100288296_2000546130_Rev A
Service Manual
Models: 56 - 400
WARNING
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Knight Wall Hung Fire Tube 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.
Save this manual for future reference.
Contents
CONTENTS........................................................................ 2
Hazard Definitions .............................................................. 2
PLEASE READ BEFORE PROCEEDING ........................ 3
Handling Ceramic Fiber Materials ...................................... 3
When servicing boiler ................................................... 4
Boiler operation............................................................ 4
Boiler water ................................................................... 4
Freeze protection fluids ................................................ 4
WHAT IS IN THIS MANUAL .............................................. 5
1. SERVICE
The Knight Wall Hung Fire Tube Boiler Display ................ 6
Control Inputs ............................................................... 7
Control Outputs............................................................. 8
General Operation ........................................................ 9
Sequence of Operation ............................................... 10-11
Display Panel Menu Access ............................................ 12
Display Panel Parameter Access ................................ 13-14
Parameter Table.......................................................... 15-18
Viewable and Changeable Control Parameters .......... 19-29
2. MAINTENANCE
Maintenance and Annual Startup ................................ 30-35
3. TROUBLESHOOTING
Before Troubleshooting .................................................... 36
Check Control Module Fuses .......................................... 36
Table 3-1 - Troubleshooting Chart - No Display .............. 37
Checking Temperature Sensors ...................................... 38
Table 3-3 - Troubleshooting Chart - Noisy System ......... 39
Table 3-4 - Troubleshooting Chart - Fault Messages . 40-46
Combustion Analysis Procedure ................................. 46-47
Table 3-5 - Flue Products ................................................ 46
Table 3-6 - Troubleshooting Chart - Combustion Levels 47
Gas Valve Adjustment Procedure .................................... 47
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
WARNING injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
CAUTION 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.
2
Service Manual
Please read before proceeding
WARNING
Installer – Read all instructions,
including this manual and the Knight
Wall Hung Fire Tube Boiler Installation
and Operation Manual, before installing.
Perform steps in the order given.
NOTICE
User – This manual is for use only by
a qualified heating installer/service
technician. Refer to the Knight Wall
Hung Fire Tube Boiler User’s Information
Manual for your reference.
Have this boiler serviced/inspected by
a qualified service technician at least
annually.
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 Hung Fire Tube Boiler Installation
and Operation Manual).
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
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
WARNING The combustion chamber insulation in this appliance 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).” Normal operating temperatures in this
appliance are below the level to convert ceramic fibers to cristobalite. Abnormal operating conditions
would have to be created to convert the ceramic fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic
materials it is advisable that the installer follow these safety guidelines.
Avoid breathing dust and contact with skin and eyes.
• 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.
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent airborne dust.
 Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.
 Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
 Eye: Irrigate immediately.
 Breathing: Fresh air.
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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
corrosion due to sediment.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger, and
causes failure. Addition of oxygen carried in by makeup
water can cause internal corrosion. Leaks in boiler
piping must be repaired at once to prevent the
introduction of makeup water.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
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Service Manual
What is in this manual?
Service
Maintenance
The Knight Wall Hung Fire Tube Boiler
display
• 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
• Display panel readout, buttons and their functions
Control module inputs
• Control module inputs and options
Control module outputs
• Control module outputs and options
General
• How the boiler operates
• How the control module operates
• Access modes -- user and installer
• Sequence of operation -- Domestic Hot Water
(DHW)/space heating
Control panel menu access
• Accessing programming mode and locating menus
(See separate guide covering the interface.)
Control panel parameter access
• Accessing and changing parameters from the display panel
Quick start information -- parameter
table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
Knight Wall Hung Fire Tube Boiler
parameters
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on
boiler interface
• Combustion analysis procedure
• Gas valve adjustment procedure
• General
• Temperature Setting
• Data Logging
• Functions
• DHW Settings
• Outdoor Reset
• Anti-cycling
• Control Modes
• Building Management System (BMS)
• Circulation Pumps
• Service Notification
• Basic Setup
• USB
5
Service Manual
1
Service
The Knight Wall Hung Fire Tube Boiler display
SERVICE
MODE
BUTTON
USB
PC
CONNECTION
RESET KEY
DIR #2000544469 00
LEFT SELECT KEY
RIGHT SELECT 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
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1
Service
(continued)
Control inputs
DHW RECIRCULATION SENSOR
SYSTEM PUMP SPEED CONTROL
GAS PRESSURE SWITCH
DHW TANK THERMOSTAT
ROOM THERMOSTAT /
ZONE CONTROL
FLOW SWITCH
LOW VOLTAGE
CONNECTION
BOARD
DHW TANK SENSOR
SYSTEM SUPPLY SENSOR
OUTDOOR SENSOR
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
LOW WATER CUTOFF
LOUVER PROVING SWITCH
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE /
HI-LIMIT SENSOR
FLUE GAS SENSOR
FLAME SENSOR
BLOCKED DRAIN / AIR
PRESSURE SWITCH
DISPLAY PANEL
SMART CONTROL
MODULE
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Service
Control outputs
DHW RECIRCULATION
PUMP RELAY
ALARM BELL
LOW VOLTAGE
CONNECTION
BOARD
LOUVER RELAY
RUN TIME CONTACTS
BUILDING MANAGEMENT
SYSTEM
BOILER PUMP
SYSTEM PUMP
DHW PUMP
DHW RECIRCULATION PUMP
IGNITOR
BLOWER
SMART CONTROL
MODULE
GAS VALVE
DISPLAY PANEL
8
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1
Service
(continued)
General Operation
Access modes
How the boiler operates
User
The Knight Wall Hung Fire Tube 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.
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.
How the control module operates
Saving parameters (reference the Parameter Table -
The Knight Wall Hung Fire Tube 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, DHW recirculation,
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
Installer
Most parameters are available only to the installer, accessible
by entering the installer password (5309).
Table 1-4 on pages 15 - 18 of this manual)
NOTICE
Please note that the brackets ([]) denote
screen status.
To save parameters and exit programming:
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
To enter a parameter and continue programming:
Press the RIGHT SELECT [SAVE] key 1 time to return to the
parameter listings; press again to return to the menu listings.
Remember to press the RIGHT SELECT [HOME] key when
finished programming in order to save the changes made.
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.
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Service Manual
1
Service
Table 1-1 Sequence of Operation
OPERATION
1. Upon a call for heat, the gas pressure switch(es) must be closed.
2. 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.
3. The control turns on power to the louver relay. The louver
proving switch, and blocked drain / air pressure switch must
close.
4. The control starts a prepurge cycle by starting the blower.
5. The control starts a trial for ignition by firing the spark
electrode and opening the gas valve.
6. 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.
10
DISPLAY
Service Manual
1
Service
(continued)
Table 1-1 (continued from previous page) Sequence of Operation
OPERATION
7. If flame is detected, it holds the firing rate steady for a few
seconds to let the 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).
DISPLAY
a
8. If the 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
will turn off (boiler and DHW pump operation briefly overlap to
ensure flow is maintained through the unit). This will divert the
boiler’s outlet water from the heating system and send it to the
tank coil instead. The control will then modulate to maintain the
outlet temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one
of them is satisfied.
10. Once both calls for heat are satisfied, the control will turn off
the burner. The blower will continue to run during the postpurge
period.
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 anti-cycle
period will start, which will delay any new call for heat until it
times out.
12. In Standby, ready to start a new cycle.
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1
Service
Display panel menu access
Table 1-2 Use this procedure to access menus from the display panel
BUTTON
SCREEN
STATUS
OPERATION
[MENU]
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 counterclockwise
until 9 is displayed.
[SAVE]
12
Press the RIGHT SELECT soft key [SAVE].
DISPLAY
Service Manual
1
Service
(continued)
Display panel parameter access
Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN
SH Setpt
BUTTON
SCREEN
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 (>) is next to TEMPERATURE SETTINGS.
Press the NAVIGATION dial one time.
Rotate the NAVIGATION dial counterclockwise until
the arrow (>) is next to MIN SETPT.
Press the NAVIGATION dial one time.
Rotate the NAVIGATION dial to the desired
temperature.
