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KBII-SER Rev D
Service Manual
Models: 81 - 286
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read
all
instructions,
including this manual and the
Knight Boiler Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Table of Contents
Troubleshooting
Related Manuals for Knight 81 - 286
Summary of Contents for Knight 81 - 286
- Page 1 KBII-SER Rev D Service Manual Models: 81 - 286 This manual must only be WARNING used by a qualified heating installer / service technician. Read instructions, including this manual and the Knight Boiler Installation and Operation Manual, before installing. Perform steps in the order given.
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Page 2: Table Of Contents
Table 3-5 - Flue Products ..........46 Near Boiler Piping .............. 6 Table 3-6 - Troubleshooting Chart - Combustion Levels 47 The Knight Boiler Display ........... 7 Gas Valve Adjustment Procedure ........47 Control Inputs ............... 8 Revision Notes ..........Back Cover Control Outputs ............. -
Page 3: Please Read Before Proceeding
Please read before proceeding Installer – Read all instructions, When calling or writing about the boiler WARNING NOTICE including this manual and the Knight – Please have the boiler model and serial Boiler Installation Operation number from the boiler rating plate. -
Page 4: When Servicing Boiler
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. -
Page 5: What Is In This Manual
• Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior The Knight boiler display • Clean condensate trap • Check all piping for leaks • Display panel readout, buttons and their functions •... -
Page 6: Service Near Boiler Piping
Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the Knight boiler. This piping scheme is important for proper operation of the SMART SYSTEM control. See the Knight Boiler Installation and Operation Manual for more detailed piping diagrams. -
Page 7: The Knight Boiler Display
Service Manual Service Service (continued) The Knight boiler display NAVIGATION DIAL 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... -
Page 8: Control Inputs
Service Manual Service Service Control inputs SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL LOW VOLTAGE CONNECTION FLOW SWITCH BOARD SYSTEM SENSOR OUTDOOR SENSOR SEQUENCER / BUILDING MANAGMENT SYSTEM LOW WATER CUTOFF O-TEMP HEAT EXCHANGER SWITCH INLET TEMPERATURE SENSOR OUTLET TEMPERATURE /... -
Page 9: Control Outputs
Service Manual Service Service (continued) Control outputs ALARM BELL LOW VOLTAGE LOUVER RELAY CONNECTION BOARD RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER SMART CONTROL MODULE GAS VALVE DISPLAY PANEL PC INTERFACE... -
Page 10: General Operation
How the boiler operates User The user can adjust space heating and tank target temperatures The Knight boiler uses an advanced stainless steel heat by pressing the NAVIGATION dial when “SETPOINTS” is exchanger and an electronic control module that allows flashing at the bottom of the display. - Page 11 Service Manual Service Service (continued) Table 1-1 Sequence of Operation OPERATION DISPLAY 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).
- Page 12 Service Manual Service Service Table 1-1 (continued from previous page) Sequence of Operation OPERATION DISPLAY 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.
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Page 13: Display Panel Menu Access
Service Manual Service Service (continued) Display panel menu access Table 1-2 Use this procedure to access menus from the display panel SCREEN BUTTON OPERATION DISPLAY STATUS [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES]. Press and hold the LEFT SELECT soft key [MENU] [MENU] for five (5) seconds. -
Page 14: Display Panel Parameter Access
Service Manual Service Service Display panel parameter access Table 1-3 This is a typical example of accessing, adjusting, and saving a parameter, shown for parameter Temperature Settings, MIN SH Setpt SCREEN BUTTON OPERATION DISPLAY STATUS 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. -
Page 15: Parameter Table
Service Manual Service Service (continued) Parameter table Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Page Display Modify Display Modify Time and Date Software Version (read only) Temperature Units (ºC/ºF) SH Night Setback Offset SH Night Setback On Times... - Page 16 Service Manual Service Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Page Display Modify Display Modify DHW Boiler Set Point Tank Set Point Tank Set Point Differential DHW Boiler Offset...
