OPERATION DISPLAY Press the RIGHT SELECT soft key SHDN Press the LEFT SELECT soft key YES Press and hold the LEFT SELECT soft key MENU for five 5 seconds Rotate the NAVIGATION dial clockwise until 5 is displayed first digit on the left Press the NAVIGATION dial to select the next digit Rotate the NAVIGATION dial clockwise until 3 is shown in the display Press the NAVIGATION dial 2 times to move to the last digit Rotate the NAVIGATION dial c
32. ange of this parameter is 0 F 0 C to 20 11 C The default value is 10 F 6 C In Cascade this parameter will override the boiler offset parameter 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 adjusted by the installer by accessing the Cascade Off On Differential parameter The temperature range of this parameter is 0 F 0 C to 60 33 C The default value is 20 F 11 C In Cascade this parameter will override the boiler differential parameter Service Manual WALL MOUNT BOILER Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum ON and OFF time for each unit The installer can adjust this time by accessing the Minimum On Off Time parameter The minimum setting is 0 seconds and the maximum setting is 10 minutes The default is 30 seconds Minimum Next On Time In order to reduce the risk of temperature overshoot with a Cascade this parameter defines the minimum time delay from starting one unit until the next unit may be started The installer can adjust this time delay by accessing the Minimum Next On Time parameter The minimum setting is 0 minutes and the maximum setting is 10 minutes The default is 60 seconds Boiler Size When boilers of different sizes are connected together in a Cascade the Le
33. ced jumper on the Low reset once the condition l Voltage Connection Board L ted P The gas pressure switch contacts on the 7 Hs Low Voltage Connection Board are open e Check for the addition of a device wired across the gas the RESET button on the pressure switch terminals on the Low Voltage SMART SYSTEM display Connection Board to reset Check boiler pump operation on a call for heat Check for closed valves or obstructions in the boiler Flow Switch piping LWCO Either the optional flow switch or the optional Glaser EnEn low water cutoff is not making reset once condition has been corrected Press Check for loose or misplaced jumpers if flow switch or the RESET button on the LWCO is not installed on the Low Voltage SMART SYSTEM display Connection Board to reset Blown fuse e Replace fuse F3 on the control board see page 33 l of this manual Blocked Drain SW will require a manual i Check wire harness and replace jumper if necessary TAR RN The blocked drain jumper has been removed Check for loose wiring connection at wire harness NAN i orga from the wire harness plugs SMART SYSTEM display to reset e Verify system is full of water and all air has been purged from the system Check the wiring connections to switch Wires should be connected to the common and normally closed terminals e Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight
34. d Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring l Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings l 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 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 Wall Mount Installation and Operation Manual Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame l di Inspect flame through observation window If the flame is unsatisfactory 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 Remove the burner reference FIG 2 2 below When replacing the burner ensure gasket is in good condition and positioned correctly FIG 2 2 Service Manual WALL MOUNT BOILER Figure 2 2 Burner Assembly Check flame signal l BURNER PLATE GASKET BURNER PLATE INSULATI
35. des User The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when SETPOINTS is flashing at the bottom of the display The date and time and the temperature units can also be changed Installer Most parameters are available only to the installer accessible only by entering the installer password 5309 For accessing adjusting and saving parameters reference Tables 1 2 and 1 3 on pages 13 14 of this manual us Service Manual WALL MOUNT BOILER 1 Service continued Sequence of operation OPERATION DISPLAY Upon a call for heat the gas pressure switch es must be closed Once the gas pressure switch es are closed the control turns on the appropriate pumps system and boiler pumps for space heating DHW pump for DHW The flow switch and or LWCO must close The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch must close The control starts the prepurge cycle by initiating the blower The control starts the trial for ignition by firing the spark electrode and opening the gas valve If flame is not detected after the sparking ends the control will perform a postpurge then start another prepurge cycle and try to light the burner again The control will perform a total of 4 attempts before locking out If flame is detected it holds the firing rate steady for a few seconds to let t
36. does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 31 of this manual for removal and cleaning procedures Replace if necessary e Replace the main control board I 38 SSA WALL MOUNT BOILER ast Service Manual 3 Troubleshooting continued Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION CORRECTIVE ACTION Check wiring harness connection at the gas valve and at the main control board Inspect spark electrode and associated wiring for damage and connection Reference page 31 of this manual for removal and cleaning procedures Replace if necessary Check for proper electrical grounding of the unit Check incoming supply gas pressure 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 Wall Mount Boiler Installation and Operation Manual for detailed information concerning the gas supply Flame Fail Verify that the plastic hose from the gas valve to the air Running inlet is connected and is not damaged will require a manual Verify that the vent air intake pipes are correctly easiest The unit was running and lost the flame signal ins
37. e Knight Wall Mount Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Check boiler relief valve 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 Wall Mount Installation and Operation Manual before proceeding further 30 Safety relief valves should be re inspected a WANS 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 detectable 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 nat