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1
Service
Display panel parameter access (cont.)
Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN
SH Setpt
BUTTON
SCREEN
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.
[SAVE]
Press the RIGHT SELECT soft key [SAVE] one time.
[EXIT]
Press the LEFT SELECT soft key [EXIT] if all
desired changes have been made.
[HOME]
Press the LEFT SELECT soft key [HOME].
Wait for the new settings to be saved.
14
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1
Service
(continued)
Parameter table
Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them
DHW SETTINGS
DATA
FUNCTIONS LOGGING
TEMPERATURE SETTINGS
GENERAL
Menu
Description
See
User Access
Page
Installer
Access
Vacation Mode (On/Off)
19
Yes
Yes
Time and Date
19
Yes
Yes
Software Version (read only)
19
No
Yes
Temperature Units (ºC/ºF)
19
Yes
Yes
SH Night Setback Offset
IF SH NSB > 0:
i. SH Night Setback On Times
ii. SH Night Setback Off Times
19
No
Yes
DHW Night Setback Offset
IF DHW NSB > 0:
i. DHW Night Setback On Times
ii. DHW Night Setback Off Times
20
No
Yes
Display Timeout
20
No
Yes
Display Contrast
20
Yes
Yes
SH1 Set Point User
20
Yes
Yes
Minimum SH Set Point
20
No
Yes
Maximum SH Set Point
20
No
Yes
Offset SH1 Set Point
20
No
Yes
Differential SH1 Set Point
20
No
Yes
SH2 Set Point User
20
Yes
Yes
Offset SH2 Set Point
20
No
Yes
Differential SH2 Set Point
20
No
Yes
SH3 Set Point User
20
Yes
Yes
Offset SH3 Set Point
20
No
Yes
Differential SH3 Set Point
20
No
Yes
3-Way Valve Time
20
No
Yes
Reset Last 10 Errors
20
No
Yes
Service Mode Delay
21
No
Yes
Freeze Protection Pump On
21
No
Yes
Freeze Protection Burner On
21
No
Yes
Freeze Protection Burner Differential
21
No
Yes
Tank Set Point
21
Yes
Yes
Tank Set Point Differential
21
No
Yes
DHW Boiler Set Point
21
No
Yes
Boiler Set Point Offset
21
No
Yes
Boiler Set Point Differential
21
No
Yes
DHW Recirc Pump Offset
21
No
Yes
DHW Recirc Pump Differential
21
No
Yes
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Service
Parameter table
Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where
to access them
DHW SETTINGS (CONT.)
Menu
Description
See
User Access
Page
Installer
Access
Tank Minimum Set Point
22
No
Yes
Tank Maximum Set Point
22
No
Yes
DHW Max Rate
22
No
Yes
DHW Type (normal, zone)
i. SH/DHW Switching Time
ii. DHW/SH Switching Time
ELSE:
i. DHW FORCES SYSP (YES/NO)
ii. DHW BLOCKS SYSP (YES/NO)
22
No
Yes
Low Outdoor Temperature 1
22
No
Yes
High Outdoor Temperature 1
22
No
Yes
SH1 Set Point at Low Outdoor Temp
23
No
Yes
SH1 Set Point at High Outdoor Temp
23
No
Yes
Outdoor Shutdown Temp 1
23
No
Yes
Outdoor Shutdown Differential 1
23
No
Yes
Shift Heat Curve 1
23
No
Yes
Low Outdoor Temperature 2
23
No
Yes
High Outdoor Temperature 2
23
No
Yes
SH2 Set Point at Low Outdoor Temp
23
No
Yes
SH2 Set Point at High Outdoor Temp
23
No
Yes
Outdoor Shutdown Temp 2
23
No
Yes
Outdoor Shutdown Differential 1
23
No
Yes
Shift Heat Curve 2
23
No
Yes
Low Outdoor Temperature 3
23
No
Yes
High Outdoor Temperature 3
23
No
Yes
SH3 Set Point at Low Outdoor Temp
23
No
Yes
SH3 Set Point at High Outdoor Temp
23
No
Yes
Outdoor Shutdown Temp 3
23
No
Yes
Shift Heat Curve 3
23
No
Yes
Boost Temperature
IF Boost Temperature > 0
i. Boost Time
24
No
Yes
OUTDOOR RESET
IF Outdoor Sensor Connected:
16
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
Page
User Access
Installer
Access
Anti-cycling Time
24
No
Yes
Anti-cycling Override Differential
24
No
Yes
Ramp Delay (Enable/Disable)
24
No
Yes
Modulation Factor
24
No
Yes
Controlling Sensor(Outlet/System Supply/Inlet)
25
No
Yes
25
No
Yes
Boiler Size
i. Cascade Address
ii. Type
iii. Input
26
No
Yes
BMS (Active, Inactive)
IF Active:
i. BMS Type (Power, Set Point)
IF Power:
1. Power at Minimum Volts
2. Power at Maximum Volts
ELSE:
1. Set Point at Minimum Volts
2. Set Point at Maximum Volts
ii. Minimum Volts
iii. Maximum Volts
iv. TStat Input (Active, Inactive)
IF Inactive:
1. On Volts
2. Off Differential Volts
27
No
Yes
ModBus/BACNet (Active, Inactive)
IF Active:
i. BAS Timeout
27
No
Yes
ANTI-CYCLING
Menu
Description
CONTROL MODES
Cascade Address
IF Address = 0:
Maximum Cascade Outlet Set Point
Cascade Offset
Cascade Differential
Cascade Type (L/L, EFF)
Minimum On/Off Time
Minimum Next On Time
Minimum Pumps On
ELSE IF Address = 1:
Alternate Leader? (Y/N)
IF Yes:
Maximum Cascade Outlet Set Point
Cascade Offset
Cascade Differential
Cascade Type (L/L, Eff)
Minimum On/Off Time
Minimum Next On Time
Minimum Pumps On
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Service
Parameter table
Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where
to access them
USB
BASIC SETUP
SERVICE
NOTIFICATION
CIRCULATION PUMPS
Menu
18
Description
See
User Access
Page
Installer
Access
System Pump Delay
28
No
Yes
Boiler Pump Delay
28
No
Yes
DHW Pump Delay
28
No
Yes
System Pump Anti-Seize Delay
28
No
Yes
Boiler Pump Anti-Seize Delay
28
No
Yes
DHW Pump Anti-Seize Delay
28
No
Yes
System Pump Type (CFH, WWSD)
28
No
Yes
Boiler Pump Delta T Set Point
28
No
Yes
Boiler Pump Minimum Volts
28
No
Yes
Service Notification Months
28
No
Yes
Service Notification Running Time
28
No
Yes
Service Notification Cycles
28
No
Yes
Reset Service Reminder
29
No
Yes
Installer Name
29
No
Yes
Installer Phone Number
29
No
Yes
Time & Date
29
No
Yes
IF Outdoor Sensor Connected:
i. Low Outdoor Temperature 1
ii. High Outdoor Temperature 1
iii. SH1 Set Point at Low Outdoor Temperature
iv. SH1 Set Point at High Outdoor Temperature
v. Outdoor Shutdown Temperature
vi. Outdoor Shutdown Differential 1
29
No
Yes
Cascade Address
IF Address = 0:
i. Maximum Cascade Set Point
ii. Cascade Offset
iii. Cascade Differential
iv. Cascade Type (L/L, EFF)
29
No
Yes
BMS (Active, Inactive)
IF Active:
i. BMS Type (Power, Set Point)
IF Power:
1. Power at Minimum Volts
2. Power at Maximum Volts
ELSE:
1. Set Point at Minimum Volts
2. Set Point at Maximum Volts
ii. Minimum Volts
iii. Maximum Volts
iv. TStat Input (Active, Inactive)
IF Inactive:
1. On Volts
2. Off Differential Volts
29
No
Yes
29
No
Yes
IF USB Drive Contains “Lochinvar” Folder:
Existing Parameter Files Displayed
ELSE IF USB Drive Does Not Contain “Lochinvar”
Folder:
Option to Create “Lochinvar” Folder
Service Manual
1
Service
(continued)
Viewable and changeable control parameters
CAUTION
Before changing parameters, note the
settings so that the unit can be returned to
its original operating parameters.