- Page 17 Service Manual Service (continued) Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Page Display Modify Display Modify Boost Temperature Boost Time Anti-Cycling Time Anti-Cycling Override Differential Ramp Delay...
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Page 18: Parameter Table
Service Manual Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them User Access Installer Access Menu Description Page Display Modify Display Modify BMS Type Volts at Min Volts at Max Rate at Min Volts Rate at Max Volts... -
Page 19: Viewable And Changeable Control Parameters
Service Manual Service (continued) Viewable and changeable control parameters Before changing parameters, note the Space Heating (SH) and Domestic Hot Water (DHW) CAUTION settings so that the unit can be returned to Night Setback On Times its original operating parameters. This is the time in which the SH Night Setback Offset becomes General active. -
Page 20: Temperature Settings
Service Manual Service To save any changes and return to the Home Screen, press 3-Way Valve Time the RIGHT SELECT [HOME] key. To return to the Status The optional Lochinvar Multi-Temperature Loop Control Screen without saving the changes, press the LEFT SELECT Board (MTLCB) can be used to control the supply temperature [EXIT] key. - Page 21 DHW Type point. The default value is 125°F (52°C). This parameter determines whether the Knight boiler treats Tank Set Point Differential the indirect DHW tank as a separate load, or as a zone on the When a tank sensor is installed, the tank temperature must primary loop.
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Page 22: Outdoor Reset
Service Manual Service Outdoor Reset Set Point (1 - 3) at Low Outdoor Temperature When the outdoor air temperature drops to the Outdoor The option of controlling up to three (3) different outdoor (1 - 3) Low parameters, the calculated set point will be at resets for low outdoor temperatures is available. - Page 23 Service Manual Service Service (continued) Outdoor Air Shutdown Differential (SH1 - SH3) Boost Time The outdoor air shutdown differential parameter is the The boost time parameter sets the amount of time that must number of degrees below Outdoor Air Shutdown SH1, SH2, elapse with a SH demand before the water temperature calculated and SH3 parameters the outdoor air temperature must go set point will be increased.
- Page 24 Service Manual Service Ramp Settings The set point or modulation of the boiler may be controlled Please note that the brackets ([]) denote NOTICE through the 0 - 10V BMS input or through ModBus. When the screen status. BMS parameter is set to INACTIVE, the 0 - 10V input will be The SMART SYSTEM control can be programmed to limit the ignored.
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Page 25: Circulation Pumps
Service Manual Service (continued) The other Cascade divider method is Efficiency Minimum On/Off Time Optimization, designated as EFF in the menu. This In order to prevent units in a Cascade from short cycling, method is used, as the name implies, when it is desired this parameter defines the minimum ON and OFF time for to have the most efficient system. - Page 26 Service Manual Service Boiler Pump Delay DHW Blocks Sys Pump The SH pump delay parameter sets the length of time the When the indirect DHW tank is connected as a zone on the boiler pump will run after a SH demand has been satisfied. primary loop, the DHW Blocks Sys Pump parameter tells the Setting the delay time to 0 will disable the pump.
- Page 27 Service Manual Service (continued) Set Point at Minimum Volts Service Notification Cycles When programmed for BMS control through the 0 - 10V BMS When the boiler control determines that a scheduled input or through ModBus and the BMS Type is programmed as service is due based on the number of boiler cycles, the SETPOINT, the set point represented by the Volts at Minimum boiler display will alternate the standard boiler display...