38. e boiler has been powered off for more than four 4 hours This parameter must be accessed to set The internal clock does not adjust for Daylight Savings Time and therefore will require a manual adjustment The clock is automatically updated whenever a PC is connected and the Win_Pro Installer program is started 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 Software version is read only Temperature units C F 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 the Temperature Units parameter The default is F Space Heating SH and Domestic Hot Water DHW Night Setback Offset Once the unit s internal clock has been set correctly the Night Setback feature can be used to program a lower set point during unoccupied times Both the space heating and DHW can be programmed for night setback When in night setback the control reduces the set point by a fixed amount For space heating it subtracts the space heating night setback offset from each of the SH user set points SHI 2 and 3 Set point parameters or the calculated outdoor reset set point if lower For DHW it subtracts the DHW n
39. e reset log errors function clears the last 10 errors log Functions 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 any 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 the Service Mode Delay parameter The time range of this parameter is 1 to 10 minutes The default value is 10 minutes Freeze Protection Pump On The SMART SYSTEM control will turn on the boiler and system pump outputs whenever the inlet temperature drops below this setting This is done to prevent the water in the heat exchanger from freezing Certain low temperature applications such as snow melt can operate at temperatures around freezing so this setting needs to be lowered in these cases The installer can adjust the temperature at which the pump outputs are turned on by accessing Freeze Protection Pump On parameter The minimum setting is 3 F 19 C and the maximum setting is 45 F 7 2 C The default setting is 45 F 7 2 C Never put the Freeze Protection Pum on a du lower than the fee Protection Burner On setting 1 Service continued Freeze Protection
40. ecessary Check for proper electrical grounding of the unit Check incoming supply gas pressure 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 Wall Mount Boiler Installation and Operation Manual for detailed information concerning the gas supply Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged Verify that the vent air intake pipes are correctly installed and that there are no obstructions Check for 24 vac to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace The unit has failed to prove main burner the main control board Flame Fail Ign 9 ignition after four 4 attempts will require a manual reset once the condition has been corrected 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 Press the RESET button on the SMART SYSTEM display to reset 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
41. ed States Energy Policy and Conservation Act boilers with inputs less than 300 000 Btu hr must use either outdoor air reset or an external energy management system To use the outdoor reset feature the outdoor sensor provided with the boiler must be properly installed For better zone control three 3 individual outdoor resets for low outdoor temperatures are available If multiple zones are calling for heat the highest set point has priority Each curve is created using four 4 adjustable parameters low outdoor air temperature high outdoor air temperature set point at low outdoor air temperature and set point at high outdoor air temperature The set point is calculated using the individual curve for each zone Outdoor 1 3 Low This parameter specifies the low outdoor air temperature When the outdoor air temperature drops to this point the zone set point will be at the Set Point 1 at Low Outdoor Temp 1 Set Point 2 at Low Outdoor Temp 2 and Set Point 3 at Low Outdoor Temp 3 parameters FIG 1 1 If the outdoor air temperature drops further below this setting the set point will continue to increase This parameter can be changed by the installer by accessing the Outdoor 1 3 Low parameters The temperature range is 39 F 39 C to high outdoor air temperature set point The default value is 25 F 4 C Outdoor 1 3 High This parameter specifies the high outdoor air temperature When the outdoor air temperature rises
42. elected the installer can press the NAVIGATION dial and the day of the week will start to flash 2 The installer can adjust the day of the week to the one he wishes to set Once the day is set the installer can press the NAVIGATION dial and the hour will begin to flash 3 After setting the hour the installer can press the NAVIGATION dial and the minutes will flash Once all settings have been made the installer can press the RIGHT SELECT SAVE key The installer can now select a different trigger and adjust the settings for that trigger Please note that the brackets denote screen status 4 Once all adjustments are made the installer can press the RIGHT SELECT SAVE key to save all of the new settings and return to the General menu or press the LEFT SELECT EXIT key to return to the General menu without saving the changes Space Heating SH and Domestic Hot Water DHW Night Setback Off Times The corresponding space heating night setback stop triggers are set by accessing the SH Night Setback Off Times parameter The stop triggers for the DHW night setback feature can be adjusted by accessing the DHW Night Setback Off Times parameter The adjustment procedure for these parameters is identical to the space heating start triggers described above Night Setback Override Any Night Setback On trigger currently active or scheduled within the next seven 7 days can be skipped To skip a trigger rotate the NAVIGATION dial
43. er to the heat exchanger and set aside Remove the heat exchanger access cover and burner The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the Service Manual Failure to comply could result in severe personal injury Remove the condensate trap from the bottom of the boiler Place a bucket underneath the condensate fitting attached to the heat exchanger Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent Using a clean cloth dampened with warm water wipe out the combustion chamber Rinse out debris with a low pressure water supply Allow the heat exchanger to thoroughly dry Perform start up and check out procedures in the Check Flame and Combustion Section 10 Startup of the Knight Wall Mount Installation and Operation Manual Replace the burner access cover and condensate trap Restore boiler to operation A CAUTION Do NOT use a metal brush Oiled bearing circulators l J The circulator shipped with the Knight wall mount boiler is water lubricated No oiling is required Check other circulators in the system Oil any circulators requiring oil following circulator manufacturers instructions Over oiling will damage the circulator Replace the boiler front access cover Test low water flow conditions NOTICE This test is to be carried out once the Knight wall mount boiler is completely piped in with