General
Vacation Mode
This parameter forces the Space Heating (SH) and DHW set
points to decrease by the amounts programmed in the Night
Setback Offset parameters. It is used to save energy, such
as when the building is unoccupied for an extended period
of time. For this function to work, the Space Heating Night
Setback Offset and/or DHW Night Setback Offset parameters
must be set to a value higher than 0°. The default value of this
parameter is OFF.
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 the boiler has been powered off for more than four (4)
hours. This parameter must be accessed to set the clock.
NOTICE
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.
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 and Off Times
These are the times at which the SH Night Setback and DHW
Night Setback Offsets become active and inactive. There are
seven (7) stop times and seven (7) start times each for the SH
and DHW night setback functions. Any start or stop time may
be set to any time during the week. When a start time and a
stop time are programmed for the same day and time, the stop
time has priority (this is how a start time can be disabled).
The installer can adjust the SH Night Setback start and stop
times by accessing the parameter SH NSB On/Off Times. The
installer can access the DHW Night Setback start and stop times
by accessing the DHW NSB On/Off Times parameter. These
settings can be adjusted as follows:
1. When the screen is first accessed, start and stop triggers 1 are
displayed. If a different trigger number is desired, rotate the
NAVIGATION dial until the desired trigger number appears.
Once it is found, press the NAVIGATION dial to adjust the
start and stop times. The day of the week for the start time
will flash.
2. Rotate the NAVIGATION dial to adjust the day of the week
of the start trigger. Once it is set to the desired day of the
week, press the NAVIGATION dial again. The start time
hour will flash.
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 (SH1, 2, and 3 Set point
parameters), or the calculated outdoor reset set point (if lower).
For DHW, it subtracts the DHW night setback offset from the
tank set point (Tank Set point parameter).
3. Rotate the NAVIGATION dial to adjust the start time hour
to the desired time. Press the NAVIGATION dial again.
The start time minutes will flash.
4. This process may be continued until the start and stop days
and times are adjusted as desired. When finished with this
set of triggers, press the [SAVE] key.
5. Rotate the NAVIGATION dial to select another set of
start and stop triggers, or press the [EXIT] key to return to
the previous menu.
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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, go to the Night Setback Status Screen and press
the SKIP button. Rotate the NAVIGATION dial until the
arrow (>) 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.
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 10
minutes.
Display Contrast
The contrast of the LCD display can be adjusted to improve
readability. The contrast is adjusted automatically when
the display board is tested at the factory, but different
ambient conditions may warrant changing the setting.
This parameter can be changed by accessing the Display
Contrast setting. The range of this parameter is -10 to +10.
The default setting is 0.
Temperature Settings
Space Heating (SH1, SH2, SH3) Set Point
CAUTION
Mixing valves are required for the
protection of any low temperature
loops.
There are three (3) individual user set points for better zone
control. These are listed as SH1 Set Point through SH3 Set
Point. If multiple set points are calling for heat the highest
set point has priority. The range 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 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 Minimum
SH Set point parameter. The temperature range of this
parameter is 32°F (0°C) to the space heating maximum set
point. The default value is 60°F (16°C).
20
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 Maximum SH Set point parameter.
The temperature range of this parameter is the space heating
minimum set point to 190°F (88°C). The default value is 185°F
(85°C).
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
parameters 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 (MTLC) can be used to control the supply temperature
in 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 MTLC 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
The reset log errors function clears the last 10 errors log.
Service Manual
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Service
Functions
(continued)
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 the Freeze
Protection Pump On parameter. The minimum setting is
-4°F (-20°C), and the maximum setting is 45°F (7.2°C). The
default setting is 45°F (7.2°C).
Freeze Protection 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 -4°F (-20°C), and the maximum setting is the Freeze
Protection Pump On parameter. 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°,
and the maximum is 20°F (11°C). The default setting is 5°F
(2.8°C).
DHW Settings
DHW Tank Set Point
By installing a tank sensor, the SMART SYSTEM control can
perform the tank thermostat function. The SMART SYSTEM
control automatically detects the presence of this sensor, and
generates a DHW call for heat when the tank temperature
drops 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 is
from the tank minimum set point to the tank maximum set
point. The default value is 120°F (49°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 boiler turns back 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 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 190°F (88°C). The default value is
180°F (82°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 20°F (11°C). The default setting is 5°F
(2.8°C).
DHW Boiler Differential
This parameter reflects the degrees below DHW boiler offset
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 10°F (6°C).
DHW Recirculation Pump Offset (Recirculation Pump)
The SMART SYSTEM control will turn the DHW recirculation
pump on when the DHW return water temperature drops
below the DHW Tank Set Point minus the DHW Recirculation
Pump Offset. The range for this parameter is 0° to 54°F (30°C).
The default value is 10°F (5°C).
DHW Recirculation Pump Differential
Once the SMART SYSTEM control turns the DHW recirculation
pump on, the DHW return water temperature must increase by
the DHW Recirculation Pump Differential before the control
turns the DHW recirculation pump back off. The range of this
parameter is 0° to 90°F (50°C). The default value is 5°F (2°C).
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
minimum 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).
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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. 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.
DHW Type
This parameter determines whether the Knight Wall Hung
Fire Tube 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.
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
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 other 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 the SH/DHW Switching Time parameter. The
minimum setting is 0 minutes and the maximum setting is 55
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 55
minutes. The default setting is 30 minutes.
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.
22
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,
set the DHW Blocks Sys Pump parameter to YES. The default
setting is NO.
Outdoor Reset
Knight Wall Hung Fire Tube 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 United 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
When the outdoor air temperature drops to this point, the
water temperature 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 on page 23). If
the outdoor air temperature drops further, the set point will
continue to increase above this setting. This parameter can be
changed by the installer by accessing the Outdoor (1-3) Low
parameter. The temperature range of this parameter is -39°F
(-39°C) to high outdoor temperature set point. The default
value is 25°F (-4°C).
Outdoor (1 - 3) High
When the outdoor air temperature rises to or above this point,
the water temperature will be at 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 (FIG. 1-1 on page 23). This
parameter can be changed by the installer by accessing the
Outdoor (1-3) High parameter. The temperature range of this
parameter is low outdoor temperature set point to 104°F (40°C).
The default value is 70°F (21°C).
Service Manual
1
Service
(continued)
Figure 1-1 Outdoor Air Reset Curve
SET POINT AT
LOW OUTDOOR
TEMPERATURE
(SH)
SET POINT
SET POINT AT
HIGH OUTDOOR
TEMPERATURE
HIGH OUTDOOR
TEMPERATURE
LOW OUTDOOR
TEMPERATURE
Set Point (1 - 3) at Low Outdoor Temperature
Outdoor Air Shutdown (SH1 - SH3)
When the outdoor air temperature drops to the Outdoor
(1 - 3) Low parameters, the calculated set point will be
at this setting (FIG. 1-1). If the outdoor air temperature
drops further, the set point will continue to increase above
this setting. However, if SH1, SH2, and SH3 are set lower,
the water temperature will be limited by these set points
instead. 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 190°F (88°C). The default
value is 180°C (82°C).
When the outdoor temperature rises above this point, the
control will block the corresponding SH demand (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).
Set Point (1 - 3) at High Outdoor Temperature
When the outdoor air temperature rises to or above
Outdoor (1 - 3) High parameters, the calculated set point
will be at this setting (FIG. 1-1). These parameters can
be changed by the installer by accessing 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 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 the corresponding SH demand. These
parameters can be changed by the installer by accessing
the Outdoor Air Shutdown Differential SH1, SH2, and SH3
parameters The temperature range of this 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 parameter for each outdoor reset curve.
The shift reset 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 -18°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).
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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 feature will be active if this parameter is set
to anything other than 0°F (0°C).
Boost Time
The boost time parameter sets the amount of time that must
elapse with a SH demand before the water temperature
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 minutes
to 55 minutes. The default value is 0 minutes.
Anti-Cycling
Anti-Cycling Time
Once the burner turns off, a set amount of time must elapse
before the control will respond to a new 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 present at the boiler when it shuts off as
the starting point. If the inlet 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 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.
