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Knight High Efficiency Condensing Boiler Service Manual

1. J i ra 3 Service Notification Boiler Cycles 22 No No Yes Yes 4 Reset Service Notification Counter 22 No No Yes Yes z NOTICE The parameters for Building Management System operation are not listed in this table They are only accessible using the PC interface software See separate documentation for access information See page 21 of this manual for a brief discussion 16 1 Service continued Service Manual Viewable and changeable control parameters CAUTION Before changing parameters note the settings so that the unit can be returned to its original operating parameters A General Boiler model The control will display Knight Boiler as the model number because the same control is used on several models This will be displayed when parameter Al has been accessed This parameter is not changeable User code The User Code allows the user to access and change a limited number of control parameters The access code can be changed by the user or the installer to a code of their choosing To change the code parameter A2 must be accessed The default code is 0704 The code can be changed one digit at a time by using the arrow keys on the display 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
2. 9 9 9 B Temp Settings the selectable line A General The caret symbol gt highlights DOWN Press 1 time to highlight second listing ihe selectahle ling gt Data Logging The menu toggles to the next two DOWN Press 1 time to toggle menu listing Dr mientiopion gt E DHW Settings The menu toggles to the next two DOWN Press 2 times to toggle menu listing ndo uc D menu options gt G Anti Cycling The menu toggles to the next two DOWN Press 2 times to toggle menu listing H Control Modes menu options gt I Circulation Pumps The menu toggles to the next two Press 2 tim le menu listin DOWN Umes totogg emenu Ising 15 a EEC EERIE MENU Options ENTER RES Press 1 time to list parameters EIC 11 wil fash lt lt 4 4 4 Pump 12 will flash UP Press 1 time to change parameter 12 Rostrun Time 45 Pump I2 Postrun Time SH 12 will stop flashing parameter Pr 1 tim rameter ENTER RES ess 1 times to select paramete RT ITUR value will appear Post Ti SH ill i Press to increase or decrease value Parameter will increase or decrease or DOWN Pump 0 67 minutes depending on button pressed Hess Press 1 time to save SH OFF Display will change to normal or press MENU EXIT to continue OUT 123 7 F display as you exit menu mode PTE Tre Press 1 time to return to normal SH Pre Purge Thi
3. A WARNING This manual must only be ENERGY STAR Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters HEATING Hi Service Manual Models 80 500 8 Lochinyar High K fficieney Water Heaters Boilers and Pool Heaters Save this manual for future reference used by a qualified heating installer service technician Read all instructions including this manual and the Knight Boiler Installation and Operation Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Krus Service Manual Contents 2 Hazard Gofinitions 2 Please read before proceeding 0 0 3 What is in this manual hanh D Tl SOFVICO RH CR 2 Maintenance cece ede ee eee B RS R RH RH A RR ee 29 3 Troubleshooting eee eee 20 Troubleshooting Chart No Display ccce nnn 29 Troubleshooting Chart Noisy System 31 N Troubleshooting Chart Fault Messages Combustion Analysis Procedure 40 Gas V
4. Check incoming supply gas pressure Natural gas pressures should be between 4 10 5 inches w c and LP gas pressures should be between 8 13 inches w c Refer to Section 7 Gas Connections of the Knight 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 Flame Ign the ignition attempt If no voltage is present replace will require a manual the main control board reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset If 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail fault If 24 vac is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized
5. Gas valve adjustment procedure Service Manual 1 Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight boiler This piping scheme is important for proper operation of the SMART SYSTEM control See the Knight Boiler Installation and Operation Manual for more detailed piping diagrams FROM L4 SYSTEM DOMESTIC HOT WATER PUMP SYSTEM PUMP eo INDIRECT 2d DOMESTIC HOT WATER TANK TO FLOOR DRAIN Krus Service Manual 1 Service continued The Knight boiler display Press to turn boiler off or Hold 5 seconds to enter code Input Mode Menu Mode SHUTDOWN Bresse do Press to select a menu item 4 ve up dd Press after parameter programming in Menu Mode or to exit Menu Mods to store parameter data Press to exit Service Mode ENTER RESET DISPLAY SCREEN SHUTDOWN T ENTER RESET MENU EXIT KniG H HEATING BOILER CONNECTION PORT 4 Loc High Efficiency Water Heaters Boilers and Pool Heaters UP DOWN PREVIOUS NEXT MR be Press to toggle display during normal temperature set point during normal operation Press to change displayed data values in Menu Mode Press to navigate through menu listing in Menu Mode operation to show outlet and return temperatures fan speed and flame signal Press to toggl
6. Offset SH The offset SH sets how many degrees above set point the temperature has to go before the boiler will shut off This parameter can only be changed by the installer by accessing parameter B4 The temperature range of this parameter is O F to 86 F The default value is 10 F 17 1 Service Differential SH The differential SH sets how many degrees below the turn off temperature the temperature has to go before the boiler will turn on This parameter can only be changed by the installer by accessing parameter B5 The temperature range of this parameter is 0 F to 86 F The default value is 20 F C Data logging SH hours running The SH hours running parameter shows the total number of hours the boiler has been in the SH firing position This parameter can be viewed by the user and the installer by accessing parameter Cl DHW hours running The DHW hours running parameter shows the total number of hours the boiler has been in the DHW firing position This parameter can be viewed by the user and the installer by accessing parameter C2 Burner starts The burner starts parameter shows the total number of times the boiler has attempted to fire This parameter can be viewed by the user and the installer by accessing parameter C3 Show last 10 errors The control will log the 10 most current errors with the date and time the error occurred This parameter can be viewed by the user and the installer by accessing parame
7. There are six 6 limiting steps used to limit temperature overshoot and short cycles see FIG 2 on page 21 of this manual This feature can be turned on or off depending on the installation This parameter can be changed by the installer by accessing parameter G3 The control range of this parameter is 0 Off 1 Ramp Up Only and 2 Ramp Up and Ramp Down The default value is 0 Ramp delay settings The time for each of the six 6 ramp delays as well as the power level for each of the six 6 ramp delays are adjustable These parameters are adjustable by the installer by accessing parameter G4 The time range for each ramp delay is adjustable from 1 minute to 40 minutes with the total of all six 6 ramp delays not to exceed 109 minutes The default time for each ramp delay is 1 minute The power range for each ramp delay is adjustable from 0 to 100 The defaults for each ramp delay is ramp delay 1 50 ramp delay 2 80 ramp delay 3 100 ramp delay 4 100 ramp delay 5 100 and ramp delay 6 100 see FIG 2 1 Service continued Figure 2 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 H Control modes Controlling sensor The controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate This parameter is adjustable by the installer by accessing parameter H1 The sensor selections are as follows The outlet sensor regula