44. es 100 and the calculated load is still increasing it will start the next boiler at 20 and reduce the previous boiler to equal the demand thus eliminating the sudden jump in total output of the Cascade When the calculated load is decreasing and the last boiler gets down to 20 fire it will hold it there and start lowering the firing rate on the next to last boiler When the next to last boiler reaches 20 it will turn the last boiler off and raise the rate of the next to last boiler to 40 thus eliminating the sudden drop in total output of the Cascade 1 Service continued The other Cascade divider method is Efficiency Optimization designated as EFF in the menu This method is used as the name implies when it is desired to have the most efficient system When the first boiler reaches a certain rate default 90 it lowers its rate to 45 and turns on the next boiler at 45 The two 2 boilers then modulate at the same rate As the calculated load increases further and both boilers ramp up to 90 it lowers the rate of the first two 2 boilers to 60 and brings the next boiler on at 60 The three 3 boilers then modulate together As the calculated load decreases the boilers will reach a lower threshold default 30 at which time the last boiler the third in our example will turn off and the Cascade will increase the rates of the remaining boilers to provide the equivalent total output as before 3 x 30 2 45 in
45. et Point through SH3 Set Point When outdoor reset is used these set points provide an upper limit to the reset curve for each zone If multiple space heating set points are calling for heat the highest set point has priority If the outdoor sensor is not connected the boiler will operate at SH Set Point For models requiring outdoor air reset WH 55 285 the display screen will indicate Outdoor Sensor Fault until the sensor is reconnected The range of this parameter is SH Minimum Set Point to SH Maximum Set Point The default is 125 F 52 C Space Heating SH Minimum Set Point The SH Minimum Set Point sets the minimum water temperature set point allowed for SH Set Point 1 3 adjustment 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 the Minimum SH Set Point parameter The temperature range is 32 F 0 C to the space heating maximum set point The default value is 32 F Space Heating SH Maximum Set Point The SH Maximum Set Point sets the maximum water temperature 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 the Maximum SH Set Point parameter The temperature range of this parameter is the space heating minimum set point to 180 F 82 C The default value is
46. for this parameter is 0 1 second to 40 minutes The default time is 30 seconds 25 1 Service Boiler Pump Delay The SH pump delay parameter sets the length of time the boiler pump will run after a SH demand has been satisfied This parameter is adjustable by the installer by accessing the Boiler Pump Delay parameter The time range for this parameter is 0 1 second 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 This parameter is adjustable by the installer by accessing the DHW Pump Delay parameter The time range for this parameter is 10 seconds to 40 minutes The default time is I minute Boiler Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by the Boiler Pump Anti Seize Delay parameter The range of this setting is 0 seconds to 50 minutes The default setting is 20 seconds Boiler Pump Minimum Voltage The speed of the boiler pump can be controlled by the SMART SYSTEM control in order to maintain a minimum AT through the heat exchanger Thus as the firing rate decreases the speed of the boiler pump can decrease as well The SMART SYSTEM control outputs a 0 10V signal to the boiler pump to control its speed The Boiler Pump Minimum Voltage parameter determines the min
47. geable Control Parameters 19 27 Hazard definitions 2 MAINTENANCE Maintenance and Annual Startup 28 32 3 TROUBLESHOOTING Before Troubleshooting 000 vnr ravn 33 Check Control Module Fuses 33 Table 3 1 Troubleshooting Chart No Display 34 Checking Temperature Sensors 35 Table 3 3 Troubleshooting Chart Noisy System 36 Table 3 4 Troubleshooting Chart Fault Messages 37 44 Combustion Analysis Procedure 45 Table 3 5 Troubleshooting Chart Combustion Levels 45 Table 3 6 Flue Products 45 Gas Valve Adjustment Procedure 46 Revision Notes Back Cover 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 A DANGER injury A WARNING injury A CAUTION injury CAUTION NOTICE DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided
48. hanges made to Table 3 6 on page 45 Revision G ECO 011102 reflects outdoor air reset updates Revision H ECO C12763 revised the maximum CO2 and the minimum O2 R06021 on page 45 Revision I ECO C13178 reflects edits made to the condensate trap Revision J ECO C14411 reflects the addition of the low water flow test procedure on page 32 WH SER Rev J 1 14
49. he flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal PRE PURGE t ara TE TAHE OUTDOOR MEHO 2SCREEH SHOH PRE PURGE i SrolEN LIE F TRMK 120 F01253 OUTDOOR 26 F MEHL eat SCREEH SHOH PRE PURGE t ara TERMS LIE Ie TAHE 125 Fc1253 OUTDOOR 26 F MENU et SCREEH SHUN PRE PURGE f ava TERMS Lif Fl TRMK 129 FC 1 OUTDOOR JEF HEHU ga5LKEEEN SHOH IGNITION A oro TERMS 1 DHW TAHKE 1 OUTDOOR MEHU gasSLKEEEN SHOH POST PURGE avo TEM TAHE OUTDOOR HEHU ga5LKEEN SHOH 4246 ft SYSTEM 117 FX TAHE E OUTDOOR JEF MEHO SISCREEH SHOH 1 16 F 125 Fc125 S r 19 30 Kuscer Service Manual WALL MOUNT BOILER 1 Service Sequence of operation continued 8 Ifthe space heating call for heat is active and the tank thermostat or sensor starts a DHW call for heat the boiler will switch to the DHW mode If programmed for normal DHW operation not as a zone the DHW pump will turn on first then the boiler pump SYSTEM will turn off 2 boiler and DHW pump operation briefly overlap to TAHE ensure flow is maintained through the unit This will divert the OUTDOOR boiler s outlet water from the heating system and send it to the MEHI 4A3SCREENO SHDN tank coil instead The control will then modulate to maintain the outlet temperature to the DHW boiler set point If the boiler is not part of a Cascade
50. he 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 The inlet temperature control is only available with a stand alone 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 24 Service Manual BMS Thermostat Input When controlling the boiler through the 0 10V BMS input or through ModBus the boiler can be enabled one of two ways With the BMS Thermostat Input parameter set to ACTIVE the boiler will be enabled by closing the Heat Loop Demand 1 input When set to INACTIVE the boiler will be enabled by the voltage level on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE BMS The set point or modulation of the boiler may be controlled through the 0 10V BMS input or through ModBus When the BMS parameter is set to INACTIVE the 0 10V input will be ignored When set to ACTIVE the set point or modulation will be controlled by the voltage on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE ModBus When BMS is set