Modulation Factor
This parameter allows the installer to reduce the responsiveness
of the temperature control function, for situations where, for
example, redundant heating capacity is installed. The values
that are available are 40, 50, 60, 70, 80, 90, and 100, with 100
being the most responsive. The default value is 100.
Figure 1-2 Ramp Delay Interval
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(continued)
Ramp Settings
NOTICE
Maximum Cascade Set Point
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 or BMS set point 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 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 40 minutes. The limit value can be set
between 0% and 100%.
Control modes
Controlling Sensor
The SH controlling sensor parameter selects the sensor the
control will use to regulate the boiler firing rate. This
parameter is adjustable by the installer by accessing the
Controlling Sensor parameter. The sensor selections are as
follows: The outlet sensor regulates the firing rate based on
the outlet water temperature of the boiler and the inlet sensor
regulates the firing rate based on the inlet water temperature
of the boiler. If the outlet sensor is selected, and the optional
system supply sensor is connected, the control will regulate the
firing rate based on the system supply sensor temperature. The
default sensor is the Outlet Sensor.
Cascade Address
The boiler designated as the Leader needs to be programmed
with address 0. All the Member boilers require addresses
from 1 to 7, and the addresses must be different for each
Member. The addresses can be in any order, regardless of the
order in which the units are wired together. This parameter
is adjustable by the installer by accessing the Cascade Address
parameter. The outdoor air (if used) and system supply sensor
must be connected to the Leader boiler. The default address
is 1.
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 boiler(s) 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, that 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 programmed as normal.
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 190°F (88°C). The
default maximum cascade set point is 185°F (85°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 range of this
parameter is 0° to 20°F (11°C) The default value is 10°F (6°C).
Cascade 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 Differential parameter. The
temperature range of this parameter is 0°F to 60°F (33°C) The
default value is 20°F (11°C).
Cascade Type (L/L / EFF)
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. This
method will modulate the last two (2) boilers that are firing.
This provides for smooth transitions when a boiler turns on or
off. When the last boiler reaches 100% and the calculated load
is still increasing, it will start the next boiler at 20% and reduce
the previous boiler to 80%, 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.
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 100% rate, it lowers its
rate to 50% and turns on the next boiler at 50%. The two (2)
boilers then modulate at the same rate.
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As the calculated load increases further and both boilers
ramp up to 100%, it lowers the rate of the first two (2)
boilers to 67% and brings the next boiler on at 67%. The
three (3) boilers then modulate together. As the calculated
load decreases, the boilers will reach 20%, 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 20%) / 2
= 30% in our example).
Alternate Leader
This parameter allows the Member 1 boiler to automatically
assume control of the Cascade should it lose communication
with the Leader boiler. When programmed to YES, it is
recommended that the Member 1 boiler have its own set of
external sensors installed (such as the system supply sensor),
to maintain the same level of temperature control as with the
Leader boiler. Voltage signals (such as the 0 - 10V system
pump speed input) can be connected to both boilers.
Efficiency optimization is automatically selected when
boilers of different sizes are programmed into the Leader
control (see Boiler Size on page 26).
WARNING
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.
Minimum Number of Pumps On
When the boiler is a Cascade Leader, it can force a
minimum number of boiler pump outputs to be on
continuously, regardless of how many boilers are firing.
This is normally used when the boilers are piped in a
full-flow configuration, and the boiler pump outputs are
controlling isolation valves. The Leader will force the
boiler pump output on the highest priority boiler to turn
on first, then the boiler pump output on the second highest
priority boiler, and so forth, until the minimum number of
pump outputs are turned on. The range of this parameter
is 0 to 8. The default value is 0.
DO NOT connect the sensors connected to
the Leader boiler to the Member 1 boiler.
The actual water temperatures will be higher
than expected, which could lead to property
damage, personal injury, or death.
When communication is re-established with the Leader boiler,
Member 1 will automatically relinquish control of the Cascade
to the Leader boiler.
The default value of this parameter is NO.
Boiler Size
When boilers of different sizes are connected together in a
Cascade, the Leader 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 kBtu/hr):
1.
2.
3.
4.
5.
When the Boiler Size screen is first accessed, Cascade
Address (SELF) is shown.
Press the NAVIGATION dial twice to access the
Input setting. Rotate the NAVIGATION dial to increase the
boiler input. Input settings 0 - 400 kBtu/hr can be adjusted
in increments of 5 (5000 Btu/hr). When the closest
approximate boiler size is shown, press the RIGHT SELECT
[SAVE] key.
Rotate the NAVIGATION dial to select the address of the
next boiler in the Cascade. Repeat Step 2.
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.
If no 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.
If the Leader boiler is controlling larger boilers (e.g., Copperfin II), those members will send their sizes to the Leader boiler
automatically. Do not program those sizes into the Leader
boiler.
26
Service Manual
1
Service
(continued)
Building Management System (BMS)
BMS
The set point or modulation of the boiler may be controlled
through the 0 - 10V BMS input, BACnet, or 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 or BACnet. The default value is
INACTIVE.
BMS Type
When programmed for BMS control through the 0 - 10V BMS
input or through ModBus/BACnet, 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.
Rate at Minimum Volts
When programmed for BMS control through the 0 - 10V
BMS input or through ModBus/BACnet 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 Volts parameter. The minimum value is 0%
and the maximum is the Rate at Maximum Volts setting. The
default value is model dependant.
Rate at Maximum Volts
When programmed for BMS control through the 0 - 10V
BMS input or through ModBus/BACnet 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%.
Set Point at Minimum Volts
When programmed for BMS control through the 0 - 10V
BMS input or through ModBus/BACnet 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 (21°C).
Set Point at Maximum Volts
When programmed for BMS control through the 0 - 10V
BMS input or through ModBus/BACnet 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 190°F
(88°C). The default value is 180°F (82°C).
Volts at Minimum
When programmed for BMS control through the 0 10V BMS input or through ModBus/BACnet, 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 value. The
default setting is 2.0V.
Volts at Maximum
When programmed for BMS control through the 0 10V BMS input or through ModBus/BACnet, 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 value to 10.0V. The
default value is 10.0V.
BMS Thermostat Input
When controlling the boiler through the 0 - 10V BMS input,
BACnet, or 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 BACnet or ModBus. The default value is
INACTIVE.
On Volts
When programmed for BMS control through the 0 10V BMS input or through ModBus/BACnet 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/BACnet 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.
ModBus/BACnet
When BMS is set to ACTIVE (see BMS Active / Inactive) and
the boiler is being controlled through BACnet or ModBus,
set ModBus/BACnet parameter to ACTIVE. Otherwise, set
the ModBus/BACnet parameter to INACTIVE. Note that
the boiler can still be monitored by ModBus or BACnet
with this parameter set to INACTIVE. The default value is
INACTIVE.
27
Service Manual
1
Service
BAS T/O
This is 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 BAS
T/O parameter. The adjustment range of this parameter is 5
seconds to 2 minutes. The default value is 10 seconds.
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 or outdoor shutdown has begun. This
parameter is adjustable by the installer by accessing the
System Pump Delay parameter. The time range for this
parameter is 1 second to 40 minutes. The default time is 30
seconds.
Boiler Pump Delay
The SH pump delay parameter sets the length of time the
boiler pump will run after a SH demand has been satisfied.
Setting the delay time to 0 will disable the pump. This
parameter is adjustable by the installer by accessing the Boiler
Pump Delay parameter. The time range for this parameter is
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 1 minute.
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 System Pump Anti-Seize
Delay parameter. The range of this setting is 0 seconds to 40
minutes. The default setting is 20 seconds.
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 40
minutes. The default setting is 20 seconds.
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 DHW Pump Anti-Seize
Delay parameter. The range of this setting is 0 seconds to 40
minutes. The default setting is 20 seconds.
28
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 all three (3) SH demands go 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.
Boiler Pump Delta T Set Point
When using a variable speed boiler pump, and controlling it
by means of the 0 - 10V Boiler Pump Speed Output, the boiler
pump will be controlled in order to maintain a minimum Delta
T across the heat exchanger in the boiler (other factors may
override this target). This feature is to be used with Primary /
Secondary piping systems only. A system supply sensor MUST
be installed. This parameter sets the target minimum Delta T
it will use. The range of this parameter is 15°F (8°C) to 60°F
(33°C). The default value is 20°F (11°C).