8. major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF the power to the boiler at the external line switch 2 Remove top access cover 3 Remove the control module cover 4 Inspect fuses F2 F3 F4 and F5 see FIG 5 below Figure 5 Control Module Fuses F3 1 25 AMP FUSE Y rh p 9 UNS igh m 1 n e e 5 The boiler is shipped with three 3 spare fuses in a plastic bag attached to the control module cover 6 If necessary replace open fuse is 1 25 amps F2 and F4 are 3 15 amps and F5 is 5 amps Note Fuses F2 F5 are all slow blow fuses A WARNING Do not jumper fuse replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage 7 Install control module cover and top access cover after fuse inspection 8 Restore power to the boiler at the external line switch and verify boiler operation Section 10 Start up in the Knight Boiler Installation and Operation Manual after completing boiler service Keser Service Manual 3 Troubleshooting continued Table 6 Troubleshooting Chart No Display No 120 vac supplied to unit Check external line switch fuse or breaker Check position of ON OFF switch Turn switch to the ON position Check 120 vac through the ON OFF switch Check w
9. Boiler Installation and Operation Manual 2 Maintenance continues Flue vent system and air piping 1 Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 3 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 4 Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do notleak Replace any leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for suggested best lo
10. Remove the PVC cap retaining screw from the PVC cap FIG 3 3 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 3 4 Remove any sediment in the trap 5 Fill with fresh water until the water begins to pour out of the drain 6 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 7 Replace the retaining screw 24 A WARNING The boiler should be inspected annually only by a qualified service technician In addition the maintenance Figure 3 Condensate Trap 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING r SCREW CONDENSATE FROM HEAT EXCHANGER PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN A WARNING The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Check all piping for leaks Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections of the Knight
11. time range for this parameter is 0 hours to 100 000 hours The default time is 10 000 hours Service notification boiler cycles When the boiler control determines that a scheduled service is due based on the number of boiler cycles the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter J3 The range for this parameter is 0 cycles to 100 000 cycles The default is 10 000 cycles Reset service notification counter Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing parameter J4 Once accessed press the RESET key to reset the service notification counter 22 Krus Service Manual IGHT Service Manual 2 Maintenance Maintenance and annual startup Table 5 Service and Maintenance Schedules Service technician Owner maintenance see the Knight User s Information Manual for see the following pages for instructions Check boiler area Address reported problems Check pressure temperature Inspect interior clean and vacuum if gauge necessary Clean condensate trap and fill with fresh water Check for leaks water gas flue condensate Verify flue and air lines in good condition and sealed tight Check vent piping Check system water pressure system piping expansion
12. time that must elapse with a SH demand before the water temperature set point will be increased This parameter can be changed by the installer by accessing parameter F9 The time range for this parameter is 1 minute to 60 minutes The default value is 20 minutes 20 Service Manual G Anti cycling Anti cycling time Once a SH demand has been satisfied a set amount of time must elapse before the control will respond to a new SH demand The control will block the new heat demand and anti cycling will be shown in the display until the time has elapsed or the water temperature drops below parameter G2 This parameter can be changed by the installer by accessing parameter G1 The time range for this parameter is 0 minutes to 40 minutes The default value is 1 minute Inlet temperature differential for ending anti cycling The control will bypass the anti cycling time if the water temperature drops too quickly The control will use the water temperature the boiler was at when it shut off as the starting point If the temperature drops below the temperature parameter the control will abort anti cycling and allow the boiler to fire This parameter can be changed by the installer by accessing parameter G2 The temperature range of this parameter is 0 F to 86 F The default value is 10 F Ramp delay on off When the ramp delay on off parameter is active the ramp delay limits the boiler firing rate when a SH cycle has started
13. 7 1 Minimum Air Temperature 18 No No Yes Yes 2 Maximum Air Temperature 18 No No Yes Yes 3 Maximum SH Set Point 19 No No Yes Yes w es 4 Minimum SH Set Point 19 No No Yes Yes t utdoor Air Shutdown es es es es lt 5 Outdoor Air Shutd 19 Ye Ye Ye Ye 6 ou oor 5 19 Yes Yes Yes Yes Differential 7 Shift Air Reset 19 No No Yes Yes o 8 Boost Temperature 20 Yes Yes Yes Yes 9 Boost Time 20 Yes Yes Yes Yes 15 Service Manual 1 Service Parameter table continued Table 4 continued from previous page This table lists SMART SYSTEM control module parameters and where to access them SEE USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE z DISPLAY MODIFY DISPLAY MODIFY 1 Anti cycling Time 20 No No Yes Yes o 2 Temperature Differential 20 No No vou von m G or Ending Anti Cycling 3 Ramp Delay On Off 20 No No Yes Yes lt 4 Ramp Delay Settings 20 No No Yes Yes cl 9 o 1 Controlling Sensor 21 Yes Yes a H utlet System Inlet ul Outlet S S g 2 SH Control Thermostat BMS 21 Yes Yes o zZ 1 Pump Delay System Pump 21 No No Yes Yes Ps 2 Pump Delay SH Pump 21 No No Yes Yes 2 a 3 Pump Delay DHW Pump 21 No No Yes Yes o z 1 Service Notification in Month 22 No No Yes Yes 2 Pg Notification Running 22 No No
14. Inspect condensate trap for blockage Clean if necessary Bad blocked drain switch Replace switch Check supply voltage for proper polarity Check external wiring for voltage feedback Check the flame rod and make sure it is clean Check the internal wiring for bad connections Replace main control board Check wiring harness connection at the gas valve and at the main control board Replace the gas valve wire harness Replace the gas valve Replace the main control board Service Manual 3 Troubleshooting continued Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAUT DESCRIPTION CORRECTIVE ACTION The main control board has received a call The control board will release the call for heat after a for heat too quickly after the previous call for set time period heat has ended Anti cycling The control board will release the call for heat if the outlet temperature drops too quickly The unit has failed to prove main burner Inspect spark electrode and associated wiring for ignition after four 4 attempts damage and connection Reference page 26 of this manual for removal and cleaning procedures Exception The 500 Model will lock out after Replace if necessary one 1 try for ignition It will require a manual reset before attempting to fire again Check for proper electrical grounding of the unit
15. Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection EUM 10 Place the boiler back into normal operation 5 Locate the pinhole button above the in the Knight logo on the display board see page 7 Press the button A WARNING You must replace the flue gas temperature once and hold for 5 seconds to place the boiler into sensor to prevent flue gas spillage into the Service Mode In Service Mode the boiler will fire at room Failure to comply could result in ignition speed and will then modulate up to full fire severe personal injury death substantial property damage 6 Insertthe probe from a combustion analyzer into the hole PERSE 5 left by the removal of the flue temperature sensor 7 Oncethe boiler has modulated up to full fire measure the combustion The values should be in the range listed in Table 11 above The CO levels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the chart below for possible causes and corrective actions Table 10 Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Refer to Section 3 General Venting of the Knight Boiler Installation and Operation Manual Vent Air Intake Length for the proper venting and air intake methods for the Knight boiler or Obstruction Check for obstructions at the vent air intake terminals Gas Su
16. a change in pressure should occur If the pressure change does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Replace the main control board 33 Service Manual 3 Troubleshooting Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION CORRECTIVE ACTION The unit was running and lost the flame Inspect spark electrode and associated wiring for signal The unit then failed to relight the main damage and connection Reference page 26 of this burner after four 4 tries manual for removal and cleaning procedures Replace if necessary dE Check for proper electrical grounding of unit Check incoming supply gas pressure Natural gas pressures should be between 4 10 5 inches w c and LP gas pressures should be between 8 13 inches w c Refer to Section 7 Gas Connections of the Knight 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 installed correctly and there are no obstructions C
17. able 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface The outlet water temperature has exceeded the fixed setting of the automatic reset high limit or the setting of an optional manual reset high limit Auto Reset High Limit will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The actual fan RPM is 30 lower than what is being called for Fan Low ie Fan Speed Low will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Blown fuse CORRECTIVE ACTION Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating System Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight 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 Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump If the system pump is a variable speed pump ensure that the system flow is not less than the boiler flow If operating on something other than an outlet sensor check temperature setting o
18. al property damage and care of the boiler designated in Table 5 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 A WARNING Er noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of the Knight Boiler 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 Boiler Installation and Operation Manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 2
19. alve Adjustment Procedure 41 4 Notes Page A Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or A CAUTION moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Please read before proceeding Installer Read all instructions including this manual and the Knight Boiler 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 Boiler User s Information Manual for your reference Have thi
20. anger and set aside Krus Service Manual 5 Remove the heat exchanger access cover cover gasket s and chamber insulation assembly ANWARNING The boiler contains ceramic fiber materials Use care when handling these 10 11 12 13 materials per instructions on page 3 of this manual Failure to comply could result in severe personal injury Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent Finish cleaning using a clean cloth dampened with warm water Install access cover gasket chamber insulation assembly and cover Secure nuts on the studs DO NOT overtighten Re install the blower assembly gas air arm using the bolts set aside in Step 3 Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler When the boiler has been flushed restore boiler to operation Perform start up and check out procedures in the Knight Boiler Installation and Operation Manual Oiled bearing circulators The circulator shipped with the Knight boiler is water lubricated No oiling is required Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator Replace the boiler front access c
21. anytime the boiler has been powered off for more than 30 days To set the clock parameter A3 must be accessed The date and time are displayed as W hh mm YY year MM month DD date W day 1 Sunday 2 Monday etc hh hour 24 hour time 2 00 PM 14 00 mm minutes 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 Unit C or F The control can be configured to display temperature in either or F This parameter can be changed by the user or the installer by accessing parameter A5 The default is F Night setback temperature Once the internal clock has been set correctly the night setback feature can be used to program a lower water temperature set point for space heating This parameter can be changed by the user or the installer by accessing parameter A6 The temperature range for this parameter is 32 F to 140 The feature is turned off with a setting of 32 F The default value is 32 F Night setback times If parameter is set to anything other than 32 F the night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures are required These times can be changed by the user o
22. associated wiring Measure the resistance of the flue sensor and compare to Table 7B on page 30 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace the main control board The temperature rise across the heat exchanger has exceeded the set parameters for the boiler Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating System Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler Check for 120 vac to the boiler pump motor on a call Temp O Shoot for heat If voltage is not present check the wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump Verify that the boiler pump is set to the proper speed or that the pump is the proper size Reference Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications Outlet water temperature has exceeded the Verify that the system is full of water and that all air maximum outlet water temperature has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Se