51. he system flow is not less than the boiler flow continued If operating on something other than an outlet sensor will require a manual check temperature setting of the main control board reset once the condition hes er ore ed Pe e Check resistance of water sensors and compare to the RESET button on the Table 3 2A and 3 2C on page 35 of this manual SMART SYSTEM display Replace sensor if necessary to reset e Replace the main control board if necessary Louver Proving Sw will require a manual Mestad eee eee AN optional remote proving switch is not RESA io se Gs making the RESET button on the SMART SYSTEM display to reset e Check function of remote devices Check for loose or misplaced jumper if auxiliary proving switch is not installed on the Low Voltage Connection Board Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight Wall Mount Installation and Operation Manual for proper lengths Fan Speed Check for obstruction or blockage in the vent air intake pipes or at terminations will require a manual reset once the condition has been corrected Press Check the wiring connections at the fan and at the the RESET button on the main control board SMART SYSTEM display to reset Replace the fan The actual fan RPM is 30 lower or higher than what is being called for Replace the main control board Replace fuse F2 on the control board
52. ight setback offset from the tank set point Tank Set point parameter NOTE The DHW night setback will not work without a tank sensor installed The installer may adjust the space heating night setback offset by accessing the SH Night Setback Offset parameter and the DHW night setback offset by accessing the DHW Night Setback Offset parameter The minimum setting is 0 F 0 C and the maximum setting is 90 F 50 C Space Heating SH and Domestic Hot Water DHW Night Setback On Times This is the time in which the SH Night Setback Offset becomes active There are 7 start times and 7 stop times each for the space heating and DHW night setback features Both may be set to any time within a 7 day week These settings are referred to as triggers Multiple start or stop triggers may be set within a single day if desired When a start trigger and a stop trigger are set to the same time the stop trigger has priority The installer may adjust the space heating night setback start triggers by accessing the SH Night Setback On Times parameter The DHW start triggers in the DHW Night Setback On Times parameter This screen shows the start trigger number the day of the week and the time of day NOTICE 1 When the screen is first accessed start trigger number 1 is shown If a different trigger number is desired the installer can rotate the NAVIGATION dial until the desired trigger number is displayed Once the desired trigger number is s
53. ime is 12 months This feature has been disabled by the manufacturer To enable this feature change Service Notification in Months parameter to the desired time range Service Notification Running Time When the boiler control determines that a scheduled service is due based on the hours of actual operation the boiler display will turn yellow and a new status screen will appear informing the installer that maintenance is required This parameter is adjustable by the installer by accessing the Service Notification Running Time parameter The time range for this parameter is 0 hours to 17 500 hours The default time is 8 760 hours Service Manual WALL MOUNT BOILER Service Notification Cycles When the boiler control determines that a scheduled service is due based on the number of boiler cycles the boiler display will turn yellow and a new status screen will appear informing the installer that maintenance is required This parameter is adjustable by the installer by accessing the Service Notification Cycles parameter The range for this parameter is 0 cycles to 100 000 cycles The default is 50 000 cycles Reset Maintenance Reminder Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing the Reset Maintenance Reminder parameter Once accessed press the RESET key to reset the service notification counter Service Name and Phone Number NOTICE
54. imum voltage given to the boiler pump thereby setting its minimum speed The range of this setting is 2 5V to 10V The default setting is 3 5V System Pump Type The system pump can be programmed to operate in response to any of the Room Thermostat inputs or to run continuously until the boiler goes into Outdoor Shutdown To program the system pump to operate only with a space heating call for heat set the System Pump Type parameter to CFH To program the system pump to run continuously until outdoor shutdown starts set the System Pump Type parameter to WWSD The default setting is CFH DHW Forces Sys Pump When the indirect DHW tank is connected as a zone on the primary loop the DHW Forces Sys Pump parameter tells the system pump if it must run when there is a DHW demand To have the system pump constantly running during a DHW demand set the DHW Forces Sys Pump parameter to YES the parameter DHW Blocks Sys Pump must be set to NO If this parameter and the DHW Blocks Sys Pump parameter are both set to NO the system pump operation will be based strictly on the System Pump Type parameter setting The default setting of this parameter is YES 26 Service Manual WALL MOUNT BOILER DHW Blocks Sys Pump When the indirect DHW tank is connected as a zone on the primary loop the DHW Blocks Sys Pump parameter tells the system pump if it is allowed to run during a DHW demand To force the system pump to turn off during a DHW demand
55. inspection 8 Restore power to the boiler at the external line switch and verify boiler operation Section 10 Start up in the Knight Wall Mount Installation and Operation Manual after completing boiler service 33 us Service Manual WALL MOUNT BOILER 3 Troubleshooting Table 3 1 Troubleshooting Chart No Display FAULT CAUSE CORRECTIVE ACTION No 120 vac supplied to unit e Check external line switch fuse or breaker e Check 120 vac e Check wiring harness ribbon cable connection between display board and main control board Connect harness at both points Bad display board e Replace board Bad main control board Replace the main control board Blown fuse e Replace fuse F3 on the main control board see page 33 of this manual No Display Main control board temperature set point e Review temperature setting Satisfied Review remote thermostat setting Outside air temperature above Warm Check location of outside air sensor Check No Burner Weather Shutdown WWSD set point for resistance of outdoor air sensor and compare to Table Operation main control board 3 2B on page 35 of this manual Remote thermostat s satisfied Unit locked out on fault e Consult display for specific fault Refer to fault descriptions on page 37 44 of this manual for corrective actions Unit in Shutdown Mode e Take unit out of Shutdown Mode Ramp delay active