Boiler Pump Minimum Voltage
The speed of the boiler pump can be controlled by the SMART
SYSTEM control in order to maintain a minimum T 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 minimum 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.
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 user
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 time is 13 months.
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 user 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 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
user 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.
Service Manual
1
Service
(continued)
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
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. A 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.
Basic Setup
The Basic Setup Menu contains the most frequently used
parameters from the list above. See the descriptions above to
set these parameters.
Loch-N-Link™
Parameter files can be copied directly to and from a USB flash
drive. When USB is selected from the Main Menu, the display
will ask you to insert a flash drive into the USB-A (rectangular)
port next to the display. Once a drive is inserted, the display
will search the root directory of this drive for a folder named
“lochinvar”. If it does not find it, the display will ask if you
want it to create this folder? Press either the [YES] or [NO]
key. If you press [NO], no further operations are allowed, so
you must remove the flash drive. If you press [YES], it will
create the folder in the flash drive. If the flash drive contains
a folder named lochinvar, the display will show all of the
parameter files stored in that folder.
If you wish to copy the parameters from the Smart System
control into the flash drive, press the [SAVE] key. The display
will create a file name based on the current date and time
(year-month-date-hours-minutes). If you wish to cancel this
operation, press the [NO] key. If you wish to change the
filename, press the NAVIGATION dial. The first character of
the filename will flash. Rotate the NAVIGATION dial to change
this character. Once it is correct, press the NAVIGATION dial
again, and edit the next character as before. When the new
filename is ready, press the [SAVE] key. The control will save
the parameters to the flash drive, and the new file will appear
in the list of parameter files. Press the [EXIT] key to return to
the Main Menu.
If you wish to copy a parameter file from the flash drive into
the Smart System control, rotate the NAVIGATION dial until
the file you wish to copy is selected. Press the NAVIGATION
dial once. The display will ask you if you want to load the
parameters from the file you selected. You can press [NO] to
cancel the operation, or press [YES] to continue with writing
the parameters into the control. Once the loading process is
complete, the display will return to the Main Status Screen.
29
Service Manual
2
Maintenance
Maintenance and annual startup
Table 2-1 Service and Maintenance Schedules
Service technician
(see the following pages for instructions)
General:
Owner maintenance
(see the Knight Wall Hung Fire Tube Boiler User’s
Information Manual for instructions)
• Address reported problems
• Inspect interior; clean and vacuum if
necessary;
• Clean condensate trap and fill with fresh
water
• Check boiler area
Daily
• Check pressure/temperature
gauge
• Check for leaks (water, gas, flue,
condensate)
ANNUAL START-UP
• Verify flue and air lines in good condition
and sealed tight
• Check system water pressure/system
piping/expansion tank
• Check vent piping
• Check fill water meter
• Check air piping
• Test boiler water. When test indicates,
clean system water with approved
system restorer following manufacturer’s
information
Monthly
• Check air and vent termination
screens
• Check relief valve
• Check control settings
• Check condensate drain system
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check air vents
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section
10 in the Knight Wall Hung Fire Tube
Boiler Installation and Operation
Manual.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
Periodically
• Test low water cutoff
• Reset button (low water cutoff)
Every
6 months
• Check boiler piping (gas and
water) for leaks
• Operate relief valve
• Clean the heat exchanger if flue
temperature is more than 54°F (30°C)
above return water temperature.
• Test low water flow conditions.
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheel
30
End
of season
months
• Shut boiler down (unless boiler
used for domestic hot water)
Service Manual
2
Maintenance
(continued)
WARNING
Follow the Service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler
or system. Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
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.
WARNING
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except
as 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. To remove the condensate trap from the unit, loosen the
compression fitting located on top of the condensate (FIG.
2-1). Condensate fluid may run out of the heat exchanger.
3. The provided condensate trap is equipped with a ball
that acts as a seal against harmful flue gases escaping in
case there is no condensate 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 located in the trap, acting as a seal against flue gases.
2. Verify that air intake area is free of any of the
contaminants listed in Section 1 of the Knight Wall
Hung Fire Tube 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 Wall Hung Fire Tube Boiler Installation
and Operation Manual.
4. Fill condensate trap with enough water to make the ball
float (FIG. 2-1).
Inspect boiler interior
6. Ensure condensate tubing slopes down and away from
the boiler into a drain or condensate neutralizing filter (if
installed).
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.
5. Reinstall the condensate trap onto the condensate drain.
The stainless steel retaining ring, which allows the trap to
be pushed on, but not pulled off, must be installed between
the rubber sealing gasket and the compression fitting. The
compression fitting must be tightened.
Figure 2-1 Condensate Trap
COMPRESSION
FITTING
Inspect condensate trap
RETAINING
RING
GASKET
1. Inspect the condensate trap and drain line monthly
to ensure it is properly installed and there are no
obstructions in the drain line.
2. Inspect the neutralizing kit (if installed) monthly to
ensure the condensate is draining properly and there is
an adequate amount of neutralizing agent available.
FLOAT BALL
CONDENSATE
DRAIN
Annual cleaning
1. The condensate trap should be cleaned at least once
annually, or at the end of each heating season. Remove
the clean out cap on the bottom of the trap (FIG. 2-1).
Let the condensate and any debris drain out and clean
out any sediment that exists. Ensure the gasket is
seated in the cap before reinstalling.
REMOVABLE CAP TO
CLEAN OUT TRAP
IMG00209
31
Service Manual
2
Maintenance
Check all piping for leaks
WARNING
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 Wall Hung Fire Tube
Boiler Installation and Operation Manual.
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.
WARNING
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise 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 not leak. Replace any
leaking vents.
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder type.
See Section 6 - Hydronic Piping of the Knight Wall Hung
Fire Tube Boiler Installation and Operation Manual
for suggested best location of expansion tanks and air
eliminators.
Check fill water meter
1.
Check fill water meter for water usage. If the amount
exceeds 5% of your system volume, you could have a
leak. Have the system checked for leaks and fixed by a
qualified service technician.
32
Test boiler water
1.
Test boiler water. Reference the Knight Wall Hung
Fire Tube Installation and Operation Manual for
guidelines. When test indicates, clean system water with
approved system restorer following the manufacturer’s
information.
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 Wall Hung Fire Tube Boiler Installation and
Operation Manual before proceeding further.
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE
YEARS, by a licensed plumbing contractor
or authorized inspection agency, to ensure
that the product has not been affected
by corrosive water conditions and to
ensure that the valve and discharge line
have not been altered or tampered with
illegally. Certain 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 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.
WARNING
2. 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.
Service Manual
2
Maintenance
(continued)
Inspect ignition and flame sense
electrodes
Check burner flame
1.
Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
2.
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.
3.
Remove the burner, reference FIG. 2-2.
4.
When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 2-2).
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
Figure 2-2 Burner Assembly
2. Verify all wiring is in good condition and securely
attached.
FAN TOP PLATE
3. Check ground continuity of wiring using continuity
meter.
FAN TOP PLATE GASKET
4. Replace ground wires if ground continuity is not
satisfactory.
Check all boiler wiring
BURNER GASKET
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
BURNER
FIBER BOARD
Check control settings
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
this manual. Adjust settings if necessary. See Section 1
of this manual for adjustment procedures.
DIR #2000544497 00
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1.
Start boiler and perform checks and tests specified in
Section 10 - Start-up of the Knight Wall Hung Fire Tube
Boiler Installation and Operation Manual.
2.
Verify cold fill pressure is correct and that operating
pressure does not go too high.
33
Service Manual
2
Maintenance
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the flame
sense electrode.
3. See Section 3 - Troubleshooting in this manual for other
procedures to deal with low flame signal.
Review with owner
1. Review the Knight Wall Hung Fire Tube Boiler User’s
Information Manual with the owner.
2. Emphasize the need to perform the maintenance schedule
specified in the Knight Wall Hung Fire Tube 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 Section 10 - Startup of the Knight Fire
Tube 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 top and front access panels (no tools
required for removal) along with the bezel.