23. boiler set point Krus Service Manual Service Sequence of operation continued Table 1 continued from previous page Sequence of operation space heating and DHW OPERATION DISPLAY If the DHW thermostat remains on for more than 30 minutes and the space heating call for heat is also on then the control will turn on the boiler pump turn off the DHW pump after 2 SH 41 RATE seconds and resume modulating based on the space heating set point As long as both the space heating and DHW calls for 123 0F 129 heat remain active the control will switch back and forth between the two modes until one of them is satisfied Once both calls for heat are satisfied the control will turn off the burner The blower will remain on for the 10 second postpurge cycle Any pumps that are running will continue to run for their 127 4F 129 respective pump delay times then turn off Standby 124 7F 129 11 System pump off Standby 122 92 129 10 Boiler pump off system pump continues its delay if longer 12 1 Service continued Display panel menu access Table 2 Use this procedure to access menus from the display panel Service Manual DISPLAY COMMENTS Boiler turns off this ensures uninterrupted programming Enter Menu Code 0000 flashing Digit shown underlined at left will flash Enter Menu Code 0009 Digit shown under
24. cation of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual before proceeding further Service Manual Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain 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 WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to
25. ction 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check 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 Krus 3 Troubleshooting Service Manual Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet water temperature has exceeded the maximum outlet water temperature Temp O Shoot continued will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset External control is cycling too often Rem Ctril Fit After downloading parameters from laptop or pocket pc the main control board must be reset Parameters Progr will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset EH 35 EM 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 Boiler Installation and Operation Manual for boiler pump specifications Replace the main control board Check set po
26. cycle PREPURGE 123 9 129 Once the prepurge cycle is complete and the blocked drain IGNITION switch and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the 123 9F 129 spark electrode and opening the gas valve If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge another prepurge and tries to light the burner again If the burner does not light after 4 trials 1 trial on the 500 model the control locks 123 9F 129 out for 1 hour and then tries another set of 4 trials except on the 500 model which is 10096 lockout If the control detects a flame before the trial for ignition ends it begins to modulate the burner in order to maintain the set point SH 20 RATE If the boiler lights due to space heating call for heat and the 3 ramp delay function is active default is active the modulation 124 8F 129 will be held to a series of increasing limits after the burner has lit If the space heating call for heat is active and the DHW thermostat closes the control will turn on the DHW pump wait DHW 85 RATE 2 seconds and then turn off the boiler pump This will divert 177 8 180 the hot water away from the heating zone s and send it to the i DHW tank instead The control will then modulate to maintain the outlet temperature to the DHW
27. d be at least 10 microamps 2 A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode 3 See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner 1 Review the Knight Boiler User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the Knight Boiler User s Information Manual and in this manual as well 3 Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger 1 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in the Knight Boiler Installation and Operation Manual Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow time for the boiler to cool to room temperature if it has been firing 3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exch
28. e between digits when entering access code or between hour minutes etc when entering date and time 1 Service Control inputs GAS PRESSURE SWITCH OPTIONAL DHW THERMOSTAT OPTIONAL ROOM THERMOSTAT ZONE CONTROL FLOW SWITCH OPTIONAL SYSTEM SENSOR OPTIONAL OUTDOOR SENSOR SEQUENCER BUILDING MANAGMENT SYSTEM OPTIONAL LOW WATER CUTOFF OPTIONAL INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR HIGH LIMIT SENSOR FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE OPTIONAL Krus Service Manual LOW VOLTAGE CONNECTION BOARD SMART SYSTEM Service Manual 1 Service continued Control outputs ALARM BELL OPTIONAL LOW VOLTAGE CONNECTION BOARD AUX DEVICE RELAY OPTIONAL RUN TIME CONTACTS OPTIONAL SEQUENCER BUILDING MANAGMENT SYSTEM OPTIONAL BOILER PUMP SYSTEM PUMP OPTIONAL DHW PUMP OPTIONAL A IGNITER BLOWER GAS VALVE DISPLAY PANEL y PC INTERFACE OPTIONAL SMARTI SYSTEM m EH 1 Service General Operation How the boiler operates The Knight 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 bo
29. erly purge all air from the piping system Low system water pressure Verify system pressure is a minimum of 12 psi Blown fuse Replace fuse F5 on the control board see page 28 of Operation this manual Boiler Pump Notes JU System Pump sure pump amperage does not exceed DHW Faulty pump Replace pump Internal fault on control board 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 Relief Valve valve with a higher rated valve up to the maximum Opening pressure of the heat exchanger Improperly sized expansion tank 131 Service Manual Krus 3 Troubleshooting Table 9 Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Flow Switch will require a manual reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Block Drain Flame Sequence will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset GV Control Fail will require a manual reset once the condition has been corrected Press
30. f the main control board If the optional manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 7A on page 30 of this manual Replace sensor if necessary Replace high limit Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Knight Boiler Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the fan and at the main control board Replace the fan Replace the main control board Replace fuse F4 on the control board see page 28 of this manual 35 Krus Service Manual 3 Troubleshooting Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The actual fan RPM is 30 higher than what Vent air intake lengths exceed the maximum allowed is being called for lengths Refer to Section 3 General Venting of the Knight Boiler Installation and Operation Manual for proper lengths Fan High OR Check for obstruction or blockage in the vent air Fan Speed High intake pipes or at terminations will require a manual reset once the condition Check the wiring connections at the fan and at the has been corrected Press main control board the RESET button on the SMART SYSTEM d