56. low If operating on something other than an outlet sensor check temperature setting of the main control board Check resistance of water sensors and compare to Table 3 2A and 3 2C on page 35 of this manual Replace sensor if necessary e Replace the main control board if necessary Adjust the set point of the manual reset limit to a higher setting up to a maximum of 210 F Reference Section 10 Operating Information of the Installation and Operation Manual for adjusting procedures e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight Wall Mount Installation and Operation Manual for the proper piping methods for the Knight wall mount boiler Check 120 vac to boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board e If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump WALL MOUNT BOILER Kuce Service Manual 3 Troubleshooting continued Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The outlet water temperature has exceeded the setting of the manual reset high limit Outlet e If the system pump is a variable speed pump ensure MRHL that t
57. may result in property damage 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 A WARNING Installer Read all instructions including this manual and the Knight Wall Mount 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 Wall Mount 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 NOTICE REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can A WARNING PP be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to crist
58. n the AT reaches 60 F the control module will turn off the burner If the control module shuts down the test was successful Disconnect the jumper wire from the low voltage terminal strip connected in Step 2 Completely open the isolation valve on the outlet piping of the boiler Resume operation Figure 2 3 Low voltage terminal strip and enable contacts ENABLE CONTACTS LOW VOLTAGE JP CONNECTION BOARD IMG00164 ADJUST OUTLET ISOLATION VALVE ONLY IMG00656 3 Troubleshooting A WARNING 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 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 ins
59. nal wiring for bad connections WALL MO 3 Troubleshooting Service Manual UNT BOILER Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION The outlet water temperature has exceeded Outlet the setting of the automatic reset high limit ARHL The outlet water temperature has exceeded the setting of the manual reset high limit Outlet MRHL will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset CORRECTIVE ACTION Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200 F Reference Section 10 Operating Information of the Installation and Operation Manual for adjusting procedures e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the boiler is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Knight Wall Mount Installation and Operation Manual for the proper piping methods for the Knight wall mount boiler Check 120 vac to boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board e If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump e If the system pump is a variable speed pump ensure that the system flow is not less than the boiler f
60. nimum tank set point Tank Minimum Set point parameter and the maximum setting is 190 F 88 C The default value is 140 F 60 C DHW Type This parameter determines whether the Knight wall mount boiler treats the indirect DHW tank as a separate load or as a zone on the primary loop When programmed as a separate load the boiler will turn on the DHW pump and then turn off the boiler pump when an indirect DHW demand begins When programmed as a zone the boiler will turn on the DHW pump leave the boiler pump on and change the system set point to the DHW boiler set point DHW Boiler Set point parameter This setting may be changed by the installer by accessing the DHW Type parameter The choices are NORMAL and ZONE The default setting is NORMAL Fan Speed Limiting for Indirect DHW Tank This parameter determines the maximum fan speed and therefore the maximum rate to be used when heating an indirect DHW tank when the DHW Type is set to Normal This setting may be used when the tank is unable to accept all of the BTU s available from the boiler This parameter may be adjusted by the installer by accessing the Fan Speed Limiting for Indirect DHW Tank parameter The default value is the maximum fan speed for that model 21 1 Service Outdoor Reset Knight Wall Hung boilers are equipped with outdoor reset a feature that saves energy by reducing the boiler water temperature as the heating load decreases In accordance with the Unit
61. nsate in the trap If this ball is not present flue gases may be able to pass through the trap when there is no condensate present resulting in an unsafe environment It is important to check and make sure the ball is still located in the trap acting as a seal against flue gases at least once annually and after every cleaning 3 After the condensate trap is cleaned or serviced it must be checked to ensure that it is installed and draining properly Figure 2 1 Condensate Trap rta Poehinvan CONDENSATE DRAIN BOTTOM CAP IMG00046 The stainless steel retaining ring must RINO be installed between the rubber sealing gasket and the compression fitting The compression fitting must be tightened The condensate trap must have the float ball in place during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to ensure the float ball is in place 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 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7
62. nsor and generates a DHW call for heat when the tank temperature drops below the tank set point differential Tank Set point Differential parameter and finishes the call for heat when the tank temperature reaches tank set point This parameter can be changed by the installer by accessing the DHW Tank Set point parameter The temperature range of this parameter tank minimum set point to tank maximum set point The default value is 125 F 52 C Tank Set Point Differential When a tank sensor is installed the tank temperature must drop this amount below the tank set point DHW Tank Set point parameter before the heater will turn on The installer can adjust this setting by accessing the Tank Set point Differential parameter The minimum setting is 0 0 C and the maximum is 40 F 22 C The default setting is 6 F 3 C DHW Boiler Offset This parameter reflects the degrees above DHW boiler set point the temperature has to go before the boiler will shut off The range is 0 F 0 C to 40 F 22 C The default setting is 10 F 6 C DHW Boiler Differential This parameter reflects the degrees below DHW boiler set point the temperature has to go before the boiler turns back on The range is 0 F 0 C to 60 F 33 C The default setting is 20 F 13 C Service Manual WALL MOUNT BOILER SH DHW Switching Time When a boiler has a space heating demand and it receives a DHW demand it will immediately switch to the DHW