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Page 28: Maintenance
Service Manual Maintenance Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Owner maintenance Service technician (see the Knight User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •... -
Page 29: Address Reported Problems
2. Verify that air intake area is free of any of the contaminants listed in Section 1 of the Knight Boiler Installation and Operation Manual. If any of these are present in the boiler intake air vicinity, they must be removed. -
Page 30: Check Expansion Tank
Tanks may be open, closed or diaphragm or bladder type. may result. If no water flows, valve is See Section 6 - Hydronic Piping of the Knight Boiler inoperative. Shut down the boiler until a Installation and Operation Manual for suggested best new relief valve has been installed. -
Page 31: Check Control Settings
1. Start boiler and perform checks and tests specified in condition, and ground continuity is satisfactory, replace Section 10 - Start-up of the Knight Boiler Installation the flame sense electrode. and Operation Manual. -
Page 32: Review With Owner
Oiled bearing circulators 7. Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. 1. The circulator shipped with the Knight boiler is water- Re-vacuum the heat exchanger. lubricated. No oiling is required. -
Page 33: Troubleshooting
• Minimum: 4 inches w.c. (natural), 8 inches w.c. 8. Restore power to the boiler at the external line switch and (LP) with gas flowing (verify during boiler verify boiler operation (Section 10 - Start-up in the Knight startup) Boiler Installation and Operation Manual) after completing... -
Page 34: Table 3-1 - Troubleshooting Chart - No Display
Service Manual Troubleshooting 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. •... -
Page 35: Checking Temperature Sensors
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 Boiler Installation and Operation Manual for correct terminal location. -
Page 36: Table 3-3 - Troubleshooting Chart - Noisy System
CORRECTIVE ACTION - Supply gas problem. Natural gas pressures should be between 4 inches w.c. and • Refer to Section 7 - Gas Connections of the Knight 14 inches w.c. LP gas pressures should Boiler Installation and Operation Manual for detailed... -
Page 37: Table 3-4 - Troubleshooting Chart - Fault Messages
- Either the optional manual reset low gas Gas Pressure SW pressure switch or the optional manual reset • Refer to Section 7 - Gas Connections of the Knight high gas pressure switch tripped. Boiler Installation and Operation Manual for detailed (will require a manual information concerning the gas supply. -
Page 38: Corrective Action
SMART SYSTEM LP gas pressures should be between 8 - 14 inches w.c. display to reset.) Refer to Section 7 - Gas Connections of the Knight Boiler Installation and Operation Manual for detailed information concerning the gas supply. - Page 39 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit has failed to prove main burner • Verify that the plastic hose from the gas valve to the air ignition after four (4) attempts.
- Page 40 Refer to Section 6 - Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler. • Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.
- Page 41 • Replace high limit. • Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting of the Knight Boiler Installation and Operation Manual for Fan Low/High proper lengths. • Check for obstruction or blockage in the vent/air...
- Page 42 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check the sensors and their associated wiring. Sensor Shorted Repair or replace the sensor or wiring if damaged. (will require a manual reset once the condition has been Either the inlet water or outlet water...
- Page 43 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check wiring to sensor. Make sure wiring is connected and not damaged. Reconnect / repair Flue Sensor Fault wiring if necessary.
- Page 44 Refer to Section 6 - Hydronic Piping of the Knight Boiler Installation and Operation Manual for the proper piping methods for the Knight boiler. • Check for 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring...
- Page 45 Refer to Section 6 - Hydronic Piping of the Knight Boiler Installation Operation Manual for the proper piping methods for the Knight Service Blk boiler. • Check 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board.
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Page 46: Combustion Analysis Procedure
Service Manual 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. • Check wiring connections at the low voltage 120 vac input to the main control board has Low 24 vac terminal strip. -
Page 47: Table 3-6 - Troubleshooting Chart - Combustion Levels
Table 3-6 Troubleshooting Chart - Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION • Refer to Section 3 - General Venting of the Knight Boiler Installation and Operation Manual Vent/Air Intake Length for the proper venting and air intake methods for the Knight boiler. -
Page 48: Revision Notes
Revision Notes: Revision A (ECO #C05747) initial release. Reflects the new model numbers for the Knight upgrade. Revision B (ECO #C06234) reflects changes made to the Service Notification parameter. Revision C (ECO #C07981) reflects changes made to the parameter table, parameter descriptions, updates to the troubleshooting chart, and the addition of the O-temp HEX switch.
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