4. Remove the wiring from the ignitor, flame rod, and the
fan. Remove the reference tubing from the air intake.
5. Loosen the band clamp on the air intake coupling using
a field provided 5/16" driver.
6. Remove the 4 mm screws holding the fan to the heat
exchanger top plate.
7. Loosen the union on the venturi
8. The fan and the venturi may now be removed from the
unit together by sliding the fan away from the air intake.
9. Remove the 10 mm nuts securing the heat exchanger top
plate to gain access to the heat exchanger and set aside.
34
WARNING The boiler contains ceramic fiber materials.
Use care when handling these materials
per instructions on page 3 of this manual.
Failure to comply could result in severe
personal injury.
10. Remove the condensate trap from the bottom of the
boiler. Place a bucket underneath the condensate drain
attached to the heat exchanger.
11. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
12. Using a clean cloth dampened with warm water, wipe out
the combustion chamber. Rinse out debris with a low
pressure water supply.
13. Allow the heat exchanger to thoroughly dry.
14. Reassemble the unit in reverse order of component
removal, and re-install the condensate trap.
Damaged gaskets and seals in the
CAUTION system can result in substantial property
damage. Ensure that damaged or torn
gaskets are replaced.
15. Perform a combustion analysis by following the
instructions in Section 3 - Troubleshooting - Check
Flame and Combustion on pages 46 and 47 of this
manual.
16. Resume operation.
Service Manual
2
Maintenance
(continued)
Test low water flow conditions
NOTICE
Figure 2-3 Adjust outlet isolation valve
This test is to be carried out once the
Knight Wall Hung Fire Tube boiler
is completely piped in with 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
ADJUST OUTLET
ISOLATION VALVE ONLY
1. Locate the pinhole button above the RESET button on
the display board (see page 6). 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.
In Service Mode the boiler will fire at ignition speed and
will then modulate up to full fire.
2. Allow the unit to progress through its normal diagnostics
and pre-purge programming.
3. Allow the unit to fire and operate until the temperatures
stabilize. This occurs when the inlet and outlet
temperatures are rising together and the Delta T ( T)
is maintained.
DIR #2000543632 00
4. When the unit stabilizes, begin to slowly shut off the
isolation valve on the outlet piping of the boiler (see
FIG. 2-3). This will begin to restrict the flow and
simulate a low flow condition.
5.
While slowly shutting off the isolation valve, refer to the
Status Screens to watch the behavior of the boiler. These
screens allow you to monitor the inlet temperature,
outlet temperature, and T.
6.
When the T reaches 55˚F (13°C), the control will
attempt to modulate the firing rate down to protect it
from low flow conditions.
7.
When the T reaches 60°F (16°C), the control module
will turn off the burner. If the control module shuts
down, the test was successful.
8.
Completely open the isolation valve on the outlet piping
of the boiler.
9.
Resume operation.
NOTE: This lockout is a soft lockout. Once the T has
decreased to an acceptable level and there is a call for
heat, the unit will fire again to meet the demand.
35
Service Manual
3
Troubleshooting
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
WARNING
except for momentary testing as
outlined in the Troubleshooting
chart. Severe personal injury, death,
or substantial property damage can
result.
Before troubleshooting:
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 front access cover.
3.
Remove the control module cover.
4.
Inspect fuses F1, F2, and F3, see FIG 3-1 below.
Figure 3-1 Control Module Fuses
1. Have the following items:
a.
b.
c.
Voltmeter that can check 120 VAC, 24 VAC, and
12 VDC.
Continuity checker.
Contact thermometer.
2. Check for 120 VAC (minimum 102 VAC to
maximum 132 VAC) to boiler.
3. Make sure thermostat is calling for heat and contacts
(including appropriate zone controls) are closed.
Check for 24 VAC between thermostat wire nuts and
ground.
4. Make sure all external limit controls are installed and
operating.
Check the following:
1. Wire connectors to control module are securely
plugged in at the module and originating control.
2. Gas pressures:
• Maximum: 14 inches w.c. (3.5 kPa) (natural and
LP) with no flow (lockup) or with boiler on
• Minimum: 4 inches w.c. (1.0 kPa) (natural),
8 inches w.c. (2.0 kPa) (LP) with gas flowing (verify
during boiler startup)
36
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 attached to the control module cover.
6. If necessary, replace open fuse (F3 is .80 amps, F2 is 3.15
amps and F1 is 5 amps).
Note: Fuses F1, F2, and F3 are all slow blow fuses.
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 front 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
Wall Hung Fire Tube Boiler Installation and Operation
Manual) after completing boiler service.
Service Manual
3
Troubleshooting
(continued)
Table 3-1 Troubleshooting Chart - No Display
FAULT
CAUSE
CORRECTIVE ACTION
• Check external line switch, fuse, or breaker.
- No 120 vac supplied to unit.
• Check position of ON/OFF switch. Turn switch to the
ON position.
• Check 120 vac through the ON/OFF switch.
• Check wiring harness connection between display
board and main control board. Connect
harness at both points.
No Display
- No voltage through the switch.
• Replace switch.
- Bad display board.
• Replace board.
- Bad main control board.
• Replace the main control board.
- Blown fuse.
• Replace fuse F3 on the main control board, see
page 36 of this manual.
- Main control board temperature set point
• Review temperature setting.
satisfied.
- Remote thermostat satisfied.
No Burner
Operation
• Review remote thermostat setting.
- Outside air temperature above Warm • Check location of outside air sensor.
Check
Weather Shutdown (WWSD) set point for
resistance of outdoor air sensor and compare to Table
main control board.
3-2B on page 38 of this manual.
- Unit locked out on fault.
• Consult display for specific fault. Refer to fault
descriptions on page 40 of this manual for corrective
actions.
- Unit in Shutdown Mode.
• Take unit out of Shutdown Mode.
• Check ramp delay parameter settings.
- Ramp delay active.
• Turn ramp delay feature off. See page 24 of this
manual for instructions on how to turn this feature off.
Unit Does
Not Modulate
Above 50%
- Boiler controlled by BMS.
• Check BMS parameter settings.
• Verify that the flue sensor is located in the flue outlet.
- Flue sensor open.
• Check wiring connections at the flue sensor.
• Check the resistance of the flue sensor and compare
to Table 3-2D on page 38 of this manual.
37
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
It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing. These devices
are designated as S1a/S1b, outlet sensor and S3a/S3b, flue sensor. Please reference the wiring diagram in the Knight Wall Hung
Fire Tube Boiler Installation and Operation Manual for correct terminal location.
Table 3-2A - Inlet Water/System Sensor Resistance vs.
Temperature
Table 3-2B - Outdoor Air Sensor Resistance vs.
Temperature
Temperature Resistance Temperature Resistance
Temperature Resistance Temperature Resistance
50
18,780
158
1,990
68
12,263
176
1,458
86
8,194
194
1,084
104
5,592
212
817
122
3,893
140
2,760
-50
-40
-30
-20
10
0
10
490,813
336,606
234,196
165,180
118,018
85,362
62,465
20
30
40
50
60
70
80
46,218
34,558
26,099
19,900
15,311
11,883
9,299
Table 3-2C - Outlet Water Sensor Resistance vs. Temperature
S1a
S1b
(Wire Color - R/BK and Y)
(Wire Color - G and Y)
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
50
68
86
104
122
140
19,553
12,690
8,406
5,715
3,958
2,786
158
176
194
212
2,004
1,464
1,084
816
50
68
86
104
122
140
40,030
25,030
16,090
10,610
7,166
4,943
158
176
194
212
3,478
2,492
1,816
1,344
Table 3-2D - Flue Sensor Resistance vs. Temperature
S3a
S3b
(Wire Color - W/B and Y)
(Wire Color - PR and Y)
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
50
68
86
104
122
140
38
40,030
25,030
16,090
10,610
7,166
4,943
158
176
194
212
3,478
2,492
1,816
1,344
50
68
86
104
122
140
258,500
125,500
80,220
52,590
35,270
24,160
158
176
194
212
16,870
12,000
8,674
6,369
Service Manual
3
Troubleshooting
(continued)
Table 3-3 Troubleshooting Chart - Noisy System
FAULT
CAUSE
-
Noisy
Operation
CORRECTIVE ACTION
Supply gas problem. Natural gas
pressures should be between 4 inches • Refer to Section 7 - Gas Connections of the Knight Wall
w.c. and 14 inches w.c. LP gas pressures Hung Fire Tube Boiler Installation and Operation Manual
should be between 8 inches w.c. and 14 for detailed information concerning the gas supply.
inches w.c.