63. obalite Service Manual When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location see the Knight Wall Mount Installation and Operation Manual Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines M Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 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 e Wear long sleeved loose fitting clothing gloves and eye protection M Apply enough water to the combustion chamber lining to prevent airborne dust HM Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal HM Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH s
64. ontrol module Check wiring to sensor Make sure wiring is connected and not damaged Reconnect repair wiring if necessary Measure the resistance of the sensor and compare to the resistance in Table 3 2D on page 35 of this manual Replace sensor if necessary Restore control parameter defaults from optional PC software Replace control module Kise Service Manual WALL MOUNT BOILER 3 Troubleshooting continued Table 3 4 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION CORRECTIVE ACTION Inspect the heat exchanger Reference page 32 of this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the flue sensor and associated wiring Flue Temp High Measure the resistance of the flue sensor and The stack temperature has exceeded the compare to Table 3 2D on page 35 of this manual set parameters for the boiler Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace main control board Inspect the heat exchanger Reference page 32 of this manual for the procedure on how to clean Flue Temp Limit the flue side of the heat exchanger will require a manual reset once the condition Inspect the flue sensor and associated wiring DEE The stack temperature has exceeded the Measure the resistance of the flue sensor and Nome Flue Temp Limit set par
65. ors lele Yes Yes i CEE Yes ves Ke EN e e KN WALL MOUNT BOILER ast Service Manual 1 Service Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them Installer Access So See Description La Modify Display Modify 2 DHW Boiler Set Point Tank Set Point Tank Set Point Differential DHW Boiler Offset DHW Boiler Differential SH DHW Switching Time DHW SH Switching Time DHW SETTINGS Tank Minimum Set Point Tank Maximum Set Point DHW Type Fan Speed Limiting for DHW Outdoor 1 Low Outdoor 1 High Set Point 1 at Low Outdoor Temp 1 Set Point 1 at High Outdoor Temp 1 Outdoor Air Shutdown SH1 Outdoor Air Shutdown Differential SH1 Shift Reset Curve SH1 Outdoor 2 Low Outdoor 2 High Set Point 2 at Low Outdoor Temp 2 N Y N N N N N N N N N N N N N N N N N N N N Set Point 2 at High Outdoor Temp 2 Outdoor Air Shutdown SH2 N Outdoor Air Shutdown Differential SH2 Shift Reset Curve SH2 2 Ves Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 8 DQ lt OD v OUTDOOR RESET md O WALL MOUNT BOILER Kuscer Service Manual 1 Service continued Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them See Installer Acces
66. ounterclockwise until 9 is displayed Press the RIGHT SELECT soft key SAVE Rotate the NAVIGATION dial counterclockwise to select a category STANDBY OUTLET IHLET MEHL 4 SETPOINTS SHOH STANDBY SHUT COMM SHUTDOLJN IHLET 1172F OUTLET 128 F MEHL SETPOINTS SHOH SHUTDOWN PASSWORD DOGG EALT HEAT SAWE SHUTDOWN PASSWORD 2000 EAIT HEAT SAUE SHUTDOWN PASSWORD 23300 EALT HEAT SAWE SHUTDOWN PASSWORD 3309 EALT HEAT SAWE SHUTDOWN gt GENERAL TEMPERATURE SETTINGS DATA LOGGING FUNCTIONS HOME 44 SCROLL 13 WALL MOUNT BOILER 1 Service Display panel parameter access Service Manual EP SEE EE EEE rs Se SE Er EEE ne ee Eee el Table 1 3 This is a typical example of accessing adjusting and saving a parameter shown for parameter Temperature Settings MIN SH Setpt SCREEN BUTTON STATUS OPERATION DISPLAY This example shows how to access parameter Temperature Settings The first display shown is at the beginning of the menu listings after entering the installer access code Rotate the NAVIGATION dial counterclockwise until the arrow gt is next to TEMPERATURE SETTINGS Press the NAVIGATION dial one time Rotate the NAVIGATION dial counterclockwise until the arrow gt is next to MIN SETPT Press the NAVIGATION dial one time Rotate the NAVIGATION dial to the desired temperature Select SAVE Press the RIGHT SELECT soft key SAVE one time
67. our example Efficiency optimization is automatically selected when boilers of different sizes are programmed into the Leader control see Boiler Size on this page Maximum Cascade Set Point This parameter determines the set point used by the individual boilers in a Cascade when a system sensor is connected to the Leader boiler 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 maximum cascade set point the boiler will then modulate down on its own in order to keep its outlet temperature within the maximum 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 the Maximum Cascade Set point parameter The temperature range of this parameter is 32 F 0 C to 180 82 C The default maximum cascade set point is 180 F 82 C 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 the Cascade Offset parameter The temperature r
68. s Description Page Display Modify Display Modify Boost Temperature Boost Time Anti Cycling Time Anti Cycling Override Differential Ramp Delay Ramp Settings Controlling Sensor BMS Tstat Input M ModBus ModBus T O Op Cascade Address Cascade Type Max Cascade Set Point Cascade Offset Cascade Differential Min On Off Time Min Next On Time OUTDOOR CONTROL MODES ANTI CYCLING RESET Fi Boiler Size System Pump Delay Boiler Pump Delay DHW Pump Delay Boiler Pump Anti Seize Delay Boiler Pump Min Voltage System Pump Type DHW Blocks Sys Pump DHW Forces Sys Pump DHW Pump Anti Seize Delay N A gt n zZ e E lt l O oc O System Pump Anti Seize Delay 17 WALL MOUNT BOILER ast Service Manual 1 Service Parameter table Table 1 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them ene re fot Description Page p 7 SERVICE NOTIFICATION 18 1 Service continued Service Manual WALL MOUNT BOILER Viewable and changeable control parameters Before changing parameters note the CAUTION A settings so that the unit can be returned to its original operating parameters General Time and Date The control uses an internal clock for the night setback feature and for logging of events For these features to work correctly the clock must be set when the boiler is first installed or anytime th