31. he boiler will respond to a SH demand This parameter can be changed by the user or the installer by accessing parameter F6 The temperature range of this parameter is 0 F to 90 F The default value is 10 F Shift reset curve The shift reset curve parameter shifts the actual set point above the calculated set point the number of degrees in this parameter This parameter can be changed by the installer by accessing parameter F7 The temperature range of this parameter is 27 F to 27 F The default value is 0 F This feature will be active if this parameter is set to anything other than OF 19 1 Service 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 the maximum set point has been reached Once the SH demand has been satisfied the set point will revert back to its calculated setting The boost temperature can be changed by the installer by accessing parameter F8 The temperature range of this parameter is O F to 45 F The default value is 0 F This feature will be active if this parameter is set to anything other than 0 Boost time The boost time parameter sets the amount of
32. he code A General gt B Temp Settings The caret symbol gt highlights the selectable line gt C Data Logging D Functions The menu toggles to the next two menu options gt Settings F Outdoor Reset The menu toggles to the next two menu options gt G Anti cycling H Control Modes The menu toggles to the next two menu options Y DOWN Press 1 time to highlight second listing Y DOWN Press 1 time to toggle menu listing Y DOWN Press 2 times to toggle menu listing v DOWN Press 2 times to toggle menu listing wv DOWN Press 2 times to toggle menu listing H A H K e H w H o B 5 n J Service Notification The menu toggles to the next two menu options To select a highlighted menu press the ENTER RESET button one time The display will change to the first parameter under that menu with the first characters flashing 13 Service Manual 1 Service Display panel parameter access Table 3 This is a typical example of accessing a parameter shown for parameter I2 boiler pump delay BUTTON OPERATION DISPLAY COMMENTS This example shows how to access parameter I2 boiler pump delay The first display shown is at the beginning of the menu listings after entering the installer access code D 0 H w H The caret symbol gt highlights Beginning of menu listings
33. heck 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 No Flame Run main control board will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to If 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board reset can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail fault If 24 vac is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 26 of this manual for removal and cleaning procedures Replace if necessary Replace the main control board EH 34 Em 34 3 Troubleshooting continued Service Manual T
34. iler 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 boiler control module receives input from boiler sensors The control module activates and controls the blower and gas valve to regulate heat input and switches boiler DHW and system pumps on and off as needed The user installer programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation can be based on boiler outlet water temperature boiler return water temperature or system supply temperature depending on the parameter setting Sequence of operation Table 1 shows control module normal sequences of operation for space heating and DHW operation The combined operation sequence is for a typical application programmed to provide DHW priority 10 Service Manual Access modes User The user can adjust space heating set point using the UP and DOWN buttons at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In user mode the following parameters can be viewed but not changed Boiler outlet water temperature in DHW mode boiler model number software version total operating hours and total cycles Installer Most parameters are available only
35. int of the external control Check the wiring between the external control and the unit Replace the control Press the ENTER RESET button on the SMART SYSTEM display panel Krus Service Manual 3 Troubleshooting continued Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAUT DESCRIPTION CORRECTIVE ACTION While the unit is in Service Mode the outlet Establish a heating load to remove the heat from the temperature has exceeded 185 F boiler loop Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating System Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight Service boiler Check 120 vac to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size Reference Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications 120 vac input to the main control board has Check 120 vac supply to
36. iring harness connection between display board control board Connect harness at both points No Display No voltage through the switch Replace switch Bad display board Replace board Bad main control board Replace the main control board Blown fuse Replace fuse F3 on the main control board see page 28 of this manual Main control board temperature set point Review temperature setting satisfied Remote thermostat satisfied Review remote thermostat setting LOE TT Outside air temperature above Warm Check location of outside air sensor Check resistance Operation Weather Shutdown WWSD set point for of outdoor air sensor and compare to Table 7C on page main control board 30 of this manual Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 32 of this manual for corrective actions 29 Service Manual 3 Troubleshooting Checking temperature sensors The boiler temperature sensors inlet water outlet water system water flue and outdoor air are all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its corresponding table replace the sensor Table 7A Inlet Outlet System Sensor Resistance vs Temperature Table 7B F
37. isplay Replace the fan to reset Replace the main control board Either the inlet water outlet water or flue Check the sensors and their associated wiring Sensor Open temperature sensor has been disconnected Repair or replace the sensor or wiring if damaged will require a manual reset once the condition Measure the resistance of the sensors and compare has been corrected Press the resistance to the tables on page 30 of this the RESET button on the manual SMART SYSTEM display RE Replace the sensor if necessary Either the inlet water outlet water or flue Check the sensors and their associated wiring ett temperature sensor has been shorted Repair or replace the sensor or wiring if damaged will require a manual dest area tire Measure the resistance of the sensors and compare hasbeen corrected Press the resistance to the tables on page 30 of this the RESET button on the manual SMART SYSTEM display 0 Replace the sensor if necessary EH 36 EH Keasel Service Manual 3 Troubleshooting continued Table 9 continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAUT DESCRIPTION CORRECTIVE ACTION The stack temperature has exceeded the set inspect the heat exchanger Reference page 27 of parameters for the boiler this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the flue sensor and
38. lace ground wires if ground continuity is not satisfactory Check all boiler wiring 1 Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings 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 1 2 Start boiler and perform checks and tests specified Section 10 Start up of the Knight Boiler Installation and Operation Manual Verify cold fill pressure is correct and that operating pressure does not go too high 26 Krus Service Manual Check burner flame mm 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 4 below When replacing the burner ensure gasket is in good condition and positioned correctly FIG 4 Figure 4 Burner Assembly AIR GAS ARM GASKET SCREWS p QTY 3 2 Maintenance continued Check flame signal 1 At high fire the flame signal shown on the display shoul