- Gas/air mixture problem.
• Refer to the Gas Valve Adjustment Procedure on
page 47 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 Hung Fire Tube Boiler Installation and
Operation Manual.
- Dirty/damaged burner.
• Refer to page 33 in this manual for the burner removal
and inspection procedure. Clean or replace the burner
as necessary.
• Refer to Section 6 - Hydronic Piping of the Knight Wall
Hung Fire Tube Boiler Installation and Operation Manual
- Low water flow through the heat exchanger.
for minimum flow rates. Verify 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.
No Pump
Operation - - Blown fuse.
Boiler Pump
System Pump
or
- Faulty pump.
DHW Pump
No Blower
Operation
Relief Valve
Opening
• Replace fuse F1 on the control board, see page 36 of
this manual.
Note: Make sure pump amperage does not exceed
1.8 amps.
• Replace pump.
- Internal fault on control board.
• Replace main control board.
- Internal fault on control board.
• Replace control board.
- Faulty blower.
• Replace blower.
• Lower the system pressure below the 30 psi rating of
the supplied relief valve or replace the standard relief
- System pressure exceeds relief valve valve with a higher rated valve up to the maximum
setting.
pressure of the heat exchanger.
• Improperly sized expansion tank.
- Failed external relay.
No Pump
Operation
- DHW
Recirculation
Pump
• Check function of external relay.
- Line voltage shut off.
• Check line voltage to external relay.
- Faulty pump.
• Check recirculation pump.
- Faulty DHW recirculation sensor.
• Check DHW recirculation sensor.
- Fault in connection board.
• Check low voltage connection board.
- Fault in control board.
• Replace control board.
39
Service Manual
3
Troubleshooting
Table 3-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
Gas Pressure SW
(will require a manual
reset once the condition
- The gas pressure switch contacts on the
has been corrected. Press
Low Voltage Connection Board are open.
the RESET button on the
SMART SYSTEM display
to reset.)
• Check for a loose or misplaced jumper on the Low
Voltage Connection Board.
• Check for the addition of a device wired across the
gas pressure switch terminals on the Low Voltage
Connection Board.
• Check boiler pump operation on a call for heat.
Flow Switch/
LWCO
• Check for closed valves or obstructions in the boiler
piping.
- Either the optional flow switch or the
low water cutoff (LWCO) is not making.
(will require a manual
reset once condition has
been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
• 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.
• Replace LWCO.
- Blown fuse.
• Replace fuse F3 on the control board, see page 36
of this manual.
• Check the wiring connections to switch. Wires should
be connected to the common and normally closed
terminals.
Blocked Drain SW
(will require a manual
reset once condition has
been corrected. Press
Air pressure switch contacts are open.
the RESET button on the
SMART SYSTEM display
to reset.)
• Air intake lengths exceed the maximum allowed
lengths. Reference Section 3 - General Venting of
the Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for proper lengths.
• Check hoses connected to the air pressure switch for
blockage or obstruction.
• Inspect the burner and heat exchanger. Reference
pages 33 and 34 of this manual for removal and
cleaning procedures. Replace if necessary.
• Faulty air pressure switch. Replace switch.
Too Many
Recyclings
One or more limit switches has opened more
than five (5) times during the last call for heat.
• Check the following limit switches for intermittent
operation:
- Louver Proving Switch
- Air Pressure Switch
- Gas Pressure Switch
• Check harness connections at the control board and
low voltage connection board.
40
Service Manual
3
Troubleshooting
(continued)
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
Anti-cycling
DESCRIPTION
The burner recently turned off.
CORRECTIVE ACTION
• The control board will release the call for heat after a
set time period.
• The control board will release the call for heat if the
outlet temperature drops too quickly.
• Inspect spark electrode and associated wiring for
damage and connection. Reference page 33 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
Hung Fire Tube 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.
Flame Fail Ign
(will require a manual
reset once the condition The unit has failed to prove main burner
has been corrected.
ignition after several attempts.
Press the RESET button
on the SMART SYSTEM
display to reset.)
• 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 main control board.
• If 24 vac is present at the main control board, check
the wiring between the main control board and the gas
valve. Replace the wiring if necessary. Do not
disconnect the wiring from the gas valve and attempt to
measure voltage at that point. The main control board
can detect if the gas valve is not connected and will
display the Gas Valve 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 33 of this manual for removal and
cleaning procedures. Replace if necessary.
• Inspect and clean the heat exchanger as necessary.
Reference page 34 of this manual for cleaning
procedures.
• Inspect the burner. Reference page 33 of this manual
for removal and cleaning procedures. Replace if
necessary.
• Replace the main control board.
41
Service Manual
3
Troubleshooting
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
Flame Sequence
CORRECTIVE ACTION
• Check supply voltage for proper polarity.
(will require a manual
reset once the condition
The flame detector circuit is seeing a flame
has been corrected.
signal while the gas valve is off.
Press the RESET button
on the SMART SYSTEM
display to reset.)
• 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.
• Adjust the set point of the auto reset limit to a higher
setting up to a maximum of 200°F. Reference the
Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for adjusting procedures.
• 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 Hung Fire Tube Boiler Installation and
Operation Manual for the proper piping methods for the
Knight Wall Hung Fire Tube boiler.
Outlet ARHL
The outlet water temperature has exceeded
the setting of the automatic reset high limit.
• 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.
• 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 of the main control board.
• Check resistance of water sensors and compare to
Table 3-2A on page 38 of this manual. Replace
sensor if necessary.
• 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 the
Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for adjusting procedures.
Outlet MRHL
• Verify that the system is full of water and that all air
(will require a manual
has been properly purged from the system.
reset once the condition
The outlet water temperature has exceeded • Verify that the boiler is piped properly into the heating
has been corrected.
the setting of the manual reset high limit.
system. Refer to Section 6 - Hydronic Piping of the
Press the RESET button
Knight Wall Hung Fire Tube Boiler Installation and
on the SMART SYSTEM
Operation
Manual for the proper piping methods for the
display to reset.)
Knight Wall Hung Fire Tube 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.
42
Service Manual
3
Troubleshooting
(continued)
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• If 120 vac is present on a call for heat and the boiler
pump is not operating, replace the pump.
Outlet MRHL
(cont’d)
• If the system pump is a variable speed pump, ensure
that the system flow is not less than the boiler flow.
(will require a manual
• If operating on something other than an outlet sensor,
reset once the condition The outlet water temperature has exceeded
check temperature setting of the main control board.
has been corrected. Press the setting of the manual reset high limit.
• Check resistance of water sensors and compare to
the RESET button on the
Table 3-2A on page 38 of this manual. Replace
SMART SYSTEM display
sensor if necessary.
to reset.)
• Replace the main control board if necessary.
• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 3 - General Venting of the
Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for proper lengths.
• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.
Fan Speed
The actual fan RPM is 30% lower or higher
(will require a manual
• Check the wiring connections at the fan and at the
than the fan speed target.
reset once the condition
main control board.
has been corrected. Press
• Check the fan using the RLY20119 / 100167625 fan
the RESET button on the
test tool.
SMART SYSTEM display
to reset.)
• Replace the fan.
• Replace the main control board.
Blown fuse.
Inlet, Outlet, or
Flue Sensor Fault
• Replace fuse F2 on the control board, see page 36
of this manual.
• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.
(will require a manual
Either the flue, inlet water, or outlet water
• Measure the resistance of the sensors and compare
reset once the condition
temperature sensor has been disconnected
the resistance to the tables on page 38 of this
has been corrected. Press
or shorted.
manual.
the RESET button on the
SMART SYSTEM display
• Replace the sensor if necessary.
to reset.)