69. spillage into the 7 Once the boiler has modulated up to full fire measure room Failure to comply could result in the combustion The values should be in the range listed severe personal injury death or substantial in Table 3 6 above The CO levels should be less than property damage 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 3 5 Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION e Refer to Section 3 General Venting of the Knight Wall Mount Installation and Operation Vent Air Intake Length Manual for the proper venting and air intake methods for the Knight wall mount boiler or Obstruction e Check for obstructions at the vent air intake terminals ef ETT og o VA SITA Refer to Section 7 Gas Connections of the Knight Wall Mount Installation and Operation Manual for the proper gas supply for the Knight wall mount boiler e Refer to page 31 of this manual for burner removal and cleaning procedures Dirty Damaged Burner e Replace burner if necessary EE EA ETNE TE ad Refer to page 46 of this manual for the gas valve adjustment procedure 45 3 Troubleshooting Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedures Locate the throttle adjustment screw on the side of the venturi valve FIG 3 2 Using
70. t 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 e 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 and seals used in hydronic systems What is in this manual Service Near boiler piping Typical system components The Knight wall mount boiler display Display panel readout buttons and their functions Control module inputs e Control module inputs and options Control module outputs e Control module outputs and options General e How the boiler operates e How the control module operates e Access modes user and installer e Sequence of operation Domestic Hot Water DHW space heating Control panel menu access Accessing programming mode and locating menus See separate guide covering the PC interface Control panel parameter access Accessing and changing parameters from the display panel Quick start information table e An index of available adjustments and readouts where to access them and where to find detailed information parameter Knight wall mount boiler operation General Temperature Setting Data Logging e Functions e DH
71. talled and operating Check the following 1 Wire connectors to control module are securely plugged in at the module and originating control 2 Gas pressures Maximum 14 inches w c natural and LP with no flow lockup or with boiler on Minimum 4 inches w c natural 8 inches w c LP with startup gas flowing verify during boiler Service Manual WALL MOUNT BOILER 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 FI F2 and F3 see FIG 3 1 below Figure 3 1 Control Module Fuses F3 80 AMP FUSE 24V DC POWER SUPPLY F1 5 AMP FUSE PUMPS F2 3 15 AMP FUSE BLOWER 5 The boiler is shipped with three 3 spare fuses in a plastic bag provided with the unit 6 If necessary replace open fuse F3 is 80 amps F2 is 3 15 amps and FI is 5 amps Note Fuses F1 F2 and F3 are all slow blow fuses A WARNING 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
72. talled and that there are no obstructions EADS anA This condition occurred five 5 straight times Press the RESET during the same call for heat Check for 24 vac to the gas valve at the 2 pin button on the SMART connection on the side of the main control board during SYSTEM display to the ignition attempt If no voltage is present replace reset 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 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 and clean the heat exchanger as necessary Reference page 32 of this manual for cleaning procedures Flame Sequence e Check supply voltage for proper polarity will require a manual e Check external wiring for voltage feedback reset once the condition si The flame detector circuit is seeing a flame has been corrected signal while no flame is present Press the RESET 9 i button on the SMART SYSTEM display to e Replace main control board reset e Check the flame rod and make sure it is clean e Check the inter
73. tated First Aid HM Eye Irrigate immediately HM Breathing Fresh air Kuscer Service Manual WALL MOUNT BOILER Please read before proceeding When servicing boiler e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e Do not block flow of combustion or ventilation air to the boiler Should overheating 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 e 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 e Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces hea
74. the Set point 1 at High Outdoor Temp 1 Set point 2 at High Outdoor Temp 2 and Set point 3 at High Outdoor Temp 3 parameters The temperature range of this parameter is 68 F 20 C to 190 F 88 C The default value is 70 F 21 C Outdoor Air Shutdown SH1 SH3 The Outdoor Air Shutdown parameter specifies the outdoor air temperature at which there is no longer space heating demand When the outdoor temperature rises above this point the control will block all SH demands DHW demands will still be active These parameters can be changed by the installer by accessing the Outdoor Air Shutdown SH1 SH2 and SH3 parameters The temperature range of this parameter is 32 F 0 C to 104 F 40 C The default value is 70 F 21 C Figure 1 1 Outdoor Air Reset Curve WATER TEMPERATURE VI SET POINT Da SET POINT AT LOW OUTDOOR TEMPERATURE Default 180F SH SET POINT Default 125F SET POINT AT HIGH OUTDOOR TEMPERATURE Default 70F LOW OUTDOOR 22 TEMPERATURE Default 25F OUTDOOR AIR TEMPERATURE HIGH OUTDOOR TEMPERATURE Default 70F 1 Service continued Outdoor Air Shutdown Differential SH1 SH3 The outdoor air shutdown differential parameter is the number of degrees below Outdoor Air Shutdown SH1 SH2 and SH3 parameters the outdoor air temperature must go before the boiler will respond to a SH demand These parameters can be changed by the installer by accessing the Outdoor
75. the control will abort anti cycling and allow the boiler to fire This parameter can be changed by the installer by accessing the Anti Cycling Override Differential parameter The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Ramp Delay Enable Disable This parameter allows the installer to enable or disable the SH ramp delay The default setting is disabled MINUTES TIME 5 TIME 23 1 Service Ramp Settings NOTICE Please note that the brackets denote screen status The SMART SYSTEM control can be programmed to limit the firing rate for a fixed period of time at the start of a space heating demand There are six 6 possible limits each with their own time delay The first limit applies as soon as the burner starts Once its time delay expires the second limit is applied and its timer begins The control steps through these limits until the 6th sixth limit expires Note however that the 6th limit will also limit the rate for the rest of that heat demand The installer can adjust the firing limits and time delays by accessing the Ramp Settings parameter Once this parameter is selected the screen will show the step number the time delay for that step and the limit value corresponding with that step If the installer wishes to adjust one of the values in that step he can press the NAVIGATION dial until the value he wishes to change is flashing The installer can