39. lined at left will flash Enter Menu Code 0009 Digit shown underlined at left will flash Enter Menu Code 0309 Digit shown underlined at left will flash Enter Menu Code 0309 Digit shown underlined at left will flash BUTTON OPERATION ENTER RES Press 1 time in normal operation MENU EXIT Hold for 5 seconds display will change A UP Press 9 times to change last digit _ _ readout to 9 4 PREVIOUS Press 2 times to move to the second dd digit A UP Press 3 times to change second digit in readout to 3 ES PREVIOUS Press 1 time to change to the first mom digit A UP Press 5 times to change first digit in readout to 5 Enter Menu Code 5309 Digit shown underlined at left will flash If you enter a digit incorrectly you can move to the digit by using the NEXT and PREVIOUS buttons asn eeded until the digit you want is flashing Then use UP and or DOWN buttons to change the value ENTER RES Press to enter the code Enter Menu Code INSTALLER CODE The words INSTALLER CODE will flash while displayed amp After 2 seconds display shows menus press ENTER RESET to select a menu gt A General Temp Settings The caret symbol gt highlights the selectable line If the code is entered incorrectly the display will return to its previous mode You will have to start over at step 1 to enter t
40. lue Temperature Sensor Resistance vs Temperature ow wm w ww ow sm o ow Table 7C Outdoor Air Sensor Resistance vs Temperature E EC RN 2 s omes om 9 o um o pose fw om 30 Keasel Service Manual 3 Troubleshooting continued Table 8 Troubleshooting Chart Noisy System CORRECTIVE ACTION Supply gas problem Natural gas pressures Refer to Section 7 Gas Connections of the Knight should be between 4 inches w c Boiler Installation and Operation Manual for detailed 10 5 inches w c LP gas pressures should information concerning the gas supply be between 8 inches w c and 13 inches w c Gas air mixture problem Refer to the Gas Valve Adjustment Procedure on page 41 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Knight Boiler Installation and Operation Manual Noisy Dirty damaged burner Refer to page 26 in this manual for the burner removal Operation and inspection procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping of the Knight Boiler Installation and Operation Manual for minimum flow rates Verify that the boiler is piped in a primary secondary fashion and that the boiler and system pump are running on a call for heat Air in the piping system Prop
41. mode and locating menus See separate guides covering the PC and pocket PC interfaces Control panel parameter access Accessing and changing parameters from the display panel Quick start information parameter table An index of available adjustments and readouts where to access them and where to find detailed information Knight boiler operation General B Temperature Setting C Data Logging D Functions E DHW Settings F Outdoor Air Reset Curve Anti cycling H Control Modes I Circulation Pumps J Service Notification Service Manual Maintenance Service and maintenance schedules Address reported problems Inspect boiler area and boiler interior Clean condensate trap Check all piping for leaks Check air openings Flue vent system and air piping Check water system Check expansion tank Check boiler relief valve Inspect ignition electrode Check ignition ground wiring Check all boiler wiring Check control settings Perform start up and checks Check burner flame Check flame signal Check flue gas temperature General maintenance Review with owner Cleaning boiler heat exchanger Oiled bearing circulators Troubleshooting Troubleshooting table No display Checking temperature sensors Sensor tables Troubleshooting table Fault messages displayed on boiler interface Combustion analysis procedure
42. over 27 3 Troubleshooting HERR 0 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 A WARNING Never jumper bypass any device except for momentary testing as outlined in the Troubleshooting chart Severe personal injury death or substantial property damage can result Before troubleshooting 1 Have the following items a Voltmeter that can check 120 vac 24 vac and 12 vdc b Continuity checker c Contact thermometer Check for 120 vac minimum 102 VAC to maximum 132 vac to boiler 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 Make sure all external limit controls are installed and operating Check the following 1 Wire connectors to control module are securely plugged in at the module and originating control Gas pressures Maximum 10 5 inches w c natural 13 inches w c LP with no flow lockup or with boiler on Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during boiler startup 28 Keser Service Manual Check control module fuses Notice Always check control module fuses before replacing control module or any
43. pply Pressure C Refer to Section 7 Gas Connections of the Knight Boiler Installation and Operation Manual for the proper gas supply for the Knight boiler Refer to page 26 of this manual for burner removal and cleaning procedures Dirty Damaged Burner Replace burner if necessary Gas Valve Adjustment Refer to page 41 of this manual for the gas valve adjustment procedure 40 3 Troubleshooting continued Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedures Note The procedures below are model specific Models 80 285 Locate the throttle adjustment screw on the side of the venturi valve FIG 6 Using a screwdriver turn the screw a 1 4 turn clockwise to increase CO2 levels or a 1 4 turn counterclockwise to decrease CO2 levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measure the combustion If combustion 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 10 on page 40 or replace the gas valve Figure 6 Gas Valve Adjustment Models 80 285 THROTTLE ADJUSTMENT SCREW ADJUSTMENT Service Manual Krus Model 399 CAUTION Under normal operating conditions this
44. r the installer by accessing parameter A7 Each day of the week Sunday through Saturday will have an on and off time Example Monday ON 22 30 Tuesday OFF 6 45 If you wish to skip a day and have no night setback leave the on and off times the same The default times for each day will be 00 00 midnight B Temperature settings SH set point user The SH set point user sets the water temperature set point for fixed operation or the maximum temperature set point when the outdoor air sensor is used This parameter can be changed by the user or the installer by accessing parameter B1 The temperature range of this parameter is 50 F to 190 F The default value is 125 F Minimum SH set point The minimum SH set point sets the minimum water temperature set point that can be used for space heating operation The user or installer will not be able to program the control with a lower SH set point This parameter can only be changed by the installer by accessing parameter B2 The temperature range of this parameter is 32 F to 190 F The default value is 70 F Maximum SH set point The maximum SH 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 parameter B3 The temperature range of this parameter is 32 F to 190 F The default value is 190 F