43
Service Manual
3
Troubleshooting
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
Louver Proving
Sw
(will require a manual reset
An optional remote proving switch is not
once the condition has been
making.
corrected. Press the RESET
button on the SMART
SYSTEM display to reset.)
CORRECTIVE ACTION
• Check function of remote devices.
• Check for loose or misplaced jumper if louver
proving switch is not connected.
• Check wiring to sensor.
Make sure wiring is
connected and not damaged. Reconnect / repair
wiring if necessary.
Outlet Temp Diff
(will require a manual reset
once the condition has been The temperature difference between the
corrected. Press the RESET two (2) outlet sensors is too high.
button on the SMART
SYSTEM display to reset.)
• Measure the resistance of the sensor and compare to
the resistance in Table 3-2C on page 38 of this manual.
Replace sensor if necessary.
• Restore control parameter defaults from optional PC
software.
• Replace control module.
• Inspect the heat exchanger. Reference page 34 of
this manual for the procedure on how to clean the flue
side of the heat exchanger.
Flue Temp Limit
(will require a manual reset
once the condition has been The stack temperature has exceeded the
corrected. Press the RESET Flue Temp Limit set parameters.
button on the SMART
SYSTEM display to reset.)
• Inspect the flue sensor and associated wiring.
Measure the resistance of the flue sensor and
compare to Table 3-2D on page 38 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.
Fatal Error
The control module has detected parameter
settings that are corrupted.
• Restore the parameter defaults from the optional PC
software.
• Replace control module.
Memory Error
44
A lockout occurs at the same time as a
power outage.
• Reset control module.
Service Manual
3
Troubleshooting
(continued)
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• Inspect the heat exchanger. Reference page 34 of
this manual for the procedure on how to clean the flue
side of the heat exchanger.
Flue Temp High
• Inspect the flue sensor and associated wiring.
Measure the resistance of the flue sensor and
The stack temperature has exceeded the set
compare to Table 3-2D on page 38 of this manual.
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 the main control board.
• 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 Hung Fire Tube Boiler Installation and
Operation Manual for the proper piping methods for
the Knight Wall Hung Fire Tube boiler.
Delta T High
The temperature rise across the heat
exchanger has exceeded the set parameters
for the boiler.
• Check for 120 vac to the boiler pump motor on a call
for heat. If voltage is not present, check the wiring
back to the main control board. Replace the main
control board if necessary.
• If 120 vac is present on a call for heat and the boiler
pump is not operating, replace the pump.
• Verify that the boiler pump is set to the proper speed
or that the pump is the proper size. Reference Section
6 - Hydronic Piping of the Knight Wall Hung Fire Tube
Boiler Installation and Operation Manual for boiler
pump specifications.
• 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 Hung Fire Tube Boiler Installation and
Operation Manual for the proper piping methods for
the Knight Wall Hung Fire Tube boiler.
Outlet Temp
High
• 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
Outlet water temperature has exceeded the
board if necessary.
maximum outlet water temperature.
• 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 Hung
Fire Tube Boiler Installation and Operation Manual for
boiler pump specifications.
• Replace the main control board.
45
Service Manual
3
Troubleshooting
Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• Check 120 vac supply to the transformer.
Low 24 vac
120 vac input to the main control board has
dropped below 80 vac.
• Check wiring connections at the low voltage terminal
strip.
• Check the wire size/length to remote devices.
• Replace the transformer.
Watch Dog Error
Write EEProm
The main control board has detected an • Cycle power to the boiler.
internal fault.
• Replace the main control board.
The main control board has detected an • Cycle power to the boiler.
internal fault.
• Replace the main control board.
CRC Parameters
The main control board has detected an • Cycle power to the boiler.
internal fault.
• Replace the main control board.
No Error Stored
The particular lockout information has been • Press the RESET button.
lost.
• Replace the main control board.
Combustion Analysis Procedure
1. Turn the main power off to the boiler by placing the “On/
Off” switch in the OFF position.
Figure 3-2 CPVC Tee Supplied with the Boiler
CPVC TEE AND STARTER
PIECE SUPPLIED WITH BOILER
(MODELS 56 - 286 ONLY)
2. When using PVC/CPVC remove the 1/2" combustion
plug from the tee supplied in the installation kit for
models 56 - 286 only. For all other venting options,
remove the flue temperature sensor. Note: Combustion
measurements will be made at this point.
3. Turn the main power on to the boiler by placing the
“On/Off” switch in the ON position.
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (see page 6).
5. Locate the pinhole button above the RESET button on
the display board (page 6). 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.
In Service Mode the boiler will fire at ignition speed and
will then modulate up to full fire.
6. Insert the probe from a combustion analyzer into the
hole left by the removal of the 1/2" combustion plug or
the flue temperature sensor.
DIR #2000544797 00
Table 3-5 Flue Products
Input
Rate
High Fire
Low Fire
9.2%
4.5%
9.0% - 10.5% 2.1% - 4.8%
9.0%
4.8%
8.8% - 9.5%
3.9% - 5.2%
Propane
Input
Rate
High Fire
Low Fire
46
Natural Gas
Target
Range
CO2
O2
CO2
O2
Target
CO2
O2
10.8%
10.5%
4.5%
5.0%
Range
CO2
O2
10.5% - 11.5% 3.5% - 5.0%
10.0% - 11.0% 4.2% - 5.8%
Service Manual
3
Troubleshooting
(continued)
Model WH400
7. Once the boiler has modulated up to full fire, measure the
combustion. The values should be in the range listed in
Table 3-5 on page 46. The CO levels should be less than
200 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference Table 3-6 for possible causes and corrective
actions.
8. Once the combustion analysis is complete, test the safety
shutoff device by turning the manual shutoff valve to the
OFF position and ensuring that the boiler shuts down
and registers an alarm. Turn the manual shutoff
switch to the ON position and reset the control.
9. Turn the main power off to the boiler and re-install the
1/2" combustion plug or replace the flue temperature
sensor.
Locate the throttle adjustment screw on the side of the venturi
valve, see FIG. 3-4. Using a screwdriver, turn the screw 1/4
turn counterclockwise to increase CO2 levels or 1/4 turn
clockwise to decrease CO2 levels.
After one adjustment on the valve, follow the Combustion
Analysis Procedure on pages 46 and 47 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 3-6 or replace the gas valve.
10. Place the boiler back into normal operation.
Figure 3-3 Gas Valve Adjustment - Models WH56 - 286
You must replace the flue gas temperature
WARNING
sensor / 1/2" combustion plug (depending
on venting option) to prevent flue gas
spillage into the room. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
THROTTLE ADJUSTMENT SCREW
Gas valve adjustment procedure
If adjustment of the gas valve is deemed necessary, use the
following procedure:
CAUTION
Under normal operating conditions this
valve should not need adjusting.
Figure 3-4 Gas Valve Adjustment - Model WH400
THROTTLE ADJUSTMENT
SCREW
Models WH56 - 286
Locate the throttle adjustment screw on the top of the gas valve,
see FIG. 3-3. Using a 2.5 mm Allen wrench, turn the screw
1/8 turn counterclockwise to increase CO2 levels or 1/8 turn
clockwise to decrease CO2 levels.
Table 3-6 Troubleshooting Chart - Combustion Levels
POSSIBLE CAUSE
Vent/Air Intake Length
or Obstruction
CORRECTIVE ACTION
• Refer to Section 3 - General Venting of the Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for the proper venting and air intake methods for the Knight Wall Hung Fire
Tube boiler.
• Check for obstructions at the vent/air intake terminals.
Gas Supply Pressure
Dirty/Damaged Burner
Gas Valve Adjustment
• Refer to Section 7 - Gas Connections of the Knight Wall Hung Fire Tube Boiler Installation and
Operation Manual for the proper gas supply for the Knight Wall Hung Fire Tube boiler.
• Refer to page 33 of this manual for burner removal and cleaning procedures.
• Replace burner if necessary.
• Refer to this page for the gas valve adjustment procedure.
47
Revision Notes: Revision A (PCP# 3000008912 / CN# 500009028)
initial release.
MM #100288296_DIR #2000546130_Rev A
06/17
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