76. tible 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 Wall Mount Installation and Operation Manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Knight Wall Mount Installation and Operation Manual Inspect boiler interior 1 Remove the top access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Inspect condensate trap Monthly inspection 1 The condensate trap should be inspected monthly to ensure the trap is properly installed and connected to the condensate pipe under the boiler see FIG 2 1 2 The condensate line should be inspected monthly for obstructions making sure it allows free flow for condensate to drain 3 Inspect the neutralizing kit if installed monthly to ensure the condensate is draining properly and there is still an adequate amount of neutralizing agent available Annual cleaning 1 The condensate trap should be cleaned at least once annually or at the end of each heating season by removing the bottom cap and cleaning out any sediment that exists 2 The provided condensate trap is equipped with a ball that acts as a seal against harmful flue gases escaping in case there is no conde
77. to ACTIVE see BMS Active Inactive and the boiler is being controlled through ModBus set the ModBus parameter to ACTIVE Otherwise set the ModBus parameter to INACTIVE Note that the boiler can still be monitored by ModBus with this parameter set to INACTIVE The default value is INACTIVE ModBus T O The amount of time the unit controls will wait to receive a communication string from the BMS controller before reverting back to its own internal parameters This parameter is adjustable by the installer by accessing the ModBus T O parameter The adjustment range of this parameter is 5 seconds to 2 minutes The default value is 10 seconds Cascade Address The boiler designated as the Leader of the Cascade 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 the Cascade Address parameter The outdoor air if used and system supply sensor must be connected to the boiler designated as the Leader The default address is 1 Cascade Type There are two 2 options for the way a Cascade divides the load between its heaters The first is Lead Lag designated as L L in the menu This method is used when it is desired to have the least amount of total flow through the boilers When the last boiler reach
78. to or above this point the water temperature set point will be at Set point 1 3 at High Outdoor Temp 1 3 parameters FIG 1 1 Service Manual WALL MOUNT BOILER This parameter can be changed by the installer by accessing the Outdoor 1 3 High parameters The temperature range is low outdoor air temperature set point to 104 F 40 C The default value is 70 F 21 C Set Point 1 3 at Low Outdoor Temperature When the outdoor air temperature drops to the Outdoor 1 3 Low parameter the set point will be at this setting FIG 1 1 However the outdoor reset curve is limited by the SH 1 3 Set Points If SH1 SH2 and SH3 are set lower the water temperature will be at these set points instead If the outdoor air temperature continues to drop below the Outdoor 1 3 Low parameter the set point will continue to increase above this setting until SH1 1 3 Set Point is met These parameters can be changed by the installer by accessing the Set point 1 at Low Outdoor Temp 1 Set point 2 at Low Outdoor Temp 2 and Set point 3 at Low Outdoor Temp 3 parameters The temperature range of this parameter is 68 F 20 C to 180 F 82 C The default value is 180 C 82 C Set Point 1 3 at High Outdoor Temperature When the outdoor air temperature rises to or above the Outdoor 1 3 High parameter the calculated set point will be at this setting FIG 1 1 These parameters can be changed by the installer by accessing
79. ugh ModBus the Volts at Maximum parameter should be set to the maximum voltage signal sent to the SMART SYSTEM control The range of this parameter is the Volts at Minimum to 10 0V The default value is 10 0V Rate at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Minimum parameter is set by the Rate at Minimum parameter The minimum value is 0 and the maximum is the Rate at Maximum Volts setting The default value is 20 Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Maximum parameter is set by the Rate at Maximum Volts parameter The minimum value is the Rate at Minimum Volts setting and the maximum is 100 The default value is 100 1 Service continued Set Point at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Minimum parameter is set by the Set point at Minimum Volts parameter The minimum value is 32 F 0 C and the maximum is the Set Point at Maximum Volts setting The default value is 70 F DIO Set Point at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through Mod
80. until the arrow gt is next to the trigger you wish to skip Press the NAVIGATION dial once SK will appear next to that trigger to indicate that it will be skipped You can restore an upcoming trigger by selecting that trigger and pressing the NAVIGATION dial again The SK next to that trigger will disappear 19 1 Service To save any changes and return to the Home Screen press the RIGHT SELECT HOME key To return to the Status Screen without saving the changes press the LEFT SELECT EXIT key Display Timeout This is the time in which the display remains illuminated The range is 10 seconds to 10 minutes The default is 3 minutes Temperature Settings CAUTION Mixing valves are required for the protection of any low temperature loops Space heating SH set point parameters limit boiler operating set point When the outdoor air sensor is connected the boiler operating set point is calculated using the outdoor reset curve Residential boilers with inputs less than 300 000 Btu hr require the use of a control that automatically adjusts water temperature in relation to heat demand Outdoor reset is a feature that increases the temperature setting of the boiler as outdoor temperatures rise The outdoor reset parameters can be accessed through the Outdoor Reset menu Space Heating SH1 SH2 SH3 Set Point There are three 3 individual space heating set points for better zone control These are listed as SH1 S
81. urally 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 Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes 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 2 Maintenance continued Check ignition ground wiring l Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attache

continued - Lochinvar

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