45. r this time period has expired the control will revert to SH Mode If a DHW call is still active the timer will reset After the time period has expired the control will revert back to DHW Mode This will continue until one of the demands has been satisfied This parameter can be changed by the installer by accessing parameter E2 The time range of this parameter is 10 minutes to 240 minutes The default value is 30 minutes F Outdoor air reset Outdoor air reset operation When the outdoor air sensor is installed the control will calculate the water temperature set point based on the outdoor air temperature As the outdoor air temperature drops the water temperature set point increases This feature allows the boiler to be more efficient in periods of mild weather see FIG 1 on page 19 Minimum air temperature When the minimum air temperature drops to or below this point the water temperature will be at its maximum setting FIG 1 This parameter can be changed by the installer by accessing parameter Fl The temperature range of this parameter is 30 F to 90 F The default value is 25 Maximum air temperature When the maximum air temperature rises to or above this point the water temperature will be at its minimum setting FIG 1 This parameter can be changed by the installer by accessing parameter F2 The temperature range of this parameter is 30 F to 90 F The default value is 70 F 1 Service continued Figure 1 Ou
46. s boiler serviced inspected by a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING NOTICE 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 Boiler Installation and Operation Manual Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee ARNING The combustion chamber door insulation in this product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 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 approved respirators Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal Avoid breathing dust and contact wi
47. s display example assumes operation 00 123 7 a call for space heating is present 14 1 Service continued Parameter table Table 4 This table lists SMART SYSTEM control module parameters and where to access them Service Manual SEE USER ACCESS INSTALLER ACCESS MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Boiler Model 17 Yes No Yes No 2 User Code Yes Yes Yes Yes 3 Time and Date 17 Yes Yes Yes Yes 2 o A 4 Software Version 17 Yes No Yes No 5 Unit or F 17 Yes Yes Yes Yes 6 Night Setback Temperature 17 Yes Yes Yes Yes 9 7 Night Setback Times 17 Yes Yes Yes Yes 1 SH Set Point User 170 Yes Yes Yes Yes t P o 2 Minimum SH Set Point 17 No No Yes Yes r 4 B S Maximum SH Set Point 17 No No Yes Yes LI 2 4 Offset SH 17 No No Yes Yes z0 u 5 Differential SH 18 No No Yes Yes 1 SH Hours Running 18 Yes No Yes No o 2 2 DHW Hours Running 18 Yes No Yes No urner Starts es o es o a o 3 B Start 18 Yi N Y N l 4 Show Last 10 Errors 18 Yes No Yes No o 2 o 1 Reset Last 10 Errors 18 No No Yes Yes E D 2 Service Mode Delay 18 No No Yes Yes 2 2 Le z 2 1 DHW Boiler Set Point 18 Yes Yes Yes Yes rm E a E 2 SH DHW Switching Time 18 Yes ies Yes Yes
48. sion due to sediment Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion Leaks in boiler piping must be repaired at once to prevent the introduction of makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems What is in this manual Service Near boiler piping Typical system components The Knight boiler display Display panel readout buttons and their functions Control module inputs Control module inputs and options Control module outputs Control module outputs and options General How the boiler operates How the control module operates Access modes user and installer Sequence of operation Domestic Hot Water DHW space heating Control panel menu access Accessing programming
49. tank Check control settings Monthly Check relief valve Check ignition and flame sense electrodes sand off any deposits clean Check condensate drain system and reposition Check wiring and connections Check automatic air vents Perform start up checkout performance verification per Section 10 in the Knight Installation and Operation Jer Manual d Periodically Test low water cutoff if used Flame inspection stable uniform Reset button low water cutoff Check air piping lt o gt 2 zZ Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Check boiler piping gas and Every water for leaks 6 months Operate relief valve If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel End Shut boiler down unless boiler of season used for domestic hot water months 2 Maintenance WARNING Service Manual Krus Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substanti
50. tdoor Air Reset Curve WATER TEMPERATURE SET POINT MAXIMUM RESET Default 180 USER SET POINT Default 125 MINIMUM RESET Default 70 Default 25 OUTDOOR AIR Service Manual Keser Default 70 OUTDOOR AIR AT MINIMUM RESET OUTDOOR TEMPERATURE AT MAXIMUM RESET Maximum SH set point When the maximum SH set point drops to or below its minimum setting the water temperature will be at this point if the SH set point is set higher FIG 1 This parameter can be changed by the installer by accessing parameter F3 The temperature range of this parameter is 0 F to 190 F The default value is 180 F Minimum SH set point When the minimum SH set point rises to or above its maximum setting the water temperature will be at this point FIG 1 This parameter can be changed by the installer by accessing parameter F4 The temperature range of this parameter is 0 F to 190 F The default value is 70 F Outdoor air shutdown When the outdoor air shutdown rises above this point the control will block all SH demands DHW demands will still be active This parameter can be changed by the user or the installer by accessing parameter F5 The temperature range of this parameter is 0 F to 120 F The default value is 80 F Outdoor air shutdown differential The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before t
51. ter C4 D Functions Reset last 10 errors The reset last 10 errors parameter allows the error counter to be reset to 0 This parameter can only be cleared by the installer by accessing parameter D1 Once accessed press the RESET key to clear the counter Service mode delay By pressing the pin button on the front of the display for five 5 seconds the control will be placed in Service Mode This will override all other heat demands The Service Mode allows the installer to set the unit to either maximum firing rate or minimum firing rate for the purpose of combustion analysis The delay sets the length of time the boiler will stay in the Service Mode if no keys have been pressed before going back to its original state This parameter can only be changed by the installer by accessing parameter D2 The time range of this parameter is 0 to 40 minutes The default value is 20 minutes 18 Service Manual E DHW settings DHW boiler set point When a DHW call for heat becomes active the control will use the DHW boiler set point to determine the firing rate of the boiler based on the actual water temperature This parameter can be changed by the installer by accessing parameter El The temperature range of this parameter is 50 F to 190 The default value is 180 F SH DHW switching time The SH DHW switching time parameter sets the length of time the control will stay in DHW Mode when a SH call has been received Afte
52. tes the firing rate based on the outlet water temperature of the boiler and the inlet sensor regulates the firing rate based on the inlet water temperature of the boiler If the outlet sensor is selected and the optional system sensor is connected the control will regulate the firing rate based on the system sensor temperature The default sensor is the Outlet Sensor SH control The SH control parameter selects the method used to control the modulation of the boiler This parameter is adjustable by the installer by accessing parameter H2 The control methods are as follows 1 The control modulates the boiler based on the user set point and the temperature of the selected controlling sensor 2 BMS Building Management System The control modulates the boiler based on the 0 10 vdc signal delivered to the appropriate terminals on the connection board When BMS is selected additional parameters for BMS operation will have to be adjusted These can only be accessed by the optional PC software See PC software information for additional BMS parameter information The default control is Thermostat Service Manual Keser MINUTES I Circulation pumps Pump delay system pump The pump delay system pump 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 parameter I1 The time range for this parameter is 0 minutes
53. th skin and eyes Use NIOSH certified dust respirator N95 NIOSH website at http www cdc gov niosh homepage html manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Bl Apply enough water to the combustion chamber lining to prevent airborne dust Oo Oo thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air Wash potentially contaminated clothes separately from other clothing Rinse clothes washer Service Manual Please read before proceeding When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should 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 Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corro
54. the RESET button on the SMART SYSTEM display to reset Either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped Available only on 500 models Either the optional flow switch or the optional low water cutoff is not making The blocked drain switch has detected excessive condensate build up inside the unit The flame detector circuit is seeing a flame signal while no flame is present The main control board did not detect the gas valve Reset the pressure switches Measure the supply gas pressure to determine cause of failure Natural gas pressures should be between 4 10 5 inches w c and LP gas pressures should be between 8 13 inches w c Refer to Section 7 Gas Connections of the Knight Boiler Installation and Operation Manual for detailed information concerning the gas supply Correct the supply gas pressure if necessary Check for a loose or misplaced jumper if pressure switches are not installed Check boiler pump operation on a call for heat Check for closed valves or obstructions in the boiler piping Verify system is full of water and all air has been purged from the system Check for a loose or misplaced jumper if flow switch is not installed Blown fuse Replace fuse F2 on the control board see page 28 of this manual Check condensate tube from unit to floor drain for proper installation and obstructions
55. the transformer dropped below 80 vac Check wiring connections at the low voltage terminal Low 24 vac strip Check the wire size length to remote devices Replace the transformer The main control board has detected an Replace the main control board EV Col TT dd internal fault The main control board has detected an Replace the main control board LLL CM sid MEE internal fault P The main control board has detected an Replace the main control board internal fault The main control board has detected an Replace the main control board internal fault 39 mE Krus Service Manual 3 Troubleshooting Combustion Analysis Procedure Table 11 Flue Products 1 Turn the main power off to the boiler by placing the Propane On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue pipe in J connection Note Combustion measurements will be 10 0 11 0 made at this point 3 Turn the main power on to the boiler by placing the 8 Once the combustion analysis is complete press the On Off switch in the ON position SHUTDOWN button on the display board see page 7 to take the boiler out of Service Mode The boiler will go 4 Place the boiler into the active position by pressing the to shutdown and the display will show BOILER OFF SHUTDOWN button on the display board see page 7 until BOILER Standby appears in the display window 9
56. the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 25 2 Maintenance Inspect ignition and flame sense electrodes Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Rep
57. to 40 minutes The default time is 30 seconds Pump delay SH pump The pump delay SH pump 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 parameter 12 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds Pump delay DHW pump The pump delay DHW pump 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 parameter 13 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds 21 1 Service J Service Notification Service notification in months When the boiler control determines that a scheduled service is due based on days of installation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter J1 The time range for this parameter is 0 months to 36 months The default time is 12 months Service notification running hours When the boiler control determines that a scheduled service is due based on the hours of actual operation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter J2 The
58. to the installer accessible only by entering the installer access code 5309 Saving parameters To save parameters Press the ENTER RESET button To keep parameter settings only for a current operating cycle Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Krus Service Manual 1 Service continued Sequence of operation Table 1 Sequence of operation space heating and DHW OPERATION DISPLAY Upon call for heat the control turns on the appropriate pumps BLR Standby system and boiler pumps for space heating call DHW pump Kojoj PA No EAN for DHW call The control connects 120 vac to the blower The blower does not run at this time If the unit is equipped with a flow switch or low water cutoff it must close before the control powers up the blower If the unit is equipped with a manual reset high limit it must be closed before the control powers up the blower BLR Standby If the unit is equipped with a solenoid valve and or a vent d valve they will be energized along with the blower OUT 123 8F 129 If the unit is equipped with a gas pressure switch it must close at this time If there is an auxiliary device connected to the unit the unit will then provide 24 vac to its enable relay If the auxiliary device has a proving switch it must close before the sequence continues The control then starts a 10 second prepurge
59. valve should not need adjusting There is no adjustment for the gas valve on the 399 model Revisit the possible causes in Table 10 on page 40 or replace the gas valve Model 500 Locate the throttle adjustment screw on top of the gas valve see FIG 7 Using screwdriver turn the screw 1 4 turn clockwise to increase CO2 levels or a 1 4 turn counterclockwise to decrease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 40 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 10 on page 40 or replace the gas valve Figure 7 Gas Valve Adjustment Model 500 THROTTLE SCREW 41 Service Manual 4 Notes 42 Service Manual 4 Notes 43 KB SER 01 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 CP 3M 09 05 www Lochinvar com

Knight High Efficiency Condensing Boiler Service Manual

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